7.Installation,Operation & Maintenance(IOM)

IO

nstallation, peration

&M

aintenance anual

Packaged Air Conditioners

PACV-S

Table of Contents 1

Introduction

4

Nomenclature . . . . . . . . . . . . . . . . . . . . 5 Safety Instructions . . . . . . . . . . . . . . . . . . 5 Specific Hazards. . . . . . . . . . . . . . . . . . . . 5 Points To Remember. . . . . . . . . . . . . . . . . . 6 Component Features . . . . . . . . . . . . . . . . . 7 Liquid Line Controls . . . . . . . . . . . . . . . . . . 9 Electrical Control panel . . . . . . . . . . . . . . . 10 Room Unit . . . . . . . . . . . . . . . . . . . . . 11 2

Installation Receiving of Equipment . . . . . . . . . . . . . . . 13 Rigging . . . . . . . . . . . . . . . . . . . . . . 13 Handling . . . . . . . . . . . . . . . . . . . . . . 13 Storage . . . . . . . . . . . . . . . . . . . . . . 14 Location & Space Requirements . . . . . . . . . . . 14 Pre-Installation Checkup. . . . . . . . . . . . . . . 15

Preparation For Installation . . . . . . . . . . . . . 16 Carrying Out Installation. . . . . . . . . . . . . . . 16 Condensate Draining . . . . . . . . . . . . . . . . 16 3

Operation Pre-Startup Checklist . . . . . . . . . . . . . . . . 17 Pre-Startup Procedure . . . . . . . . . . . . . . . . 17 Service Record . . . . . . . . . . . . . . . . . . . 18 Unit Startup . . . . . . . . . . . . . . . . . . . . 19 Display & Keypad Operation . . . . . . . . . . . . . 20 Alarms . . . . . . . . . . . . . . . . . . . . . . . 21 List of alarms in the unit controller . . . . . . . . . . 21 Operation of the Room Unit . . . . . . . . . . . . . 22 Setting the address of the room unit . . . . . . . . . 22 switching in and switching off the unit . . . . . . . . 22 Commissioning Test Report . . . . . . . . . . . . . 25

4

Maintenance Periodic Maintenance . . . . . . . . . . . . . . . . 26 Leak Testing, Evacuation & Charging Procedures . . . . . . . . . . . . . . . . 28 Fan . . . . . . . . . . . . . . . . . . . . . . . . 32

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Bearing . . . . . . . . . . . . . . . Fan Belt Adjustment. . . . . . . . . . Fan Pulley Adjustment (For variable pitch pulleys only) . . . . Alignment of Shafts & Sheaves . . . . . Mold In And Around Drain Pans . . . . . Coil . . . . . . . . . . . . . . . . . Coil Cleaning . . . . . . . . . . . . . Compressor Oil . . . . . . . . . . . . Adding Oil . . . . . . . . . . . . . . Dismantling & Disposal . . . . . . . . Expansion valve service & maintenance . Hot gas by pass . . . . . . . . . . . . Refrigerant Recovery, Recycling & Reclamation . . . . . . . . . . . . . Trouble Shooting . . . . . . . . . . . 5

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35 35 36 37 37 37 37 38 38 40

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Appendix Appendix I . . . . . . . . . . . . . . . . . . . . . 49 Loading Points . . . . . . . . . . . . . . . . . 49 Appendix II . . . . . . . . . . . . . . . . . . . . . 51 Dimensional Data . . . . . . . . . . . . . . . . 51 Appendix III . . . . . . . . . . . . . . . . . . . . 55 Refrigerant Piping Layout . . . . . . . . . . . . 55 Appendix V . . . . . . . . . . . . . . . . . . . . . 57 Filter Dimension . . . . . . . . . . . . . . . . 57 Appendix IV . . . . . . . . . . . . . . . . . . . . 58 Spare parts . . . . . . . . . . . . . . . . . . . 58 Appendix VII . . . . . . . . . . . . . . . . . . . . 57 Typical wiring diagram . . . . . . . . . . . . . . 57

Appendix VIII . . . . . . . . . . . . . . . . . . . . 62 Typical Wiring Diagram . . . . . . . . . . . . . 62 Appendix IX . . . . . . . . . . . . . . . . . . . . 63 Instructions For Downloading/Upgrading The Software For Microprocessor . . . . . . . . . . . 63 Appendix X . . . . . . . . . . . . . . . . . . . . . 64 P-T Chart . . . . . . . . . . . . . . . . . . . . 64

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INSTALLATION, OPERATION & MAINTENANCE

Introduction This manual must be carefully read and followed in order to avoid unnecessary/dangerous conditions in the machine and to guarantee the safety of the equipment. The contents in this manual are mainly the installation and operating instructions of your Package Air Conditioning unit. The precautions mentioned through out this manual should be taken seriously to derive maximum safety for all. Installation, service and start up of any air-conditioning equipment should be done only by a qualified personnel or service technician. Always observe precautions in the manual and be familiar of all the symbols / labels attached in the unit when dealing or working with the equipment.

Unit Description The PACV-S series is a modern, diversified and environment friendly series of packaged air conditioners which use R - 134a as the refrigerant. The complete PACV-S package provides an extremely rugged, heavy duty, long-life, energy efficient and self-contained package air conditioner that will provide cooling at higher efficiency over a long and extended life. What makes PACV-S series the pride of SKM products is the use of : • High efficiency totally sealed hermetic scroll compressor. • Totally enclosed, Class F insulated, IP55 protected condenser and evaporator fan motors. • Heavy duty condenser and evaporator coils optimised in design for long-life maintenance free operation. • Cabinet construction specifically designed for Gulf climates. • IP 54 Electrical panel. • Factory installed, advanced and user friendly microprocessor based control system. • Interface capability with major BMS protocols (option). The SKM PACV-S series packaged air conditioning units are durable, dependable, strong, reliable, versatile, quiet and energy efficient. Wherever a heavy duty packaged air-conditioner is required, the PACV-S series should be an automatic choice.

Note:- It is not the intention of this manual to cover all possible variations in systems that may occur or to provide comprehensive information concerning every possible contingence that may be encountered during an installation, operation and maintenance. If additional information is required or if specific problems arise that are not fully discussed in this manual, contact your local office. Always heed all WARNING and SAFETY INSTRUCTION boxes. Always read and heed all instructions in this manual carefully. Failure to follow WARNING, SAFETY INSTRUCTIONS and all other instructions could result in severe personal injuries and death.

For the representation and understanding of the points of caution, attention, danger, and information. Following symbols are used throughout the manual.

General Warning

CAUTION

ATTENTION

DANGER

MODEL POWER SUPPLY (V/Ph/Hz) CONTROL VOLTAGE(V/Ph/Hz) COMPRESSOR MODEL

INFORMATION Indicates dangers by high voltage

HIGH VOLTAGE Indicates dangers by moving/rotating parts

ITEM CODE

Qty

Indicates dangers through electrical shock, system pressure, and location.

General Information.

Unit Name Plate Typical SKM Air Cooled Packaged Unit nameplate is as shown. Check the nameplate data with the P.O/ Submittal when receiving the unit.

Take special attention and points to be noted.

LRA

RLA

MOVING/ROTATING PARTS CONDENSER MOTOR Qty EVAPORATOR MOTOR Qty MIN.CIR AMPS/MAX. FUSE AMPS HEATER KW/NO. OF STAGES R-134A CHARGE(KGS) MANUFACTURING SERIAL NO

KW KW

FLA FLA

MANUFACTURED IN SHARJAH,UNITED ARAB EMIRATES

4 |

Indicates dangers by hot pipes

Factory/Field

HOT PIPES

INSTALLATION, OPERATION & MAINTENANCE

Refer product name plate, wiring diagrams and catalogues for the electrical characteristic, of the equipment to select correct wire sizes and isolators prior to the insulation.

Nomenclature PAC V - 5 1 008 S Y

It is the responsibility of the user or the person installing the equipment to provide proper grounding and branch circuit protection according to NEC, Local & National safety regulations.

Power Supply Code

Packaged Air Conditioner

Y: 380-415V/3Ph/50Hz P: 440V/3Ph/50Hz R: 380V/3Ph/60Hz E: 460V/3Ph/60Hz T: 220V/3Ph/60Hz

V-shaped condenser construction

This Air Conditioning equipment must be disconnected from the mains if any repair work is to be carried out.

Power supply frequency 5 = 50 Hz 6 = 60 Hz

Do not use the units if damaged. If problems occur, switch the unit off and disconnect it from the power supply.

No. of Refrigerant Circuits Nominal Capacity (TR)

The control ON/OFF switch in the control panel does not disconnect the equipment from the mains and thus it is not to be used as a safety switch.

Scroll Compressor (R-134a)

Do not attempt to repair, move, alter or reinstall the unit. If performed by an unauthorized personal, these operations may cause electrical shock or fires.

SKM reserves the right to change, in part or in whole the specifications of its Air Conditioning Equipment at any time in order to add the latest technology. Therefore, the enclosed information may change without any prior notice.

Always remember to inspect the units, refrigerant tubes and protection regularly. These operations should be performed by a qualified personnel only. Contact SKM After sales in case any technical support is required.

Safety Instructions Specific Hazards Carefully read the content of this manual before installing the air conditioning equipment. For maximum safety installers should always follow the list of warnings. During the installation process care should be taken to avoid any accidents related to: 1.

High voltage

2.

High pressure in the system

3.

Hot pipes due to discharge temperature

4.

Moving/Rotating parts

This manual explains how to install, operate and maintain SKM PACV-S series, Air cooled packaged unit. The manufacturer shall not be responsible for damages arising from wrong p practices used. So SKM recommends to do the installation including the connection of electricity, operation and maintenance by a person qualified for the air- conditioning and refrigeration work only. The manufacturer shall not be responsible for damages originating from unauthorized changes or the improper connection of electricity and not adhering to the operation limits included in the manual. Also this shall invalidate the warranty. The air conditioning equipment should be used only for the applications for which it has been designed.

Noise Emission The sound emission expected in normal use of the fan should be duly taken into account.

Wear ear defenders when working near to or on the running fan!

Heavy Loads The heavy weight of fans and their components entail the following risks during maintenance: • Risk of being trapped, crushed or cut by moving or toppling machinery. • Danger of falling components. •

Do not stand or work under suspended loads.

•

Wear a hard hat, safety shoes and gloves.

Rotating Shafts and Impellers • •

Objects fixed to rotating shafts and impellers can fly off at an angle and cause serious injury. Articles of clothing and hair can get caught in rotating shafts and impellers. | 5

INSTALLATION, OPERATION & MAINTENANCE

•

Do not remove during operation.

guards

•

Do not wear loose-fitting clothing when working near rotating shafts and impellers.

•

Wear goggles.

Points To Remember Being an electromechanical machine, the unit may fail or cause difficulties. Remembering the following few points will ensure correct and prompt rectification and continued optimal performance.

Hot Surfaces •

There is a risk of sustaining burns or scalds on hot surfaces during operation. •

Do not touch the Motor, Compressor body, Discharge line during operation.

•

When the condenser fan has stopped wait until the motor has cooled down.

•

Wear protective gloves.

Electrical Shock Hazards •

All power must be disconnected prior to installation and servicing this equipment. More than one source of power may be present. Disconnect all power sources to avoid electrocution or shock injuries.

Fiber glass Insulation! This Product contains fiber glass wool. Disturbing the insulation in this product during installation, maintenance or repair will expose you to airborne particles of glass wool fibers and ceramic fibers. All necessary Personal Protective Equipment (PPE) including gloves, eye protection, mask, long sleeves and pants must be worn when working with products containing fibreglass wool. Exposition to glass wool fibers without all necessary PPE equipment could result in cancer, respiratory, skin or eye irritation, which could result in death or serious injury. • Avoid breathing fiber glass dust.

