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Office Pro 63 Service Manual

1. 19 6 1 Circuit Diagram and Control Box AC460 V 34 60 Hz JAP G RST 990 1TB1 Fa La 460 V_230 V Condensate Pump _ TA Xa E ie 317 RTH THS DS HPRS mee fos obs mA pa le 1 ey id Oo 4 1 a o q La El E CF2 A e pre 4 P ie LO JR el 1661 661 661 GO albi h ls g G ieo J9 9 99 099 99 o HS CF1 88 J10 J101 J102 3108 3104 i ae ARA FOMENTO J E 8 Ria Josie er CHIS BS fam E O oe aa negi oe Mo re RBE 8 cs Sel n A P Attachment Plug IOLF Inner Overload Relay of Fan Motor TB 1 Terminal Block IOLC Inner Overload Relay of Compressor TB 2 Terminal Block D S Full Drain Warning Switch C B Control Board T H S Freeze Protection Thermistor R B Relay Board RTH Room Thermistor MEF 1 Condenser Fan Motor G Grounding MF2 Evaporator Fan Motor HPRS High Pressure Switch M C Compressor Motor MCC Relay for Compressor and Condenser Fan Motor CF 1 Capacitor for Condenser Motor MDP Condensate Pump Motor C F 2 Capacitor for Evaporator Motor FDS Drain Float Switch RPHR Phase Reversal Relay ODS Drain Overflow Swit
2. lt Cap gt Me E Input Signal E Terminals E Latch eN a Output Signal PIES Terminals Lis A I 1001888 Repair Section 7 TROUBLESHOOTING 7 1 Troubleshooting Before troubleshooting the system the following inspection should be performed 1 Inspection of power source voltage e Check the voltage of the power source Three phase 460 V 60 Hz e Check the phase sequence of the power source lt NOTE gt If the phase sequence is reversed control panel display turns off In this case exchange any two wires out of the three wires to correct the phase sequence e 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 Inspection of condensate pump Remove any dirt or debris which may collect in the bottom of the reservoir tank e On a monthly basis check the condensate drain hose for kinks blockage or any other damage that may obstruct condensate pump from draining properly e Make sure that motor s cover is closed to keep electrical parts free of dust dirt and any other foreign material e Condensate pump overflow switch can stop the compressor operation if the pump is malfunction To test the condensate pump overflow switch pinch the drain outlet hose and
3. 1001937 Screws 6 1001938 1001939 Repair Section 55 5 Turn the fan motor around and place on mounting bracket Secure condenser fan motor with two 2 nuts 6 Remove six 6 screws from ring 7 Loosen four 4 nuts that are securing the fan casing Lift the enclosure off its mounting Slide the condenser fan out through opening 2 Removal of evaporator fan and fan motor 1001940 1 Loosen the set screw using a hex key Then remove six 6 screws on the ring Then remove this ring and evaporator fan Repair Section 1001941 8 5 Removal of Condensate Pump Drain Hose Drain Hose Connector 1001942 Screws 2 1001943 gt 1001944 2 Remove evaporator fan motor wire and two 2 ties Remove four 4 nuts from housing while holding fan securely with one hand Then remove evaporator fan motor 1 Remove fourteen 14 screws from front right panel See page 46 2 Remove the two 2 drain hoses 3 Disconnect condensate pump connector 4 Remove two 2 screws from condensate pump 5 Remove tab from condensate pump Repair Section 57 8 6 Removal of Transformer Screws Upper Cover Side Cover Side Co
4. N 1001947 Spring Washer Plate Washer Cushion Steel Collar 1001818 1 Install clearance of 0 12 in 3 mm minimum on each blower fan for evaporator Allow a side of the evaporator fan Z CAUTION e Tightening torque 10 84 2 17 ftelbf 15 2 7 Nem 2 Install clearance of 0 12 in 3 mm minimum on each blower fan for condenser Allow a side of the condenser fan Z CAUTION e Tightening torque 10 84 2 17 ftelbf 15 2 7 Nem Repair Section 75 10 4 Wiring Notice e Secure the wires using clamps so that they do not come into contact with the edges of the structure etc Secure the wires using clamps in the same position they were before removal 10 5 Perform the Inspection e Perform the inspection of cooling performance and check for abnormal noise or abnormal vibration 10 6 Caster Maintenance e Lubricate bearings in caster as needed with standard bearing grease using the zerk fitting lt NOTE gt Casters should roll and swivel freely Check for dirt or dust build up Remove dust or dirt build up 76 Repair Section 10 7 Schematic lt Wi
5. Evaporator 1001952 Operation Section 5 2 Compressor The compressor used for the unit is hermetically sealed The compressor and the compressor motor are in one casing 1 Compressor theory of operation The scroll utilizes an involuted 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 As this motion occurs the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume When the pocket reaches the center of the scroll form the gas which is now at a high pressure is discharged out of a port located at the center During compression several pockets are being compressed simultaneously resulting in a very smooth process Both the suction process outer portion of the scroll members and the discharge process inner portion are continuous 2 Compressor operation 1 2 3 4 5 1001767 1 Compression in the scroll is created by the interaction of an orbiting spiral and a stationary spiral Gas enters the outer openings as one of the spirals orbits 2 The open passages are sealed off as gas is drawn into the spiral 3 4 5 Actually during operation all six gas passages are in various sta
6. Wet Bulb Temp F C Wet Bulb Temp F C E 23 4 13 2 a 2 60 21 6 12 x gt 55 19 8 11 3 s 50 18 0 10 a O 16 2 9 9 45 E 2 14 4 8 40 95 35 a 12 6 7 O 86 80 10 8 6 a ER 3 68 20 7 2 4 a 30 40 50 60 70 80 E 50 59 68 77 Relative Humidity 10 15 20 25 Wet Bulb Temp F C lt Power Consumption Curve gt lt Current Consumption Curve gt 8 0 12 S lt Z 70 5 S a a E 2 6 0 8 z E 9 o 5 50 a 4 0 4 95 35 _ 95 35 O O u 86 30 u 86 30 a c 5 77 25 5 7725 E 2 2 Z 68 20 3 68 20 gt gt A 68 77 86 95 A 68 77 86 95 20 25 30 35 20 25 30 35 1001951 Operation Section 16 5 REFRIGERANT SYSTEM 5 1 Refrigerant System Construction The component parts of the refrigerant system include the following Compressor Evaporator Condenser Capillary tube High Pressure Switch These parts are all connected by copper tubing All the connections have been brazed Evaporator Condenser Evaporator Pipe Capillary Tube Compressor Discharge Pipe ge P Evaporator Outlet Pipe Condenser Inlet Pipe Compressor Compressor Suction Pipe Condenser Outlet Pipe lt Flow of Refrigerant
7. the ohm meter fails to move from 0 shorted A replace the capacitor 2 Capacitance tester method e Using a capacitance tester and the chart on page 23 test the capacitor for the value indicated If the value tested is not within 10 of indicated capacitance replace the capacitor Z WARNING e Properly discharge the capacitor s before testing and after testing has been completed Failure to do so could cause damage to test equipment or the unit and or result in personal injury electrical shock or death 8 8 Inspection of Drain Switch e Check for continuity between terminals 1 and 2 when drain switch is pressed With drain switch Top of Base Plate depressed there is no continuity between Drain Switch terminals 1 and 2 Replace drain switch if continuity does not satisfy the above condition To J103 1001809 Repair Section 61 8 9 Inspection of Fan Motor 1 Condenser fan motor e Measure resistance across the terminals of the fan motor All terminals must be disconnected Condenser na Mpip from the unit e Between terminals at 77 F 25 C J6 CF11 Approx 3 5 ohm J6 CF12 Approx 6 0 ohm Ground Green Yellow J5 Low Red CF11 CF12 Approx 9 1 ohm CF12 Brown White CF11 White or Orange If the measured resistance is not equal to these J6 High Black lt 1001775 standard values replace the fan motor 2 Evaporator fan m
8. In case there is a leak obstruction or trouble in the refrigerant system of the Office Pro 63 replace or repair the part in question After replacing any component all connections must be brazed 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 It is necessary to preheat the base metal properly depending on the shape size or thermal conductivity of the brazed fitting The most important point in flame brazing is to bring the whole brazed fitting to a proper brazing temperature Care should be taken to not cause overflow of brazing filler metal oxidization of brazing filler metal or deterioration due to the overheating of flux Brazed fittings and fitting clearance In general the strength of brazing filler metal is Clearance lower than that of the base metal So the 0 001 0 003 in shape and clearance of the brazed fitting are a 0 025 0 075 mm quite important As for the shape of the brazed i fitting it is necessary to maximize its adhesive Jol j area The clearance of the brazed fitting must be minimized to facilitate brazing filler metal to Clearance From The Pipe Fitting and Tubing flow into it by capillary action osas Cleaning brazing filler metal and pipe When the refrigerant system has been opened up ex
