SERVICE MANUAL

OFFICE PRO 60
SERIAL NUMBER FROM APRIL 2007 (0407) TO PRESENT

DocID: 00G00016E
© 2008 DENSO SALES CALIFORNIA, INC.
All rights reserved. This book may not be reproduced or copied, in
whole or in part, without the written permission of the publisher. DENSO
SALES CALIFORNIA, INC. reserves the right to make changes without
prior notice. MovinCool is a registered trademark of DENSO
Corporation.
 Table of Contents

Table of Contents
Operation Section

1. PRECAUTIONS FOR SAFETY

1.1 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2. GENERAL DESCRIPTION
2.1 Spot Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Compact Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Easy Transportation and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Energy Conservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3. CONSTRUCTION
3.1 Exterior Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Exterior Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Internal Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Basic Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Compressor and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 Condensate Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.8 Drain Tanks (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4. SPECIFICATIONS
4.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Characteristics (at 230 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Characteristics (at 208 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5. REFRIGERANT SYSTEM
5.1 Refrigerant System Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.4 Capillary Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.5 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.6 High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6. ELECTRICAL SYSTEM
6.1 Circuit Diagram and Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Basic Operation of The Office Pro 60 Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
 Table of Contents

6.3 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.4 Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.5 Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.6 Condensate Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.7 Drain Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.8 Automatic Restart after Power Interruption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.9 Compressor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.10 Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.11 Fan Mode Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.12 Temperature Scale Display Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.13 Warning Signal Connection (Output Signal Terminal L+ and L-) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.14 Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-) . . . . . . . . . . . . . . . . . . . . . 30
 Table of Contents

Repair Section

7. TROUBLESHOOTING
7.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 Self-Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.4 Basic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8. DISASSEMBLY
8.1 Parts Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3 Removal of Electrical Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.4 Removal of Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.5 Removal of Condensate Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.6 Inspection of Capacitor (for Fan Motor and Compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.7 Inspection of Drain Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.8 Inspection of Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.9 Inspection of Compressor Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.10 Inspection of Wiring Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.11 Inspection of Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

9. REFRIGERANT SYSTEM REPAIR

9.1 Repair of Refrigerant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2 Removal of Refrigeration Cycle Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.3 Charging the System with R-410A Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.4 Refrigerant Charging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

10. REASSEMBLY
10.1 Removal of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10.2 Compressor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10.3 Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10.4 Wiring Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.5 Perform the Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.6 Caster Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.7 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
 Operation Section
6

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 60.

1.2 Definition of Terms

Describes precautions that should be observed in order to prevent injury to

WARNING
the user during installation or unit operation.
Describes precautions that should be observed in order to prevent damage to
CAUTION
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.

1.3 General Precautions

WARNING
• All electrical work if necessary, should only be performed by qualified electrical
personnel. Repair to electrical components by non-certified technicians may result in
personal injury and/or damage to the unit. All electrical components replaced must be
genuine MovinCool parts, purchased from an authorized reseller.
• When handling refrigerant, always wear proper eye protection and do not allow the
refrigerant to come in contact with your skin.
• Do not expose refrigerant to an open flame.
• The proper electrical outlet for MovinCool units must be equipped with a “UL” approved
ground-fault breaker to prevent electrical shock from the unit.
• When brazing any tubing, always wear eye protection, and work only in a well ventilated
area.
• Disconnect power before servicing unit.
• Be careful of any sharp edges when working on unit.
 Operation Section
7

2. GENERAL DESCRIPTION

2.1 Spot Cooler

• In general, conventional air conditioners cool
the entire enclosed environment. They act as
“heat exchangers”, requiring an interior unit
(evaporator) to blow cool air into the interior
Condenser Evaporator
and an exterior unit (condenser) to exhaust (Outdoor Unit) (Indoor Unit)
exchanged heat to the outdoors.
• Unlike conventional air conditioners, the
MovinCool Office Pro 60 is a spot cooler which
I000501
directs cool air to particular areas or objects.
MovinCool Office Pro 60 has the following features:

2.2 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
I001905
need to be cooled.
 Operation Section
8

3. CONSTRUCTION

3.1 Exterior Dimensions

(55.0)

(30.2)
(DIA. 15.7)
(18.7)

(65.0)
(62.2)
(27.6)
(10.0)

(6.1)

(2.6) (2.6)
(3.6) (3.6) (8.5) (40.8) (2.4)
(29.9) (51.6)

(Unit: inch) I001906

 Operation Section
9

3.2 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
 Operation Section
10

3.3 Internal Structure

Fan Motor Fan Fan Motor
(Evaporator) (Condenser) (Condenser)
(Behind Fan)

Fan
(Evaporator)

Evaporator

High Pressure
Switch

Capillary Tube

Drain Pan

Condensate Pump
Compressor Condenser Drain Switch Control Box
I001908

3.4 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.
 Operation Section
11

3.5 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

Condenser Air In
Evaporator Air In

I001909

3.6 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).
 Operation Section
12

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 Plate Fin
Condenser Plate Fin
Refrigerant Control Capillary Tube
Refrigerant/Enclosed quantity R-410 A/3.97 lb (1.80 kg)
Ventilation Equipment For Fan Type Centrifugal
Evaporator Max. Air Flow-high/low 1940/1770 CFM (3300/3000 m3/h)
Motor Rated Output-high/low at 230 V 0.60/0.33 kW
Max. External Static Pressure 0.9 IWG (224 Pa)
Ventilation Equipment For Fan Type Centrifugal
Condenser Max. Air Flow - high/low 2830/2650 CFM (4810/4500 m3/h)
Motor Rated Output-high/low at 230 V 1.20/0.92 kW
Max. External Static Pressure 0.85 IWG (212 Pa)
Electronic Characteristics Power Requirement 208/230 V, 1 PH 60 Hz
MIN. MAX. Voltage MIN 198 V, MAX 253 V
Current Consumption-208/230 V*1 32/29 A
Total Power Consumption-208/230 V*1 6.6/6.6 kW
Power Factor-208/230 V*1 99/99 %
Starting Current 160 A
Recommended Fuse size 50 A
Power Cord NEMA Plug Configuration 6-50
Gauge x Length 6 AWG (3-core) x 6 ft
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 623 lb (283 kg)
 Operation Section
13

