Movincool OFFICE PRO 10 Service Manual
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Movincool OFFICE PRO 10 Service Manual

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M A N U A L
S E R V I C E
OFFICE PRO 10

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Summary of Contents for Movincool OFFICE PRO 10

  • Page 1 M A N U A L S E R V I C E OFFICE PRO 10...
  • Page 2 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.
  • Page 3 S E R V I C E M A N U A L O F F I C E P R O 10...

  • Page 5: Foreword

    FOREWORD This manual has been published to service the MovinCool Office Pro 10. Please use this service manual only when servicing the Office Pro 10. DEFINITION OF TERMS WARNING: Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation.

  • Page 7: Table Of Contents

    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 ......................13 TROUBLESHOOTING & REPAIR ................... 19...

  • Page 9: General Description

    EVAPORATOR (INDOOR UNIT) Unlike conventional air conditioners, the CONDENSER (OUTDOOR UNIT) 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: Conventional Air Conditioner 1. Compact Design...
  • Page 10 GENERAL DESCRIPTION...

  • Page 11: Construction, Specifications, & Data

    CONSTRUCTION, SPECIFICATIONS, and DATA CONTROL PANEL COOL AIR VENT EVAPORATOR FAN / MOTOR EVAPORATOR CONTROL BOX CONDENSER DRAIN HOSE FAN / MOTOR CONDENSER COMPRESSOR DRAIN SWITCH DRAIN TANK Construction of Office Pro 10...
  • Page 12 Construction Diagram 1. Basic Construction The MovinCool Spot Cooling System is compact in construction because the condenser and the evapora- tor are enclosed in one unit. The interior is divided into three sections. The upper back section is equipped with the evaporator and drain tank. The rear section contains the condenser. The compressor and the...
  • Page 13 CONSTRUCTION, SPECIFICATIONS, and DATA 2. Air Flow Air is drawn from the intake ducts then passes through the condenser which extracts the heat. This hot air is blown out through the exhaust air duct. Air taken in from the rear face is cooled by the evaporator and then blown through the cool EVAPORATOR AIR IN...
  • Page 14 CONSTRUCTION, SPECIFICATIONS, and DATA 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 115V power consumption ..............1.25 Kw current consumption ..............11.5 Amps power factor ................
  • Page 15 CONSTRUCTION, SPECIFICATIONS, and DATA 14.92 1.80 1.30 13.50 9.50 Exterior Dimensions (units: inches)
  • Page 16 DATA Cooling Capability Curve Cool Air Temperature Difference Curve @AC 115V @AC 115V 1 2(47.6) 1 5 (2 7 .0 ) 1 4 (2 5 .2 ) 1 0(39.7) 1 3 (2 3 .4 ) 1 2 (2 1 .6 ) 8(31.7) 1 1 (1 9 .8 ) 6(23.8)

  • Page 17: Refrigerant System

    REFRIGERANT SYSTEM 1. The component parts of the refrigerant system include the following: • Compressor • Evaporator • Condenser • Accumulator • Capillary tube These parts are all connected by copper tubing. All the connections have been brazed. EVAPORATOR INLET PIPES CAPILLARY TUBE PRESSURE REGULATING VALVE...
  • Page 18 REFRIGERANT SYSTEM 1. Compressor DISCHARGE The compressor used for the unit is hermetically HOLE SPRING sealed. The compressor and the compressor DISCHARGE motor are in one casing. VALVE SUCTION HOLE A. Compressor Construction BLADE The construction of a rotary type compressor is divided into two mechanisms.
  • Page 19 REFRIGERANT SYSTEM 3. Capillary Tube The capillary tubes are long thin tubes utilizing HIGH TEMP. / HIGH PRESS. line flow resistance to serve as an expansion LIQUID REFRIGERANT 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.
  • Page 20 REFRIGERANT SYSTEM EVAPORATOR INLET PIPES CAPILLARY TUBE PRESSURE REGULATING VALVE COMPRESSOR SUCTION PIPE (INSULATED) COMPRESSOR DISCHARGE PIPE ACCUMULATOR Refrigerant System Piping...

