SERVICE MANUAL OFFICE PRO 60
© 2001 DENSO SALES CALIFORNIA, INC. All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher. DENSO SALES CALIFORNIA, INC. reserves the right to make changes without prior notice. MovinCool is a registerd trademark of DENSO Corporation.
SERVICE MANUAL O F F I C E P R O 60
FOREWORD This manual has been published to service the MovinCool Office Pro 60. Please use this service manual only when servicing the Office Pro 60. DEFINITION OF TERMS WARNING: Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation. CAUTION: Describes precautions that should be observed in order to prevent damage to the unit or its components, which may occur during installation or unit operation if sufficient care is not taken.
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TABLE OF CONTENTS FOREWORD ............................................................................................................................... i DEFINITION OF TERMS ............................................................................................................ i GENERAL PRECAUTIONS ........................................................................................................ i TABLE OF CONTENTS ...............................................................................
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GENERAL DESCRIPTION CONDENSER (OUTDOOR UNIT) Generally speaking, conventional air conditioners cool the entire enclosed environment. They act as “heat exchangers”, requiring an interior unit (evaporator) to blow cool air into the interior and an exterior unit (condenser) to exhaust exchanged heat to the outdoors. Unlike conventional air conditioners, the MovinCool Spot Cooling System is a spot cooler which directs cool air to particular areas or objects.
GENERAL DESCRIPTION 2
CONSTRUCTION, SPECIFICATIONS, and DATA EVAPORATOR FAN EXHAUST AIR OUTLET EVAPORATOR MOTOR EVAPORATOR CONDENSER FAN CONDENSER MOTOR COOL AIR VENT CAPILLARY TUBE DRAIN PAN DRAIN SWITCH (BEHIND CONTROL BOX) CONDENSER CONDENSATE PUMP COMPRESSOR CONTROL BOX Construction of Office Pro 60 3
CONSTRUCTION, SPECIFICATIONS, and DATA POWER CORD EVAPORATOR FAN MOTOR EVAPORATOR FAN TOP PANEL EXHAUST AIR OUTLET COOL AIR VENT SIDE PANEL BACK HANDLE CONTROL PANEL CONDENSER FAN MOTOR FRONT HANDLE CONDENSER FAN CONDENSER FRONT PANEL CAPILLARY TUBES EVAPORATOR COMPRESSOR DRAIN PUMP POWER CORD CASTER Construction Diagram 4
CONSTRUCTION, SPECIFICATIONS, and DATA 1. Basic Construction The MovinCool Spot Cooling System is compact in construction because the condenser and the evaporator are enclosed in one unit. The interior is divided into three sections. The upper front face is equipped with the evaporator, while the lower front face contains the drain tank (optional). The rear section contains the condenser, the compressor and the control box. 2.
CONSTRUCTION, SPECIFICATIONS, and DATA Rating Conditions dry bulb ...................................................................................... 95˚ F (35˚ C) wet bulb ..................................................................................... 83˚ F (28.2˚ C) humidity ..................................................................................... (60%) Specifications power frequency ........................................................................ 60Hz line voltage ...........
30.3 CONSTRUCTION, SPECIFICATIONS, and DATA 27.10 22.80 10.2 40.80 24.20 51.70 30.31 Exterior Dimensions (units: inches) 7 4.16 6.75 9.90 64.40 18.70 2.
DATA @ 230V @230V 273 (65) 252 (60) Temperature ˚C (˚F) Cooling Capability (x103 KCAL/h (BTU/h)) 14 (25.2) 231 (55) 12 (21.6) 10 (18.0) 8 (14.4) 210 (50) 6 (10.8) 189 (45) 1 2 3 4 5 40 6 50 60 70 Relative Humidity of Inlet Air (%) @230V 8 33 (91.4) 28 (82.4) Power Consumption (kW) 7.5 23 (73.4) 18 (64.4) 12 (53.6) 17 (62.6) 22 (71.6) 27 (80.6) Wet Bulb Temperature ˚C (˚F) Cooling Capability Curve 7 6.5 6 5.
