Service Manual: 2003 – 04/2007 Models
Contents
1. 1 7 Kw current consumption power factor starting current power wiring Cooling Unit cooling capability 4 230 Kcal hr 16 800 BTU hr direct expansion Blower type of fan centrifugal fan air VOLUME un 11 Evaporator Hi speed 540 ft min 913 m3 h Condenser Hi speed 770 ft min 1301 m3 h 1111101 1 1110 0 24 Hi n 0 19 Kw Lo Compressor refrigerant type refrigerant capacity 1 54 Ibs 0 70 kg Safety Devices compressor overload relay included fan motor protector included anti freezing thermistor included full drain tank switch included power interruption feature included time delay feature included Dimensions amp Weight WxDxH in 21 x 27 4 x 44 533 4 x 696 x 1118 weight Ibs kg 210 95 Operating Conditions inlet air relative humidity 95 F 35 C lt 60 65 F 18 3 C gt 60 Control Device temperature control included programmable timer included two speed fan included Specifications Specifications are subject to change without notice CONSTRUCTION AND SPECIFICATIONS Exterior Di2. BRAIN WATER 7 lt gt Di at 41 777 Operation of Drain Switch 7 How to re start the unit If the program Run LED is flashing press the Cool On Off button to continue running the program If the program Run LED is illuminated continuously program activated no further steps are necessary If no program exists or the program was deactivated press one of the fan mode buttons or the Cool On Off button The unit will return to the previous Temperature Set Point 8 Condensate Pump Kit optional The Office Pro 18 model comes standard with a drain tank which collects the water that forms on the evaporator during normal cooling operation If the unit is required to operate continuously without periodic emptying of this tank a condensate pump may be needed A condensate pump kit CPK 3 is available for the Office Pro 18 model 9 Automatic Restart after Power Interruption The program within the microprocessor of the Office Pro 18 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 Any Preset Program will also be retained in the memory in the event power loss occurs ELECTRICAL SYSTEM 10 11 12 Compressor Protection There is a Time Delay program within the microprocessor This p
3. Fats and oils may stick to the pipe from handling All these factors will reduce effectiveness of brazing It is necessary to eliminate excess brazing filler metal using sand paper and by cleaning Brazing Filler Metal thoroughly with a solvent such as Trichlene USE OF DRY NITROGEN GAS During brazing the inside of the pipe under goes an oxidative reaction due to the brazing flame Introduce dry nitrogen gas 1l min adjust with the flow regulator through the pinch off tube of the refrigerant cycle to prevent oxidation Vertical Down Joint NOTE Take care not to allow dirt water oil etc to enter into the pipe e VERTICAL JOINT Heat the whole brazed fitting to a proper brazing temperature Bring the brazing filler metal into contact with the fitting so that the brazing filler metal starts flowing by itself Stop heating the fitting as soon as the brazing filler metal has flown into the clear ance Since the brazing filler metal flows Burner easily into the portion heated to a proper temperature it is essential to keep the whole fitting at a proper brazing temperature Brazing Filler Metal TROUBLESHOOTING AND REPAIR B Removal of Refrigeration Cycle Components ACAUTION 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 conduct
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5. compression mechanism compressor When the rotor shaft of the motor drive mechanism turns the roller of the compres sor compression mechanism rotates to compress the refrigerant B Basic Compressor Operation DISCHARGE HOLE The roller compression mechanism is set DISCHARGE SPRING eccentrically with a certain distance given YALVE SUCTION from the axis of the center of the cylinder A 5 spring loaded blade is mounted on the cylinder The roller turns to compress the refrigerant in the space between the cylinder and eccentrically mounted roller The blade is in contact with the roller by means of spring force It partitions the space between the suction side and the discharge CYLINDER side to keep compressed refrigerant from returning to the suction side Compressor Operation There is no suction valve The discharge valve is designed not to open until the pressure of the refrigerant within the cylinder reaches or exceeds that of the refrigerant on the discharge side This design prevents the backward flow of discharge gas 3 Condenser The condenser is a heat exchanger with copper tubes that are covered with thin aluminum projections called plate fins 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 REFRIGERANT SYSTEM 4 Capillary Tube HIGH TEMP HIGH PRESSURE The capillary tube is a long thin tube
