MovinCool Classic 40 Service Manual
Contents
1. Dip Switch 1 On Fan Stop Mode Fan Auto G YRC RIS CTS HPRS ON Off Fan Operate Mode Fan On External AC220 V 3 Phase 60 Hz Controller 9 O c or eft gt BE E NA Geer 1 2 3 4 4 0n The Buzzer Sound Disabled OCH i t MF a Es Ur S s a 1 Ua 2 ch 97 98 4 Control Box 224 n Vif ve OCF2 7 o 3L 34 w11 97 88 3 42 LL 08 a Ss Lg 6 co 99 Ss RCE 206 rane s2 e te 95 96 152CM CN15 CN16 CN03 ent EUR IN I Ho l 4 OC crot 1214 els ct E AU Hei 6 010 5 8220 V ON UT a TE A faco A2 a eA CA ap Dip Switch He 784 Ka OCF2 el socer Iz 520D1 520D2 Tl el He Z1 t 1 9 T m v22 RB H 3l ja tft 75 177 5 Ne o y leng CH34leel CN21 99 9 CNZ OOOO 0000 CN23 ras i w22 Cas 4 m a slote amp 9 Fire Alarm G ji Output Input On Board Signal Controll ol jo CEP AP Attachment Plug MC Compressor Motor TB1 Terminal Block RB Relay Board TB2 Terminal Block CN1 Connector for RPHR TB3 Terminal Block CN2 Connector for RTS TB4 Terminal Block CN3 Connector for HPRS MF1 Evaporator Fan Motor RTS Room Thermistor MF2 Condenser Fan Motor CTS Freeze Protection Thermistor RPHR Reverse Phase Protector CB Control Board MCF Fan Motor Relay G Grounding MCC Compressor Motor Relay I2. Unit inch 1003082 8 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 Starting Current Min 198 V Max 242 V 72A Recommended Fuse Size 25A Cooling Capacity and Power Consumption Evaporator 95 F 35 C Total Cooling Capacity 39000 Btu h 11400 W 60 RH Sensible Cooling Capacity 16500 Btu h 4830 W RE SC Power Consumption 4 20 kW Current Consumption 14 0A Power Factor 79 Refrigerant Circuit Compressor Compression Type Hermetic Scroll Output 2 30 kW Evaporator Plate Fin Condenser Plate Fin Evaporator Type of Fan Centrifugal Fan Air Flow 1060 CFM 1800 m3 h Max External Static Pressure 2 1 72 IWG 430 Pa Motor Output 0 75 kW Condenser Type of Fan Propeller Fan Air Flow 2650 CFM 4500 m3 h Max External Static Pressure 0 05 IWG 12 Pa Motor Output 0 40 kW Refrigerant Type R 410A Amount 3 90 Ib 1 77 kg Signal Connection Fire Alarm Input Dry contact type recommended No voltage contact input Contact resis tance less than 100 ohm Warning Signal Output 2 A at 30 V DC AC or less resistive load Shipping Power Cord NEMA Plug Configuration L15 3
3. Operation Section 37 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 Time Delay 120 sec 1st Time After initial set up reset circuit breaker etc Compressor turns off and on immediately within 120 sec Turn ON Example Compressor turns off and on more than 120 sec ae Controller Status OFF Compressor ON Status EE 52CM i X VL Uess than 5 sec Delay Time SR 120 sec ile e for Extended Period Delay Time 120 sec after last turn off Reference Initial turn on Within 120 sec after the power cord is connected to the power supply the compressor will start with delay timer After 120 sec since the power cord was connected to the power supply the compressor will start without delay timer 1001688 5 Automatic restart and recovery function The microprocessor contains a feature that automatically restart the unit after power is lost and regained and also has memory to store and recover operation status in the even of a power loss Status of memory during power interrupti
4. display turns El off Replace fuse on the relay board 5 Transformer Defective transformer Replace transformer 6 Reverse phase protector Open circuit or insufficient Replace reverse phase contact protector 1 Display code E1 Improper room thermistor Check connection connection Defective room thermistor Replace room thermistor short or open 2 Display code E2 Improper freeze protection Check connection thermistor connection Defective freeze protection Replace freeze protection thermistor short or open thermistor 3 Display code E4 Defective fan motor Replace fan motor cm Control Defective overcurrent relay Replace overcurrent relay ontro oe Panel See Stops after running a while of Troubleshooting on a display page 48 display oh a error 4 Display code CF Defective compressor Replace compressor codes page 48 See Stops after running a while of Troubleshooting on 5 Display code HP Improper high pressure switch connection Check connection Defective high pressure switch short or open Replace high pressure switch page 48 See Stops after running a while of Troubleshooting on 6 Display code AL Input fire alarm signal from fire alarm system Check fire alarm system 48 Repair Section Possible Cause Condition Remedy C
5. 1 Connecting wall thermostat to unit Operation Section 27 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 G Fan On Off Y Cooling On Off and RC Cooling Transfer Common Wall Thermostat Connector Name Unit Connector Name Function RC RC Common Y Y Cool On Off G G Fan On Off 4 Connect the wire harness from the terminal of the unit to the thermostat according to the labels shown below Thermostat B UR RERO RU G Y W RCRH O Remove Factory Installed Jumper 1003023 NOTE gt Use thermostat that is compatible with millivolt system Do not connect thermostat to AC power source 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 Heat
6. 30 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 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 NOTE Use recommended fire alarm signal wire size from 16 AWG to 26 AWG for a solid wire or 16 AWG to 22 AWG for a stranded wire with ring terminal for 6 stud size Connect the fire alarm device to terminal E Unit Terminal Fire Alarm Device A Ear o and E according to its polarities Open Dry Contact 2Aat 30 VDC or 2Aat 30 VAC resistive load pce cn 1003206 Operation Section 31 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 N 1 COOL sch J mo AUTO 1 COOL ON OFF Button Activates deactivates the cool mode turns the unit off 2 FAN Button Activates deactivates the fan only mode turns the unit off 3 SET TEMP Buttons A V Increases decreases the temperature set point during cool mode 4 Room Temperature Shows a blinking set point temperature for 5 sec t
7. 86 30 X 77 25 68 20 59 15 68 20 77 25 86 30 Wet Bulb Temp F C Dry Bulb Temp F C 50 i 1 45 40 35 7 VALL 30 25 Cooling Capability X103 Btu h 20 7 D 400 600 800 1000 1200 7 10 14 17 20 Total Air Volume CFM X10 m3 h 1003084 Operation Section 3 Power consumption curve 2 68 20 SS 7 86 95 104 25 30 35 40 Wet Bulb Temp F C 113 45 104 40 95 35 86 30 77 25 68 20 Dry Bulb Temp F C 1 SEN l E m 400 600 800 1000 1200 7 10 14 17 20 Total Air Volume CFM X10 m3 h 1003085 4 Current consumption curve Operation Section ML 68 20 SS 7 86 95 104 25 30 35 40 Wet Bulb Temp F C 113 45 104 40 95 35 86 30 77 25 68 20 Dry Bulb Temp F C SS 16 SS 13 8 12 E SS 11 cpu 400 600 800 1000 1200 7 10 14 17 20 Total Air Volume CFM X10 m3 h 1003086 Operation Section 5 Cool air temperature differ
