Movincool Classic 18 User manual

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

SERIAL NUMBER LOCATION AND IDENTIFICATION
© 2012 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®, Office Pro® and SpotCool® are registered
trademarks of DENSO Corporation.
Nameplate Label Position
Nameplate Label
COOLING AMPS. WITH PUMP
COMPR. OUTPUT
REFRIGERANT/TOTAL CHARGE
DESIGN PRESSURE LO/HI
PART NO./WEIGHT
SERIAL NO.
Month Model
Sequential
Number
Year

Table of Contents
Table of Contents
Operation Section
1. PRECAUTIONS FOR SAFETY
1.1 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. SPECIFICATIONS
2.1 Exterior Dimension Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. CONSTRUCTION
3.1 Internal Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. REFRIGERATION SYSTEM
4.1 Refrigeration System Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Capillary Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. ELECTRICAL SYSTEM
5.1 Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Control Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5 Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.6 Temperature Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.7 Drain Tank Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6. CONNECTION AND SETTING
6.1 Warning Signal Connection (Output Signal Terminal L+ and L-) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2 Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-). . . . . . . . . . . . . . . . . . . . . 31
7. OPERATION
7.1 Operation of Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Table of Contents
Repair Section
8. TROUBLESHOOTING
8.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.2 Self-Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.4 Basic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.5 Compressor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.6 Fan Motor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.7 Capacitor Inspection (For Fan Motor and Compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.8 Auxiliary Relay Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.9 Full Drain Switch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.10 Thermistor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.11 Wiring Connection Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.12 Refrigeration System Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9. DISASSEMBLY
9.1 Parts Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.3 Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.4 Removal of Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.5 Full Drain Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10. REFRIGERATION SYSTEM REPAIR
10.1 Repair of Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.2 Removal of Refrigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10.3 Charging the System with R-410A Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
10.4 Refrigerant Charging Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11. REASSEMBLY
11.1 Reassembly of Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.2 Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.3 Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.4 Wiring Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Operation Section 5
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
1.3 General Precautions
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. All electrical components replaced must be genuine MovinCool parts,
purchased from an authorized reseller.
• Before replacing any refrigeration components, recover the refrigerant using standard
recovery procedures and equipment.
• 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 power supply for this unit should be a dedicated single outlet circuit with a UL
recognized short-circuit and ground-fault protective 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 this unit.
• Be careful of any sharp edges when working on this unit.
Describes precautions that should be observed in order to prevent injury to
the user during installation or unit operation.
Describes precautions 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.
WARNING
CAUTION

Operation Section
6
2. SPECIFICATIONS
2.1 Exterior Dimension Diagram
ILL00580-00
3.7 6.9
13.8
13.0
16.5
19.3
20.73.1 1.8
25.6
41.3
11.5 19.6 6.63.3
6-M6
(Unit: inch)
DIA. 4.9
DIA. 13.8

Operation Section 7
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
Range Max. 250 V
Min. 198 V
Starting Current 33 A/36 A
Recommended Fuse Size 15 A
FLA 9.1 A/8.8 A
LRA 33 A/36 A
Cooling Capacity and Power Consumption
Evaporator: 95 °F (35 °C),
60 %RH
Condenser: 95 °F (35 °C),
60 %RH
Total Cooling Capacity 18000 Btu/h (5280 W)/
18000 Btu/h (5280 W)
Sensible Cooling Capacity 8600 Btu/h (2520 W)/
8600 Btu/h (2520 W)
Power Consumption 1.90 kW/1.90 kW
Current Consumption 9.1 A/8.8 A
EER 9.5/9.5
Power Factor 99%/94%
Compressor Type Hermetic Rotary
Output 1.12 kW
Evaporator Type of Evaporator Plate Fin
Type of Fan Centrifugal Fan
Air Flow 510 CFM (867 m3/h)/
530 CFM (901 m3/h)
Max. External Static Pressure 0.48 IWG (120 Pa)
Motor Output *1 0.29 kW/0.35 kW
Condenser Type of Condenser Plate Fin
Type of Fan Centrifugal Fan
Air Flow 1100 CFM (1870 m3/h)/
1180 CFM (2006 m3/h)
Max. External Static Pressure 0.25 IWG (62 Pa)
Motor Output *1 -
Refrigerant Refrigerant Control Capillary Tube
Type R-410A
Amount 1.76 lb (0.80 kg)
Signal Connection Fire Alarm Input (Signal Type) •No-voltage contact input
•Contact resistance less than 100 ohm
Warning Signal Output 2 A at 30 V DC/AC max. with resistive load

