SERVICE MANUAL OFFICE PRO 36 SERIAL NUMBER FROM DECEMBER 2004 (1204) TO MARCH 2007 (0307)
© 2008 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 registered trademark of DENSO Corporation.
Table of Contents Table of Contents Operation Section 1. PRECAUTIONS FOR SAFETY 1.1 Foreword .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.2 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 1.3 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 6.4 Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .22 6.5 Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23 6.6 Power Cord with LCDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23 6.7 Drain Switch . . . . . . . . .
Table of Contents Repair Section 7. TROUBLESHOOTING 7.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 7.2 Self-Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 7.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29, 30, 31, 32, 33, 34 7.4 Basic Inspection .
Operation Section 6 1. PRECAUTIONS FOR SAFETY 1.1 Foreword UÊ/ ÃÊ>Õ>Ê >ÃÊLiiÊ«ÕLà i`ÊÌÊÃiÀÛViÊÌ iÊ Û Ê"vwViÊ*ÀÊÎÈ°Ê*i>ÃiÊÕÃiÊÌ ÃÊÃiÀÛVi manual only when servicing the Office Pro 36. 1.2 Definition of Terms WARNING Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation.
Operation Section 7 2. GENERAL DESCRIPTION 2.1 Spot Cooler Ê Ê Ê Ê Ê UÊ Ê}iiÀ>]ÊVÛiÌ>Ê>ÀÊV`ÌiÀÃÊV 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.
Operation Section 8 3. CONSTRUCTION %XTERIOR $IMENSIONS (51.7) (6.6) (24.2) (42.1) (18.7) (DIA. 15.7) (2.9) (30.2) (42.1) (2.8) (3.8) (2.8) (3.8) (29.8) (9.2) (27.1) (40.0) (3.
Operation Section 9 %XTERIOR #OMPONENTS Operation Panel Cold Air Outlet Grill Evaporator Air Inlet Grill Condenser Air Outlet Duct Office Pro 60 Drain Tanks Caster Condenser Air Inlet Panel Power Cord Service Panel I002270C
Operation Section 10 3.3 Internal Structure Fan Motor (Evaporator) Fan (Condenser) Fan Motor (Condenser) (Behind Fan) Fan (Evaporator) Evaporator High Pressure Switch Capillary Tube Drain Pan Condensate Pump (Optional) Compressor Condenser Drain Switch Control Box I002271 3.4 Basic Construction Ê Ê Ê Ê Ê Ê UÊÊ / iÊ Û Ê "vwViÊ *ÀÊ ÎÈÊ ÃÊ V«>VÌÊ Ê VÃÌÀÕVÌÊ LiV>ÕÃiÊ Ì iÊ V`iÃiÀÊ >`Ê Ì i evaporator are enclosed in one unit. The interior is divided into three sections.
Operation Section 11 3.5 Air Flow Ê Ê Ê UÊÊ ÀÊ `À>ÜÊ vÀÊ Ì iÊ À} ÌÊ Ã`iÊ v>ViÊ «>ÃÃiÃÊ Ì ÀÕ} Ê Ì iÊ V`iÃiÀÊ Ü V Ê iÝÌÀ>VÌÃÊ Ì iÊ i>Ì°Ê / Ã hot air is blown out through the upper exhaust air duct. Air taken in from the front face is cooled by the evaporator and then blown through the cool air vent. All the air inlets are equipped with filters, and the exhaust air duct is protected by metal grill. Exhaust Air Out Cool Air Out Condenser Air In Evaporator Air In I001762C 3.
Operation Section 12 4. SPECIFICATIONS 4.1 Technical Specifications ITEM Electronic Features SPECIFICATIONS Control Panel Electronic Thermostat Control Electronic Cooling Capacity*1 Capacity-208 V/230 V Refrigerant Circuit Compressor Compression Type Motor Rated Output at 230 V Condenser Plate Fin Ventilation Equipment For Fan Type Evaporator Max. Air Flow-high/low Motor Rated Output-high/low at 230 V Max. External Static Pressure Ventilation Equipment For Fan Type Condenser Max.