8. 5 ELECTRICAL SYSTEM 5 1 Circuit DIagralis eheu bet de Ee Bahia Ee Hasson Cath a A Shonen nan 22 5 2 Control Box and Relay Board 23 5 3 Power Supply Requirements 0 00 eect eee ene 24 5 4 Wall Thermostat Connection 27 5 5 Warning Signal Connection Output Signal Terminal L and 29 5 6 Fire Alarm Control Panel Connection Input Signal Terminal E and E 30 b Basic Operation a sed e L eure e ge de i tede ia 31 0 8 Polay BOO oo eet ebbe Reb npa Ax PU eC pd Ae deg eder 33 5 9 Control Specifications 2 2 6 hr 36 5 10 Gompr sSOr ara a apuro EE MENU EE RUE aie Rn Ue RA S E RARUS AULAE RE EXER RADAR d 38 LG FanMOtorz xsv Eve peru qu ku ER epe Gace EXEAT REY 39 b412 Gontrol BOX amens toe ree etn ear CE tr des nier eo OD Ree dire UE Ere a 40 Table of Contents 5 13 Compressor Motor Pelz 40 5 14 Fan MotorRelay ces Rt E ERR Sheath eaten a ER EET 41 5 15 Overcurrent Helay ss 41 516 Temperature ThermiStOr Suse masa as a Ai dE dE E AE RRE eie Table of Contents Repair Section 6 TROUBLESHOOTING 6 1 Troubleshooting sn a a a ra A E EB pi a eee DER CA a 43 6 2 Self Diagnostic Codes 44 6 3 Troubleshooting Chat 45 6 4 Basic Inspection erret xe ER RE ex Oh Rea RR KNEES ERE NE EE SD ERES 49 6 5 Inspection of Fan Motor 51 6 6 Inspection of Compressor Motor 52 6 7 ThermistorInspectioni i e tn LER ede eee he eee EET I ER EET E 52 6 8 Wiring Connection In
9. NOTE When the compressor shuts off the compressor motor may run backward for a moment or two until internal pressures is equalized This has no effect on compressor durability but may cause an unexpected sound after the compressor is turned off and should not be diagnosed as a malfunction 20 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 4 4 Capillary Tube The capillary tube is a long thin tube that 4 5 utilizes line flow resistance as an expansion 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 The high pressure high temperature liquid refrigerant sent from the condenser expands rapidly as the refrigerant is sprayed out through gt C oue High Temp High Pressure Liquid Refrigerant Low Temp Low Pressure Gas and Liquid Mixture 1001887 the fixed orifice in the capillary tube As a result the temperature and state of the refrigerant becomes low and mist like and therefore evaporates easily Evaporator The evaporator is a heat exchanger covered with plate fins Heat is remo
10. of Refrigerant A Cylinder To Process Tube Fitting Charging Hose Green Cylinder R 410A Refrigerant 1001901 Valve Setting LO Hi LO HI Closed Open Gauge Reading Closed Closed 57 psi 390 kPa Low Pressure Valve Closed Valve jn Cylinder R 410A Refrigerant Cylinder Valve Open 7 Side Tube Refrigerant Open High Pressure Process Tube Fitting High Pressure 1002228 1 Remove the charging hose green from the vacuum pump and connect the hose to the refrigerant cylinder R 4104 2 Loosen the nut on the gauge manifold side of the charging hose green 3 Open the valve of refrigerant cylinder perform air purging in the charging hose green Then tighten the nut 4 Open the high pressure valve of the gauge manifold Charge the system with refrigerant until the low pressure gauge indicates 57 psi 390 kPa After charging is complete close the high pressure valve 5 Open the valve of refrigerant cylinder perform air purging in the charging hose green Then tighten the nut 6 Check carefully for gas leaks inside the refrigerant system using the gas leak tester 7 Repair any leak WARNING Do not attempt any repair on a charged system WARNING Before checking for gas leaks fully confirm that there is nothing flammable in the area to cause an explosion or fire Contact of refrigerant with
11. 3 Connect the charging hoses red high pressure side for the gauge manifold to the process tube fitting lt NOTE gt Connect the hoses using care not to mistake the high pressure side for the low pressure side and vice versa 4 Connect the charging hose green at the center of the gauge manifold to the vacuum pump 1 Open the high pressure valve HI of the gauge manifold 2 Turn on the vacuum pump to start evacuation Evacuate the system for approximately 15 min 3 When the low pressure gauge indicates 30 inHg 100 kPa or larger turn off the vacuum pump and close the high pressure valves of the gauge manifold Repair Section 67 3 Checking vacuum Waive Satin 1 Leave the high pressure valve and the low L Ives closed for 5 GER pressure valve of the gauge manifold closed for pressure gauge returning to five min or more and confirm that the gauge zero indicates there is a leak pio pointer does not return to zero 2 If the gauge pointer returns gradually to zero there is a leak somewhere in the system this Pipe Brazing could also include gauge manifold Perform leak 1002184 check according to procedure indicated in the next step Once leak has been found and repaired evacuate the system once more and confirm system holds vacuum 68 Repair Section 4 Checking gas leak Valve Setting LO Closed Air Purging E Open The Valve
12. power supply wires from the terminal and disconnect the ground wire Tr Power Supply Wires NI SS Ca v Ro e Ground Wire 902630 5 Take out the eight 8 bolts and then remove the Left Panel left panel 1002631 56 Repair Section Right Panel Bolts 8 1002632 Bolts 6 Exhaust Air Dust 1002633 pio LS 1002738 rs Screws 4 1002634 6 Take out the eight 8 bolts and then remove the right panel 7 Take out the six 6 bolts and then remove the exhaust air duct 1 Disconnect the two connectors 11 pin 5 pin from the control panel 2 Take out the eight 8 screws and then remove the control panel Repair Section 57 7 4 Removal of Condenser Fan Assembly aa c 1002637 Terminal C Ground Wire 1002638 1002639 Motor Stay Fan Motor NANA AN 1002640 1 Take out the two 2 screws and then remove the sub control box cover 2 Disconnect the three 3 power supply wires from the terminal and disconnect the ground wire 3 Take off the nut left handed screw and two 2 washers and
13. When the FAN button is pressed again the fan stops 3 Cool mode When the COOL ON OFF button is pressed the FAN ON LED illuminates and room temperature is shown on the display At this time the compressor and fan begin to operate to provide cooling When the COOL ON OFF button is pressed again the compressor and fan stop When the COOL ON OFF button is pressed in fan only mode room temperature is shown on the display and the compressor operates to provide cooling If room temperature reaches the set temperature during cooling operations the compressor stops and only the fan continues to operate Fan operate mode Initial setting NOTE gt The fan only mode will not operate after the cool mode has been activated Once the cool mode is activated the unit cannot be turned off by pressing the fan button Rather the COOL ON OFF button must be pressed Fan stop mode In fan stop mode if room temperature reaches the set temperature during cooling operations both the compressor and fan stop The fan stop mode setting can be changed using the dip switch on the relay board For details see Dip switch setting on page 35 During cooling operations when in the fan stop mode the FAN AUTO LED illuminates 4 Change temperature mode C and F The temperature display can be switched between C and F by holding down the SET TEMP buttons A V and the FAN button simultaneously for at