REFRIGERANT SYSTEM 1. The component parts of the refrigerant system include the following: • Compressor • Evaporator • Condenser • Modulating tank • Capillary tube These parts are all connected by copper tubing. All the connections have been brazed.
REFRIGERANT SYSTEM 1. Compressor The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in one casing. A. Compressor Theory of Operation The scroll utilizes an involute spiral which, when matched with a mating scroll form, generates a series of crescent-shaped gas pockets between the two members. During compression, one scroll remains stationary (fixed scroll) while the other form (orbiting scroll) is allowed to orbit (but not rotate) around the first form.
REFRIGERANT SYSTEM 4) By the time the gas arrives at the center port, discharge pressure has been reached. 5) Actually, during operation, all six gas passages are in various stages of compression at all times, resulting in nearly continuous suction and discharge. NOTE: Upon compressor shut-off, the compressor may run backward for a moment or two until internal pressures equalize.
REFRIGERANT SYSTEM 3. Capillary Tubes The capillary tubes are long thin tubes utilizing line flow resistance to serve as an expansion valve. The length and the inner diameter of the capillary tubes are determined by the capacity of the refrigeration system, specified operating conditions, and the amount of refrigerant. HIGH TEMP. / HIGH PRESS.
REFRIGERANT SYSTEM 6. High Pressure Switch The high pressure switch prevents the condenser and compressor from being damaged by excessively high pressure in the high pressure line of the refrigeration cycle. The switch is normally closed. The snap disk responds to variations in pressure and, if pressure is abnormally high, the snap disk moves down to push the pin down, causing the internal contacts to open.
REFRIGERANT SYSTEM CONDENSER INLET PIPE CAPILLARY TUBE COMPRESSOR DISCHARGE PIPE HIGH PRESSURE SWITCH PIPE (CONDENSER TO CAPILLARY TUBE) EVAPORATOR INLET PIPE COMPRESSOR SUCTION PIPE (EVAPORATOR TO COMPRESSOR, INSULATED) CONDENSER OUTLET PIPE Refrigerant System Piping 14
ELECTRICAL SYSTEM AP G T1 T DS 230V 1 PHASE 60Hz RTH CC HPRS THS R R1 MCC TB MC 1 IOLC C J8 J7 J6 J5 J4 J3 J2 J1 G G CF1 HI LO MF1 IOLF CF2 G HI 1 J201 J202 J203 J204 RB J9 J201 CB 10 J10 10 ODS MF2 LO FDS IOLF CONDENSATE PUMP MDP G G AP TB CB RB MF1 MF2 MC CF1 CF2 CC IOLF Attachment Plug Terminal Block Control Board Relay Board Condenser Fan Motor Evaporator Fan Motor Compressor Motor Capacitor for Condenser Fan Motor Capacitor for Evaporator Fan Motor Capacitor for C
ELECTRICAL SYSTEM 1. Basic Operation of Office Pro 60 Electrical Circuit There are two basic components used to control the operation of the Office Pro 60 Electrical System: • Control Panel Assembly • Control Box The Control Panel Assembly contains the Control Panel, Control Board (with inputs for the freeze and room temperature thermistors), drain switch, and a microprocessor. A.
ELECTRICAL SYSTEM the J4 terminal (Relay Board) where the wire from the Compressor wire harness is connected. COMPRESSOR CAPACITOR RELAY BOARD 2. Control Box A. Capacitors EVAPORATOR FAN CAPACITOR The capacitors are used to temporarily boost the power output available to the fan motor and the compressor at start-up.
ELECTRICAL SYSTEM could result in damage to the unit and/or to components. It will also void the warranty of the unit. 3. Fan Motor (Evaporator) The fan motor is a single phase, induction type two-speed motor. EVAPORATOR FAN MOTOR Specifications: Rated Voltage: 230 Volts 60 Hz Rated Output: (low) 326 watts (high) 500 watts GROUND (GREEN/YELLOW) J7 (RED) CF22 (BROWN/WHITE) CF21 (ORANGE) J8 (BLACK) 4. Fan Motor (Condenser) The condenser fan motor is a single phase induction type two-speed motor.