Operation Section 13 Operating Condition Sound Level*2 ITEM SPECIFICATIONS Inlet air: Maximum 95 °F (35 °C), 60 %RH Inlet air: Minimum 65 °F (18.3 °C), 50 %RH With Condenser Duct-high/low 65/62 dB (A) Without Condenser Duct-high/low 67/66 dB (A) Max. Duct Equivalent Length-Per Cold Duct Hose/Hot Duct Hose Condensate Tank Capacity Ê Ê UÊ-«iVwV>ÌÃÊ>ÀiÊÃÕLiVÌÊÌÊV >}iÊÜÌ ÕÌÊÌVi° < NOTE > *1 :Rating Condition: 95 °F (35 °C), 60 %RH *2 :Measured at 3 ft (1.0 m) from surface of unit.
Operation Section 14 4.2 Characteristics ( at 230V ) 45 40 21.6(12) 35 19.8(11) 30 18.0(10) Delta-T °F (°C) Cooling Capacity (x103 Btu/h) 23.4(13) 25 20 Dry Bulb Temp. °F (°C) 95(35) 16.2(9) 14.4(8) 12.6(7) 10.8(6) 86(30) 9.0(5) 77(25) 7.2(4) 68(20) 30 50 (10) 59 68 (15) (20) Wet Bulb Temp. °F (°C) 70 80 25 Current Consumption (A) 4.0 3.0 2.0 20 15 10 1.
Operationl Section 14A 4.3 Characteristics (at 208 V) 45 23.4(13) 40 21.6(12) 35 19.8(11) 30 18.0(10) Delta-T °F ( °C) Cooling Capacity (x103 Btu/h) 25 20 Dry Bulb Temp. °F (°C) 95(35) 16.2(9) 14.4(8) 12.6(7) 86(30) 10.8(6) 77(25) 9.0(5) 68(20) 7.2(4) 30 50 (10) 70 80 Current Consumption (A) 25 4.0 3.0 2.0 20 15 10 1.
Operation Section 15 5. REFRIGERANT SYSTEM 2EFRIGERANT 3YSTEM #ONSTRUCTION 4HE COMPONENT PARTS OF THE REFRIGERANT SYSTEM INCLUDE THE FOLLOWING Ê Ê Ê Ê Ê UÊ «ÀiÃÃÀ]Ê Û>«À>ÌÀ]Ê `iÃiÀ]Ê >«>ÀÞÊÌÕLi]Ê } Ê*ÀiÃÃÕÀiÊ-ÜÌV These parts are all connected by copper tubing. All the connections have been brazed.
Operation Section 16 5.2 Compressor Ê ÊÊ Ê Ê UÊÊ / iÊV«ÀiÃÃÀÊÕÃi`ÊvÀÊÌ iÊÕÌÊÃÊ iÀiÌV>ÞÊÃi>i`°Ê/ iÊV«ÀiÃÃÀÊ>`ÊÌ iÊV«ÀiÃÃÀ motor are in one casing. #OMPRESSOR THEORY OF OPERATION UÊÊ / iÊÃVÀÊV«ÀiÃÃÀÊÕÌâiÃÊ>ÊÛÕÌi`ÊëÀ>ÊÜ V ]ÊÜ iÊ>ÌV i`ÊÜÌ Ê>Ê>Ì}ÊÃVÀÊvÀ] generates a series of crescent-shaped gas pockets between the two members.
