Movincool Classic 60 Service Manual
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Movincool Classic 60 Service Manual

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SERVICE MANUAL
CLASSIC 60
SERIAL NUMBER FROM APRIL 2009 (0409) TO PRESENT
DocID: 00G00043E

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Summary of Contents for Movincool Classic 60

  • Page 1 SERVICE MANUAL CLASSIC 60 SERIAL NUMBER FROM APRIL 2009 (0409) TO PRESENT DocID: 00G00043E...
  • 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 Control Box ..............38 5.14 Compressor Motor Relay .
  • Page 5 Table of Contents Repair Section 6. TROUBLESHOOTING Troubleshooting ..............41 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 60. Please use this service manual only when servicing the Classic 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.

  • Page 7: Specifications

    Operation Section 2. SPECIFICATIONS 2.1 Exterior Dimension Diagram DIA. 1.0 15.8 22.0 11.5 49.4 DIA. 25.1 10.2 4xDIA. 0.5 25.2 29.9 31.5 (Unit: inch) I003016...

  • Page 8: Technical Specifications

    Operation Section 2.2 Technical Specifications Technical Specifications Classic 60 Control Panel Electronic Electronic Features Thermostat Control Electronic Cooling Capacity Capacity 60000 Btu/h (17600 W) Voltage Requirement 3 Phase, 460 V, 60 Hz Total Power Consumption 5.90 kW Electronic Characteristics Current consumption 8.8 A...

  • Page 9: 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 10 Operation Section (2) Cooling capacity curve 1100 1300 1500 1700 (15) (19) (22) (26) (29) 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) I003047...
  • Page 11 Operation Section (3) Power consumption curve 1100 1300 1500 1700 (15) (19) (22) (26) (29) 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) I003048...
  • Page 12 Operation Section (4) Current consumption curve 10.5 10.0 1100 1300 1500 1700 (15) (19) (22) (26) (29) 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) I003049...
  • Page 13 Operation Section (5) Cool air temperature difference curve 27.0(15) 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) 1100 1300 1500 1700 (15) (29) (19) (22) (26) Relative Humidity (%) Total Air Volume CFM (X10 I003050...
  • Page 14 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 2000 (850) (1700) (2550) (3400) Total Air Volume CFM (m I003051...

  • Page 15: Construction

    Operation Section 3. CONSTRUCTION 3.1 Internal Structure Condenser Air Outlet Condenser Fan and Motor Evaporator Air Outlet Control Box Controller Evaporator Condenser Evaporator Fan and Motor High Pressure Room Thermistor (RTS) Switch (HPRS) Freeze Protection Thermistor (CTS) I003017...

  • Page 16: Basic Construction

    • Cooling air duct (optional) can be installed to cool the object. • All air inlets are provided with air filters. CAUTION The Classic 60 should always be placed on the floor. It should not be hung from the ceiling.

  • Page 17: 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 Condenser Compressor Discharge Pipe...

  • Page 18: 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 19: 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 20: 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 21: 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 AC460 V, 3 Phase, 60 Hz #2 : N/A Controller Off (Default) #3 : N/A #4 : On : The Buzzer Sound Disabled 1 2 3 4...

  • Page 22: Control Box And Relay Board

    Operation Section 5.2 Control Box and Relay Board Overcurrent Relay Terminal Block Compressor Motor Relay (for Evaporator Fan Motor) (for Signal Connection) (for Compressor and Condenser Fan Motor) Terminal Block Fan Motor Relay (for Power Cord) (for Evaporator Fan Motor) Transformer Relay Board Fuse R S T...

  • Page 23: Power Supply Requirements

    Colored Wire Fuse 20 A (20 A MAX.) Grounding Terminal Terminal Block of Classic 60 I003021 CAUTION Use a specified 20 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 24 Tightening torque: 0.96 ft•lbf (1.3 N•m) < NOTE > • Classic 60 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 25: 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 26 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 27: 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 28: 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 29: 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 30 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 31: 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 32 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 33 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 34: 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 35 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 36: 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 37: 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 460 V Rated Output 750 W I003027 < NOTE > An internal overload relay is used to protect the fan motor.

  • Page 38: Transformer

    Operation Section 5.12 Transformer • The transformer is designed to convert 460 V to 460 V 215 V and supply power to the control circuit. • An internal protector which activated at 248 °F 240 V (120 °C) is installed on the primary coil of the transformer, and will isolate the power supply when unusual temperature rises occur to prevent the coil from burning.

  • Page 39: Compressor Motor Relay

    Operation Section 5.14 Compressor Motor Relay • The compressor motor relay is a normal open contact relay. 3/L2 5/L3 1/L1 • When the unit is operating in COOL mode, the current is flowing through terminal A1 and A2 of the relay’s coil and causes contactor terminals 1/L1 and 2/T1, 3/L2 and 4/T2, 5/L3 and 6/T3, 13 and 14 to become closed, and the power is supplied to compressor and condenser fan...

