Movincool OFFICE PRO 18 Service Manual
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Movincool OFFICE PRO 18 Service Manual

Movincool OFFICE PRO 18 Service Manual

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SERVICE MANUAL
OFFICE PRO 18
SERIAL NUMBER FROM APRIL 2007 (0407) TO PRESENT
DocID: 00G00014EB

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Summary of Contents for Movincool OFFICE PRO 18

  • Page 1 SERVICE MANUAL OFFICE PRO 18 SERIAL NUMBER FROM APRIL 2007 (0407) TO PRESENT DocID: 00G00014EB...
  • 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®, Office Pro® and SpotCool® are registered trademarks of DENSO Corporation.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Operation Section 1. PRECAUTIONS FOR SAFETY Foreword............... 6 Definition of Terms .
  • Page 4 Table of Contents 5.10 Automatic Restart after Power Interruption..........27 5.11 Compressor Protection .
  • Page 5 Table of Contents Repair Section 6. TROUBLESHOOTING Troubleshooting ..............31 Self-Diagnostic Codes .

  • Page 6: Precautions For Safety

    Operation Section 1. PRECAUTIONS FOR SAFETY 1.1 Foreword • This manual has been published to service the MovinCool Office Pro 18. Please use this service manual only when servicing the Office Pro 18. 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.

  • Page 7: Construction

    Operation Section 2. CONSTRUCTION 2.1 Exterior Dimensions (DIA. 11.6) (1.4) (1.4) (3.5) (3.5) (19.3) (4.6) (20.9) (2.0) (27.4) (Unit: inch) I002232...

  • Page 8: Exterior Components

    Operation Section 2.2 Exterior Components Operation Panel Cold Air Outlet Grill Evaporator Air Inlet Grill Condenser Air Outlet Duct Drain Tank Cover Caster Condenser Air Inlet Panel Power Cord Service Panel I002233...

  • Page 9: Internal Structure

    I002234 2.4 Basic Construction • The MovinCool Office Pro 18 is compact in construction because the condenser and the evaporator are enclosed in one unit. The interior is divided into three sections. The upper front face is equipped with the evaporator, and the lower front face contains the drain tank and condensate pump (Optional).

  • Page 10: Air Flow

    2.7 Drain Tank • A 5.0 gal (19 L) drain tank is supplied with the Office Pro 18. The condensate (water) is collected into the tank. The drain switch activates and stops the operation when tank reaches the level of approximately...

  • Page 11: Technical Specifications

    Operation Section 3. SPECIFICATIONS 3.1 Technical Specifications ITEM SPECIFICATIONS Electronic Features Operation Digital Programmable Electrical Characteristics Voltage Requirement Single-Phase, 115 V, 60 Hz Operating Voltage Max. 127 V Range Min. 104 V Starting Current 65 A Recommended Fuse Size 20 A 15.6 A 65 A Cooling Capacity and Power Consumption...
  • Page 12 Operation Section ITEM SPECIFICATIONS Refrigerant Refrigerant Control Capillary Tube Type R-410A Amount 1.70 lb (0.77 kg) 1.63 lb (0.74 kg) Signal Connection Fire Alarm Input (Signal Type) •No-voltage contact input •Contact resistance less than 100 ohm Warning Signal Output 2 A at 30 V (DC/AC) or less (resistive load) Power Cord NEMA Plug Configuration 5-20...

  • Page 13: Characteristics

    Operation Section 3.2 Characteristics <Cooling Capacity Curve> <Cool Air Temperature Difference Curve> 25.2(14) 23.4(13) 21.6(12) 19.8(11) 18.0(10) 16.2(9) 14.4(8) 95(35) 12.6(7) 86(30) 10.8(6) 77(25) 9.0(5) 68(20) Relative Humidity (%) (10) (15) (20) (25) Wet Bulb Temp. °F (°C) <Power Consumption Curve> <Current Consumption Curve>...

  • Page 14: Refrigeration System Construction

    Operation Section 4. REFRIGERATION SYSTEM 4.1 Refrigeration System Construction The component parts of the refrigeration system include the following: • Compressor, Evaporator, Condenser, Capillary tube These parts are all connected by copper tubing. All the connections have been brazed. Condenser Evaporator Condenser Evaporator Pipe...

