Movincool CLASSIC 40 Service Manual
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Movincool CLASSIC 40 Service Manual

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SERVICE MANUAL
CLASSIC 40
SERIAL NUMBER FROM MAY 2009 (0509) TO PRESENT
DocID: 00G00044EA

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Summary of Contents for Movincool CLASSIC 40

  • Page 1 SERVICE MANUAL CLASSIC 40 SERIAL NUMBER FROM MAY 2009 (0509) TO PRESENT DocID: 00G00044EA...
  • 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

    Table of Contents Table of Contents Operation Section 1. PRECAUTIONS FOR SAFETY Foreword............... 6 Definition of Terms .
  • Page 4 Table of Contents 5.13 Compressor Motor Relay ............40 5.14 Fan Motor Relay .
  • Page 5 Table of Contents Repair Section 6. TROUBLESHOOTING Troubleshooting ..............43 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 Classic 40. Please use this service manual only when servicing the Classic 40. 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: Specifications

    Operation Section 2. SPECIFICATIONS 2.1 Exterior Dimension Diagram DIA. 0.6 12.9 20.7 10.0 43.5 23.6 41.3 DIA. 20.7 4xM20 11.8 11.8 37.8 22.4 (Unit: inch) I003082...

  • Page 8: Technical Specifications

    Operation Section 2.2 Technical Specifications ITEM SPECIFICATIONS Electronic Features Operation Electronic Control Electronic Electronic Characteristics Voltage Requirement 3 Phase, 220 V, 60 Hz Min. - Max. Voltage Min. 198 V, Max. 242 V Starting Current 72 A Recommended Fuse Size 25 A Cooling Capacity and Power Consumption Evaporator: 95 °F (35 °C),...
  • Page 9 Operation Section Operating Condition Range Max. Inlet Air 113 °F (45 °C), 50 % RH Min. Inlet Air 75 °F (24 °C), 50 % RH Maximum Sound Level Measured at 3.28 ft (1 m) 72 dB (A) from surface of unit. •...

  • Page 10: Characteristics

    Operation Section 2.3 Characteristics (1) How to read the cooling capacity curve Example <Condition> <Cooling Capacity> Dry Bulb : 95 °F (35 °C) MIN. : 50500 Btu/h Wet Bulb : 77 °F (25 °C) MAX. : 58000 Btu/h Air Volume : 1500 CFM (2550 m 1100 1300 1500...
  • Page 11 Operation Section (2) Cooling capacity curve 1000 1200 (10) (14) (17) (20) Total Air Volume CFM (X10 113 (45) 104 (40) 95 (35) 86 (30) 77 (25) 68 (20) (15) (20) (25) (30) Wet Bulb Temp. °F (°C) I003084...
  • Page 12 Operation Section (3) Power consumption curve 1000 1200 (10) (14) (17) (20) Total Air Volume CFM (X10 113 (45) 104 (40) 95 (35) 86 (30) 77 (25) 68 (20) (40) (20) (25) (30) (35) Wet Bulb Temp. °F (°C) I003085...
  • Page 13 Operation Section (4) Current consumption curve 1000 1200 (10) (14) (17) (20) Total Air Volume CFM (X10 113 (45) 104 (40) 95 (35) 86 (30) 77 (25) 68 (20) (40) (20) (25) (30) (35) Wet Bulb Temp. °F (°C) I003086...
  • Page 14 Operation Section (5) 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) 12.6(7) 10.8(6) 9.0(5) 1000 1200 (20) (10) (14) (17) Relative Humidity (%) Total Air Volume CFM (X10 I003087...
  • Page 15 Operation Section (6) Extension static pressure and air volume curve of cool air 2.5 (623) USAGE RANGE 2.0 (498) 1.5 (374) 1.0 (245) 0.5 (125) 0 (0) 1000 1500 (850) (1700) (2550) Total Air Volume CFM (m I003088...

  • Page 16: Construction

    Operation Section 3. CONSTRUCTION 3.1 Internal Structure Condenser Fan and Motor Condenser Air Outlet Evaporator Fan Motor Evaporator Air Outlet Controller Control Box Evaporator Room Thermistor (RTS) Condenser Power Cord Freeze Protection Thermistor (CTS) I003089...

  • Page 17: Basic Construction

    Operation Section 3.2 Basic Construction • The interior of Classic 40 is divided into two sections. The front section houses the evaporator and control box, and the rear section houses the condenser and the compressor. 3.3 Air Flow (1) Air flow for the condenser •...

  • Page 18: Refrigerant System Construction

    Operation Section 4. REFRIGERANT SYSTEM 4.1 Refrigerant System Construction The component parts of the refrigerant system include the following: • Compressor, Evaporator, Condenser, Capillary tube The parts above are all connected by copper pipes with brazed connections. Condenser Inlet Pipe Condenser Compressor Discharge Pipe Condenser...

