Movincool Office Pro 60 User manual

SERVICE MANUAL
OFFICE PRO 60

© 2001 DENSO SALES CALIFORNIA, INC.
All rights reserved. This book may not be reproduced or copied, in whole or in part, without the
written permission of the publisher. DENSO SALES CALIFORNIA, INC. reserves the right to
make changes without prior notice. MovinCool is a registerd trademark of DENSO Corporation.

SERVICE MANUAL
OFFICE PRO 60

FOREWORD
This manual has been published to service the MovinCool Office Pro 60. Please use this
service manual only when servicing the Office Pro 60.
DEFINITION OF TERMS
WARNING: Describes precautions that should be observed in order to prevent injury
to the user during installation or unit operation.
CAUTION: Describes precautions that should be observed in order to prevent damage
to the unit or its components, which may occur during installation or unit operation if
sufficient care is not taken.
NOTE: Provides additional information that facilitates installation or unit operation.
GENERAL PRECAUTIONS
WARNINGS:
•All electrical work if necessary, should only be performed by qualified electrical
personnel. Repair to electrical components by non-certified technicians may result in
personal injury and/or damage to the unit. All electrical components replaced must
be genuine MovinCool, purchased from an authorized reseller.
• When handling refrigerant, always wear proper eye protection and do not allow the
refrigerant to come in contact with your skin.
•Do not expose refrigerant to an open flame.
• The proper electrical outlet for MovinCool units must be equipped with a “UL” ap-
proved ground-fault breaker to prevent electrical shock from the unit.
•When brazing any tubing, always wear eye protection and work only in a well venti-
lated area.
•Disconnect power before servicing unit.
•Be careful of any sharp edges when working on unit.
i

ii

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

iv

GENERAL DESCRIPTION
1
CONDENSER
(OUTDOOR UNIT)
EVAPORATOR
(INDOOR UNIT)
Conventional Air Conditioner
Office Pro 60
Generally speaking, conventional air conditioners
cool the entire enclosed environment. They act as
“heat exchangers”, requiring an interior unit (evapora-
tor) 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 Spot Cooling System is a spot cooler
which directs cool air to particular areas or objects.
MovinCool Spot Cooling Systems have the following
features:
1. Compact Design
The innovative design of MovinCool has resulted
in one compact unit, replacing the need for two
separate units.
2. Easy Transportation and Installation
With the whole cooling system built into one
compact unit, MovinCool requires no piping and
can be easily transported and installed.
3. Energy Conservation
MovinCool is economical because it cools only
the area or objects which need to be cooled.

GENERAL DESCRIPTION
2

CONSTRUCTION, SPECIFICATIONS, and DATA
3
CONDENSER MOTOR
CONDENSER FAN
EXHAUST AIR OUTLET
EVAPORATOR FAN
EVAPORATOR MOTOR
EVAPORATOR
COOL AIR VENT
CAPILLARY TUBE
DRAIN PAN
CONDENSATE PUMP
DRAIN SWITCH
(BEHIND CONTROL BOX)
CONTROL BOX
COMPRESSOR
CONDENSER
Construction of Office Pro 60

CONSTRUCTION, SPECIFICATIONS, and DATA
4
EVAPORATOR FAN
EVAPORATOR
FAN MOTOR
TOP PANEL
POWER
CORD
EXHAUST AIR OUTLET
SIDE PANEL
BACK HANDLE
CONDENSER FAN MOTOR
CONDENSER FAN
CONDENSER
COMPRESSOR
POWER CORD
COOL AIR VENT
CONTROL PANEL
FRONT HANDLE

