Movincool Office Pro 60 Service Manual
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Movincool Office Pro 60 Service Manual

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M A N U A L
S E R V I C E
OFFICE PRO 60

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  • Page 1 M A N U A L S E R V I C E OFFICE PRO 60...
  • Page 2 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.
  • Page 3 S E R V I C E M A N U A L O F F I C E P R O 60...

  • Page 5: Definition Of Terms

    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.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS FOREWORD ..........................i DEFINITION OF TERMS ......................i GENERAL PRECAUTIONS ......................i TABLE OF CONTENTS ......................iii GENERAL DESCRIPTION ......................1 CONSTRUCTION, SPECIFICATIONS, & DATA ............... 3 REFRIGERANT SYSTEM ......................9 ELECTRICAL SYSTEM ......................15 TROUBLESHOOTING & REPAIR ................... 21...

  • Page 9: General Description

    (condenser) to exhaust exchanged heat to the outdoors. Unlike conventional air conditioners, the MovinCool Spot Cooling System is a spot cooler EVAPORATOR which directs cool air to particular areas or objects.
  • Page 10 GENERAL DESCRIPTION...

  • Page 11: Construction, Specifications, & Data

    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...
  • Page 12 CONSTRUCTION, SPECIFICATIONS, and DATA POWER EVAPORATOR CORD 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...
  • Page 13 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).
  • Page 14 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 ................. single phase 208/230V power consumption ..............7.1 Kw current consumption ..............33 Amps power factor ................
  • Page 15 CONSTRUCTION, SPECIFICATIONS, and DATA 16 ø 22.80 10.2 40.80 24.20 51.70 30.31 Exterior Dimensions (units: inches)
  • Page 16 DATA @ 230V @230V 273 (65) 14 (25.2) 252 (60) 12 (21.6) 10 (18.0) 231 (55) 8 (14.4) 210 (50) 6 (10.8) 189 (45) Relative Humidity of Inlet Air (%) Cool Air Temperature Difference Curve 38 (100.4) @230V 33 (91.4) 28 (82.4) 23 (73.4) 18 (64.4)

  • Page 17: Refrigerant System

    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. EVAPORATOR MODULATING TANK CONDENSER...
  • Page 18 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.
  • Page 19 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 com- pression 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.
  • Page 20 REFRIGERANT SYSTEM 3. Capillary Tubes The capillary tubes are long thin tubes utilizing HIGH TEMP. / HIGH PRESS. line flow resistance to serve as an expansion LIQUID REFRIGERANT 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.
  • Page 21 REFRIGERANT SYSTEM 6. High Pressure Switch The high pressure switch prevents the condenser and compressor from being damaged by exces- sively 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.
  • Page 22 REFRIGERANT SYSTEM CONDENSER CAPILLARY INLET PIPE TUBE COMPRESSOR HIGH PRESSURE DISCHARGE PIPE SWITCH PIPE (CONDENSER TO CAPILLARY TUBE) EVAPORATOR INLET PIPE COMPRESSOR SUCTION PIPE CONDENSER (EVAPORATOR OUTLET PIPE TO COMPRESSOR, INSULATED) Refrigerant System Piping...

