Office Pro W20 Service Manual
Contents
1. A E o o HL t p E z E gt Oo Hi EA O o A o Y G JN 1 4 1 4 A 5 L65 3 19 3 4 6 20 9 2 0 27 4 i Unit inch ILL00132 00 8 Operation Section 2 2 Technical Specifications ITEM SPECIFICATIONS Electronic Features Operation Digital Programmable Electrical Characteristics Voltage Reguirement Single Phase 115 V 60 Hz Operating Max 127V Voltage Range Min 104 V Starting Current 65A Recommended Fuse Size 15A FLA 11 7A LRA 65A Cooling Capacity and Power Consumption Air 80 F 27 C 50 RH Total Cooling Capacity 15700 Btu h 4590 W Water EWT LWT 85 F Sensible Cooling Capacity 10800 Btu h 3180 W 95 F 29 C 35 C Power Consumption 1 28 kW Current Consumption 11 7A EER 12 3 Power Factor 95 Compressor Type of Compressor Hermetic Rotary Output 1 16 kW Evaporator Type of Evaporator Plate Fin Type of Fan Centrifugal Fan Air Flow High 565 CFM 960 m3 h Low 540 CFM 918 m3 h Max External Static Pressure 0 31 IWG 77 Pa Motor Output High 112W Low 87 W Cond2. 11 REFRIGERANT AND WATER SYSTEM REPAIR 11 1 Repair of Refrigerant and Water System 1 2 3 In case there is a leak obstruction or problem in the refrigerant and water system of this unit replace or repair the part in question After replacing any component all connections must be brazed except the flare connections of the water regulating valve Proper brazing techniques It is desirable to use a slightly reduced 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 9 02550 078 mm quite important As for the shape of the brazed fitting itis necessary to maximize its adhesive s E area The clearance of the brazed fitting must be minimized to facilitate brazing filler metal to Clearance Fro
3. Cap Unit Terminal Fire Alarm Device T Latch ILLOOO80 00 ILL00078 00 Operation Section 8 OPERATION 8 1 Automatic Restart after Power Interruption Automatic Recovery Function The program within the microprocessor of this unit 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 8 2 Temperature Scale Display Switch 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 8 3 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 8 4 Compressor Pro
4. Low Pressure Valve High Pressure Gauge High P ressure Valve High P ressure Side Tube Vacuum Pump in Operation 1002227 1 Properly remove the crushed end of the pinch off tubes at the high pressure side and the low pressure side of the refrigerant cycle with a pipe cutter 2 Fit the process tube fitting to the pinch off tube on both sides 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 minutes 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 Repair Section 71 1 Leave the high pressure valve and the low pressure valve of the gauge manifold closed for 5 minutes 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
5. indication of LCD 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 C 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 When this button is pressed again fan stops 2 Cool mode 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 seconds delay This sends line voltage 115 VAC to the J4 terminal relay board where compressor wire is connected Then compressor turns on for Cooling Operation 6 3 Control Box 1 Capacitors Operation Section 29 The capacitors are used to temporarily boost the power output available to the fan motor and the compressor at start up The specifications of each capacitor are listed below Capacitor Application Voltage Rating Capacitance Fan Motor 370 VAC 7 5 UF Compressor 370 VAC 60 uF lt C ontrol Box gt Terminal Block Signal Connections Terminal Block Compressor Capacitor Dip Switch eee Relay Board Fuse Relay Board a Fan Motor Capacitor gy p 1LL00138 00 30 Operati
6. 29 35 Entering Water Temp F C Water Flow GPM ILL00224 00 How to read the power consumption curve Example EWT 85 F 29 C Water flow 7 2 GPM gt Power Consumption 1 22 kW 18 E Reference es ia E Value d auk ees o C J lt 2 1 3 E SR 1 3 5 S qm 912 e e E RN 2 Q 11 f Ji 5 5 l 9 3 7 DA o E o T 0 9 t 09 A E m 0 8 Lol I Lol 14 oL Lol I Lol or Lol i Lol 4 fe LIILIDLIIILE 0 8 35 45 55 65 79 85 95 2 4 3 6 4 8 6 0 7 2 2 7 13 18 24 29 35 Entering Water Temp F C Water Flow GPM ILL00225 00 lt NOTE gt Water flow rate at 4 8 GPM is a reference value corresponding to various power consumption at various entering water temperature From reference curve read power consumption at various water flow rate see example of how to read power consumption Operation Section 3 Current consumption curve T ur E p wj T 3 ud wm El 3 c E E S r a 1 f 2 E E 3 2 L 2 10 5 O E 9L o r 3 8 Li 1 1 1 1 1 1 1 1 1 1 1 1 I 1 1 1 1 1 L L L L L LELE Ll1 35 45 55 65 75 85 95 2 4 3 6 4 8 6 0 72 2 7 13 18 24 29 85 Entering Water Temp F C Water Flow GPM ILL00226 00 How
7. from its pivots Repair Section 56 ILL00147 00 SS Screws 3 y h Screws 7 No N Screws 3 N SL e gt Ne ILLO0148 00 Screws 2 i Screws 3 gt NIST Screws 3 ILL00149 00 Screws 3 ILL00150 00 5 Remove five 5 screws from service panel 6 Remove thirteen 13 screws from rear panel 7 Remove eight 8 screws from upper panel 8 Remove seven 7 screws from left panel Repair Section 9 Remove twelve 12 screws from right panel lt b gt lt A Screws 6 Screws 3 my fm Y ILL00151 00 58 Repair Section 10 3 Removal of Evaporator Fan Assembly Fan Motor Control Panel Stay Evaporator Fan Casing ILL00154 00 Nut 1 Nut 1 N P 1 J o e Fa Nut 1 ILL00155 00 Nuts 2 Set Screw 1002220 Repair Section 59 1 Remove four 4 nuts as shown Then remove the motor stay together with the fan motor 2 Loosen the set screw using a hex key Then remove the fan motor by loosening four 4 nuts Repair Section 60 10 4 Removal of Electrical Components N WARNING Disconnect power prior to servicing the relay board Failure to follow this warning may lead to electrical shock 1 Control box 1 Remove five 5 screws from service panel See page
8. Check and repair connection NPT or Flare connection 6 Water regulating valve Cracks in the sealed parts in Replace the valve the valve 4 Abnormal noise or vibration To prevent abnormal noise or vibration carefully determine the source of the problem and come up with proper countermeasures to solve the problem so that it does not occur again Condition Check Area Possible Cause Remedy 1 Fan Fan interference Repair interfering section Fan deformation Replace fan Abnormal noise or itis 2 Compressor fixing nuts Loose nuts Tighten nuts further vibration 3 Piping Pipe interference Repair interfering section 4 Panel fixing screws Loose screws Tighten screws further Repair Section 48 9 4 Basic Inspection Perform the following inspection before disassembly 1 Inspection of plate fins To inspect the plate fins of the evaporator open the front panel door and inspect the plate fins for any dirt dust lint or debris that may have caused insufficient cooling performance of the A unit If cleaning of the fins is necessary it is recommended that this service be performed by a qualified service technician Ce O 1001780 2 Examination of operating environment Operating environments can vary depending on location climate and surrounding conditions Installation location also can ca
9. the compressor The Points relay interrupts the flow of current when there is an overload condition and high temperature builds up in the compressor Bimetal _ Terminal 1001691 Operating Temperature OFF Open Contacts ON Closed Contacts Non Operating Limit at 176 F 100 C A Marking 302 F 150 C 156 F 69 C 19 0 MRA4720 12027 6 7 Power Cord with LCDI This unit is equipped with a UL recognized LCDI cord and NEMA plug configuration 5 15 The appropriate outlet must be used for this plug type LCDI is used for monitoring leakage current Once leakage current is detected LCDI de energizes the unit Test Button Reset Button 1002239 Operation Section 7 CONNECTION AND SETTING 7 1 Warning Signal Connection Output Signal Terminal L and L 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 conditions Relay contactor is closed when any of the following conditions has occurred Tank Full Temperature sensor fails High pressure switch error 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 1 Remove service panel from
