Movincool OFFICE PRO 36 Service Manual
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Movincool OFFICE PRO 36 Service Manual

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MANUAL
SERVICE
OFFICE PRO 36
SERIAL NUMBER FROM APRIL 2007 (0407) TO PRESENT
DocID: 00G00010EA

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Summary of Contents for Movincool OFFICE PRO 36

  • Page 1 MANUAL SERVICE OFFICE PRO 36 SERIAL NUMBER FROM APRIL 2007 (0407) TO PRESENT DocID: 00G00010EA...
  • 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 registered trademark of DENSO Corporation.

  • Page 3: Table Of Contents

    Basic Operation of The Office Pro 36 Electrical Circuit ....... .
  • Page 4 Table of Contents Fan Motor ..............23 Compressor Motor .
  • Page 5 Table of Contents Repair Section 7. TROUBLESHOOTING Troubleshooting ..............29 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 36. Please use this service manual only when servicing the Office Pro 36. 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: General Description

    (Outdoor Unit) (Indoor Unit) exchanged heat to the outdoors. • Unlike conventional air conditioners, the MovinCool Office Pro 36 is a spot cooler which I000501 directs cool air to particular areas or objects. MovinCool Office Pro 36 has the following features: 2.2 Compact Design...

  • Page 8: Construction

    Operation Section 3. CONSTRUCTION 3.1 Exterior Dimensions (42.1) (DIA. 15.7) (2.8) (2.8) (9.2) (27.1) (3.8) (3.8) (29.8) (40.0) (3.7) (Unit: inch) I002269...

  • Page 9: Exterior Components

    Operation Section 3.2 Exterior Components Operation Panel Cold Air Outlet Grill Evaporator Air Inlet Grill Condenser Air Outlet Duct Drain Tanks Caster Condenser Air Inlet Panel Power Cord Service Panel I002270...

  • Page 10: Internal Structure

    I002271 3.4 Basic Construction • The MovinCool Office Pro 36 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 tanks and condensate pump (Optional).

  • Page 11: Air Flow

    3.7 Drain Tanks • A set of two 5.0 gal (19 L) drain tanks are supplied with the Office Pro 36. The condensate (water) is collected into both tanks. The drain switch activates and stops the operation when tanks reach the level of approximately...

  • Page 12: Technical Specifications

    Operation Section 4. SPECIFICATIONS 4.1 Technical Specifications ITEM SPECIFICATIONS Electronic Features Control Panel Electronic Thermostat Control Electronic Cooling Capacity Capacity-208 V/230 V 35000/36000 Btu/h (10258/10551 W) Refrigerant Circuit Compressor Compression Type Hermetic Scroll Motor Rated Output at 230 V 2.30 kW Evaporator Plate Fin Condenser...
  • Page 13 Operation Section ITEM SPECIFICATIONS Operating Condition Inlet air: Maximum 95 °F (35 °C), 60 %RH Inlet air: Minimum 65 °F (18.3 °C), 50 %RH Sound Level With Condenser Duct-high/low 65/62 dB (A) Without Condenser Duct-high/low 67/66 dB (A) Max. Duct Equivalent Length-Per Cold Duct Hose/Hot Duct Hose 40/60 ft (12.2/18.3 m) Condensate Tank Capacity 5 ±...

  • Page 14: Characteristics (At 230 V)

    Operation Section 4.2 Characteristics (at 230 V) <Cooling Capacity Curve> <Cool Air Temperature Difference Curve> 55(13) 54(12) 52(11) 50(10) 48(9) 46(8) 45(7) 95(35) 43(6) 86(30) 41(5) 77(25) 39(4) 68(20) Relative Humidity (%) (10) (15) (20) (25) Wet Bulb Temp. °F (°C) <Power Consumption Curve>...

  • Page 15: Characteristics (At 208 V)

    Operation Section 4.3 Characteristics (at 208 V) <Cooling Capacity Curve> <Cool Air Temperature Difference Curve> 55(13) 54(12) 52(11) 50(10) 48(9) 46(8) 45(7) 95(35) 43(6) 86(30) 41(5) 77(25) 39(4) 68(20) Relative Humidity (%) (10) (15) (20) (25) Wet Bulb Temp. °F (°C) <Power Consumption Curve>...

  • Page 16: Refrigerant System Construction

    Operation Section 5. REFRIGERANT SYSTEM 5.1 Refrigerant System Construction The component parts of the refrigerant system include the following: • Compressor, Evaporator, Condenser, Capillary tube, High Pressure Switch These parts are all connected by copper tubing. All the connections have been brazed. Condenser Condenser Outlet Pipe...