14. an open fire generates toxic gas Repair Section 69 5 Evacuation repeat Valve Setting 1 Close the valve of the refrigerant cylinder Then Galig a a remove the charging hose green from the 30 inHg 100 kPa or larger refrigerant cylinder and connect it to the Low Pressure Valve High Pressure Gauge refrigerant recovery machine High Pressure Valve NOTE gt High Pressure Keep the high pressure valve and the low Side Tube Vacuum Pump in Operation pressure valve of the gauge manifold closed 1002227 2 Using procedure in the Evacuation evacuate the system until the low pressure gauge indicates 30 inHg 100 kPa or larger For 15 min or more 3 After evacuation is complete close the high and the low pressure valves of the gauge manifold N CAUTION Make sure to evacuate the system twice or more using the repetitive vacuum method Evacuate the system an additional time on rainy or humid days 70 Repair Section 8 4 Refrigerant Charging Work 1 Refrigerant charging Valve Setting LO Closed Air Purging KN F Open The Valve of Refrigerant Cylinder To Process Tube Fitting Charging Hose Green Refrigerant Cylinder R 410A 1001901 Valve Setting LO Hi Specified Amount Lo HI gt Closed Open of Refrigerant Closed Closed High Pressure Valve Valve of Refr
15. curls thereby opening the output contact across terminals 95 and 96 This output contact shuts off the auxiliary relay circuit and brings the unit to a stop Set the current dial according to the table shown below Operation Section 41 1003096 1 L1 2 T1 3 L2 4 T2 1 L1 2 T1 Contact Rating Tripping Current For evaporator fan motor 220V 3A 2 8 A For condenser fan motor 220 V 3 A 2 0A 5 L3 6 T3 3 2 S LI Current Setting Dial 97 95 412 63 98 96 o A2 1003034 42 Operation Section 5 16 Temperature Thermistor e The room upstream of the evaporator evaporator inlet temperature as a resistance value e The freeze protection thermistor CTS is installed in the evaporator outlet piping and detects low temperature on the evaporator as a resistance value thermistor RTS is installed and detects 1001695 Freeze Protection Thermistor CTS 5k ohm at 77 F 25 C 83 C or more 0 3 k ohm or less at 181 F 83 C or more Specification Type Characteristic Short Detection Open Detection 0 3 k oh t181 F 180koh t 29 F Room Thermistor RTS _ 5 k ohm at 77 F 25 C ROC us Meg 34 C or less 180 k ohm or more at 29 F 34 C or less Repair Section 6 TROUBLESHOOTING 6 1 Troubleshooting Before trouble
16. device abnormal higher than relay s page 47 current setting value 2 To Reset Hold down the SET TEMP A V buttons simultaneously for 3 N sec M Loss of cooling When the room temperature minus 1 See Trouble shooting chart on O O detection the freeze protection temperature is page 47 less than 9 F 5 C for 1 minute 2 To Reset Hold down the SET and this condition occurs 3 times TEMP A V buttons simultaneously for 3 N sec 4 Activation of high When high pressure switch is 1 See Trouble shooting chart on O O pressure switch activated 3 times in 24 hr HP page 47 blinks 2 To Reset Hold down the SET When high pressure switch is TEMP A V buttons activated 10 times in 24 hr HP simultaneously for 3 turns on sec Detection of unit stop Input fire alarm signal from fire alarm 1 Check fire alarm signal off O O signal from fire alarm system 2 To Reset Hold down the SET System TEMP A V buttons simultaneously for 3 sec SS Repair Section 45 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 1 Insufficient cooling Cooling system problem generally results from electrical or mechanical components such as fan m
17. least three sec 5 Diagnostic code Most of the diagnostic codes can be RESET by holding down the SET TEMP buttons A V simultaneously for at least 3 sec For details see Self Diagnostic Codes on Page 44 Operation Section 33 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 Lastly the relay board also contains the dip switch 1 Relay board fuse The relay board fuse is the only serviceable component on the relay board assembly This fuse provides protection against damage to the step down transformer The fuse must be replaced with the exact same part or a suitable equivalent Specifications 5A 250 VAC N CAUTION Failure to use the exact same fuse may result in damage to the unit and or components and will also void the unit warranty 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 SW1 ON OFF Button On off control for unit operation Turns the unit on and o
18. then remove the condenser fan N CAUTION Tightening torque for Installation 32 5 3 6 ftelbf 44 1 4 9 Nem 4 Take off the four 4 nuts and then remove the condenser fan motor 58 Repair Section 7 5 Removal of Evaporator Fan Assembly Center Panel Evaporator Fan Inlet Ring Evaporator Fan Evaporator Fan Motor Evaporator Fan Casing Cover 1002642 Terminal LE oe T Power Supply Wires BA e 1002643 qu round Wire 1002644 1002650 Wing Nuts 4 1002645 Repair Section 59 1 Disconnect the three 3 power supply wires from the terminal 2 Disconnect the ground wire 3 Take off the two 2 wing nuts and then remove the cover 4 Take off the four 4 wing nuts and then remove the evaporator fan casing Repair Section 60 o Set Bolt Evaporator Fan os 1002646 Ge 1002647 Fan Motor K Inlet Ring 1002648 5 Loosen the set bolt using a box wrench and then remove the evaporator fan N CAUTION Set Bolt Torque Value for Installation 18 3 0 6 ftelbf 18 0 0 8 Nem 6 Take off t
19. 0 Gauge x Length 12 AWG 4 core x 6 ft Dimension WxDxH 25 8 x 43 5 x 38 0 in 656 x 1106 x 965 mm Weight Net 344 Ib 156 kg 396 Ib 180 kg Operation Section 9 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 Specifications are subject to change without notice NOTE 1 Rated at evaporator external static pressure 0 63 IWG 157 Pa 2 Confirm pressure drop of duct Operation Section 2 3 Characteristics 1 How to read the cooling capacity curve Example Condition Dry Bulb 95 F 35 C Wet Bulb 77 F 25 C Air Volume 1500 CFM 2550 m h lt Cooling Capacity gt MIN 50500 Btu h MAX 58000 Btu h 113 45 104 40 86 30 A 77 25 68 20 59 68 15 20 Wet Bulb Temp F C 86 30 70 EE se s E JS e E E x 55 o 50 O E 45 O 40 SS 900 1100 1304 1500 700 15 19 22 26 29 Total Air Volume CFM X10 m3 h C Dry Bulb Temp F 1003046 2 Cooling capacity curve Operation Section XK 113 45 N 104 40 A 95 35
20. 1 Air flow for the condenser Air drawn from the sides and rear inlets passes through the condenser which extracts the heat This hot air is blown out through the exhaust air duct on top of the unit 2 Air flow for the evaporator Air drawn from the front inlet passes through the evaporator and is cooled This cool air is blown out through the upper outlet on top of the unit Cooling air duct optional can be installed to cool the object All air inlets are provided with air filters 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 2 by viui a By Ac TA AUTO Ea N de Compressor Evaporator Capillary Tube Flow of Refrigerant Capillary Tubes gt ll t Compressor Evaporator 1003090 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 involu