10. to procedure indicated in the next step Once leak has been found and repaired evacuate the system once more and confirm the system holds vacuum 72 Repair Section 4 Checking gas leak Valve Setting LO Closed Closed Air Purging 3 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 Open High Pressure Valve Process Tube Fitting Refrigerant Cylinder Valve Open 2 High Pressure Side Tube Cylinder R 410A YY Refrigerant 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 pressure gauge indicates 57 psi 0 39 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 refrigeration system usi
11. to read the current consumption curve Example EWT 85 F 29 C Water flow 7 2 GPM gt Current Consumption 1 12 A T 14 T a r Reference Value y o 13 5 T ul m Tel a 5 o 11 o E o 10 _ S 9 O E of o 3 8 Ej L Ji 1 1 1 1 1 J I l 1 L i L i L 1 i L L L L LLLI LLLI III LLLI 8 35 45 55 65 75 85 95 2 4 3 6 4 8 6 0 7 2 2 7 13 18 24 29 85 Entering Water Temp F C Water Flow GPM ILL00227 00 lt NOTE gt Water flow rate at 4 8 GPM is a reference value corresponding to various current consumption at various entering water temperature From reference curve read current consumption at various water flow rate see example of how to read current consumption Operation Section 4 Cool air temperature difference curve Delta T F C 35 19 4 30 16 7 25 13 9 20 11 1 15 8 3 10 5 6 30 40 50 60 Relative Humidity 70 80 ILL00228 00 Operation Section 15 3 1 Exterior Compon
12. 3 M Open The Valve of Refrigerant A Cylinder To Process Tube Fitting Charging Hose Green Refrigerant Cylinder R 410A 1001901 Valve Setting LO ui Specified Amount Lo HI gt Closed Open of Refrigerant Closed Closed High Pressure Valve Valve of Refrigerant Cylinder Process Tube Fitting High Pressure Side Tube 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 Ib 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 1 76 lb 0 8 kg N CAUTION 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 2 Removal of gauge manifold 3 Pinch O
13. 56 2 Remove electrical parts Terminal block Remove two 2 screws from control box Terminal block signal connection Remove two 2 screws from control box Capacitor Remove two 2 screws from control box Control Box Dip Switch Fa p Ser lt Terminal Block E ee DAP bon a Fan Motor Capacitor Signal Connections 7 ley 2 Terminal Block Compressor Capacitor ILL00138 00 Repair Section 61 2 Relay board 1 Remove five 5 screws from service panel See page 56 2 Disconnect seven 7 connectors and remove five 5 screws from relay board Temperature Scale Display Switch Dip Switch Q9 Quar To Control Board 10 pin yy ee i Fan Mode Control Switch De To Condensate Pump 2 pin U Flo QOO gt m To Compressor Black Power T1 OnTerminal Block ST a n z sl Power R1 OnTerminal Block alo jg To Fan Motor LO a P To Fan Motor HI Oe En O Relay Board Fuse 1002212 3 Control board 1 Remove two 2 screws from control panel stay Screws 2 ILL00152 00 2 Remove two 2 screws from the control panel stay 1002246 Repair Section 62 ILL00153 00 a 1001804 3 Disconnect the following connectors from the control board A J201 10 pi
14. 67 1 Disconnect four brazing points A D as shown When brazing cover the area E with a wet cloth to prevent damage 2 Remove two 2 nuts from the bracket Then remove the water cooled condenser 3 Loosen six 6 nuts to move the bracket for adjusting the new condenser position 68 2 Removal of water regulating valve Repair Section ILL00192 00 AS Cc ZS 7 Flare Nuts 2 ILL00193 00 Screws 4 ILL00194 00 1 Disconnect a brazing point as shown 2 Remove two 2 flare nuts Then remove the water pipes 3 Remove four 4 screws and two 2 brackets Then remove the water regulating valve 11 3 Charging the System with R 410A Refrigerant Repair Section 69 Always ensure that the refrigeration system has been properly evacuated before charging with the specified amount of R 410A Equipment is for R 410A only Liquid charge no gas charge 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 protection 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 op
15. Compressor relay on the Open circuit or insufficient Replace relay board relay board contact Compressor insulation Insulation failure on Replace compressor resistance compressor Temperature of fan motor Operation of safety device Replace fan motor abnormally high IOLF due to fan motor malfunction Temperature of Operation of safety device Replace compressor Unit stops Control compressor abnormally IOLC due to compressor after panel high malfunction running for displa j 2 PEY Refrigerant leakage Insufficient refrigerant or gas Repair and charge refrigerant a while normally leakage Dirt on evaporator Insufficient cooling of evaporator Clean evaporator 5 Duct connection state Improper connection Repair duct connection 1 To RESET the controller press ON OFF and HI LO buttons simultaneously for 5 seconds Repair Section 47 3 Overflow of water from the unit Condition Check Area Possible Cause Remedy 1 Drain pan Cracks in drain pan Check and replace 2 Water level in drain pan Clogged drain hose Check and repair 3 Drain hole Reversed air flow from drain Insert a trap on discharge hole drain hose 4 Clogged air filter Reversed air flow from drain Clean air filter hole due to the excessive Overflow from the unit negative pressure inside of the unit 5 Water system Water leak from soldering
16. OPERATION 8 1 Automatic Restart after Power Interruption Automatic Recovery Function 35 8 2 Temperature Scale Display Switch 0 0 0 000 cette Y a 35 8 3 Temperature Control VY o 35 8 4 CompressorProtection YYYF YF FR FE EF FF a La 35 8 5 Fan ModerControli Switch ee LE ra Pee Meee ee ad WU meu beds fa 36 9 6 Drain Switch ono in Nei DS FR A NL ce O YD 37 8 7 Condensate Pump Kit optional YFYF FF FF FR A ns 38 Table of Contents Repair Section 9 TROUBLESHOOTING 9 17 Troublesh ooling aueh RES AD DA dw Red ERE ea d ss 39 9 2 Self Diagnostic Codes FFF AF FFF teens 40 9 3 Troublesheoting Ghart 2 ehi darla RR LO UE wd 42 9 4 Basic lrispectlon i ooi a E eerie RP EE RR NE RE a doe EU GOR E 48 9 5 Inspection of Capacitor for Fan Motor and Compressor V Y eens 49 9 6 Inspection of Drain Switch LF YF hh hh 49 9 7 Inspection of Fan Motor FY I FF e hr 50 9 8 Inspection of Compressor Motor VV FY Y FR FF FA EF FR aY a 50 9 9 Inspection of Thermistor YY Y o 50 9 10 Inspection of Wiring Connection LY YF FF Rn 50 9 11 Inspection of Refrigeration System LYYF FR FF RF es 51 9 12 Inspection of Water System LY ete eee 52 10 DISASSEMBLY 10 17 Parts Construction au Gee rupe exul pu EE Res Gw DAU RISE Per Y an e
17. SERVICE MANUAL OFFICE PRO W20 SERIAL NUMBER FROM April 2011 0411 TO PRESENT MOVINCOOL THE 1 SPOT COOLING SOLUTION DoclD 00G00074E 2011 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 amp Office Pro and SpotCool are registered trademarks of DENSO Corporation Table of Contents Table of Contents Operation Section 1 PRECAUTIONS FOR SAFETY 1 1 Foreword hic adh See A eae va INA S uit ood a tenes bet wee d bebe raf 6 1 2 Definition of Terms eto Ca dt a eu a bine bane Alias ai ME E 6 t3 General Preca tions ive REIR ex DL tI OE a a a ed pue qs 6 2 SPECIFICATIONS 2 1 Exterior Dimensions Diagram FFF tees 7 2 2 Technical Specifications liliis hh 8 2 3 Characteristics ta ee tru f Li ue EL E 10 3 CONSTRUCTION 3 1 Exterior Components Y cc ehh 15 39 2 Internal Stuc toes ce etek eee A A Rod ate hec boe recie cru bla ede e he 16 3 8 Basic Construction s seras es aaan een FL ua 16 3 4 AICF IOW 2 hee Ra dt ei A ea AAA os Be e p ee ERR C 17 3 5 Compressor and Fan see vsus inest upbUR a dad 17 3 6 Drain Tanks Gaetan me t pera bade RETI oer iad epee Me BRE ty See E 17 Oil Water FOW soie taxe t e heces Y FD YY