  • Page 40: Overcurrent Relay

    Operation Section 5.16 Overcurrent Relay • For the three-phase fan motor, an overcurrent 1/L1 3/L2 5/L3 relay is usually used as a safety device. This prevents the motor coil from burning if an overcurrent situation has occured due to abnormal load on the fan motor, extraordinary Current Setting Dial change in supply voltage, or loss of current in one phase.

  • Page 41: 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 460 V (60 Hz) • Check the phase sequence of the power source. <...

  • Page 42: 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 43: 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 44 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 45 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 46 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 47: 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 48 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 43 to 47.

  • Page 49: Inspection Of Transformer

    Repair Section 6.5 Inspection of Transformer • Measure resistance across the terminals of the 460 V transformer. (All terminals must be disconnected from the unit.) 240 V • Resistance value between terminals at 68 °F (20 °C) - 460 V to 01: 75.0 ohm - 240 V to 02: 27.0 ohm •...

  • Page 50: Inspection Of Compressor Motor

    Repair Section 6.7 Inspection of Compressor Motor • Measure resistance across the terminals of the compressor motor. (All terminals must be disconnected from the unit.) • Between terminals (at 77 °F (25 °C)) - R-C Approx. 0.4 ohm - C-S Approx. 0.6 ohm - S-R Approx.

  • Page 51: Refrigerant System Inspection

    Repair Section 6.10 Refrigerant System 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 •...

  • Page 52: Parts Construction

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

  • Page 53: Disassembly

    Repair Section 7.2 Disassembly 1) Remove the four air filters. Bolts (7) 2) Take out the seven (7) bolts, and then remove the front panel. Front Panel Air Filter Air Filter I002652 3) Take out the ten (10) bolts, and then remove the evaporator panel.
  • Page 54 Repair Section 6) Loosen the two (2) screws, fixing the conduit and disconnect the power cord. Power Cord I002656 7) Take out the ten (10) bolts, and then remove the upper front panel. Bolts (4) Bolts (3) Bolts (3) Upper Front Panel I002657 8) Take out the eight (8) bolts, and then remove the left panel.

  • Page 55: Removal Of Control Panel

    Repair Section 10) Take out the eight (8) bolts, and then remove the Bolts (8) Exhaust Air Duct exhaust air duct. I002660 7.3 Removal of Control Panel 1) Disconnect the two connectors (11-pin, 5-pin) from the control panel. Control Box Cover Connectors Control Panel I002661...

  • Page 56: Removal Of Condenser Fan Assembly

    Repair Section 7.4 Removal of Condenser Fan Assembly 1) Disconnect the five (5) wires of the condenser fan motor from the terminals. Terminal Wires (5) Terminal I002666 2) Disconnect the ground wire. Ground Wire I002667 3) Take off the nut (left-handed screw) and two (2) Nut (1) washers, and then remove the condenser fan.
  • Page 57 Repair Section 4) Take off the three (3) nuts, and then remove the Nuts (3) condenser fan motor. Motor Stay Fan Motor I002740...

  • Page 58: Removal Of Evaporator Fan Assembly

    Repair Section 7.5 Removal of Evaporator Fan Assembly Evaporator Fan Motor Center Panel Motor Stay Evaporator Fan Inlet Ring Evaporator Fan Evaporator Fan Casing I002742...
  • Page 59 Repair Section 1) Disconnect the five (5) power supply wires from Terminals the terminals. Wires (5) I002743 2) Disconnect the ground wire. Ground Wire I002667 3) Take out the four (4) screws, and then remove the inlet ring. I002745...
  • Page 60 Repair Section 4) Take off the four (4) nuts, and then remove the evaporator fan motor together with the motor Nuts (4) stay, inlet ring, and fan. Fan Motor Motor Stay I002746 5) Take off the nut (left-handed screw). Nut (1) (Left-Handed Screw) CAUTION Set Screw...

  • Page 61: Removal Of Electrical Components

    Repair Section 7.6 Removal of Electrical Components (1) Control box 1) Take out the seven (7) bolts, and then remove the front panel. (See “Disassembly” on page 53.) 2) Take out the three (3) screws, and then open the control box cover. (See “Disassembly” on page 53.) 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 60, 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 cutter. Refrigerant 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 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 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 cylinder Air Purging (R-410A). Open The Valve of Refrigerant 2) Loosen the nut on the gauge manifold side of the Cylinder 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 0.12 in (3 mm) or more on side of the evaporator fan. 0.12 in 0.12 in (3 mm) (3 mm) or more or more CAUTION • Tightening torque: - 32.5 ±...
  • Page 74 DENSO SALES CALIFORNIA, INC. Long Beach, CA 90810 www.movincool.com P/N: SV0034-00 First Issue: April 2009...

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