  • Page 19: 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 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 20: Condenser

    Operation Section 4.3 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 propeller fan. The air is then expelled through the exhaust air duct.

  • Page 21: High Pressure Switch

    Operation Section 4.6 High Pressure Switch • The high pressure switch prevents the Pressure of Refrigerant condenser compressor from being Snap Disk damaged by excessively high pressure in the Movable Point high pressure line of the refrigeration cycle. Stationary Point The switch is normally closed.

  • Page 22: Electrical System

    Operation Section 5. ELECTRICAL SYSTEM 5.1 Circuit Diagram Dip Switch #1 : On : Fan Stop Mode (Fan Auto) HPRS Off : Fan Operate Mode (Fan On) External AC220 V, 3 Phase, 60 Hz Controller #2 : N/A Off (Default) #3 : N/A #4 : On : The Buzzer Sound Disabled 1 2 3 4...

  • Page 23: Control Box And Relay Board

    Operation Section 5.2 Control Box and Relay Board Compressor Motor Relay (for Compressor and Condenser Fan Motor) Relay Board Fuse Terminal Block Relay Board Reverse Phase Protector Overcurrent Relay (for Signal Connection) (for Evaporator Fan Motor) Terminal Block Terminal Block Fan Motor Relay Overcurrent Relay (for Power Cord)

  • Page 24: Power Supply Requirements

    • Make sure the AC outlet is free of dirt, dust, oil, water, or any other foreign matter. • The Classic 40 is equipped with an approved NEMA plug configuration (L15-30). The appropriate outlet must be used for this plug type.
  • Page 25 Colored Wire Fuse 25 A (25 A MAX.) Grounding Terminal Terminal Block of Classic 40 I003102 CAUTION Use a specified 25 A fuse. Do not use wiring, copper wire or soldering instead of the fuse. The use of non-specified fuses can cause machine failure or fire.
  • Page 26 Tightening torque: 0.96 ft•lbf (1.3 N•m) < NOTE > • Classic 40 is equipped with phase protectors. - The phase sequence is in order of R, S, and T. If the phase sequence is reversed, the unit does not operate. At this condition, exchange two of the power wires for R, S and T terminals.

  • Page 27: Wall Thermostat Connection

    Operation Section 5.4 Wall Thermostat Connection (1) Connecting wall thermostat to unit 1) Set the wall thermostat to cooling system mode, since most wall thermostats are designed for both heating and cooling. 2) Prepare the wire harness for connection from the unit to the thermostat. Recommended wire type and size: Thermostat cable / Solid wire 16 - 26 AWG 3) Identify the thermostat connectors labeled G, Y, and RC.
  • Page 28 Operation Section 5) Install the wall thermostat to the proper location inside the room where it can be conveniently accessed. Do not install the wall thermostat where unusual heating conditions may occur (i.e. hot stove, hot pipe, fireplace, direct sunlight, etc.) Most thermostats provide these basic functions: - Fan Mode: On / Auto (Select the desired fan mode) - System: Cool / Heater (Select Cool only)

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

    Operation Section 5.5 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 unit operates abnormally. •...

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

    Operation Section 5.6 Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-) • The controller is equipped with a normal open input signal connection, which can be connected directly from the fire alarm control panel. This input signal terminal should only be connected to a close or open dry contact signal.

  • Page 31: Basic Operation

    Operation Section 5.7 Basic Operation (1) Control panel • Before operating the unit, it is important to be familiar with the basic operation of the control panel. Activates/deactivates the cool mode; turns the unit off. COOL ON/OFF Button Activates/deactivates the fan only mode; turns the unit off. FAN Button SET TEMP Buttons ( / ) Increases/decreases the temperature set point during cool mode.
  • Page 32 Operation Section (2) Fan only mode • When the FAN button on the control panel is pressed, the FAN “ON” LED illuminates, and the fan operates. At this time, the compressor is off, and only the fan is in operation. When the FAN button is pressed again, the fan stops.

  • Page 33: Relay Board

    Operation Section 5.8 Relay Board • The relay board contains the compressor and fan on relays, in addition to a step-down transformer that converts the line voltage (215/220 VAC) to 12 V. This voltage 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, further being reduced to 5 V for the system logic.
  • Page 34 Operation Section (2) Input signal • The relay board receives inputs from the control panel, sensors, and external devices to perform device control. Control Panel Input Symbol Indication Function Connector ON/OFF Button On/off control for unit operation. Turns the unit on and off. Changes the fan control mode between continuous and automatic FAN Button on/off control.
  • Page 35 Operation Section (3) Dip switch setting • The controller is equipped with a four position dip switch that defaults in the OFF position. The dip switch can be set to configure the following functions: Symbol Item Function On --- Disable “onboard buzzer” DSW4 Buzzer Off --- Enable “onboard buzzer”...