Operation Section 17 5.3 Condenser ÊÊ Ê Ê UÊ/ iÊV`iÃiÀÊÃÊ>Ê i>ÌÊiÝV >}iÀÊÜÌ ÊV««iÀÊÌÕLiÃÊÌ >ÌÊ>ÀiÊVÛiÀi`ÊÜÌ ÊÌ Ê>ÕÕ projections called plate fins. Ê ÊÊ Ê Ê UÊ i>ÌÊÃÊ}ÛiÊvvÊ>`Ê>LÃÀLi`ÊLÞÊ>ÀÊLi}Ê«Õi`Ê>VÀÃÃÊÌ iÊV`iÃiÀÊwÃÊLÞÊÌ iÊViÌÀvÕ}> fan and then expelled through the exhaust air duct. #APILLARY 4UBE Ê ÊÊ Ê Ê UÊ / iÊ V>«>ÀÞÊ ÌÕLiÊ ÃÊ >Ê }Ê Ì Ê ÌÕLiÊ ÕÌâ} line flow resistance to serve as an expansion High Temp.
Operation Section 18 6.
Operation Section 19 "ASIC /PERATION OF 4HE /FlCE 0RO %LECTRICAL #IRCUIT ÊÊ Ê Ê Ê UÊ / iÀiÊ>ÀiÊÌÜÊL>ÃVÊV«iÌÃÊÕÃi`ÊÌÊVÌÀÊÌ iÊ«iÀ>ÌÊvÊÌ iÊ"vwViÊ*ÀÊÎÈÊiiVÌÀV> system: - Control panel assembly - Control box Ê ÊÊ Ê Ê Ê UÊÊÊ/ iÊVÌÀÊ«>iÊ>ÃÃiLÞÊVÌ>ÃÊÌ iÊVÌÀÊ«>i]ÊVÌÀÊL>À`ÊÜÌ Ê«ÕÌÃÊvÀÊÌ iÊvÀiiâi and room temperature thermistors), drain switch, high pressure switch and a microprocessor (1) Fan mode (IGH &AN -ODE When the “High” Fan Mode button on the control
Operation Section 20 (1) Capacitors The capacitors are used to temporarily boost the power output available to the fan motor and the compressor at start-up. The specifications of each capacitor are listed below: Capacitor Application Voltage Rating Capacitance Evaporator Fan Motor 440 VAC 5.0 μF Condenser Fan Motor 440 VAC 15.0 μF Compressor 370 VAC 50.
Operation Section 21 2ELAY BOARD UÊ / iÊ Ài>ÞÊ L>À`Ê ÀiViÛiÃÊ Ã}>ÃÊ >`Ê ÕÌ«ÕÌÃ from the control board that contains a Dip Switch microprocessor. The relay board contains the compressor, fan on and fan mode (speed) relays. Ê ÊÊ Ê UÊ ÌÊ >ÃÊ VÌ>ÃÊ >Ê ÃÌi«`ÜÊ ÌÀ>ÃvÀiÀÊ Ì >Ì converts the line voltage (208/230 VAC) to 12 V.
Operation Section 22 6.4 Fan Motor &OR EVAPORATOR UÊ/ iÊv>ÊÌÀÊÃÊ>ÊÃ}iÊ« >Ãi]Ê`ÕVÌÊÌÞ«i Evaporator Fan Motor two-speed motor. 3PECIlCATIONS - Rated Voltage: 230 V, 60 Hz - Rated Output: High 210 W, Low 129 W Ground (Green/Yellow) J7 Low (Red) CF22 (Brown/White) CF21 (White) J8 High (Black) I001774 (2) For condenser UÊ/ iÊv>ÊÌÀÊÃÊ>ÊÃ}iÊ« >Ãi]Ê`ÕVÌÊÌÞ«i Condenser Fan Motor two-speed motor.
Operation Section 23 6.5 Compressor Motor &OR EVAPORATOR UÊ/ iÊV«ÀiÃÃÀÊÌÀÊÃÊ>ÊÃ}i« >ÃiÊÌÀÊ>`ÊÃÊVÌ>i`ÊÜÌ ÊÌ iÊÃ>iÊ ÕÃ}Ê>ÃÊÌ i compressor. 3PECIlCATIONS - Rated Voltage: 230 V, 60 Hz - Rated Output : 2200 W < NOTE > When the compressor shuts off, the compressor motor may run backward for a moment or two until internal pressures is equalized.