6 |

•

Use a NIOSH approved dust/mist respirator.

•

Avoid contact with the skin or eyes. Wear long-sleeved, loose-fitting clothing, gloves, and eye protection.

•

Wash clothes separately from other clothing: rinse washer thoroughly.

•

Operations such as sawing, blowing, tear-out, and spraying may generate fibre concentrations requiring additional respiratory protection. Use the appropriate NIOSH approved respiration in these situations.

A correct installation ensuring proper clearances for correct condenser air flow and maintenance as per the drawings shown for “recommended clearances” Proper level base on foundation with appropriate vibration mount. All connections and hook up to be followed as per instructions, which ensures long term trouble free operation and performance. If power fuse is blown off, be sure to replace the same with a new fuse having pre designed Amperage. Do not use a steel wire or copper wire instead of proper fuse. Genuine fuse ensures safety and proper protection. Incorrect fusing may cause fire or trouble with your equipment. Before replacing any fuse or opening any electrical panel door, make sure the main switch is OFF. Do not spray or sprinkle water directly over or into the air conditioning equipment for cleaning because electric insulations and terminal of the components are opened. The microprocessor controller is programmed to stop functioning the Air conditioning equipment including the compressor in the event of a safety device trips. The problem should be investigated and repaired or rectified as per trouble shooting instruction in this manual before attempting to reset and restarting the machine. Following a power supply interruption during operation, the microprocessor is programmed to restart the unit automatically when power supply has returned to normal. This Air conditioning equipment is meant to be installed out doors and suitable to normal environment elements. Do not try to cover or block any inlets or discharge openings to condenser. Periodical maintenance of the unit will give better performance in the long run than only break down maintenance. Insist on maintenance from a reputable maintenance contractor to ensure a trouble free operation.

INSTALLATION, OPERATION & MAINTENANCE

Component Features NOT covered under the manufacturer’s limited warranty.

Compressor Compressors used in PACV-S packaged unit series are hermetically sealed, compact scroll with the following features: • High Efficiency. •

Quite operation, Low Sound levels.

•

Compact and light .

•

Limited wear.

•

70% fewer moving parts than comparably sized reciprocating compressors

•

Unique ability to handle liquid refrigerant.

•

Suction gas motor cooling.

•

Centrifugal oil pumps with filter and magnet.

•

Brazed fittings or Rotalock as options.

•

Multiple refrigerant circuits on larger units provides efficient part load.

Vacuum operation! Compressor damage! Scroll compressors should never be used to evacuate a refrigeration or air-conditioning system. Do not pump down the scroll compressor into a vacuum!

Three phase compressors only: On initial startup, if the compressor sound is abnormally high and the readings of suction and discharge pressures are outside normal range, there is a possibility that the compressor rotation is in the reverse direction. In this case, interchange any two legs of the power supply and attempt to restart. Running a scroll compressor in reverse direction for an extended period of time will cause damage to the compressor. such damage is not covered under manufacturer’s limited warranty.

Reverse rotation for 5 to 15 minutes will result in the overheating of motor windings. In this case, the thermostat in the motor windings open and result in stopping of the compressor. Continued reverse operation of scroll compressor will result in failure of scroll compressors. Such failures are

Parallel Operation A parallel compressors installation, with common suction line and common discharge line, gives a reduced operating cost through greater control of capacity and power consumption. This is achieved by staggering compressor switch-on sequences that allow the parallel system to match its power with the capacity needed. By switching-off individual compressor from parallel installation, while other compressor is operating 100%, the improved part load efficiency can be achieved. The specially developed and adopted oil equalization system ensures correct compressors operation, oil balancing between compressors and reliability.

Condensers Condenser coils are manufactured of seamless copper tubes mechanically bonded to aluminum fins to ensure optimum heat transfer. All coils are tested against leakage by air pressure of 450 psig (3100 kPa) under water. All standard coils are 2,3 or 4 rows/14 FPI, 3/8” (9.5 mm) O.D. tubes. An integral subcooling circuit is provided to increase the cooling capacity, without additional operating cost. For different application requirements, other optional condenser fin materials are available: •

Copper fins.

•

Electrotinned Copper Fins.

•

Copper finned coils with electro-tinned after manufacturing.

•

Precoated Aluminum fins The pre-coated is hydrophobic polyurethane resin. This option provides substantial corrosion protection beyond standard coil construction.

•

Aeris Guard Coil Coating The Aeris Guard Coil is a self etching high performance modified epoxy finish that is specifically designed to coat and protect Aluminum and Copper surfaces. In addition, the coating is ideal for the protection of ferrous and non ferrous materials.

SKM PACV-S series, all models, are restricted to a 14FPI (1.8 mm) fin spacing condenser coil. Gulf dust storms and the general level of available maintenance in Gulf countries ensures this condenser coil design shall provide long life and maintenance free operation with the least possibility operational blockage on the condenser. Ample condenser surface and sensible air flow across the condenser ensures a low temperature differential between condensing temperature and the high Gulf ambients making the PACV-S packaged unit perform efficiently and durably.

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INSTALLATION, OPERATION & MAINTENANCE

Condenser Fans

Fan Section

Condenser fans are propeller type, aluminium alloy blades, directly driven by electric motors. Motors are Totally Enclosed Air Over (TEAO) six pole with class ‘F’ insulation and minimum IP55 protection. The TEAO and class ‘F’ insulation features ensure long life and are unique for SKM.

Fans in the PACV-S units are selected for the best sound characteristics based on maximum fan efficiency. More than one arrangement of evaporator fans are used in the PACV-S series packaged units due to the wide range of air flow rates.

The motors are factory wired, using wires specially selected for high ambients operation, to unit control panel where the motor contactors are located to control the operation of these motors.

Above 15 kW motor sizes are equipped with fixed pitch pulleys s standard and adjustable pitch pulleys are option. Specify PP.

The condenser fans are individually statically and dynamically balanced at the factory. Complete fan assembly is provided with suitable acrylic coated fan guard.

Evaporator Evaporator coils are manufactured of seamless copper tubes mechanically bonded to aluminium fins to ensure optimum heat transfer. All evaporator coils are tested against leakage by air pressure of 300 psig (2068 kPa) under water. The DX evaporator coils are complete with headers of seamless copper tubing. Supply headers incorporate a correctly sized distributor. For different application requirements, other evaporator coil material and/or treatment are available on request. • Copper fins. •

Electrotinned Copper fins.

•

Copper finned coils with electro-tinned after manufacturing.

•

Precoated Aluminum fins. The pre-coated is hydrophobic polyurethane resin. This option provides substantial corrosion protection beyond standard coil construction.

•

Aeris Guard Coil Coating. The Aeris Guard Coil is a self etching high performance modified epoxy finish that is specifically designed to coat and protect Aluminum and Copper surfaces. In addition, the coating is ideal for the protection of ferrous and non ferrous materials.

Evaporator coil supplied with suitable size thermostatic expansion valve(s) and multicircuited distributors providing capacity modulation to match the compressors. The cross wave fins and staggered tubes design uses the evaporator surface effectively by creating uniform air turbulence and optimum heat transfer over the entire finned surface. Requirements for higher face velocities can be handled by use of moisture eliminators to avoid carryover.

8 |

Commonly, all fans are double inlet, double width, centrifugal type with forward curved impellers provide the combination of efficiency and quietness of operation. All fans are statically and dynamically balanced, belt driven by motor sizes up to 15 kW are provided with adjustable pitch pulleys as standard.

Single fan is used for PACV-51008S, PACV-51010S, PACV61009S & PACV-61012S models. Models PACV-51014S~PACV52055S & PACV- 61018S~PACV- 62066S are equipped with two fans. These fans are mounted on a single heavy duty shaft driven by a single electric motor. Shaft end insert into over sized, tapered lock self aligning long life bearings. The motor is mounted on an adjustable base, so that belt tension can be easily adjusted. Models PACV-52065S and PACV-62076S onwards, use single fan assembly, which has maximum strength, high performance, quietness and reliability. These fans use self aligned ball or pillow block bearings that are greased for life. Pillow block bearings are provided with re-greasing fittings. The motor is mounted on an adjustable base, so that belt tension can be easily adjusted. The complete fan-motor drive assembly is mounted on a floating sub-base. In order to limit transmission of noise and vibration, the complete fan motor sub-base assembly is mounted on antivibration mounts. Flexible connection is provided between fan discharge and casing panel to avoid transmission of vibration to the connecting duct. The optional modular construction units for models PACV51008S~PACV-52055S & PACV-61009S~62066S are also using the same fan specifications as mentioned above. The electric motors are foot mounted, 4 pole, totally enclosed fan cooled (TEFC), IP-55 protected, Class F insulation with Class B temperature rise. Drive package is factory selected for the medium air flow rate as shown in the capacity ratings. Alternative drive packages to meet specific job or client requirements can be provided.

Refrigerant Circuit PACV-S series comes complete, as standard, with correctly sized and piped refrigerant lines including sight glass, filter drier, thermostatic expansion valve, solenoid valve, shut-off valve, and a full operating charge of R-134a in each circuit. Piping is fabricated from ACR grade copper piping. Suction line is insulated with ½” (12 mm) wall thickness closed cell pipe insulation.

Filter Section PACV-S series can be with a range of filter sections and filters to meet requirements for the most demanding applications. • Flat or vee filter sections to accommodate 1” or 2” cleanable aluminium media filters can be provided. • A bag filter section to house 22”, 30” or 36” deep bag filters having efficiencies as desired can also be provided, as required. Filter sections come with latches to provide easy access for removal and for maintenance.

INSTALLATION, OPERATION & MAINTENANCE

•

•

On 100% fresh air applications an initial sand trap louvre can effectively minimize entrance of sand into the air stream. High efficiency mini pleat panel filters are available as an alternative for bag filter where space is limited. Filter sections come with latches to provide easy access for removal and for maintenance.

To order a sand trap louvre from SKM specify fresh air opening size with option ASL.

Casing/Structure

Solenoid Valve It is used to stop the flow of refrigerant within the refrigeration system. The valve is typically a normally-closed type of valve so that it is closed when it is energized

Shut Off Valve/Ball Valve Usually used so that portions of refrigeration system can be isolated for service or repairs.

Designed for ease of handling and low cost to install. The PACV-S Air Cooled Packaged Units are factory assembled and mounted on a rigid base. The unit casing used in PACV-S Packaged units is made of zinc coated galvanized steel sheets conforming to JIS-G 3302 and ASTM A653 which is phosphatized then baked after an electrostatic powder coat of approximately 60 microns. This finish and coating pass a 1000 hours in 5 % salt spray testing at 95°F (35°C) and 95% relative humidity as per ASTM B117. The entire casing panels are designed to be leak proof against rain and ensure rain cannot enter the PACV-S series packaged air conditioner interior. Evaporator section sealed by the use of vinyl gasketing material. The evaporator section is insulated from all sides with blackneoprene faced heavy density 1” thick fiber glass insulation for models up to PACV-52055S & 62066S and 2” thick fiber glass insulation for models PACV-52065S & 62076S onwards. The insulation cum sound liner meets the fire requirements of NFPA90A and is secured with mechanical fasteners in addition to water resistant adhesive. For applications requiring an inner skin in the evaporator section, option DSE provides 0.7 mm galvanized inner skin. Suitable isolation to ensure no cold-bridges and no condensation on the exterior of the units is provided. The condensate drain pan is heavily insulated to ensure that condensation may not occur. Stainless steel condensate drain pans are available on request.

Sight glass Used to observe the flow of liquid refrigerant. Bubbles or foaming in the sight glass indicate a shortage of refrigerant or restriction in the liquid line that can adversely affect system operation. Sight glasses are widely used as a means of determining if the system is adequately charged.