  • Page 15: Compressor

    Operation Section 4.2 Compressor • The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in one casing. (1) Compressor construction •The construction of a rotary type compressor is divided into two mechanisms; the drive mechanism (compressor motor), and the compression mechanism (compressor).
  • Page 16 Operation Section (2) Basic compressor operation •The roller (compression mechanism) is set Discharge eccentrically with a certain distance given from Hole Spring Discharge the axis of the center of the cylinder. A spring Suction Valve Hole loaded blade is mounted on the cylinder. The Blade roller turns to compress the refrigerant in the space between the cylinder and eccentrically...
  • Page 17 Operation Section (3) Operation 1) Start of compression 1) The cylinder is filled with low pressure gas. Discharge Blade Valve 2) Since pressure in the discharge chamber is higher than in the cylinder, the discharge valve is kept closed. Roller I001676 2) Suction and compression 1) The pressure in the cylinder increases...

  • Page 18: Condenser

    Operation Section (4) Compressor lubrication •The lubrication system is comprised of a hollow shaft, an oil scraper mounted at the end face, hollow shaft, a shaft journal (shaft bearing), Rotor and the lubrication groove for the shaft journal. The lubrication groove is wider than the oil hole.

  • Page 19: Evaporator

    Operation Section 4.5 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. 4.6 Accumulator •The accumulator is mounted on the suction gas From Evaporator...

  • Page 20: Electrical System

    Operation Section 5. ELECTRICAL SYSTEM 5.1 Circuit Diagram and Control Box φ AC 115 V 1 60 Hz Jumper Line J101 J102 J103 J104 J106 J201 IOLF J108 J105 Attachment Plug I O L F Inner Overload Relay of Fan Motor T B 1 Terminal Block O L C...

  • Page 21: Basic Operation Of Electrical Circuit

    Operation Section 5.2 Basic Operation of Electrical Circuit • There are two basic components used to control the operation of electrical system: - Control panel assembly - Control box • The control panel assembly contains the control panel, control board (with inputs for the freeze and room temperature thermistors), drain switch and a microprocessor.

  • Page 22: Control Box

    Operation Section 5.3 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 Fan Motor 370 VAC...
  • Page 23 Operation Section (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 Display Switch relays.

  • Page 24: Fan Motor

    Operation Section 5.4 Fan Motor • The fan motor is a single phase, induction type two-speed motor. The motor rotates the fan on both the evaporator side and the condenser side at the same time. Specifications: CF1 (White) CF2 (Brown/White) Rated Voltage 115 V, 60 Hz Ground...

  • Page 25: Compressor Overload Relay

    MRA4720-12027 5.7 Power Cord with LCDI • Office Pro 18 is equipped with UL recognized LCDI cord and NEMA plug configuration (5-20). The appropriate outlet must be used for this plug type. LCDI is used for monitoring leakage current. Once leakage current is detected, LCDI de-energizes the unit.

  • Page 26: Drain Switch

    Operation Section 5.8 Drain Switch • The Office Pro 18 is equipped with a drain tank switch. When the drain tank accumulates approximately 4.0 gal (15 L) of condensate (water) in the drain tank, the drain tank switch sends a signal to the microprocessor. The microprocessor stops all operation of the unit, flashes the "TANK FULL”...

  • Page 27: Condensate Pump Kit (Optional)

    COOL ON/OFF button. The unit returns to the previous temperature set point. 5.9 Condensate Pump Kit (optional) • The Office Pro 18 model comes standard with a drain tank, which collect the water that forms on the evaporator during normal cooling operation. If the unit is required to operate continuously without periodic emptying of this tank, a condensate pump may be needed.

  • Page 28: Fan Mode Control Switch

    Operation Section 5.13 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.

  • Page 29: Warning Signal Connection (Output Signal Terminal L+ And L-)

    Operation Section 5.15 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 •...

  • Page 30: Fire Alarm Control Panel Connection (Input Signal Terminal E+ And E-)

    Operation Section 5.16 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.

  • Page 31: Troubleshooting

    Repair Section 6. TROUBLESHOOTING 6.1 Troubleshooting • Before troubleshooting the system, the following inspection should be performed. WARNING • Disconnect power prior to servicing the relay board. • Failure to follow this warning may lead to electrical shock. (1) Inspection of power source voltage •...

  • Page 32: Self-Diagnostic Codes

    Repair Section 6.2 Self-Diagnostic Codes • Self-diagnostic codes are displayed on the control board under the following conditions. LCD Display Description Condition Reset/Remedy Drain tank is full When the drain tank is filled with 1) Drain away. drain water. (LCD indicates “TANK”) (“TANK FL”...
  • Page 33 Repair Section LCD Display Description Condition Reset/Remedy Show LCD and LED Press HI/LO and  buttons After 5 seconds., display goes MO TU WE TH FR SA SU all on mode simultaneously for 3 seconds. back to normal mode. START PROGRAM STOP (To check LCD segments and LED...