9. Time delay type Class cc Rated volt 600 V Rated amp 15 A UL listed 6 5 Fan Motor 1 For evaporator e The fan motor is a single phase induction type two speed motor Specifications Rated Voltage 230 V 60 Hz Rated Output High 590 W Low 360 W 2 For condenser e The fan motor is a single phase induction type two speed motor Specifications Rated Voltage 230 V 60 Hz Rated Output High 1195 W Low 932 W Operation Section 25 FUSE BN iS ji Fuse Control Box Bi J 0 Q 1001956 Evaporator Fan Motor 3 Ground Green Yellow lt J7 Low Red lt 3 CF22 Brown White lt CF21 White lt J8 High Black 1001774 Condenser Fan Motor Ground Green Yellow J5 Low Red CF12 Brown White CF11 White or Orange J6 High Black 1001775 26 Operation Section 6 6 Compressor Motor The compressor motor is a three phase motor and is contained within the same housing as the compressor Specifications Rated Voltage 460 V 60 Hz Rated Output 3890 W lt NOTE gt An internal overload relay is used to protect the fan motors and the compressor motor This relay is built into the fan motors and compressor motor lt interrupts the flow of current when there is an over current situation or if abnormally high temperature builds up in the fan m
10. display goes back to normal mode 2 00 LOCKED HI F FAN 5 ON SET TEMP COOL Key lock mode LCD displays LOCKED Press ENTER and SET CLOCK buttons simultaneously for 5 sec Press ENTER and SET CLOCK buttons simultaneously for 5 sec again to cancel the key lock mode UP E Indication of model name Press ENTER and SET CLOCK buttons simultaneously for 5 sec or turn on Reset to normal display automatically after 5 sec HL RM Detection of unit stop signal from fire alarm system Press input signal from fire alarm becomes on Unit stops output signal J106 turns on and buzzer sounds 1 After input signal turns off 2 Reset the system To RESET Press ON OFF and HI LO buttons on the control box simultaneously for 5 sec 36 Repair Section LCD Display Description Condition Reset Remedy LU DE L pz Indication of service code Press ON OFF and A buttons simultaneously for 3 sec Indication contents is as follows LCD Description Value DF Defrost status FZ Evap out pipe 261 09F temperature 26 X9 Outdoor ARS oD temperature 0 00 1 See page 36 and 37 2 Press ON OFF button UP b Change model setting For installing new controller PCB if a different model name appears when the unit is reset or turned on change model name according to the correct p
11. 2 Evacuation Valve Setting LO HI jl LO HI Closed Open Closed Closed 30 inHg 100 kPa or larger Gauge Low Pressure Valve High Pressure Gauge High Pressure Valve High Pressure Side Tube Vacuum Pump in Operation 1002227 1 Properly remove the crushed end of the pinch off tube at the high pressure side and the low pressure side of the refrigerant cycle with a pipe cutter 2 Fitthe process tube fitting to the pinch off tube on both sides 3 Connect the charging hoses red high pressure side for the gauge manifold to the process tube fitting lt NOTE gt 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 1 Open the high pressure valve HI of the gauge manifold 2 Turn on the vacuum pump to start evacuation Evacuate the system for approximately 15 min 3 When the low pressure gauge indicates 30 inHg 100 kPa or larger turn off the vacuum pump and close the high pressure valves of the gauge manifold 3 Checking vacuum Valve Setting Pressure Gauge Return Leave valves closed for 5 min or more Pointer of pressure gauge returning to zero indicates there is a leak Pipe Brazing 1002184 Repair Section 69 1 Leave the high pressure valve and the low pres
12. N 9 des Condensate nan a 18 Pump T Grommet 1001920 lt NOTE gt The condensate pump maximum lift is 17 ft 5 2 m at 460 VAC Please check the drainage performance after installation It is important that the drainage line from the condensate pump is free of kinks and is not pinched Power fluctuation or low voltage could result in incorrect drainage 6 8 Operation Section 29 Drain Switch The Office Pro 63 is equipped with a drain tank switch When the drain tanks accumulates 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 This system utilizes a 0 1 A 125 250 VAC micro switch for this function When drain water accumulates approximately 8 0 gal 30 L in the drain tanks the drain tank base plate which is supported at its fulcrum is pushed down in the arrow direction as shown in the figure below When the drain tank base plate is forced down the top of the drain tank base plate turns off the contacts 1 2 of the micro switch This causes the ground signal at the J103 connector of the control panel assembly to go open When the microprocessor detects this event it shuts the unit off flashes the TANK FULL LED indicates TANK FL on the LCD and closes the contact of
13. To RESET Press ON OFF and ban Ho JE open and signal output J106 turns HI LO buttons on the control box coal YAA on simultaneously for 5 sec Defect short or open When room thermistor connecting Disconnect and reconnect the of room thermistor to J101 becomes short or open room thermistor GH RT Signal output J106 turns on If it doesn t work then change it UP EN HI F FAN 5 ON SET TEMP COOL Repair Section 35 LCD Display Description Condition Reset Remedy SH RT HI 7 F FAN 5 FTE COOL DP EN HI F FAN 5 ON SET TEMP COOL Defect short or open of freeze protection thermistor When freeze protection thermistor connecting to J102 becomes short or open Signal output J106 turns on Disconnect and reconnect the freeze protection thermistor If it doesn t work then change it Ub Ol UU Show running hours Press ON OFF and V buttons simultaneously for 3 sec total operation hours of compressor is indicated by 6 digit hours Example in left 807 h After 5 sec display goes back to normal mode n MO TU WE TH FR SA SU START AM PROGRAM kisa y i 2 i ii an cLock PM LOCKED HI F F c c FAN LO SET TEMP ON COOL OFF ROOM TEMP Show LCD and LED all on mode Press HI LO and A buttons simultaneously for 3 sec To check LCD segments and LED display After 5 sec
14. o Hoek eee dee ae eee tee Fees Ana aa a Ee eRe 63 9 REFRIGERANT SYSTEM REPAIR 9 1 Repair of Refrigerant System 2 2 0 tenets 64 9 2 Removal of Refrigeration Cycle Components 000 e eee eee eee 66 9 3 Charging the System with R 410A Refrigerant 0 0 0 0 0 0 ccc eens 67 9 4 Refrigerant Charging Work 0 000 cc ttt eee eee 72 10 REASSEMBLY 10 1 RemovalotUnit its tetas doe ned otide ira ddr birds 74 10 2 Compressor Mounting o ocoocooccoc tenets 74 10 3 Blower Assembly acra ranira a o ME Sie Le edd ae Pa RE Sie eee 74 10 4 Wiring Notice 0000 erissa he Be eRe ete Ltn ef ee i wd wb Gee eye 75 10 5 Perform the Inspection 0 cece ee eee 75 10 6 Caster Maintenance 75 107 SchematiC aitaa aa et ben et Ate bee oh LA lds AI Bik a ee 76 6 Operation Section 1 PRECAUTIONS FOR SAFETY 1 1 Foreword e This manual has been published to service the MovinCool Office Pro 63 Please use this service manual only when servicing the Office Pro 63 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 A 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 NOTE Provides additional information that facilitates installation or un
15. output signal When the drain tanks is removed or the drain tanks 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 close This provides a ground to the microprocessor through the J103 connector Top Base Plate S A Evaporator Drain Switch n 0 4l Drain Pan Drain Tube Taea yS a E e ooo Drain Tanks Drain Water lt gt J Spring a pal AT Base Base Plate 1002230 30 Operation Section 1 How to re start the unit e If the LCD indicates PROGRAM ON press the COOL ON OFF button to continue running the 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 9 Automatic Restart after Power Interruption The program within the microprocessor of the Office Pro 63 contains a feature that automatically restarts 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 All preset programs are retained in the memory in the event power loss occurs 6 1
16. such as fan motor compressor control switch lt NOTE gt e There is a possibility of insufficient cooling due to clogging of the air filter So make sure to first check if the air filter is clogged or not e Check the power supply because of the possibility of power source failure e Check the installation site for operating temperature and installation space unobstructed airflow 38 Repair Section Possible Cause Symptom Remedy Checking Area Cause 1 Usage conditions Operation near usage limits Review the installation high temperature place 2 Dirt in condenser or Insufficient heat exchange Clean fins Compressor evaporator operates 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 Nr volun condenser refrigerant normal 1 Compressor coil resistance Short or open circuit Replace compressor 0 ohm or ohm In case of short check the compressor relay Compressor 5 Compressor relay Open circuit or insufficient Replace compressor does not contact relay operate AT ar 3 Compressor relay on the Open circuit or insufficient Replace relay board relay board contact 4 Voltage Low voltage Repair power 1 Coil resistance of fan motor Short or open circuit Replace fan motor 0 ohm or ohm