6. thirteen 13 screws from rear panel H Remove ten 10 screws eight shown from upper rear panel and two 2 screws on top Removal of Back and Upper Rear panel Screws 10 Removal of Electrical Parts 18 60Hz 666666 3 102 101 AUX 5 AUX2 le 0 J201 J104 qm Attachment Plug Inner Overload Relay of Compressor Terminal Block Full Drain Warning Switch Control Board Freeze Protection Thermistor Relay Board Room Thermistor Fan Motor Ground Compressor Motor Capacitor for Fan Motor Capacitor for Compressor Auxiliary Connector Internal Overload Relay of Fan Motor Auxillary Connector Jumper 5 RELAY BOARD FUSE DIP SWITCH 000 TERMINAL BLOCK COMPRESSOR CAPACITOR FAN CAPACITOR Removal of Electrical Parts in the Control Box 26 TROUBLESHOOTING AND REPAIR TO FAN MOTOR TERMINAL BLOCK LOW SPEED F TERMINAL TO FAN MOTOR TO COMPRESSOR HIGH SPEED TERMINAL BLOCK 74 0 R TERMINAL 7 J2 Xl RELAY BOARD GROUND NOT USED OPERATE DA 250V DIP SWITCH RELAY BOARD FUSE 1 0 25 TEMPERATURE SCALE DISPLAY SWITCH 19 stop 9 FAN MODE CONTROL SWI
7. utilizing line LIQUID REFRIGERANT flow resistance to serve as an expansion valve gt The length and the inner diameter of the capillary tube are determined by the capacity of the refrigeration system specified operating condi tions and the amount of refrigerant The capillary tube causes the high pressure high temperature liquid refrigerant sent from the gt condenser to expand rapidly as the refrigerant is LOW TEMP LOW PRESSURE sprayed out through the fixed orifice in the GAS AND LIQUID MIXTURE capillary tube As a result the temperature and state of the refrigerant become low and mist like Capillary Tube respecitively causing it to evaporate easily 5 Evaporator The evaporator like the condenser is a heat exchanger covered with spine 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 FROM EVAPORATOR 6 Accumulator The accumulator is mounted on the suction gas piping between the evaporator and the compres Sor The accumulator separates the liquid refriger ant from the gas refrigerant letting only the gas refrigerant enter the compressor In the accumu lator suction gas is led into a vessel having a cylindrical body and the gas speed is decreased inside the vessel This separates the refrigerant contained in the gas by the force of gravity causing it to accumulate at the bottom of the vessel This p
8. I Then remove the charging hose green eios ee from the refrigerant cylinder and connect 0 ME 5 5 High P G it to the refrigerant recovery machine sauge NOTE Keep the high pressure valve and the low war High Pressure Valve pressure valve of the gauge manifold closed 2 Using procedure 20B evacuate the system until the low pressure gauge T indicates 750mmHg 30in HG or greater y 2g PLR Side Tube For 15 minutes or more m PSE Vacuum Pump lin operation 3 After evacuation is complete close the high and the low pressure valves of the gauge manifold A CAUTION Be sure to evacuate the system twice or more using the repetitive vacuum method Evacuate the system an additional time on rainy or humid days 38 TROUBLESHOOTING AND REPAIR Valve Setting 22 Refrigerant Charging Work HI _ A Refrigerant Charging Closed Closed WII 1 Remove the charging hose green from the vacuum pump and connect it to the Open The Valve 7 refrigerant cylinder R 22 of Refrigerant Air Purging Cylinder di 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 Blue Charging Hose green Hed To Process Tube Fitting E Refrigerant wi Cylinder 5 22 Valve Setting 3 Securely place the refrigerant cylinder on m o a scale w
9. Remove nine 9 screws from right side panel G Remove two 2 screws from the control panel stay Remova H Remove two 2 screws from the control panel stay Removal of Control Panel 30 TROUBLESHOOTING AND REPAIR Disconnect the following connectors from the control board 1 Wire Harness Relay Board to Control Board J201 10 pin 2 Room Temperature Thermistor J101 2 pin 3 Freeze Thermistor J102 2 pin with black tape 4 Drain Tank Switch J103 2 pin 9 Auxillary 2 J104 Jumper NOTE Mark each of the 2 pin connectors with a different color marker to ensure the correct orienta tion when they are reconnected or label all wire sets with tape Numbering the wire sets from one 1 thru four 4 J Remove the five 5 screws from the control board on the control panel assembly Remove the control board Removal of Control Board 12 Inspection of Capacitor for Fan Motor and Compressor Ohmeter Method Set the ohmeter to the 100KQ range Place the two probes against the two terminals of the capacitor At first the ohmeter should indicate OQ then the reading should gradually increase towards infinity This indicates that the capacitor is charging If the reading indicates infinity right away shorted or the ohmeter fails to move from 00 open replace the capacitor 13 Capacitance Tester Method Using a capacitance tester and the chart on page Inspection