ELECTRICAL SYSTEM condensate pump, which collects the water that forms on the evaporator during normal cooling operation and eliminates the need for a drain tank. When the water collects to level (A) in the pump reservoir, the drain pump begins to operate and discharges the water. When the water level drops below level (B), the drain pump will stop.
ELECTRICAL SYSTEM This causes the ground signal at the J103 connector of the control panel assembly to close. When the microprocessor detects this event, it shuts the unit off and flashes the “Tank Full” LED. When the drain tank is removed (or the drain tank is emptied), the top of the drain tank base plate returns to its original position from the tension of the coil spring. Then contacts (1) – (2) of the drain tank switch open. This provides a ground to the microprocessor through the J103 connector. 8.
TROUBLESHOOTING AND REPAIR Before troubleshooting the system, the following inspection should be performed. 1. Inspection of Power Source Voltage Check the voltage of the power source. Single phase 230 volts (60Hz) Check the operation and condition of the fuse or circuit breaker in the power source. 2. Inspection of Air Filters Remove the air filters and check the element. If the element is dirty, wash it as described in the OPERATION MANUAL supplied with the unit. 3.
TROUBLESHOOTING AND REPAIR 5. Pump Maintenance WARNING: When performing any maintenance and/or troubleshooting, make sure that all electrical power is off. This means before service, unplug the unit from the electrical outlet or if permanently wired, make sure the circuit breaker is in the off position. 1) Remove any dirt or debris which may collect in the bottom of the reservoir tank.
TROUBLESHOOTING AND REPAIR 6. Hose Installation Note: The OP60 is equipped with a 20 foot (6 m) hose. DRAIN OUTLET SPOUT Feed the 20 foot (6m) hose through the grommet on the right side of the unit and connect to the drain outlet spout. GROMMET Note: Do not use more than 18 feet (5.5 m) of drain hose vertically. This is the maximum head (lift) of the Condensate Pump. DRAIN HOSE When securing the drain hose to the highest vertical position (no more than 18 feet (5.
TROUBLESHOOTING AND REPAIR 7.
TROUBLESHOOTING AND REPAIR In case of trouble, perform the following inspection before disassembly. 8. Inspection of Plate Fins To inspect the plate fins of either the evaporator or condenser you must remove the air filters. After removal of the air filters, inspect the plate fins for any dirt, dust, lint, or debris that may have caused poor cooling performance of the unit. If cleaning of the fins is necessary, it is recommended that this service be performed by a qualified service technician.
TROUBLESHOOTING AND REPAIR 11.
TROUBLESHOOTING AND REPAIR A. Remove drain tank (if equipped). Removal of Drain Tank (if equipped) B. Remove twelve (12) screws from upper front panel. 4 3 3 2 Removal of Upper Front Panel Screws C. Slide upper front panel forward and remove.
TROUBLESHOOTING AND REPAIR D. Louver can be removed from upper front panel by unsnapping the lock tab and removing the louver from its pivots. Removal of Air Outlet Louver E. Remove thirteen (13) screws from left rear panel. Then remove four (4) screws from the service panel. 2 4 4 4 3 Removal of Service Panel and rear panel F. 8 Removal of upper rear panel 28 Remove eight (8) screws from right upper rear panel.
TROUBLESHOOTING AND REPAIR G. Remove fourteen (14) screws from right front panel. 10 4 Removal of right front panel H. Remove fourteen (14) screws from upper panel. 8 3 3 Removal of upper panel screws I. Remove nine (9) screws from rear panel.
TROUBLESHOOTING AND REPAIR J. Remove twelve (12) screws from left front panel. 12 Removal of left front panel 12.
