Movincool CLASSIC 18 Service Manual
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Movincool CLASSIC 18 Service Manual

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SERVICE MANUAL

CLASSIC 18
Unit Serial Number Range: 0211XXXXC18 to Present
DocID: 00G00090E

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Summary of Contents for Movincool CLASSIC 18

  • Page 1: Service Manual

    SERVICE MANUAL CLASSIC 18 Unit Serial Number Range: 0211XXXXC18 to Present DocID: 00G00090E...

  • Page 2: Serial Number Location And Identification

    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............... 5 Definition of Terms .
  • Page 4 Table of Contents Repair Section 8. TROUBLESHOOTING Troubleshooting ..............34 Self-Diagnostic Codes .

  • Page 5: Precautions For Safety

    Operation Section 1. PRECAUTIONS FOR SAFETY 1.1 Foreword • This manual has been published to service the MovinCool Classic 18. Please use this service manual only when servicing the Classic 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 6: Specifications

    Operation Section 2. SPECIFICATIONS 2.1 Exterior Dimension Diagram 6-M6 13.0 20.7 16.5 19.3 25.6 (Unit: inch) ILL00580-00...

  • Page 7: Technical Specifications

    Operation Section 2.2 Technical Specifications ITEM SPECIFICATIONS Electronic Features Operation Digital Programmable Electrical Characteristics Voltage Requirement Single-Phase, 208 V/230 V 60 Hz Operating Voltage Max. 250 V Range Min. 198 V Starting Current 33 A/36 A Recommended Fuse Size 15 A 9.1 A/8.8 A 33 A/36 A Cooling Capacity and Power Consumption...
  • Page 8 Operation Section ITEM SPECIFICATIONS Power Cord NEMA Plug Configuration 6-15 × Gauge x Length 14 AWG (3-core) 6 ft (1.8 m) × × × × Dimension 19.4 26.5 41.5 in × × (493 1054 mm) Weight 164 lb (74 kg) Shipping 205 lb (93 kg) Drain Tank Capacity...

  • Page 9: Characteristics

    Operation Section 2.3 Characteristics (1) Cooling capacity curve at 208/230 V 20.6 19.0 17.5 15.9 12.7 104 (40) 95 (35) 86 (30) 77 (25) (15) (20) (25) (30) Wet Bulb Temp. °F (°C) ILL00581-00 (2) Power consumption curve at 208/230 V 104 (40) 95 (35) 86 (30)
  • Page 10 Operation Section (3) Cool air temperature difference curve at 208/230 V 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) Relative Humidity. % ILL00583-00...

  • Page 11: Construction

    Operation Section 3. CONSTRUCTION 3.1 Internal Structure Control Panel Evaporator Inlet Air Thermistor (RTS) Condenser Air Outlet Cooling Air Duct Housing for Housing for Condenser Fan Evaporator Fan Condenser Fan Evaporator and Motor Freeze Protection Thermistor (CTS) Condenser Capillary Tube Compressor and Drain Tank Accumulator...

  • Page 12: 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, Accumulator, Capillary tube The parts above are all connected by copper piping with brazed connections. Evaporator Outlet Pipe Condenser Evaporator Evaporator Inlet Pipe...

  • Page 13: 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 14 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 15 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 gradually.

  • Page 16: 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 Rotor bearing), and the lubrication groove for the shaft journal. The lubrication groove is wider Hollow Shaft than the oil hole.

  • Page 17: Capillary Tube

    Operation Section 4.4 Capillary Tube • The capillary tube is a long thin tube that High Temp./High Pressure utilizes line flow resistance as an expansion Liquid Refrigerant valve. The length and the inner diameter of the capillary tube are determined according to the capacity of the refrigeration system, operating conditions, and the amount of refrigerant.

  • Page 18: Electrical System

    Operation Section 5. ELECTRICAL SYSTEM 5.1 Circuit Diagram Dip Switch OFF (Default) IOLF #1 : ON: Fan Stop Mode (Fan Auto) OFF: Fan Operate Mode (Fan On) #2 : N/A #3 : N/A #4 : ON: The Buzzer Sound Disabled Output Signal AUX2 On Board...

