1 SERVICE MANUAL OFFICE PRO 60 Unit Serial Number Range: 0407XXXX600 to Present (From April 2007 to Present)
2 SERIAL NUMBER LOCATION AND IDENTIFICATION Nameplate Label COOLING AMPS. WITH PUMP COMPR. OUTPUT REFRIGERANT/TOTAL CHARGE DESIGN PRESSURE LO/HI Nameplate Label Position PART NO./WEIGHT SERIAL NO. Month Year Model Sequential Number 2016 DENSO PRODUCTS AND SERVICES AMERICAS, 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 PRODUCTS AND SERVICES AMERICAS, INC. reserves the right to make changes without prior notice. MovinCool, Office Pro, and SpotCool are registered trademarks of DENSO Corporation.
3 Table of Contents Table of Contents Operation Section 1. PRECAUTIONS FOR SAFETY 1.1 Foreword Definition of Terms General Precautions GENERAL DESCRIPTION 2.1 Spot Cooler Compact Design Easy Transportation and Installation Energy Conservation CONSTRUCTION 3.1 Exterior Dimensions Exterior Components Internal Structure Basic Construction Air Flow Compressor and Fans Condensate Pump Drain Tanks (optional) SPECIFICATIONS 4.1 Technical Specifications Characteristics at 230 V Characteristics at 208 V REFRIGERANT SYSTEM 5.1 Refrigerant System Construction Compressor Condenser Capillary Tube Evaporator High Pressure Switch ELECTRICAL SYSTEM 6.1 Circuit Diagram and Control Box Basic Operation of The Office Pro 60 Electrical Circuit
4 Table of Contents 6.3 Control Box Fan Motor Compressor Motor Condensate Pump Drain Switch Automatic Restart after Power Interruption Compressor Protection Temperature Control Fan Mode Control Switch Temperature Scale Display Switch Warning Signal Connection (Output Signal Terminal L+ and L-) Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-)
5 Table of Contents Repair Section 7. TROUBLESHOOTING 7.1 Troubleshooting Self-Diagnostic Codes Troubleshooting Chart Basic Inspection DISASSEMBLY 8.1 Parts Construction Disassembly Removal of Electrical Parts Removal of Blower Assembly Removal of Condensate Pump Inspection of Capacitor (for Fan Motor and Compressor) Inspection of Drain Switch Inspection of Fan Motor Inspection of Compressor Motor Inspection of Wiring Connection Inspection of Thermistor Inspection REFRIGERANT SYSTEM REPAIR 9.1 Repair of Refrigerant System Removal of Refrigeration Cycle Components Charging the System with R-410A Refrigerant Refrigerant Charging Work REASSEMBLY 10.1 Removal of Unit Compressor Mounting Blower Assembly Wiring Notice Perform the Inspection Caster Maintenance Schematic
6 6 Operation Section 1. PRECAUTIONS FOR SAFETY 1.1 Foreword This manual has been published to service the MovinCool Office Pro 60. Please use this service manual only when servicing the Office Pro Definition of Terms WARNING CAUTION NOTE Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation. 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. Provides additional information that facilitates installation or unit operation. 1.3 General Precautions WARNING All electrical work should only be performed by qualified electrical technician. 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 dealer. Disconnect power supply from the unit before performing any service. Before replacing any refrigeration components, recover the refrigerant using standard recovery procedures and equipment. 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 a 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. Be careful of any sharp edges when working on unit.
7 Operation Section 7 2. GENERAL DESCRIPTION 2.1 Spot Cooler In general, conventional air conditioners cool the entire enclosed environment. They act as heat exchangers, requiring an interior unit (evaporator) to blow cool air into the interior and an exterior unit (condenser) to exhaust exchanged heat to the outdoors. Unlike conventional air conditioners, the MovinCool Office Pro 60 is a spot cooler which directs cool air to particular areas or objects. MovinCool Office Pro 60 has the following features: Condenser (Outdoor Unit) Evaporator (Indoor Unit) I Compact Design The innovative design of MovinCool Office Pro 60 has resulted in one compact unit, replacing the need for two separate units. 2.3 Easy Transportation and Installation With the whole cooling system built into one compact unit, MovinCool Office Pro 60 requires no piping and can be easily transported and installed. 2.4 Energy Conservation MovinCool Office Pro 60 is economical because it cools only the area or objects which need to be cooled. I001905
9 Operation Section Exterior Components Operation Panel Cold Air Outlet Grill Evaporator Air Inlet Grill Condenser Air Outlet Duct Caster Condenser Air Inlet Panel Power Cord Service Panel I001907
10 10 Operation Section 3.3 Internal Structure Fan (Evaporator) Fan Motor (Evaporator) (Behind Fan) Fan (Condenser) Fan Motor (Condenser) Evaporator High Pressure Switch Capillary Tube Drain Pan Condensate Pump Compressor Condenser Drain Switch Control Box I Basic Construction The MovinCool Office Pro 60 is compact in construction because the condenser and the evaporator are enclosed in one unit. The interior is divided into three sections. The upper front face is equipped with the evaporator, and the lower front face contains the condensate pump and optional drain tanks. The rear section contains the condenser, the compressor and the control box.