ITEM SPECIFICATIONS
Operating Condition Inlet air: Maximum 105 °F (41 °C), 50 %RH
Inlet air: Minimum 65 °F (18.3 °C), 50 %RH
Sound Level*2 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 : Measured at 3.28 ft (1 m) from surface of unit.
 Operation Section
14

4.2 Characteristics (at 230 V)

<Cooling Capacity Curve> <Cool Air Temperature Difference Curve>

65
Cooling Capacity (x103 Btu/h)

23.4(13)
60 21.6(12)

55 19.8(11)

50 18.0(10)

Delta-T °F (°C)
16.2(9)
45
14.4(8)
40
95(35) 12.6(7)
Dry Bulb Temp. °F (°C)

86(30) 10.8(6)

77(25) 9.0(5)

68(20) 7.2(4)
30 40 50 60 70 80
50 59 68 77 Relative Humidity (%)
(10) (15) (20) (25)
Wet Bulb Temp. °F (°C)

<Power Consumption Curve> <Current Consumption Curve>

8.0 35
Power Consumption (kW)

Current Consumption (A)

7.0 30

6.0 25

5.0 20

4.0 15
95(35) 95(35)
Dry Bulb Temp. °F (°C)

Dry Bulb Temp. °F (°C)

86(30) 86(30)

77(25) 77(25)

68(20) 68(20)

68 77 86 95 68 77 86 95
(20) (25) (30) (35) (20) (25) (30) (35)
Wet Bulb Temp. °F (°C) Wet Bulb Temp. °F (°C)
I001910
 Operation Section
15

4.3 Characteristics (at 208 V)

<Cooling Capacity Curve> <Cool Air Temperature Difference Curve>

65
Cooling Capacity (x103 Btu/h)

23.4(13)
60 21.6(12)

55 19.8(11)

50 18.0(10)

Delta-T °F (°C)
16.2(9)
45
14.4(8)
40
95(35) 12.6(7)
Dry Bulb Temp. °F (°C)

86(30) 10.8(6)

77(25) 9.0(5)

68(20) 7.2(4)
30 40 50 60 70 80
50 59 68 77 Relative Humidity (%)
(10) (15) (20) (25)
Wet Bulb Temp. °F (°C)

<Power Consumption Curve> <Current Consumption Curve>

8.0 40
Power Consumption (kW)

Current Consumption (A)

7.0 35

6.0 30

5.0 25

4.0 20
95(35) 95(35)
Dry Bulb Temp. °F (°C)

Dry Bulb Temp. °F (°C)

86(30) 86(30)

77(25) 77(25)

68(20) 68(20)

68 77 86 95 68 77 86 95
(20) (25) (30) (35) (20) (25) (30) (35)
Wet Bulb Temp. °F (°C) Wet Bulb Temp. °F (°C)
I001911
 Operation Section
16

5. REFRIGERANT SYSTEM

5.1 Refrigerant System Construction

The component parts of the refrigerant system include the following:
• Compressor, Evaporator, Condenser, Capillary tube, High Pressure Switch
These parts are all connected by copper tubing. All the connections have been brazed.

Evaporator
Evaporator
Evaporator
Condenser Inlet Pipe
Compressor
Capillary
Suction Pipe
Tube
Compressor
Discharge Pipe
Evaporator
Condenser Outlet Pipe
Inlet Pipe
Condenser
Outlet Pipe
Compressor
Compressor

Condenser

Flow of Refrigerant

Condenser

Condenser
Fan
Evaporator
Capillary Fan
Tubes

Compressor
Evaporator
I001912
 Operation Section
17

5.2 Compressor
• The compressor used for the unit is hermetically sealed. The compressor and the compressor
motor are in one casing.

(1) Compressor theory of operation

• The scroll utilizes an involuted spiral which, when matched with a mating scroll form, generates
a series of crescent-shaped gas pockets between the two members. During compression, one
scroll remains stationary (fixed scroll) while the other form (orbiting scroll) is allowed to orbit (but
not rotate) around the first form. As this motion occurs, the pockets between the two forms are
slowly pushed to the center of the two scrolls while simultaneously being reduced in volume.
When the pocket reaches the center of the scroll form, the gas, which is now at a high pressure,
is discharged out of a port located at the center. During compression, several pockets are being
compressed simultaneously, resulting in a very smooth process. Both the suction process (outer
portion of the scroll members) and the discharge process (inner portion) are continuous.

(2) Compressor operation

1㧕 2㧕 3㧕 4㧕 5㧕

I001767

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.
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.
 Operation Section
18

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
I001887
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.
Pin
The switch is normally closed. The snap disk Stationary Point

responds to the variations in pressure and, if Case

Terminal
pressure is abnormally high, the snap disk
Lead Wires
moves down to push the pin down, causing the Molding by Resin
I001768
internal contacts to open. This interrupts the
ground signal at the control board (J104 connector) which turns the compressor off.
• Possible causes of this trouble include:
- The condenser air filter is dirty, restricting air flow.
- The condenser blower is defective.
 Operation Section
19

6. ELECTRICAL SYSTEM

6.1 Circuit Diagram and Control Box

AC 208/230 V 1φ 60 Hz
CC Condensate Pump
AP MCC
TB1 1L1 2T1 1 2 MC G G
G T1 T R R1 MDP
3L2 4T2 IOLC RTH THS DS HPRS
FDS ODS 3 1
5L3 6T3
2
A1 A2
MCC
G

CF2
1 2 HI
MF2 LO J8
IOLF G J7 J9
J6 J10 J101 J102 J103 J104
CF1
1 2 TB2
HI J5
LO L-
MF1 J4 J106
G J201 L+
IOLF J3
E-
J2 J105 J108
E+
J1 RB CB

