Movincool Classic 40 Service Manual User Manual

SERVICE MANUALCLASSIC 40SERIAL NUMBER FROM MAY 2009 (0509) TO PRESENTDocID: 00G00044EA

Operation Section102.3 Characteristics(1) How to read the cooling capacity curveI003046<Condition>Dry Bulb : 95 °F (35 °C)59 68 77 86(15)113 (45

Operation Section11(2) Cooling capacity curveI003084Dry Bulb Temp. °F (°C)Wet Bulb Temp. °F (°C)20253035404550Cooling Capability (X103 Btu/h)Total Air

Operation Section12(3) Power consumption curveI003085Dry Bulb Temp. °F (°C)113 (45)104 (40)95 (35)68 (20)77 (25)86 (30)Wet Bulb Temp. °F (°C)68 77 86

Operation Section13(4) Current consumption curveI003086Dry Bulb Temp. °F (°C)113 (45)104 (40)95 (35)68 (20)77 (25)86 (30)Wet Bulb Temp. °F (°C)68 77 8

Operation Section14(5) Cool air temperature difference curveI003087Total Air Volume CFM (X102 m3/h)400(7)800(14)1000(17)1200(20)600(10)㪛㪼㫃㫋㪸㪄㪫㩷 °F (°C

Operation Section15(6) Extension static pressure and air volume curve of cool airI003088USAGE RANGETotal Air Volume CFM (m3/h)External Static pressure

Operation Section163. CONSTRUCTION3.1 Internal StructureI003089EvaporatorRoom Thermistor(RTS)Freeze ProtectionThermistor (CTS)Power CordControllerCond

Operation Section173.2 Basic Construction• The interior of Classic 40 is divided into two sections. The front section houses the evaporatorand control

Operation Section184. REFRIGERANT SYSTEM4.1 Refrigerant System ConstructionThe component parts of the refrigerant system include the following:• Compr

Operation Section194.2 Compressor• The compressor used for the unit is hermetically sealed. The compressor and the compressormotor are in one casing.(

© 2010 DENSO SALES CALIFORNIA, INC.All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission

Operation Section204.3 Condenser• The condenser is a heat exchanger with copper tubes that are covered with thin aluminumprojections called plate fins

Operation Section214.6 High Pressure Switch• The high pressure switch prevents thecondenser and compressor from beingdamaged by excessively high press

Operation Section225. ELECTRICAL SYSTEM5.1 Circuit DiagramI003091SW1 COOL ON/OFF SwitchControl BoardDIGSW2 FAN SwitchSW3 SET TEMP SwitchSW4 SET TE

Operation Section235.2 Control Box and Relay BoardI003092TRSE+E-L+L-RCYGTerminal Block(for Signal Connection)Terminal Block (for Signal Connection)Rel

Operation Section245.3 Power Supply Requirements(1) Plug Connection• Check the prongs and surface of the power cord plug for dust/dirt. If dust and/or

Operation Section25(2) Field Wiring Connection1) Power supply• AC 220 V ± 10 %, 3 phase and 60 Hz. Do not connect the unit to any other power supply.•

Operation Section262) Power supply wires• Use at least 12 AWG for the power wires.Cord type (4 wires): SJO, SJOT, SJOOW or equivalentVoltage rating: 3

Operation Section275.4 Wall Thermostat Connection(1) Connecting wall thermostat to unit1) Set the wall thermostat to cooling system mode, since most w

Operation Section285) Install the wall thermostat to the proper location inside the room where it can be convenientlyaccessed. Do not install the wall

Operation Section295.5 Warning Signal Connection (Output Signal Terminal L+ and L-)• The controller is equipped with a warning signal output relay typ

Table of ContentsTable of ContentsOperation Section1. PRECAUTIONS FOR SAFETY1.1 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Section305.6 Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-)• The controller is equipped with a normal open input sign

Operation Section315.7 Basic Operation(1) Control panel• Before operating the unit, it is important to be familiar with the basic operation of the con

Operation Section32(2) Fan only mode • When the FAN button on the control panel is pressed, the FAN “ON” LED illuminates, and thefan operates. At this

Operation Section335.8 Relay Board• The relay board contains the compressor and fan on relays, in addition to a step-downtransformer that converts the

Operation Section34(2) Input signal• The relay board receives inputs from the control panel, sensors, and external devices to performdevice control.Co

Operation Section35(3) Dip switch setting• The controller is equipped with a four position dip switch that defaults in the OFF position. Thedip switch

Operation Section365.9 Control Specifications(1) Fan control• When the FAN button is pressed, the 52ID (fan motor on/off) relay on the relay board tur

Operation Section37(4) Compressor time delay control (compressor protection)• Compressor protection consists of a time delay program within the microp

Operation Section38(6) Temperature control• During cool mode, temperature control changes the 52CM (compressor on/off) relay statusaccording to RTS te

Operation Section395.11 Fan Motor(1) For evaporator• The fan motor is a three-phase, induction type. • The following table shows the specifications of

Table of Contents5.13 Compressor Motor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Section405.12 Control Box(1) Reverse Phase Protector• The reverse phase protector is operated atnominal voltage of three-phase, 220 V. • If

Operation Section415.14 Fan Motor Relay• The fan motor relay is a normal open contactrelay.• When the unit is operating, the current isflowing through

Operation Section425.16 Temperature Thermistor• The room thermistor (RTS) is installedupstream of the evaporator, and detectsevaporator inlet temperat