10. SERVICE MANUAL OFFICE PRO 18 UL MOVINCOOL THE PORTABLE SPOT COOLING SOLUTION 2003 DENSO SALES CALIFORNIA INC All rights reserved This book may not be reproduced or copied in whole or in part without the written permission of the publisher DENSO SALES CALIFORNIA INC reserves the right to make changes without prior notice MovinCool is a registerd trademark of DENSO Corporation FOREWORD This manual has been published to service the MovinCool Office Pro 18 Please use this service manual only when servicing the Office Pro 18 DEFINITION OF TERMS AWARNING 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 unit operation GENERAL PRECAUTIONS AWARNINGS 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 purchased from an autho rized reseller When handling refrigerant always wear proper eye protection and do not allow the refrigerant to come in contact wit
11. TCH STOPS OPERATE o D RELAY BOARD TO CONTROL PANEL C JUMPER OR 2 PIN CONNECTOR OF CONDENSATE PUMP KIT CPK 3 OPTIONAL Connections to Relay Board JUMPER DRAIN TANK SWITCH FREEZE THERMISTOR ROOM THERMISTOR MAIN WIRING HARNESS CONTROL PANEL TO RELAY BOARD Connections to Control Board 27 TROUBLESHOOTING AND REPAIR 11 Removal of Blower Assembly Control Panel Right Stay 9 d Control Panel Left Stay 2i Air Diverter Evaporator Fan 5 Moto e Middle Frame Sub Assy 1 r Stay Fan Motor Condenser Fan Casing Assy z Condenser Fan Ring Sub Assy Disassembly of Blower 28 TROUBLESHOOTING AND REPAIR A Loosen the set screw using an allen wrench and then remove the centifugal fan B Remove the two 2 nuts A on the inside of the housing in the locations shown Then remove the blower housing condenser A NUT C Remove the two 2 nuts A and two 2 screws B as shown Then remove the motor bracket together with the fan motor A NUT B SCREW D Remove the centrifugal fan by loosening the set screw on the shaft Remove the fan motor by loosening nuts A Removal of Fan Motor 29 TROUBLESHOOTING AND REPAIR E Remove seven 7 screws from left side panel F
12. difference in temperature between the inlet ofthe evaporator and the cool air vent Ifthe difference is out of the range given in the graphs on page 8 proceed with the remedy suggested in the troubleshooting chart on page 19 AIR OUT THERMOMETER E EVAPORATOR AIR IN Cooling Capacity 22 TROUBLESHOOTING AND REPAIR 9 Disassembly 1 Control Panel Right Handle Room Thermistor Left Panel Blower Housing evap d o Blower Housing Condenser Fan 2 1 0 Drain Pan Assy Rear Panel e Freeze Thermistor Drain Tank Panel Assy Service Panel Disassembly 23 TROUBLESHOOTING AND REPAIR 9 i S gt tc E Removal of Drain Tank Removal of Upper Front Panel Screws gt E c G c d c 6 gt o O Removal of Upper Front Panel TROUBLESHOOTING AND REPAIR D Louver can be removed from upper front panel by unsnapping it rearward Removal of Air Outlet Louver E Remove four 4 screws from service panel Removal of Service panel Disconnect the three 3 lead wires of the power cord Removal of Power Cord Screws 25 TROUBLESHOOTING AND REPAIR G Remove
13. e Wiring Diagrams on page 39 and check for connection of each wire 18 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 19 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 A Inspection of Clogged System 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 Inspection of Refrigerant Leak 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 Insufficient Refrigerant In case the unit is judged to be deficient in cooling capacity be sure to perform the inspections in 18A and 18B to confirm the cause of trouble After that charge the system with refrigerant to the specified amount 33 TROUBLESHOOTING AND REPAIR 20 Repair of Refrigerant System In case there is leak obstruction or trouble in the refrigerant system of the Spot Cooling System replace or repair the part in question After replacing any compone
14. ective Relay Board Defective Control Board Insufficient Cooling cont d Compressor not operating Defective Overload Relay Defective Fan Motor Defective Compressor Motor Defective Relay Board Defective Compressor Motor Defective Overload Relay Defective Fan Motor Drain Tank Full Fan Mode Switch is set to Stop and compressor cycled off Drain Tank not installed Drain Tank is defective cracked Drain Pan hole is obstructed Loose Compressor mounting nut Deformed or worn rubber grommet on the compressor mounting bolt Internal interference with other components Damaged or out of balance fan and scroll Fan Motor not operating Clogged spine fins or Evaporator or Condenser running unit without filter s Fan mode switch on Low Defective fan motor Environmental conditions exceed design specifications Clogged air filter 20 Clogged plate fins Set point temperature exceeds room temperature Defective room temperature thermistor Leak in refrigerant system Restriction in refrigerant system Compressor not operating Set point temperature exceeds room temperature Unit is operating in Fan Only Mode Cool Mode not activated Jumper on Control Board J104 not installed correctly Jumper on Relay Board J8 or J10 not installed correctly Defective Condensate Pump optional Defective Compressor Capacitor Defective overload relay Defective Thermistor Defective Compressor Motor Check wiri