A P Attachment Plug IOLF Inner Overload Relay of Fan Motor

T B 1 Terminal Block IOLC Inner Overload Relay of Compressor
T B 2 Terminal Block D S Full Drain Warning Switch
C B Control Board T H S Freeze Protection Thermistor
R B Relay Board R T H Room Thermistor
M F 1 Condenser Fan Motor G Grounding
M F 2 Evaporator Fan Motor HPRS High Pressure Switch
M C Compressor Motor M C C Relay for Compressor and Condenser Fan Motor
C F 1 Capacitor for Condenser Motor M D P Condensate Pump Motor
C F 2 Capacitor for Evaporator Motor F D S Drain Float Switch
C C Capacitor for Compressor O D S Drain Overflow Switch

TB2 Terminal Block

(Signal Connection)

Dip Switch
Compressor
Capacitor Relay Board

Fan Capacitor Relay Board Fuse

(Evaporator)

Terminal Block
Relay
TB1

Fan Capacitor G

(Condenser)

I001913
 Operation Section
20

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
Condenser Fan
(27 °C) or below, fan mode is switched to
HIGH. When room temperature is increased to (LO)

88 °F (31 °C) or higher, fan mode is switched

Room Temperature 80 °F 88 °F
from HIGH to LO. (27 °C) (31 °C)

I001914

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.
 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)
Condenser Fan
or 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
 Operation Section
22

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)

Dip Switch
Compressor
Capacitor Relay Board

Fan Capacitor Relay Board Fuse

(Evaporator)

Terminal Block
Relay
TB1

Fan Capacitor G

(Condenser)

I001916
 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) I001772
• 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 <Relay Board>
Fuse
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

I001773

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.
 Operation Section
24

6.4 Fan Motor

(1) For evaporator
• The fan motor is a single phase, induction type
Evaporator Fan Motor
two-speed motor.
Specifications:
- Rated Voltage: 230 V, 60 Hz
- Rated Output: High-590 W, Low-360 W
Ground (Green/Yellow)
J7 Low (Red)
CF22 (Brown/White)
CF21 (White)
J8 High (Black)
I001774

(2) For condenser

• The fan motor is a single phase, induction type
Condenser Fan Motor
two-speed motor.
Specifications:
- Rated Voltage: 230 V, 60 Hz
- Rated Output: High-1195 W, Low-932 W
Ground (Green/Yellow)
J5 Low (Red)
CF12 (Brown/White)
CF11 (White or Orange)
J6 High (Black) I001775

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: 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.
 Operation Section
25

6.6 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
Drain Outlet Spout Cover
pump reservoir, the condensate pump begins
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 I001918

- When the water level drops below level (B),

the condensate pump stops and compressor
restarts after delay time has expired.

A
B

I001919
< NOTE >
• 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.
 Operation Section
26

- To insure proper drainage, locate the highest

vertical position, no more than 17 ft (5.2 m) at
230 VAC (13 ft (4 m) at 208 VAC), and run the
drain hose on a downward slope at a
1/4 in (6.25 mm)
minimum rate of 1/4 in (6.25 mm) per foot. Taper Per Foot

17 ft (5.2 m) Max
Condensate
Pump

Grommet
I001920

< 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.
 Operation Section
27

6.7 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
DS2
Drain Pan
2
1

Drain Tube
DS1

To J103 Drain Tanks

Drain Water
Spring Fulcrum

Base Base Plate

I002230
 Operation Section
28

(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:
- 120 ± 20 sec.

6.10 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 U/V buttons on the control panel. The adjustment range of the temperature set
point is 65 °F to 90 °F (18 °C to 32 °C).
 Operation Section
29

6.11 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.)
 Operation Section
30

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, etc.
Connecting warning signal from controller
- Remove service panel from the rear of the unit.
- Squeeze the inner latches and push out the black cap from inside the panel. (See drawing of
cap and inner latch shapes.)
- Use recommended warning signal wire size from 16 AWG to 26 AWG or a solid wire, or 16
AWG to 22 AWG for a stranded wire with ring terminal for #6 stud size.
- Connect warning device to terminal L+ and L- according to its polarities.

6.14 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>

Input Signal
Terminals
Latch
Output Signal
Terminals

I001888
 Repair Section
31

7. 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 tank is 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.
Detailed information is contained in the OPERATION MANUAL supplied with the unit.
 Repair Section
32

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 is full When the drain tanks (optional) is 1) Drain away.
filled with drain water. (LCD indicates “TANK”)
(“TANK FL” LED flashes and signal 2) Press ON/OFF button.
output (J106) turns on.)

Condensate pump When condensate pump is 1) Fix the condensate pump.

TU
AM problem damaged or broken. 2) Reset the system.
(J8 input of relay board turns to To RESET: Press ON/OFF and
HI F
FAN open and signal output (J106) turns HI/LO buttons on the control box
SET TEMP
ON
COOL
on.) simultaneously for 5 sec.

Defect (short or open) When room thermistor (connecting Disconnect and reconnect the
of room thermistor to J101) becomes short or open. room thermistor.
(Signal output (J106) turns on.) If it doesn’t work, then change it.
HI F
FAN
SET TEMP
ON
COOL

HI F
FAN
SET TEMP
ON
COOL

Defect (short or open) When freeze protection thermistor Disconnect and reconnect the
of freeze protection (connecting to J102) becomes short freeze protection thermistor.
thermistor or open. If it doesn’t work, then change it.
FAN
HI F
(Signal output (J106) turns on.)
SET TEMP
ON
COOL

HI F
FAN
SET TEMP
ON
COOL

Show running hours Press ON/OFF and V buttons After 5 sec., display goes back to
simultaneously for 3 sec, total normal mode.
operation hours of compressor is
indicated by 6-digit (hours).
Example in left: 807 h
 Repair Section
33

LCD Display Description Condition Reset/Remedy

Show LCD and LED Press HI/LO and U buttons After 5 sec., display goes back to
MO TU WE TH FR SA SU
START AM
PROGRAM
all on mode simultaneously for 3 sec. normal mode.
STOP
ON
CLOCK PM
LOCKED
(To check LCD segments and LED
HI F F
FAN
LO
C C
display.)
SET TEMP
ON
COOL
OFF ROOM TEMP

Key lock mode (LCD Press ENTER and SET CLOCK Press ENTER and SET CLOCK
TU
AM displays “LOCKED”.) buttons simultaneously for 5 sec. buttons simultaneously for 5 sec
LOCKED
again to cancel the key lock mode.
HI F
FAN
SET TEMP
ON
COOL

Indication of model Press ENTER and SET CLOCK Reset to normal display
name buttons simultaneously for 5 sec or automatically after 5 sec.
turn on.