Repair Section436. TROUBLESHOOTING6.1 Troubleshooting• Before troubleshooting the system, the following inspection should be performed.(1) Inspection

Repair Section446.2 Self-Diagnostic Codes• Self-diagnostic codes are displayed on the control board under the following conditions andclear method is

Repair Section456.3 Troubleshooting Chart• To accurately troubleshoot the problem, it is important to carefully confirm the nature of theproblem. Typi

Repair Section46ConditionPossible CauseRemedyChecking Area CauseAir volumenormalCompressor operates.1. Usage conditions(high temperature).Operation ne

Repair Section47(2) Unit does not start (operate)ConditionPossible CauseRemedyChecking Area CauseDoes not operate at allControl Panel display turns of

Repair Section48ConditionPossible CauseRemedyChecking Area CauseStops immediately after startingControl panel display normally.1. Fan on-off relay on

Repair Section49(3) Abnormal noise or vibration• To prevent abnormal noise or vibration, carefully determine the source of the problem and comeup with

Table of ContentsRepair Section6. TROUBLESHOOTING6.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Section50(3) Inspection of cooling capacity performance• Measure the difference in temperature between the inlet of the evaporator and the cool

Repair Section516.5 Inspection of Fan Motor• Measure resistance across the terminals of thefan motor (except the ground terminal). (Allterminals must

Repair Section526.6 Inspection of Compressor Motor• Measure resistance across the terminals ofthe compressor motor. (All terminals must bedisconnected

Repair Section536.8 Wiring Connection Inspection• While referring to the wiring diagrams, check the connection of each wire.CAUTIONSecure the wires us

Repair Section547. DISASSEMBLY7.1 Parts ConstructionI003099Power CordCoverCover forSub-Control Box Front Right PanelFront Left PanelTerminal BlockLeft

Repair Section557.2 Disassembly1) Remove the four air filters.2) Take out the four (4) bolts, and then remove thefront panel.3) Take out the three (3)

Repair Section566) Take out the eight (8) bolts, and then remove theright panel.7) Take out the six (6) bolts, and then remove theexhaust air duct.7.3

Repair Section577.4 Removal of Condenser Fan Assembly1) Take out the two (2) screws, and then remove thesub-control box cover.2) Disconnect the three

Repair Section587.5 Removal of Evaporator Fan AssemblyI002642Center PanelEvaporator Fan MotorEvaporator Fan Inlet RingEvaporator FanEvaporator Fan Cas

Repair Section591) Disconnect the three (3) power supply wires fromthe terminal.2) Disconnect the ground wire.3) Take off the two (2) wing nuts, and t

Operation Section61. PRECAUTIONS FOR SAFETY1.1 Foreword• This manual has been published to service the MovinCool Classic 40. Please use this servicema

Repair Section605) Loosen the set bolt using a box wrench, and thenremove the evaporator fan.CAUTION• Set Bolt Torque Value (for Installation):- 13.3

Repair Section617.6 Removal of Electrical Components(1) Control box1) Take out the four (4) bolts, and then remove the front panel. (See “Disassembly”

Repair Section628. REFRIGERANT SYSTEM REPAIR8.1 Repair of Refrigerant System• In case there is a leak, obstruction, or trouble in the refrigerant sys

Repair Section63(4) Use of dry nitrogen gas• During brazing, the inside of the pipe undergoes an oxidative reaction due to the brazing flame.Introduce

Repair Section648.2 Removal of Refrigeration Cycle ComponentsCAUTION• Before any refrigeration cycle component can be replaced, it is necessary to rec

Repair Section658.3 Charging the System with R-410A Refrigerant• Always ensure that the refrigerant system has been properly evacuated before charging

Repair Section66(1) Connection of gauge manifold1) Properly remove the crushed end of the pinch-offtube at the high pressure side and the lowpressure

Repair Section67(3) Checking vacuum1) Leave the high pressure valve and the lowpressure valve of the gauge manifold closed forfive min or more, and co

Repair Section68(4) Checking gas leak1) Remove the charging hose (green) from thevacuum pump, and connect the hose to therefrigerant cylinder (R-410A)

Repair Section69(5) Evacuation (repeat)1) Close the valve of the refrigerant cylinder. Thenremove the charging hose (green) from therefrigerant cylind

Operation Section72. SPECIFICATIONS2.1 Exterior Dimension DiagramI003082(Unit: inch)10.05.125.8DIA. 13.8DIA. 22.010.020.712.943.55.110.24.36xM62x6xM6D

Repair Section708.4 Refrigerant Charging Work(1) Refrigerant charging1) Remove the charging hose (green) from thevacuum pump, and connect it to the re

Repair Section71(2) Removal of gauge manifold1) Crimp the pinch-off tube with a pinch-off tool.2) Remove the gauge manifold and the processtube fittin

Repair Section729. REASSEMBLY9.1 Removal of Unit• Reassemble the unit in the reverse order of removal. Described below are the parts that requirespeci

Repair Section739.4 Evaporator Fan Assembly• Install evaporator fan. Allow a clearance of 0.06in (1.5 mm) or more on side of the evaporator fan.CAUTIO

DENSO SALES CALIFORNIA, INC.Long Beach, CA 90810www.movincool.comP/N: SV0033-01 Second Issue: June 2010

Operation Section82.2 Technical SpecificationsITEM SPECIFICATIONSElectronic Features Operation ElectronicControl ElectronicElectronic Characteristics

Operation Section9• Specifications are subject to change without notice.< NOTE >*1 Rated at evaporator external static pressure 0.63 IWG (157 Pa