Operation Section
8
• Specifications are subject to change without notice.
< NOTE >
*1 :One motor rotates both the evaporator and the condenser fans.
*2 :Measured at 3 feet (1.0 m) from surface of the unit.
Power Cord NEMA Plug Configuration 6-15
Gauge x Length 14 AWG (3-core) ×6 ft (1.8 m)
Dimension W ×D ×H 19.4 ×26.5 ×41.5 in
(493 ×673 ×1054 mm)
Weight Net 164 lb (74 kg)
Shipping 205 lb (93 kg)
Drain Tank Capacity 5.0 gal (19 L)
Operating Condition
Range Inlet Air Temperature Max. 104 °F (40 °C), 50 %RH
Min. 70 °F (21 °C), 50 %RH
Maximum Duct Length Cold Duct 50 ft (15.2 m)
Hot Duct 60 ft (18.3 m)
Sound Level *2 With Condenser Duct 63 dB (A)
Without Condenser Duct 67 dB (A)
Safety Devices Compressor Overload Protector Included
Fan Motor Overload Protector Included
Freeze Protection Thermistor Included
Full Drain Tank Switch Included
Automatic Restart (Power Interruption) Included
Compressor Time Delay 120 sec
Signal Input/Output Included
Control Devices Temperature Control Included
ITEM SPECIFICATIONS

Operation Section 9
2.3 Characteristics
(1) Cooling capacity curve
(2) Power consumption curve
ILL00581-00
6859
at 208/230 V
77 86
(15) (20) (25) (30)
77 (25)
86 (30)
95 (35)
104 (40)
12.7
15.9
17.5
19.0
20.6
Cooling Capacity. x103Btu/hDry Bulb Temp. °F (°C)
Wet Bulb Temp. °F (°C)
ILL00582-00
77 86 95
(25)
68
(20) (30) (35)
77 (25)
86 (30)
95 (35)
104 (40)
1.4
1.6
1.8
2.0
2.2 at 208/230 V
Power Consumption. kWDry Bulb Temp. °F (°C)
Wet Bulb Temp. °F (°C)

Operation Section
10
(3) Cool air temperature difference curve
ILL00583-00
(Delta-T) °F (°C)
at 208/230 V
Relative Humidity. %
40 50 60 70
Temperature Difference Between Inlet and Outlet
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)

Operation Section 11
3. CONSTRUCTION
3.1 Internal Structure
ILL00584-00
Capillary Tube
Condenser
Evaporator
Compressor and
Accumulator
Condenser Fan
and Motor
Housing for
Condenser Fan Housing for
Evaporator Fan
Control Box
• Relay Board
• Capacitor
• Auxiliary Relay
Condenser Air Outlet
Cooling Air Duct
Freeze Protection
Thermistor (CTS)
Evaporator Inlet Air Thermistor (RTS)
Drain Tank
Caster (Rear)
Full Drain Switch
Locking Swivel Caster
(Front)
Control Panel

Operation Section
12
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.
ILL00585-00
Condenser Flow of
Refrigerant
Capillary
Tube
Compressor
Fan
Motor
Evaporator
Condenser
Condenser
Inlet Pipe
Condenser
Outlet Pipe
Connecting Pipe
(Evaporator to Compressor)
Connecting Pipe
(Condenser to Capillary Tube)
Compressor
Suction Pipe
Capillary Tube
Evaporator Inlet Pipe
Evaporator
Evaporator Outlet Pipe
Compressor
Compressor
Discharge Pipe
Accumulator
Accumulator

Operation Section 13
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). When the
rotor shaft of the motor (drive mechanism) turns, the roller (compression mechanism) rotates to
compress the refrigerant.
I001675
To Condenser
Accumulator
Strainer
From Evaporator
Blade
Discharge Valve
Oil
Lubricator
Roller
Cylinder
Rotor
Stator
Terminal

Operation Section
14
(2) Basic compressor operation
• The roller (compression mechanism) is set
eccentrically with a certain distance given from
the axis of the center of the cylinder. A spring
loaded blade is mounted on the cylinder. The
roller turns to compress the refrigerant in the
space between the cylinder and eccentrically
mounted roller. The blade is in contact with the
roller by means of spring force. The blade
partitions the space between the suction side
and the discharge side to keep compressed refrigerant from returning to the suction side. There
is no suction valve. The discharge valve is designed not to open until the pressure of the
refrigerant within the cylinder reaches or exceeds discharge side pressure. As a result, the
discharge valve prevents the backward flow of refrigerant gas.
I000510
Discharge
Hole
Cylinder
Blade
Spring
Suction
Hole
Discharge
Valve
Shaft
Roller