Filter Driers Driers are mounted in the refrigerant liquid line to ensure that all the refrigerant in circulation passes through the drier each time it circulates through the system so as to remove any moisture or foreign matter from the refrigerant stream.

Liquid Line Controls Thermostatic Expansion Valve For controlling the flow of liquid refrigerant into the evaporator, an orifice in the valve meters the flow into the evaporator, the rate of being modulated as required by needle type plunger and seat, which varies the orifice opening.

Low Pressure Switch This switch is fitted in the suction side of each refrigerant circuit and is wired to the unit controller digital input. Its function is to protect the compressors against low suction pressure. If the refrigerant circuit is On to meet the cooling demand and this switch remains open for a specific time (low pressure alarm delay set point), then the unit controller will switch off that circuit and generate Low suction pressure alarm.

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INSTALLATION, OPERATION & MAINTENANCE

High Pressure Switch

Electrical Control Panel

This switch is fitted in the discharge side of each refrigerant circuit and is wired to the unit controller digital input. Its function is to protect the compressors against high discharge pressure. If this switch remains open for one second, then the unit controller will switch off the corresponding refrigerant circuit and generate High Discharge pressure alarm.

The unit mounted control panel enclosure is fabricated out of heavy gauge sheet steel in phosphatized powder coated baked finish. The enclosure conforms to IP54 as per guidelines in IEC 529. A hinged access door and key-fastener is provided for easy access and security. The panel is factory wired in accordance with NEC 430 & 440, labelled, tagged and features 220V/240v controls.

Discharge Pressure Transducer

•

All compressors are with DOL starting.

•

Individual compressor, condenser fan motors and evaporator fan motor contactors.

•

Motor protector circuit breaker for condenser and evaporator fan motors.

•

Control circuit breaker.

•

Control circuit on/off switch.

•

Microprocessor control boards.

•

Control Relays.

•

Power and control terminal blocks.

This transducer is fitted in the discharge side of each refrigerant circuit and is wired to the analogue input of the unit controller. Through this transducer, the unit controller will monitor the discharge pressure of the refrigerant circuits and cycle the condenser fans (when compressors are running) in order to maintain proper head pressure.

Factory settings for pressure switches and Fan cycling Factory Switch Settings Description

Cut Out (PSIG)

Cut In (PSIG)

Low Pressure Switch

14.5

29

High Pressure Switch

300

200 Table 1

Factory Fan Cycling Settings in Unit Controller (Units with 4 fans) Description

On (PSIG)

Off (PSIG)

Fan Cycling Stage- 1

180

130

Fan Cycling Stage- 2

200

150

Fan Cycling Stage- 3

220

170

Fan Cycling Stage- 4

240

190 Table 2

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Microprocessor Controller All PACV-S series package units are equipped with a full function microprocessor based controller as a standard feature. The controller is factory programmed for the control of evaporator fan, compressors and condenser fans. The controller comes with a built in keypad and display for simple but meaningful man machine interface. This controller provides complete operational control for the unit and has built-in auto diagnostic capability that can signal normal operation or alarm conditions as well as shutting down the unit or system if necessary. .The Main Features of the controller are as follows: • Built in LCD display with back light. •

Roll & push knob and 3 function buttons.

•

Battery backed up built in real time clock.

•

Multiple authorization level to provide tight security for the control system.

•

Capacity control based on room temperature or return air temperature.

•

Alarm history.

•

A sleek & elegant design room unit.

INSTALLATION, OPERATION & MAINTENANCE

Display Information

Room unit display (Operator Controls)

SKM Pacvs series package units offer LCD display which allows the operator to access different parameters of the unit. Operator can view and change the unit parameters. The display information includes: • Status • Outputs • Inputs • Alarms • Set points • Password

System Protection The intelligent microprocessor based controller monitors all the safeties related to the unit and makes the necessary protections,by shutting down the entire unit or the effected circuit. The protection includes • Low suction pressure. • High discharge pressure. • High compressor motor temperature. (For compressors with internal motor protector). • Compressor short cycling. • Evaporator fan motor overload

A brief description of each button in the room unit is shown in table below: ON/OFF

Button for Time scheduler, pressing this button allows date/time setting, Program while holding it allows schedule programming

Minus

Button for set-point adjustment, each operation of the Minus (-) button reduces the set point by differential which is defined in controller’s setting

Plus

Button for set-point adjustment, each operation of the Plus (+) button increases the set point by differential which is defined in controller’s setting

OK

Button for confirmation of date/time and scheduler settings. Long press of this button can toggle between measurement units -oC and oF

Fan

Button for fan mode either continuous mode or auto mode

Mode

Button for unit mode: Cool, heat, ventilation and or cool-heat auto changeover (*Cool-Heat is available only if heat mode is applicable)

BMS Connectivity (Optional) Volt free contacts for run status, common fault status, auto mode status and provision for remote on/off shall be provided as option if required. In addition, the PACVS microprocessor can support the major BMS protocols such as BACnet, Modbus & LON. Extra hardware may be required depending on the protocol.

Room Unit The controller comes with a loose supplied sleek and elegant design room unit for installing in the conditioned space. Communication between unit controller and room unit is through two wire interface. The communication cable should be 2 core, twisted pair, unscreened with stranded conductors, as per KNX specification. Maximum distance between room unit and controller can be 700 meters. The room unit has a built in sensor for measuring the room temperature. It transmits room temperature, set point, unit operating mode etc. to the unit controller. Control of the compressors is based on room temperature and the set point, as standard. If unit control needs to be based on duct temperature, please specify during time of order.

Button for unit power on or unit power off

Table 3

Control or data communication cables should not be routed along with power cables. Sufficient distance is to be maintained while routing the cables between Power and data communication cables (If any).

Room Unit Installation Installation must be carried with unit power off.

| 11

INSTALLATION, OPERATION & MAINTENANCE

Step One: Location and Mounting Select a mounting location with good air circulation away from ventilation inlets, doors, windows, or other fresh air entry points or near direct heat sources. For room installation, the room unit should be mounted at least 4-1/2 feet above the floor. Avoid direct sunlight and draught. Admissible ambient conditions are to be observed. The room unit is designed for semi-flush surface mounting with recessed conduit box. Cable entry is through the rear of the unit. The unit comprises front housing and rear housing. These can be locked together and released by snap mechanism. Both the housings are plastic. Use the back plate as a template for locating holes for screws and wiring. Mount the back plate using screws provided. Wall anchors are recommended for drywall installations.

Figure 2

The communication cable between room unit and microprocessor controller should be 2 core, twisted pair, unscreened with stranded conductors (As per KNX Specification). Maximum distance between room unit and controller can be 700 meters. Step Four: Cover Installation Install cover plate as shown. Cover plate may be removed using a screwdriver as needed to access the terminals for wiring.

The room unit is not protected against accidental connection to AC 230 V

Figure 1

Step Two: Remove back cover Open the back cover of the room unit as shown using a screwdriver.

Step Three: Back plate Wiring Install wiring into terminal blocks as indicated, and push slack wire back into wall or junction box.

12 |

The microprocessor controller & room unit include electrical and electronic components and must not be disposed off as domestic waste. Current local laws on disposal of electronic waste are to be observed.

INSTALLATION,

Receiving of Equipment Responsibility should be assigned to a dependable individual at the job site to receive material. Each shipment should be carefully checked against the bill of lading. The shipping receipt should not be signed until all items listed on the bill of lading have been accounted for. When uncrating, care should be taken to prevent damage. Heavy equipment should be left on its shipping base until it has been moved to the final location. Check carefully for concealed damage. Any shortage or damages should be reported to the delivering carrier. Damaged material becomes the delivering carrier’s responsibility, and should not be returned to the manufacturer unless prior approval is given to do so.

Handling •

Rigging holes are provided on the sides of the unit.

•

Avoid twisting or uneven lifting of the unit

•

The cable length from bracket to the hook should always be longer than the distance between the outer lifting points.

•

If the unit is stored at the construction site for an intermediate period, follow these additional precautions: a. Support the unit well along the length of the base rail b.

Level the unit (no twists uneven ground surface)

c.

Provide proper draining around the unit to prevent flooding of the equipment

d.

Provide adequate protection from vandalism, mechanical contact, etc.

e.

Securely close the doors

f.

Cover the supply and return air openings an limits without isolation dampers.

Use all lifting points. Improper lifting can cause severe personal injury and property damage. HOOK

The packing list included with each shipment should be carefully checked to determine if all parts and equipment have been received. Any accessories such as starters, contactors or controls should be fastened to the basic unit to avoid loss and prevent possible interchanging with other units.

SLING

SPREADER

Make sure that wiring diagrams and IOM manuals are available within the equipment control panel. WOODEN PIECE

Rigging • Regardless of the packaging used in transporting of the units, it should preferably be lifted with a fork lift truck or a crane and belts. The units should be unpacked as close as possible to its final installation position. The unit should always be left standing upright. •

Before positioning the unit, it is advisable to re-check the weights.

•

Remove the wooden pallet from underneath the machine before installation

•

Use protectors to prevent sling or cable as per Figure 3-4.

•

All protection/spreader bars shown in the rigging illustration should be provided by the customer on site.

SHACKLE

Figure 3

WOODEN PIECE

HOOK

4No.EQUAL SLING

SHACKLE

Figure 4

| 13

INSTALLATION,

Single Unit Installation SPACING FOR SERVICE

When the PACV-S units need to be stored in a prolonged period prior to installation, the following protective measures are required: • Units must be stored in a protected area and safe from construction debris. Do not remove the wooden coil guard. • Check the pressure in high pressure side of refrigerant circuit to confirm that the refrigerant charge is intact in every three months. Take note of the ambient while checking. Contact SKM After Sales Office or SKM sales representative. • Keep the liquid line Shut Off valve closed.

A

DUCT

A

B

PACV- 51008 S TO 52055 S PACV- 61009 S TO 62066 S

When selecting a location for the unit, the following points should be considered: • There should be enough space for air movement beside the condenser coils which should be approximately equal to the height of the coils. • The discharged air from the condenser fan should not be obstructed by any roofing, ducting etc which could cause air short circuiting. • There should be sufficient area provided to enable for the servicing of the unit.

Figure 5 SPACING FOR AIR FLOW

DUCT

The schematic shown in Figures 5-9 gives the recommended clearance areas around the unit for both maintenance and air flow.

A

DUCT B

Figure 6

50 66

DUCT

52

60

DUCT

78

54

B

72

PACV- 53070 S TO 54125 S PACV- 63085 S TO 64145 S

66

p

82 96 78 86 78

46 [1165]

SPACING FOR BOTH AIR FLOW AND SERVICE

Figure 7

Multiple Unit Installation SPACING FOR AIR FLOW

SPACING FOR SERVICE

108

104

84

108 114 121 124 128 134 142

-

DUCT

DUCT

Table 4

A*

72

ALL DIMENSIONS ARE IN INCHES

14 |

A*

C

*

61009-S 61012-S 61018-S 62018-S 61020-S 62020-S 62024-S 62028-S 62033-S 62036-S 62037-S 62046-S 62055-S 62060-S 62066-S 62076-S 63085-S 63090-S 63095-S 63100-S 63105-S 63110-S 64120-S 64130-S 64136-S 64145-S

B

B

51008-S 51010-S 51014-S 52015-S 51017-S 52017-S 52020-S 52023-S 52026-S 52030-S 52032-S 52038-S 52045-S 52050-S 52055-S 52065-S 53070-S 53075-S 53080-S 53085-S 53090-S 53095-S 54100-S 54110-S 54115-S 54125-S

A

78 [1981]

PACV- 52065 S PACV- 62076 S

Location and Space Requirements PACV-S

A

Storage

C

PACV- 51008 S TO 52055 S PACV- 61009 S TO 62066 S

Figure 8

INSTALLATION,

•

If there are walls on one or two adjacent sides of the unit. The walls may be of any height. If there are walls on more than two adjacent sides of the unit. The walls should not be higher than the unit.