  • Page 21: Electrical System

    ELECTRICAL SYSTEM AC115V 1Ø 60HZ (AUX1) (AUX2) IOLF IOLF Attachment Plug Overload Relay of Compressor Terminal Block Full Drain Warning Switch Control Board Freeze Protection Thermistor Relay Board Room Thermistor Fan Motor of Evaporator Remote Receiver Board Fan Motor of Condenser Ground Compressor Motor Connector for Drain Pump (Unit Side)
  • Page 22 ELECTRICAL SYSTEM 1. Basic Operation of Office Pro 10 Electrical Circuit There are two basic components used to control the operation of the Office Pro 10 Electrical System: • Control Panel Assembly • Control Box The Control Panel Assembly contains the Control Panel, Control Board (with inputs for the freeze and room temperature thermistors), drain switch, and a microprocessor.
  • Page 23 ELECTRICAL SYSTEM A. Capacitors CAPACITOR VOLTAGE CAPACITANCE APPLICATION RATING (µf) The capacitors are used to temporarily boost the power output available to the fan motor Evaporator Fan Motor and the compressor at start-up. The specifi- Evaporator Fan Motor cations of each capacitor are listed on the Compressor left.
  • Page 24 CF31 J3 Condenser Fan Motor 6. Condensate Pump The Office Pro 10 model has an optional condensate pump, which collects the water that forms on the evaporator during normal cooling operation and eliminates the need for a drain tank. REMOVABLE PANEL...
  • Page 25 7. Drain Switch The Office Pro 10 is equipped with a drain tank switch. When the drain tank accumulates approximately 3.0 gallons (11.4 liters) of condensate (water) in the drain tank, the drain tank switch sends a signal to the microprocessor.
  • Page 26 ELECTRICAL SYSTEM 10. 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”...

  • Page 27: Troubleshooting & Repair

    CLOCK TANK FULL TIMER SET PROGRAM DAY HOUR MIN Office Pro 10 4. Self-Diagnostic Codes Self-Diagnostic codes will be displayed on the control board under the following conditions: When the evaporator antifreeze thermistor disengages the compressor. When the drain tank switch shuts off the unit (full tank LED flashes).

  • Page 28: Troubleshooting And Repair

    TROUBLESHOOTING AND REPAIR 5. Troubleshooting Chart Trouble Probable Cause Trouble Probable Cause Unit does not operate at all • Check for Power at Unit is not responding to control • Unit is in the programming mode Receptacle board / buttons. No diagnostic and locked out.
  • Page 29 TROUBLESHOOTING AND REPAIR In case of trouble, perform the following inspection before disassembly. 6. Inspection of Plate Fins To inspect the plate fins of either the evaporator or condenser you must remove the air filters. After removal of the air filters, inspect the plate fins for any dirt, dust, lint, or debris that may have caused poor cooling performance of the unit.
  • Page 30 TROUBLESHOOTING AND REPAIR 9. Disassembly EVAPORATOR FAN HOUSING ROOM THERMISTOR AIR OUTLET LOUVERS DRAIN PAN ASSEMBLY EVAPORATOR FILTER CONTROL PANEL FREEZE THERMISTOR BACK PANEL REMOTE SENSOR ASSEMBLY CONDENSER FILTER POWER CORD FRONT PANEL DRAIN TANK PIVOTING CASTOR PIVOTING ACCESS (SIDE) PANEL CASTOR CONDENSER FAN WITH BREAK...
  • Page 31 TROUBLESHOOTING AND REPAIR B. Remove five (5) plastic caps with a small screw driver or pin. Removal of Caps C. Remove the ten (10) screws from the front panel. Removal of Front Panel Screws D. Slide front panel forward and disconnect the remote control sensor wire harness.
  • Page 32 TROUBLESHOOTING AND REPAIR E. Louver can be removed from upper front panel by unsnapping the lock tab and remov- ing the louver from its pivots. Removal of Air Outlet Louver Gently push air louver up. Then pullout to remove. Removal of Air Outlet Louver (continued) G.