21. 3 Insufficient refrigerant In case the unit is judged to be deficient in cooling capacity make sure to perform the inspections 1 and 2 described in Repair of Refrigerant System on page 62 to confirm the cause of trouble Then charge the system with refrigerant to the specified amount Repair Section 54 1 DISASSEMBLY 7 1 Parts Construction Upper Panel Rear Right Panel Air Filter for Condenser Air Filter for Condenser Filter Frame Filter Frame Control Box Rear Left Gover Panel SS ANAIS DADAS SNS www Freeze Protection SI Thermistor d i S Right Panel RA a Pd Air Filter for Condenser iN E L Filter Frame D gt E A Ss SR s t Eu SONS S AR ALY 72 Kai SSS 25 w a S d AN gt Cover for x SS H Front Right Sub Control Box BS 2 E Panel b d E o Connector e Front Panel l F Terminal Block M Filter Frame Left Panel Front Left Panel Room Thermistor Power Cord l Air Filter for Evaporator 6 over 1003099 Repair Section 55 7 2 Disassembly 1 Remove the four air filters 2 Take out the four 4 bolts and then remove the gt front panel Tse N Bolts 4 pat Air Filter 1002628 3 Take out the three 3 screws and then open the Screws 3 control box cover q E Control Box Cover 1002629 4 Disconnect the three 3
22. Evaporator Air In 1003097 Repair Section 51 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 68 F 20 CH Evaporator fan motor Approx 5 93 ohm at 68 F 20 CH If the measured resistance is not equal to the standard values listed above replace the fan motor Ground Terminal 1003098 Repair Section 6 6 Inspection of Compressor Motor Measure resistance across the terminals of Maximum Ci aranc the compressor motor All terminals must be 0 08 in 2 mm Compressor disconnected from the unit Front View of Connector Cap N CAUTION To disconnect from the terminals pull out the Connector Cap LR plastic connector cap from the compressor Do not pull the electrical wires Wire To reconnect to the terminals insert the plastic 1002595 connector cap straight into the terminals Do not apply excessive force when inserting the plastic connector cap into the terminals Maximum clearance space between compressor and plastic connector is 0 08 in 2 mm Resistance value between terminals at 77 F 25 C R C Approx 1 23 ohm C S Approx 1 47 ohm S R Approx 2 7 ohm If the measured resistance is not equal to these S T2 st
23. NO2 CN03 CNO4 CN11 CN12 CN13 JE E EFT E 4 Position Dip Switch UL 52CM GI CN17 CN25 O 9 00 Me Relay Board Fuse 5A o Emo d CN24 CN21 CN22 CN23 OFF Position 23 1003092 1003081 24 Operation Section 5 3 Power Supply Requirements 1 Plug Connection Check the prongs and surface of the power cord plug for dust dirt If dust and or dirt are present wipe off with a clean dry cloth Check the power cord plug and prongs for damage or excess play If any damage or excess play is found contact your MovinCool reseller or a qualified technician for repair WARNING If the power cord or plug is damaged repair should only be performed by qualified electrical personnel Do not connect disconnect the power cord or attempt to operate buttons with wet hands This could result in electrical shock The power supply should be a dedicated single outlet circuit with a UL approved short circuit and ground fault protective breaker with a recommended fuse size of 25 A 25 A maximum Because of potential safrety hazards under a certain condition we strongly recommend against the use of an extension cord However if you still elect to use an extension cord it is absolutely necessary that it is a UL listed 4 wire grounding ty
24. OLF1 Inner Overload Relay of MF1 HPRS High Pressure Switch IOLF2 Inner Overload Relay of MF2 OCF1 Overcurrent Relay MF1 IOLC Inner Overload Relay of Compressor OCF2 Overcurrent Relay MF2 Control Board DIG S cna SW1 COOL ON OFF Switch 9 i 9 SW2 FAN Switch EE 22 SW3 SET TEMP Y Switch SW Ss HE SW4 SET TEMP A Switch 1003091 5 2 Control Box and Relay Board Compressor Motor Relay for Compressor and Condenser Fan Motor Reverse Phase Protector Overcurrent Relay for Evaporator Fan Motor Operation Section Relay Board Fuse Terminal Block for Signal Connection Relay Board XE l t o QJ o mao BA BLA o jo O Terminal Block for Power Cord Fan Motor Relay for Evaporator Fan Motor O Terminal Block for Signal Connection Overcurrent Relay for Condenser Fan Motor CN15 CN16 CN14 C
25. Perform the Inspection Perform the inspection of cooling performance and check for abnormal noise or abnormal vibration DENSO DENSO SALES CALIFORNIA INC Long Beach CA 90810 www movincool com P N SV0033 01 Second Issue June 2010
26. SERVICE MANUAL CLASSIC 40 SERIAL NUMBER FROM MAY 2009 0509 TO PRESENT MOVINCOOL THE 1 SPOT COOLING SOLUTION DoclD 00G00044EA O 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 of the publisher DENSO SALES CALIFORNIA INC reserves the right to make changes without prior notice MovinCool is a registered trademark of DENSO Corporation Table of Contents Table of Contents Operation Section 1 PRECAUTIONS FOR SAFETY 1 1 Foreword aean Dsk Barr eee ee ete A a a a aa a eae a oh eNom 6 1 2 Definitionof Terms eto ebur aa ien ats Gow bu aub so Du See 6 T3 General Preca tions 2 zoe ete ee RR REI Ruhe RIq s 6 2 SPECIFICATIONS 2 1 Exterior Dimension Diagram 1 0 2 2 0 0 re E m hr 7 2 2 Technical Specifications tenet eee eee 8 2 9 Characteristics senta ana piano Sa E ate B AST Rc de ea aan pU A E 10 3 CONSTRUCTION 3 1 Internal Structure ux dan aie a eI a a aed td a ak a erat 16 3 2 Basic Gonstrugtion 0 17 DES dao EE 17 4 REFRIGERANT SYSTEM 4 1 Refrigerant System Construction 0 2000 18 42 COMPreSSOR as rare 4 a and a EE ER 19 4 3 CondensSer cx caetera deeper eoe a A ang ele DU a AR 20 44 Capillary Tube 20 d Evaporator s s gg a Fer eee Deg dal Peewee a ee Diode dre 20 4 6 High Pressure Switch 2 0 2 0 0c tents 21
27. andard values replace the compressor The overload relay is internal to the compressor T 6 7 Thermistor Inspection Use an ohmmeter to check the resistance across the 2 pin connector at normal temperature 77 F 25 C Specification Type Characteristic Room Thermistor RTS 5 k ohm at 77 F 25 C Freeze Protection Thermistor k oh 77 F 253 CTS 5 k ohm at 25 C 1001695 Repair Section 53 6 8 Wiring Connection Inspection While referring to the wiring diagrams check the connection of each wire N 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 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 Check the component parts of the refrigerant system including piping that could be clogged with refrigerant If clogged with refrigerant only the clogged part is frosted partially In such a case change the part in question 2 Inspection of refrigerant leak Carefully check all connections and each component for leaks whenever the refrigerant system is installed or repaired Use an electronic gas leak tester to inspect the system
28. ce dry nitrogen gas 0 27 gal min 1 L min adjust with the flow regulator through the pinch off tube of the refrigerant NOTE gt Take care not to allow dirt water oil etc to enter into the pipe 5 Vertical Joint Heat the whole brazed fitting to a proper brazing temperature Bring the brazing filler Vertical Down Joint Brazing Filler Metal metal into contact with the fitting so that the Burner brazing filler metal starts flowing by itself Stop heating the fitting as soon as the brazing filler metal has flown into the clearance Since the brazing filler metal flows easily into the portion heated to a proper temperature it is essential to keep the whole fitting at a proper brazing temperature Vertical Up Joint Burner Brazing Filler Metal 1001725 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 During any component replacement involving brazing shield nearby parts with a steel plate etc to protect them from the flame Evaporator Capillary tube Condenser Compressor High Pressure S