17. the problem and come up with proper countermeasures to solve the problem so that it does not occur again lt NOTE gt Internal dry type distribution transformer may produce a humming noise up to 31 dB A at maximum operated voltage 506 V during stand by state erie Possible Cause Bone Checking Area Cause 1 Fan Fan interference Repair interfering section Fan deformation Replace fan Abnormal noise or 2 Compressor fixing nuts Looseness of nuts Tighten nuts further vibration 3 Transformer fixing nuts Looseness of nuts Tighten nuts further 4 Piping Pipe interference Repair interfering section 5 Panel fixing screws Looseness of screws Tighten screws further 7 4 Basic Inspection Perform the following inspection before disassembly 1 Inspection of plate fins To inspect the plate fins of either the evaporator or condenser the air filter must be removed SSS After removal of the air filters inspect the plate fins for any dirt dust lint or debris that may A have caused insufficient cooling performance eo of the unit If cleaning of the fins is necessary it S is recommended that this service be performed by a qualified service technician Q 2 Examination of operating environment 1001780 e Operating environments can vary depending on location climate and surrounding conditions Installation location also can cause
18. 0 6 12 Fan Mode Control Switch 1 2 20 31 6 13 Temperature Scale Display Switch sasaaa 000 cee tenes 31 6 14 Warning Signal Connection Output Signal Terminal L and L 0 0000 e eens 32 6 15 Fire Alarm Control Panel Connection Input Signal Terminal E and E 2 5 32 Table of Contents Repair Section 7 TROUBLESHOOTING dl TrOUBIESHOOLING eean eer a e aa a a ais 33 7 2 Self Diagnostic Codes o o oooooocr teens 34 7 3 Troubleshooting Chart 0 0 teen eee 37 14 Basic INSPOCON ss sa cios A de ee al ate eed a RA wk ea ete ee 42 8 DISASSEMBLY 8 1 Parts Construction ai a e e a teen eens 44 8 2 Disassembly lt a oaea yak dog a ad Pee A ed be ae Piedad e 45 8 3 Removal of Electrical Pans tesa ipea a a tees 48 8 4 Removal of Blower Assembly 2 000 eee ee 53 8 5 Removal of Condensate Pump 0 000 ccc teens 56 8 6 Removal of Transformi cno spesie rer e EA OA eee eee 57 8 7 Inspection of Capacitor for Fan Motor and Compressor n sssaaa aaaeeeaa 60 8 8 Inspection of Drain Switch o ooooocooccooco tenes 60 8 9 Inspection of Fan Motor oooooooooorr eee 61 8 10 Inspection of Compressor MOtOF o oococcoocooo teens 61 8 11 Inspection of Transformer 00 eE EES ete 62 8 12 Inspection of Wiring Connection 00 0c ete eee 62 8 13 Inspection of Thermistor 0 0 eee 62 B14 INSPOCHON aici ck tee se tica e
19. 0 Compressor Protection e There is a time delay program within the microprocessor This prevents a heavy load from being applied on the compressor motor when restarting the unit cool mode after a very short period of time This delay is in effect any time when the compressor is turned on by either the COOL ON OFF button temperature set point thermostatic control power interruption restart or condensate pump optional operation Specifications Time delay 120 20 sec 6 11 Temperature Control The compressor operation cool mode is controlled by the microprocessor which receives input signals from the room temperature thermistor evaporator inlet air and the setting of the temperature set point The temperature set point desired room temperature can be adjusted by pressing the A V buttons on the control panel The adjustment range of the temperature set point is 65 F to 90 F 18 C to 32 C Operation Section 31 6 12 Fan Mode Control Switch e The fan motor operation is controlled by relays on the relay board through a microprocessor in 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 e There are two settings 1 Cool to stop e When the DIP switch is set in the downward or STOP position the microprocessor controls the fan motor using the same room temperature thermistor that it uses to control the compress
20. 0A Power Cord NEMA Plug Configuration L16 20 Gage x Length 12 AWG 4 core x 6 ft Signal Connection Net weight Fire Alarm Input e Dry contact type recommended e No Voltage Contact Input Contact resistance Less than 100 ohm Warning Signal Output 2 A at 30 V DC AC or less resistive load 705 Ib 320 kg Operation Section ITEM SPECIFICATIONS Operating Condition Inlet air Maximum 105 F 41 C 50 RH Inlet air Minimum 65 F 18 3 C 50 RH Sound Level 3 With Condenser Duct high low 69 67 dB A Without Condenser Duct high low 71 69 dB A Max Duct Equivalent Length Per Cold Duct Hose Hot Duct Hose 40 100 ft 12 1 30 5 m Condensate Pump 1 30 HP 230 V 0 5 A 75 W Discharge 3 8 in 9 53 mm OD barbed e Specifications are subject to change without notice lt NOTE gt 1 Rating Condition 95 F 35 C 60 RH 2 Measured at 3 28 ft 1 m from surface of unit 3 Internal dry type distribution transformer may produce a humming noise up to 31 dB A at maximum operated volt age 506 V during stand by state 4 2 Characteristics Operation Section 15 lt Cooling Capacity Curve gt 65 lt Cool Air Temperature Difference Curve gt
21. Board Holder OS Battery New 1001807 5 1 Disassemble control board See page 49 and 50 2 See diagram for battery removal 3 Insert new battery securely in the direction shown in the drawing Specifications Type 3 V CR2450 or equivalent A CAUTION When inserting the battery make sure the direction of polarity plus minus is correct as shown Repair Section 52 5 Fuse Replacement of Control Box 1001961 1 See diagram for fuse removal 2 Insert new fuse securely Specifications Time delay type Class cc Rated volt 600 V Rated current 15 A UL listed AN WARNING Disconnect power before remove fuse 8 4 Removal of Blower Assembly Evaporator Fan a y Evaporator Fan Casing Condenser Housing Box Condenser Fan Motor Condenser Fan Casing Condenser Fan Control Panel Center Panel Repair Section 53 Stay Control Panel Control Panel Stay 1001932 Repair Section 1 Removal of condenser fan and fan motor PARAS ASA Set Screw 1001933 Ties 3 1001935 1001936 1 Loosen the set screw using a hex key 2 Remove six 6 nuts in the location shown 3 Remove fan motor wire from three 3 ties 4 Lift fan motor up then pull rear motor backward and remove the fan motor Centrifugal fan drops into condenser fan housing
22. Display Switch C F Fan Mode Control Switch Temperature Scale SE STOPSOPERATE 1001772 power is sent to the control panel assembly where it is further reduced to 5 V for the system logic e The relay board also contains the DIP switch e The DIP switch is used to change the fan mode operation from stop to operate and change both the set point and room temperature display from Fahrenheit to Celsius lt NOTE gt The relay board must be serviced as a complete assembly lt has component the fuse see below 4 Relay board fuse e This fuse provides protection against damage to the step down transformer It must be replaced with the exact type of fuse or an equivalent Specifications 2 10 A 250 V A CAUTION lt Relay Board gt O oecnArE E ae 08 F O E A 484500 1840 only one serviceable 1001773 Failure to use the exact type of fuse could result in damage to the unit and or to components It could also void the warranty of the unit 5 Fuse For Transformer e This fuse provides protection against damage to the transformer The fuse is located in the secondary circuit of the transformer e It must be replaced with the exact type of fuse or an equivalent Specifications
23. SERVICE MANUAL OFFICE PRO 63 SERIAL NUMBER FROM JANUARY 2008 0108 TO PRESENT Duis MOVINCOOL THE 1 SPOT COOLING SOLUTION DoclD 00G00017E O 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 A NN 6 1 2 Definition of Terms basa a a ana 6 1 3 General PrecaltiONS aiii a ea Be wR ee a a 6 2 GENERAL DESCRIPTION 251 CSpot COOlen satis vans chicane eae EA ed nee ee dod Rede gen he Pee eb 7 2 2 Compact Desiginsie sinc ecru in Crem de vis adie yee Mates be id Sela oq dia 7 2 3 Easy Transportation and Installation 0 20 00 eee 7 2 4 Energy Conservation ema tonta yea ea einai a Yagi ds peu adores yada Moga Yas 7 3 CONSTRUCTION 3 1 Exterior DIMENSIONS errik l oe os eee en E ed ea ee ee tee Seley bed 8 3 2 Exterior Components s aerian en ada ttt eee ee 9 3 3 Internal Structure mes craid a ia tnt eee 10 3 4 Basic Construction 200242 daras aria ada ddr 10 3D JAI FIOWS 22 a AA ame ead AO AAA AA PE SR 11 3 6 Electrical System i iiia era a a Pee ee ec ued ay Gaba ed 11 3 7 Compressor and Fans Tels Sela eaten A Poke ode A wa