18. TEMP COOL Defect short or open of room thermistor When room thermistor connecting to J101 becomes short or open Signal output J106 turns on SH RT HI F FAN G ON SET TEMP COOL UF EN HI F FAN G 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 UB DI UU Show running hours of compressor Press ON OFF and V buttons simultaneously for 3 seconds total operation hours of compressor is indicated by 6 digit hours Example in left 807 hours After 5 seconds display goes back to normal operation mode Repair Section 41 LCD Display Description Condition Show LCD and LED Press HI LO and A buttons simultaneously for 3 seconds to check LCD mm emma alonmode segments and LED display starry x AM uc PR d DH EN crock PM LOCKED HI F F c c FAN ig ON SET TEMP COOL OFF Room Temp After 5 seconds display goes back to normal operation mode E 2 00 LOCKED HI F FAN nN JE ay gt cooL Key lock mode LCD displays LOCKED Press ENTER and SET CLOCK buttons simultaneously for 5 seconds to lock all buttons on the controller panel except keypad lock and unlock operations To unlock press and hold ENTER and SET CLOCK buttons simultaneously for 5 seconds again Indication of mod
19. al Repair Section 77 12 5 Perform the Inspection Perform the inspection of cooling performance and check for abnormal noise or abnormal vibration 12 6 Caster Maintenance 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 DENSO DENSO SALES CALIFORNIA INC Long Beach CA 90810 www movincool com P N SV0036 00 First Issue April 2011
20. at water flow rate of 4 8 GPM Water Flow rate has small effect on cooling capacity Approx 1 effect at the range from 2 4 to 7 2 GPM Operation Section How to read the cooling capacity curve Cooling Capacity at 4 8 GPM kBtu h Relative Humidity 96 Example Dry bulb 95 F 35 C 60 RH EWT 85 F 29 C gt Cooling Capacity 20 kBtu h 24 T Pad E 7 w 22 DL 4 L L 2 L vet Pod 20 yis Nd E NP 47 L NE gt oU T e 18 E LOST Bet E El ett C P ud a Pap Je 16 E ei O 2 ys s C Ps E K 2 Y Le NU o 14 A uu L d amp Pd r pe eu 12 F et DES 10 C LL e Ll 1 PEEL Ll Wet Bulb Temp F C 40 50 60 70 E 80 E 90 F 100 Erie i NG Ne AN II YN IG N a NG DON GN 50 55 60 65 70 75 80 85 90 95 10 13 16 18 21 24 27 29 32 35 Dry Bulb Temp F C ILL00223 00 Operation Section 2 Power consumption curve 35r 15 E J u CL 14 E 4 E of o E LS co 13 EL 113 c y E 3 9 L J a c 12 f 12 E 1 1 11 2 E Jo o 5 i 9 o E J E D 0 9 E j 0 9 z E J a B o a Hl gu 35 45 55 65 75 85 95 2 4 3 6 4 8 6 0 7 2 2 7 13 18 24
21. cumulated sediment sediment Clean the water system to remove accumulated Air volume See page 52 and 53 normal 6 Water source Insufficient water flow Adjust flow of the supplied water source See page 52 1 Compressor coil resistance Short or open circuit Replace compressor 0 ohm or ohm In case of short check the compressor relay Congre 2 Compressor relay on the Open circuit or insufficient Replace relay board coss mai relay board contact operate 3 Capacitor for compressor Capacitor malfunction Replace capacitor motor 4 Voltage Low voltage Repair power 1 Coil resistance of fan motor Short or open circuit Replace fan motor 0 ohm or ce ohm No air 2 Fan on off relay on the relay Open circuit or insufficient Replace relay board i board contact 3 Fan HI LO change relay on Open circuit or insufficient Replace relay board Insufficient the relay board contact air volume 1 Air filter Clogged air filter Clean air filter 2 Evaporator Clogged evaporator or Repair and clean fins or Insufficient crushed fins replace it air volume 3 Duct connection state Improper connection Repair duct connection 4 Fan motor Insufficient rotation Replace motor 44 Repair Section 2 Unit does not operate NOTE e In this case there is a possibility of safety device activating due to the clogged air f
22. da E 54 10 2 Disassembly 5 53 o eb ble A dnd 55 10 3 Removal of Evaporator Fan Assembly 0 000 cece eee 58 10 4 Removal of Electrical Components YY FFF teens 60 11 REFRIGERANT AND WATER SYSTEM REPAIR 11 1 Repair of Refrigerant and Water System 0 0 0 0 200000 tees 64 11 2 Removal of Refrigeration and Water System Components 20000 cence eee eee 66 11 3 Charging the System with R 410A Refrigerant liliis 69 11 4 Refrigerant Charging Work Y FF FF FL ms 74 12 REASSEMBLY 12 1 Reassembly of Umit ee Su i A A A Pee aa aes 76 12 2 Compressor Mounting F FF hh 76 12 3 EvaporatorFan Assembly sic ua GY dales GG LY UG AU 76 12 4 Wiririg NOLICe oe Hoa ede been ead GARU GW OU IADAU AME ERE MEE 2 76 12 5 Performthelnspection Y FY FFR E Fu ug 77 12 6 Gaster Maintenance eld eee tio Ru Cd epus 77 6 Operation Section 1 PRECAUTIONS FOR SAFETY 1 1 Foreword This manual has been published to service the MovinCool Office Pro W20 Please use this service manual only when servicing this unit 1 2 Definition of Terms N 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 suf
23. discharge valve prevents the backward flow of refrigerant gas 3 Operation Discharge 1001676 Discharge 1001677 Discharge Roller 1001678 Discharge Valve 1001679 Operation Section 21 1 Start of compression 1 The cylinder is filled with low pressure gas 2 Since pressure in the discharge chamber is higher than in the cylinder the discharge valve is kept closed 2 Suction and compression 1 The pressure in the cylinder increases gradually 2 Refrigerant suction begins on the suction side of the cylinder 3 The discharge valve remains closed 3 Discharge 1 The pressure in the cylinder exceeds that in the discharge chamber and the discharge valve opens 2 On the suction side refrigerant suction continues 4 Completion of compression 1 When compression is completed all of the refrigerant has been drawn from the suction chamber 2 Operation then returns to step 1 Start of compression and the above process of suction and compression continues repeatedly in succession Operation Section 4 Compressor lubrication The lubrication system is comprised of a hollow shaft an oil scraper mounted at the end face hollow shaft a shaft journal shaft bearing n La Rotor and the lubrication groove for the shaft journal The lubrication groove is wider than the oil hole When the shaft turns oil is scraped Hollo
24. docs ane Freue kaa eater aes Y 17 4 REFRIGERATION SYSTEM 4 1 Refrigeration System Construction Y FF hn 18 A2 SGOmDpressol 25 2 csset e Vo LU ed y be e etus 19 4 9 CODdenser cote sou E uentus debita cites fau dietis Behe Yn 22 4 4 Capillary TUDE si oe ek hd Raab E rex eee nubi a Noe ers a Men hr he ex ads 22 4 5 Evaporator vo epi Ed wbbEdswa deu feti een Pes MAREN Cee d debba Dee PF 23 4 6 Accumulator se o A E e MEINES Ue Mele PARE ERERIGIE ERE ME 23 4 7 High Pressure Switch 1 2 0 0 ccc ehh 23 5 WATER SYSTEM 5 1 Water Regulating Valve VV hh hne 24 5 2 Default Water Regulating Valve Setting and Operation Range VY Y uu 24 5 3 Adjustment of Water Regulating Valve Setting VV FN Lad 25 6 ELECTRICAL SYSTEM 6 1 Circuit Diagram and Control BOX Y I I FF FFF eee 27 6 2 Basic Operation of Electrical Circuit lile 28 6 3 Gontrol BOX ou ie ro TRU Bee GAU a E A Cy WIE Dw Fn IA 29 Table of Contents 6 4 Ean Motor aen GA eds Let I ae t iis 31 6 5 Compressor Motor FI I FI Y A FF EF FF FF FF RF hh 31 6 6 Compressor Overload Relay FY FF FF n 32 6 7 Power Cord with LCD erect tata a Bete eee A dae EA DEU ee 32 7 CONNECTION AND SETTING 7 1 Warning Signal Connection Output Signal Terminal L and L YY Y Ya 33 7 2 Fire Alarm Control Panel Connection Input Signal Terminal E and E 34 8