15. ed flow rate 11 through the pinch off tube during any brazing operation 3 During any component replacement involving brazing shield nearby parts with a steel plate asbes tos etc to protect them from the flame 1 Evaporator 2 Capillary tube 3 Condenser 4 Compressor NOTE Hold the compressor body not the tube when carrying the compressor PART TO REPLACE DISCONNECT AT Compressor B amp D Condenser A amp C Capillary Tube E F amp G Evaporator D amp E Refrigeration Cycle Components 35 TROUBLESHOOTING AND REPAIR 21 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 AWARNING When handling refrigerant R 22 the following precautions should always be observed Always wear proper eye protection while handling refrigerant Maintain the temperature of the refrigerant container below 40 C 104 F Perform repairs in a properly ventilated area Never in an enclosed environment Never smoke while performing repairs especially when handling refrigerant Do not expose refrigerant to an open e Be careful the liquid refrigerant does not come in contact with the skin 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 j
16. elly to the skin Go immediately to a physician or to a hospital for professional treatment STEP1 CONNECTION OF MANIFOLD GAUGE STEP2 EVACUATING THE SYSTEM 15 MINUTES OR MORE 750 mmHg inHg OR WHEN LEAK IS FOUND REPAIR THE MORE OF VACUUM CONNECTION OR COMPONENTS STOP EVACUATI ING THE SYSTEM CHECK THE VACUUM 2 LEAVE FOR 5 MINUTES Z D STEP3 CONNECT TO REFRIGERANT CYLINDER TTT 4 TESTING THE SYSTEM FOR LEAK Y STEPS CHARGING TH AMOUNT OF HCFC22 E SYSTEM WITH SPECIFIED n STEP6 REMOVAL OF MANIFOLD GAUGE A Connection of Gauge Manifold 1 Properly remove the crushed end of the pinch off tube at the high pressure side and the low pressure side of the refriger ant cycle with a pipe cutter Refrigerant Cycle 2 Fit the process tube fitting to the pinch off tube on both sides E Pinch off Tube TROUBLESHOOTING AND REPAIR 3 Connect the charging hoses red high pressure side blue low pressure side of Low Pressure Ng the gauge manifold to the process tube Valve Closed PNO High Pressure Valve 4 Closed Green Hose E d _ Red Hose fittings NOTE Connect the hoses using care not to mistake Process Tube Fitting the high pressure side for the low pressure side and vice versa High P
17. esent at Cycle Side the pinched off portion and the brazed end 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 23 Compressor Mounting Mount the compressor on the frame using cushions steel collars spring washers plate washers and nuts 24 Blower Assembly E Install blower fans for evaporator and con A Compressor denser ibas Tightening torque O 10 84 2 17 Ibfeft 150 30 kgfecm 25 Wiring Notice Secure the wires using clamps so that they do Cushion Steel Collar not come into contact with the edges of the structure etc Secure the wires using clamps in the same position they were before removal 26 Perform the inspection of cooling capacity and check for abnormal noise or abnormal vibration 0 06 inches 0 06 inches 1 5 mm or more more 40 TROUBLESHOOTING AND REPAIR 27 Schematic Jeduunf Jojsiuueu wooly J04SIWISOUL uonooe104g 929914 YOUMS 1055310101042 rolf CE exnv 001 LOLP exnv LXNV HLY SHL sa 370 JOJO Uey Aejay peono 16055310101042 5 J4010 N
18. essor at start up RELAY BOARD The specifications of each capacitor are RELAY BOARD FUSE DIR SWITCH listed below CAPACITOR VOLTAGE APPLICATION RATING uf TERMINAL BLOCK Fan Motor 370 Compressor 370 B Relay Board The Relay Board receives signals and outputs COMPRESSOR MES from the control board that contains a micro processor The relay board contains the compressor fan on and fan mode speed relays It also contains a step down trans former that converts the line voltage 115 VAC to 12 volts This is then converted from AC to DC and used for relay coil activation The 12V DC power is sent to the Control Panel Assembly where it is further reduced to 5 volts for the system logic Control Box The relay board also contains the DIP Switch The DIP Switch is used to change the Fan Mode operation from Stop to Operate and change both the Set Point and Room tem perature display from F to Note The relay board must be serviced as a com plete assembly It has only one serviceable compo nent the fuse See below DIP Switch Temperature Scale Display Switch C Fan Mode Control Switch STOP gt OPERATE Relay Board Fuse Note The relay board fuse is the only serviceable component on the relay board assembly DIP Switch This fuse provides protection against damage to the step down transformer It must be replaced with the exact