24. ails High pressure switch error e The relay output contactor is rated 2 A at 30 VDC or 2 A at 30 VAC resistive load and it is compatible with various warning devices such as alarm speaker light indicators etc Connecting warning signal from controller Remove service panel from the rear of the unit Squeeze the inner latches and push out the black cap from inside the panel See drawing of cap and inner latch shapes Use recommended warning signal wire size from 16 AWG to 26 AWG or a solid wire or 16 AWG to 22 AWG for a stranded wire with ring terminal for 6 stud size Connect warning device to terminal L and L according to its polarities 6 15 Fire Alarm Control Panel Connection Input Signal Terminal E and E The controller is equipped with a normal open input signal which can be connected directly from the fire alarm control panel When receiving the signal from the fire alarm control panel the unit turns off and does not turn back until it has been reset Connecting fire alarm control panel to controller Remove service panel from the rear of the unit Squeeze the inner latches and push out the black cap from inside the panel See drawing of Cap and inner latch shapes Use recommended warning signal wire size from 16 AWG to 26 AWG for a solid wire or 16 AWG to 22 AWG for a stranded wire with ring terminal for 6 stud size Connect warning device to terminal E and E according to its polarities
25. ation failure on Replace compressor resistance compressor 7 Reverse phase protector Open circuit or insufficient Replace reverse phase contact protector 1 Temperature of fan motor Operation of safety device Replace fan motor abnormally high IOLF due to fan motor malfunction 2 Temperature of compressor Operation of safety device Replace compressor Stops after Control abnormally high IOLC due to compressor anel running a a 3 malfunction ispla while P a 3 Refrigerant leakage Insufficient refrigerant or gas Repair and charge normally leakage refrigerant 4 Dirt on evaporator or Insufficient cooling of Clean evaporator or condenser evaporator or condenser condenser 5 Duct connection state Improper connection Repair duct connection 3 Overflow of drain water Symptom Possible Cause Checking Area Cause Remedy Overflow from the unit 1 Drain pan Cracks in drain pan Check and repair 2 Water level in drain pan Clogged drain hose Check and replace 3 Drain hole Reversed air flow from drain hole Insert a trap on discharge drain hose 4 Clogged air filter Reversed air flow from drain hole due to the excessive negative pressure inside of the unit Clean air filter Repair Section 4 Abnormal noise or vibration To prevent abnormal noise or vibration carefully determine the source of
26. capacity of the unit Charge to the specified amount always observing the scale graduations while charging 5 Close the high pressure valve of the gauge manifold and the valve of the refrigerant cylinder 2 Removal of gauge manifold Pinch Off Tool To Gauge Manifold Side To Refrigerant Cycle Side 1002185 Repair Section 73 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 Repair Section 10 REASSEMBLY 10 1 Removal of Unit e 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 10 2 Compressor Mounting e Mount the compressor on the frame using cushions steel collars spring washers plate Nut washers and nuts 10 3 Blower Assembly lt Evaporator Blower Assy gt Min 0 12 in Min 0 12 in 3 mm lt 1002229 lt Condenser Blower Assy gt Min 0 12 in 3 mm A Min 0 12 in 3 mm
27. ch TNS Transformer F Fuse 25 A Terminal Block 7 o mag T Fuse Signal Connection LL lo L lt dor Transformer ERE ve Fell Terminal Block Buse Hele Reverse Phase Protector gt E ano UA E Dip Switch Reverse Phase Protector i j e Ul_ Relay Board Fan Capacitor O SL Relay Board Fuse Evaporator So eo Relay 11 fasta ERIK ald a E ssl Terminal Block Fan Capacitor gq p Condenser j 0 1001953 20 Operation Section 6 2 Basic Operation of The Office Pro 63 Electrical Circuit e There are three basic components used to control the operation of the Office Pro 63 electrical system Transformer 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 high pressure switch and a microprocessor 1 Fan mode High Fan Mode e When the FAN MODE button on the control panel is pressed the microprocessor turns on FAN HI COOL OFF indication of LCD and activates both the fan on relay and fan mode relay This sends line voltage 230 VAC from the fan on relay to the N O normally open contacts of the fan mode relay This output is connected to the J8 terminal relay board where the high speed wire of the fan motor is connected e When this button is pressed again fan turns to low mode see below Press again fan stops
28. e High fan mode is automatically switched depending on room temperature When room High temperature is decreased down to 80 F Condenser Fan 27 C or below fan mode is switched to HIGH When room temperature is increased to LO 88 F 31 C or higher fan mode is switched ae ae from HIGH to LO Room Temperature 570 O 1001914 Low Fan Mode e When the FAN MODE button on the control panel is pressed again the microprocessor turns on FAN LO COOL OFF indication of LCD and activates both the fan on relay and fan mode relay This sends line voltage 230 VAC from the fan on relay to the N C normally closed contacts of the fan mode relay This output is connected to the J7 terminal relay board where the low speed wire of the fan motor is connected e When this button is pressed again fan stops Operation Section 21 2 Cool mode e In addition to fan mode as described above when the COOL ON OFF button on the control panel is pressed the microprocessor turns on COOL ON indication of LCD and if the temperature set point is less than the current room temperature activates the compressor relay relay board after 120 sec delay This sends line voltage 230 VAC to the J4 terminal relay board and compressor auxiliary relay is excited Then compressor and condenser fan motor turn on Cooling Operation Condenser fan mode is automatically switched depending on room temperature When
29. ews 3 O me 1002180 1 Remove two 2 screws from the control panel stay 2 Remove three 3 screws from the control panel stay Repair Section 50 F G 1002182 1001804 3 Slowly slide control panel assembly out of box 4 Disconnect the following connectors from the control board A J201 10 pin Wire Harness Relay Board to Control B J101 2 pin Room Temperature Thermistor C J102 2 pin with black tape Freeze Protection Thermistor D J103 2 pin Drain Tank Switch E J104 2 pin High Pressure Switch F J106 2 pin Output signal terminal G J108 2 pin Input signal terminal lt NOTE gt Mark each of the 2 pin connectors with a different color marker to ensure the correct orientation when they are reconnected or label all wire sets with tape Numbering the wire sets from A through G 5 Remove the five 5 screws from the control board on the control panel assembly Remove the control board Repair Section 51 4 Battery replacement of control board e When the power is unplugged from the unit and control board is automatically resetting clock and program it is time to change the battery on the control board to avoid resetting of clock and program Sl PS sa Y SQ SS Battery Control Board w 1001805 Control Board Holder O Battery Old 1001806 Control
30. ged in or removed during service The internal relay of a reverse phase protector is energized and LED is on when the phase sequence is correct If the phases are reverse the out put relay will not energize e The automatically upon correction of the fault reverse phase protector is reset Specifications Rated Line Voltage 440 480 V Rated Output 8 A resistive at 240 V Mounting Plug in socket 8 pin octal plug 2 Capacitors Operation Section 23 Terminal Block lt Wiring Diagram gt R S Reverse Phase Protector LED T Power Source dde 8 to J2 Normally Closed to TB1 Ri 1001955 The capacitors are used to temporarily boost the power output available to the fan motor at start up The specifications of each capacitor are listed below Capacitor Application Voltage Rating Capacitance Evaporator Fan Motor 440 VAC 15 uF Condenser Fan Motor 370 VAC 25 UF 24 Operation Section 3 Relay board The relay board receives signals and outputs board microprocessor The relay board contains the from the control that contains a compressor fan on and fan mode speed relays e It also contains a step down transformer that converts the line voltage 230 VAC to 12 V e This 12 V is then converted from AC to DC and used for relay coil activation The 12 V DC lt Dip Switch gt Dip Switch a y Ed