29. ence curve 40 50 60 Relative Humidity 70 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 AAS 400 600 800 1000 1200 7 10 14 17 20 Total Air Volume CFM X102 m3 h Delta T F C 1003087 6 Extension static pressure and air volume curve of cool air Operation Section External Static pressure IWG Pa 2 5 623 2 0 498 1 5 374 1 0 245 0 5 125 USAGE RANGE 500 1000 850 1700 Total Air Volume CFM m h 1500 2550 1003088 Operation Section 3 CONSTRUCTION 3 1 Internal Structure Condenser Fan and Motor Condenser Air Outlet Evaporator Fan Motor Evaporator Air Outlet b Controller de j li Control Box j Evaporator Room Thermistor RTS ley Condenser Power Cord Freeze Protection Thermistor CTS 1003089 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
30. er Select Cool only For wall thermostat operation see the operation manual supplied with the wall thermostat 2 Setting unit for wall thermostat connection 1 Press and hold FAN button SET TEMP UP A and DOWN V buttons simultaneously to activate wall thermostat connection 2 Press SET TEMP UP A button to select Sb indicates on LED display for wall thermostat enable function Ho indicates on display for wall thermostat disable function 3 Press COOL button to set wall thermostat function If COOL button is not pressed within 10 sec the setting is automatically confirmed Operation Section eg 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 The relay output contactor is rated 2 A at 30 VDC or 2 A at 30 VAC resistive load and it is compatible with various warning devices such as alarm speaker light indicators etc NOTE Use recommended warning signal wire size from 16 AWG to 26 AWG for a solid wire or 16 AWG to 22 AWG for a stranded wire with ring terminal for 6 stud size Connect the warning device to terminal L and Unit Terminal Warning Device L according to its polarities Relay Output Contactor Open Dry Contact DC12 V 0 01 A 0 02 A 1003205
31. everse Phase Protector Relay Board TB Ga S E Si OQ OT e Terminal Block 1 Fan Motor Relay Overcurrent Relay 2 Terminal Block 3 for Power Cord for Evaporator Fan Motor for Condenser Fan Motor for Signal Connection 1003100 Repair Section 8 REFRIGERANT SYSTEM REPAIR 8 1 Repair of Refrigerant System 1 2 3 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 Proper brazing techniques It is desirable to use a slightly reducing flame Oxyacetylene is commonly used since it is easy to judge and adjust the condition of the flame Unlike gas welding a secondary flame is used for brazing It is necessary to preheat the base metal properly depending on the shape size or thermal conductivity of the brazed fitting The most important point in flame brazing is to bring the whole brazed fit
32. ff Changes the fan control mode between continuous and automatic sw2 FAN Button on off control WS SET TEMP A Increases the set temperature CN17 Button SW4 SET TEMP V Decreases the set temperature Button Sensor Input Specification Symbol Type Connector Characteristic Short Detection Open Detection 5 k ohm at 77 F 181 F 83 C or 29 F 34 C or RTS Room Thermistor S CN11 25 C more less Freeze Protection 5k ohm at 77 F 181 F 83 C or 29 F 34 C or CTS CN12 Thermistor 25 C more less External Input Signal Specification Symbol Signal Specification Function Connector On Activates Defect control On Between 10 to 20 Contact Normally open E E Fire Alarm Input mA at DC12 V p CN15 Off No signal LED shows AL Output signal ON 3 On board buzzer sound OCF1 Th Rela On Between 10 to 20 Off Activates Defect control 5 erma OCF2 Protecti mA at DC12 V Contact Normally closed CN16 rotection Off No signal LED shows FL Output signal ON Off High Pressure Le 1 120 sec Compressor stops HPRS J mA at DC5 V z acid SC CN13 Switch Off No signal 2 120 sec lt Compressor stops LED shows HP output signal ON 3 Dip switch setting Operation Section 35 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 functi
33. he four 4 nuts and then remove the evaporator fan motor together with the inlet ring 7 Take out the three 3 nuts and then remove the evaporator fan motor Repair Section 61 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 4 Remove electrical parts Compressor motor relay Remove two 2 screws and two 2 washers from the holder Fan motor relay Remove the fan motor relay from the holder Reverse phase protector Remove four 4 supports from the control box Over current relay 1 Remove two 2 screws and two 2 washers from the control box Over current relay 2 Remove two 2 screws and two 2 washers from the control box Terminal block 1 Remove two 2 screws from the control box Terminal block 2 Remove two 2 screws from the control box Terminal block 3 Remove two 2 screws from the control box Relay board fuse Take out the fuse from the relay board Relay board Remove six 6 supports from the control box Compressor Motor Relay Terminal Block 2 for Compressor and Condenser Fan Motor Relay Board Fuse for Signal Connection Overcurrent Relay 1 for Evaporator Fan Motor E R
34. hecking Area Cause 1 Fan on off relay on the relay Open circuit or insufficient Replace relay board board contact Stops Control 2 Compressor motor relay Open circuit or insufficient Replace compressor immediately panel contact motor relay after display 3 Compressor relay on the Open circuit or insufficient Replace relay board starting normally relay board contact 4 Reverse phase protector Open circuit or insufficient Replace reverse phase contact protector 1 Resistance of compressor Operation of safety device See Inspection of IOLC due to compressor Compressor Motor on malfunction page 52 2 Refrigerant leakage Insufficient refrigerant or gas Repair and charge Stops after Control leakage refrigerant anel running a s E 3 Dirt on evaporator or Insufficient cooling of Clean evaporator or while PEY condenser evaporator or condenser condenser normally 4 Duct connection condition Leak or clogged by improper Repair duct connection duct connection 5 Duct length and diameter Too long or too small Fix duct diameter of duct Repair Section 49 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 Cause 1 Fan Fan interference Repair
35. hen continuously indicates room Set Point Display temperature 5 Temperature Scale LED Illuminates to indicate the current temperature being displayed is either in C or F 6 ON LED llluminates during fan only mode and cool mode using fan operate mode 7 AUTO LED llluminates during cool mode using fan stop mode LED Display Indication In normal operation LED displays the following indication Display Indication Conditions Right decimal segment is on Power stand by or during fan only mode Im Indicates wall thermostat enable Lit during wall thermostat connection function is set r1 L1 Indicates room temperature when display is solid During cool mode LI Left fig Room temp at 78 F l1 IT Indicates set point temperature During set point temperature adjustment when display is flashing or cool mode on I l Left fig Set Point temp at 75 F 5 sec 1003025 lt NOTE gt The room temperature display range is from 0 F to 109 F When displayed in C the range is from 9 C to 60 C e In Fahrenheit only when the display value is greater than 99 F 100 F 101 F and 109 F are displayed as 00 01 and 09 respectively 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