CAPILLARY TUBES
FRONT PANEL
EVAPORATOR
DRAIN PUMP
CASTER
Construction Diagram

CONSTRUCTION, SPECIFICATIONS, and DATA
5
1. Basic Construction
The MovinCool Spot Cooling System is compact
in construction because the condenser and the
evaporator are enclosed in one unit. The interior
is divided into three sections. The upper front
face is equipped with the evaporator, while the
lower front face contains the drain tank (optional).
The rear section contains the condenser, the
compressor and the control box.
2. 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,
while the exhaust air outlet is protected by wire
mesh.
3. Compressor and Fans
The compressor is hermetically sealed. A two-
speed fan motor is used with two centrifugal fans
to draw air across the evaporator and condenser.
4. Drain Tank (Optional)
The capacity of the drain tank is 5.0 gallons (19
liters). The unit is equipped with a “Tank Full” LED
and a device to automatically stop the operation
of the unit when the drain tank reaches a level of
approximately 4.0 gallons (15 liters).
5. Condensate Pump
The condensate pump will pump water from the
pump’s main tank to a nearby sink or floor drain.
The pump will lift the water a vertical distance of
18 feet. A plastic hose is supplied with the pump.
The condensate pump is included with the Office
Pro 60. It is important that the drain line from the
pump is not kinked or bent.
EXHAUST
AIR OUT
CONDENSER
AIR IN
EVAPORATOR
AIR IN
COOL
AIR OUT COOL
AIR OUT
Air Flow

CONSTRUCTION, SPECIFICATIONS, and DATA
6
Specifications Specifications are subject to change without notice.
Rating Conditions
dry bulb ...................................................................................... 95˚F (35˚C)
wet bulb ..................................................................................... 83˚F (28.2˚C)
humidity ..................................................................................... (60%)
Specifications
power frequency ........................................................................ 60Hz
line voltage ................................................................................. single phase 208/230V
power consumption .................................................................... 7.1 Kw
current consumption .................................................................. 33 Amps
power factor ............................................................................... 94%
starting current ........................................................................... 140A
power wiring ............................................................................... 6 (3-core) AWG
Power Requirements
transformer size ......................................................................... 20 KVA
Cooling Unit
cooling capability ....................................................................... 15,100 Kcal/hr
60,000 BTU/hr
cooling system ........................................................................... direct expansion
Blower
type of fan .................................................................................. centrifugal fan
air volume: Evaporator (High speed) ........................ 1940 ft 3/min (3296 m3/h)
Evaporator (Lo speed) ............................ 1770 ft 3/min (3007 m3/h)
Condenser (High speed) ........................ 2830 ft 3/min (4804 m3/h)
Condenser (Lo speed) ........................... 2650 ft 3/min (4502 m3/h)
motor output: Condenser (High) ................................... 1.12 Kw
Condenser (Low) ................................... 0.93 Kw
Evaporator (High) ................................... 0.50 Kw
Evaporator (Low) .................................... 0.33 Kw
Compressor
type ............................................................................................ Hermetic scroll
output ......................................................................................... 4.7 Kw
refrigerant type ........................................................................... R-22
refrigerant capacity .................................................................... 6.83 lbs (3.1 kg)
Safety Devices
compressor overload protector .................................................. included
fan motor protector .................................................................... included
anti-freezing thermistor .............................................................. included
full drain tank switch .................................................................. included
automatic restart (power interruption) ........................................ included
compressor time delay program ................................................ included
Dimensions & Weight
W x D x H (in)............................................................................. 30" x 52" x 64.4"
W x D x H (mm) ......................................................................... 760 x 1320 x 1635
weight (lbs/kg) ............................................................................ 625 / 283
Operating Conditions
inlet air (relative humidity) .......................................................... 106˚F (41˚C)
65˚F (18.3˚C), (50%)
Control Devices
temperature control .................................................................... included
programmable timer ................................................................... included
two speed fan ............................................................................ included

CONSTRUCTION, SPECIFICATIONS, and DATA
7
16 ø
40.80
51.70
10.2
22.80
64.40
6.75
27.109.90
4.16
18.70
30.3
2.80
24.20
30.31
Exterior Dimensions (units: inches)