31. ges of compression at all times As the spiral continues to orbit the gas is compressed into two increasingly smaller pockets By the time the gas arrives at the center port discharge pressure has been reached resulting in nearly continuous suction and discharge lt NOTE gt When the compressor shuts off the compressor motor may run backward for a moment or two until internal pressures is equalized This has no effect on compressor durability but may cause an unexpected sound after the compressor is turned off and should not be diagnosed as a malfunction Operation Section 5 3 Condenser The condenser is a heat exchanger with copper tubes that are covered with thin aluminum projections called plate fins e Heat is given off and absorbed by air being pulled across the condenser fins by the centrifugal fan and then expelled through the exhaust air duct 5 4 Capillary Tube e The capillary tube is a long thin tube utilizing High Temp High Pressure line flow resistance to serve as an expansion Liquid Refrigerant valve The length and the inner diameter of the gt capillary tube are determined by the capacity of the refrigeration system specified operating conditions and the amount of refrigerant The capillary tube causes the high pressure high gt o Low Temp Low Pressure temperature liquid refrigerant sent from the Gas and Liquid Mixture 1001887 condenser to expand rapidly a
32. ir 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 lt P Cool Air Out uf i ith sir THE eet A et hi 94 Condenser Air In Evaporator Air In 1001909 3 6 Electrical System The MovinCool Office Pro 63 is equipped with a compressor operated at 460 V 3 phase and a dry type distribution transformer operated 460 V single phase at primary side and 230 V single phase at secondary side which supply power source for fan motors relay board and condensate pump 3 7 Compressor and Fans The compressor is hermetically sealed Two sets of a two speed fan motor with a centrifugal fan are used to draw air across the evaporator and condenser 3 8 Transformer e The transformer is a dry type distribution transformer rated 5 KVA at 460 V primary side and 230 V secondary side Operation Section 3 9 Condensate Pump The condensate pump and a 20 ft 6 m drain hose are included with the Office Pro 63 to provide continuous operation without the need of the drain tanks The condensate pump has a maximum head lift of 17 ft 5 2 m at system operated voltage of 460 VAC 3 10 Drain Tanks optional e A set of two 5 0 gal 19 L drain tanks are supplied as op
33. it operation 1 3 General Precautions Z WARNING All electrical work if necessary should only be performed by qualified electrical personnel Repair to electrical components by non certified technicians may result in personal injury and or damage to the unit All electrical components replaced must be genuine MovinCool parts purchased from an authorized reseller When handling refrigerant always wear proper eye protection and do not allow the refrigerant to come in contact with your skin Do not expose refrigerant to an open flame e The proper electrical outlet for MovinCool units must be equipped with a UL approved ground fault breaker to prevent electrical shock from the unit e When brazing any tubing always wear eye protection and work only in a well ventilated area e Disconnect power before servicing unit Be careful of any sharp edges when working on unit Operation Section 7 2 GENERAL DESCRIPTION 2 1 Spot Cooler e In general 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 Condenser Evaporator and an exterior unit condenser to exhaust Outdoor Unit Indoor Unit exchanged heat to the outdoors e Unlike conventional air conditio
34. ller Metal 1001725 Repair Section 66 9 2 Removal of Refrigeration Cycle Components A CAUTION e Before any refrigeration cycle component can be replaced it is necessary to recover the refrigerant using standard recovery procedures and equipment e To prevent oxidation dry nitrogen should be conducted flow rate 0 27 gal min 1 L min through the pinch off tube during any brazing operation e During any component replacement involving brazing shield nearby parts with a steel plate etc to protect them from the flame Evaporator e Capillary tube Condenser e Compressor e High Pressure Switch lt NOTE gt When replacement of the compressor attach the two pipes Pipe 1 Pipe 2 which are packaged in Compressor Assy as following figure Part to Replace Disconnect At Compressor A amp F Condenser A amp B e Capillary Tube C amp D Evaporator C amp E 1002170 Repair Section 67 9 3 Charging the System with R 410A Refrigerant Always ensure that the refrigerant system has been properly evacuated before charging with the specified amount of R 410A e Equipments is only for R 410A e Liquid charge no gas charge e Make sure not to use more than 90 of the initial weight of R 410A in the cylinder AX WARNING When handling refrigerant R 410A the following precautions should always be observed Always wear proper eye protec
35. move 4 Louver can be removed from upper front panel by unsnapping the lock tap and removing the louver from its pivots Repair Section 46 S 5 Remove nine 9 screws from service panel and crews 13 thirteen 13 screws from rear left panel Screws 9 J 1001926 Screws 8 6 Remove eight 8 screws from rear right panel ed Tyla 1001927 7 Remove fourteen 14 screws from front right pz PS ZA panel yo Screws 4 8 Remove fourteen 14 screws from upper panel aal 1001929 47 Repair Section 9 Remove nine 9 screws from rear panel 10 Remove twelve 12 screws from front left panel 1001930 Screw 12 1001959 Repair Section 8 3 Removal of Electrical Parts 1 Control box 1 Remove nine 9 screws from service panel See page 46 2 Remove electrical parts Relay Remove four 4 screws from control box Reverse phase protector Pull out reverse phase protector from terminal block Terminal block Remove four 4 screws from control box Terminal block signal connection Remove two 2 screws from control box Terminal block reverse phase protector Remove two 2 screws from control box Capacitor Remove two 2 screws from control box Fuse holder Remove one 1 screw form control box Terminal Block Signal Con
36. n 9 3 2 Exterior Components Operation Panel Cold Air Outlet Grill Evaporator Air Inlet Grill Condenser Air Outlet Duct eT E go o i i o A lE f cl Caster Condenser Air Inlet Panel Power Cord Service Panel 1001907 Operation Section 3 3 Internal Structure Fan Motor Fan Evaporator Condenser Behind Fan Fan Evaporator Evaporator High Pressure Switch Capillary Tube Drain Pan Condensate Pump Transformer Compressor Condenser 3 4 Basic Construction Fan Motor Condenser Drain Switch Control Box 1001950 e The MovinCool Office Pro 63 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 and the lower front face contains the condensate pump and optional drain tanks The rear section contains the condenser the compressor the transformer and the control box Operation Section 3 5 Air Flow e Air drawn from the right side face passes through the condenser which extracts the heat This hot a
37. nection Fuse Holder Terminal Block Reverse Phase Protector ___ i Reverse Phase Protector ya Dip Switch El e o Pila Relay Bae RT O Peay poard TUSE Fan Capacitor Evaporator eile Relay Te ae Sl eyes Te _A e ae ee Terminal Block 5 L Fan Capacitor Condenser a 1001960 2 Relay board 1 Remove nine 9 screws from service panel See page 46 Repair Section 2 Disconnect ten 10 connectors and remove five 5 screws from relay board 49 Temperature Scale Display Switch Dip Switch o O o S1 s eM o 2 To Control Board 10 pin E dl i l To Condensate Pump 2 pin a E To Comp Driver Relay veas w pe To Evap Fan Motor LO Fi 2 10A 250V OA Relay Board Fuse 7 de Fan Mode Control Switch tl To Evap Fan Motor HI To Comp Relay LA MO eae l To Cond Fan Motor HI To Cond Fan Motor LO Power R1 On Terminal Block Power T1 On Terminal Block 3 Control board Screws 2 1002179 A Scr
38. ners the MovinCool Office Pro 63 is a spot cooler which 1000501 directs cool air to particular areas or objects MovinCool Office Pro 63 has the following features 2 2 Compact Design e The innovative design of MovinCool Office Pro 63 has resulted in one compact unit replacing the need for two separate units 2 3 Easy Transportation and Installation e With the whole cooling system built into one compact unit MovinCool Office Pro 63 requires no piping and can be easily transported and installed it eter meter Faia ALLEL TILIL Er HY TTL Peete TH ataca He afte rt ron DA HEE Te ete e i HH Hi HE HS TT es es 2 4 Energy Conservation MovinCool Office Pro 63 is economical because it cools only the area or objects which 1001905 need to be cooled 8 Operation Section 3 CONSTRUCTION 3 1 Exterior Dimensions B 55 0 z A or o na Y DIA 15 7 ll 40 8 i 2 4 51 6 al 1001906 Unit inch Operation Sectio