Operation Section 24 $RAIN 3WITCH &OR EVAPORATOR UÊ/ iÊ"vwViÊ*ÀÊÎÈÊÃÊiµÕ««i`ÊÜÌ Ê>Ê`À>ÊÌ>ÊÃÜÌV °Ê7 iÊÌ iÊ`À>ÊÌ>ÃÊ>VVÕÕ>Ìi approximately 8.0 gal (30 L) of condensate (water) in the drain tanks, the drain tank switch sends a signal to the microprocessor. The microprocessor stops all operation of the unit, flashes the “TANK FULL” LED, indicates “TANK FL” on the LCD and closes the contact of output signal.
Operation Section 25 (OW TO RE START THE UNIT UÊÊ vÊ Ì iÊ Ê `V>ÌiÃÊ º*," , Ê " »]Ê «ÀiÃÃÊ Ì iÊ "" Ê " É" Ê LÕÌÌÊ ÌÊ VÌÕiÊ ÀÕ}Ê Ì i program. If the LCD indicates “PROGRAM ON” continuously (program activated), no further steps are necessary. If no program exists or the program was deactivated, press the FAN MODE button or the COOL ON/OFF button. The unit returns to the previous temperature set point. 6.
Operation Section 26 &AN -ODE #ONTROL 3WITCH Ê ÊÊ Ê ÊÊÊ Ê UÊ / iÊ v>Ê ÌÀÊ «iÀ>ÌÊ ÃÊ VÌÀi`Ê LÞÊ Ài>ÞÃÊ Ê Ì iÊ Ài>ÞÊ L>À`Ê Ì ÀÕ} Ê >Ê VÀ«ÀViÃÃÀÊ the control panel assembly. The fan program in the microprocessor can be changed by a DIP switch on the left side of the relay board located in the control box.
Operation Section 27 7.
Repair Section 28 clear method is as follows. LCD Display Description Condition Reset/Remedy Drain tanks are full When the drain tanks are filled with drain water. (“TANK FL” LED flashes) Drain away. Condensate pump problem When (optional) condensate pump is damaged or broken. Fix the condensate pump. Activation of freeze protection Evaporator is freezing. See “Stops after running a while” of Troubleshooting on page 33.
Repair Section 29 4ROUBLESHOOTING #HART UÊ/Ê>VVÕÀ>ÌiÞÊÌÀÕLià ÌÊÌ iÊ«ÀLi]ÊÌÊÃÊ«ÀÌ>ÌÊÌÊV>ÀivÕÞÊVwÀÊÌ iÊ>ÌÕÀiÊvÊÌ i problem. Typical problems are: - Insufficient cooling. - Unit does not start (operate). - Overflow of drain water. - Abnormal noise or vibrations. - Others. )NSUFlCIENT COOLING Ê ÊÊ Ê ÊÊÊ Ê UÊ }ÊÃÞÃÌiÊ«ÀLiÊ}iiÀ>ÞÊÀiÃÕÌÃÊvÀÊiiVÌÀV>ÊÀÊiV >V>ÊV«iÌÃÊÃÕV Ê>ÃÊv> motor, compressor, control switch.
Repair Section 30 Possible Cause Symptom Remedy Checking Area 1. Usage conditions Cause Operation near usage limits. (high temperature). 2. Dirt in condenser or Compressor operates. Air volume place. Insufficient heat exchange. Clean fins. evaporator. 3. Frost in refrigeration cycle. Clogging at the frost section. Replace clogged section. 4. No temperature difference Insufficient refrigerant. Check the leaking part, between evaporator and then repair and charge condenser. refrigerant. 1.