•

Do not locate outside air intakes near exhaust vents or other sources of contaminated air.

•

If the unit is installed where windy conditions are common, install wind screens around the unit.

•

Units surrounded by screens or solid walls must have no over head obstructions over any part of the unit.

•

The area above the condenser must be installed unobstructed to allow vertical air discharge.

•

A flat concrete foundation or floor which can support the weight of the equipment must provided as the unit must be level for proper operation and functioning of controls.

•

Under certain critical conditions it is recommended that vibration isolators of rubber-in-shear or spring type be installed under the base refer to loading points (Page 49).

DUCT

DUCT

Multiple Units Installation (Modular B Construction)

t.

PACV- 51008 S TO 52055 S PACV- 61009 S TO 62066 S

Figure 9

Foundation Recommendations It is a necessity that the units are installed with adequate free space around them to ensure proper circulation of air that is rejected by the condensers and to provide adequate space for unit access for servicing and maintenance. There is a possibility of recycling of air if the rejected air from condenser encounters any obstacles leading to an increase in the ambient air temperature surrounding the units. Air distribution across the entire heat exchange area will be impaired if the air outlet is obstructed. These conditions lead to a reduction in the heat exchange capacity of the coils causing an increase in discharge pressure of the compressors. This leads to a loss of capacity & increase in compressor power input

Units should not be completely shrouded with higher uninterrupted wind shield in order to prevent reversing of air flow. In case, such a configuration cannot be avoided, a properly designed exhaust duct or hood that does not influence any additional pressure a properly designed exhaust duct or hood that does not influence any additional pressure on the fans and which of the same hight as surrounding shield to be installed.

A flat level concrete foundation which can support the weight of the equipment must be provided. Where units are to be located, over steel trusses or on a steel platform, careful analysis to ensure proper distribution of weight onto the structural members should be ensured. The steel platform should be strong enough to hold the operating weight.

Pre-Installation Check-Up Electrical IMPORTANT: When installing the unit, always disconnect the electric supply. •

Make sure that the power supply is compliant with current safety standards. Always install the air conditioner in compliance with current local safety standards.

•

Verify that suitable grounding connection is available.

•

Verify that the voltage and frequency of the power supply comply with the specifications and that the installed power is sufficient to ensure the operation of any other domestic appliance connected to the same electric lines.

•

Verify that the air conditioner is connected to the power supply in accordance with the instructions provided in the wiring diagram included in the manual.

•

Verify that electric connections (cable entry, section of leads, protections....) are compliant with the electric specification and with the instructions provided in the wiring scheme. Verify that all connections comply with the standards applicable to the installation of air conditioners.

| 15

OPERATION

Preparation For Installation When deciding on the location of the unit with the owner, the following restrictions must be taken into consideration:

The discharge air from the condenser fan should not be obstructed by any roofing, shelter, ducting etc. Any obstruction will cause short circuiting of condenser fans leading to reduction in capacity or nuisance tripping of the PACV-S package unit from the high pressure control and sometimes in motor burnout .

General

1.

Unpack the unit carefully.

2.

Unfasten or dismantle transport locks.

3.

Packing material to be fully removed and disposed.

4.

The unit base frame must be fixed without stresses to the supporting structure.

5.

AVM to be regularly placed around centre of gravity and firmly fixed. Check whether AVM is balanced under load.

6.

No forces or vibrations may be transferred from other plant parts.

7.

The flexible connections at intake and/or discharge should be installed, well aligned and freely moving.

8.

The AVM should be freely moving and under even load.

9.

The impeller should be turning idly and should not touch the intake cone.

10. The stability against collapse of the unit should be checked.

Do NOT install the equipment in a location where it will come in contact with the following elements : •

Combustible gases

•

Saline air

•

Machine oil

•

Sulphide gas

•

Special environment conditions, if you must install the unit in such conditions, first consult SKM.

Avoid installing the equipment in the following:

16 |

Carrying Out Installation

•

In areas where it is exposed to direct sunlight. Close to any heat source.

•

In damp areas or locations where it could come into contact with water.

•

In areas where curtains and furniture could affect the supply and discharge of air.

•

In areas in which there is no enough space around the unit. (Must install as per the required/ recommended spacing, shown in the lay out drawings).

•

On surfaces that are unable to support the weight of the unit without deforming, breaking or causing vibrations when the unit is running.

Condensate Draining It is mandatory to install a properly sized drain trap in order to ensure proper draining of condensate collected in the drain pan. Below mentioned are recommendations for sizing a drain trap. Measure the maximum negative static pressure upstream from the fan. The height “H1 ” shown in below figures must be greater than or equal to the negative static pressure at design conditions. Ensure that there is sufficient water in the trap before starting in order to maintain the seal. H1= 1” for each 1” of negative static pressure + 1” H2= H1/2 H= H1 + H2+ Pipe Diameter + Insulation Condensate traps serving the cooling coils should be of sufficient height to be effective. The unit should be located on a suitable base to provide adequate height from the ground in order to accommodate the drain trap.

Figure 10

OPERATION

Pre Startup Checklist •

Make sure the power supply voltage and frequency are as given in the unit name plate.

•

Make sure that unit has been installed in accordance with the installation instruction and applicable codes.

•

Check all electrical connections in unit control panel; tighten them as required.

•

Make sure the compressor oil level is within the sight glass range.

•

Check the power supply phase sequence for proper direction of rotation of motors.

•

Make sure all system hand valves are in fully open position and system contains an operating charge of refrigerant.

•

Switch on the power supply to the unit

•

Crank case heaters of all compressors to be energized at least 24 hours prior to start up.

Pre-Startup Procedure After the installation has been completed, the following points should be covered before the system is placed in operation. a.

Check electrical connections. Be sure they are all tight.

b.

the oil charge has been properly adjusted to maintain the oil level at the center of the sight glass.

PACV-S unit is factory charged

Please make sure to open supply air dampers fully (if any) before starting the fan motor. Otherwise, blower fan can be damaged due to back pressure and warranty will be void.

Precaution: Carry out a fan test run

Risk of injury from rotating impeller! Never reach into the impeller when the fan is in operation.

•

Take measures to prevent centrifugal fan from being switched on accidentally.

Observe compressor oil level before start-up. The oil level should be at or slightly above the center of the sight glass. Use only oil approved by compressor manufacturer.

•

Clear the ducting system and fan of all foreign bodies (tools, small parts, construction waste, etc.).

•

Close all the inspection openings.

c.

Remove or loosen shipping retainers under motor- compressors. Make sure hold down nuts on spring mounted compressors are not touching the compressor feet.

•

Switch on fan and check direction of rotation of impeller by comparing it with the arrow on the fan indicating the direction of rotation.

•

d.

Check high and low pressure controls, pressure regulating valves and all other safety controls, and adjust if necessary.

If the direction of rotation is wrong, reverse the polarity of the motor having due regard to the safety instructions.

•

e.

Check refrigerant used in the system.

f.

Wiring diagrams, instruction bulletins, etc attached to PACV-S units should be read and filed for future reference.

Once operating speed has been reached measure the current consumption and compare it with the nominal motor current on the fan type plate or motor rating plate.

•

If there is continuous overload switch the centrifugal fan off immediately.

•

Check that the fan runs smoothly and quietly. Ensure that there are no unusual oscillations or vibrations.

•

Check the motor for any abnormal noises.

g.

h.

i.

j.

Make the proper refrigerant connections and charge the unit with the refrigerant to be used. Weigh the refrigerant drum before charging so an accurate record can be kept of the weight of refrigerant put in the system. Observe system pressures during charging and initial operation. Do not add oil while the system is short of refrigerant, unless oil level is dangerously low. Continue charging until system has sufficient refrigerant for proper operation. Do not overcharge. Remember that bubbles in a sight glass may be caused by a restriction as well as a shortage of refrigerant. Do not leave unit unattended until the system has reached normal operating conditions and

If the state of the fan does not allow adapted action for repair it has to be put out of order immediately and to be replaced if required.

Prior to starting up the unit, we recommend checking if the following steps have been carried out:

| 17

OPERATION

Operational Check-Out After the system has been charged and has operated for at least two hours at normal operating conditions without any indication of malfunction, it should be allowed to operate over-night on automatic controls. Then a thorough recheck of the entire system operation should be made as follows:

A permanent data sheet should be prepared on each installation, with a copy for the owner and the original for the installing contractor’s files. If any other firms are to handle service and maintenance, additional copies should be prepared as necessary. The form of the data sheet may vary, but a complete record of sizes and identification of all components used in the installation, together with any pertinent information should be included. Following is suggested check-off list:

a.

Check compressor head and suction pressures. If not within system design limits, determine why and take corrective action.

b.

Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is required, leak test all connections and system components and repair any leaks before adding refrigerant.

a.

Compressor manufacturer model and serial number.

b.

Equipment manufacturer model and serial number.

c.

Design operating temperatures.

When applicable, observe oil level in compressor crankcase sight glass, and add oil as necessary to bring level to center of the sight glass.

d.

Refrigerant and weight of charge.

e.

Electrical service, volts, cycles, phase, wire size.

f.

Control circuit, voltage, breaker size.

g.

Contactor or starter, manufacturer, model, size, part number.

h.

Compressor motor protection(if available), type, size, part number.

i.

Data on relays or other electrical components.

j.

Pressure control, type, size, model number, setting.

k.

Data on miscellaneous components such as pressure controls, crankcase heaters, solenoids, valves, etc.

l.

Liquid line drier, manufacturer, size, model number, connections.

c.

d.

e.

f.

18 |

Service Record

Thermostatic expansion valves must be checked for proper superheat settings. Sensing bulbs must be in positive contact with the suction line. Valves with high superheat settings produce little refrigeration and poor oil return. Too little superheat causes low refrigeration capacity and promotes liquid slugging and compressor bearing washout. Liquid refrigerant must be prevented from reaching the crankcase. If proper control cannot be achieved with the system in normal operation, a suction accumulator must be installed in the suction line just a head of the compressor to prevent liquid refrigerant from reaching the compressor. Using suitable instruments, carefully check line voltage and amperage at the compressor terminals. If high or low voltage indicated, notify the power company. The current normally should not exceed 120% of the nameplate rating. If amperage draw is excessive, immediately determine the cause and take corrective action. On three phase motor-compressors, check to see that a balanced load is drown by each phase. All fan motors on air cooled condensers, evaporators, etc should be checked for proper rotation. Fan motor mounts should be carefully checked for tightness and proper alignment. If belt drives are used, check the belt tension. All motors requiring lubrication should be oiled or greased as necessary.

m. Schematic diagram of refrigerant piping. n.

Final settings on all pressure, regulating and safety controls.

o.

Microprocessor details

OPERATION

Unit Start Up •

Switch on the three phase power supply to the unit.

•

Switch on the control circuit breakers. Unit controller will start up.

•

Check for any alarms in the controller. If there are any alarms, correct the cause and clear them.

•

Turn on the Run/Stop toggle switch in the unit control panel.

•

Press the power button in the room unit. Then supply fan will start.

•

Make sure the refrigerant circuits are enabled in the relevant circuit screen in the controller display.

•

Compressors will start based on the temperature set point set in the room unit and the indoor temperature. Make sure that the unit is in cooling mode, which can be selected from the room unit.

•

Condenser fans will start with compressors and will cycle based on discharge pressure.

•

module (if available in compressor) are healthy. If above are satisfied, solenoid valve will be opened and when the low pressure switch closes, compressor will be started.