  • Page 23: Electrical System

    ELECTRICAL SYSTEM 230V 1 PHASE 60Hz HPRS G T1 T IOLC J201 J202 J203 J204 J201 IOLF CONDENSATE PUMP IOLF Attachment Plug IOLC Inner Overload Relay of Compressor Terminal Block Full Drain Tank Warning Switch Control Board Freeze Protection Thermistor Relay Board Room Thermistor Condenser Fan Motor...
  • Page 24 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.
  • Page 25 ELECTRICAL SYSTEM the J4 terminal (Relay Board) where the wire from the Compressor wire harness is con- nected. COMPRESSOR RELAY BOARD 2. Control Box CAPACITOR A. Capacitors EVAPORATOR FAN CAPACITOR The capacitors are used to temporarily boost RELAY BOARD the power output available to the fan motor FUSE and the compressor at start-up.
  • Page 26 6. Condensate Pump The Office Pro 60 model comes standard with a CONDENSATE PUMP Condenser Fan Motor...
  • Page 27 7. Drain Switch (If drain tank is equipped) The Office Pro 60 is equipped with a drain tank switch. When the drain tank accumulates approximately 4.0 gallons (15 liters) of condensate (water) in the drain tank, the drain tank switch sends a signal to the micro- processor.
  • Page 28 9. Automatic Restart after Power Interruption The program within the microprocessor of the Office Pro 60 contains a feature that will automatically re- start the unit after power is lost and then regained. The unit also has memory in order to return itself back to the operating mode (either Manual or Preset Program) it was in prior to the loss of power.

  • Page 29: Troubleshooting & Repair

    (full tank LED flashes). When unit disengages the compressor while the condensate pump is discharging water. FAN ON/OFF When the high pressure switch disengages START TIME the compressor. END TIME SET CLOCK COOL ON/OFF PROGRAM Office Pro 60 OP60 Control Panel...

  • Page 30: Troubleshooting And Repair

    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.
  • Page 31 TROUBLESHOOTING AND REPAIR 6. Hose Installation Note: The OP60 is equipped with a 20 foot (6 m) DRAIN OUTLET SPOUT hose. Feed the 20 foot (6m) hose through the grommet on the right side of the unit and connect to the drain GROMMET outlet spout.
  • Page 32 TROUBLESHOOTING AND REPAIR 7. Troubleshooting Chart Trouble Probable Cause Trouble Probable Cause Unit does not operate at all • Check for Power at Insufficient Air Flow • Clogged fins on Evaporator or Receptacle Condenser (running unit • Fan mode DIP switch is set to without filter(s)) “Stop”...
  • Page 33 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.
  • Page 34 TROUBLESHOOTING AND REPAIR 11. Disassembly UPPER PANEL TOP FRONT PANEL CONTROL PANEL FRONT RIGHT AIR OUTLET GRILLE PANEL FREEZE BLOWER HOUSING CONDENSER FAN THERMISTOR ROOM THERMISTOR UPPER BACK FILTER ELEMENT PANEL FRONT PANEL FILTER ASSEMBLY LEFT FRONT PANEL SIDE PANEL EVAPORATOR FAN FILTER DOOR CONDENSATE PUMP...
  • Page 35 TROUBLESHOOTING AND REPAIR A. Remove drain tank (if equipped). Removal of Drain Tank (if equipped) B. Remove twelve (12) screws from upper front panel. Removal of Upper Front Panel Screws C. Slide upper front panel forward and remove. Removal of Upper Front Panel...
  • Page 36 TROUBLESHOOTING AND REPAIR D. Louver can be removed from upper front panel by unsnapping the lock tab and remov- ing 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.
  • Page 37 TROUBLESHOOTING AND REPAIR G. Remove fourteen (14) screws from right front panel. Removal of right front panel H. Remove fourteen (14) screws from upper panel. Removal of upper panel screws Remove nine (9) screws from rear panel. Removal of back panel screws...