11 Operation Section Air Flow Air drawn from the right side face passes through the condenser which extracts the heat. This hot air is blown out through the upper exhaust air duct. Air taken in from the front face is cooled by the evaporator and then blown through the cool air vent. All the air inlets are equipped with filters, and the exhaust air duct is protected by metal grill. Exhaust Air Out Cool Air Out Evaporator Air In Condenser Air In I Compressor and Fans The compressor is hermetically sealed. Two sets of a two-speed fan motor with a centrifugal fan are used to draw air across the evaporator and condenser. 3.7 Condensate Pump The condensate pump and a 20 ft (6 m) drain hose are included with the Office Pro 60 to provide continuous operation without the need of the drain tanks. The condensate pump has a maximum head lift of 17 ft (5.2 m) at 230 VAC or 13 ft (4.0 m) at 208 VAC. 3.8 Drain Tanks (optional) A set of two 5.0 gal (19 L) drain tanks are supplied as optional accessory for Office Pro 60. When drain tanks are used instead of condensate pump, the condensate (water) is collected into both tanks. The drain switch activates and stops the operation when tanks reach the level of approximately 8.0 gal (30 L).
12 12 Operation Section 4. SPECIFICATIONS 4.1 Technical Specifications ITEM SPECIFICATIONS Electronic Features Control Panel Electronic Thermostat Control Electronic Cooling Capacity *1 Capacity-208/230 V 58500/60000 Btu/h (17145/17585 W) Refrigerant Circuit Compressor Compression Type Hermetic Scroll Motor Rated Output at 230 V 3.89 kw Evaporator Condenser Refrigerant Control Plate Fin Plate Fin Capillary Tube Refrigerant/Enclosed quantity R-410A/4.10 lb (1.86 kg) *2 R-410A/3.97 lb (1.80 kg) *3 Ventilation Equipment For Evaporator Ventilation Equipment For Condenser Fan Type Max. Air Flow-high/low Motor Rated Output-high/low at 230 V Max. External Static Pressure Fan Type Max. Air Flow - high/low Motor Rated Output-high/low at 230 V Max. External Static Pressure Centrifugal 1940/1770 CFM (3300/3000 m 3 /h) 0.60/0.33 kw 0.9 IWG (224 Pa) Centrifugal 2830/2650 CFM (4810/4500 m 3 /h) 1.20/0.92 kw 0.85 IWG (212 Pa) Electronic Characteristics Power Requirement 208/230 V, 1 PH 60 Hz Min. Max. Voltage Current Consumption-208/230 V *1 Total Power Consumption-208/230 V *1 Min.198 V, Max.253 V 32/29 A 6.6/6.6 kw Power Factor-208/230 V *1 99/99% Starting Current 134 A *2 160 A *3 Recommended Fuse size 50 A Power Cord NEMA Plug Configuration 6-50 Gauge x Length 6 AWG (3-core) x 6 ft
13 Operation Section 13 ITEM SPECIFICATIONS Signal Connection Fire Alarm Input Dry contact type (recommended) No-Voltage Contact Input/Contact resistance less than 100 ohm Warning Signal Output 2 A at 30 V (DC/AC) or less (resistive load) Net weight 611 lb (277 kg) *2 623 lb (283 kg) *3 Operating Condition Inlet air: Max. 105 F (41 C), 50%RH Inlet air: Min. 65 F (18.3 C), 50%RH Sound Level *4 With Condenser Duct-high/low 69/67 db (A) Without Condenser Duct-high/low 71/69 db (A) Max. Duct Equivalent Length-Per Cold Duct Hose/Hot Duct Hose 40/100 ft (12.1/30.5 m) Condensate Pump 1/30 HP, 230 V, 0.5 A, 75 W, Discharge: 3/8 in (9.53 mm) OD barbed Specifications are subject to change without notice. < NOTE > *1 :Rating Condition: 95 F (35 C), 60%RH *2 :Serial number from 0716XXXX600 to Present *3 :Serial number from 0407XXXX600 to 0616XXXX600 *4 :Measured at 3.28 ft (1 m) from surface of unit. Please refer to page 2 for the position of the nameplate showing the serial number on the unit.