A typical two compressor control is as shown below:

Sequence of Operation

Condenser fans

The unit may be enabled or disabled through the Run/ Stop toggle switch in the unit mounted control panel or from the room unit on/off button. Control is based on room temperature sensed by room unit(for units with duct sensor ,control is based on duct temp). Evaporator fan motor starts first. Compressors will be staged based on the set point and actual room temperature. On an increase in room temperature, cooling stages will be added and on a decrease in room temperature, cooling stages will be removed from the system. Sequence for the compressors and motors are as given below:

Condenser fans will switch on with associated compressor(s) and cycle based on discharge pressure.

Supply Fan Supply fan will be switched on if the below conditions are satisfied.

•

For single compressor units or units with circuits having independent condenser fans, condenser fans will be switched on based on the discharge pressure of that circuit. Each fan will switch on if pressure is above the stage on value and will switch of if the pressure is below stage off value.

•

For units with more than one compressor sharing the condenser fans, the highest pressure among the circuits will be taken to cycle the fans.

Unit Controller Display and Keypad The keypad/display of the controller consists of a 64 x 144 screen resolution 5 line 22 character display screen,3 buttons and a push & turn knob for navigation.

•

Controller start up is finished.

•

Run/Stop switch in the unit control panel is ON.

•

Room unit power icon is ON.

•

Room unit schedule is ON (If schedule is disabled, then unit will run continuously)

•

Communication between unit controller and room unit is healthy.

•

Motor overload is healthy.

Buttons

•

Voltage Monitor is healthy.

Info button: This is used to enter the unit information screen where the SKM Unit model & serial number can be viewed.

Supply fan has two modes; ON (continuously ON) or AUTO (ON when there is cooling or heating demand).

Compressor Compressor will switch on if the below conditions are satisfied. • Compressor minimum OFF time completed. • Supply fan runs for 30 seconds. • Circuit enable (from controller display) is enabled. • Unit is in cool mode. • Demand for compressor is present. • Discharge pressure and motor protector

Alarm button: This is used to enter directly the alarm screen for viewing the alarm details & to reset them manually if required. Esc button: This is a back button to move back to the previous screen or to the home screen.

Push & Turn Knob This is a navigation wheel that can be rotated as well as pushed. Rotating the wheel navigates between the lines of the screen and also to change/edit the changeable values on the screen. Clockwise rotation increases the values and anti-clockwise rotation decreases the value. Pushing the wheel acts as an “Enter” button to acknowledge the changed value.

| 19

OPERATION

Display and Keypad operation The main display screen consists of a 5 line display, with the first line displaying the page title and a numeric display e symbol if any of the number of alarms along with the alarms are present. Second & third lines display the date & time respectively. There are three sub menus in the display namely, SYSTEM OVERVIEW, PASSWORD & ALARMS. Every page can consist of data fields, either changeable or with information only. As the cursor moves over each line, the text in the line is highlighted with a black box around it and the text turning white. As the navigation wheel is rotated the subsequent lines get highlighted with a black box around them. When a line consists of an arrow in the far right of the page, it is referred to as a menu group. When the navigation wheel is pushed, the display goes to a new page consisting of the submenus. The title of the menu group appears as the title of the new page. Figure: Rotation of the navigation wheel

Figure: Pushing the navigation wheel

The system overview menu consists of information on the supply fan, circuits, condenser fans, and set points. These submenus give more information on the unit including safeties and status of compressors, motors and set points. Different screens of the controller are as given below.

If supply fan is not starting, navigate to these screens to find out the reason. In order for the supply fan to start, the Run/Stop input should be “Run”, Room Unit should be “On”, Schedule Status should be “On” in case the schedule is enabled, Motor over load should be “healthy” and Voltage monitor should be healthy.

Circuit Screen Each circuit screen will show the status of all the inputs and outputs related to that circuit.

These will show the status of supply fan motor (On or Off), Circuit enable/disable selection, Unit mode (Cool, Heat, Auto or Vent), Discharge pressure (Healthy or Trip), Suction pressure (Healthy or Trip), compressor motor protectors if available (Healthy or Trip), compressors (On or Off) and liquid line solenoid valve (Open or Closed). Note that circuit can be enabled or disabled from the controller display itself. In order to do that, highlight the Circuit Enable line and then press the navigation wheel. Then rotate the navigation wheel in order to enable or disable the circuit and then press the wheel. Unit operating mode selection is from the Room unit.

Condenser fans These screens will show the discharge pressures of each circuit and status of the condenser fans.

Main Screen This screen will show date & time, system over view, password & alarms.

Schedule

System Overview

The schedule screen will allow setting the On time and Off time for each day of the week. If the schedule is enabled, then unit will work based on this schedule only.

Selecting the system overview will lead to below screens

Set points From the above two screens, further navigation is possible to different screens which will give information about supply fan, each refrigerant circuit, condenser fans, schedule and set points.

This screen will show the temperature set point and actual indoor temperature (or duct ct temperature if optional duct sensor s is used).

Supply fan The below screens will give information about all the inputs and outputs related to supply fan.

20 |

If factory password is entered, then set points screen will show access to factory parameters as well.

OPERATION

Factory parameters will show Compressor Minimum off time, Compressor Minimum On time, Low pressure alarm delay, Cooling step, Cooling Differential, Condenser Stage1 On pressure, Condenser Stage1 Off pressure, Condenser On Differential pressure, Condenser Off Differential pressure, Schedule enable/disable, Clearing alarm history and software BSP version of the controller.

Note that factory parameters should be changed only by SKM.

•

Below Screen will appear. pp

•

Rotate the Navigation wheel and then screen will show Exe...

•

Press the navigation wheel and all the alarms which are g reset. not active will get

Unit Information This screen will provide the information about the unit model name and SKM serial number. List of Alarms in the Unit Controller Below are the various alarms configured in the Unit controller. Supply Fan Motor: Trip This alarm occurs when the overload of supply fan motor detects an overload condition in the motor. When this alarm happens, entire unit will be switched off. This alarm is auto reset as standard.

Alarms This screen will show alarm list and alarm history.

Voltage Monitor: Trip This alarm occurs when the voltage monitor connected in the main incomer detects an under voltage or over voltage or phase reversal or phase imbalance or single phasing condition. When this alarm happens, entire unit will be switched off. This alarm is auto reset as standard. Room Unit Communication: Lost

Pressing the alarm list will show all the active alarms. All alarms will be with date & time and will be in easily readable English language.

This alarm occurs when the unit controller looses communication with the room unit. When this alarm happens, entire unit will be switched off. This alarm is auto reset as standard. Circuit-# Suction Pressure: Trip

Note that some of the alarms (like high discharge pressure) are manual reset. In order to acknowledge the manual reset alarms, follow below steps. •

Enter the user password “1234” (Refer Passwords)

•

Go to alarm list screen and press acknowledge

This alarm occurs when the low pressure switch senses a low suction pressure in the refrigerant circuit. This alarm will be generated, if one refrigerant circuit is On for cooling demand and the low pressure switch doesn’t close for a specific time (low pressure alarm delay set point). When this happens, corresponding circuit will be switched off and alarm will be generated. This alarm is automatic reset as standard. Circuit-# Discharge Pressure: Trip This alarm occurs when the high pressure switch senses a high discharge pressure in the refrigerant circuit. This alarm will be generated, if the high pressure switch remains open for one second. When this happens, corresponding circuit will be switched off and alarm will be generated. This alarm is manual reset as standard. Compressor-# Motor Protector: Trip This alarm will be generated only for those compressors with a built in electronic motor protector module. It occurs when the motor

| 21

OPERATION

protector module senses a high internal temperature in the compressor. When this happens, corresponding circuit will be switched off and alarm will be generated. This alarm is automatic reset as standard.

Passwords In order to enter the password, use Password screen. Follow the below steps. Go to the “Password” screen in the Main Menu. •

•

Use the navigation wheel to enter password passw (Rotate to change and Press to select.). If user password is required, enter 1234.

Operation of the Room Unit The room unit displays indoor temperature (duct temperature if optional duct sensor is used), temperature set point, unit on/off status, unit operating mode, fan mode, day of the week, time of the day and schedule. Room unit will let the user to make the unit on/off, change the operating mode, change the fan mode, adjust the set point, change the temperature measurement unit, change date & time and operating schedule.

Setting the address in Room Unit Adjust the set point, change the temperature measurement unit, change date & time and operating schedule.

•

22 |

•

If the room unit address is not set correctly, it will display as below (“P- -” blinking).

•

Press “power button”, “mode button”, “minus button” and “plus button” simultaneously as shown below.

Power Button

Mode Button

Minus Button

Plus Button

•

Room unit will display the software version as below.

•

Press “mode button”; room unit will display parameter 001 as below, with 001 blinking

Once the password is entered, a number corresponding to the password level will appear on left top of the screen. For user password, it will be 4.

OPERATION

•

Press “plus button” multiple times to reach parameter 005. At this stage parameter 005 will be blinking. On pressing “mode button”; parameter value will start blinking. Use “plus button” or “minus button” to make it 005 as shown below (if it is already 0005, no need to do this step). Press “mode button” again, then parameter 005 will start blinking.

Switching on and switching off the unit Press the button to make the unit on and off. When the unit is on, will be shown on the display.

Changing the Unit operating mode Operating mode of the unit can be changed by pressing button. There are two modes for cooling only units and four modes for units with electric heater. The modes are cool ( ), heat ( ), auto cool-heat ( ) and Vent ( ). Note that in vent mode, compressors or heaters ( if available ) will not operate.

Changing the fan operating mode •

Press “plus button” to reach parameter 006. At this stage parameter 006 will be blinking. Press “mode button” and then use “plus button” or “minus button” to make the value 0002 (if it is already 0002, no need to do this step). Press “mode button” again, then g parameter 006 will start blinking.

Operating mode of the fan can be changed by pressing the button. There are two modes for the fan which are Auto ( ) and On ( )). Auto means the supply fan will run only when there is cooling or heating demand. On means supply fan will run continuously. In the units where there is much changes in temperature, always use On mode.

Changing the Set point in Room Unit Press “+” and “-” buttons to adjust the temperature set point.

Changing the Temperature display unit Long press the button to toggle the temperature display unit between oCelsius and oFahrenheit. •

Press “plus button” to reach parameter 007. At this stage parameter 007 will be blinking. Press “mode button” and then use “plus button” or “minus button” to make the value 0003 (if it is already 0003, no need to do this step). Press “mode button” again, then parameter 007 will start blinking.

Alarm Indication In case if there is any alarm present in the unit, will blink on the room unit display. Once the alarms are cleared from the unit controller, then the alarm symbol will disappear.

Time and Day of the week Room unit will show the time in 12 hour format and the day of the week. Day of the week will be 1 for Monday, 2 for Tuesday, 3 for Wednesday, 4 for Thursday, 5 for Friday, 6 for Saturday and 7 for Sunday.

•

•

Press “plus button” multiple times to get back to parameter 001. Then press “power button”, the version screen will be displayed.

Time and Date Setting By pressing the button, user will enter time and date setting. Pressing “+” or “-”button can change the variables those are blinking on the screen, while pressing button will confirm the changes and the cursor will move to the next variable automatically. •

The first view is time setting, user can change 3 items: hour, minute and time for-mat. The view is showed as follows:

•

Firstly the hour area will be blinking; pressing “+” or “-” can change the number of hour, pressing will confirm the changes and the cursor will move to the minute area automatically.

•

After the number of minute is confirmed, the whole time area will blink. Pressing “+” or “-”button will switch time format between 12-hour with AM/PM and 24-hour. It will shows as

Press “power button” again, then room unit p y as below. will show normal display

| 23

OPERATION

follows in 24-hour time format:

•

•

After the year is confirmed, it will jump to the view of month and day. The view is showed as follows:

•

d day is confirmed, HMI-SG will return After the month and to the view of time. Press button PROG or there is no any operation for 1 minute, it will exit the setting.