  • Page 19: Control Box

    Operation Section 5.2 Control Box TB2: Terminal Block2 RB: Relay Board TB1: Terminal Block1 RX: Auxiliary Relay CC: Capacitor for Compressor CF: Capacitor for Fan Motor ILL00590-00 (1) Capacitor • The capacitor is used to improve the rotational power of the fan motor and compressor at startup.
  • Page 20 Operation Section (2) Auxiliary relay • The auxiliary relay is normally closed when the unit is in operation (fan or cool), and supplies power to the fan motor. • When current flows across A1 and A2, terminals 13 and 14, 23 and 24, 33 and 34, 43/41 and 44/42 conduct.
  • Page 21 Operation Section (3) Relay board • The relay board contains the dip switch, compressor and fan relays, and a step-down transformer that reduces the line voltage from 208/230 VAC to approximately 12.7 VAC. This voltage is then rectified from 12.7 VAC to 12 VDC and used for relay coil activation. The 12 VDC voltage is sent to the control panel assembly, further being reduced to 5 V for the system logic.
  • Page 22 Operation Section 3) 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 23 Operation Section 4) 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 24: Control Specifications

    • When the FAN button is pressed, the 52ID (fan motor on/off) relay on the relay board turns on, operating the fan. • For the Classic 18, the 52ID relay turns the auxiliary relay on to operate the fan. Specifications:...
  • Page 25 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 26 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 27: Compressor

    Operation Section 5.4 Compressor (1) Compressor motor • The compressor motor is a single-phase motor and is contained within the same housing as the compressor. Specifications: Rated Voltage 208/230 V Rated Power Output 1120 W I002355 (2) Compressor overload relay •...

  • Page 28: Fan Motor

    Operation Section 5.5 Fan Motor • The fan motor is a single phase, induction type. The motor rotates the fan on both the evaporator side and the condenser side at the same time. Specifications: Rated Voltage 208/230 V Rated Power Output 290/350 W I001692 <...

  • Page 29: Drain Tank Switch

    Operation Section 5.7 Drain Tank Switch • The drain switch activates and stops the operation of compressor motor and fan motor when approximately 4.4 gal (16 L) of drain water accumulates in the drain tank. At the same time, control panel display "FL", and compressor and fan operations stop. This system uses a 250 V, 0.1 A rating micro switch for this function.

  • Page 30: Connection And Setting

    Operation Section 6. CONNECTION AND SETTING 6.1 Warning Signal Connection (Output Signal Terminal L+ and L-) • The controller is equipped with a warning signal output relay type (Form C, normally open dry contact) which can be used to monitor the failure conditions. Relay contactor is closed if any of the following conditions has occurred: - Tank Full - Temperature sensor fails...

  • Page 31: Fire Alarm Control Panel Connection (Input Signal Terminal E+ And E-)

    Operation Section 6.2 Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-) • The controller is equipped with a normally 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 on until it has been reset.

  • Page 32: Operation Of Control Panel

    Operation Section 7. OPERATION 7.1 Operation of Control Panel (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 FAN Button Activates/deactivates the fan only mode;...
  • Page 33 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 34: Troubleshooting 8.1 Troubleshooting

    Repair Section 8. TROUBLESHOOTING 8.1 Troubleshooting • Before troubleshooting the system, the following inspection should be performed. WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. (1) Inspection of power supply voltage •...

  • Page 35: Self-Diagnostic Codes

    Repair Section 8.2 Self-Diagnostic Codes • Self-diagnostic codes are displayed on the control board under the following conditions. Output Buzzer Indication Condition Signal (On Board) When the fire alarm control panel input signal is CLOSED, the unit turns off, the LED displays “AL”, and the buzzer turns on.