14 14 Operation Section 4.2 Characteristics at 230 V Cooling Capacity (x10 3 Btu/h) Dry Bulb Temp. F ( C) <Cooling Capacity Curve> (35) 86(30) 77(25) 68(20) 50 (10) 59 (15) 68 (20) Wet Bulb Temp. F ( C) 77 (25) Delta-T F ( C) <Cool Air Temperature Difference Curve> 23.4(13) 21.6(12) 19.8(11) 18.0(10) 16.2(9) 14.4(8) 12.6(7) 10.8(6) 9.0(5) 7.2(4) Relative Humidity (%) <Power Consumption Curve> 8.0 <Current Consumption Curve> 35 Power Consumption (kw) Current Consumption (A) Dry Bulb Temp. F ( C) (35) 86(30) 77(25) 68(20) 68 (20) 77 (25) 86 (30) 95 (35) Dry Bulb Temp. F ( C) 15 95(35) 86(30) 77(25) 68(20) 68 (20) 77 (25) 86 (30) 95 (35) Wet Bulb Temp. F ( C) Wet Bulb Temp. F ( C) I001910a
15 Operation Section Characteristics at 208 V Cooling Capacity (x10 3 Btu/h) Dry Bulb Temp. F ( C) <Cooling Capacity Curve> (35) 86(30) 77(25) 68(20) 50 (10) 59 (15) 68 (20) Wet Bulb Temp. F ( C) 77 (25) Delta-T F ( C) <Cool Air Temperature Difference Curve> 23.4(13) 21.6(12) 19.8(11) 18.0(10) 16.2(9) 14.4(8) 12.6(7) 10.8(6) 9.0(5) 7.2(4) Relative Humidity (%) <Power Consumption Curve> 8.0 <Current Consumption Curve> 40 Power Consumption (kw) Current Consumption (A) Dry Bulb Temp. F ( C) (35) 86(30) 77(25) 68(20) 68 (20) 77 (25) 86 (30) 95 (35) Dry Bulb Temp. F ( C) 20 95(35) 86(30) 77(25) 68(20) 68 (20) 77 (25) 86 (30) 95 (35) Wet Bulb Temp. F ( C) Wet Bulb Temp. F ( C) I001911a
16 16 Operation Section 5. REFRIGERANT SYSTEM 5.1 Refrigerant System Construction The component parts of the refrigerant system include the following: Compressor, Evaporator, Condenser, Capillary tube, High Pressure Switch These parts are all connected by copper tubing. All the connections have been brazed. Evaporator Condenser Compressor Suction Pipe Compressor Discharge Pipe Condenser Inlet Pipe Condenser Outlet Pipe Evaporator Evaporator Inlet Pipe Capillary Tube Evaporator Outlet Pipe Compressor Compressor Condenser Flow of Refrigerant Condenser Capillary Tubes Condenser Fan Evaporator Fan Evaporator Compressor I001912
17 Operation Section Compressor The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in one casing. (1) Compressor theory of operation The scroll utilizes an involuted spiral which, when matched with a mating scroll form, generates a series of crescent-shaped gas pockets between the two members. During compression, one scroll remains stationary (fixed scroll) while the other form (orbiting scroll) is allowed to orbit (but not rotate) around the first form. As this motion occurs, the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume. When the pocket reaches the center of the scroll form, the gas, which is now at a high pressure, is discharged out of a port located at the center. During compression, several pockets are being compressed simultaneously, resulting in a very smooth process. Both the suction process (outer portion of the scroll members) and the discharge process (inner portion) are continuous. (2) Compressor operation I ) Compression in the scroll is created by the interaction of an orbiting spiral and a stationary spiral. Gas enters the outer openings as one of the spirals orbits. 2) The open passages are sealed off as gas is drawn into the spiral. 3) As the spiral continues to orbit, the gas is compressed into two increasingly smaller pockets. 4) By the time the gas arrives at the center port, discharge pressure has been reached. 5) Actually, during operation, all six gas passages are in various stages of compression at all times, resulting in nearly continuous suction and discharge. < NOTE > When the compressor shuts off, the compressor motor may run backward for a moment or two until internal pressures is equalized. This has no effect on compressor durability but may cause an unexpected sound after the compressor is turned off and should not be diagnosed as a malfunction.