36. igerant Cylinder Process Tube Fitting m High Pressure Side Tube a Cylinder R 410A VSAY 9 Refrigerant 1001903 1 Remove the charging hose green from the vacuum pump and connect it to the refrigerant cylinder R 410A 2 Loosen the nut on the gauge manifold side of the charging hose green Open the valve of the charging hose green Open the valve of the refrigerant cylinder After air purging tighten this nut and close the valve of the refrigerant cylinder 3 Securely place the refrigerant cylinder on a scale with a weighing capacity of 70 Ib 30 kg that is graduated by 0 2 oz 5 g 4 Open the high pressure valve of the gauge manifold and the valve of the refrigerant cylinder Charge the system with refrigerant to the specified amount Standard Amount of Refrigerant 3 90 Ib 1 77 kg N CAUTION The amount of refrigerant charged has a great effect on the cooling capacity of the unit Charge to the specified amount always observing the scale graduations while charging 5 Close the high pressure valve of the gauge manifold and the valve of the refrigerant cylinder 2 Removal of gauge manifold Pinch Off Tool To Gauge Manifold Side To Refrigerant Cycle Side 1002185 Repair Section 71 1 Crimp the pinch off tube with a pinch off tool 2 Remove the gauge manifold and the process tube fitting Crush the end of the pinch off tube 3 Braze the e
37. interfering section Fan deformation Replace fan Abnormal noise or EAT 2 Compressor fixing nuts Loose nuts Tighten nuts further vibration 3 Piping Pipe interference Repair interfering section 4 Panel fixing screws Looseness of screws Tighten screws further 6 4 Basic Inspection Perform the following inspection before disassembly 1 Inspection of plate fins To inspect the plate fins of either the evaporator or 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 N have caused insufficient cooling performance Q of the unit If cleaning of the fins is necessary it N is recommended that this service be performed N by a qualified service technician Q 1001780 2 Examination of operating environment Operating environments can vary depending on location climate and surrounding conditions Installation location also can cause operational problems Consult your reseller concerning operational environment requirements 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 m JI Thermometer
38. n Apply clean petroleum jelly to the skin Go immediately to a physician or to a hospital for professional treatment Step 1 Connect manifold gauge E 1 Evacuate the system 15 min or more Step 2 30 inHg 100 kPa or more of vacuum When leak is found 2 Stop evacuating the system repair the connection Leave for 5 min or components 3 Check the vacuum Step 3 Connect to refrigerant source Step 4 Test the system for leaks Charge the system with R 410A Step 5 See specifications on page 8 Step 6 Remove manifold gauge 1003045 66 Repair Section 1 Connection of gauge manifold Charging Hose Side Refrigerant Cycle Side Pinch Off Tube 1002183 Low Pressure Valve Closed High Pressure Valve Closed Red Hose Process Tube Fitting High Pressure c Side Tube when stopped 1000568 2 Evacuation Valve Setting LO HI LO HI Closed Open Closed Closed 30 inHg 100 kPa or larger Gauge Low Pressure Valve High Pressure Gauge High Pressure Valve High Pressure Side Tube Vacuum Pump in Operation 1002227 1 Properly remove the crushed end of the pinch off tube at the high pressure side and the low pressure side of the refrigerant cycle with a pipe cutter 2 Fitthe process tube fitting to the pinch off tube on both sides
39. n Contacts ON Closed Contacts Current Minimum Maximum 221 F 105 C 142 F 61 C 47 A 2 10 Operation Section 39 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 DN y Specifications Rated Voltage 220 240 V Rated Output 750W A SN A 1003093 lt NOTE gt An internal overload relay is used to protect the fan motor This relay is built into the fan motor and interrupts the flow of current when abnormally high temperature builds up in the fan motor 2 For condenser 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 400 W 1003094 40 Operation Section 5 12 Control Box 1 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 e The automatically upon correction of the fault reverse phase protector is reset Specifications Rated Line Voltage 220 V 5 13 Compressor Motor Relay The compressor motor relay is a normal open contact relay When the unit is operating in COOL mode the current is flowing through terminal A1 and A2 of the relay
40. nd of the pinch off tube 4 Ensure that a gas leak is not present at the pinched off portion and the brazed end 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 9 2 Compressor Mounting Mount the compressor on the frame using cushions steel collars plate washers and nuts 9 3 Condenser Fan Assembly 1002641 Nut a Plate Washer Cushion Steel Collar 32 5 3 6 ftelbf 44 1 4 9 Nem 1003042 e Install condenser fan Allow a clearance of 0 2 in 5 mm or more on side of the condenser fan dm N CAUTION 5 mm Tightening torque Repair Section 13 9 4 Evaporator Fan Assembly e Install evaporator fan Allow a clearance of 0 06 v v u 2 in 1 5 mm or more on side of the evaporator fan o CAUTION Xe Tightening torque 0 06 in 1 5mm 1 5 mm 13 3 0 6 ftelbf 1 8 0 0 8 Nem ormore IA or more dl Secure the wires using clamps so that they do not come into contact with the edges of the 9 5 Wiring Notice structure etc Secure the wires using clamps in the same position they were before removal 9 6
41. on When the input power is off the status items below are saved in the memory Running status on or off Operating mode Cool mode or fan only mode Set temperature Temperature mode F or C Fan mode Fan operation mode fan on or fan stop mode fan auto 38 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 CH 52CM Compressor Relay OFF Set Temp 3 F Set Temp Set Temp 1 7 C Inlet Air Temperature When compressor operation continues within this range for more than 5 minutes the 52CM relay stops 1002624 7 Fire alarm signal control When receiving the signal from the fire alarm control panel the buzzer sounds and the 52CT signal output relay on the relay board turns on 5 10 Compressor 1 Compressor motor The compressor motor is a three phase motor and is contained within the same housing as the compressor Specifications Rated Voltage 230 V Rated Output 2300 W 2 Compressor overload relay An internal compressor overload relay is used to protect the compressor motor The relay interrupts the flow of current when there is an overload condition and high temperature builds up in the compressor Operating Temperature Trip Time in Seconds OFF Ope