  • Page 38: Removal Of Electrical Parts

    TROUBLESHOOTING AND REPAIR J. Remove twelve (12) screws from left front panel. Removal of left front panel 12. Removal of Electrical Parts 230V 1 PHASE 60Hz HPRS G T1 T IOLC J201 J202 J203 J204 J201 IOLF CONDENSATE PUMP IOLF Attachment Plug IOLC Inner Overload Relay of Compressor...
  • Page 39 TROUBLESHOOTING AND REPAIR DIP SWITCH TEMPERATURE SCALE DISPLAY SWITCH ˚C ˚F FAN MODE CONTROL SWITCH STOP OPERATE 2 PIN CONNECTOR OF CONDENSATE PUMP TO EVAPORATOR FAN MOTOR (HIGH SPEED) TO COMPRESSOR (DRIVER RELAY) TO EVAPORATOR FAN MOTOR (LOW SPEED) TO COMPRESSOR TO CONDENSER RELAY FAN MOTOR (HIGH SPEED)
  • Page 40 TROUBLESHOOTING AND REPAIR 13. Removal of Blower Assembly SET SCREW CONTROL PANEL STAY CONDENSER EVAPORATOR FAN CASING HOUSING BOX EVAPORATOR FAN MOTOR RING SUB-ASSEMBLY SET SCREW EVAPORATOR FAN RING SUB-ASSEMBLY MOTOR CONDENSER FAN MOTOR CONDENSER FAN MIDDLE FRAME SUB-ASSEMBLY CONDENSER FAN HOUSING Disassembly of Blower 14.
  • Page 41 TROUBLESHOOTING AND REPAIR B. Remove the six (6) nuts on the inside of the housing in the locations shown. Removal of Blower Housing C. Remove motor wires from the three (3) motor wiring ties. Removal of Fan Motor Assembly D. Lift fan motor up then pull rear motor forward and remove.
  • Page 42 TROUBLESHOOTING AND REPAIR B. Remove the ring sub-assembly by removing the six (6) screws. 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. Removal of Fan Casing Nuts Removal of Evaporator Fan Motor A.
  • Page 43 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. Removal of Control Panel Screws B. Remove three (3) screws from the control panel stay.
  • Page 44 TROUBLESHOOTING AND REPAIR D. Disconnect the following connectors from the control board: (A) Wire Harness, Relay Board to Control Board J201 (10-pin) (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 orienta-...
  • Page 45 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 approxi- mately equal these standard values ±10%, GROUND (GREEN/YELLOW) J5 (RED)
  • Page 46 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.
  • Page 47 TROUBLESHOOTING AND REPAIR • BRAZED FITTING AND ITS CLEARANCE In general, the strength of brazing filler metal CLEARANCE is lower than that of the base metal. So, the 0.025 ~ 0.075 mm shape and clearance of the brazed fitting are quite important.
  • Page 48 TROUBLESHOOTING AND REPAIR 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.
  • Page 49 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: •...
  • Page 50 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 HIGH PRESSURE VALVE VALVE (CLOSED) (CLOSED) (3) Connect the charging hoses (red - high RED HOSE pressure side, blue - low pressure side) of GREEN HOSE...
  • Page 51 TROUBLESHOOTING AND REPAIR D. Checking Gas Leak VALVE SETTING (1) Remove the charging hose (green) from the vacuum pump, and connect the hose CLOSED CLOSED to the refrigerant cylinder (R-22). AIR PURGING OPEN THE VALVE OF REFRIGERANT CYLINDER BLUE CHARGING HOSE (GREEN) TO PROCESS TUBE FITTING Checking Gas leak (2) Loosen the nut on the gauge manifold...
  • Page 52 TROUBLESHOOTING AND REPAIR 25. Refrigerant Charging Work VALVE SETTING A. Refrigerant Charging (1) Remove the charging hose (green) from CLOSED CLOSED the vacuum pump, and connect it to the AIR PURGING OPEN THE VALVE refrigerant cylinder (R-22). OF REFRIGERANT CYLINDER (2) Loosen the nut on the gauge manifold side of the charging hose (green).
  • Page 53 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 COMPRESSOR cushions, steel collars, spring washers, plate SPRING...
  • Page 54 TROUBLESHOOTING AND REPAIR 31. Schematic Wiring Diagram...
  • Page 55 DENSO SALES CALIFORNIA, INC. TECHNICAL SERVICE DEPARTMENT First Issue: January 2002 DSCA P/N: LA990009-0842 Printed in U.S.A.
  • Page 56 (800) 264-9573 www.movincool.com DSCA P/N: LA990009-0842...

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