Repair Section 31 (2) Unit does not start (operate) < NOTE > Ê ÊÊ Ê Ê UÊÊ ÊÌ ÃÊV>Ãi]ÊÌ iÀiÊÃÊ>Ê«ÃÃLÌÞÊvÊÃ>viÌÞÊ`iÛViÊ>VÌÛ>Ì}Ê`ÕiÊÌÊÌ iÊV}}i`Ê>ÀÊwÌiÀ°Ê-Ê>i sure to first clean the air filter and then start up again to confirm if the problem lies with the air filter. Ê ÊÊ Ê Ê UÊ iVÊÌ iÊÃÌ>>ÌÊÃÌiÊvÀÊ«iÀ>Ì}ÊÌi«iÀ>ÌÕÀiÊ>`ÊÃÌ>>ÌÊë>ViÊÕLÃÌÀÕVÌi`Ê>ÀyÜ®° Possible Cause Symptom Remedy Checking Area Does not operate at all 1. Voltage. Power failure. Repair power.
Repair Section 32 Possible Cause Symptom Remedy Checking Area 1. Display code “FL”. Cause Drain tanks are filled with Discharge the drain water. the drain water. Improper drain switch Check connection. connection. Defective drain switch. 2. Display code “AS”. Control panel display turns on Replace drain switch. Improper routing of drain Repair drain hose, then reset hose. unit. Control Defective condensate pump. Repair or replace Panel display condensate pump, then reset shows error unit.
Repair Section 33 Possible Cause Symptom Remedy Checking Area Cause 1. Fan on-off relay on the relay board. the relay board. Control immediately panel after display starting normally. Replace relay board. contact. 2. Fan HI/LO change relay on Stops Open circuit or insufficient Open circuit or insufficient Replace relay board. contact. 3. Fan motor insulation Insulation failure on fan resistance. Replace fan motor. motor. 4. Compressor relay. 5. Compressor relay on the relay board.
Repair Section 34 !BNORMAL NOISE OR VIBRATION Ê ÊÊ Ê UÊ/Ê«ÀiÛiÌÊ>LÀ>ÊÃiÊÀÊÛLÀ>Ì]ÊV>ÀivÕÞÊ`iÌiÀiÊÌ iÊÃÕÀViÊvÊÌ iÊ«ÀLiÊ>`ÊVi up with proper countermeasures to solve the problem so that it does not occur again. Possible Cause Symptom Remedy Checking Area 1. Fan. Abnormal noise or vibration. Cause Fan interference. Repair interfering section. Fan deformation. Replace fan. 2. Compressor fixing nuts. Looseness of nuts. Tighten nuts further. 3. Piping. Pipe interference.
Repair Section 35 Measure the diffence in temperature between the inlet of the evaporator and the cool air vent. If the difference is out of the range given in the graphs on page 14 and 14A, proceed with the remedy suggested in the troubleshooting chart on page 27 to 35.
Repair Section 36 8. DISASSEMBLY 8.
Repair Section 37 $ISASSEMBLY 1) Remove drain tanks. I001783 Screws (7) Screws (2) Screws (3) 2) Remove twelve (12) screws from upper front panel. I001924C 3) Slide upper front panel forward and remove. I001925C 4) Louver can be removed from upper front panel by unsnapping the lock tap and removing the louver from its pivots.
Repair Section 38 5) Remove twenty (20) screws from upper panel. Screws (14) Screws (6) I002273 6) Remove thirteen (13) screws from rear panel. Screws (3) I002274 C Screws (10) I002274C 7) Remove ten (10) screws from rear right panel. Screws (6) Screws (3) Screw (1) I002275 8) Remove eight (8) screws from front right panel.
Repair Section 39 9) Remove six (6) screws from service panel and six (6) screws from rear left panel. Screws (6) Screw (1) Screws (5) I002278C 10) Remove eight (8) screws from front left panel.
Repair Section 40 (1) Remove six (6) screws from service panel. (See page 39) (2) Remove electrical parts. - Relay: Remove two (2) screws from control box. - Terminal block: Remove four (4) screws from control box. - Capacitor: Remove two (2) screws from control box.