Detection of unit stop Press input signal from fire alarm 1) After input signal turns off.
signal from fire alarm becomes on. 2) Reset the system.
system (Unit stops, output signal (J106) To RESET: Press ON/OFF and
turns on and buzzer sounds.) HI/LO buttons on the control box
simultaneously for 5 sec.

Indication of service Press ON/OFF and U buttons 1) See page 36 to 38.

code simultaneously for 3 sec. Indication 2) Press ON /OFF button.
contents is as follows.
LCD Description Value
DF Defrost status
Evap. out pipe 26⇔109F
FZ
temperature (“26”⇔“X9”)
Outdoor
OD 0 (“00”)
temperature

Change model setting For installing new controller PCB, if 1) While pressing U and V
a different model name appears buttons, plug the power cord.
when the unit is reset or turned on, <Condition>
change model name according to LCD indicates current setting
the correct procedure. model name and buzzer sounds.
2) After setting the model type by
pressing U and V button,
unplug the unit.
 Repair Section
34

LCD Display Description Condition Reset/Remedy

Activation of high When high pressure switch Find the cause of high pressure to
TU pressure switch (connected to J104) activates address it.
AM

(=J104 input turns to open) 3 times Check the following.

FAN
HI F
in 24 h, “HP” is indicated and signal Ambient air temperature
SET TEMP
COOL
ON
output (J106) turns on. (65 °F (18.3 °C), 50 %RH⇔
When it activates 10 times in 24 h, 95 °F (35 °C), 60 %RH)
“FAIL HP” is indicated and buzzer Air filter (if dirty, wash up.)
sounds. 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).
 Repair Section
35

Possible Cause
Symptom Remedy
Checking Area Cause
1. Usage conditions Operation near usage limits. Review the installation
(high temperature). place.
2. Dirt in condenser or Insufficient heat exchange. Clean fins.
Compressor evaporator.
operates. 3. Frost in refrigeration cycle. Clogging at the frost section. Replace clogged section.
4. No temperature difference Insufficient refrigerant. Check the leaking part,
between evaporator and then repair and charge
condenser. refrigerant.
Air volume 1. Compressor coil resistance. Short or open circuit. Replace compressor.
normal (0 ohm or ∞ ohm) (In case of short, check
the compressor relay.)
2. Compressor relay. Open circuit or insufficient Replace compressor
Compressor contact. relay.
does not
3. Compressor relay on the Open circuit or insufficient Replace relay board.
operate.
relay board. contact.
4. Capacitor for compressor Capacitor malfunction. Replace capacitor.
motor.
5. Voltage. Low voltage. Repair power.
1. Coil resistance of fan motor. Short or open circuit. Replace fan motor.
(0 ohm or ∞ ohm)
2. Fan on-off relay on the relay Open circuit or insufficient Replace relay board.
No air.
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.
 Repair Section
36

(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).

Possible Cause
Symptom Remedy
Checking Area Cause
1. Voltage. Power failure. Repair power.

Control 2. Ground fault breaker trip. Ground fault or defective Repair ground fault section.
Does not ground fault breaker.
Panel Reset or repair breaker.
operate at
display turns
all 3. Fuse. Fuse blown. Repair shorting section.
off.
Replace fuse on the relay
board.
 Repair Section
37

Possible Cause
Symptom Remedy
Checking Area Cause
1. Display code “FL”. Drain tanks (optional) are Discharge the drain water.
filled with the drain water.
Improper drain switch Check connection.
connection.
Defective drain switch. Replace drain switch.
2. Display code “AS”. Improper routing of drain Repair drain hose, then reset
hose. unit.
To RESET: Press ON/OFF
and HI/LO buttons on the
control box simultaneously
for 5 sec.
Defective condensate pump. Repair or replace
condensate pump, then reset
unit.
To RESET: Press ON/OFF
and HI/LO buttons on the
control box simultaneously
for 5 sec.
Missing jumper connector. Connect jumper connector.
Control 3. Display code “RT”. Improper room thermistor Check connection.
Control
Panel connection.
panel
display
display Defective room thermistor Replace room thermistor.
shows error
turns on (short or open).
codes.
4. Display code “FT”. Improper freeze protection Check connection.
thermistor connection.
Defective freeze protection Replace freeze protection
thermistor (short or open). thermistor.
5. Display code “HP”. Improper high pressure Check connection.
switch connection.
Defective high pressure Replace high pressure
switch (short or open). switch.
See “Stops after running a while” of Troubleshooting on
page 38.
6. Display code “ALRM”. Turn the input signal on and 1) Check external input
continue it. signal.
2) Reset the system.
To RESET: Press ON/OFF
and HI/LO buttons on the
control box simultaneously
for 5 sec.
7. Display code “FZ”. See “Stops after running a while” of Troubleshooting on
page 38.
 Repair Section
38

Possible Cause
Symptom Remedy
Checking Area Cause
1. Fan on-off relay on the Open circuit or insufficient Replace relay board.
relay board. contact.
2. Fan HI/LO change relay Open circuit or insufficient Replace relay board.
on the relay board. contact.