19. f the compressor The relay will interrupt the flow of current when there is an overload caused by a high temperature condition in the compressor ELECTRICAL SYSTEM 6 Drain Switch The Office Pro 18 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 microprocessor The microprocessor stops all operation of the unit and flashes the Tank Full LED This system utilizes a 1 AMP 250 VAC micro switch for this function When drain water accumulates approximately 4 0 gallons 15 liters in the drain tank 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 and flashes the Tank Full LED When the drain tank is removed or the drain tank is emptied the top of the drain tank base plate returns to its original position from the tension of the coil spring Then contacts 1 2 of the drain tank switch close This provides a ground to the microprocessor through the J103 connector DRAIN TUBE oS SEN 7 2 DRAIN TANK
20. h your skin Do not expose refrigerant to an open flame The proper electrical outlet for MovinCool units must be equipped with a UL approved ground fault breaker to prevent electrical shock from the unit When brazing any tubing always wear eye protection and work only in a well ventilated area TABLE OF CONTENTS POPE WORD ES Su 002 i DEFINITION OF TERMS aang GENERAL PRECAUTIONS ze eis alien i TABEE OR CONTENTS ernennen iii GENERAL DESCRIPTION e 1 CONSTRUCTION SPECIFICATIONS amp DATA cessere 3 REFRIGERANT SYSTEM 2 scie aes cl tua see 9 ELECTRICAL SYSTEM p irn 13 TROUBLESHOOTING S REPAIR en 19 EVAPORATOR CONDENSER INDOOR UNIT OUTDOOR UNIT Conventional Air Conditioner Office Pro 18 GENERAL DESCRIPTION Generally speaking conventional air conditioners cool the entire enclosed environment They act as heat exchangers requiring an interior unit evaporator to blow cool air into the interior and an exterior unit condenser to exhaust exchanged heat to the out doors Unlike conve
21. hecking Gas Leak 1 Remove the charging hose green from the vacuum pump and connect the hose to the refrigerant cylinder R22 2 Loosen the nut on the gauge manifold side of the charging hose green TROUBLESHOOTING AND REPAIR Valve Setting Closed Closed e Air Purging Open The Valve E5 of Refrigerant _ Y Cylinder Blue Charging Hose green Red To Process Tube Fitting E Refrigerant amp Cylinder 22 3 Valve Setting LO HI Low Pressure LO HI Closed Open Gauge Reading Closed Closed 3 Open the high pressure valve of the ieee gauge manifold Charge the system with ne 57 refrigerant until the low pressure gauge TA w Pressur e v indicates 57 PSIG 4 kg cm G After ae a charging is complete close the high Pressure vaiva pressure valve J 5 4 Check carefully for gas leaks inside the Refrigerant X High Pressure refrigerant system using the gas leak ic s MEE tester E gt 5 ANWARNING Do not attempt any repair a AWARNING Before checking for gas leaks fully charged system 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 E Evacuation Repeat Valve Setting Low Pressure Gauge 1 Close the valve of the refrigerant cylinder LO Hi LO H
22. ith a weighing capacity of 70 Ibs Closed Open of Refrigerant Closed 30 kg that is graduated by 0 2 oz 6 g Open the high pressure of the SE gauge manifold and the valve of the Refrigerant 9 refrigerant cylinder Charge the system ard il with refrigerant to the specified amount Standard Amount of Refrigerant u 24 64 1 54 Ibs 700g If the system cannot be charged with the specified amount of refrigerant under this condition follow the steps below a Close the high pressure valve of manifold b Operate the refrigerant system Slowly open the low pressure valve while observing the scale reading d When the scale reads the specified amount immediately close the low pressure valve e Bring the system to a stop ACAUTION The amount of refrigerant charged has a great effect on the cooling 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 39 TROUBLESHOOTING AND REPAIR B Removal of Gauge Manifold 1 Crimp the pinch off tube with a pinch off Pinch off Tool tool a To Gauge N Manifold Side 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 To Refrigerant 4 Ensure that a gas leak is not pr