39. nted ogee es 11 SiG gt Transto mer hes A a ta 11 3 9 Condensate Pump o ooocooocc etn eee ee 12 3 10 Drain Tanks optional dese triana tnt tee 12 4 SPECIFICATIONS 4 1 Technical Specifications st neria ia tg tee saben pte a aN a doe Gate alee ee ed 13 AD Characteristics ors sa ce aia Sacre bike A E wea ENS ey aac site se a te a 15 5 REFRIGERANT SYSTEM 5 1 Refrigerant System Construction 000 ccc tet 16 5 2 COMPLESSOF vet sedis ds wale na ra da weet a he 17 Do GONNA A ee ee OR ae 18 9 4 Capilla Tue ven ato aia iw See adn 18 55 EVaporator est oe vee hein eee eae eee bs BN ae dee ied death ede a Stee eae eee 18 5 6 High Pressure Switch 0 0 cette nee eee 18 Table of Contents 6 ELECTRICAL SYSTEM 6 1 Circuit Diagram and Control Box 00 c ttt 19 6 2 Basic Operation of The Office Pro 63 Electrical Circuit o o ooooooooooomoooomoo 20 6 3 Mansom eree eet ete Sait ene A ae aed A E tA Se SA oes 22 6 4 Control BON ele a ara tte ene nh Anette eae ra sen eee 23 60 FANM a a a a A Ai ra 25 6 67 Compressor Motor pi io rd a ia a EA fe 26 6 7 Condensate Pump y serice siin cece Cn Ea oaa R a bia E p aTa EAEE 27 6 8 Drain SWIER a ale A i eae ae A td eine ht 29 6 9 Automatic Restart after Power Interruption 0 0 eee 30 6 10 Compressor Protecti0N ooooocoocooor tte 30 6 11 Temperature Control eines aisashse el ede Be aveeaet tea a Gok Loe ee Uk eee ee 3
40. oet 2 Fan on off relay on the relay Open circuit or insufficient Replace relay board f board contact 3 Fan HI LO change relay on Open circuit or insufficient Replace relay board the relay board contact Peron 1 Air filter Clogged air filter Clean air filter air volume 2 Evaporator Clogged evaporator or Repair and clean fins or crushed fins replace it Insufficient 7 3 3 Duct connection state Improper connection Repair duct connection air volume 4 Fan motor Insufficient rotation Replace motor 5 Transformer Low voltage Replace transformer Secondary side Repair Section 39 2 Unit does not start operate lt NOTE gt e In this case there is a possibility of safety device activating due to the clogged air filter So make sure to first clean the air filter and then start up again to confirm if the problem lies with the air filter e Check the installation site for operating temperature and installation space unobstructed airflow e Check the phase sequence of the power source If the phase sequence is reversed the control panel display and reverse phase protector LED in the control box turn off Possible Cause Symptom Remedy Checking Area Cause 1 Voltage Power failure Repair power 2 Phase sequence of the Phase sequence is Change any 2 of the 3 wires power source reversed for power source wires 3 Ground fault breake
41. operational problems Consult your reseller concerning operational environment requirements Repair Section 43 3 Inspection of cooling capacity performance e Measure the difference 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 15 proceed with the remedy suggested in the troubleshooting chart on page 37 to 42 filer 1001922 Repair Section 8 DISASSEMBLY 8 1 Parts Construction Blower housing Condenser Fan E Front Right Panel Rear Right Panel Side Panel Filter Assy Rear Panel Power Cord _ A Sa Pivoting Caster Upper Panel Upper Front Panel Control Panel ae Freeze Protection 4 Thermistor Front Panel Filter Assy Front Left Panel Evaporator Fan Condensate Pump Drain Tank Panel Drain Pan Assy Pivoting Caster Drain Tanks Optional Middle Frame Sub Assy Rear Left Panel Transformer Assy Service Panel 1001958 8 2 Disassembly 1001783 Screws YA ae a n Screws 2 gt 1001924 1001925 1001786 Repair Section 45 1 Remove drain tanks optional 2 Remove twelve 12 screws from upper front panel 3 Slide upper front panel forward and re
42. or In this case both the fan and the compressor stop when the microprocessor receives a sufficiently low intake air room temperature signal from the thermistor equal to or less than the set point When the temperature increases exceeds the set point the microprocessor restarts the fan and compressor automatically However if the unit has been off for less than 120 sec the fan starts before the compressor time delay feature 2 Cool to operate e When the DIP switch is set to the upward or OPERATE position the microprocessor controls the fan operation using control panel inputs only The fan operates continuously during fan only and cool modes This is the factory default setting 6 13 Temperature Scale Display Switch e When the DIP switch is set in the down or C position the set point and room temperature are displayed in degrees Celsius C is indicated on the LCD When the DIP switch is set in the up or F position the set point and room temperature are displayed in degrees Fahrenheit F is indicated on the LCD This is the factory default setting 32 Operation Section 6 14 Warning Signal Connection Output Signal Terminal L and L e The controller is equipped with a warning signal output relay type Form C normal open dry contact which can be used to monitor the failure condition Relay contactor is closed when the following condition has occurred Tank Full Temperature sensor f
43. otor e Measure resistance across the terminals of the i Evaporator Fan Motor fan motor All terminals must be disconnected j from the unit e Between terminals at 77 F 25 C J8 CF21 Approx 7 6 ohm J8 CF22 Approx 10 4 ohm CF21 CF22 Approx 17 7 ohm If the measured resistance is not equal to these 3 Ground Green Yellow lt J7 Low Red lt 2 CF22 Brown White lt CF21 White lt J8 High Black 1001774 standard values replace the fan motor 8 10 Inspection of Compressor Motor e Measure resistance across the terminals of the compressor motor All terminals must be disconnected from the unit e Between terminals at 77 F 25 C R C Approx 0 4 ohm C S Approx 0 6 ohm S R Approx 0 9 ohm If the measured resistance is not equal to these 1001945 standard values replace the compressor The overload relay is internal to the compressor 62 Repair Section 8 11 Inspection of Transformer e Measure resistance across the terminals of the H1 H4 transformer Saar All terminals must be disconnected from the Ao e oN unit El A E e Between terminals at 77 F 25 C 4 de E b H1 H4 Approx 0 3 ohm 5 LD X1 X4 Approx 0 3 ohm a s 98 o X1 H4 Approx Open x4 X1 1002169 If the measured resistance is not equal to these standard values re
44. otors and compressor motor 6 7 Condensate Pump Operation Section 27 e The Office Pro 63 is equipped with a condensate pump which collects the water that forms on the evaporator during normal cooling operation and eliminates the need for a drain tanks When the water collects to level A in the pump reservoir the condensate pump begins to operate and discharge the water During condensate pump operating period the compressor cycles off 3 8 in 9 53 mm I D Motor Fan Drain Outlet Spout Cover with Check Valve 1 in 25 4 mm Inlet Drain Hole L Eemi Reservoir Mounting Ear Main Control Float 1001918 When the water level drops below level B the condensate pump stops and compressor restarts after delay time has expired lt NOTE gt a 1001919 e If for any reason the water level exceeds that of level A in the pump reservoir an overflow drain switch stops the compressor operation lf the fan mode control DIP switch has been set from the cool to the stop position the fan also turns off while the condensate pump is discharging the water 28 Operation Section To insure proper drainage locate the highest vertical position no more than 17 ft 5 2 m at 460 VAC and run the drain hose on a downward slope at a minimum rate of 1 4 in 1 4 in 6 25 mm 6 25 mm per foot Taper Per Foot 3 E
45. place the transformer 8 12 Inspection of Wiring Connection e Refer to the Wiring Diagrams on page 19 and check for connection of each wire 8 13 Inspection of Thermistor e 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 10 k ohm Repair Section 63 8 14 Inspection e 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 1 Inspection of clogged system e Check the component parts of the refrigerant system including piping that could be clogged with refrigerant If clogged with refrigerant only the clogged part is frosted partially In such a case change the part in question 2 Inspection of refrigerant leak e Carefully check all connections and each component for leaks whenever the refrigerant system is installed or repaired Use an electronic gas leak tester to inspect the system 3 Insufficient refrigerant e In case the unit is judged to be deficient in cooling capacity make sure to perform the inspections in 64 9 1 1 and 64 9 1 2 to confirm the cause of trouble Then charge the system with refrigerant to the specified amount Repair Section 9 REFRIGERANT SYSTEM REPAIR 9 1 Repair of Refrigerant System 1 2 3
