Movincool Classic 40 User manual

SERVICE MANUAL
CLASSIC 40
SERIAL NUMBER FROM MAY 2009 (0509) TO PRESENT
DocID: 00G00044EA

© 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. SPECIFICATIONS
2.1 Exterior Dimension Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. CONSTRUCTION
3.1 Internal Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Basic Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. REFRIGERANT SYSTEM
4.1 Refrigerant System Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Capillary Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.6 High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5. ELECTRICAL SYSTEM
5.1 Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Control Box and Relay Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Wall Thermostat Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5 Warning Signal Connection (Output Signal Terminal L+ and L-) . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6 Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-). . . . . . . . . . . . . . . . . . . . . 30
5.7 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.8 Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.9 Control Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.10 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.11 Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.12 Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Table of Contents
5.13 Compressor Motor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.14 Fan Motor Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.15 Overcurrent Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.16 Temperature Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Table of Contents
Repair Section
6. TROUBLESHOOTING
6.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Self-Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4 Basic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.5 Inspection of Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.6 Inspection of Compressor Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.7 Thermistor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.8 Wiring Connection Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.9 Refrigerant System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7. DISASSEMBLY
7.1 Parts Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.3 Removal of Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.4 Removal of Condenser Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
7.5 Removal of Evaporator Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.6 Removal of Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8. REFRIGERANT SYSTEM REPAIR
8.1 Repair of Refrigerant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.2 Removal of Refrigeration Cycle Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.3 Charging the System with R-410A Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.4 Refrigerant Charging Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9. REASSEMBLY
9.1 Removal of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.2 Compressor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.3 Condenser Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.4 Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.5 Wiring Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.6 Perform the Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Operation Section
6
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
1.3 General Precautions
WARNING
• 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.
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 7
2. SPECIFICATIONS
2.1 Exterior Dimension Diagram
I003082
(Unit: inch)
10.0
5.1
25.8
DIA. 13.8
DIA. 22.0
10.0
20.7
12.9
43.5
5.1
10.2
4.3
6xM6
2x6xM6
DIA. 0.6
2.8
37.8
4xM20
2.8 30.1
41.3
4.8
6.9
5.1
22.4
1.9 2.3
8.9 8.9
3.9
DIA. 20.7
11.811.8
23.6
1.6
1.6
1.2

Operation Section
8
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 Min. 198 V, Max. 242 V
Starting Current 72 A
Recommended Fuse Size 25 A
Cooling Capacity and Power Consumption
Evaporator: 95 °F (35 °C),
60 % RH/
Condenser: 95 °F (35 °C),
60 % RH
Total Cooling Capacity*1 39000 Btu/h (11400 W)
Sensible Cooling Capacity *1 16500 Btu/h (4830 W)
Power Consumption *1 4.20 kW
Current Consumption *1 14.0 A
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 *2 0.05 IWG (12 Pa)
Motor Output 0.40 kW
Refrigerant Type R-410A
Amount 3.90 lb (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)
Power Cord NEMA Plug Configuration L15 - 30
Gauge x Length 12 AWG (4-core) x 6 ft
Dimension W x D x H 25.8 x 43.5 x 38.0 in
(656 x 1106 x 965 mm)
Weight Net 344 lb (156 kg)
Shipping 396 lb (180 kg)

Operation Section 9
• 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.
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)
from surface of unit. 72 dB (A)

Operation Section
10
2.3 Characteristics
(1) How to read the cooling capacity curve
I003046
<Condition>
Dry Bulb : 95 °F (35 °C)
59 68 77 86
(15)
113 (45)
Total Air Volume CFM (X102m3/h)
900
(15)
1300
(22)
1500
(26)
1700
(29)
40
45
50
55
60
65
70
1100
(19)
104 (40)
95 (35)
68 (20)
77 (25)
86 (30)
Example
MIN. : 50500 Btu/h
MAX. : 58000 Btu/h
Wet Bulb : 77 °F (25 °C)
Air Volume : 1500 CFM (2550 m3/h)
<Cooling Capacity>
Cooling Capability (X103 Btu/h)
(30)(25)(20)
Dry Bulb Temp. °F (°C)
Wet Bulb Temp. °F (°C)