42. ons Symbol Item Function On Disable onboard buzzer Se SSC Off Enable onboard buzzer DSW3 N A DSW2 N A Change Fan Mode DSW1 Fan Mode On Fan stop mode Fan AUTO Off Fan operate mode Fan ON 1002623 36 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 521D 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 When the ON OFF button is pressed the 52CM relay on the relay board turns on operating the compressor Specifications 52CM Compressor On Off relay output 20 A at AC 250 V 3 Anti freeze control Anti freeze controls turns the compressor on and off by turning the 52CM relay on in accordance with the freeze protection thermistor CTS temperature As a result decreases in cooling performance due to frost buildup on the evaporator are prevented Compressor off conditions Freeze protection thermistor CTS temperature lt 28 F 2 2 C Compressor on recovery conditions CTS temperature gt 60 F 15 6 C ON 52CM OFF 28 F 60 F gt CTS temperature 2 2 C 15 6 C Evaporator out temperature 1003026
43. otor compressor control switch NOTE n 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 Check the installation site for operating temperature and installation space unobstructed airflow Check the phase sequence of the power source If the phase sequence is reversed the display of the control panel and the LED of the reverse phase protector turn off 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 operates 3 Frost in refrigeration cycle Clogging at the frost section Replace the clogged section pipe 4 No temperature difference Insufficient refrigeration Check the leaking part between evaporator and then repair and charge Air volume condenser refrigerant normal 1 Compressor coil resistance Short or open circuit Replace compressor O ohm or ohm In case of short check the compressor relay EEN 2 Compressor motor relay Compressor motor relay Replace compressor coss mai does not work motor relay operate 3 Compressor relay on the Open circuit or insufficient Replace relay board relay board con
44. pe appliance extension cord having a 4 blade grounding plug and a 4 slot receptacle that plugs into the appliance The marked rating of the extension cord should be 220 V 25 A or equivalent N CAUTION The AC outlet should be rated minimum 25 A at 220 VAC 3 phase 60 Hz Do not share the out let with any other instrument or equipment NOTE 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 Operation Section 25 2 Field Wiring Connection 1 Power supply AC 220 V 10 3 phase and 60 Hz Do not connect the unit to any other power supply The power supply should be a dedicated single outlet circuit with a UL approved short circuit and ground fault protective breaker with a recommended fuse size of 25 A 25 A maximum Securely tighten each terminal Power Source AC 220 V 3 Phase 60 Hz T G We i 0 7 L Circuit Breaker With i Ground Fault Protective Li im e i i I I i I I 3l a 1 1 i Green T EN i p Colored Wire Fuse 25 A 25 A MAX i jo Da Ma 1 i 1 i 1 Grounding mies ee 4 Terminal Terminal Block of Classic40 e R S T G 1003102 N 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 cau
45. recautions that should be observed in order to prevent damage to the unit or its components which may occur during installation or unit operation if sufficient care is not taken NOTE Provides additional information that facilitates installation or unit operation 1 3 General Precautions WARNING e All electrical work if necessary should only be performed by qualified electrical personnel Repair to electrical components by non certified technicians may result in personal injury and or damage to the unit All electrical components replaced must be genuine MovinCool parts purchased from an authorized reseller When handling refrigerant always wear proper eye protection and do not allow the refrigerant to come in contact with your skin Do not expose refrigerant to an open flame The proper electrical outlet for MovinCool units must be equipped with a UL approved ground fault breaker to prevent electrical shock from the unit When brazing any tubing always wear eye protection and work only in a well ventilated area Disconnect power before servicing unit Be careful of any sharp edges when working on unit Operation Section 7 2 SPECIFICATIONS 2 1 Exterior Dimension Diagram 23 6 DIA 20 7 Lo 30 1
46. s coil and causes contactor terminals 1 L1 and 2 T1 3 L2 and 4 T2 5 L3 and 6 T8 13 and 14 to become closed and the power is supplied to compressor and condenser fan motor Specifications Contact Rating 600 V max 30A 240 V max 0 037 A Coil Rating Reverse Phase Protector Wiring Diagram AC220 V CN 60 Hz oi H R 4 l S Lc S er Eq ho uer TE U i 1 AG eh load 4 1003095 14 A2 2 71 4 T2 6 T3 14 1003032 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 Specifications Contact Rating 240 V max 15 A Coil Rating 240 V max 0 025 A 5 15 Overcurrent Relay For the three phase fan motor an overcurrent 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 change in supply voltage or loss of current in one phase If overcurrent flows into the heating coil wound around the bimetalic strip the bimetalic strip
47. se machine failure or fire 26 Operation Section 2 Power supply wires Use at least 12 AWG for the power wires Cord type 4 wires SJO SJOT SJOOW or equivalent Voltage rating 300 V Minimum Heat resistance 140 F 60 C or above Prepare three power wires for power lines and one wire green for grounding Make sure to use conduit tubing when installing power wires 3 Connection to unit 1 Remove three 3 screws from the upper Screws 3 panel on the control panel side and open the upper panel Conduit Hole 2 Pass the power wire through the conduit hole in the left side panel 3 Attach the conduit tubing to the conduit hole Trade size of conduit is 1 2 inch 4 Connect the power wires to the R S T and 1003022 Grounding terminal Tightening torque 0 96 ftelbf 1 3 Nem 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 Do not use an extension cord on a cord connected unit WARNING All electrical work should only be performed by qualified electrical personnel Repair to electrical components by non certified technicians may result in personal injury and or damage to the unit 5 4 Wall Thermostat Connection
48. shooting 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 NOTE If the phase sequence is reversed control panel display turns off In this case exchange any two wires out of the three wires to correct the phase sequence Check the operation and condition of the fuse or circuit breaker in the power source 2 Inspection of air filters Remove the air filters and check the element If the element is dirty wash it as described in the OPERATION MANUAL supplied with the unit 44 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 O O connection problem open or shorted room thermistor If it does not work replace room thermistor Se M Freeze protection When freeze protection thermistor Disconnect and reconnect the O O thermistor connection becomes open or shorted freeze protection thermistor problem If it does not work replace freeze protection thermistor N OF Activation of When current of fan motor is 1 See Trouble shooting chart on O O protective