18 18 Operation Section 5.3 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. 5.4 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 capillary tube are determined by the capacity of the refrigeration system, specified operating conditions, and the amount of refrigerant. The capillary tube causes the high pressure, high Low Temp./Low Pressure temperature liquid refrigerant sent from the Gas and Liquid Mixture I 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. 5.5 Evaporator The evaporator, like the condenser, is a heat exchanger covered with plate fins. Heat is removed from the air being pulled across the evaporator by the centrifugal fan and the resulting cool air is expelled through the cool air vent. 5.6 High Pressure Switch The high pressure switch prevents the Pressure of Refrigerant condenser and compressor from being Snap Disk damaged by excessively high pressure in the Movable Point high pressure line of the refrigeration cycle. The switch is normally 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 Stationary Point Case Molding by Resin Pin Terminal Lead Wires ground signal at the control board (J104 connector) which turns the compressor off. Possible causes of this trouble include: - The condenser air filter is dirty, restricting air flow. - The condenser blower is defective. I001768
19 Operation Section ELECTRICAL SYSTEM 6.1 Circuit Diagram and Control Box AC 208/230 V 1φ 60 Hz AP MCC TB1 1L1 2T1 G T1 TRR1 3L2 4T2 5L3 6T3 A1 A2 MCC G CC 1 2 MC IOLC G Condensate Pump G MDP FDS ODS RTH THS DS HPRS CF2 1 2 CF1 1 2 HI MF2 LO IOLF G HI MF1 IOLF LO G J8 J7 J6 J5 J4 J3 J2 J1 J10 RB J9 J101 J102 J103 J104 TB2 J201 J106 L- L+ J105 J108 E- E+ CB A P T B 1 T B 2 C B R B M F 1 M F 2 M C C F 1 C F 2 C C Attachment Plug Terminal Block Terminal Block Control Board Relay Board Condenser Fan Motor Evaporator Fan Motor Compressor Motor Capacitor for Condenser Motor Capacitor for Evaporator Motor Capacitor for Compressor IOLF IOLC D S T H S R T H G HPRS MCC M D P F D S O D S Inner Overload Relay of Fan Motor Inner Overload Relay of Compressor Full Drain Warning Switch Freeze Protection Thermistor Room Thermistor Grounding High Pressure Switch Relay for Compressor and Condenser Fan Motor Condensate Pump Motor Drain Float Switch Drain Overflow Switch TB2 Terminal Block (Signal Connection) Compressor Capacitor Fan Capacitor (Evaporator) Relay Dip Switch Relay Board Relay Board Fuse Terminal Block TB1 Fan Capacitor (Condenser) G I001913
20 20 Operation Section 6.2 Basic Operation of The Office Pro 60 Electrical Circuit There are two basic components used to control the operation of the Office Pro 60 electrical system: - Control panel assembly - Control box The control panel assembly contains the control panel, control board (with inputs for the freeze and room temperature thermistors), drain switch, high pressure 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 (208/230 VAC) from the fan on relay to the N.O. (normally open) contacts of the fan mode relay. This output is connected to the J8 terminal (relay board) where the high speed wire of the fan motor is connected. When this button is pressed again, fan turns to low mode (see below). Press again, fan stops. High fan mode is automatically switched depending on room temperature. When room (High) temperature is decreased down to 80 F (27 C) Condenser Fan or below, fan mode is switched to HIGH. When room temperature is increased to 88 F (31 C) (LO) or higher, fan mode is switched from HIGH to LO. Room Temperature 80 F (27 C) 88 F (31 C) I Low Fan Mode When the FAN MODE button on the control panel is pressed again, the microprocessor turns on FAN LO COOL OFF indication of LCD and activates both the fan on relay and fan mode relay. This sends line voltage (208/230 VAC) from the fan on relay to the N.C. (normally closed) contacts of the fan mode relay. This output is connected to the J7 terminal (relay board) where the low speed wire of the fan motor is connected. When this button is pressed again, fan stops.
21 Operation Section 21 (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 sec delay. This sends line voltage (208/230 VAC) to the J4 terminal (relay board) and compressor auxiliary relay is excited. Then compressor and condenser fan motor turn on (Cooling Operation). Condenser fan mode is automatically switched depending on room temperature. When room (LO) temperature is approximately. 100 F (38 C) or Condenser Fan greater, fan mode is switched LO to HIGH. When room temperature is approximately. (High) 95 F (35 C), fan mode is switched HI to LO. Room Temperature 95 F 100 F (35 C) (38 C) I001915
22 22 Operation Section 6.3 Control Box (1) Capacitors The capacitors are used to temporarily boost the power output available to the fan motor and the compressor at start-up. The specifications of each capacitor are listed below: Capacitor Application Voltage Rating Capacitance Evaporator Fan Motor 440 VAC 15 µf Condenser Fan Motor 370 VAC 25 µf Compressor 370 VAC 80 µf <Control Box> TB2 Terminal Block (Signal Connection) Compressor Capacitor Fan Capacitor (Evaporator) Relay Dip Switch Relay Board Relay Board Fuse Terminal Block TB1 Fan Capacitor (Condenser) G I001916
23 Operation Section 23 (2) Relay board The relay board receives signals and outputs <Dip Switch> from the control board that contains a Dip Switch microprocessor. The relay board contains the compressor, fan on and fan mode (speed) Temperature Scale relays. Display Switch It also contains a step-down transformer that ( C F) converts the line voltage (208/230 VAC) to Fan Mode Control Switch 12 V. (STOP OPERATE) I 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. 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 to the step-down transformer. It must be replaced with the exact type of fuse or an equivalent. Fuse Specifications: - 2/10 A, 250 V <Relay Board> Fuse CAUTION Failure to use the exact type of fuse could result in damage to the unit and/or to components. It could also void the warranty of the unit. I001773
24 24 Operation Section 6.4 Fan Motor (1) For evaporator The fan motor is a single phase, induction type two-speed motor. Specifications: - Rated Voltage: 230 V, 60 Hz - Rated Output: High-590 W, Low-360 W Evaporator Fan Motor Ground (Green/Yellow) J7 Low (Red) CF22 (Brown/White) CF21 (White) J8 High (Black) I (2) For condenser The fan motor is a single phase, induction type two-speed motor. Specifications: - Rated Voltage: 230 V, 60 Hz - Rated Output: High-1195 W, Low-932 W 6.5 Compressor Motor Condenser Fan Motor Ground (Green/Yellow) J5 Low (Red) CF12 (Brown/White) CF11 (White or Orange) J6 High (Black) I The compressor motor is a single-phase motor and is contained within the same housing as the compressor. Specifications: - Rated Voltage: 208/230 V, 60 Hz - Rated Output : 3890 W (at 230 V) < NOTE > An internal overload relay is used to protect the fan motors and the compressor motor. This relay is built into the fan motors and compressor motor. It interrupts the flow of current when there is an over current situation or if abnormally high temperature builds up in the fan motors and compressor motor.
