SERVICE MANUAL OFFICE PRO 24 DENSO SALES CALIFORNIA, INC. REGISTERED TO ISO 9002 FILE NO.
© 2000 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 OFFICE PRO 24
FOREWORD This manual has been published to service the MovinCool Office Pro 24. Please use this service manual only when servicing the Office Pro 24. 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 EXHAUST AIR DUCT COOL AIR VENT CENTRIFUGAL FAN EVAPORATOR CONDENSER CAPILLARY TUBES DRAIN TANK COMPRESSOR CONTROL BOX DRAIN SWITCH Figure 2-1: Construction of Office Pro 24 3
CONSTRUCTION, SPECIFICATIONS, and DATA EVAPORATOR FAN CONTROL PANEL TOP PANEL EXHAUST AIR VENT RIGHT HANDLE COOL AIR VENT SIDE PANEL FAN MOTOR FRONT PANEL CONDENSER FAN CAPILLARY TUBE EVAPORATOR COMPRESSOR ACCUMULATOR DRAIN TANK CONDENSER CASTER POWER CORD Figure 2-2: 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 ar e enclosed in one unit. The interior is divided into thr ee sections. The upper fr ont face is equipped with the evaporator , while the lower fr ont face contains the drain tank. The r ear section contains the condenser , the compr essor and the contr ol box. 2.
CONSTRUCTION, SPECIFICATIONS, and DATA Rating Conditions dry bulb ......................................................................95º F (35º C) wet bulb .....................................................................83º F (28.2º C) humidity .....................................................................(60%) Specifications power frequency ........................................................ 60Hz line voltage ................................................................
2.40 21.20 CONSTRUCTION, SPECIFICATIONS, and DATA 18.50 3.80 11.30 43.90 7.50 ø11.575 12.40 4.60 16.50 20.67 27.40 19.30 Figure 2-4: Exterior Dimensions (units: inches) 7 2.
DATA @ 115V @ 115V 3.6 (14.3) 14 (25.2) Temperature ˚C (˚F) Cooling Capability (x103 kcal/h (BTU/h)) 3.2 (12.7) 2.8 (11.1) 12 (21.6) 10 (18.0) 8 (14.4) 2.4 (9.5) 6 (10.8) 40 50 60 70 Relative Humidity of Inlet Air (%) 2.0 (7.9) Cool Air Temperature Difference Curve 30 (86) 25 (77) @ 115V 1.6 20 (68) 10 (50) 15 (59) 20 (68) 1.4 25 (77) Power Consumption (kW) 15 (59) Wet Bulb Temperature ˚C (˚F) Cooling Capability Curve 1.2 1.0 0.
REFRIGERANT SYSTEM 1. The component par ts of the refrigerant system include the following: • Compr essor • Evaporator • Condenser • Accumulator • Capillary tube These par ts ar e all connected by copper tubing. All the connections have been brazed.
REFRIGERANT SYSTEM 2. Compressor The compr essor used for the unit is her metically sealed. The compr essor and the compr essor motor ar e in one casing. A. Compr essor Constr uction The constr uction of a r otar y type compr essor is divided into two mechanisms. The drive mechanism (compr essor motor) and the compr ession mechanism (compr essor). When the r otor shaft of the motor (drive mechanism) tur ns, the r oller of the compr essor (compr ession mechanism) r otates to compr ess the r efrigerant. B.
REFRIGERANT SYSTEM 4. Capillary Tubes The capillar y tubes ar e a long thin tubes utilizing line flow r esistance to ser ve as an expansion valve. The length and the inner diameter of the capillar y tubes ar e deter mined by the capacity of the r efrigeration system, specified operating conditions, and the amount of r efrigerant. High Temp. / High Press.
REFRIGERANT SYSTEM EVAPORATOR INLET PIPE CONDENSER OUTLET PIPE EVAPORATOR OUTLET PIPE ASSY COMPRESSOR SUCTION PIPE (Insulated) COMPRESSOR DISCHARGE PIPE CAPILLARY TUBE CONDENSER INLET PIPE HIGH PRESSURE SWITCH PIPE (Condenser to Capillary Tube) CONNECTING PIPE (Evaporator to Compressor) Figure 3-5: Refrigerant System Piping 12
ELECTRICAL SYSTEM AP RTH THS DS 3 G T R HPRS 1 CC 1 2 2 TB MC IOLC G G CF 1 2 L0 MF HI J4 IOLF J101 J102 J103 J104 J8 (AUX1) J5 G J6 J9 J201 J2 J1 J3 AP TB CB RB MF MC CF CC RB Attachment Plug Terminal Block Control Board Relay Board Fan Motor Compressor Motor Capacitor for Fan Capacitor for Compressor IOLC IOLF HPRS DS THS RTH G J8 (AUX1) CB Internal Overload Protector of Compressor Internal Overload Protector of Fan Motor High Pressure Switch Full Drain Warning Switch Freeze Pr
ELECTRICAL SYSTEM 1. Basic Operation of Of fice Pro 24 Electrical Cir cuit Ther e ar e two basic components used to contr ol the operation of the Classic Plus 26 Electrical System: • Contr ol Panel Assembly • Contr ol Box The Contr ol Panel Assembly contains the Contr ol Panel, Contr ol Boar d (with inputs for the fr eeze and room temperatur e ther mistors), drain switch, and a micr oprocessor . A.