25. el name Press UP and DOWN buttons simultaneously for 5 seconds to display a model name After 5 seconds display goes back to normal operation mode HL RM Detection of unit stop signal from fire alarm system Signal is input from the fire alarm Unit stops output signal J106 turns on and buzzer sounds LU De L pz Indication of service code Press ON OFF and A buttons simultaneously for 3 seconds Indication contents is as follows LCD Description Value DF Defrost status E Evap out pipe 26109F temperature 26 X9 Outdoor ung OD temperature 0 007 To exit service code press ON OFF button 2 00 HI F FAN 5 ON SET TEMP COOL FA IL HP Activation of high pressure switch When high pressure switch connected to J104 is activated J104 input turns to open for the first 2 times in 24 hours LCD indicates HP but goes away as the high pressure switch resets If the high pressure switch is activated 3 times in 24 hours LCD indicates blinking HP and signal output J106 turns on When the high pressure switch is activated 10 times in 24 hours LCD indicates FAIL HP and signal output J106 turns on then buzzer sounds 42 Repair Section 9 3 Troubleshooting Chart To accurately troubleshoot the problem it is important to carefully confirm the nature of the problem Common problems are Insu
26. en flame Never smoke while performing repairs especially when handling refrigerant Take caution so that 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 jelly to the skin Go immediately to a physician or to a hospital for professional treatment E When leak is found repair the connection or components Step 1 Connect manifold gauge 1 Evacuate the system 15 minutes or more Step 2 30 inHg 100 kPa or more of vacuum 2 Stop evacuating the system Leave for 5 minutes 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 See Technical Specifications for the specified amount Remove manifold gauge Step 6 ILL00084 00 70 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 Green Hose Red Hose Process Tube Fitting High Pressure d Side Tube when stopped 1000568 2 Evacuation Valve Setting LO HI x LO HI Closed Open Closed Closed 30 inHg 100 kPa or larger Gauge
27. enser Type of Condenser Water Cooled Coaxial Coil Type of Water Control Refrigerant Discharge Pressure Refrigerant Refrigerant Control Capillary Tube Type R 410A Amount 1 76 Ib 0 8 kg Water Connection Water Inlet and Outlet Unit side 1 2 in 13 mm NPT Female Water Inlet and Outlet Adapters GHT Female to 1 2 in 13 mm NPT Male Signal Connection Fire Alarm Input Signal Type No voltage contact input Contact resistance less than 100 ohm Warning Signal Output 2 A at 30 V DC AC or less resistive load Power Cord NEMA Plug Configuration 5 15 Gauge x Length 14 AWG 3 core x 10 ft 3 0 m Dimension WxDxH 21 0 x 27 0 x 41 5 in 538 x 685 x 1055 mm Operation Section 9 ITEM SPECIFICATIONS Weight Net 178 Ib 81 kg Shipping 209 Ib 95 kg Drain Tank Capacity 5 0 gal 19 L Operating Condition Range Inlet Air Max 95 F 35 C 60 RH Temperature Min 65 F 18 C 50 RH Entering Water Max 90 F 32 C Temperature Min 40 F 4 4 C Water Pressure 150 psi 1034 kPa Recommended Water Flow Rate 4 8 gal min 18 L min Maximum Duct Length Cold Duct 25 ft 7 6 m Sound Level High 62 dB A Low 60 dB A Safety Devices Compressor Overload Protector Included Fan Motor Overload Protector Included Freeze Protection Thermistor Included Ful
28. ents f P Control Panel Water Outlet E vaporator Air 1 2 NPT Female Connector With Plug Outlet Grill Evaporator Air Inlet Panel lir o o o o FFF HU RH E d e ce P Hi 4 O o pa o o AY ME 4 q il if F n M y Water Inlet 1 2 NPT Female With Plug Service Panel Drain Tank Cover Caster Power Cord 1LL00133 00 Operation Section 3 2 Internal Structure Fan Motor Fan Evaporator i i Water Regulating j i Valve Capillary T2 j iG Tube if AE i pi Service Panel Drain Pan Condenser Control Box Drain Tank Drain Switch Compressor 1LL00134 00 3 3 Basic Construction The unit 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 drain tank and condensate pump Optional The rear section contains the condenser the compressor and the control box Operation Section 3 4 Air Flow Air taken in from the front face is cooled by the evaporator and then blown through the cool air vent The air inlet is equipped with a filter hone m Tn LL Cool Air Out AU rere WWW LI WW WI BILL Ls um m HIE MUS Evaporator Air In gt atl 1LL00135 00 3 5 Com
29. ff Tool To Gauge Manifold Side a 7 Aa To Refrigerant Cycle Side cis Process Tube Fitting 1002185 Repair Section 75 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 12 REASSEMBLY 12 1 Reassembly of Unit 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 12 2 Compressor Mounting Mount the compressor on the frame using cushions steel collars plate washers and nuts Plate Washer Cushion Steel Collar ILL00178 00 12 3 Evaporator Fan Assembly Blower Assy gt Install the evaporator fan Allow a clearance of 0 06 inch 1 5 mm or more between the h evaporator fan and the fan casing 1 0 06 in 1 5 mm N CAUTION or more Tightening torque 10 84 2 17 ftelbf 7 4 0 7 Nem 1LL00158 00 12 4 Wiring Notice 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 remov
30. fficient cooling Unit does not operate Overflow of drain water Abnormal noise or vibrations Others 1 Insufficient cooling Cooling system problem generally results from electrical or mechanical components such as fan motor compressor control switch lt NOTE gt 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 Check the power supply because of the possibility of power source failure Check the water line to make sure the water source is supplying enough water flow and the entering water temperature is not exceeding 90 F 32 C Check the installation site for operating temperature and installation space unobstructed airflow Repair Section 43 Condition Insufficient Cooling Check Area Possible Cause Remedy Compressor operates 1 Usage conditions high temperature Operation near usage limits place Review the installation 2 Dirt in evaporator Insufficient heat exchange Clean fins 3 Frost in refrigeration cycle Clogging at the frost section Replace clogged section 4 No temperature difference between evaporator and condenser Insufficient refrigerant refrigerant Check the leaking part then repair and charge 5 Water system water line condenser water regulating valve Water system is clogged with ac
31. ficient care is not taken NOTE Provides additional information that facilitates installation or unit operation 1 3 General Precautions Z WARNING All electrical work 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 Before replacing any refrigeration and water system components recover the refrigerant using standard recovery procedures and equipment and drain the water from the unit 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 The power supply for this unit should be a dedicated single outlet circuit with UL recognized short circuit and ground fault protective breaker to prevent electrical shock from the unit When brazing any tubing always wear eye protection and work only in a well ventilated area Disconnect power before servicing unit Be careful of any sharp edges when working on unit Operation Section 7 2 SPECIFICATIONS 2 1 Exterior Dimensions Diagram 21 4