  • Page 36: Troubleshooting Chart

    Repair Section 8.3 Troubleshooting Chart • To accurately troubleshoot the problem, it is important to carefully confirm the nature of the problem. Common problems are: - Insufficient cooling. - Unit does not operate. - Overflow of drain water. - Abnormal noise or vibrations. - Others.
  • Page 37 Repair Section Condition Possible Cause Remedy Insufficient Cooling Check Area Cause 1. Coil resistance of fan motor. Short or open circuit. Replace fan motor. (0 ohm or ∞ ohm) 2. Fan motor on-off relay (52ID) Open circuit or bad contact. Replace relay board.
  • Page 38 Repair Section Possible Cause Condition Remedy Unit stops operation. Check Area Cause 2. Display code “AS”. Optional condensate pump Remove any blockage or stops pumping water due to kinks from the drain line any kinks/blockage in the or improve hose drain line or due to improper installation.
  • Page 39 Repair Section (3) Drain water overflow Possible Cause Condition Remedy Check Area Cause 1. Drain pan. Cracks in drain pan. Check and replace. 2. Water level in drain pan. Clogged drain hose. Check and replace. 3. Drain hole. Reversed air flow from drain Insert a trap on the hole.

  • Page 40: Basic Inspection

    Repair Section 8.4 Basic Inspection • Perform the following inspections before disassembly. (1) Inspection of plate fins • To inspect the plate fins of the condenser, the air filter must be removed. After removal of the air filters, inspect the plate fins for any dirt, dust, lint, or debris that may have caused insufficient cooling performance of the unit.

  • Page 41: Compressor Inspection

    Repair Section 8.5 Compressor Inspection (1) Compressor motor inspection • Measure resistance across the terminals of the compressor motor. Resistance at 77 °F (25 °C) Approx. 2.41 ohm Approx. 3.05 ohm • If the measured resistance is not equal to the I002356 standard values listed above, replace the compressor.

  • Page 42: Capacitor Inspection (For Fan Motor And Compressor)

    Repair Section 8.7 Capacitor Inspection (For Fan Motor and Compressor) (1) Ohmmeter method • Set the ohmmeter to the 10 M ohm range. Place the two probes against the two terminals Control Box of the capacitor. At first, the ohmmeter indicates small value, then the reading should gradually increase...

  • Page 43: Auxiliary Relay Inspection

    Repair Section 8.8 Auxiliary Relay Inspection • Measure the resistance across terminals A1 and A2. - Standard resistance: 1.6 ~ 2.4 k ohm • If the resistance is out of the range specified above, replace the auxiliary relay. • Check the continuity across the terminals 13 and 14, when the test button is depressed as well as when released.

  • Page 44: Thermistor Inspection

    Repair Section 8.10 Thermistor Inspection • Use an ohmmeter to check the resistance across 2-pin connector normal temperature (77 °F (25 °C)). Specification Type Characteristic Evaporator Inlet Air Thermistor 5 k ohm at 77 °F (25 °C) (RTS) Freeze Protection Thermistor 5 k ohm at 77 °F (25 °C) (CTS) I001695...

  • Page 45: Parts Construction

    Repair Section 9. DISASSEMBLY WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. 9.1 Parts Construction Evaporator Inlet Air Thermistor Upper Panel Cooling Air Duct Control Panel Right Side Panel...

  • Page 46: Disassembly

    Repair Section 9.2 Disassembly 1) Remove the drain tank. Cooling Air Duct Screws (8) 2) Unfasten the two clips and the lower-side hook, and then remove the front panel. 3) Take out the eight (8) screws, and then remove the two cooling air ducts. Front Panel Drain Tank I002611...
  • Page 47 Repair Section 6) Take out the thirteen (13) screws, and then remove the rear panel. Screws (13) Rear Panel I002612 7) Take out the fourteen (14) screws, and then Upper Panel Screws (2) remove the upper panel. Screws (4) CAUTION The two screws (2*) used on the front side of the upper panel differ from the rest.
  • Page 48 Repair Section 10) Unfasten the two connectors (11-pin, 5-pin) from Connectors the control panel. Board Clamp Upper Panel 11) Remove the wiring harnesses from the clamp Control Panel and board clamp. Clamp I001749 12) Take out the seven (7) screws, and then remove the left-side panel.