DATA
8
@ 230V
40 50 60 70
Relative Humidity of Inlet Air (%)
6 (10.8)
8 (14.4)
10 (18.0)
12 (21.6)
14 (25.2)
Temperature ˚C (˚F)
Cool Air Tem
p
erature Difference Curve
38 (100.4)
33 (91.4)
28 (82.4)
23 (73.4)
18 (64.4) 12
(53.6)
17
(62.6)
22
(71.6)
27
(80.6)
32
(89.6)
Dry Bulb Temperature ˚C (˚F)
Wet Bulb Temperature ˚C (˚F)
Power Consumption Curve
8@230V
7.5
7
6.5
6
5.5
5
123456
Power Consumption (kW)
273 (65)
@230V
252 (60)
231 (55)
210 (50)
189 (45)
123456
Cooling Capability
(x10
3
KCAL/h (BTU/h))
38 (100.4)
33 (91.4)
28 (82.4)
23 (73.4)
18 (64.4)
12
(53.6)
17
(62.6)
22
(71.6)
27
(80.6)
Dry Bulb Temperature ˚C (˚F)
Wet Bulb Temperature ˚C (˚F)
Cooling Capability Curve

REFRIGERANT SYSTEM
9
EVAPORATOR
MODULATING

TANK
CAPILLARY
TUBE
CONDENSER
COMPRESSOR
CAPILLARY
TUBES
FLOW OF
REFRIGERANT
CONDENSER
COMPRESSOR
MODULATING
TANK
CONDENSER
FAN
EVAPORATOR
FAN
EVAPORATOR
Refrigerant System
1. The component parts of the refrigerant system include the following:
• Compressor • Evaporator
• Condenser • Modulating tank
• Capillary tube
These parts are all connected by copper tubing. All the connections have been brazed.

REFRIGERANT SYSTEM
10
1. Compressor
The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in
one casing.
A. Compressor Theory of Operation
The scroll utilizes an involute spiral which, when matched with a mating scroll form, generates a series
of crescent-shaped gas pockets between the two members. 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.
B. Compressor Operation
1) Compression in the scroll is created by the
interaction of an orbiting spiral and a
stationary spiral. Gas enters the outer
openings as one of the spirals orbits.
2) The open passages are sealed off as gas
is drawn into the spiral.
3) As the spiral continues to orbit, the gas is
compressed into two increasingly smaller
pockets.

REFRIGERANT SYSTEM
11
4) By the time the gas arrives at the center
port, discharge pressure has been
reached.
5) Actually, during operation, all six gas
passages are in various stages of com-
pression at all times, resulting in nearly
continuous suction and discharge.
NOTE: Upon compressor shut-off, the compressor
may run backward for a moment or two until
internal pressures equalize. This has no effect on
compressor durability but may cause an unex-
pected sound after the compressor is turned off
and should not be diagnosed as a malfunction.
2. Condenser
The condenser is a heat exchanger utilizing plate
fins. Heat is given off and absorbed by air being
pulled across the condenser fins by the centrifu-
gal fan and then expelled through the exhaust air
outlet.

REFRIGERANT SYSTEM
12
HIGH TEMP. / HIGH PRESS.
LIQUID REFRIGERANT
LOW TEMP. / LOW PRESS.
GAS AND LIQUID MIXTURE
FROM EVAPORATOR
MODULATING

TANK
TO COMPRESSOR
TO EVAPORATOR
INLET
Capillary Tube
Modulating Tank
3. Capillary Tubes
The capillary tubes are long thin tubes utilizing
line flow resistance to serve as an expansion
valve. The length and the inner diameter of the
capillary tubes are determined by the capacity of
the refrigeration system, specified operating
conditions, and the amount of refrigerant.
The capillary tubes cause the high pressure, high
temperature liquid refrigerant sent from the
condenser to expand rapidly as the refrigerant is
sprayed out through the fixed orifice in the
capillary tubes. As a result, the temperature and
state of the refrigerant become low and mist-like
respecitively, causing it to evaporate easily.
4. Evaporator
The evaporator, like the condenser, is a heat
exchanger utilizing 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. Modulating Tank
The modulating tank consists of a copper pipe
and tank sections, each being separated from the
other. The pipe connects to the evaporator outlet
at one end and to the compressor at the other;
the tank connects to the evaporator inlet. The
modulating tank is covered with insulation to
reduce thermal effects of ambient temperature. It
varies the quantity of refrigerant in the refrigerat-
ing cycle for optimum operating condition; it
stores part of refrigerant under light load and
delivers additional refrigerant to the cycle under
heavy load.