  • Page 17: Compressor

    Operation Section 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.

  • Page 18: Condenser

    Operation Section 5.3 Condenser • The condenser is a heat exchanger with copper tubes that are covered with thin aluminum projections called plate fins. • Heat is given off and absorbed by air being pulled across the condenser fins by the centrifugal fan and then expelled through the exhaust air duct.

  • Page 19: Electrical System

    Operation Section 6. ELECTRICAL SYSTEM 6.1 Circuit Diagram and Control Box φ AC 208/230 V 1 60 Hz T R R1 HPRS IOLC Jumper Line IOLF J101 J102 J103 J104 J106 J201 IOLF J108 J105 Attachment Plug Capacitor for Compressor T B 1 Terminal Block I O L F...

  • Page 20: Basic Operation Of The Office Pro 36 Electrical Circuit

    Operation Section 6.2 Basic Operation of The Office Pro 36 Electrical Circuit • There are two basic components used to control the operation of the Office Pro 36 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.

  • Page 21: Control Box

    Operation Section 6.3 Control Box (1) Capacitors • The capacitors are used to temporarily boost the power output available to the fan motor and the compressor at start-up. • The specifications of each capacitor are listed below: Capacitor Application Voltage Rating Capacitance Evaporator Fan Motor 440 VAC...
  • Page 22 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 relays. Display Switch (°C ⇔...

  • Page 23: Fan Motor

    Operation Section 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-210 W, Low-129 W Ground (Green/Yellow) J7 Low (Red) CF22 (Brown/White) CF21 (White)

  • Page 24: Compressor Motor

    6.6 Power Cord with LCDI • Office Pro 36 is equipped with a UL approved LCDI cord and an approved NEMA plug configuration (6-30). The appropriate outlet must be used for this plug type. LCDI is used for monitoring leakage current.

  • Page 25: Drain Switch

    Operation Section 6.7 Drain Switch • The Office Pro 36 is equipped with a drain tank switch. When the drain tanks accumulate 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”...

  • Page 26: Condensate Pump Kit (Optional)

    COOL ON/OFF button. The unit returns to the previous temperature set point. 6.8 Condensate Pump Kit (optional) • The Office Pro 36 model comes standard with 2 drain tanks, 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 27: Fan Mode Control Switch

    Operation Section 6.12 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 28: Warning Signal Connection (Output Signal Terminal L+ And L-)

    Operation Section 6.14 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...

  • Page 29: Troubleshooting

    Repair Section 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 •...

  • Page 30: Self-Diagnostic Codes

    Repair Section 7.2 Self-Diagnostic Codes • Self-diagnostic codes are displayed on the control board under the following conditions and clear method is as follows. LCD Display Description Condition Reset/Remedy Drain tanks are full When the drain tanks are filled with 1) Drain away.
  • Page 31 Repair Section LCD Display Description Condition Reset/Remedy Show LCD and LED Press HI/LO and buttons After 5 sec., display goes back to MO TU WE TH FR SA SU all on mode simultaneously for 3 sec. normal mode. START PROGRAM STOP (To check LCD segments and LED CLOCK...

  • Page 32: Troubleshooting Chart

    Repair Section LCD Display Description Condition Reset/Remedy Activation of high When high pressure switch Find the cause of high pressure to pressure switch (connected to J104) activates address it. (=J104 input turns to open) 3 times Check the following. in 24 h, “HP” is indicated and signal Ambient air temperature SET TEMP output (J106) turns on.
  • Page 33 Repair Section 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. evaporator. Compressor operates. 3. Frost in refrigeration cycle. Clogging at the frost section.
  • Page 34 Repair Section (2) Unit does not start (operate) < NOTE > • In this case, there is a possibility of safety device activating due to the clogged air filter. So make sure to first clean the air filter and then start up again to confirm if the problem lies with the air filter. •...
  • Page 35 Repair Section Possible Cause Symptom Remedy Checking Area Cause 1. Display code “FL”. Drain tanks are filled with Discharge the drain water. 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.
  • Page 36 Repair Section Possible Cause Symptom Remedy Checking 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 37: 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 Symptom Remedy Checking Area...
  • Page 38 Repair Section (3) Inspection of cooling capacity performance • Measure the difference in temperature between the inlet of the evaporator and the cool air vent. If the difference is out of the range given in the graphs on page 14 and 15, proceed with the remedy suggested in the troubleshooting chart on page 32 to 37.