  • Page 49: Fan Motor Removal

    Repair Section 9.3 Fan Motor Removal Housing for Evaporator Fan Condenser Fan Evaporator Fan Partition Plate Motor Bracket Fan Motor Housing for Condenser Fan ILL00633-00...
  • Page 50 Repair Section 1) Loosen the set screw with a hex key, and then Condenser Fan remove the condenser fan. CAUTION • Set Screw Torque Value (for Installation) - 10.80 ± 2.17 ft•lbf (14.7 ± 3.0 N•m) Set Screw I002571 2) Take off the two (2) nuts, and then remove the Housing for condenser fan housing.
  • Page 51 Repair Section 5) Take off the four (4) nuts, and then remove the fan motor. Nuts (4) Fan Motor I002616...

  • Page 52: Removal Of Electrical Components

    Repair Section 9.4 Removal of Electrical Components WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. (1) Removal of control panel 1) Take out the eight (8) screws, and then remove the control panel.
  • Page 53 Repair Section (2) Removal of wire-harness in control box • Disconnect all the wires from the electrical parts in control box. E- (Red) E+ (Red) TB2: Terminal Block 2 2-P (Brown) L+ (Brown) 2-P (Black) L- (Brown) 3-P (Black) 3-P (Red) 2-P (Red) 52CM4 (White) RB: Relay Board...
  • Page 54 Repair Section (3) Removal of control box 1) Take off the three (3) nuts, and then remove the Control Box control box. Nuts (3) I002606...
  • Page 55 Repair Section (4) Removal of electrical parts • Terminal block 1 (power connection): Remove the two (2) screws from the control box. • Terminal block 2 (signal connection): Remove the two (2) screws from the control box. • Capacitor for compressor: Remove the two (2) screws from the control box. •...

  • Page 56: Full Drain Switch Removal

    Repair Section 9.5 Full Drain Switch Removal 1) Take out the two (2) screws, and then remove the full drain switch cover. Full Drain Switch Cover Screws (2) I002609 2) Unfasten the wiring harness connector. Harness Connector 3) Take out the two (2) screws, and then remove the full drain switch.

  • Page 57: Refrigeration System Repair

    Repair Section 10. REFRIGERATION SYSTEM REPAIR 10.1 Repair of Refrigeration System • When there is a leak, obstruction, or problem in the refrigeration system of the unit, replace or repair the defective refrigeration component. After replacing any refrigeration component, all the connections must be brazed.
  • Page 58 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 cycle to prevent oxidation.

  • Page 59: Removal Of Refrigeration System Components

    Repair Section 10.2 Removal of Refrigeration System Components WARNING • Before replacing any refrigeration component, recover the refrigerant using standard recovery procedures and equipment. • When recovering the refrigerant, use the pinch-off tubes at the low pressure side (tube 1) and high pressure side (tube 2) as shown in figure below.
  • Page 60 Repair Section (1) Removal of compressor assembly 1) Disconnect CC1 and CC2 wires (white) from the TBT Wire capacitor for compressor in the control box. Disconnect TBT wire (black) from the terminal TB1: Terminal Block1 block 1 in the control box. CC2 Wire Control Box WARNING...

  • Page 61: Charging The System With R-410A Refrigerant

    Repair Section 10.3 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 for R-410A only. • Liquid charge (no gas charge). •...
  • Page 62 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 63 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 64 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 65: Refrigerant Charging Work

    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 66 Repair Section 3) Securely place the refrigerant cylinder on a scale Valve Setting Specified Amount with a weighing capacity of 70 lb (30 kg) that is Closed Open of Refrigerant Closed Closed graduated by 0.2 oz (5 g) increments. High Pressure Valve 4) Open the high pressure valve of the gauge Valve of manifold and the valve of the refrigerant cylinder.

  • Page 67: Reassembly

    Repair Section 11. REASSEMBLY 11.1 Reassembly 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 68: Fan Assembly

    Repair Section 4) Braze pipe 1 at point A and H, then braze pipe 2 at point B and G. < NOTE > Pipe 1 and pipe 2 are packaged in the supplied compressor assembly. Pipe 2 5) Re-install overload relay, wires, and plastic cover Pipe 1 after brazing.
  • Page 69 P/N: SV0070-00 First Issue: June 2012...

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