  • Page 36: Control Specifications

    Operation Section 5.9 Control Specifications (1) Fan control • When the FAN button is pressed, the 52ID (fan motor on/off) relay on the relay board turns on, operating the fan. • The 52ID relay turns the auxiliary relay on to operate the fan. Specifications: - 52ID (Fan motor On-Off) relay output: 5 A at AC 250 V (2) Compressor start control...
  • Page 37 Operation Section (4) Compressor time delay control (compressor protection) • Compressor protection consists of a time delay program within the microprocessor. This program prevents a heavy load from being applied to the compressor motor when restarting the unit (cool mode) after a very short period of time. This “delay” is in effect any time the compressor is turned on by either the COOL ON/OFF button, or power interruption restart (automatic recovery.) Specifications:...

  • Page 38: Compressor

    Operation Section (6) Temperature control • During cool mode, temperature control changes the 52CM (compressor on/off) relay status according to RTS temperature in the available range (-4 °F to 140 °F (-20 °C to 60 °C)). 52CM (Compressor Relay) (Set Temp. -3 °F) Set Temp (Set Temp.

  • Page 39: Fan Motor

    Operation Section 5.11 Fan Motor (1) For evaporator • The fan motor is a three-phase, induction type. • The following table shows the specifications of the fan motor. Specifications: Rated Voltage 220/240 V Rated Output 750 W I003093 < NOTE > An internal overload relay is used to protect the fan motor.

  • Page 40: Control Box

    Operation Section 5.12 Control Box (1) Reverse Phase Protector Reverse Phase Protector • The reverse phase protector is operated at nominal voltage of three-phase, 220 V. • If the phases are reverse, the output relay will not energize. • The reverse phase protector...

  • Page 41: Fan Motor Relay

    Operation Section 5.14 Fan Motor Relay • The fan motor relay is a normal open contact relay. • When the unit is operating, the current is flowing through terminal A1 and A2 of the relay’s coil and causes contactor terminals 13 and 14, 23 and 24, 33 and 34, 43 and 44 to become closed, and the power is supplied to the evaporator fan motor.

  • Page 42: Temperature Thermistor

    Operation Section 5.16 Temperature Thermistor • The room thermistor (RTS) is installed upstream of the evaporator, and detects evaporator inlet temperature as a resistance value. • The freeze protection thermistor (CTS) is installed in the evaporator outlet piping, and detects low temperature on the evaporator as a resistance value.

  • Page 43: Troubleshooting

    Repair Section 6. TROUBLESHOOTING 6.1 Troubleshooting • Before troubleshooting the system, the following inspection should be performed. (1) Inspection of power source voltage • Check the voltage of the power source. - Three-phase 220 V (60 Hz) • Check the phase sequence of the power source. <...

  • Page 44: Self-Diagnostic Codes

    Repair Section 6.2 Self-Diagnostic Codes • Self-diagnostic codes are displayed on the control board under the following conditions and clear method is as follows. Controller Display Description Condition Reset/Remedy Room thermistor When room thermistor becomes Disconnect and reconnect the connection problem open or shorted.

  • Page 45: 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 start (operate). - Overflow of drain water. - Abnormal noise or vibrations. - Others.
  • Page 46 Repair Section Possible Cause Condition 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 3. Frost in refrigeration cycle. Clogging at the frost section. Replace the clogged operates.
  • Page 47 Repair Section (2) Unit does not start (operate) Possible Cause Condition Remedy Checking Area Cause 1. Voltage. Power failure. Repair power supply. 2. Phase sequence of the Phase sequence is Change any 2 of the 3 wires power source. reversed. for power source wires.
  • Page 48 Repair Section Possible Cause Condition Remedy Checking Area Cause 1. Fan on-off relay on the relay Open circuit or insufficient Replace relay board. board. contact. 2. Compressor motor relay. Open circuit or insufficient Replace compressor Stops Control contact. motor relay. immediately panel after...

  • Page 49: Basic Inspection

    Repair Section (3) 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 Checking Area...
  • Page 50 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, proceed with the remedy suggested in the troubleshooting chart on page 45 to 49.

  • Page 51: Inspection Of Fan Motor

    Repair Section 6.5 Inspection of Fan Motor • Measure resistance across the terminals of the Condenser Fan Motor fan motor (except the ground terminal). (All terminals must be disconnected from the unit.) - Condenser fan motor: Approx. 16.2 ohm (at Evaporator Fan Motor 68 °F (20 °C)) - Evaporator fan motor: Approx.