Repair Section 41 2ELAY BOARD (1) Remove six (6) screws from service panel. (See page 39.) (2) Disconnect ten (10) connectors, and remove five (5) screws from relay board. Temperature Scale Display Switch Dip Switch Fan Mode Control Switch To Control Board (10 pin) To Condensate Pump (2 pin) To Comp. Driver Relay To Evap. Fan Motor (HI) To Comp. Relay To Evap. Fan Motor (LO) To Cond. Fan Motor (HI) To Cond.
Repair Section 42 3) Slowly slide control panel assembly out of box.
Repair Section 43 2EMOVAL OF "LOWER !SSEMBLY Control Panel Stay Control Panel Control Panel Stay Evaporator Fan Casing Condenser Fan Casing Evaporator Fan Evaporator Fan Motor Condenser Fan Motor Condenser Fan Center Panel I001795
Repair Section 44 2EMOVAL OF CONDENSER FAN AND FAN MOTOR 1) Remove four (4) nuts and three (3) screws in the location shown. Then remove fan motor wire. Nuts (4) Screws (3) Fan Motor Wire I002280 2) Loosen the set screw using a hex key. Then remove the fan and fan motor. Set Screw I001797 2EMOVAL OF EVAPORATOR FAN AND FAN MOTOR Set Screw 1) Loosen the set screw using a hex key. Then Ring remove three (3) screws on the ring. Then remove this ring and evaporator fan.
Repair Section 45 8.5 Inspection of Capacitor (for Fan Motor and Compressor) two probes against the two terminals of the capacitor. At first, the ohm-meter should indicate small value, then the reading should gradually increase towards infinity. This indicates that the capacitor is charging. If the reading indicates infinity right away (open) or the ohm-meter fails to move from 0. (shorted), I001808 replace the capacitor.
Repair Section 46 8.7 Inspection of Fan Motor (1) Condenser fan motor Ê ÊÊ Ê ÊÊÊ Ê UÊ i>ÃÕÀiÊÀiÃÃÌ>ViÊ>VÀÃÃÊÌ iÊÌiÀ>ÃÊvÊÌ i fan motor. (All terminals must be disconnected Condenser Fan Motor from the unit.) Ê ÊÊ Ê ÊÊÊ Ê UÊ iÌÜiiÊÌiÀ>ÃÊ>ÌÊÇÇÊc ÊÓxÊc ®® - J6-CF12 Approx. 12.06 ohm - J6-CF11 Approx. 11.81 ohm -J5-J6 Approx. 7.
Repair Section 47 Refer to the Wiring Diagrams on page 18 and check for connection of each wire. Using an Ohm-meter, check the resistance value across the 2-pin connector. At normal. temperature (77 °F (25 °C)) either thermistor (room or freeze) should measure approximately 10K ohm. 8.11 Inspection In most cases, the probable cause for insufficient cooling is a clogged system, leakage or an incorrect amount of refrigerant. In such cases, inspect the system according to the following procedure.
Repair Section 48 9. REFRIGERANT SYSTEM REPAIR 2EPAIR OF 2EFRIGERANT 3YSTEM Ê Ê Ê UÊ Ê V>ÃiÊ Ì iÀiÊ ÃÊ >Ê i>]Ê LÃÌÀÕVÌ]Ê ÀÊ ÌÀÕLiÊ Ê Ì iÊ ÀivÀ}iÀ>ÌÊ ÃÞÃÌiÊ vÊ Ì iÊ "vwViÊ *ÀÊ ÎÈ] replace or repair the part in question. After replacing any component all connections must be brazed. 0ROPER BRAZING TECHNIQUES Ê Ê Ê UÊ ÌÊ ÃÊ `iÃÀ>LiÊ ÌÊ ÕÃiÊ >Ê Ã} ÌÞÊ Ài`ÕV}Ê y>i°Ê "ÝÞ>ViÌÞiiÊ ÃÊ VÞÊ ÕÃi`Ê ÃViÊ ÌÊ ÃÊ i>ÃÞ to judge and adjust the condition of the flame.