32. g 1 Compressor construction The construction of a rotary type compressor is divided into two mechanisms the drive mechanism compressor motor and the compression mechanism compressor When the rotor shaft of the motor drive mechanism turns the roller compression mechanism rotates to compress the refrigerant To Condenser n From Evaporator yne Accumulator Blade Discharge Valve Oil 1001675 20 Operation Section 2 Basic compressor operation The roller compression mechanism is set eccentrically with a certain distance given from the axis of the center of the cylinder A 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 The blade partitions the space between the suction side Discharge Hole Discharge Valve S pring Suction Shaft Roller y 1000510 and the discharge side to keep compressed refrigerant from returning to the suction side 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 discharge side pressure As a result the
33. ilter So make sure to first clean the air filter and then start up again to confirm if the problem lies with the air filter Check the installation site for operating temperature and installation space unobstructed airflow e f cooling water is not supplied to the unit a safety device is activated Check the water flow to confirm if the problem lies with the water flow Condition Check Area Possible Cause Remedy Unit does not operate 1 Voltage Power failure Repair power 2 Ground fault breaker trip Ground fault or defective Repair ground fault section Control ground fault breaker Reset or repair breaker Unit does Panel 3 LCDI power cord trip Leakage current detected Reset power cord not operate display Replace power cord turns off 4 Fuse Fuse blown Repair shorting section Replace fuse on the relay board 1 Display code FL Drain tank optional is filled Discharge the drain water with the drain water RESET the controller Loose drain switch Reconnect the drain switch connection and check the connection RESET the controller Defective drain switch Replace drain switch RESET the controller Control Control 2 Display code AS Optional condensate pump Remove any blockage or cul Panel stops pumping water due to kinks from the drain line or oa display any kinks and or blockage in improve hose installation Mes em shows error the dra
34. in line or due to RESET the controller codes improper routing of the drain line Defective condensate pump Replace the condensate pump RESET the controller Missing jumper connector Insert the jumper connector and check the connection RESET the controller 1 To RESET the controller press ON OFF and HI LO buttons simultaneously for 5 seconds Repair Section 45 Condition Unit does not operate Check Area Possible Cause Remedy Control Control Panel panel i display display shows error turns on codes 3 Display code RT Loose room thermistor connection Reconnect the room thermistor and check the connection RESET the controller Defective room thermistor short or open Replace room thermistor 4 Display code FT Loose freeze protection thermistor connection Reconnect the freeze protection thermistor and check the connection RESET the controller Defective freeze protection thermistor short or open Replace freeze protection thermistor 5 Display code HP and FAIL HP Operating outside of the operating temperature range Check environmental condition Do not use the unit outside the operating condition range See page 9 RESET the controller Insufficient water flow Connect water inlet of the unit and water supply line correctly RESET the co
35. ing procedure 1 Insufficient Water flow Sufficient water flow is required while the unit is operating Insufficient water flow can activate the high pressure switch causing the unit to stop The recommended supplied water source should have a minimum flow rate of 4 8 gal min 18 L min at 7psi 50 kPa or higher Insufficient water flow can be estimated by measuring the leaving water temperature LWT During normal operation the LWT should be less than or equal to 104 F 40 C The unit s maximum LWT is 120 F 49 C If the LWT is higher than the maximum value adjust the supplied water source to meet the recommended minimum flow rate or higher 2 Clogged water system In case a self diagnostic code HP is displayed there are two possible causes Condensing capacity is reduced by accumulated sediment Water line is clogged with accumulated sediment Clean inside of the water system to remove accumulated sediment For details see below 3 Cleaning inside of the water system The water regulating valve in the water system can be manually flushed to clear any sediment accumulated inside of the water system 1 Stop the unit and unplug the power cord Then shut off the water supply and disconnect the water pipes or hoses 2 Connect tap water to the water inlet of the unit Connect water outlet of the unit to drain 3 Remove five 5 screws from the service panel on Qu the rear side of the unit Screw
36. l Drain Tank Switch Included Automatic Restart Power Interruption Included Compressor Time Delay 120 sec High Pressure Interruption Included Signal Input Output Included Control Devices Temperature Control Included Programmable Timer Included Two Speed Fan Included Specifications are subject to change without notice lt NOTE gt 1 If the entering water temperature is below 68 F 20 C or above 86 F 30 C adjustment of the unit s water regulating valve setting is required 2 Measured at 3 feet 1 0 m from surface of the unit Operation Section 2 3 Characteristics All characteristic values are within 10 96 tolerance EWT shown in the graphs is an abbreviation of Entering Water Temperature 1 Cooling capacity curve 24 Eu E F d 5 e a 22 T P d 4 x C e d B 20 ee i k o Pd o o 4T X e F ydd 205 18 ave a T L oO Pid 47 gt B iat pe 5 E PM z Je c 16 E IA Q9 2 Rs E id K Na o E 27 9 a Pid gt 14 EEN amp N L Pis K S 9 d qu O 42 F ze VE 10 Ey 1 i Ll Ll ee Tu 1 Ll Ll 1 Wet Bulb Temp F C 40 gt o E I o 2 3 o oc 60 65 70 75 80 85 90 95 16 18 21 24 27 29 32 35 Dry Bulb Temp F C ILL00222 00 lt NOTE gt Cooling capacity listed
37. lating valve is returned to the original default setting Rotate the adjusting bolt with a wrench to adjust the valve temperature setting according to the Valve Setting Guide Table on page 26 The painted line on adjusting bolt and housing is for rotational reference to complete one rotation 360 9 ILL00179 00 Default Marking Line Adjusting Plate ILL00185 00 Direction of Rotation Temperature Setting Clockwise Lower Counterclockwise Higher lt NOTE gt The default marking line on the housing is for adjustment reference The painted line on adjusting bolt and housing is for rotational reference Each completed rotation of the adjusting bolt is resulting in about 0 04 inch 1 mm displacement of the adjusting plate 26 Operation Section Valve Setting Guide Table 7 Write the value setting with a permanent marker on the adjustment record table on the inside panel of the unit lt NOTE gt Recording the value setting is very important for reference when making future adjustments Setting Direction of Valve Rotation Number of Rotation Valve Opening Temperature Minimum Water Temperature A Clockwise 4 72 F 22 C 40 F 4 4 C B N 3 75 F 24 C 47 F 8 C B C 2 79 F 26 C 54 F 12 C D 1 82 F 28 C 61 F 16 C E Defau
38. low this warning may lead to electrical shock 1 Inspection of power source voltage Check the voltage of the power source Single phase 115 V 60 Hz Check the operation and condition of the fuse or circuit breaker in the power source 2 Inspection of air filter Remove the air filter and check the element If the element is dirty wash it as described in the OPERATION MANUAL supplied with the unit 3 Inspection of drain tank Make sure tank is fully drained The following pages page 40 to 47 are self diagnostic codes and troubleshooting information 40 Repair Section 9 2 Self Diagnostic Codes Self diagnostic codes are displayed on the control board under the following conditions Refer to the troubleshooting chart on page 44 to 46 for the remedies LCD Display Description Condition TH NK FL Drain tank is full When the drain tank is filled with drain water TANK FL LED flashes and signal output J106 turns on Sao 2 00 HI F FAN 5 ON SETTEMP COOL Condensate pump problem When the optional condensate pump stops pumping water due to any kink and or blockage in the drain line or due to improper routing of the drain line the compressor shuts off and LCD indicates AS J8 input of relay board turns to open and signal output J106 turns on SH RT HI F FAN G ON SET TEMP COOL UP EN HI F FAN 5 ON SET