Operation Section 15
(3) Operation
1) Start of compression
1) The cylinder is filled with low pressure gas.
2) Since pressure in the dischargechamber is higher
than in the cylinder, the discharge valve is kept
closed.
2) Suction and compression
1) The pressure in the cylinder increases gradually.
2) Refrigerant suction begins on the suction side of
the cylinder.
3) The discharge valve remains closed.
3) Discharge
1) The pressure in the cylinder exceeds that in the
discharge chamber, and the discharge valve
opens.
2) On the suction side, refrigerant suction continues.
4) Completion of compression
1) When compression is completed, all of the
refrigerant has been drawn from the suction
chamber.
2) Operation then returns to step 1) (Start of
compression) and the above process of suction
and compression continues repeatedly in
succession.
I001676
Blade
Discharge
Valve
Roller
I001677
Blade
Discharge
Valve
Roller
I001678
Blade
Discharge
Valve
Roller
I001679
Blade
Discharge
Valve
Roller

Operation Section
16
(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
bearing), and the lubrication groove for the
shaft journal. The lubrication groove is wider
than the oil hole. When the shaft turns, oil is
scraped upward by the oil scraper along the
inside diameter of the hollow shaft. The oil is
fed through the oil hole by centrifugal force,
then supplied to the lubrication groove for each
shaft journal, lubricating the bearing. In this
lubrication system, oil enters into each bearing
separately and returns to the oil reservoir. This
system effectively prevents bearing
temperature increases, and offers high
reliability. In addition, the specially treated
shaft journal keeps the bearing from being damaged during high temperature operation.
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
centrifugal fan and then expelled through the
exhaust air duct.
I001680
Oil Feed Groove
Oil Hole Oil Scrapper
Roller
Rotor
Cylinder
Hollow Shaft Eccentric Shaft
I002351

Operation Section 17
4.4 Capillary Tube
• The capillary tube is a long thin tube that
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 refrigerantis sprayed out through
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.
4.5 Evaporator
• The evaporator is a heat exchanger covered
with spine fins. Heat is removed 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 Accumulator
• The accumulator is mounted on the suction
gas piping between the evaporator and the
compressor. The accumulator separates the
liquid refrigerant from the gas refrigerant,
allowing only the gas refrigerant to enter the
compressor. In the accumulator, suction gas is
led into a cylindrical vessel where the speed of
the gas is decreased. This process separates
the refrigerant contained in the gas by the force
of gravity, causing the refrigerant to accumulate at the bottom of the vessel. As a result, the
compressor is protected from possible damage caused by liquid refrigerant intake.
I001887
High Temp./High Pressure
Liquid Refrigerant
Low Temp./Low Pressure
Gas and Liquid Mixture
I002352
I000514
From Evaporator
To Compressor

Operation Section
18
5. ELECTRICAL SYSTEM
5.1 Circuit Diagram
ILL00589-00
Dip Switch
#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
OFF (Default)
ON
12 3 4
TB1 Terminal Block1
TB2 Terminal Block2
RB Relay Board
MF Fan Motor
MC Compressor Motor
CF Capacitor for Fan Motor
CN Connector for Option
Drain Pump
CTS Freeze Protection Thermistor
RTS Room Thermistor (Evaporator Inlet Air Thermistor)
G Ground
CB Control Board
RX Auxiliary Relay
Control Box
On Board
Controller
CB
AUX1
CTS
CN
CN01
G
G
G
1
1 2
1413
A1 A2
1
TB1
Dip Switch
T1
COM
5
230V
F1 R
T
R
AC208/230V
1PHASE
60Hz
2
OLC
S C
CCCF
RX
2
R
MC
MF
IOLF
AP
Jumper
Line
Jumper
Line
RTS Drain Tank SW
CC Capacitor for Compressor
OLC Overload Protector
Ground (G)
AUX2
L-
L+
E-
E+
11
1
5
1
TB2 Output Signal
Fine Alarm
Input
CN23
CN22
CN21 CN24
CN25
CN13
CN17
1
1
1 3
CN12
1 3 3
CN11
1
1
ON
2 3 4
2
CN15 52CM
52CT
52ID
520D1520D2
1 2 4 3
CN16
1
1151 2135
5
11
RB
CN03
1
5

Operation Section 19
5.2 Control Box
(1) Capacitor
• The capacitor is used to improve the rotational
power of the fan motor and compressor at
startup. The specification for each capacitor is
shown below.
Specifications:
Capacitor Rated Voltage Capacitance
For Fan Motor 400 V 10 µF
For Compressor 400 V 35 µF
ILL00590-00
RB: Relay Board
CF: Capacitor for Fan Motor
TB2: Terminal Block2
TB1: Terminal Block1
CC: Capacitor for Compressor
RX: Auxiliary Relay
I001693
Check capacitance

Operation Section
20
(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.
Specifications:
Rated Voltage AC 230 V
Rated Current 10 A
I001694
13
14
A1
A2