23. mensions units inches 115V anne mee Ej d 7 8 1 4 4 7 1 2 6 13 23 4 a 12 2 1 6 BS T 11 19 8 NNI m Een Sc 10 18 0 x x 3 5 14 8 9 16 2 3 0 X Ee y NK 6 1 0 8 30 40 50 60 70 80 won ANN Cool Air Temperature Difference Curve NS 3 0 12 L 25 77 20 68 50 59 68 77 Wet Bulb Temperature C SEI Cooling Capability Curve 4 Dry Bulb Temperature C F Power Consumption kW ER UA 20 68 Zar ra 2 Dry Bulb Temperature C F Power Consumption Curve REFRIGERANT SYSTEM 1 The component parts of the refrigerant system include the following Compressor e Evaporator Condenser Accumulator Capillary tube These parts are all connected by copper tubing All the connections have been brazed EVAPORATOR CONDENSER CAPILLARY TUBE ACCUMULATOR COMPRESSOR REFRIGERANT FLOW 4 ACCUMULATOR CAPILLARY 1 ____ EVAPORATOR S COMPRESSOR Refrigerant System REFRIGERANT SYSTEM 2 Compressor The compressor used for the unit is hermetically sealed The compressor and the compressor motor are in one casing A Compressor Construction The construction of a rotary type compressor is divided into two mechanisms The drive mechanism compressor motor and the
24. ng connections Defective Relay Board Defective Control Board Fan mode switch is set to Stop and current Set Point Temperature exceeds Room Temperature Fan mode switch is set to Stop and unit has been equipped with optional Condensate Pump that is defective Fan mode switch is set to Stop and Jumper on Control Board J104 or Relay Board J8 or J10 is not installed correctly Check wire connections Defective fan motor capacitor Defective fan motor Defective Relay Board Defective Control Board TROUBLESHOOTING AND REPAIR In case of trouble perform the following inspection before disassembly 6 Inspection of Plate Fins To inspect the plate fins of either the evaporator or condenser you must remove the air filters After removal of the air filters inspect the plate fins for any dirt dust lint or debris that may have caused poor cooling performance of the unit If cleaning of the fins is necessary it is recom mended that this service be performed by a qualified service technician Examination of Operating Environment Operating environments will vary depending on location climate and surrounding conditions Installation location also can cause operational problems Consult your reseller concerning operational environment requirements 5 Plate Fins Operating Environment TROUBLESHOOTING AND REPAIR 8 Inspection of Cooling Capacity Measure the
25. nt all connections must be brazed A Proper Brazing Techniques It is desirable to use 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 FITTING AND ITS CLEARANCE In general the strength of brazing filler metal is lower than that of the base metal So the shape and clearance of the brazed fitting are Clearance quite important As for the shape of the 0 025 0 075 mm brazed fitting it is necessary to maximize its adhesive area The clearance of the brazed Te pup fitting must be minimized to facilitate brazing fel Reh filler metal to flow into it by capillary action CLEANING OF BRAZING FILLER METAL AND PIPE When the refrigerant system has been Form the Pipe Fitting with a Tubing Tool opened up exposure 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
26. ntional air conditioners the MovinCool Spot Cooling System is a spot cooler which directs cool air to particular areas or objects MovinCool Spot Cooling Systems have the following features 1 Compact Design The innovative design of MovinCool has resulted in one compact unit replacing the need for two separate units 2 Easy Transportation and Installation With the whole cooling system built into one compact unit MovinCool requires no piping and can be easily transported and installed 3 Energy Conservation MovinCool is economical because it cools only the area or objects which need to be cooled GENERAL DESCRIPTION CONSTRUCTION AND SPECIFICATIONS EVAPORATOR CAPILLARY ACCUMULATOR IE COMPRESSOR ion of Office Pro 18 CONSTRUCTION AND SPECIFICATIONS EVAPORATOR FAN CONTROL PANEL 2 T T T 3 COOL AIR VENT gg LL FRONT PANEL EVAPORATOR e DRAIN TANK CASTER Construction Diagram TOP PANEL e e EXHAUST AIR VENT e RIGHT HANDLE e SIDE PANEL e 1 gt ___FAN MOTOR CAPILLARY TUBE e COMPRESSOR PZN ACCUMULATOR CONDENSER ar POWER CORD CONSTRUCTION AND SPECIFICATIONS 1 Basic Construction The MovinCool S
27. of Capacitor 15 test the capacitor for the value indicated If the value tested is not within 1096 of indicated capacitance replace the capacitor AWARNING Properly discharge the capacitor s before testing and after testing has been com pleted Failure to do so could cause damage to test equipment or the unit and or result in per sonal injury electrical shock or death TROUBLESHOOTING AND REPAIR 14 Inspection of Drain Switch Check for continuity between terminals 1 and 2 Continuity should exist With switch depressed no continuity should exist between terminals 1 and 2 If continuity is not as specified above replace the switch DRAIN SWITCH To J103 Inspection of Drain Switch 15 Inspection of Fan Motor Measure resistance across the terminals of the fan motor Terminals at 77 F 25 C J6 CF1 Approx 3 39 J5 CF1 Approx 4 49 CF1 CF2 Approx 33 8Q If the measured resistance is not equal to these standard values replace the fan motor Inspection of Fan Motor 16 Inspection of Compressor Motor Measure resistance across the terminals of the compressor motor Terminals at 77 F 25 C R C Approx 0 69 C S Approx 1 69 S R Approx 2 19 If the measured resistance is not equal to these standard values replace the compressor The overload relay is internal to the compressor Inspection Of Compressor 32 TROUBLESHOOTING AND REPAIR 17 Inspection of Wiring Connection Refer to th