25 Operation Section Condensate Pump The Office Pro 60 is equipped with a condensate pump, which collects the water that forms on the evaporator during normal cooling operation and eliminates the need for a drain tanks. - When the water collects to level (A) in the 3/8 in (9.53 mm) I.D. Motor Fan pump reservoir, the condensate pump begins Drain Outlet Spout Cover with Check Valve to operate and discharge the water. During 1 in (25.4 mm) condensate pump operating period the Inlet Drain Hole compressor cycles off. Reservoir Mounting Ear Main Control Float I When the water level drops below level (B), the condensate pump stops and compressor restarts after delay time has expired. B A < NOTE > I If for any reason the water level exceeds that of level (A) in the pump reservoir, an overflow drain switch stops the compressor operation. If the fan mode control DIP switch has been set from the cool to the stop position, the fan also turns off while the condensate pump is discharging the water.
26 26 Operation Section - To insure proper drainage, locate the highest vertical position, no more than 17 ft (5.2 m) at 230 VAC /13 ft (4m) at 208 VAC, and run the drain hose on a downward slope at a minimum rate of 1/4 in (6.35 mm) per foot. 17 feet (5.2 m) Max. 1/4 inch (6.35 mm) Taper Per Foot Condensate Pump Grommet I001920a < NOTE > The condensate pump maximum lift is 17 ft (5.2 m) at 230 VAC or 13 ft (4 m) at 208 VAC. Please check the drainage performance after installation. It is important that the drainage line from the condensate pump is free of kinks and is not pinched. Power fluctuation or low voltage could result in incorrect drainage.
27 DS2 DS1 Operation Section Drain Switch The Office Pro 60 is equipped with a drain tank switch. When the drain tanks accumulates approximately 8.0 gal (30 L) of condensate (water) in the drain tanks, the drain tank switch sends a signal to the microprocessor. The microprocessor stops all operation of the unit, flashes the TANK FULL LED, indicates TANK FL on the LCD and closes the contact of output signal. This system utilizes a 0.1 A, 125/250 VAC micro-switch for this function. When drain water accumulates approximately 8.0 gal (30 L) in the drain tanks, the drain tank base plate, which is supported at its fulcrum, is pushed down in the arrow direction as shown in the figure below. When the drain tank base plate is forced down, the top of the drain tank base plate turns off the contacts #1-#2 of the micro switch. This causes the ground signal at the J103 connector of the control panel assembly to go open. When the microprocessor detects this event, it shuts the unit off, flashes the TANK FULL LED, indicates TANK FL on the LCD and closes the contact of output signal. When the drain tanks is removed (or the drain tanks is emptied), the top of the drain tank base plate returns to its original position from the tension of the coil spring. Then contacts #1-#2 of the drain tank switch close. This provides a ground to the microprocessor through the J103 connector. Top Base Plate Evaporator Drain Switch NC C 2 1 Drain Pan Drain Tube To J103 Drain Tanks Spring Drain Water Fulcrum Base Base Plate I002230
28 28 Operation Section (1) How to re-start the unit If the LCD indicates PROGRAM ON, press the COOL ON/OFF button to continue running the program. If the LCD indicates PROGRAM ON continuously (program activated), no further steps are necessary. If no program exists or the program was deactivated, press the FAN MODE button or the COOL ON/OFF button. The unit returns to the previous temperature set point. 6.8 Automatic Restart after Power Interruption The program within the microprocessor of the Office Pro 60 contains a feature that automatically restarts the unit after power is lost and then regained. The unit also has memory in order to return itself back to the operating mode (either manual or preset program) it was in prior to the loss of power. All preset programs are retained in the memory in the event power loss occurs. 6.9 Compressor Protection 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. Time Delay Specifications: ± 20 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 / buttons on the control panel. The adjustment range of the temperature set point is from 65 F to 90 F (18 C to 32 C).