After the time format is confirmed, HMI-SG will jump to the view of year. It will show as follows:

An Overview Of Menu Structure

MAIN MENU DATE TIME SYSTEM OVERVIEW PASSWORD ALARMS

HMI PASSWORD ENTER PASSWORD CLOSE ACCOUNT

SYSTEM OVERVIEW SUPPLY FAN CIRCUIT-1 CIRCUIT-2 CONDENSER FANS SCHEDULE SETPOINTS

ENTER PASSWORD ENTRY ALARMS ALARMLIST ALARMHISTORY

****

SUPPLY FAN RUN/STOP INPUT ROOM UNIT ON/OFF SCHEDULE SCHEDULE STATUS FAN MODE MOTOR OVERLOAD VOLTAGE MONITOR SUPPLY FAN MOTOR

: STOP : ON : ENABLE : ON : ON : TRIP : TRIP : OFF

CIRCUIT-1 SUPPLYFAN MOTOR CIRCUIT1 ENABLE UNIT MODE DISCH.PRES.-1 SUCT.PRES-1 COMPRESSOR-1 SOL.VALVE-1

: OFF : ENABLE : VENT : TRIP : HEALTHY : OFF : CLOSED

CIRCUIT-2 SUPPLYFAN MOTOR CIRCUIT2 ENABLE UNIT MODE DISCH.PRES.-2 SUCT.PRES-2 COMPRESSOR-2 SOL.VALVE-2

: OFF : ENABLE : VENT : TRIP : HEALTHY : OFF : CLOSED

CONDENSER FANS DISCH.PRES.-1 : XX.X PSI DISCH.PRES.-2 : XX.X PSI _____________________________ FAN-1 : OFF FAN-2 : OFF FAN-3 : OFF FAN-4 : OFF SCHEDULE MONDAY: SCHEDULE-1: HH: MM-HH:MM TUESDAY: SCHEDULE-1: HH: MM-HH:MM WEDNESDAY: SCHEDULE-1: HH: MM-HH:MM THURSDAY: SCHEDULE-1: HH: MM-HH:MM FRIDAY: SCHEDULE-1: HH: MM-HH:MM SATURDAY: SCHEDULE-1: HH: MM-HH:MM SUNDAY: SCHEDULE-1: HH: MM-HH:MM SETPOINTS TEMP.SETPOINT INDOOR TEMP FACTORY SETTINGS

FACTORY SETTINGS COMP.MIN.OFF TIME COMP.MIN.ON TIME LP ALARM DELAY COOLING STEP COOLING DIFF. COND.STG1 ON COND.STG1 OFF COND.DIFF.ON COND.DIFF.OFF CLEAR ALM HIST ON/OFF SCHEDULE BSP VERSION

24 |

: XX.X C : XX.X C

: XXX s : XXX s : XXX s : XX.X C : XX.X C : XXX PSI : XXX PSI : XXX PSI : XXX PSI : Enable : PASSIVE : X.XX

OPERATION

Table 5

| 25

MAINTENANCE

Periodic Maintenance Following Checklist describes the suggested maintenance schedule to maintain proper operation of the unit. Detailed procedures are mentioned in the corresponding pages.

Component

Evaporator Fan/Motor Section

Filter Section

Evaporator Coil Section

Checklist

Weekly

General Check for Corrosion and Repaint as Necessary Check amperage draw on blower motor Check condensate line and clean if necessary Check for correct voltage at unit Motors General Check Check for unusual noise from the motor Check all wiring for loose connections Air filter to be washed & cleaned Check for Debris / Blockage over fins & clean coil if necessary Check connecting lines, joints & coil for evidence of oil leaks Oil Level at Sight Glass

Yes

Monthly

Control Panel

Condenser Fan & Motor

Condenser Coil Section

Crank Case Heater Operation Refrigerant Sub cooling in Liquid Line Operating Pressures Dust & Debris on Power Terminals/ Contactors /Loose Cable Lugs Check for correct voltage at unit (Unit operating) Check Unit Operation Check for alarms in Unit Microprocessor Check for Vibrations & Noise Check unbalance of the Fan Motor Bearings to be checked Corrosion Fan Blades to be checked /Balancing Check connecting lines , joints & coil for evidence of oil leaks Clean & inspect outdoor coil , wash with water if necessary

Annually Yes

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

Superheat at Compressor Operation Level Maintenance

Half Yearly

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Table 6

The above mentioned schedule is typical and will vary largely based on site conditions. 26 |

MAINTENANCE

Maintenance The maintenance of this equipment shall be in accordance with the regulation of authorities having jurisdiction and all applicable codes. It is the responsibility of the installer to determine and follow the applicable codes. Low head pressure may lead to poor, erratic refrigerant feed control at the thermostatic expansion valve. The units have automatic control of the condenser fans which should provide adequate head pressure control down to 50 ºF (10 ºC) provided the unit is not exposed to windy conditions. The system design is responsible for assuring the condensing section is not exposed to excessive wind or air recirculation.

Procedures It is quite probable that a majority of operating failures can be traced to careless or inadequate maintenance procedures. The following instructions have been prepared to help the service engineer systematically cover the many points which must be considered to provide each installation with trouble free performance. Take extreme care to keep refrigeration tubing clean and dry prior to installation. The following procedures should be followed:

Brazing Procedures

1

. When copper is heated in the presence of air, Copper oxide forms. To prevent copper oxide from forming inside the tubing during brazing, an inert gas should be passed through the line at low pressure to prevent scaling and oxidation inside the tubing. Dry nitrogen is preferred. Nitrogen displaces air in the tubing and prevents oxidation of the interior surfaces. A pressure regulating valve is to be used to control the flow.

2

. Ensure that the tubing surfaces to be brazed are clean, reaming at the ends of tubes is to be done to remove any burrs and keep the surface even.

6

. Apply heat evenly over the length and circumference of the joint to draw the brazing material into the joint by capillary action. Remove the brazing rod and flame from the joint as soon as a complete fillet is formed to avoid possible restriction in the line.

7

. Visually inspect the connection after brazing to locate any pin holes or crevices in the joint .

Never use oxygen for pressurizing a system; an explosion may occur if oil is present in the system. Always use a gauge equipped pressure regulator on the high pressure back-up gas, and never interconnect the refrigerant cylinder and the inert gas cylinder through a gauge manifold. Nitrogen and carbon dioxide cylinder pressures can rupture a refrigerant cylinder.

Never solder, braze or weld on refrigerant lines or any unit components with pressures that are above atmospheric pressure or where refrigerant may be present. Always remove refrigerant by following the local guidelines. After refrigerant removal, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs. Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion. Excessive heat from soldering, brazing or welding with refrigerant vapours present can form highly toxic gases Failure to follow all proper safe refrigerant handling practices could result in death or serious injury!

3

. Make sure the inner and outer tubes of the joint are symmetrical and have a close clearance, providing an easy slip fit. If the joint is too loose, the tensile strength of the connection will be significantly reduced. The overlap distance should be equal to the diameter of the inner tube.

4

. Wrap the body of each refrigerant line component like “expansion valve, solenoid valve, Hot gas bypass” with a wet cloth to keep it cool during brazing. Move any tube entrance grommets away for the brazing area.

5

. Flux , when used is to be applied in small quantities only. Excessive flux, when used, can enter the system and contaminate the refrigerant system.

| 27

MAINTENANCE

Using OFN (oxygen free nitrogen) during brazing:

Leak Testing, Evacuation & Charging Procedures:

All pipe work shall be cut square with a proprietary pipe cutter to give a clean cut, without copper fragmentation. Hacksaws must not be used. When brazing, all pipe work shall be purged with low-pressure oxygen-free nitrogen, above atmospheric pressure (to provide a positive pressure in the pipe) to prevent the formation of copper oxides and scale, and to prevent moisture from the surrounding air entering the system. Any annulus between the oxygen-free nitrogen feed pipe and the refrigerant pipe shall be sealed to prevent the ingress of air due to the ejector effect of the higher pressure oxygen free nitrogen.

The below mentioned procedures are to be followed whenever any major repair or replacement is done on the system. These procedures of Leak Testing, Evacuation & Charging are required to be made in order to bring the system back to its original operating condition after any major repair or replacement. MANIFOLD GAUGE

The pipe work should be flushed with oxygen free, highpressure nitrogen to ensure that any moisture and debris are removed. All fittings should be kept to a minimum to reduce the number of joints (i.e. potential leaks) and frictional losses. Swept bends should be formed using a bending tool with the correct dies/mandrill /spring to prevent reeking or barreling.

“Do NOT release refrigerant to the atmosphere! Use appropriate procedures as per local directives.”

“Use only dry nitrogen with a pressure regulator for pressurizing unit. Do not use acetylene, oxygen or compressed air or mixtures of a hydrogen containing refrigerant and air above atmospheric pressure containing them for pressure testing as they may become flammable and could result in an explosion. Refrigerant, when used as a trace gas should only be mixed with dry nitrogen for pressurizing units.”“Failure to follow these recommendations could result in death or serious injury or equipment !”

28 |

Figure 11

Warning - use of Manifolds with sight glass: This guide assumes the use of Refrigerant Manifold and Gauges. It is essential that the manifold does not have a sight glass. These sight glasses have been known to fail and risk causing serious injury to the engineer carrying out the test. The manifold gauges and service lines must be in good condition. Manifolds with sight glasses are only suitable for refrigerant recovery. Handling of nitrogen cylinders: When the cylinder is not being used ensure the valve is closed. Never transport or store the cylinder with the regulator fitted.

Dangers of Use of Nitrogen: You will be pressure testing at high pressures with nitrogen. The pressures are high enough to cause serious injury or death. Nitrogen is an asphyxiant – it will suffocate you in high concentrations. The following guidelines show how to minimise risk during pressure testing.

MAINTENANCE

Leak testing procedure If there is any residual refrigerant left in the system this must be recovered prior to follow this procedure. 1.

Ensure the nitrogen cylinder is either secured or located in a position so that it cannot fall over.

2.

Ensure the regulator valve is wound fully out (counter clockwise / anti clockwise).

3.

Fit the regulator to the cylinder.

4.

Fit gauges to the system and ensure there are no isolated sections within the part of the system to be pressure tested.

5.

Fit the common manifold hose to the nitrogen cylinder.

6.

Open the system valves and open the high side manifold valve (to avoid damaging the low side manifold gauge do not pressurise the low side of the manifold with the test pressure).

7.

Open the nitrogen cylinder valve.

8.

Slowly wind the nitrogen regulator (clockwise) to pressurise the system:

9.

Pressurise the system using Nitrogen to the below mentioned pressures based on the refrigerant being used in the system.

Maximum Pressure, bar g

Maximum Pressure, psig

Suitable Regulator

R 22

23.6

342

Maximum output of 33 Bar

R 134 a

13.7

200

Maximum output of 26 Bar

R 407 C

23.6

342

Maximum output of 33 Bar

R 410 A

33

478

Maximum output of 40 Bar

Refrigerant

Table 7

LEAK TESTING

in

•

Pressurise the system in stages of no more than 3 bar (45 psi) at a time;

•

Ensure you only pressurise the relevant sections of the system to their maximum allowable pressure.

•

Listen for audible pressure loss at every pressure increment increase; Figure 12

When the maximum system allowable pressure (Refer to Table No: 7 has been reached, close the nitrogen cylinder valve and the high pressure manifold valve.