ELECTRICAL SYSTEM 2. Control Box A. Capacitors The capacitors ar e used to temporarily boost the power output available to the fan motor and the compr essor at star t-up. Relay Board The specifications of each capacitor ar listed below: Relay Board Fuse DIP Switch Terminal Block e CAPACITOR APPLICA TION VOLTAGE RATING CAPACITANCE (µf) Fan Motor Compr essor 440 440 12.5 50 B. Relay Boar d The Relay Boar d receives signals and outputs from the contr ol boar d that contains a micr oprocessor .
ELECTRICAL SYSTEM 3. Fan Motor The fan motor is a single phase, induction type two-speed motor . The motor r otates fans on the evaporator side and the condenser side at the same time. Specifications: Rated V oltage: 230 volts 60 Hz Rated Output: 480 watts 410 watts 4. Compressor Motor The compr essor motor is a single phase motor is contained within the same housing as the compr essor. Specifications: .
ELECTRICAL SYSTEM 6. Drain Switch The Of fice Pr o 24 is equipped with a drain tank switch. When the drain tank accumulates appr oximately 4.0 gallons (15 liters) of condensate (water) in the drain tank, the drain tank switch sends a signal to the micr oprocessor . The micr oprocessor stops all operation of the unit and flashes the “T ank Full” LED. This system utilizes a .1 AMP , 250 VAC micr o-switch for this function. When drain water accumulates approximately 4.
ELECTRICAL SYSTEM 10. Compressor Protection Ther e is a T ime Delay pr ogram within the micr oprocessor . This pr events a heavy load fr om being applied on the Compr essor Motor when r estar ting the unit (Cool Mode) after a ver y shor t period of time. This “delay” is in ef fect any time when the compr essor is tur ned on by either the “Cool On/Of f” button, temperatur e set point (ther mostatic contr ol), power inter ruption r estar t or Condensate Pump (optional) operation.
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 In case of trouble, perform the following inspection before disassembly. 5. 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 8. Disassembly Control Panel Top Front Panel Right Handle Upper Rear Panel Right Panel Air Outlet Grille Left Handle Filter Element Front Panel Filter Assy Side Panel Filter Door Filter Element Room Thermistor Left Panel Blower Housing (evap.
TROUBLESHOOTING AND REPAIR A. Remove drain tank. Figure 5-5: Removal of Drain Tank B. Remove four (4) screws from upper front panel. Figure 5-6: 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 tap and removing the louver from its pivots. PIVOTS TABS Figure 5-8: Removal of Air Outlet Louver E. Remove four (4) screws from service panel. 4 Figure 5-9: Removal of Service Panel F. DISCONNECT DISCONNECT DISCONNECT Figure 5-10: Removal of Power Cord Screws 23 Disconnect the three (3) lead wires of the power cord.
TROUBLESHOOTING AND REPAIR G. Remove thirteen (13) screws from rear panel. " H. Remove ten (10) screws (eight shown) from upper rear panel and two (2) screws on top. ! ! ! Figure 5-11: Removal of Back and Upper Rear panel Screws 9.
TROUBLESHOOTING AND REPAIR ! $ !'2 - + $ . ! !#! -1!) % ". ! !$% ! !" # $ # # % & '( + ! '#! !, -!%# ! . ! " # &$% / # + /+ Figure 5-13: Connections to Relay Board ! " & ! " #! ! # ! ! " 0 !& " - !# & ".
TROUBLESHOOTING AND REPAIR 10.
TROUBLESHOOTING AND REPAIR A. Remove the ring sub-assy Figure 5-16: Removal of Ring Sub-Assy B. Loosen the set screw using an allen wrench and then remove the centrifugal fan. Figure 5-17: Removal of Centrifugal Fan C. Remove the two (2) nuts “A” on the inside of the housing in the locations shown. Then remove the blower housing (condenser). A - NUT Figure 5-18: Removal of Blower Housing D. Remove the two (2) nuts “A” and two (2) screws “B” as shown.