29 Operation Section 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 sec, the fan starts before the compressor (time delay feature). (2) Cool to operate When the DIP switch is set to the upward or OPERATE position, the microprocessor controls the fan operation using control panel inputs only. The fan operates continuously during fan only and cool modes. (This is the factory default setting.) 6.12 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.)
30 30 Operation Section 6.13 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 condition. Relay contactor is closed when the following condition 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. Connecting warning signal from controller - Remove service panel from the rear of the unit. - Squeeze the inner latches and push out the black cap from inside the panel. (See drawing of cap and inner latch shapes.) - Use recommended warning signal wire size from 16 AWG to 26 AWG or a solid wire, or 16 AWG to 22 AWG for a stranded wire with ring terminal for #6 stud size. - Connect warning device to terminal L+ and L- according to its polarities Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-) The controller is equipped with a normal open input signal, which can be connected directly from the fire alarm control panel. When receiving the signal from the fire alarm control panel, the unit turns off and does not turn back until it has been reset. Connecting fire alarm control panel to controller - Remove service panel from the rear of the unit. - Squeeze the inner latches and push out the black cap from inside the panel. (See drawing of Cap and inner latch shapes.) - Use recommended warning signal wire size from 16 AWG to 26 AWG for a solid wire, or 16 AWG to 22 AWG for a stranded wire with ring terminal for #6 stud size. - Connect warning device to terminal E+ and E- according to its polarities. <Cap> Latch Input Signal Terminals Output Signal Terminals I001888
31 Repair Section TROUBLESHOOTING 7.1 Troubleshooting 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 208/230 V (60 Hz) Check the operation and condition of the fuse or circuit breaker in the power source. (2) Inspection of air filters Remove the air filters and check the element. If the element is dirty, wash it as described in the OPERATION MANUAL supplied with the unit. (3) Inspection of condensate pump Remove any dirt or debris which may collect in the bottom of the reservoir tank. On a monthly basis, check the condensate drain hose for kinks, blockage or any other damage that may obstruct condensate pump from draining properly. Make sure that motor's cover is closed to keep electrical parts free of dust, dirt and any other foreign material. Condensate pump overflow switch can stop the compressor operation if the pump is malfunction. To test the condensate pump overflow switch, pinch the drain outlet hose and pour water into the reservoir inlet drain hole. Continue to fill the reservoir until the rising water lifts the overflow switch and stops the operation. If the compressor continues to operate when the reservoir is full, check your installation procedure. After testing is completed, release the drain outlet hose to enable the condensate pump to empty its reservoir. Make sure the 9 in (230 mm) section of hose is installed into the inlet drain hole of the pump reservoir. (4) Inspection of drain tanks (optional) Make sure tanks are fully drained. < NOTE > If the fan mode control DIP switch is set to the stop position, the entire unit (including fan operation) turns off. The following pages (page 32 to 39) are self-diagnostic codes and troubleshooting information.
32 32 Repair Section 7.2 Self-Diagnostic Codes Self-diagnostic codes are displayed on the control board under the following conditions and clear method is as follows. LCD Display Description Condition Reset/Remedy Drain tanks are full. When the drain tanks (optional) are filled with drain water. ( TANK FL LED flashes and signal output (J106) turns on.) 1)Drain away. (LCD indicates TANK ) 2)Press ON/OFF button. TU HI FAN ON COOL AM SET TEMP F Condensate pump problem When condensate pump is damaged or broken. (J8 input of relay board turns to open and signal output (J106) turns on.) 1) Fix the condensate pump. 2)Reset the system. To RESET: Press ON/OFF and HI/LO buttons on the control box simultaneously for 5 sec. Defect (short or open) of room thermistor When room thermistor (connecting to J101) becomes short or open. (Signal output (J106) turns on.) Disconnect and reconnect the room thermistor. If it doesn t work, then change it. HI FAN F ON COOL SET TEMP HI FAN F ON COOL SET TEMP HI FAN F Defect (short or open) of freeze protection thermistor When freeze protection thermistor (connecting to J102) becomes short or open. (Signal output (J106) turns on.) Disconnect and reconnect the freeze protection thermistor. If it doesn t work, then change it. ON COOL SET TEMP HI FAN F ON COOL SET TEMP Show running hours Press ON/OFF and buttons simultaneously for 3 sec, total operation hours of compressor is indicated by 6-digit (hours). Example in left: 807 h After 5 sec., display goes back to normal mode.