Operation Section 11
(2) Cooling capacity curve
I003084
Dry Bulb Temp. °F (°C)
Wet Bulb Temp. °F (°C)
20
25
30
35
40
45
50
Cooling Capability (X103 Btu/h)
Total Air Volume CFM (X102m3/h)
400
(7)
800
(14)
1000
(17)
1200
(20)
600
(10)
113 (45)
104 (40)
95 (35)
68 (20)
77 (25)
86 (30)
59 68 77 86
(15) (30)(25)(20)

Operation Section
12
(3) Power consumption curve
I003085
Dry Bulb Temp. °F (°C)
113 (45)
104 (40)
95 (35)
68 (20)
77 (25)
86 (30)
Wet Bulb Temp. °F (°C)
68 77 86 95
(20) (35)
104
(40)
(30)(25)
Total Air Volume CFM (X102m3/h)
400
(7)
800
(14)
1000
(17)
1200
(20)
600
(10)
Power Consumption (kW)
2
3
4
5
6
7
8

Operation Section 13
(4) Current consumption curve
I003086
Dry Bulb Temp. °F (°C)
113 (45)
104 (40)
95 (35)
68 (20)
77 (25)
86 (30)
Wet Bulb Temp. °F (°C)
68 77 86 95
(20) (35)
104
(40)
(30)(25)
Total Air Volume CFM (X102m3/h)
400
(7)
800
(14)
1000
(17)
1200
(20)
600
(10)
11
12
13
14
15
16
17
Current Consumption (A)

Operation Section
14
(5) Cool air temperature difference curve
I003087
Total Air Volume CFM (X102m3/h)
400
(7)
800
(14)
1000
(17)
1200
(20)
600
(10)
㪛㪼㫃㫋㪸㪄㪫㩷 °F (°C)
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)
25.2(14)
40 50 7060
Relative Humidity (%)

Operation Section 15
(6) Extension static pressure and air volume curve of cool air
I003088
USAGE RANGE
Total Air Volume CFM (m3/h)
External Static pressure IWG (Pa)
0
(0)
500
(850)
1000
(1700)
1500
(2550)
0 (0)
0.5 (125)
1.0 (245)
1.5 (374)
2.0 (498)
2.5 (623)

Operation Section
16
3. CONSTRUCTION
3.1 Internal Structure
I003089
Evaporator
Room Thermistor
(RTS)
Freeze Protection
Thermistor (CTS)
Power Cord
Controller
Condenser
Condenser Fan
and Motor
Evaporator Fan Motor
Evaporator Air Outlet
Condenser Air Outlet
Control Box

Operation Section 17
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
(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
18
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.
I003090
Condenser
Condenser
Fan
Evaporator
Fan
Evaporator
Compressor
Capillary
Tubes
Flow of Refrigerant
High Pressure Switch
Capillary Tube
Compressor
Condenser
Condenser
Condenser
Condenser Inlet Pipe
Condenser Outlet Pipe
Compressor Suction Pipe
Compressor Discharge Pipe
Evaporator

Operation Section 19
4.2 Compressor
• The compressor used for the unit is hermetically sealed. The compressor and the compressor
motor are in one casing.
(1) Compressor theory of operation
• The scroll utilizes an involuted spiral which, when matched with a mating scroll form, generates
a series of crescent-shaped gas pockets between the two members. 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
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) As the spiral continues to orbit, the gas is compressed into two increasingly smaller pockets.
4) By the time the gas arrives at the center port, discharge pressure has been reached.
5) Actually, during operation, all six gas passages are in various stages of compression at all times,
resulting in nearly continuous suction and discharge.
< 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.
I001767
1㧕3㧕4㧕5㧕2㧕

Operation Section
20
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
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 plate 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.
I001887
High Temp./High Pressure
Liquid Refrigerant
Low Temp./Low Pressure
Gas and Liquid Mixture