TROUBLESHOOTING AND REPAIR TEMPERATURE SCALE DISPLAY SWITCH ˚C ˚F DIP SWITCH 31 C C2 J9 F C1 K1 D1 FAN MODE CONTROL SWITCH STOP OPERATE C3 K2 D2 C4 2 PIN CONNECTOR OF CONDENSATE PUMP J10 K3 D3 C5 R2 R3 FT1 D4 D7 K4 Q1 TO COMPRESSOR (DRIVER RELAY) T1 TO COMPRESSOR RELAY VR6 R1 J4 J8 J3 J7 J2 J6 J1 J5 F1 2/10A 250V NEUTRAL WIRE FOR UNIT POWER (TO BOARD) !" # # # $ % &'
TROUBLESHOOTING AND REPAIR 13. Removal of Blower Assembly SET SCREW CONTROL PANEL STAY CONDENSER HOUSING BOX EVAPORATOR FAN CASING EVAPORATOR FAN MOTOR RING SUB-ASSEMBLY SET SCREW EVAPORATOR FAN MOTOR RING SUB-ASSEMBLY CONDENSER FAN MOTOR CONDENSER FAN MIDDLE FRAME SUB-ASSEMBLY CONDENSER FAN HOUSING Disassembly of Blower 14. Removal of Condenser Fan Motor A. Loosen the set screw using a 5/16” open ended wrench.
TROUBLESHOOTING AND REPAIR B. Remove the six (6) nuts on the inside of the housing in the locations shown. 3 3 Removal of Blower Housing C. Remove motor wires from the three (3) motor wiring ties. 3 Removal of Fan Motor Assembly D. Lift fan motor up then pull rear motor forward and remove. Centrifical fan will drop into condenser fan housing. Removal of Fan Motor (Condenser) Removal of Condenser Fan A. Rest the fan motor backwards and place on mounting bracket. Secure motor with two (2) nuts.
TROUBLESHOOTING AND REPAIR B. Remove the ring sub-assembly by removing the six (6) screws. 3 3 Removal of Ring Sub-Assy C. Loosen the four (4) nuts securing the fan casing. Lift the enclosure off its mounting. Slide the condenser fan out through opening. 2 2 Removal of Fan Casing Nuts Removal of Evaporator Fan Motor A. Loosen the set screw using a 5/16” open ended wrench. SET SCREW Loosening of Set Screw B. Remove four (4) nuts from housing while holding fan securely with one hand.
TROUBLESHOOTING AND REPAIR C. Pull evaporator motor forward and remove. Removal of Fan Motor (Evaporator) Removal of Control Board A. Remove two (2) screws from the control panel stay. 2 Removal of Control Panel Screws B. Remove three (3) screws from the control panel stay. 3 Removal of Control Panel Screws C. Slowly slide control panel assembly out of box.
TROUBLESHOOTING AND REPAIR D. Disconnect the following connectors from the control board: (A) Wire Harness, Relay Board to Control Board J201 (10-pin) A B C (B) Room Thermistor J101 (2-pin) (C) Freeze Thermistor J102 (2-pin with black tape) (D) Drain Tank Switch J103 (2-pin) (E) High Pressure Switch Sub-Harness NOTE: Mark each of the 2-pin connectors with a different color marker to ensure the correct orientation when they are re-connected. Removal of Connectors from Control Panel E.
TROUBLESHOOTING AND REPAIR 17. Inspection of Condenser Fan Motor Measure resistance across the terminals of the fan motor. CONDENSER FAN MOTOR Terminals (at 77˚F (25˚C)) J6-CF12 Approx. 21.2Ω J5-CF11 Approx. 32.4Ω J5-J6 Approx. 0.592Ω If the measured resistance does not approximately equal these standard values ±10%, replace the fan motor. GROUND (GREEN/YELLOW) J5 (RED) CF12 (BROWN) CF11 (ORANGE) J6 (BLACK) Inspection of Condenser Fan Motor 18.
TROUBLESHOOTING AND REPAIR 20. Inspection of Wiring Connection Refer to the Wiring Diagrams on page 46 and check for connection of each wire. 21. Inspection of Thermistor Using an Ohmeter, check the resistance value across the 2-pin connector. At normal temperature (77˚F (25˚C)) either thermistor (room or freeze) should measure approximately 10,000 or 10K ohms. 22.