33 Repair Section 33 LCD Display Description Condition Reset/Remedy MO TU WE TH FR SA SU START AM PROGRAM STOP ON CLOCK PM LOCKED HI F F C C FAN LO SET TEMP ON COOL OFF ROOM TEMP Show LCD and LED all on mode Press HI/LO and buttons simultaneously for 3 sec. (To check LCD segments and LED display.) After 5 sec., display goes back to normal mode. TU HI FAN AM LOCKED F Key lock mode (LCD displays LOCKED.) Press ENTER and SET CLOCK buttons simultaneously for 5 sec. Press ENTER and SET CLOCK buttons simultaneously for 5 sec again to cancel the key lock mode. ON COOL SET TEMP Indication of model name Press ENTER and SET CLOCK buttons simultaneously for 5 sec or turn on. Reset to normal display automatically after 5 sec. Detection of unit stop signal from fire alarm system Press input signal from fire alarm becomes on. (Unit stops, output signal (J106) turns on and buzzer sounds.) 1) After input signal turns off. 2)Reset the system. To RESET: Press ON/OFF and HI/LO buttons on the control box simultaneously for 5 sec. Indication of service code Press ON/OFF and buttons simultaneously for 3 sec. Indication contents is as follows. 1)See page 36 to 38. 2)Press ON/OFF button. LCD Description Value DF Defrost status FZ OD Evap. out pipe temperature Outdoor temperature F ( 26 X9 ) 0 ( 00 ) Change model setting For installing new controller PCB, if a different model name appears when the unit is reset or turned on, change model name according to the correct procedure. 1)While pressing and buttons, plug the power cord. <Condition> LCD indicates current setting model name and buzzer sounds. 2)After setting the model type by pressing and button, unplug the unit.
34 34 Repair Section LCD Display Description Condition Reset/Remedy TU HI FAN ON COOL AM SET TEMP F Activation of high pressure switch When high pressure switch (connected to J104) activates (=J104 input turns to open) 3 times in 24 h, HP is indicated and signal output (J106) turns on. When it activates 10 times in 24 h, FAIL HP is indicated and buzzer sounds. Find the cause of high pressure to address it. Check the following. Ambient air temperature 65 F (18.3 C), 50%RH 105 F (41 C), 50%RH Air filter (if dirty, wash up.) Condenser fan motor (if not working, replace.) Defect of high pressure switch (if switch is open when unit is off, replace switch.) Reset the system. To RESET: Press ON/OFF and HI/LO buttons on the control box simultaneously for 5 sec. 7.3 Troubleshooting Chart To accurately troubleshoot the problem, it is important to carefully confirm the nature of the problem. Typical problems are: - Insufficient cooling. - Unit does not start (operate). - Overflow of drain water. - Abnormal noise or vibrations. - Others. (1) Insufficient cooling Cooling system problem generally results from electrical or mechanical components such as fan motor, compressor, control switch. < NOTE > 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 installation site for operating temperature and installation space (unobstructed airflow).
35 Repair Section 35 Condition Possible Cause Checking Area Cause Usage conditions Operation near usage limits (high temperature) Remedy Review the installation place. Air volume normal Insufficient air volume Compressor operates. Compressor does not operate. No air Insufficient air volume Dirt in condenser or evaporator Insufficient heat exchange Clean fins. Frost in refrigeration cycle Clogging at the frost section Replace clogged section. No temperature difference between evaporator and condenser Compressor coil resistance (0 ohm or ohm) Compressor relay Compressor relay on the relay board Capacitor for compressor motor Insufficient refrigerant Short or open circuit Open circuit or insufficient contact Open circuit or insufficient contact Capacitor malfunction Check the leaking part, then repair and charge refrigerant. Replace compressor. (In case of short, check the compressor relay.) Replace compressor relay. Replace relay board. Replace capacitor. Voltage Low voltage Repair power. Coil resistance of fan motor (0 ohm or ohm) Fan on-off relay on the relay board Fan HI/LO change relay on the relay board Short or open circuit Open circuit or insufficient contact Open circuit or insufficient contact Replace fan motor. Replace relay board. Replace relay board. Air filter Clogged air filter Clean air filter. Evaporator Clogged evaporator or crushed fins Repair and clean fins or replace it. Duct connection condition Improper connection Repair duct connection. Fan motor Insufficient rotation Replace motor.
36 36 Repair Section (2) Unit does not start (operate) < NOTE > In this case, there is a possibility of safety device activating due to the clogged air filter. So make sure to first clean the air filter and then start up again to confirm if the problem lies with the air filter. Check the installation site for operating temperature and installation space (unobstructed airflow). Condition Possible Cause Remedy Checking Area Cause Voltage Power failure Repair power. Unit does not operate at all. No display on control panel Ground fault breaker trip Ground fault or defective ground fault breaker Repair ground fault section. Reset or repair breaker. Fuse Fuse blown Repair shorting section. Replace fuse on the relay board.