  • Page 33: Removal Of Electrical Parts

    TROUBLESHOOTING AND REPAIR H. Remove four (4) screws from the electrical box cover. Removal of Electric Box Cover 10. Removal of Electrical Parts AC115V 1Ø 60HZ (AUX1) (AUX2) IOLF IOLF Attachment Plug Overload Relay of Compressor Terminal Block Full Drain Warning Switch Control Board Freeze Protection Thermistor Relay Board...
  • Page 34 TROUBLESHOOTING AND REPAIR DIP SWITCH TEMPERATURE SCALE DISPLAY SWITCH STOP OPERATE ˚C ˚F FAN MODE CONTROL SWITCH STOP OPERATE MAIN WIRING HARNESS (CONTROL PANEL TO RELAY BOARD) 2 PIN CONNECTOR J 1 0 OF CONDENSATE PUMP TO COMPRESSOR (DRIVER RELAY) TO CONDENSER FAN MOTOR TO EVAPORATOR...
  • Page 35 TROUBLESHOOTING AND REPAIR 11. Removal of Blower Assembly AIR DIVERTER EVAPORATOR BRACKET HOUSING EVAPORATOR FAN AND MOTOR MIDDLE FRAME SUB ASSEMBLY RING (EVAPORATOR) Disassembly of the Evaporator Fan Housing...
  • Page 36 TROUBLESHOOTING AND REPAIR 12. Removal of Evaporator Fan Motor A. Remove the ten (10) screws from the air diverter housing. Removal of Air Diverter B. Remove the three (3) screws from the evapo- EVAPORATOR BRACKET rator housing bracket. Removal of Evaporator Bracket C.
  • Page 37 TROUBLESHOOTING AND REPAIR D. Tag all evaporator fan wires then remove wires as shown. Wiring From the Capacitors to Evaporator Fan Motor E. Slowly pull the evaporator fan out from the evaporator fan housing. Removal of Evaporator Fan Motor...
  • Page 38 TROUBLESHOOTING AND REPAIR 13. Removal of Condenser Housing Assembly CONDENSER FAN COVER CONDENSER FAN AND MOTOR CONDENSER FAN HOUSING RING (CONDENSER) Disassembly of Condenser Fan Housing 14. Removal of Condenser Fan Motor A. To access the condenser fan, the evaporator fan housing and the drain pan must be removed.
  • Page 39 TROUBLESHOOTING AND REPAIR B. Remove the two (2) screws from the two evaporator stays. Remove the two (2) screws from the condenser stays. Removal of Evaporator Stay C. Gently tilt the evaporator to access the drain screws. Remove the two (2) screws. Removal of Drain Pan D.
  • Page 40 TROUBLESHOOTING AND REPAIR 15. Removal of Evaporator Fan Housing A. Remove four (4) screws on the evaporator fan housing. Removal of Screws for Evaporator Fan Housing B. Remove four (4) screws from the electric box. Set aside the electric box. Removal of Electric Box C.
  • Page 41 TROUBLESHOOTING AND REPAIR D. Remove the evaporator fan housing from the condenser fan housing. EVAPORATOR FAN HOUSING Removal of the Evaporator Housing E. Remove seven (7) screws from the condenser fan housing. Removal of the Condenser Fan Cover on the Condenser Fan Housing Slide the condenser fan cover out of the condenser fan housing.
  • Page 42 TROUBLESHOOTING AND REPAIR G. Remove the four (4) screws for removal of the condenser fan ring subassembly. CONDENSER FAN RING Removal of Condenser Fan Ring Sub-Assembly H. Remove the four (4) screws from the con- denser fan housing. Removal of Condenser Fan Screws Remove the condenser fan from the housing.
  • Page 43 TROUBLESHOOTING AND REPAIR 16. Removal of Control Board A. Disconnect the following connectors from the control board: (A) Main Wire Harness, Relay Board to Control Board J2 (10-pin) (B) Room Thermistor J4 (2-pin) (C) Freeze Thermistor J1 (2-pin) with black tape (D) Drain Tank Switch J5 (2-pin) (E) Remote Control Sensor J12 (3-pin) (F) Auxillary 2 / Jumper...