Stops Control 3. Fan motor insulation Insulation failure on fan Replace fan motor.
immediately panel resistance. motor.
after display 4. Compressor relay. Open circuit or insufficient Replace compressor relay.
starting normally. contact.
5. Compressor relay on the Open circuit or insufficient Replace relay board.
relay board. contact.
6. Compressor insulation Insulation failure on Replace compressor.
resistance. compressor.
1. Temperature of fan motor Operation of safety device Replace fan motor.
(abnormally high). (IOLF) due to fan motor
malfunction.
2. Temperature of Operation of safety device Replace compressor.
Control compressor (abnormally (IOLC) due to compressor
Stops after
panel high). malfunction.
running a
display
while 3. Refrigerant leakage. Insufficient refrigerant or gas Repair and charge
normally.
leakage. refrigerant.
4. Dirt on evaporator or Insufficient cooling of Clean evaporator or
condenser. evaporator or condenser. condenser.
5. Duct connection state. Improper connection. Repair duct connection.

(3) Overflow of drain water

Possible Cause
Symptom Remedy
Checking Area Cause
1. Drain pan. Cracks in drain pan. Check and repair.
2. Water level in drain pan. Clogged drain hose. Check and replace.
3. Drain hole. Reversed air flow from drain Insert a trap on discharge
hole. drain hose.
Overflow from the unit.
4. Clogged air filter. Reversed air flow from drain Clean air filter.
hole due to the excessive
negative pressure inside of
the unit.
 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.

Possible Cause
Symptom Remedy
Checking Area Cause
1. Fan. Fan interference. Repair interfering section.
Fan deformation. Replace fan.
Abnormal noise or
2. Compressor fixing nuts. Looseness of nuts. Tighten nuts further.
vibration.
3. Piping. Pipe interference. Repair interfering section.
4. 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.
I001780

(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.
 Repair Section
40

(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
 Repair Section
41

8. DISASSEMBLY

8.1 Parts Construction

Upper Panel

Upper Front Panel

Blower housing
Control Panel
Condenser Fan
Air Outlet Grill
Front Right Panel

Rear Right Panel Room Thermistor

Freeze Protection
Thermistor
Front Panel Filter Assy
Front Left Panel

Evaporator
Fan
Condensate
Pump

Drain Tank
Panel

Side Panel
Filter Assy Drain Pan Assy

Pivoting
Drain Tanks
Caster
(Optional)
Rear Panel Middle Frame
Sub-Assy Rear Left Panel
Power Cord

Pivoting Caster

Service Panel

I001923
 Repair Section
42

8.2 Disassembly
1) Remove drain tanks (optional).

I001783

Screws (7) 2) Remove twelve (12) screws from upper front

Screws (3)
panel.

Screws (2) I001924

3) Slide upper front panel forward and remove.

I001925

4) Louver can be removed from upper front panel by

unsnapping the lock tap and removing the louver
from its pivots.

I001786
 Repair Section
43

5) Remove nine (9) screws from service panel and

Screws (13)
thirteen (13) screws from rear left panel.

Screws (9)

I001926

6) Remove eight (8) screws from rear right panel.

Screws (8)

I001927

7) Remove fourteen (14) screws from front right

panel.

Screws (10)

Screws (4)

I001928

Screws (8) 8) Remove fourteen (14) screws from upper panel.

Screws (3)

Screws (3)

I001929
 Repair Section
44

9) Remove nine (9) screws from rear panel.

Screws (9)

I001930

Screws (12) 10) Remove twelve (12) screws from front left panel.

I001931
 Repair Section
45

8.3 Removal of Electrical Parts

(1) Control box
1) Remove nine (9) screws from service panel. (See page 43.)
2) Remove electrical parts.
- Relay: Remove four (4) screws from control box.
- Terminal block: Remove four (4) 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>

TB2 Terminal Block

(Signal Connection)

Dip Switch
Compressor
Capacitor Relay Board

Fan Capacitor Relay Board Fuse

(Evaporator)

Terminal Block
Relay
TB1

Fan Capacitor G

(Condenser)

I001916
 Repair Section
46

(2) Relay board

1) Remove nine (9) screws from service panel. (See page 43.)
2) Disconnect ten (10) connectors, and remove five (5) screws from relay board.

Temperature Scale Display Switch Dip Switch

Fan Mode Control Switch

To Control Board (10 pin)

To Condensate Pump (2 pin)

To Comp. Driver Relay

To Evap. Fan Motor (HI)

To Comp. Relay
To Evap. Fan Motor (LO)

To Cond. Fan Motor (HI)

To Cond. Fan Motor (LO)

Power (#R1) On Terminal Block

Relay Board Fuse Power (#T1) On Terminal Block I001793

(3) Control board

1) Remove two (2) screws from the control panel
Screws (2) stay.

I002179

2) Remove three (3) screws from the control panel

Screws (3)
stay.

I002180
 Repair Section
47

3) Slowly slide control panel assembly out of box.

I002181

4) Disconnect the following connectors from the

control board:
A B C D E
(A) J201 (10-pin) Wire Harness, Relay Board to
Control
(B) J101 (2-pin) Room Temperature Thermistor
(C) J102 (2-pin with black tape) Freeze
Protection Thermistor
F G I002182 (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

< 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).

5) Remove the five (5) screws from the control

board on the control panel assembly. Remove
the control board.

I001804
 Repair Section
48

(4) Battery replacement of control board

• When the power is unplugged from the unit, and control board is automatically resetting clock
and program, it is time to change the battery on the control board to avoid resetting of clock and
program.

1) Disassemble control board. (See page 46 and

47.)

Control
Board
Battery
I001805

2) See diagram for battery removal.

Control Board

Holder

Battery (Old)
I001806

3) Insert new battery securely in the direction shown

Control Board in the drawing.

< NOTE >

Holder Battery Specification
Type: 3 V CR2450 or equivalent

Battery (New)
CAUTION
I001807 When inserting the battery, make sure the
direction of polarity (plus/minus) is correct (as
shown).
 Repair Section
49

8.4 Removal of Blower Assembly

Control Panel Stay

Control Panel
Control Panel Stay

Evaporator Fan

Evaporator Fan Casing

Condenser Housing Box

Condenser
Fan Motor

Evaporator Fan Motor

Condenser Fan
Casing
Condenser Fan Center Panel

I001932
 Repair Section
50

(1) Removal of condenser fan and fan motor

1) Loosen the set screw using a hex key.