37 Repair Section 37 Condition Possible Cause Checking Area Cause Remedy FL Drain tanks (optional) are filled with the drain water. Discharge the drain water. Improper drain switch connection Check connection. Defective drain switch Replace drain switch. AS Improper routing of drain hose Repair drain hose, then reset unit. To RESET: Press ON/OFF and HI/LO buttons on the control box simultaneously for 5 sec. Defective condensate pump Repair or replace condensate pump, then reset unit. To RESET: Press ON/OFF and HI/LO buttons on the control box simultaneously for 5 sec. Missing jumper connector Connect jumper connector. Unit does not operate. Control Panel displays error codes. RT Improper room thermistor connection Defective room thermistor (short or open) Check connection. Replace room thermistor. FT Improper freeze protection thermistor connection Check connection. Defective freeze protection thermistor (short or open) Replace freeze protection thermistor. HP Improper high pressure switch connection Check connection. Defective high pressure switch (short or open) Replace high pressure switch. ALRM FZ See Unit stops after running for a while of Troubleshooting on page 38. Turn the input signal on and 1)Check external input continue it. signal. 2) Reset the system. To RESET: Press ON/OFF and HI/LO buttons on the control box simultaneously for 5 sec. See Unit stops after running for a while of Troubleshooting on page 38.
38 38 Repair Section Condition Possible Cause Checking Area Cause Fan on-off relay on the relay Open circuit or insufficient board contact Remedy Replace relay board. Fan HI/LO change relay on the relay board Open circuit or insufficient contact Replace relay board. Unit stops immediately after starting. Control panel displays normally. Fan motor insulation resistance Compressor relay Insulation failure on fan motor Open circuit or insufficient contact Replace fan motor. Replace compressor relay. Compressor relay on the relay board Open circuit or insufficient contact Replace relay board. Compressor insulation resistance Insulation failure on compressor Replace compressor. Temperature of fan motor (abnormally high) Operation of safety device (IOLF) due to fan motor malfunction Replace fan motor. Unit stops after running for a while. Control panel displays normally. Temperature of compressor (abnormally high) Refrigerant leakage Operation of safety device (IOLC) due to compressor malfunction Insufficient refrigerant or gas leakage Replace compressor. Repair and charge refrigerant. (3) Overflow of drain water Dirt on evaporator or condenser Insufficient cooling of evaporator or condenser Clean evaporator or condenser. Duct connection condition Improper connection Repair duct connection. Condition Checking Area Possible Cause Cause Remedy Drain pan Duct connection state Check and repair. Water level in drain pan Clogged drain hose Check and replace. Overflow of water from the unit Drain hole Clogged air filter Reversed air flow from drain hole Reversed air flow from drain hole due to the excessive negative pressure inside of the unit Insert a trap on discharge drain hose. Clean air filter.
39 Repair Section 39 (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 Abnormal noise or vibration Possible Cause Remedy Checking Area Cause Fan Fan interference Repair interfering section. Fan deformation Replace fan. Compressor fixing nuts Looseness of nuts Tighten nuts further. Piping Pipe interference Repair interfering section. Panel fixing screws Looseness of screws Tighten screws further. 7.4 Basic Inspection Perform the following inspection before disassembly. (1) Inspection of plate fins To inspect the plate fins of either the evaporator or condenser, the air filter must be removed. After removal of the air filters, inspect the plate fins for any dirt, dust, lint, or debris that may have caused insufficient cooling performance of the unit. If cleaning of the fins is necessary, it is recommended that this service be performed by a qualified service technician. I (2) Examination of operating environment Operating environments can vary depending on location, climate and surrounding conditions. Installation location also can cause operational problems. Consult your reseller concerning operational environment requirements.
40 40 Repair Section (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 and 15, proceed with the remedy suggested in the troubleshooting chart on page 34 to 39. Thermometer Cool Air Out Thermometer Evaporator Air In I001922
41 Repair Section DISASSEMBLY WARNING Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. 8.1 Parts Construction Upper Panel Blower housing Condenser Fan Front Right Panel Rear Right Panel Upper Front Panel Control Panel Air Outlet Grill Room Thermistor Freeze Protection Thermistor Front Panel Filter Assy Front Left Panel Evaporator Fan Condensate Pump Side Panel Filter Assy Drain Tank Panel Drain Pan Assy Rear Panel Middle Frame Sub-Assy Pivoting Caster Drain Tanks (Optional) Rear Left Panel Power Cord Pivoting Caster Service Panel I001923a
42 42 Repair Section 8.2 Disassembly 1) Remove drain tanks (optional). Screws (7) I Screws (3) 2) Remove twelve (12) screws from upper front panel. Screws (2) I ) Slide upper front panel forward and remove. I ) Louver can be removed from upper front panel by unsnapping the lock tap and removing the louver from its pivots. I001786
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