Repair Section 49 5SE OF DRY NITROGEN GAS Ê Ê Ê UÊ ÕÀ}Ê LÀ>â}]Ê Ì iÊ Ã`iÊ vÊ Ì iÊ ««iÊ Õ`iÀ}iÃÊ >Ê Ý`>ÌÛiÊ Ài>VÌÊ `ÕiÊ ÌÊ Ì iÊ LÀ>â}Ê y>i° Introduce dry nitrogen gas (0.3 gal (1 L/min); adjust with the flow regulator) through the pinchoff tube of the refrigerant. < NOTE > Take care not to allow dirt, water, oil, etc. to enter into the pipe. (5) Vertical Joint Ê Ê Ê UÊ i>ÌÊ Ì iÊ Ü iÊ LÀ>âi`Ê wÌÌ}Ê ÌÊ >Ê «À«iÀ brazing temperature.
Repair Section 50 2EMOVAL OF 2EFRIGERATION #YCLE #OMPONENTS CAUTION Ê Ê UÊ ivÀiÊ>ÞÊÀivÀ}iÀ>ÌÊVÞViÊV«iÌÊV>ÊLiÊÀi«>Vi`]ÊÌÊÃÊiViÃÃ>ÀÞÊÌÊÀiVÛiÀÊÌ i refrigerant using standard recovery procedures and equipment. Ê Ê UÊ /Ê«ÀiÛiÌÊÝ`>Ì]Ê`ÀÞÊÌÀ}iÊà Õ`ÊLiÊV`ÕVÌi`ÊyÜÊÀ>ÌiÊä°ÎÊ}>Ê£Ê É®ÊÌ ÀÕ} ÊÌ i pinch-off tube during any brazing operation.
Repair Section 51 #HARGING THE 3YSTEM WITH 2 2EFRIGERANT Ê Ê Ê Ê Ê UÊ Ü>ÞÃÊiÃÕÀiÊÌ >ÌÊÌ iÊÀivÀ}iÀ>ÌÊÃÞÃÌiÊ >ÃÊLiiÊ«À«iÀÞÊiÛ>VÕ>Ìi`ÊLivÀiÊV >À}}ÊÜÌ ÊÌ i specified amount of R-22. Ê Ê Ê Ê Ê UÊÊ µÕ«iÌÃÊÃÊÞÊvÀÊ,ÓÓ° WARNING Ê Ê Ê Ê Ê UÊ 7 iÊ >`}ÊÀivÀ}iÀ>ÌÊ,ÓÓ®]ÊÌ iÊvÜ}Ê«ÀiV>ÕÌÃÊà Õ`Ê>Ü>ÞÃÊLiÊLÃiÀÛi`\ - Always wear proper eye protection while handling refrigerant. - Maintain the temperature of the refrigerant container below 104 °F (40 °C).
Repair Section 52 #ONNECTION OF GAUGE MANIFOLD 1) Properly remove the crushed end of the pinch-off Charging Hose Side Refrigerant Cycle Side tube at the high pressure side and the low pressure side of the refrigerant cycle with a pipe cutter. 2) Fit the process tube fitting to the pinch-off tube on both sides.
Repair Section 53 #HECKING VACUUM Valve Setting LO HI Closed Closed Pressure Gauge 1) Leave the high pressure valve and the low Leave valves closed for 5 min or more. Pointer of pressure gauge returning to zero indicates there is a leak. pressure valve of the gauge manifold closed for five minutes or more, and confirm that the gauge pointer does not return to zero.
Repair Section 54 #HECKING GAS LEAK 1) Remove the charging hose (green) from the Valve Setting vacuum pump, and connect the hose to the LO HI Closed Closed Air Purging refrigerant cylinder (R-22). Charging Hose Red (Green) To Process Tube Fitting 2) Loosen the nut on the gauge manifold side of the Refrigerant Cylinder R-22 Open The Valve of Refrigerant Cylinder charging hose (green). 3) Open the valve of the refrigerant cylinder and perform air purging in the charging hose (green).