46. posure to heat may have caused brazing filler metal to stick to the inside and outside of the pipe Brazing filler metal may also be compounded with oxygen in the air to form oxide film Fats and oils may stick to the pipe from handling All these factors can reduce effectiveness of brazing It is necessary to eliminate excess brazing filler metal using sand paper and by cleaning thoroughly with a solvent such as trichlene A CAUTION Do not use chlorine cleaner Repair Section 65 4 Use of dry nitrogen gas e During brazing the inside of the pipe undergoes an oxidative reaction due to the brazing flame Introduce dry nitrogen gas 0 27 gal min 1 L min adjust with the flow regulator through the pinch off tube of the refrigerant lt NOTE gt Take care not to allow dirt water oil etc to enter into the pipe 5 Vertical Joint e Heat the whole brazed fitting to a proper brazing temperature Bring the brazing filler Vertical Down Joint Brazing Filler Metal metal into contact with the fitting so that the Burner brazing filler metal starts flowing by itself e Stop heating the fitting as soon as the brazing filler metal has flown into the clearance Since the brazing filler metal flows easily into the portion heated to a proper temperature it is 1000564 essential to keep the whole fitting at a proper brazing temperature Vertical Up Joint Burner Brazing Fi
47. pour water into the reservoir inlet drain hole Continue to fill the reservoir until the rising water lifts the overflow switch and stops the operation If the compressor continues to operate when the reservoir is full check your installation procedure After testing is completed release the drain outlet hose to enable the condensate pump to empty its reservoir Make sure the 9 in 230 mm section of hose is installed into the inlet drain hole of the pump reservoir 34 Repair Section 4 Inspection of drain tanks optional e Make sure tank is fully drained lt NOTE gt If the fan mode control DIP switch is set to the stop position the entire unit including fan operation turns off The following pages page 34 to 42 are self diagnostic codes and troubleshooting information Detailed information is contained in the OPERATION MANUAL supplied with the unit 7 2 Self Diagnostic Codes e Self diagnostic codes are displayed on the control board under the following conditions and clear method is as follows LCD Display Description Condition Reset Remedy Drain tanks is full When the drain tanks optional is 1 Drain away filled with drain water LCD indicates TANK TH NK TANK FL LED flashes and signal 2 Press ON OFF button El output J106 turns on L Condensate pump When condensate pump is 1 Fix the condensate pump e wi problem damaged or broken 2 Reset the system 00 J8 input of relay board turns to
48. r trip Ground fault or defective Repair ground fault section ground fault breaker Reset or repair breaker Does not Control 4 Fuse Fuse blown Repair shorting section operate at Panel Replace fuse on the relay all display turns board off Replace fuse of the transformer secondary side 5 Transformer Defective transformer Replace transformer 6 Reverse phase protector Open circuit or insufficient Replace reverse phase contact protector 40 Repair Section Possible Cause Symptom Remedy Checking Area Cause 1 Display code FL Drain tanks optional are Discharge the drain water filled with the drain water Improper drain switch Check connection connection Defective drain switch Replace drain switch 2 Display code AS Improper routing of drain Repair drain hose then reset hose unit To RESET Press ON OFF and HI LO buttons on the control box simultaneously for 5 sec Defective condensate pump Repair or replace condensate pump then reset unit To RESET Press ON OFF and HI LO buttons on the control box simultaneously for 5 sec Missing jumper connector Connect jumper connector Control Control 3 Display code RT Improper room thermistor Check connection panel Panel connection i display display Defective room thermistor Replace room thermistor shows error turns on short or open code
49. ressure gauge indicates 57 psi 390 kPa After charging is complete close the high pressure valve 5 Open the valve of refrigerant cylinder perform air purging in the charging hose green Then tighten the nut 6 Check carefully for gas leaks inside the refrigerant system using the gas leak tester 7 Repair any leak AX WARNING Do not attempt any repair on a charged system Z WARNING Before checking for gas leaks fully confirm that there is nothing flammable in the area to cause an explosion or fire Contact of refrigerant with an open fire generates toxic gas Repair Section 71 5 Evacuation repeat Valve Setting 1 Close the valve of the refrigerant cylinder Then Gauge 2 227 remove the charging hose green from the o 30 inHg 100 kPa or larger refrigerant cylinder and connect it to the Low Pressure Valve High Pressure Gauge refrigerant recovery machine High Pressure Valve lt NOTE gt 2 High Pressure Keep the high pressure valve and the low Side Tube Vacuum Pump in Operation pressure valve of the gauge manifold closed 1002227 2 Using procedure in the Evacuation evacuate the system until the low pressure gauge indicates 30 inHg 100 kPa or larger For 15 min or more 3 After evacuation is complete close the high and the low pressure valves of the gauge manifold A CAUTION Make sure to evacuate the system twice or more using
50. ring Diagram gt AC460 V 3 6 60 Hz AP A 6901781 3 IH 460 V a Y ESE yes a dE alate b SR 09 J9 98 os CFI e 1041 TB RPHR ls aN ro ie rd ey J S ot J105 osteo Mo re gC 8 ca 9 ele is 22 3 gt A P Attachment Plug IOLF Inner Overload Relay of Fan Motor TB 1 Terminal Block IOLC Inner Overload Relay of Compressor T B2 Terminal Block D S Full Drain Warning Switch C B Control Board T H S Freeze Protection Thermistor R B Relay Board RTH Room Thermistor MEF 1 Condenser Fan Motor G Grounding MF2 Evaporator Fan Motor HPRS High Pressure Switch M C Compressor Motor MCC Relay for Compressor and Condenser Fan Motor CF 1 Capacitor for Condenser Motor MDP Condensate Pump Motor C F 2 Capacitor for Evaporator Motor F D S Drain Float Switch RPHR Phase Reversal Relay ODS Drain Overflow Switch TNS Transformer F Fuse 25 A 1002172 DENSO DENSO SALES CALIFORNIA INC Long Beach CA 90810 www movincool com P N SV0003 01 Second Issue December 2008
51. rocedure 1 While pressing A and V buttons plug the power cord lt Condition gt LCD indicates current setting model name and buzzer sounds 2 After setting the model type by pressing A and V button unplug the unit ATT 2 00 HI F FAN 5 ON SET TEMP COOL F t i HP Activation of high pressure switch When high pressure switch connected to J104 activates J104 input turns to open 3 times in 24 h HP is indicated and signal output J106 turns on When it activates 10 times in 24 h FAIL HP is indicated and buzzer sounds Find the cause of high pressure to address it Check the following Ambient air temperature 65 F 18 3 C 50 RH lt 95 F 35 C 60 RH Air filter if dirty wash up Condenser fan motor if not working replace Defect of high pressure switch if switch is open when unit is off replace switch Reset the system To RESET Press ON OFF and HI LO buttons on the control box simultaneously for 5 sec Repair Section 37 7 3 Troubleshooting Chart e To accurately troubleshoot the problem it is important to carefully confirm the nature of the problem Typical problems are Insufficient cooling Unit does not start operate Overflow of drain water Abnormal noise or vibrations Others 1 Insufficient cooling e Cooling system problem generally results from electrical or mechanical components
52. room LO temperature is approximately 100 F 38 C Condenser F or greater fan mode is switched LO to HIGH ea When room temperature is approximately High 95 F 35 C fan mode is switched HI to LO 95 F 100 F Room Temperature 35 C 38 C 1001915 Operation Section 6 3 Transformer e Adry type transformer rated 5 KVA is equipped EES s Terminal Block Terminal Block within the unit to provide step down voltage Primary Secondary from 460 V single phase to 230 V single phase The terminal connection of the primary side of the transformer are labeled H1 H2 H3 and H4 Terminals H2 and H3 are shorted together to provide a series connection for 460 V application Terminals H1 and H4 are connected to 460 V power source to supply power to secondary side lt Wiring Diagram gt s Short Circuit e Terminals X2 and X3 of the secondary side are Primary also shorted together to provide 230 V output em between terminals X4 and X1 Specifications Secondary Distribution transformer 230 V Short Circuit 1001954 Type Dry type Rated VA 5000 VA Power Requirement 1 PH 60 Hz Primary Voltage 460 V Secondary voltage 230 V 6 4 Control Box 1 Reverse Phase Protector e The Reverse Phase Protector is operated at nominal voltage of 440 VAC to 480 VAC The reverse phase protector is mounted on a plug in socket terminal block where it can easily be plug