49. spection 0 00 ccc RR ns 53 6 9 Refrigerant System Inspechon 0c eet 53 7 DISASSEMBLY tel Parts Gonstruction iiu panes oi deed vores aaa heed HE a Pete gelatin ia 54 tio DISASSEMBLY eck re Kr ue eee ae rue Ge MER METER M x ete ae ER re RA 55 7 3 Removal of Control Panel 56 7 4 Removal of Condenser Fan Aesembhy l i ns 57 7 5 Removal of Evaporator Fan Assembly 00 sn 58 7 6 Removal of Electrical Components 61 8 REFRIGERANT SYSTEM REPAIR 8 1 Repair of Refrigerant System nn 62 8 2 Removal of Refrigeration Cycle Components 000 64 8 3 Charging the System with R 410A Refrigerant cc eens 65 8 4 Refrigerant Charging Work 70 9 REASSEMBLY Ol Removal OU ass cep Er eeu ER REY EMO RERO NEM Lx e Rus gener d 72 9 2 Compressor Mounting lssesslsessee rr 72 9 3 Condenser Fan Assembly 00 0 sn 72 9 4 Evaporator Fan Assembly A ebbe 73 9 00 AND Nee x asas ts poke ER REC AUN ob he DS E Nd E SIRO Meee 73 9 6 Perform the Inspection cassia Saeed Re here Eu Rae ERN RC ORE RR IR A EORR na 73 6 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 WARNING Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation A CAUTION Describes p
50. tact 4 Voltage Low voltage Repair power 1 Coil resistance of fan motor Short or open circuit Replace fan motor 0 ohm or ohm In case of short check the compressor relay 2 Fan motor relay Fan motor relay does not Replace fan motor relay No air work 3 Overcurrent relay Overcurrent relay does not Replace overcurrent work relay 4 Fan on off relay on relay Open circuit or insufficient Replace relay board board contact aime 1 Air filter Clogged air filter Clean air filter air volume 2 Evaporator Clogged evaporator or Repair and clean fins or crushed fin replace it 3 Duct connection condition Leak or clogged by improper Repair duct connection Insufficient duct connection air volume 4 Duct length and diameter Too long or too small diame Fix duct ter of duct 5 Fan motor Insufficient rotation Replace motor 6 Fan Fan interference Repair interference section 2 Unit does not start operate Repair Section 47 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 3 Ground fault breaker trip Ground fault or defective Repair ground fault section Does not Gen ground fault Reset or repair breaker operate at vob 4 Fuse Fuse blown Repair shorting section
51. ted spiral which when matched with a mating scroll torm generates a series of crescent shaped gas pockets between the two members During compression one scroll remains stationary fixed scroll while the other form orbiting scroll is allowed to orbit but not rotate around the first form As this motion occurs the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume When the pocket reaches the center of the scroll form the gas which is now at a high pressure is discharged out of a port located at the center During compression several pockets are being compressed simultaneously resulting in a very smooth process Both the suction process outer portion of the scroll members and the discharge process inner portion are continuous 2 Compressor operation 1001767 1 Compression in the scroll is created by the interaction of an orbiting spiral and a stationary spiral Gas enters the outer openings as one of the spirals orbits 2 The open passages are sealed off as gas is drawn into the spiral 3 4 5 Actually during operation all six gas passages are in various stages of compression at all times As the spiral continues to orbit the gas is compressed into two increasingly smaller pockets By the time the gas arrives at the center port discharge pressure has been reached resulting in nearly continuous suction and discharge
52. ting to a proper brazing temperature Care should be taken to not cause overflow of brazing filler metal oxidization of brazing filler metal or deterioration due to the overheating of flux Brazed fittings and fitting clearance In general the strength of brazing filler metal is Clearance lower than that of the base metal So the 0 001 0 003 in shape and clearance of the brazed fitting are a 0 025 0 075 mm quite important As for the shape of the brazed i p fitting it is necessary to maximize its adhesive Ve d area The clearance of the brazed fitting must be minimized to facilitate brazing filler metal to Clearance From The Pipe Fitting and Tubing flow into it by capillary action Wees Cleaning brazing filler metal and pipe When the refrigerant system has been opened up exposure to heat may have caused brazing filler metal to stick to the inside and outside of the pipe Brazing filler metal may also be compounded with oxygen in the air to form oxide film Fats and oils may stick to the pipe from handling All these factors can reduce effectiveness of brazing It is necessary to eliminate excess brazing filler metal using sand paper and by cleaning thoroughly with a solvent such as trichlene N CAUTION Do not use chlorine cleaner Repair Section 63 4 Use of dry nitrogen gas During brazing the inside of the pipe undergoes an oxidative reaction due to the brazing flame Introdu
53. ved from the air being pulled across the evaporator by the centrifugal fan The resulting cool air is expelled through the cooling air ducts 4 6 High Pressure Switch The high pressure switch prevents the condenser and compressor from being damaged by excessively high pressure in the high pressure line of the refrigeration cycle The switch is normally closed The snap disk responds to the variations in pressure and if pressure is abnormally high the snap disk moves down to push the pin down causing the internal contacts to open This interrupts the Operation Section 21 Pressure of Refrigerant Movable Point Stationary Point Case pl Molding by Resin X V SA Pin Snap Disk Terminal Lead Wires am 1001768 ground signal at the control board CN13 connector which turns the compressor off Possible causes of this trouble include The condenser air filter is dirty restricting air flow The condenser blower is defective 22 Operation Section 5 ELECTRICAL SYSTEM 5 1 Circuit Diagram
54. witch NOTE When replacement of the compressor attach the two pipes Pipe 1 Pipe 2 which are packaged in Compressor Assy as following figure Compressor Condenserd Part to Replace Disconnect At Condenser Inlet Pipe Compressor A amp J Condenser 1 B amp C Condenser 2 D amp E Condenser 2 Condenser 3 F amp G Evaporator H amp I Condenser 3 Evaporator 1003101 Repair Section 65 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 Make sure not to use more than 90 of the initial weight of R 410A in the cylinder WARNING When handling refrigerant R 410A the following precautions should always be observed Always wear proper eye protection while handling refrigerant Maintain the temperature of the refrigerant container below 104 F 40 C Perform repairs in a properly ventilated area Never in an enclosed environment Do not expose refrigerant to an open flame Never smoke while performing repairs especially when handling refrigerant Be careful the liquid refrigerant does not come in contact with the skin If liquid refrigerant strikes eye or skin Do not rub the eye or the skin Splash large quantities of cool water on the eye or the ski
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