10. Note the pressure shown on the high pressure gauge.

Evacuation

11. Wind the nitrogen regulator valve fully out (counter clockwise / anti clockwise). 12. Carefully remove the common hose from the regulator, slowly venting the nitrogen pressure. 13. Maintain the system at the maximum allowable pressure for the duration of the test. 14. Test each joint with leak detection spray or soapy water to identify the leak point. If leaks are found, they must not be repaired with the system pressurised.

Vacuum Pump

16. Repair any leaks found and then repeat the test procedure using OFN.

Whenever there is a replacement of system components like compressor, filter drier, expansion valve etc, the refrigerant system should be evacuated in order to remove moisture from the system.

17. When it is established that the system is safe and leak tight the OFN can be evacuated and the system can be recharged with refrigerant.

Moisture affects the proper functioning of the system. Air being a non-condensable will exist in the top of the condenser and the receiver.

15. Slowly vent the remaining nitrogen.

| 29

MAINTENANCE

Triple Evacuation Method A vacuum pump capable of pumping down to 500 microns should be connected to both the low and high side evacuation valves with Copper tube or high vacuum hoses (¼” ID minimum). If the compressor has service valves, they should be opened.

Figure 13

Increase in pressure depends on the amount of air in the system. Any time a system is running with abnormally high head pressure, air in the system is a prime suspect. The presence of air reduces the lubricating properties of the oils especially POEs which are Hygroscopic in nature. Air in the system increases the risk of Acid formation thus damaging the Copper Plating and Motor insulation, thus leading to electrical and mechanical failure of the compressor. In order to avoid these, system vacuum should be done according to the procedures mentioned:

System Evacuation Procedures Equipment Required: •

Vacuum Pump- Two stage type with Gas Ballast and a capacity matching the system volume (Using a vacuum pump larger than the system volume increases the risk of freezing the moisture in the system.

•

Connection lines (¼ in for Small Systems & ½ in for larger systems are recommended)

•

A Manifold Gauge or a Micron gauge capable of measuring vacuum down to 200 microns is to be installed between the System and the vacuum pump to allow the system pressure to be checked after evacuation

•

Nitrogen Cylinder with regulator and hose kit.

Do not turn off vacuum pump when connected to an evacuated system before closing shut off valve/ Manifold Gauge.

30 |

1.

Operate pump to bring down the system pressure to 1500 microns and continue operating for another 10 minutes.

2.

Close all the service valves and shut off the vacuum pump.

3.

Connect a nitrogen cylinder and regulator to system and open until system pressure is 5 Psig.

4.

Close all service and shut off valves and allow the system to stand for 30 minute in order to allow Nitrogen to absorb moisture in the system.

5.

Repeat steps 1- 4 again, i.e. evacuate for a second time down to 1500 microns.

6.

The triple evacuation method is completed by final operation of the pump to bring down the system pressure to 500 microns.

7.

Close all service valves on the gauge and shut off the vacuum pump.

8.

Maintain Vacuum at 500 microns for minimum of 30 minutes.

9.

Connect the cylinder of the refrigerant that is to be used in the system using gauges and open until system pressure is 10 psig or proceed to refrigerant charging procedures.

10. The triple evacuation method to a pressure of 500 microns is practical under field conditions, and represents a specification that can be met.

To evacuate a system properly requires time and care. Any slight carelessness in protecting the sealed system can undo all the precautions taken previously. But the slight extra effort required to make an evacuation properly and completely will pay big dividends in reduced maintenance and trouble free operation.

Under no conditions is the motor/ compressor to be started or operated while the system is under a high vacuum. To do so may cause serious damage to the motor windings because of the reduced dielectric strength of the atmosphere within the motor chamber.

Never use a Meghommeter to apply power to compressor while it is under vacuum, doing so will cause motor winding damage.

MAINTENANCE

Refrigerant charging The proper performance of air conditioning system is dependent on the proper refrigerant charge. An undercharged system will starve the evaporator, resulting in excessively low compressor suction pressures, loss of capacity, and possible compressor overheating. Overcharging can flood the condenser resulting in high discharge pressures, liquid refrigerant flooding, and potential compressor damage. Each system must be considered separately, since systems with the same capacity or horsepower rating may not necessarily require the same refrigerant or the same amount of charge. Therefore it is important to first determine the type of refrigerant required for the system, the unit nameplate normally identifying both the type of refrigerant and the weight of refrigerant required.

and connect it to the low side. Now with the compressor running, open the cylinder valve, purge the refrigerant and charge the system until the weight of refrigerant charged is equal to that mentioned on the name plate of the unit. Once the charging has been done as per the weight of refrigerant mentioned on the nameplate, it is necessary to check whether the refrigerant charge is sufficient. This can be done in the following ways. Figure 15

Liquid charging

•

Checking the Sight Glass: A sight glass in the liquid line is one of the easiest ways to determine whether a system is optimally charged, provided there is no sudden change in the operating conditions while observing e.g. Cycling of condenser fans, High Evaporator load etc. Even a small obstruction before the sight glass could cause flashing of refrigerant in the liquid line and cause bubbles in the sight glass even though there will be sufficient sub cooling available from the condenser.

•

Measuring the Refrigerant Sub cooling: This is best method provided the proper instrumentation is available. Check the discharge pressure and the liquid line temperature and check the saturated condensing temperature corresponding to the discharge pressure (Available on page 59). The difference between these two temperatures gives the measure of Sub cooling leaving the condenser. The optimum sub cooling for a system is 8-14 oF.

Liquid refrigerant charging is much faster than vapour charging and it is commonly used in large capacity systems. For initial charge, the following important notes should be taken into consideration. •

The compressor should not be running and any compressor service valves should be closed.

•

Charging should be done through filter drier access valve to prevent any contaminants being inadvertently introduced into the system.

•

Check the compressor oil level and make sure crank case heater is energized at least 24 Hours prior to startup.

The entire system should be pulled to a deep vacuum (See evacuation procedures) prior to liquid charging. Place refrigerant cylinder in a scale to measure the amount of refrigerant charge. Attach Figure 14 the charging line from the cylinder to the filter drier service valve ports. Purge the charging line and open the cylinder liquid valve and the charging valve. The initial vacuum in the system will cause liquid to flow through the charging line until the system pressure and the refrigerant cylinder is equalized.

Figure 16

WARNING: Never charge Liquid refrigerant to Low side of the system when the system is in the Off state •

Measuring the Refrigerant Superheat : Measure the suction pressure and obtain the saturated suction temperature from the P-T Chart. Measure the Actual Suction temperature. The difference between the two temperatures gives the measure of Superheat entering the compressor. The optimum value for superheat is 8-12 oF.

Note the weight of refrigerant charged by calculating the difference between final weight after charging and the initial weight.

Vapour charging Once the system pressure is equalized after liquid charging , shut off the cylinder liquid valve and charging valve and remove the charging line from the high side

Figure 17

| 31

MAINTENANCE

Fan For smooth operation fan must be serviced regularly. The most important maintenance measures to be made at least twice a year are: 1. Vibration and sound level to be checked. Anomalous values indicate a problem on the unit. 2. Check the presence of corrosion on the fan especially on the rotating path to prevent breaking. 3. Check if there are any objects within the range of the fan which might be sucked into the rotor once the fan is running. 4. Check whether the fans rotor rotates freely, without any friction against the casing body. 5. Check the fan design speed as it must not exceed the rotary speed. 6. Check whether the supply cables in the fan section are firmly fixed.

Bearing 1.

2.

3.

Check bearing for sound, a normal bearing generates a smooth uniform sound, while a damage bearing generates a loud and irregular sound. Excess vibrations or temperature are often a sign of possible damages Check the bearing locking and seals periodically. Check for excessive grease leakage from the bearing. Leakage of small quantity from the bearing is normal.

Replacement instructions of fan bearings assembled on Cast iron pillow blocks •

•

•

Unlock the casing cover easing screws at both sides. Using appropriate tools, hold the shaft in an appropriate position in order not to damage the inlet funnel or rotors wheel. Remove protection rings from the bearing side (only one bearing is equipped with it). After removing grease, remove sealing half-rings from the upper and lower port of the block casing. Slide down the bearings, straightening the screwed ring tongue located on the sleeve, ease at each side screwed rings with a centre pouch and hammer. Install the bearings, tighten up the sleeves with the screwed ring bend the rings tongue. Install a new sealing sleeve into grooves located in the lower part of the block. Install the lubricated shaft assembly with a bearing on the block basis. Assemble fixing ring (or more fixing rings) at a side of one bearing only (the other bearing is not adjustable). Insert the other sealing ring onto the upper block side. Put the upper block part onto the lower one and tighten up the screws. Fill the bearing with suitable grease. Turn the wheel several times in order to check if it rotates correctly.

Cover

Replacement instruction of fan bearings assembled on Cross bars •

•

•

Remove protection screws and protection rings out of the bearings. Remove protection rings out of the shaft. Using appropriate tools, hold the shaft in an appropriate position in order not to damage the rotors wheel. Remove nuts and bolts from cross bars and separate assembly from shaft and bearing. Replace the old rubber rings and bearings and assemble the new ones onto the cross bars. Install protection rings onto the bearings clamping them according to the fan’s rotations direction and secure them with fixing screws. Turn the wheel several times in order to check if it rotates correctly. Assemble cross bars on side panels and make sure to preserve coaxiality of the rotor. Tighten the nuts and bolts on cross belts to the side panels. Cross bars

Protection rings

Protection screw

Cross bars

32 |

Cast iron separate casing

Fan Motor Checking the insulation If the unit has been stored for long time or if it has been kept in a damp atmosphere, insulation resistance test for the motor should be carried out. This measurement must be carried out using a megohmmeter at 500V D.C. (do not use a magneto electric system).

Draining off condensation water Temperature variations cause condensation to form inside the motor, which must be removed before it adversely affects motor operation. Condensation drain holes, located at the bottom of the motors (bearing in mind their operating position) are sealed with plugs which must be removed and then replaced every six months (if they were not replaced, the motor degree of protection would no longer be maintained). Clean the orifices and plugs before reassembling them.

MAINTENANCE

Cleaning To ensure the motor operates correctly, remove any dust or foreign bodies which might clog the cover grille and the housing fins. Before carrying out any cleaning operation check that the motor is completely sealed (terminal box, drain holes, etc). Dry cleaning (vacuuming or compressed air) is always motor preferable to wet cleaning.

When installing new belts or during replacement, do not stretch them over the sheaves; Instead loosen the adjustable motor mounting base. Once the new belts are installed, adjust the belt tension using tension gauge.

• Disconnect and lock-out power before installation and maintenance.

Always clean at reduced pressure from the centre of the motor towards the extremities to avoid introducing dust and particles under the seals.

•

Working on or near energized equipment can result in severe injury or death.

Bearing

•

Do not operate equipment without guards in place. Exposed equipment can result in severe injury or death.

•

Periodic inspections should be performed. Failure to perform proper maintenance can result in premature product failure and personal injury.

•

To avoid damage, supporting structure including shafts and bearings must be designed to handle transmitted loads and belt tension(s).

As soon as any abnormal noise or vibration is noted on the motor or abnormal temperature rise is noted in the bearing, the condition of the bearings must be checked. Damaged bearings must be replaced as soon as possible to prevent worse damage to the motor and the fan. It is also recommended to change the bearing after 100,000 hours of operation under normal operating conditions. If one bearing needs to be replaced, the other bearing must also be replaced. The seals should be changed routinely when the bearings are changed.

Fan Belt Adjustment The supply fan belts must be inspected periodically to ensure proper unit operation. Replacement is necessary if the belts appear frayed or worn. Units with dual belts require a matched set of belts to ensure equal belt lengths.

Periodic inspections should be performed. Failure to perform proper maintenance can result in premature product failure and personal injury. Maintenance of the fan equipment should only be carried out by skilled and adequately trained staff. To ensure complete safety do not start any maintenance procedure or inspection without disconnecting the unit from the power supply and before the fan and motor have completely stopped rotating.