39. lt Setting Point 86 F 30 C 68 F 20 C F Counterclockwise 1 90 F 32 C 72 F 22 C G 2 94 F 34 C 75 F 24 C H 3 96 F 36 C 79 F 26 C 4 100 F 38 C 83 F 28 C Adjustment Record Example No Setting Date Setting No Setting Date Setting 0 z E 11 Dec 10 2010 B Apr 10 2011 D Aug 10 2011 G 10 21 N CAUTION Do not forget to write down the value setting with a permanent marker on the adjustment record table This is the only way to know the current valve setting It is difficult to exactly adjust the valve without the current valve setting Failure to adjust the valve may damage the unit and void the warranty Operation Section 6 ELECTRICAL SYSTEM 6 1 Circuit Diagram and Control Box AC 115 V 1 60 Hz R CN RTH O B1 9 CW 5 TO CC 1 2 L O J umper ae G HOP Line d ocmi 8 ii CC EL D 16 J8 NO cp HI 116 12 J5 DA O O a 9 MF Cc Ji o O IAE HE E Le J2 DO J1 RE Oe A P Attachment P lug IOLF Inner Overload Relay of Fan Motor T B 1 Terminal Block OLC Inner Overload Relay of Compressor T B 2 Terminal Block D Full Drain Warning S witch B Control Board THS Freeze Protectio
40. lure to use the exact type of fuse could result in personal injury damage to the unit and or to the components which may void the warranty Operation Section 31 6 4 Fan Motor The fan motor is a single phase induction type two speed motor The motor rotates the fan on the evaporator side Specifications Rated Voltage 115 V 60 Hz CF1 White T i CF 2 Brown Rated Output High 112 W Low 87 W J 5 Low Red Green Yellow J 6 High Black Tn lt NOTE gt An internal overload relay is used to protect the fan motor This relay is built into the fan motor and interrupts the flow of current when there is an over current situation or if abnormally high temperature builds up in the fan motor 6 5 Compressor Motor The compressor motor is a single phase motor and is contained within the same housing as the compressor Specifications Rated Voltage 115 V 60 Hz Rated Output 1160 W lt NOTE gt An internal overload relay is used to protect the compressor motor This relay is built into the compressor motor It interrupts the flow of current when there is an over current situation or if abnormally high temperature builds up in the compressor motor 32 Operation Section 6 6 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 of
41. m The Pipe Fitting and Tubing flow into it by capillary action Cleaning brazing filler metal and pipe When the refrigeration system has been 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 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 N CAUTION Do not use chlorine cleaner Repair Section 65 4 Use of dry nitrogen gas 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 NOTE Take care not to allow dirt water oil etc to enter into the pipe 5 Vertical Joint 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 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 portio
42. mally closed The snap disk responds to the variations in pressure and if pressure is abnormally high the snap disk moves down to push the pin down causing the internal contacts to open This interrupts the Pressure of Refrigerant v Snap Disk Movable Point KA Pin Lead Wires Lact ILL00229 00 Stationary Point Terminal Case Molding by Resin ground signal at the control board J104 connector which turns the compressor off Operation Section 5 WATER SYSTEM 5 1 Water Regulating Valve This unit is equipped with a water regulatin M quipp gu ating Adjusting Bolt valve to operate within wide water temperature Water Regulating Valve range This water regulating valve automatically controls the water flow rate to stabilize the refrigeration system and it has an 9 CL TTC EE CH mme adjusting bolt to adjust the valve opening temperature ILL00186 00 5 2 Default Water Regulating Valve Setting and Operation Range Default setting of the valve opening temperature is 86 F 30 C and marked on the valve housing If the entering water temperature is below 86 F 30 C there is no loss of water while the unit is not operating Adjustment of this valve setting is reguired only when the unit will be used under the following conditions Entering water temperature is below 68 F 20 C Valve setting must be adjusted to lower te
43. mperature to extend the life of the compressor Entering water temperature is above 86 F 30 C Valve setting must be adjusted to higher temperature to prevent wasted water lt NOTE This adjustment expands the minimum water temperature range Carefully control the operating range N CAUTION Failure to adjust the water regulating valve or operating the unit with entering water temperature below 68 F 20 C without adjusting the valve setting may damage the unit and void the warranty Operation Section 25 5 3 Adjustment of Water Regulating Valve Setting ILL00147 00 ILL00148 00 Adjusting Bolt a kis Painted line vo 1 Stop the unit and unplug the power cord Then shut off the water supply 2 Remove five 5 screws from the service panel on the rear side of the unit 3 Remove thirteen 13 screws from the rear panel 4 Check the valve setting guide table on the inside panel of the unit to confirm the current valve setting If the table is blank it is the first time adjustment If the table shows the previous value setting the current setting must be changed back to the original default setting prior to making any adjustment 5 Make sure the adjusting plate is aligned with the 6 gt default marking line on the housing If it is not aligned rotate the adjusting bolt with a wrench until it is aligned At this position the water regu
44. n Wire Harness Relay Board to Control B J101 2 pin Room Temperature Thermistor C J102 2 pin with black 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 tape Freeze lt NOTE 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 4 Remove the five 5 screws from the control board on the control panel assembly Remove the control board 4 Battery replacement of control board Repair Section 63 When the power is disconnected 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 E Control Board b Y SS Battery 20 1001805 Control Board Holder o Battery Old 1001806 Control Board Holder OS Battery New 1001807 5 1 Disassemble control board See page 61 and 62 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 N CAUTION When inserting the battery make sure the direction of polarity plus minus is correct as shown Repair Section
45. n Thermistor R B Relay Board R TH Room Thermistor M F Fan Motor HPRS High Pressure Switch M C Compressor Motor G Grounding C F Capacitor for Fan Motor N Connector for Option Drain Pump C C Capacitor for Compressor i 5 Relay Board Fuse Gne Fan Motor Capacitor P d Terminal Block Signal Connections E Terminal Block y Compressor Capacitor 1LL00137 00 28 Operation Section 6 2 Basic Operation of Electrical Circuit There are two basic components used to control the operation of 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 1 Fan mode High Fan Mode 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 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 When this button is pressed again fan turns to low mode see below Press again fan stops Low Fan Mode When the FAN MODE button on the control panel is pressed again the microprocessor turns on FAN LO COOL OFF