TROUBLESHOOTING AND REPAIR E. Remove the centrifugal fan by loosening the set screw on the shaft. Remove the fan motor by loosening nuts “A”. Figure 5-20: Removal of Fan Motor F. Remove seven (7) screws from left side panel. ! ! Figure 5-21: Removal of Screws for Left Side Panel ! G. Remove seven (7) screws from right side panel. ! Figure 5-22: Removal of Screws for Right Side Panel H.
TROUBLESHOOTING AND REPAIR I. Remove two (2) screws from the control panel stay. Figure 5-24: Removal of Control Panel J. Remove two (2) screws from the control panel stay. Figure 5-25: Removal of Control Panel (A) K.
TROUBLESHOOTING AND REPAIR board on the control panel assembly. Remove the control board. 11. Inspection of Capacitor (for Fan Motor and Compressor) Ohmeter Method – Set the ohmeter to the 100KΩ range. Place the two probes against the two terminals of the capacitor. At first, the ohmeter should indicate 0Ω, then the reading should gradually increase towards infinity (∞). This indicates that the capacitor is charging.
TROUBLESHOOTING AND REPAIR 15. Inspection of Compressor Motor Measure resistance across the terminals of the compressor motor. Terminals (at 77˚F (25˚C)) R-C Approx. 2.0Ω C-S Approx. 2.2Ω S-R Approx. 3.8Ω If the measured resistance is not equal to these standard values, replace the compressor. Figure 5-31: Inspection Of Compressor 16. Inspection of Wiring Connection Refer to the Wiring Diagrams on page 39 and check for connection of each wire. 17.
TROUBLESHOOTING AND REPAIR 19. Repair of Refrigerant System In case there is a leak, obstruction, or trouble in the refrigerant system of the Spot Cooling System, replace or repair the part in question. After replacing any component all connections must be brazed. A. Proper Brazing Techniques It is desirable to use a slightly reducing flame. Oxyacetylene is commonly used since it is easy to judge and adjust the condition of the flame. Unlike gas welding, a secondary flame is used for brazing.
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 20. 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 (3) Connect the charging hoses (red - high pressure side, blue - low pressure side) of the gauge manifold to the process tube fittings. NOTE: Connect the hoses using care not to mistake the high pressure side for the low pressure side and vice versa. (4) Connect the charging hose (green) at the center of the gauge manifold to the vacuum pump. Figure 5-37: Hose Connection B. Evacuation (1) Open the high pressure valve (HI) and the low pressure valve (LO) of the gauge manifold.
TROUBLESHOOTING AND REPAIR D. Checking Gas Leak (1) Remove the charging hose (green) from the vacuum pump, and connect the hose to the refrigerant cylinder (R22). Figure 5-40: Checking Gas leak (2) Loosen the nut on the gauge manifold side of the charging hose (green). (3) Open the high pressure valve of the gauge manifold. Charge the system with refrigerant until the low pressure gauge indicates 57 PSIG. (4 kg/cm2G.) After charging is complete, close the high pressure valve.
TROUBLESHOOTING AND REPAIR 21. Refrigerant Charging Work A. Refrigerant Charging (1) Remove the charging hose (green) from the vacuum pump, and connect it to the refrigerant cylinder (R-22). (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 B. Removal of Gauge Manifold (1) Crimp the pinch-off tube with a pinch-off tool. (2) Remove the gauge manifold and the process tube fitting. Crush the end of the pinch-off tube. (3) Braze the end of the pinch-off tube. (4) Ensure that a gas leak is not present at the pinched off portion and the brazed end. Figure 5-45: Removal of Gauge Manifold Reassemble the unit in the reverse order of removal. Described below are the parts that require special care in reassembling the unit.
G G T R AP TB 1 2 AP TB CB RB MF MC CF CC CF Figure 5-48: Wiring Diagram 39 G HI Attachment Plug Terminal Block Control Board Relay Board Fan Motor Compressor Motor Capacitor for Fan Capacitor for Compressor IOLF MF L0 1 CC 2 J3 J1 J2 J6 J5 J4 IOLC MC IOLC IOLF HPRS DS THS RTH G J8 (AUX1) RB J8 (AUX1) G J9 THS 2 DS 1 HPRS J201 CB J101 J102 J103 J104 3 Internal Overload Protector of Compressor Internal Overload Protector of Fan Motor High Pressure Switch Full Drain Warnin
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DENSO SALES CALIFORNIA, INC. TECHNICAL SERVICE DEPARTMENT Second Issue: June 2000 DSCA P/N: LA990009-0531 Printed in U.S.A.
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