  • Page 34: Troubleshooting Chart

    Repair Section 6.3 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 operate. - Overflow of drain water. - Abnormal noise or vibrations. - Others.
  • Page 35 Repair Section Possible Cause Condition Remedy Check 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. evaporator. Compressor operates. 3. Frost in refrigeration cycle. Clogging at the frost section.
  • Page 36 Repair Section (2) Unit does not 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. •...
  • Page 37 Repair Section Possible Cause Condition Remedy Check Area Cause 1. Display code “FL”. Drain tank (optional) is filled Discharge the drain water. with the drain water. RESET the controller Loose drain switch Reconnect the drain switch connection. and check the connection. RESET the controller Defective drain switch.
  • Page 38 Repair Section Possible Cause Condition Remedy Check Area Cause 1. Fan on-off relay on the relay Open circuit or insufficient Replace relay board. board. contact. 2. Fan HI/LO change relay on Open circuit or insufficient Replace relay board. the relay board. contact.

  • Page 39: Basic Inspection

    Repair Section (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 Condition Remedy Check Area...
  • Page 40 Repair Section (3) Inspection of cooling capacity performance • Measure the difference in temperature between the inlet of the evaporator and the cool air vent. If the difference is out of the range given in the graphs on page 13, proceed with the remedy suggested in the troubleshooting chart on page 34 to 39.

  • Page 41: Parts Construction

    Repair Section 7. DISASSEMBLY 7.1 Parts Construction Control Panel Upper Front Panel Right Handle Upper Panel Air Outlet Grill Right Panel Left Handle Filter Element Front Panel Filter Assy Right Panel Filter Assy Filter Element Room Thermistor Left Panel Blower Housing (Evaprator) Blower Housing(Condenser) Drain Pan Assy...

  • Page 42: Disassembly

    Repair Section 7.2 Disassembly 1) Remove drain tank. I002203 2) Remove four (4) screws from upper front panel. Screw (1) Screw (1) Screws (2) I002242 3) Slide upper front panel forward and remove. I002243 4) Louver can be removed from upper front panel by unsnapping the lock tap and removing the louver Pivots from its pivots.
  • Page 43 Repair Section 5) Remove seven (7) screws from service panel. Screws (7) I002207 6) Remove thirteen (13) screws from rear panel. Screws (3) Screws (7) Screws (3) I002208 7) Remove eight (8) screws from rear panel and two Screws (2) (2) screws from blower housing (condenser).

  • Page 44: Removal Of Electrical Parts

    Repair Section 9) Remove seven (7) screws from right panel. Screws (7) I002211 7.3 Removal of Electrical Parts WARNING • Disconnect power prior to servicing the relay board. • Failure to follow this warning may lead to electrical shock. (1) Control box 1) Remove seven (7) screws from service panel.
  • Page 45 Repair Section (2) Relay board 1) Remove seven (7) screws from service panel. (See page 43.) 2) Disconnect seven (7) connectors, and remove five (5) screws from relay board. Temperature Scale Display Switch Dip Switch To Control Board(10 pin) Fan Mode Control Switch To Condensate Pump(2 pin) To Compressor (Black) Power (#T1) OnTerminal Block...
  • Page 46 Repair Section 3) Disconnect the following connectors from the control board: (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 (D) J103 (2-pin) Drain Tank Switch I002247 (E) J104 (2-pin) Not in use.
  • Page 47 Repair Section (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.

  • Page 48: Removal Of Blower Assembly

    Repair Section 7.4 Removal of Blower Assembly Control Panel Stay Control Panel Stay Air Deflector Evaporator Fan Casing Evaporator Fan Motor Stay Center Panel Fan Motor Condenser Fan Casing Condenser Fan Ring ILL00082-00...
  • Page 49 Repair Section (1) Removal of condenser fan 1) Loosen the set screw using a hex key. Then remove condenser fan. Set Screw I002217 (2) Removal of evaporator fan and fan motor 1) Remove two (2) nuts on the inside of the condenser fan casing in the locations shown.

  • Page 50: Inspection Of Capacitor (For Fan Motor And Compressor)

    Repair Section 7.5 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...