53. s 4 Display code FT Improper freeze protection Check connection thermistor connection Defective freeze protection Replace freeze protection thermistor short or open thermistor 5 Display code HP Improper high pressure Check connection switch connection Defective high pressure Replace high pressure switch short or open switch See Stops after running a while of Troubleshooting on page 41 6 Display code ALRM Turn the input signal on and 1 Check external input continue it signal 2 Reset the system To RESET Press ON OFF and HI LO buttons on the control box simultaneously for 5 sec 7 Display code FZ See Stops after running a while of Troubleshooting on page 41 Repair Section 41 Possible Cause Symptom Remedy Checking Area Cause 1 Fan on off relay on the relay Open circuit or insufficient Replace relay board board contact 2 Fan HI LO change relay on Open circuit or insufficient Replace relay board the relay board contact 3 Fan motor insulation Insulation failure on fan Replace fan motor Stops Control resistance motor immediately panel 4 Compressor relay Open circuit or insufficient Replace compressor after display contact relay starting normally 5 Compressor relay on the Open circuit or insufficient Replace relay board relay board contact 6 Compressor insulation Insul
54. s the refrigerant is sprayed out through the fixed orifice in the capillary tube As a result the temperature and state of the refrigerant becomes low and mist like respectively causing it to evaporate easily 5 5 Evaporator The evaporator like the condenser is a heat exchanger covered with plate fins Heat is removed from the air being pulled across the evaporator by the centrifugal fan and the resulting cool air is expelled through the cool air vent 5 6 High Pressure Switch The high pressure switch prevents the Pressure of Refrigerant condenser and compressor from being gt Snap Disk damaged by excessively high pressure in the Movable Point high pressure line of the refrigeration cycle Dela E z VA Pi The switch is normally closed The snap disk Stationary Point I j responds to the variations in pressure and if Case pe Terminal pressure is abnormally high the snap disk l Lead Wires 1001768 moves down to push the pin down causing the Molding by Resin internal contacts to open This interrupts the ground signal at the control board J104 connector which turns the compressor off Possible causes of this trouble include The condenser air filter is dirty restricting air flow The condenser blower is defective Operation Section
55. sure valve of the gauge manifold closed for five min or more and confirm that the gauge pointer does not return to zero If the gauge pointer returns gradually to zero there is a leak somewhere in the system this could also include gauge manifold Perform leak check according to procedure indicated in the next step Once leak has been found and repaired evacuate the system once more and confirm system holds vacuum 70 Repair Section 4 Checking gas leak Valve Setting LO Closed Closed Air Purging Y Open The Valve of Refrigerant A Cylinder To Process Tube Fitting Charging Hose Green Refrigerant Cylinder R 410A 1001901 Valve Setting LO HI LO HI Closed Open Gauge Reading Closed Closed 57 psi 390 kPa Low Pressure Valve Closed Valve RG Cylinder R 410A Refrigerant Cylinder Valve Open Side Tube Refrigerant Open High Pressure Process Tube Fitting High Pressure 1002228 1 Remove the charging hose green from the vacuum pump and connect the hose to the refrigerant cylinder R 410A 2 Loosen the nut on the gauge manifold side of the charging hose green 3 Open the valve of refrigerant cylinder perform air purging in the charging hose green Then tighten the nut 4 Open the high pressure valve of the gauge manifold Charge the system with refrigerant until the low p
56. the repetitive vacuum method Evacuate the system an additional time on rainy or humid days 72 Repair Section 9 4 Refrigerant Charging Work 1 Refrigerant charging Valve Setting LO Closed Closed Air Purging Y Open The Valve of Refrigerant Cylinder ET Charging Hose 53 Red Green 3 3 To Process Tube Fitting 1001901 Valve Setting LO HI Specified Amount LO HI Closed Open of Refrigerant Closed Closed High Pressure Valve Valve of Refrigerant Cylinder Process Tube Fitting High Pressure Side Tube Refrigerant A Cylinder R 410A 9Y 9 1001903 1 Remove the charging hose green from the vacuum pump and connect it to the refrigerant cylinder R 410A 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 After air purging tighten this nut and close the valve of the refrigerant cylinder 3 Securely place the refrigerant cylinder on a scale with a weighing capacity of 70 lb 30 kg that is graduated by 0 2 oz 5 g 4 Open the high pressure valve of the gauge manifold and the valve of the refrigerant cylinder Charge the system with refrigerant to the specified amount Standard Amount of Refrigerant 4 41 Ib 2 00 kg Z CAUTION The amount of refrigerant charged has a great effect on the cooling
57. tion while handling refrigerant Maintain the temperature of the refrigerant container below 104 F 40 C Perform repairs in a properly ventilated area Never in an enclosed environment Do not expose refrigerant to an open flame Never smoke while performing repairs especially when handling refrigerant Be careful the liquid refrigerant does not come in contact with the skin e If liquid refrigerant strikes eye or skin Do not rub the eye or the skin Splash large quantities of cool water on the eye or the skin Apply clean petroleum jelly to the skin Go immediately to a physician or to a hospital for professional treatment Step 1 Connect manifold gauge ce 1 Evacuate the system 15 min or more Step 2 e 30 inHg 100 kPa or more of vacuum When leak is found 2 Stop evacuating the system repair the connection e Leave for 5 min or components 3 Check the vacuum Step 3 Connect to refrigerant source Step 4 Test the system for leaks Charge the system with R 410A Step 5 a e See specifications on page 13 Step 6 Remove manifold gauge 1002171 68 Repair Section 1 Connection of gauge manifold Charging Hose Side Refrigerant Cycle Side Pinch Off Tube 1002183 Low Pressure Valve Closed High Pressure Valve Closed Red Hose Process Tube Fitting High Pressure Side Tube when stopped 1000568
58. tional accessory for Office Pro 63 When drain tanks are used instead of condensate pump the condensate water is collected into both tanks The drain switch activates and stops the operation when tanks reach the level of approximately 8 0 gal 30 L Operation Section 13 4 SPECIFICATIONS 4 1 Technical Specifications ITEM SPECIFICATIONS Electronic Features Control Panel Electronic Thermostat Control Electronic Cooling Capacity Capacity 60000 Btu h 17585 W Refrigerant Circuit Compressor Compression Type Hermetic Scroll Motor Rated Output at 460 V 3 89 kW Evaporator Plate Fin Condenser Plate Fin Refrigerant Control Capillary Tube Refrigerant Enclosed quantity R 410 A 4 41 Ib 2 00 kg Ventilation Equipment For Fan Type Centrifugal Evaporator Max Air Flow high low 1940 1770 CFM 3300 3000 m h Motor Rated Output high low at 230 V 0 60 0 33 kW Max External Static Pressure 0 9 IWG 224 Pa Ventilation Equipment For Fan Type Centrifugal Condenser Max Air Flow high low 2830 2650 CFM 4810 4500 m3 h Motor Rated Output high low at 230 V 1 2 0 92 kW Max External Static Pressure 0 85 IWG 212 Pa Electronic Characteristics Power Requirement 460 V 3 PH 60 Hz MIN MAX Voltage MIN 414 V MAX 506 V Current Consumption 9 5A Total Power Consumption 6 6 kW Power Factor 87 Starting Current 65 A Recommended Fuse size 2
59. ver Nuts Screws Nuts Bolts f Transformer Wire 0 ad Transformer Assy Base gt Transformer Base Transformer Nuts 1001962 Repair Section 58 1 Remove the transformer wires and pipe connect oll a Tl 7 ground wire Then remove two 2 ties o i i Transformer Wire U v a m Ground Wire l AA Ties 2 1001963 2 Remove two 2 bolts and two 2 nuts from transformer assemble frame Bolts 2 1002165 3 Slide the transformer assembly out of the unit and remove Screws 4 4 Remove four 4 screws from transformer upper cover 1002166 Screws 4 7 Transformer QZ Wire 1002167 1002168 Repair Section 59 5 Remove four 4 screws from transformer side covers Then remove transformer wire 6 Remove four 4 nuts from transformer 60 Repair Section 8 7 Inspection of Capacitor for Fan Motor and Compressor 1 Ohmmeter method e Set the ohm meter to the 10M range Place the 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

Office Pro 63 Service Manual

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