Set Screw

I001933

Nuts (6) 2) Remove six (6) nuts in the location shown.

I001934

3) Remove fan motor wire from three (3) ties.

Ties (3)

I001935

4) Lift fan motor up then pull rear motor backward

and remove the fan motor. Centrifugal fan drops
into condenser fan housing.

I001936
 Repair Section
51

5) Turn the fan motor around and place on mounting

bracket. Secure condenser fan motor with two (2)
Nuts (2)
nuts.

I001937

6) Remove six (6) screws from ring.

Screws (6)

I001938

7) Loosen four (4) nuts that are securing the fan

Nuts (2) casing. Lift the enclosure off its mounting. Slide
the condenser fan out through opening.

Nuts (2)

I001939

(2) Removal of evaporator fan and fan motor

1) Loosen the set screw using a hex key. Then
Set Screw
Evaporator remove six (6) screws on the ring. Then remove
Fan
this ring and evaporator fan.

Ring

Screws (6)
I001940
 Repair Section
52

2) Remove evaporator fan motor wire and two (2)

ties. Remove four (4) nuts from housing while
holding fan securely with one hand. Then remove
Nuts (4) evaporator fan motor.
Ties (2)

I001941

8.5 Removal of Condensate Pump

1) Remove fourteen (14) screws from front right
panel. (See page 43)

2) Remove the two (2) drain hoses.

Drain Hose
3) Disconnect condensate pump connector.
Drain Hose

Connector

I001942

4) Remove two (2) screws from condensate pump.

Screws (2)

I001943

5) Remove tab from condensate pump.

OVE
REM

I001944
 Repair Section
53

8.6 Inspection of Capacitor (for Fan Motor and Compressor)

(1) Ohmmeter method
• Set the ohm-meter to the 10M range. Place the
two probes against the two terminals of the
capacitor. At first, the ohm-meter should
indicate small value, then the reading should
gradually increase towards infinity. This
indicates that the capacitor is charging. If the
reading indicates infinity right away (open) or
the ohm-meter fails to move from 0. (shorted),
I001808
replace the capacitor.

(2) Capacitance tester method

• Using a capacitance tester and the chart on page 22, test the capacitor for the value indicated.
If the value tested is not within 10 % of indicated capacitance, replace the capacitor.

WARNING
• Properly discharge the capacitor(s) before testing and after testing has been completed.
• Failure to do so could cause damage to test equipment or the unit and/or result in
personal injury (electrical shock) or death.

8.7 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 NC
DS2
2
1
DS1

I001809
 Repair Section
54

8.8 Inspection of Fan Motor

(1) Condenser fan motor
• Measure resistance across the terminals of the
Condenser Fan Motor
fan motor. (All terminals must be disconnected
from the unit.)
• Between terminals (at 77 °F (25 °C))
- J6-CF11 Approx. 3.5 ohm
Ground (Green/Yellow)
- J6-CF12 Approx. 6.0 ohm
J5 Low (Red)
- CF11-CF12 Approx. 9.1 ohm CF12 (Brown/White)
CF11 (White or Orange)
• If the measured resistance is not equal to these J6 High (Black) I001775
standard values, replace the fan motor.

(2) Evaporator fan motor

• Measure resistance across the terminals of the
Evaporator Fan Motor
fan motor. (All terminals must be disconnected
from the unit.)
• Between terminals (at 77 °F (25 °C))
- J8-CF21 Approx. 7.6 ohm
Ground (Green/Yellow)
- J8-CF22 Approx. 10.4 ohm J7 Low (Red)
- CF21-CF22 Approx. 17.7 ohm CF22 (Brown/White)
CF21 (White)
• If the measured resistance is not equal to these J8 High (Black)
I001774
standard values, replace the fan motor.

8.9 Inspection of Compressor Motor

• Measure resistance across the terminals of the
compressor motor. (All terminals must be C
T1
disconnected from the unit.)
• Between terminals (at 77 °F (25 °C)) S
T2
R
- R-C Approx. 0.4 ohm T3
- C-S Approx. 0.6 ohm
- S-R Approx. 0.9 ohm
• If the measured resistance is not equal to these
I001945
standard values, replace the compressor. The
overload relay is internal to the compressor.
 Repair Section
55

8.10 Inspection of Wiring Connection

• Refer to the Wiring Diagrams on page 19 and check for connection of each wire.

8.11 Inspection of Thermistor

• Using an Ohm-meter, check the resistance value across the 2-pin connector. At normal
temperature (77 °F (25 °C)) either thermistor (room or freeze) should measure approximately
10K ohm.

8.12 Inspection
• In most cases, the probable cause for insufficient cooling is a clogged system, leakage or an
incorrect amount of refrigerant. In such cases, inspect the system according to the following
procedure.

(1) Inspection of clogged system

• Check the component parts of the refrigerant system, including piping, that could be clogged
with refrigerant. If clogged with refrigerant, only the clogged part is frosted partially. In such a
case, change the part in question.

(2) Inspection of refrigerant leak

• Carefully check all connections, and each component for leaks whenever the refrigerant system
is installed or repaired. Use an electronic gas leak tester to inspect the system.

(3) Insufficient refrigerant

• In case the unit is judged to be deficient in cooling capacity, Make sure to perform the inspections
in 56. 9.1 (1) and 56. 9.1 (2) to confirm the cause of trouble. Then, charge the system with
refrigerant to the specified amount.
 Repair Section
56

9. REFRIGERANT SYSTEM REPAIR

9.1 Repair of Refrigerant System

• In case there is a leak, obstruction, or trouble in the refrigerant system of the Office Pro 60,
replace or repair the part in question. After replacing any component all connections must be
brazed.

(1) Proper brazing techniques

• It is desirable to use a slightly reducing flame. Oxyacetylene is commonly used since it is easy
to judge and adjust the condition of the flame. Unlike gas welding, a secondary flame is used for
brazing. It is necessary to preheat the base metal properly depending on the shape, size or
thermal conductivity of the brazed fitting.
• The most important point in flame brazing is to bring the whole brazed fitting to a proper brazing
temperature. Care should be taken to not cause overflow of brazing filler metal, oxidization of
brazing filler metal, or deterioration due to the overheating of flux.