46. n heated to a proper temperature it is 1000564 essential to keep the whole fitting at a proper brazing temperature Vertical Up Joint Burner Brazing Filler Metal 1001725 66 Repair Section 11 2 Removal of Refrigeration and Water System Components N WARNING Before replacing any refrigeration and water system component recover the refrigerant using standard recovery procedures and drain the water from the unit When recovering the refrigerant use the pinch off tubes at the low pressure side tube 1 and high pressure side tube 2 as shown in the figure below N CAUTION 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 During any component replacement involving brazing shield nearby parts with a steel plate etc to protect them from the flame L Tube 1 M f c Sa J Part to Replace Disconnect At Compressor A H C Condenser B C J K A Capillary Tube E F G Evaporator E H High Pressure Switch D Water Regulating Valve LL M Pipe 2 1LLO0157 00 NOTE When replacing the compressor attach the pipe 1 and the pipe 2 packaged in the compressor assembly 1 Removal of water cooled condenser ILL00190 00 Nuts 3 Nuts 3 ILL00191 00 Repair Section
47. ng the gas leak tester 7 Repair any leak AN WARNING Any repair on a charged system should be performed by a licensed professional only N 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 73 5 Evacuation repeat 1 Close the valve of the refrigerant cylinder Then Valve Setting Gauge 2 Lo A remove the charging hose green from the 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 High Pressure Keep the high pressure valve and the low Side Tube p gn p 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 minutes or more 3 After evacuation is complete close the high and the low pressure valves of the gauge manifold N CAUTION Make sure to evacuate the system twice or more using the repetitive vacuum method Evacuate the system an additional time on rainy or humid days 74 Repair Section 11 4 Refrigerant Charging Work 1 Refrigerant charging Valve Setting LO Closed Closed Air Purging
48. ntroller Adjust flow of the supplied water source See page 52 RESET the controller Clean water system to remove accumulated sediment See page 52 and 53 RESET the controller Loose high pressure switch connection Reconnect the high pressure switch and check the connection Defective high pressure switch short or open Replace high pressure Switch Refrigerant is over charged Charge correct amount of refrigerant See page 74 RESET the controller 1 To RESET the controller press ON OFF and HI LO buttons simultaneously for 5 seconds 46 Repair Section Condition Unit does not operate Check Area Possible Cause Remedy 6 Display code ALRM Signal is input from the fire Check the fire alarm system Control CORO alarm and confirm there is no signal panel aba input to the unit then RESET display ey the controller shows error turns on Codes 7 Display code FZ See Stops after running for a while of Troubleshooting on page 46 Fan on off relay on the Open circuit or insufficient Replace relay board relay board contact Fan HI LO change relay Open circuit or insufficient Replace relay board Unit stops Control on the relay board contact immediately panel Fan motor insulation Insulation failure on fan Replace fan motor after display resistance motor starting normally
49. on Section 2 Relay board The relay board receives signals and outputs opin switch gt from the control board that contains a Dip Switch Q microprocessor The relay board contains the compressor fan on and fan mode speed Temperature Scale o Display S witch OMS diu agn relays CSF q 000 e It also contains a step down transformer that Fan mode Control s converts the line voltage 115 VAC to 12 V Switch E dii STOPSOPERATE O This 12 V is then converted from AC to DC and used for relay coil activation The 12 V DC power is sent to the control panel assembly where it is further reduced to 5 V for the system logic 1002196 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 temperature display from Fahrenheit to Celsius NOTE The relay board must be serviced as a complete assembly It has only one serviceable component the fuse see below 3 Relay board fuse This fuse provides protection against damage relay Board gt to the step down transformer It must be replaced with the exact type of fuse or an Q Se equivalent o Specifications a m 0 25 A 250 V E O O 1002197 N CAUTION Fai
50. perate 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 8 6 Drain Switch Operation Section 37 This unit is equipped with a drain tank switch When the drain tank accumulates approximately 4 0 gal 15 L 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 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 4 0 gal 15 L 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 flashes the TANK FULL LED indicates TANK FL on the LCD and closes the contact of output signal When the drain tank is removed or the drain tank is emptied the top of the drain tank base plate returns to its original po
51. pressor and Fan The compressor is hermetically sealed A two speed motor with a centrifugal fan is used to draw air across the evaporator 3 6 Drain Tank A 5 0 gal 19 L drain tank is supplied with the unit The condensate water is collected into the tank The drain switch activates and stops the operation when tank reaches the level of approximately 4 0 gal 15 L 3 7 Water Flow This unit has two water connectors on the right side panel Water is flown in from the water inlet and extracts the heat from the water cooled condenser Then the water is flown out from the water outlet Operation Section 18 4 REFRIGERATION SYSTEM 4 1 Refrigeration System Construction The component parts of the refrigeration 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 Condenser Water Regulating Valve Capillary Tune Water Outlet Pipe High Pressure Switch Evaporator Water Inlet Pipe Compressor Suction Pipe Condenser Outlet Pipe Compressor Discharge Pipe Water Inlet lt Flow of Refrigerant Water Outlet Flow of Water Water Valve Accumulator Compressor E vaporator 1LL00136 00 Operation Section 4 2 Compressor The compressor used for the unit is hermetically sealed The compressor and the compressor motor are in one casin
52. rant sent from the Gas and Liquid Mixture 1001887 condenser to expand rapidly as 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 4 5 Evaporator Operation Section 23 The evaporator is a heat exchanger covered with plate fins Heat is removed from the air being 4 6 pulled across the evaporator by the centrifugal fan and the resulting cool air is expelled through the cool air vent Accumulator The accumulator is mounted on the suction gas 4 7 piping between the evaporator and the compressor The accumulator separates the liquid refrigerant from the gas refrigerant allowing only the gas refrigerant to enter the compressor In the accumulator suction gas is led into a cylindrical vessel where the speed of the gas is decreased This process separates the refrigerant contained in the gas by the force From Evaporator To Compressor lt 2 1000514 of gravity causing the refrigerant to accumulate at the bottom of the vessel As a result the compressor is protected from possible damage caused by liquid refrigerant intake High Pressure Switch The high pressure switch prevents the condenser and compressor from being damaged by excessive high pressure in the high pressure line of the refrigeration cycle The switch is nor