TROUBLESHOOTING AND REPAIR • In general, the strength of brazing filler metal is lower than that of the base metal. So, the shape and clearance of the brazed fitting are quite important. As for the shape of the brazed fitting, it is necessary to maximize its adhesive area. The clearance of the brazed fitting must be minimized to facilitate brazing filler metal to flow into it by capillary action. CLEARANCE 0.025 ~ 0.
TROUBLESHOOTING AND REPAIR B. Removal of Refrigeration Cycle Components CAUTION 1. Before any refrigeration cycle component can be replaced, it is necessary to recover the refrigerant using standard recovery procedures and equipment. 2. To prevent oxidation, dry nitrogen should be conducted (flow rate 1l/min) through the pinch-off tube during any brazing operation. 3. During any component replacement involving brazing, shield nearby parts with a steel plate, asbestos, etc.
TROUBLESHOOTING AND REPAIR 24. Charging the System with R-22 Refrigerant Always ensure that the refrigerant system has been properly evacuated before charging with the specified amount of R-22. WARNING When handling refrigerant (R-22), the following precautions should always be observed: • Always wear proper eye protection while handling refrigerant. • Maintain the temperature of the refrigerant container below 40˚C (104˚F). • Perform repairs in a properly ventilated area.
TROUBLESHOOTING AND REPAIR NOTE: Connect the hoses using care not to mistake the high pressure side for the low pressure side and vice versa. LOW PRESSURE VALVE (CLOSED) (3) Connect the charging hoses (red - high pressure side, blue - low pressure side) of the gauge manifold to the process tube fittings. HIGH PRESSURE VALVE (CLOSED) RED HOSE GREEN HOSE PROCESS TUBE FITTING HIGH PRESSURE SIDE TUBE (4) Connect the charging hose (green) at the center of the gauge manifold to the vacuum pump.
TROUBLESHOOTING AND REPAIR D. Checking Gas Leak VALVE SETTING LO (1) Remove the charging hose (green) from the vacuum pump, and connect the hose to the refrigerant cylinder (R-22). HI AIR PURGING BLUE OPEN THE VALVE OF REFRIGERANT CYLINDER CHARGING HOSE (GREEN) RED REFRIGERANT CYLINDER R-22 CLOSED CLOSED TO PROCESS TUBE FITTING Checking Gas leak (2) Loosen the nut on the gauge manifold side of the charging hose (green).
TROUBLESHOOTING AND REPAIR 25. Refrigerant Charging Work VALVE SETTING A. Refrigerant Charging LO (1) Remove the charging hose (green) from the vacuum pump, and connect it to the refrigerant cylinder (R-22). HI AIR PURGING (2) Loosen the nut on the gauge manifold side of the charging hose (green). Open the valve of the charging hose (green). Open the valve of the refrigerant cylinder.
TROUBLESHOOTING AND REPAIR Reassemble the unit in the reverse order of removal. Described below are the parts that require special care in reassembling the unit. Perform all wiring or rewiring as referenced in the wiring diagram. 26. Compressor Mounting Mount the compressor on the frame, using cushions, steel collars, spring washers, plate washers and nuts. COMPRESSOR NUT SPRING WASHER PLATE WASHER CUSHION STEEL COLLAR Compresor Mounting 27. Blower Assembly a. Install blower fan (for evaporator).
G G T1 T AP AP TB CB RB MF1 MF2 MC CF1 CF2 CC IOLF R R1 Wiring Diagram 46 C MCC CF2 CF1 CC IOLF G LO LO MF2 HI IOLF MF1 HI IOLC MC Attachment Plug Terminal Block Control Board Relay Board Condenser Fan Motor Evaporator Fan Motor Compressor Motor Capacitor for Condenser Fan Motor Capacitor for Evaporator Fan Motor Capacitor for Compressor Inner Overlaod Relay of Fan Motor TB 230V 1 PHASE 60Hz G IOLC DS THS RTH G HPRS MCC MDP FDS ODS J10 G MDP FDS ODS J10 RB G 10 DS HPRS
DENSO SALES CALIFORNIA, INC. TECHNICAL SERVICE DEPARTMENT First Issue: January 2002 DSCA P/N: LA990009-0842 Printed in U.S.A.
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