(2) Brazed fittings and fitting clearance

• In general, the strength of brazing filler metal is
Clearance
lower than that of the base metal. So, the 0.001~0.003 in
shape and clearance of the brazed fitting are a (0.025~0.075 mm)

quite important. As for the shape of the brazed

fitting, it is necessary to maximize its adhesive
a

area. The clearance of the brazed fitting must

be minimized to facilitate brazing filler metal to Clearance From The Pipe Fitting and Tubing.

flow into it by capillary action.

I002225

(3) Cleaning brazing filler metal and pipe

• When the refrigerant 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.

CAUTION
Do not use chlorine cleaner.
 Repair Section
57

(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
Vertical Down Joint
brazing temperature. Bring the brazing filler Brazing Filler Metal
45°
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
Tube
portion heated to a proper temperature, it is
I000564
essential to keep the whole fitting at a proper
brazing temperature.

Vertical Up Joint
Tube

Burner
45° Brazing Filler Metal
I001725
 Repair Section
58

9.2 Removal of Refrigeration Cycle Components

CAUTION
• Before any refrigeration cycle component can be replaced, it is necessary to recover the
refrigerant using standard recovery procedures and equipment.
• 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.

• Evaporator
• Capillary tube
• Condenser
• Compressor
• High Pressure Switch

< NOTE >

When replacement of the compressor, attach the two pipes (Pipe 1, Pipe 2) which are packaged
in Compressor Assy as following figure.

B
E
Part to Replace Disconnect At
Compressor A&F
Condenser A&B
Capillary Tube C&D
F Evaporator C&E
Pipe 1 Pipe 2
I001946
 Repair Section
59

9.3 Charging the System with R-410A Refrigerant

• Always ensure that the refrigerant system has been properly evacuated before charging with the
specified amount of R-410A.
• Equipments is only for R-410A.
• Liquid charge (no gas charge).
• Make sure not to use more than 90 % of the initial weight of R-410A in the cylinder.

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 open flame.
- Never smoke while performing repairs, especially when handling refrigerant.
- Be careful the liquid refrigerant does not come in contact with the skin.
• If liquid refrigerant strikes eye or skin:
- Do not rub the eye or the skin.
- Splash large quantities of cool water on the eye or the skin.
- Apply clean petroleum jelly to the skin.
- Go immediately to a physician or to a hospital for professional treatment.

Step 1 Connect manifold gauge.

1) Evacuate the system.

• 15 min or more.
• 30 inHg (100 kPa) or more of vacuum. When leak is found,
Step 2
2) Stop evacuating the system. repair the connection
• Leave for 5 min. or components.

3) Check the vacuum.

Step 3 Connect to refrigerant source.

Step 4 Test the system for leaks.

Charge the system with R-410A.

Step 5
• See specifications on page 12.

Step 6 Remove manifold gauge.

I002226
 Repair Section
60

(1) Connection of gauge manifold

1) Properly remove the crushed end of the pinch-off
Charging Hose tube at the high pressure side and the low
Side pressure side of the refrigerant cycle with a pipe
Refrigerant cutter.
Cycle Side
2) Fit the process tube fitting to the pinch-off tube on
both sides.
Seal
Pinch-Off Tube
I002183

Low Pressure 3) Connect the charging hoses (red-high pressure

Valve (Closed) side) for the gauge manifold to the process tube
High Pressure Valve
(Closed)
Green Hose fitting.
Red Hose
Process Tube Fitting < NOTE >
Connect the hoses using care not to mistake
High Pressure
Side Tube the high pressure side for the low pressure side

Vacuum Pump
and vice versa.
(when stopped) I000568
4) Connect the charging hose (green) at the center
of the gauge manifold to the vacuum pump.

(2) Evacuation

Valve Setting 1) Open the high pressure valve (Hl) of the gauge
Gauge
LO HI
Closed Open
LO HI
Closed Closed
manifold.
30 inHg (100 kPa) or larger
2) Turn on the vacuum pump to start evacuation.
Low Pressure
High Pressure Gauge
Valve (Evacuate the system for approximately 15 min.)
High Pressure Valve
3) When the low pressure gauge indicates 30 inHg
High Pressure
Side Tube (100 kPa) or larger, turn off the vacuum pump
Vacuum Pump and close the high pressure valves of the gauge
(in Operation) I002227
manifold.
 Repair Section
61

(3) Checking vacuum

1) Leave the high pressure valve and the low
Valve Setting
Leave valves closed for 5
LO HI min or more. Pointer of pressure valve of the gauge manifold closed for
Closed Closed pressure gauge returning to five min or more, and confirm that the gauge
zero indicates there is a leak.
Pressure Gauge
pointer does not return to zero.

2) If the gauge pointer returns gradually to zero

Return
there is a leak somewhere in the system (this
Pipe Brazing
could also include gauge manifold). Perform leak
I002184 check according to procedure indicated in the
next step. Once leak has been found and
repaired evacuate the system once more, and
confirm system holds vacuum.
 Repair Section
62

(4) Checking gas leak

Valve Setting
1) Remove the charging hose (green) from the
LO HI
Closed Closed
vacuum pump, and connect the hose to the
Air Purging refrigerant cylinder (R-410A).
Open The Valve
of Refrigerant
2) Loosen the nut on the gauge manifold side of the

Cylinder R-410A
Cylinder charging hose (green).

Refrigerant
Charging Hose 3) Open the valve of refrigerant cylinder perform air
Red (Green)
To Process Tube Fitting purging in the charging hose (green). Then
I001901
tighten the nut.