53. rature 77 F 25 C either thermistor room or freeze should measure approximately 10 k ohm 9 10 Inspection of Wiring Connection Refer to the Wiring Diagrams on page 27 and check for connection of each wire Repair Section 51 9 11 Inspection of Refrigeration System In most cases the probable cause for insufficient cooling is a clog in the system a leakage or an incorrect amount of refrigerant In such cases inspect the system according to the following procedure 1 Clogged refrigeration system Check the component parts of the refrigeration system including piping that could be clogged with refrigerant If clogged with refrigerant only the clogged part is partially frosted If this occurs change the part in question 2 Refrigerant leak Carefully check all connections and each component for leaks whenever the refrigeration system is installed or repaired Use an electronic gas leak tester to inspect the system 3 Insufficient refrigerant When the unit is not producing sufficient cooling follow the troubleshooting chart on page 43 to confirm the cause of the problem Then charge the system with the refrigerant to the specified amount as indicated on page 74 Repair Section 9 12 Inspection of Water System In most cases the cause for insufficient cooling is a clog in the system a leakage or an incorrect amount of water in the system In such cases inspect the system according to the follow
54. s 5 ILL00147 00 Repair Section 53 4 Remove thirteen 13 screws from the rear panel je Screws 3 Screws 7 ILL00148 00 5 Open the faucet handle to supply water 6 Insert screwdrivers under both sides of the valve spring guide of the water regulating valve and lift upwards to flush This manual flushing does not affect valve adjustment N CAUTION Do not move the adjusting bolt Valve Spring Guide Take caution to prevent any corrosion inside the copper tube if cleanser is used to clean the water line ILL00159 00 7 Keep flushing the water inside the water line through the drain until the water is clear 8 Disconnect tap water from the water inlet and outlet of the unit Repair Section 10 DISASSEMBLY 10 1 Parts Construction Control Panel Upper Front Panel Right Handle Upper Panel Right Panel cd Front Panel Filter Assy Drain Tank Panel Assy Left Handle Rear Panel o Service Panel Left Panel Power Cord ILL00144 00 10 2 Disassembly l 1002203 ILL00145 00 1002244 Repair Section 1 Remove drain tank 2 Remove four 4 screws from upper front panel 3 Slide upper front panel forward and remove 4 Louver can be removed from upper front panel by unsnapping the lock tap and removing the louver
55. sition 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 AL Evaporator Drain Switch E m a Drain Pan Drain Tube To J 103 ur o MN Drain Tank c Drain Water i Spring SURE YR Le alll I Base Base Plate 1001777 38 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 8 7 Condensate Pump Kit optional This unit comes standard with a drain tank which collect 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 is available for this unit Repair Section 9 TROUBLESHOOTING 9 1 Troubleshooting Before troubleshooting the system the following inspection should be performed AX WARNING Disconnect power prior to servicing the relay board Failure to fol
56. tection 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 Operation Section 36 8 5 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 1 Cool to stop 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 compressor 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 seconds the fan starts before the compressor time delay feature 2 Cool to o
57. the rear of the unit 2 Squeeze the inner latches and push out the black cap from inside the panel See drawing of cap and inner latch shapes 3 Insert the warning signal wire through the hole in the rear panel 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 4 Connect warning device to terminal L and L according to its polarities Cap Unit Terminal Warning Device Latch Input Signal ILL00079 00 Sener ILL00078 00 Operation Section 34 7 2 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 1 Remove service panel from the rear of the unit 2 Squeeze the inner latches and push out the black cap from inside the panel See drawing of Cap and inner latch shapes 3 Insert the fire alarm signal wire through the hole in the rear panel 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 4 Connect warning device to terminal E and E according to its polarities
58. uipment or the unit and or result in personal injury electrical shock or death 9 6 Inspection of Drain Switch 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 50 Repair Section 9 7 Inspection of Fan Motor Measure resistance across the terminals of the fan motor All terminals must be disconnected from the unit Between terminals at 77 F 25 C J6 CF1 Approx 10 6 ohm J6 CF2 Approx 50 2 ohm CF1 White J5 J6 Approx 2 3 ohm CF2 Brown i J5 Low Red If the measured resistance is not equal to these Green Yellow J6 High Black standard values replace the fan motor 9 8 Inspection of Compressor Motor Measure resistance across the terminals of the compressor motor All terminals must be disconnected from the unit Between terminals at 77 F 25 C R C Approx 0 6 ohm C S Approx 1 6 ohm S R Approx 2 1 ohm If the measured resistance is not equal to these Non standard values replace the compressor The overload relay is internal to the compressor 9 9 Inspection of Thermistor Using an Ohm meter check the resistance value across the 2 pin connector At normal tempe
59. use operational problems Consult your reseller concerning operational environment requirements 3 Inspection of cooling capacity performance 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 14 proceed with the remedy suggested in the troubleshooting chart on page 42 to 46 Thermometer um HJ Ed perreo Cookout Loer C FRU QUAM Ul Thermometer UH LLL MW Evaporator Air In ES ILLOO143 00 Repair Section 49 9 5 Inspection of Capacitor for Fan Motor and Compressor 1 Ohmmeter method Setthe 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 the ohm meter fails to move from 0 shorted ins replace the capacitor 2 Capacitance tester method Using a capacitance tester and the chart on page 29 test the capacitor for the value indicated If the value tested is not within 10 96 of indicated capacitance replace the capacitor A WARNING Properly discharge the capacitor s before testing and after testing has been completed Failure to do so could cause damage to test eq
60. w Shaft Eccentric Shaft upward by the oil scraper along the inside Cylinder diameter of the hollow shaft The oil is fed through the oil hole by centrifugal force then supplied to the lubrication groove for each shaft journal lubricating the bearing In this lubrication system oil enters into each bearing Oil Feed Groove separately and returns to the oil reservoir This Oil Hole Oil Scrapper system effectively prevents bearing temperature increases and offers high TN reliability In addition the specially treated shaft journal keeps the bearing from being damaged during high temperature operation 4 3 Condenser The condenser is a heat exchanger with coaxial tubes The inner tube is a copper tube in which the water flows The outer tube is a steel tube The refrigerant flows between inner tube and outer tube Heat is given off and absorbed by the water being passed through the condenser and then expelled through the water outlet 4 4 Capillary Tube 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 E capillary tube causes the high pressure high Low Temp Low Pressure gt temperature liquid refrige
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