Repair Section 55 %VACUATION REPEAT 1) Close the valve of the refrigerant cylinder. Then Valve Setting Gauge LO HI Closed Open LO HI Closed Closed 30 inHg (100 kPa) or larger Low Pressure Valve High Pressure Gauge High Pressure Valve remove the refrigerant charging cylinder, hose and (green) connect it from the to the refrigerant recovery machine.
Repair Section 56 2EFRIGERANT #HARGING 7ORK 2EFRIGERANT CHARGING 1) Remove the charging hose (green) from the Valve Setting LO HI Closed Closed vacuum pump, and connect it to the refrigerant Air Purging cylinder (R-22). Charging Hose Red (Green) To Process Tube Fitting 2) Loosen the nut on the gauge manifold side of the Refrigerant Cylinder R-22 Open The Valve of Refrigerant Cylinder charging hose (green). Open the valve of the charging hose (green).
Repair Section 57 2EMOVAL OF GAUGE MANIFOLD 1) Crimp the pinch-off tube with a pinch-off tool. Pinch-Off Tool Pinch-Off Tube 2) Remove the gauge manifold and the process To Gauge Manifold Side tube fitting. Crush the end of the pinch-off tube. 3) Braze the end of the pinch-off tube. Charging Hose To Refrigerant Cycle Side 4) Ensure that a gas leak is not present at the pinched off portion and the brazed end.
Repair Section 58 10. REASSEMBLY 2EMOVAL OF 5NIT Ê Ê Ê Ê Ê UÊ ,i>ÃÃiLiÊ Ì iÊ ÕÌÊ Ê Ì iÊ ÀiÛiÀÃiÊ À`iÀÊ vÊ ÀiÛ>°Ê iÃVÀLi`Ê LiÜÊ >ÀiÊ Ì iÊ «>ÀÌÃÊ Ì >ÌÊ ÀiµÕÀi special care in reassembling the unit. Perform all wiring or rewiring as referenced in the wiring diagram. #OMPRESSOR -OUNTING Ê Ê Ê Ê Ê UÊ ÕÌÊ Ì iÊ V«ÀiÃÃÀÊ Ê Ì iÊ vÀ>i]Ê ÕÃ} Nut Spring Washer cushions, steel collars, spring washers, plate Plate Washer washers and nuts.
Repair Section 59 7IRING .OTICE Ê ÊÊ Ê Ê UÊ -iVÕÀiÊÌ iÊÜÀiÃÊÕÃ}ÊV>«ÃÊÃÊÌ >ÌÊÌ iÞÊ`ÊÌÊViÊÌÊVÌ>VÌÊÜÌ ÊÌ iÊi`}iÃÊvÊÌ i structure, etc. Secure the wires using clamps in the same position they were before removal. 0ERFORM THE )NSPECTION Ê ÊÊ Ê Ê UÊ*iÀvÀÊÌ iÊëiVÌÊvÊV}Ê«iÀvÀ>ViÊ>`ÊV iVÊvÀÊ>LÀ>ÊÃiÊÀÊ>LÀ> vibration. 10.
Repair Section 60 AP TB CB RB MF1 MF2 MC CF1 CF2 CC ATTACHMENT PLUG TERMINAL BLOCK CONTROL BOARD RELAY BOARD CONDENSER FAN MOTOR EVAPORATOR FAN MOTOR COMPRESSOR MOTOR CAPACITOR FOR CONDENSER MOTOR CAPACITOR FOR EVAPORATOR MOTOR CAPACITOR FOR COMPRESSOR IOLF IOLC DS THS RTH G HPRS DPAP (AUX1) J10 INNER OVERLOAD RELAY OF FAN MOTOR INNER OVERLOAD RELAY OF COMPRESSOR FULL DRAIN WARNING SCWITCH FREE PROTECTION THERMISTOR ROOM THERMISTOR GROUND HIGH PRESSURE SWITCH DRAIN PUMP ATTACHMENT PLU
DENSO SALES CALIFORNIA, INC. Long Beach, CA 90810 www.movincool.