  • Page 51: Inspection Of Fan Motor

    Repair Section 7.7 Inspection of Fan Motor • Measure resistance across the terminals of the fan motor. (All terminals must be disconnected from the unit.) • Between terminals (at 77 °F (25 °C)) - J6-CF1 Approx. 4.0 ohm - J6-CF2 Approx. 28.2 ohm CF1 (White) - CF1-CF2 Approx.

  • Page 52: Inspection

    Repair Section 7.11 Inspection • In most cases, the probable cause for insufficient cooling is a clog in the system, a leakage or an incorrect amount of refrigerant. In such cases, inspect the system according to the following procedure. (1) Clogged refregeration system •...

  • Page 53: Refrigeration System Repair

    Repair Section 8. REFRIGERATION SYSTEM REPAIR 8.1 Repair of Refrigeration System • In case there is a leak, obstruction, or problem in the refrigeration system of this unit, replace or repair the part in question. After replacing any component, all connections must be brazed. (1) Proper brazing techniques •...
  • Page 54 Repair Section (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.

  • Page 55: Removal Of Refrigeration Cycle Components

    Repair Section 8.2 Removal of Refrigeration Cycle Components WARNING • Before replacing any refrigeration component, recover the refrigerant using standard recovery procedures. CAUTION • To prevent oxidation, dry nitrogen should be conducted (flow rate 0.27 gal/min (1 L/min)) through the pinch-off tube during any brazing operation. •...

  • Page 56: Charging The System With R-410A Refrigerant

    Repair Section 8.3 Charging the System with R-410A Refrigerant • Always ensure that the refrigeration 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). •...
  • Page 57 Repair Section (1) Connection of gauge manifold 1) Properly remove the crushed end of the pinch-off tube at the high pressure side and the low Charging Hose Side pressure side of the refrigerant cycle with a pipe cutter. Refrigerant Cycle Side 2) Fit the process tube fitting to the pinch-off tube on both sides.
  • Page 58 Repair Section (3) Checking vacuum 1) Leave the high pressure valve and the low Valve Setting pressure valve of the gauge manifold closed for 5 Closed Closed minutes or more, and confirm that the gauge 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...
  • Page 59 Repair Section (4) Checking gas leak 1) Remove the charging hose (green) from the Valve Setting vacuum pump, and connect the hose to the Closed Closed refrigerant cylinder (R-410A). Air Purging Open The Valve 2) Loosen the nut on the gauge manifold side of the of Refrigerant charging hose (green).
  • Page 60 Repair Section (5) Evacuation (repeat) 1) Close the valve of the refrigerant cylinder. Then Valve Setting remove the charging hose (green) from the Gauge Closed Open Closed Closed 30 inHg (100 kPa) or larger refrigerant cylinder, and connect it to the Low Pressure refrigerant recovery machine.

  • Page 61: Refrigerant Charging Work

    Repair Section 8.4 Refrigerant Charging Work (1) Refrigerant charging 1) Remove the charging hose (green) from the Valve Setting vacuum pump, and connect it to the refrigerant Closed Closed cylinder (R-410A). Air Purging Open The Valve 2) Loosen the nut on the gauge manifold side of the of Refrigerant charging hose (green).
  • Page 62 Repair Section (2) Removal of gauge manifold 1) Crimp the pinch-off tube with a pinch-off tool. Pinch-Off Tool 2) Remove the gauge manifold and the process To Gauge Manifold Side tube fitting. Crush the end of the pinch-off tube. Pinch-Off Tube 3) Braze the end of the pinch-off tube.

  • Page 63: Reassembly

    Repair Section 9. REASSEMBLY 9.1 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.

  • Page 64: Perform The Inspection

    Repair Section 9.5 Perform the Inspection • Perform the inspection of cooling performance and check for abnormal noise or abnormal vibration. 9.6 Caster Maintenance • Lubricate bearings in caster as needed with standard bearing grease using the zerk fitting. < NOTE > Casters should roll and swivel freely.

  • Page 65: Schematic

    Repair Section 9.7 Schematic <Wiring Diagram> φ AC 115 V 1 60 Hz Jumper Line J101 J102 J103 J104 J106 J201 IOLF J108 J105 Attachment Plug I O L F Inner Overload Relay of Fan Motor T B 1 Terminal Block O L C Inner Overload Relay of Compressor T B 2...
  • Page 66 DENSO SALES CALIFORNIA, INC. Long Beach, CA 90810 www.movincool.com P/N: SV0005-02 Third Issue: September 2011...

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