  • Page 44 TROUBLESHOOTING AND REPAIR 20. Removal of Power Cord A. Remove the two (2) screws from the connec- tor located under the base of the unit. Removal of Power Cord Connector B. Loosen the retainer from the base of the unit. Removal of Power Cord Retainer C.
  • Page 45 TROUBLESHOOTING AND REPAIR 21. Inspection of Condenser Fan Motor Measure resistance across the terminals of the fan motor. Terminals (at 77˚F (25˚C)) J3-CF32 Approx. 9.0Ω J3-CF31 Approx. 8.83Ω CF31-CF32 Approx. 18Ω If the measured resistance does not approxi- mately equal these standard values ±10%, replace the fan motor.
  • Page 46 TROUBLESHOOTING AND REPAIR 26. Inspection In most cases, the probable cause for insufficient cooling is a clogged system, too much static pressure refrigerant leakage, or an incorrect amount of refrigerant. In such cases, inspect the system according to the following procedure. A.
  • Page 47 TROUBLESHOOTING AND REPAIR • USE OF DRY NITROGEN GAS TUBE VERTICAL UP JOINT During brazing, the inside of the pipe under- goes an oxidative reaction due to the brazing flame. Introduce dry nitrogen gas (1l/min.; adjust with the flow regulator) through the pinch-off tube of the refrigerant cycle to BURNER prevent oxidation.
  • Page 48 TROUBLESHOOTING AND REPAIR 28. Charging the System with R-22 Refrigerant Always ensure that the refrigerant system has been properly evacuated before charging with the specified amount of R-22. WARNING When handling refrigerant (R-22), the following precautions should always be observed: •...
  • Page 49 TROUBLESHOOTING AND REPAIR NOTE: Connect the hoses using care not to mistake the high pressure side for the low pressure side and vice versa. LOW PRESSURE HIGH PRESSURE VALVE VALVE (CLOSED) (CLOSED) (3) Connect the charging hoses (red - high RED HOSE pressure side, blue - low pressure side) of GREEN HOSE...
  • Page 50 TROUBLESHOOTING AND REPAIR D. Checking Gas Leak VALVE SETTING (1) Remove the charging hose (green) from the vacuum pump, and connect the hose CLOSED CLOSED to the refrigerant cylinder (R-22). AIR PURGING OPEN THE VALVE OF REFRIGERANT CYLINDER BLUE CHARGING HOSE (GREEN) TO PROCESS TUBE FITTING Checking Gas leak (2) Loosen the nut on the gauge manifold...
  • Page 51 TROUBLESHOOTING AND REPAIR 29. Refrigerant Charging Work VALVE SETTING A. Refrigerant Charging (1) Remove the charging hose (green) from CLOSED CLOSED the vacuum pump, and connect it to the AIR PURGING OPEN THE VALVE refrigerant cylinder (R-22). OF REFRIGERANT CYLINDER (2) Loosen the nut on the gauge manifold side of the charging hose (green).
  • Page 52 TROUBLESHOOTING AND REPAIR 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. 30. Compressor Mounting Mount the compressor on the frame, using COMPRESSOR cushions, steel collars, steel washers and nuts.
  • Page 53 TROUBLESHOOTING AND REPAIR 34. Schematic Wiring Diagram...
  • Page 54 TROUBLESHOOTING AND REPAIR...
  • Page 55 DENSO SALES CALIFORNIA, INC. TECHNICAL SERVICE DEPARTMENT First Issue: July 2003 DSCA P/N: LA990009-1196 Printed in U.S.A.
  • Page 56 (800) 264-9573 www.movincool.com DSCA P/N: LA990009-1196...

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