  • Page 39: Parts Construction

    Repair Section 8. DISASSEMBLY 8.1 Parts Construction Upper Panel Blower housing Upper Front Panel Control Panel Condenser Fan Front Right Panel Air Outlet Grill Room Thermistor Rear Right Panel Freeze Protection Thermistor Front Panel Filter Assy Evaporator Fan Filter Element Condensate Pump (Optional)

  • Page 40: Disassembly

    Repair Section 8.2 Disassembly 1) Remove drain tanks. I001783 2) Remove twelve (12) screws from upper front Screws (7) 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.
  • Page 41 Repair Section 5) Remove twenty (20) screws from upper panel. Screws (14) Screws (6) I002273 6) Remove thirteen (13) screws from rear panel. Screws (3) Screws (10) I002274 7) Remove ten (10) screws from rear right panel. Screws (6) Screws (3) Screw (1) I002275 8) Remove eight (8) screws from front right panel.
  • Page 42 Repair Section 9) Remove seven (7) screws from service panel and six (6) screws from rear left panel. Screws (7) Screw (1) Screws (5) I002278 10) Remove eight (8) screws from front left panel. Screws (3) Screws (5) I002279...

  • Page 43: Removal Of Electrical Parts

    Repair Section 8.3 Removal of Electrical Parts (1) Control box 1) Remove seven (7) screws from service panel. (See page 42.) 2) Remove electrical parts. - Relay: Remove two (2) screws from control box. - Terminal block: Remove four (4) screws from control box. - Terminal block (signal connection): Remove two (2) screws from control box.
  • Page 44 Repair Section (2) Relay board 1) Remove seven (7) screws from service panel. (See page 42.) 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.
  • Page 45 Repair Section 3) Slowly slide control panel assembly out of box. I002181 4) 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...
  • Page 46 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 47: Removal Of Blower Assembly

    Repair Section 8.4 Removal of Blower Assembly Control Panel Stay Control Panel Control Panel Stay Evaporator Fan Casing Condenser Fan Casing Evaporator Fan Evaporator Fan Motor Condenser Condenser Fan Center Panel Fan Motor I001795...
  • Page 48 Repair Section (1) Removal of condenser fan and fan motor 1) Remove four (4) nuts and three (3) screws in the location shown. Then remove fan motor wire. Nuts (4) Screws (3) Fan Motor Wire I002280 2) Loosen the set screw using a hex key. Then remove the fan and fan motor.

  • Page 49: Inspection Of Capacitor (For Fan Motor And Compressor)

    Repair Section 8.5 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 50: Inspection Of Fan Motor

    Repair Section 8.7 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.

  • Page 51: Inspection Of Wiring Connection

    Repair Section 8.9 Inspection of Wiring Connection • Refer to the Wiring Diagrams on page 19 and check for connection of each wire. 8.10 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.

  • Page 52: Refrigerant System Repair

    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 36, replace or repair the part in question. After replacing any component all connections must be brazed.
  • Page 53 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 (1 L/min); adjust with the flow regulator) through the pinch- off tube of the refrigerant.

  • Page 54: Removal Of Refrigeration Cycle Components

    Repair Section 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 (1 L/min)) through the pinch-off tube during any brazing operation.

  • Page 55: Charging The System With R-410A Refrigerant

    Repair Section 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). •...
  • Page 56 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 Refrigerant cutter. Cycle Side 2) Fit the process tube fitting to the pinch-off tube on both sides.
  • Page 57 Repair Section (3) Checking vacuum 1) Leave the high pressure valve and the low Valve Setting Leave valves closed for 5 pressure valve of the gauge manifold closed for min or more. Pointer of Closed Closed pressure gauge returning to five minutes or more, and confirm that the gauge zero indicates there is a leak.
  • Page 58 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 Air Purging refrigerant cylinder (R-410A). Open The Valve 2) Loosen the nut on the gauge manifold side of the of Refrigerant Cylinder charging hose (green).
  • Page 59 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 60: Refrigerant Charging Work

    Repair Section 9.4 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 Air Purging cylinder Open The Valve (R-410A). of Refrigerant Cylinder 2) Loosen the nut on the gauge manifold side of the charging hose (green).
  • Page 61 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 62: Reassembly

    Repair Section 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.

  • Page 63: Wiring Notice

    Repair Section 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 •...

  • Page 64: Schematic

    Repair Section 10.7 Schematic <Wiring Diagram> φ AC 208/230 V 1 60 Hz T R R1 HPRS IOLC Jumper Line IOLF J101 J102 J103 J104 J106 J201 IOLF J108 J105 Attachment Plug Capacitor for Compressor T B 1 Terminal Block I O L F Inner Overload Relay of Fan Motor T B 2...
  • Page 65 DENSO SALES CALIFORNIA, INC. Long Beach, CA 90810 www.movincool.com P/N: SV0001- 01 Second Issue: June 2008...

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