28. ow 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 will restart the fan and compressor automatically However if the unit has been off for less than 75 sec the fan will start before the compressor time delay feature B Cool to Operate When the Dip Switch is set to the Up or Operate position the microprocessor controls the fan operation using control panel inputs only The fan will operate continuously during Fan Only and Cool Modes This is the factory default setting 13 Temperature Scale Display Switch When the DIP Switch is set in the down or C position the Set Point and Room Temperature will be displayed in degrees Celcius The LED that indicates C will also be illuminated When the DIP Switch is set in the up or F position the Set Point and Room Temperature will be displayed in degrees Farenheit F The LED that indicates F will also be illuminated this is the factory default setting TROUBLESHOOTING AND REPAIR Before troubleshooting the system the following inspection should be performed 1 Inspection of Power Source Voltage Check the voltage of the power source Single phase 115 volts 60Hz Check the operation and condition of the fuse or circuit breaker in the power source Inspection of Air Filters Remove the air filters and check the element If
29. pot 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 The rear section contains the condenser the compressor and the control box 2 Air Flow Air drawn from the right side face passes through EXHAUST the condenser which extracts the heat This hot AIR QUT 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 while the exhaust air duct is protected by wire mesh AIR OUT EVAPORATOR AIR IN A CONDENSER AIR IN Air Flow 3 Compressor and Fans The compressor is hermetically sealed A two speed fan motor is used with two centrifugal fans to draw air across the evaporator and condenser 4 Drain Tank The capacity of the drain tank is 5 0 gallons 19 liters The unit is equipped with a Tank Full LED and a device to automatically stop the operation of the unit when the drain tank reaches a level of approximately 4 0 gallons 15 liters CONSTRUCTION AND SPECIFICATIONS Rating Conditions dry bulb 95 F 85 C wet bulb 83 F 28 2 C humidity Specifications power frequency line voltage single phase 115 V power consumption
30. ressure Side Tube Low Pressure 4 Connect the charging hose green at the center of the gauge manifold to the j vacuum pump Vacuum Pump at a stop Valve Setting B Evacuation Low Pressure Gauge Lo Hi LO 1 Open the high pressure valve HI and the Open Open Closed Closed low pressure valve LO of the gauge 750 mmHg or larger manifold High Pressure 2 Turn on the vacuum pump to start evacuation Evacuate the system for approximately 15 minutes lt High Pressure Valve ea 3 When the low pressure gauge indicates 750mmHg 30in Hg or larger turn off the PA Side Tube vacuum pump and close the high and low Vacuum Pump NS pressure valves of the gauge manifold in operation C Checking Vacuum Leave valves closed for 5 minutes Valve Setting Lo T pi more Pointer of low pressure 1 Leave the high pressure valve and the nnd to zero indicates low pressure valve of the gauge manifold we ys closed five minutes or more and Low Pressure Gauge confirm that the gauge pointer does not return to zero 2 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 20D Once leak has been found and repaired evacuate the system once more and confirm system holds vacuum Brazing of Piping 37 C
31. revents 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 tem perature set point thermostatic control power interruption restart or Condensate Pump optional opera tion Time Delay Program Specifications 120 10 sec 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 W buttons on the Control Panel The adjustment range of the Temperature Set point is 65 F to 90 F 18 3 C to 32 C Fan Mode Control Switch 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 There are two settings A Cool to Stop When the Dip Switch is set in the down or stop position the microprocessor controls the fan motor using the same room temperature thermistor that it uses to control the compressor In this case both the fan and the compressor stop when the microprocessor receives a sufficiently l