Valve Setting 4) Open the high pressure valve of the gauge

LO HI LO HI
Closed Open Gauge Reading Closed Closed manifold. Charge the system with refrigerant until
57 psi
Low Pressure (390 kPa) the low pressure gauge indicates 57 psi
Valve (Closed) Open High Pressure (390 kPa). After charging is complete, close the
Valve
high pressure valve.
Process Tube Fitting
Refrigerant
Cylinder R-410A

High Pressure 5) Open the valve of refrigerant cylinder perform air

Cylinder
Refrigerant

Side Tube purging in the charging hose (green). Then

Valve
(Open)
I002228 tighten the nut.

6) Check carefully for gas leaks inside the

refrigerant system using the gas leak tester.

7) Repair any leak.

WARNING
Do not attempt any repair on a charged
system.

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
63

(5) Evacuation (repeat)

Valve Setting 1) Close the valve of the refrigerant cylinder. Then

Gauge
LO HI
Closed Open
LO HI
Closed Closed
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
< NOTE >
High Pressure Keep the high pressure valve and the low
Side Tube
Vacuum Pump
pressure valve of the gauge manifold closed.
(in Operation) I002227
2) Using procedure in the “Evacuation”, evacuate
the system until the low pressure gauge indicates
30 inHg (100 kPa) or larger. (For 15 min or more.)

3) After evacuation is complete, close the high and

the low pressure valves of the gauge manifold.

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.
 Repair Section
64

9.4 Refrigerant Charging Work

(1) Refrigerant charging

Valve Setting
1) Remove the charging hose (green) from the
LO HI
Closed Closed
vacuum pump, and connect it to the refrigerant
Air Purging cylinder
Open The Valve (R-410A).
of Refrigerant

Cylinder R-410A
Cylinder 2) Loosen the nut on the gauge manifold side of the

Refrigerant
Charging Hose charging hose (green). Open the valve of the
Red (Green)
To Process Tube Fitting
charging hose (green). Open the valve of the
I001901 refrigerant cylinder. After air purging, tighten this
nut and close the valve of the refrigerant cylinder.

Valve Setting 3) Securely place the refrigerant cylinder on a scale

HI Specified Amount
LO
Closed Open of Refrigerant
LO HI
Closed Closed
with a weighing capacity of 70 lb (30 kg) that is
graduated by 0.2 oz (5 g).
High Pressure Valve
4) Open the high pressure valve of the gauge
Valve of manifold and the valve of the refrigerant cylinder.
Process Tube Fitting
Cylinder R-410A

Refrigerant
Refrigerant

Cylinder High Pressure Charge the system with refrigerant to the

Side Tube specified amount.
Weight I001903
Standard Amount of Refrigerant: 3.97 lb
(1.80 kg)

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.
 Repair Section
65

(2) Removal of gauge manifold

1) Crimp the pinch-off tube with a pinch-off tool.
Pinch-Off Tool
To Gauge 2) Remove the gauge manifold and the process
Pinch-Off Tube Manifold Side tube fitting. Crush the end of the pinch-off tube.

3) Braze the end of the pinch-off tube.

Charging Hose 4) Ensure that a gas leak is not present at the
To Refrigerant
Cycle Side pinched off portion and the brazed end.
Process Tube Fitting
I002185
 Repair Section
66

10. REASSEMBLY

10.1 Removal 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.

10.2 Compressor Mounting

• Mount the compressor on the frame, using
cushions, steel collars, spring washers, plate Nut Spring Washer

washers and nuts.

Plate Washer

Cushion Steel Collar

I001818

10.3 Blower Assembly

<Evaporator Blower Assy> 1) Install blower fan for evaporator. Allow a

Min 0.12 in clearance of 0.12 in (3 mm) (minimum) on each
(3 mm)
side of the evaporator fan.
Min 0.12 in
(3 mm) CAUTION
• Tightening torque:
- 10.84 ± 2.17 ft•lbf (15 ± 2.7 N•m)

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<Condenser Blower Assy> 2) Install blower fan for condenser. Allow a

clearance of 0.12 in (3 mm) (minimum) on each
Min Min
0.12 in (3 mm) 0.12 in (3 mm)
side of the condenser fan.

CAUTION
• Tightening torque:
- 10.84 ± 2.17 ft•lbf (15 ± 2.7 N•m)

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 Repair Section
67

10.4 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 removal.

10.5 Perform the Inspection

• Perform the inspection of cooling performance and check for abnormal noise or abnormal
vibration.

10.6 Caster Maintenance

• Lubricate bearings in caster as needed with standard bearing grease using the zerk fitting.

< NOTE >

Casters should roll and swivel freely. Check for dirt or dust build up. Remove dust or dirt build up.
 Repair Section
68

10.7 Schematic

<Wiring Diagram>

AC 208/230 V 1φ 60 Hz
CC Condensate Pump
AP MCC
TB1 1L1 2T1 1 2 MC G G
G T1 T R R1 MDP
3L2 4T2 IOLC RTH THS DS HPRS
FDS ODS 3 1
5L3 6T3
2
A1 A2
MCC
G

CF2
1 2 HI
MF2 LO J8
IOLF G J7 J9
J6 J10 J101 J102 J103 J104
CF1
1 2 TB2
HI J5
L-
MF1 LO J4 J201
J106
G L+
IOLF J3
E-
J2 J105 J108
E+
J1 RB CB

A P Attachment Plug IOLF Inner Overload Relay of Fan Motor

T B 1 Terminal Block IOLC Inner Overload Relay of Compressor
T B 2 Terminal Block D S Full Drain Warning Switch
C B Control Board T H S Freeze Protection Thermistor
R B Relay Board R T H Room Thermistor
M F 1 Condenser Fan Motor G Grounding
M F 2 Evaporator Fan Motor HPRS High Pressure Switch
M C Compressor Motor M C C Relay for Compressor and Condenser Fan Motor
C F 1 Capacitor for Condenser Motor M D P Condensate Pump Motor
C F 2 Capacitor for Evaporator Motor F D S Drain Float Switch
C C Capacitor for Compressor O D S Drain Overflow Switch

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 DENSO SALES CALIFORNIA, INC.
Long Beach, CA 90810
www.movincool.com

P/N: SV0002- 02 Third Issue: December 2008