  • Page 52: Inspection Of Compressor Motor

    Repair Section 6.6 Inspection of Compressor Motor • Measure resistance across the terminals of Maximum Clearance 0.08 in (2 mm) the compressor motor. (All terminals must be Compressor disconnected from the unit.) Front View of Connector Cap CAUTION • To disconnect from the terminals, pull out the Connector Cap plastic connector cap from the compressor.

  • Page 53: Wiring Connection Inspection

    Repair Section 6.8 Wiring Connection Inspection • While referring to the wiring diagrams, check the connection of each wire. CAUTION Secure the wires using clamps to prevent contact with the edges of the structure, etc. Secure the wires in the same position as prior to removal. 6.9 Refrigerant System Inspection •...

  • Page 54: Parts Construction

    Repair Section 7. DISASSEMBLY 7.1 Parts Construction Exhaust Air Duct Grill Upper Panel Rear Right Panel Air Filter for Condenser Air Filter for Condenser Filter Frame Filter Frame Control Box Cover Rear Left Panel Freeze Protection Thermistor Right Panel Air Filter for Condenser Filter Frame Cover for...

  • Page 55: Disassembly

    Repair Section 7.2 Disassembly 1) Remove the four air filters. Front Panel 2) Take out the four (4) bolts, and then remove the front panel. Bolts (4) Air Filter Air Filter I002628 3) Take out the three (3) screws, and then open the control box cover.

  • Page 56: Removal Of Control Panel

    Repair Section 6) Take out the eight (8) bolts, and then remove the Right Panel right panel. Bolts (8) I002632 7) Take out the six (6) bolts, and then remove the Bolts (6) Exhaust Air Dust exhaust air duct. I002633 7.3 Removal of Control Panel 1) Disconnect the two connectors (11-pin, 5-pin) from the control panel.

  • Page 57: Removal Of Condenser Fan Assembly

    Repair Section 7.4 Removal of Condenser Fan Assembly 1) Take out the two (2) screws, and then remove the sub-control box cover. Sub-Control Box Cover Screws (2) I002637 2) Disconnect the three (3) power supply wires from Power Supply Wires (3) the terminal, and disconnect the ground wire.

  • Page 58: Removal Of Evaporator Fan Assembly

    Repair Section 7.5 Removal of Evaporator Fan Assembly Center Panel Evaporator Fan Inlet Ring Evaporator Fan Evaporator Fan Motor Evaporator Fan Casing Cover I002642...
  • Page 59 Repair Section 1) Disconnect the three (3) power supply wires from Terminal the terminal. Power Supply Wires (3) I002643 2) Disconnect the ground wire. Ground Wire I002644 3) Take off the two (2) wing nuts, and then remove the cover. Wing Nuts (2) Cover I002650...
  • Page 60 Repair Section 5) Loosen the set bolt using a box wrench, and then remove the evaporator fan. CAUTION Set Bolt • Set Bolt Torque Value (for Installation): - 13.3 ± 0.6 ft•lbf (18.0 ± 0.8 N•m) Evaporator Fan I002646 6) Take off the four (4) nuts, and then remove the evaporator fan motor together with the inlet ring.

  • Page 61: Removal Of Electrical Components

    Repair Section 7.6 Removal of Electrical Components (1) Control box 1) Take out the four (4) bolts, and then remove the front panel. (See “Disassembly” on page 55.) 2) Take out the three (3) screws, and then open the control box cover. (See “Disassembly” on page 55.) 3) Disconnect each connector, and then remove the electrical parts from the control box.

  • Page 62: Refrigerant System Repair

    8. REFRIGERANT SYSTEM REPAIR 8.1 Repair of Refrigerant System • In case there is a leak, obstruction, or trouble in the refrigerant system of the Classic 40, replace or repair the part in question. After replacing any component all connections must be brazed.
  • Page 63 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 64: Removal Of Refrigeration Cycle Components

    Repair Section 8.2 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.

  • Page 65: Charging The System With R-410A Refrigerant

    Repair Section 8.3 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 66 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 67 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 min or more, and confirm that the gauge zero indicates there is a leak.
  • Page 68 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 69 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 70: 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 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 71 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 72: 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 73: Evaporator Fan Assembly

    Repair Section 9.4 Evaporator Fan Assembly • Install evaporator fan. Allow a clearance of 0.06 in (1.5 mm) or more on side of the evaporator fan. CAUTION • Tightening torque: 0.06 in 0.06 in - 13.3 ± 0.6 ft•lbf (18.0 ± 0.8 N•m) (1.5 mm) (1.5 mm) or more...
  • Page 74 DENSO SALES CALIFORNIA, INC. Long Beach, CA 90810 www.movincool.com P/N: SV0033-01 Second Issue: June 2010...

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