32. rotects the compressor from possible damage caused by the intake of liquid refrigerant TO COMPRESSOR lt Accumulator REFRIGERANT SYSTEM EVAPORATOR CONDENSER CAPILLARY TUBE ACCUMULATOR COMPRESSOR Refrigerant System Piping ELECTRICAL SYSTEM 18 60Hz 3 102 101 AUX2 e J104 Attachment Plug Inner Overload Relay of Compressor Terminal Block Full Drain Warning Switch Control Board Freeze Protection Thermistor Relay Board Room Thermistor Fan Motor Ground Compressor Motor Capacitor for Fan Motor Capacitor for Compressor Auxiliary Connector Internal Overload Relay of Fan Motor Auxillary Connector Jumper RELAY BOARD RELAY BOARD FUSE DIP SWITCH 000 TERMINAL BLOCK COMPRESSOR CAPACITOR FAN CAPACITOR Electrical System and Control Box for Office Pro 18 ELECTRICAL SYSTEM 1 Basic Operation Of The Office Pro 18 Electrical Circuit There are two basic components used to control the operation of the Office Pro 18 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 Fan Only Mode Low Fan Mode When the Low Fan Mode bu
33. the element is dirty wash it as described in the OPERA TION MANUAL supplied with the unit Inspection of Drain Tank Be sure tank is fully drained The following chart is provided as a guide for categorized problem remedies Detailed information is contained in the OPERATION MANUAL supplied with the unit Self Diagnostic Codes Self Diagnostic codes will be displayed on the control board under the following conditions TANK dF When the evaporator anti freeze ther mistor disengages the compressor FULL FL When the drain tank switch shuts off the SETPOINT ROOM unit full tank LED flashes SET TEMP CLOCK TIMER AS When unit disengages the compressor while the condensate pump is discharg ing water FAN ON OFF LO Lowest temperature set point START TIME HI Highest temperature set point END TIME SET CLOCK SET RUN COOL ON OFF PROGRAM MOVINCOOL Office Pro 18 OP18 Control Panel TROUBLESHOOTING AND REPAIR 5 Troubleshooting Chart Probable Probable Unit does not operate at all Unit starts but stops immediately Unit operates but stops after a few minutes Water leakage from the unit Abnormal noise and or shaking Insufficient Air Flow Insufficient Cooling Check for Power at Receptacle Check for Power at Terminal Board Check for Power at Relay Board Check all wire connections Defective Drain Tank Switch Check Relay Board Fuse Def
34. tton on the control panel is pressed the microprocessor turns on the button s LED and activates the Fan On Relay Relay Board sending line voltage 115 to the Normally Closed contacts of the fan mode relay This output is connected to the J5 terminal relay board where the LOW SPEED wire of the fan motor is connected High Fan Mode When the High Fan Mode button on the control panel is pressed the microproces sor turns on the button s LED and activates both the Fan On Relay and Fan Mode Relay This sends line voltage 115 VAC from the Fan On Relay to the N O Normally Open contacts of the Fan Mode Relay This output is connected to the J6 terminal Relay Board where the HIGH SPEED wire of the Fan Motor is connected Cool Mode In addition to Fan Only Mode as described above when the Cool On Off button on the control panel is pressed the microprocessor turns on the button s LED and ifthe Temperature Set Point is less than the current room temperature activates the Compressor Relay Relay Board This sends line voltage 115 VAC to the J4 terminal Relay Board where the wire from pin 2 of the Compressor Overload Relay is connected to Pin 1 of the Compressor Overload Relay is connected by wire to the compressor ELECTRICAL SYSTEM 2 Control Box A Capacitors The capacitors are used to temporarily boost the power output available to the fan motor and the compr
35. type of fuse or an equivalent Fuse Specifications 250mA 250V ACAUTION Failure to use the exact type of fuse could result in damage to the unit and or to components It will also void the warranty of the unit JoPERATE efolr F1 0 250 250V STOP Relay Board ELECTRICAL SYSTEM 3 Fan Motor The fan motor is a single phase induction type two speed motor The motor rotates fans on the evaporator side and the condenser side at the same time Specifications Rated Voltage 115 volts 60 Hz Rated Output High 240 watts Low 190 watts 2 CF1 White CF2 Brown White NOTE An internal overload relay is used to protect dl p High lacey the fan motor This relay is built into the fan motor Green Yellow and will interrupt the flow of current when there is Fan Motor an overcurrent situation or if abnormally high temperature builds up in the fan motor 4 Compressor Motor The compressor motor is a single phase motor and is contained within the same housing as the compressor Specifications Rated Voltage 115 volts 60 Hz Rated Output 950 watts 5 Compressor Overload Relay An external compressor overload relay is used to protect the compressor motor This relay is mounted within the connector housing that attaches to the top o
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