V-Belt Installation Check List 1

Turn off and lock out power ( ) Yes ( ) No source

2

Observe all other safety procedures ( ) Yes ( ) No

3

Select proper replacement belts

( ) Yes ( ) No

4

Remove belt guard

( ) Yes ( ) No

5

Inspect drive elements–bearings, ( ) Yes ( ) No shaft, etc.

6

Inspect sheave grooves for wear ( ) Yes ( ) No

7

Check sheave alignment

( ) Yes ( ) No

8

Install new belts

( ) Yes ( ) No

9

Tension belts

( ) Yes ( ) No

10

Check sheave alignment (final)

( ) Yes ( ) No

11

Replace guard

( ) Yes ( ) No

12

Start drive (look & listen)

( ) Yes ( ) No

Re adjust the tension after first 24 ( ) Yes ( ) No 13 hours of operation Table 8.

Close any inlet or outlet damper to avoid a rotation of the impeller due to induced airflow.

| 33

MAINTENANCE

•

Never mix new and used belts on a drive.

•

Never mix belts from more than one manufacturer.

•

Always replace with the right type of V-belt.

•

Always observe V-belt matching limits.

Belt Tensioning Instructions •

Ideal tension is the lowest tension at which the belt will not slip under peak load conditions.

•

Check tension frequently during the first 24 hours of operation. Check after jog start or 1-3 minutes of operation, at 8 hours, 24 hours, 100 hours and periodically thereafter are recommended.

•

Over tensioning shortens belt and bearing life.

•

Keep belts free of foreign material which may cause slip.

•

Make v-drive inspection on a periodic basis. Under-tensioned belt drives often produce audible squeal noise. Tension when slipping.

Before doing maintenance or tensioning on belt drives, turn equipment off and lock out the power source.

Excessive belt tension shortens belt life and may cause bearing & shaft damage Note: When new belts are installed on a drive, the tension will drop rapidly during the first few hours. Thus, for new belts, tighten to the initial installation defection force shown in the tables below. Check tension frequently during the first 24 hours of operation. Subsequent re tensioning should fall between the minimum and maximum forces shown in the tables. Note: The proper tension for V-belt drive is the lowest tension at which the belts won’t slip under peak load conditions.

Belt Cross Section

Belt Deflection Force, lb

Smallest Sheave Diameter Range (inches)

RPM Range

3.4 - 4.2

860-2500 2501-4000

-

4.4 - 5.6

860-2500 2501-4000

5.3 4.5

5.8 - 8.6

860-2500 2501-4000

6.3 6.0

B, BX

Super Gripbelts Used Belt

New Belt

Gripnotch Belts Used Belt

New Belt

4.9 4.2

7.2 6.2

7.9 6.7

7.1 6.1

10.5 9.1

9.4 8.9

8.5 7.3

12.6 10.9

Table 9

In order to ensure the correct belt tension, use a belt tension checker (Figure 21-24) and use the deflection formula below and compare with the data given in Table 5 Sample: If belt span = 20 inches Belt Cross Section B, Super grip belt Small sheave PD = 5 in Deflection = (Belt span)/64

Figure 18

Solution

34 |

1.

From Table 5, check for the deflection force for type B , super grip belt with 5 inch smaller sheave , the deflection shown is 7.9 lb

2.

The deflection = 20 in/64 = 0.3125 in

3.

Tension of the belt to be increased or decreased using the adjustable motor mount until the force for 0.312 inches deflection is 7.9 lb as indicated by the tension checker tool.

4.

Check belt tension at least twice during first operating day. Re adjust the tension until the tension is maintained within the recommended range.

Figure 19

MAINTENANCE

6.

The adjustments are to be done only in half turn adjustments.

7.

Once the adjustments have been made, replace the external key and tighten the adjustment set screw.

8.

The belt may now be installed and the belt tension adjusted by using the adjustable motor mounts.

9.

Measure the RPM and the motor current drawn and record the change in current and RPM.

Alignment of shafts & sheaves Make sure that fan shafts and motor shafts are parallel and level. Common causes of misalignment are improper location of sheaves and nonparallel shafts. When shafts are not parallel, belts on one side are drawn tighter and pull more than their share of the load. Due to this, the belts wear out faster leading to replacement of the entire set before utilising it for the maximum given service. If misalignment occurs in the sheave, the belts will enter and leave the grooves at an angle , causing excessive belt /sheave wear. Alignment of Shafts: By measuring the distance between shafts at 3 or more locations to check if the distances are equal. Equal distances denote parallel shafts. Alignment of Sheaves: Figure 20

Figure 21

Fan Pulley Adjustment (For variable pitch pulleys only) Blower speeds are factory adjusted by default as per the fan selection data. The required airflow rate and the total static pressure adjustment of pulley should be done only when the actual external static pressure exceeds the design data. Adjustment of blower speeds should be done as per the following procedure: 1.

Measure the initial RPM and motor current drawn.

2.

The motor is moved towards the blower shaft via the adjustable mounting to loosen the belt tension.

3.

Loosen the two set screws in order to adjust the motor pulley flange.

4.

Blower speed shall be increased by rotating the adjustable pulley in a clockwise direction in such a way, it moves towards the fixed flange.

5.

Blower speed shall be decreased by rotating the adjustable pulley in an anti-clockwise direction in such a way, it moves away from the fixed flange.

In order to check the location of adjustable sheave on shafts, a straight edge or a string are to be used. If the sheaves are properly aligned .When the sheaves are aligned, the straightedge will touch both sheaves at the points indicated by arrows in below image. A string, drawn tight, may be used in the same manner. For uneven width sheaves, place a string in the centre groove of both sheaves and pull tight. Adjust sheaves and tighten the sheave setscrews to the proper torques. Parallel operation of the fan and motor shafts is necessary to prolong belt life. Place a level on the shafts to check horizontal alignment. The pillow block bearing with double setscrew locking arrangement requires specific tightening instructions.

NOTE: At or before start-up check the wiring of the three phase fan motor to assure proper shaft rotation. Incorrect fan rotation may loosen the locking collar resulting in pre-mature bearing failure.

Figure 22.

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MAINTENANCE

Mold In And Around Drain Pans Drain pans under cooling coils are a common source of mold and mildew problems. If the drain pan does not actually drain water— for whatever reason—mold and mildew will certainly grow in the pan and spread through the duct work to the occupied spaces. Also, if water leaks or spills out of the drain pan, mold and mildew will grow in the soaked food source. The problems fall into three categories: maintenance, pan design and drain line installation.

Solution – 1.

There must be a drain line, and it must be connected through a trap to the drain pan.

2.

The trap stem height should be greater than the pressure of the fan. (The stem height is the vertical distance between the outlet of the trap and the bottom of the drain pan.

3.

The contractor must be certain that the drain line actually connects to a drain.

Failure to provide adequate condensate piping to the drain trap may result in water damage to the equipment or building.

Maintenance: Problem – 1.

Dirt collects in the line .

Duct Connections

2.

Drain line is clogged.

3.

Pan can over flow.

4.

Possibility of mold growing.

Connections of supply and return ducting to the PACV-S series packaged units should be by means of flexible duct connections to prevent any vibrations being transmitted to the ducting. It must be ensured that the connection is weather proofed to prevent water from entering onto the unit/ducting.

Solution – 1.

Using compressed air to unclog the line.

2.

Frequently changing the filters to keep dirt and fibers from collecting in the drain pan.

Pan design: Problem – 1.

Drain pan is not long enough to catch the droplets.

2.

Pan is not slopped to its drain in two directions.

3.

Standing water in parts of the pan which never drain.

1.

All SKM cooling coils have drain pans sloped all the way to their drains.

2.

SKM drain pans length is adequate to capture water droplets coming off the coil when the system is operating at the peak dew point design condition.

Drain line installation: Problem – 1. No drain line or no connection to the line. Either the designer fails to specify a drain line, or the contractor fails to install it.

36 |

2.

No trap, or an improperly-designed trap in the drain line Without a trap, condensation cannot drain from the unit. The fan suction holds water in the pan until it overflows.

3.

Drain line not connected to a drain. Drain lines that feed water into building cavities are surprisingly common.

MAINTENANCE

to the manufacturer’s instructions. If desired, heat the solution to 150° F maximum to improve its cleaning capability.

Coil If the coil is to deliver its full cooling or heating capacity both its internal and external surfaces must be clean. 1. Periodic verification of the coil cleanliness is required. Dirty coil increases air pressure drop and reduces heat transfer potential, thus unbalancing the system. 2.

3.

4.

6.

Examine finned surface for accumulation of dirt or lent. If necessary wash down the affected areas with a mild detergent solution and a soft brush. (Take care of the fin surface while cleaning). Compressed air line may be used to blow out any solids between the fans. Do not probe the coils with a metal scraper as any damage may cause tube leaks. Clean refrigerant coils with cold water and detergent or one of the commercially available chemical coil cleaners. Inspect the drain pan and condensate drain at the same time the evaporator coil is checked. Clean the drain pan by flushing with water and removing any matters of obstructions which may be present.

Coil Cleaning

Pour the cleaning solution into the sprayer. If a highpressure sprayer is used: a.

The minimum nozzle spray angle is 15 degrees.

b.

Do not allow sprayer pressure to exceed 600 psi.

c.

Spray the solution perpendicular (at 90 degrees) to the coil face.

d.

Maintain a minimum clearance of 6” between the sprayer nozzle and the coil.

7.

Spray the leaving-airflow side of the coil first; then spray the opposite side of the coil. Allow the cleaning solution to stand on the coil for five minutes.

8.

Rinse both sides of the coil with cool, clean water.

9.

Inspect both sides of the coil; if it still appears to be dirty, repeat Steps 7 and 8.

10. Reinstall all of the components and panels removed in Step 2; then restore power to the unit. 11. With a fin comb, straighten any coil fins which were inadvertently bent during the cleaning process.

Hazardous chemicals! Coil cleaning can be either acidic or highly alkaline. Handle chemical carefully. Ensure proper handling by wearing goggles or face shield, chemical resistant gloves, boots, and apron or suit as required.

Compressor Oil

Regular coil maintenance, including annual cleaning enhances the unit’s operating efficiency by minimizing: 1. Compressor head pressure and amperage draw 2.

Fan brake horsepower and

3.

Static pressure losses.

At least once each year—or more often if the unit is located in a “dirty” environment—clean the condenser coils using the instructions outlined below. Be sure to follow these instructions as closely as possible to avoid damaging the coils. 1. To clean coils, use a soft brush and a sprayer.

If a motor burn out is suspected, use an acid test kit to check the condition of the oil. Test results will indicate an acid level has exceeded the limit if a burn out occurred. If a motor burn out has occurred, change the oil in both compressors in a tandem set. This will require that the oil equalizer tube be removed to suck the oil out of the oil sump. A catch pan must be used to catch the oil when the compressor oil equalizer line is loosened. Note: Refrigerant oil is detrimental to some roofing materials. Care must be taken to protect the roof from oil leaks or spills. Charge the new oil into the Schrader valve on the shell of the compressor.

Adding Oil

2.

Remove enough panels from the unit to gain safe access to coils.

Schrader- The oil fill connection and gauge port is a 1/4” male flare connector incorporating a schrader valve.

3.

Straighten any bent coil fins with a fin comb.

4.

Remove loose dirt and debris from both sides of the coil with a soft brush.

For compressor with access valve port oil should be added by schrader connection, for other compressor oil should be added through the suction lines.

5.

Mix the detergent with water according

To remove this excess oil an access valve port has been added to the lower shell of the service compressor replacement compressor

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MAINTENANCE

. After running the replacement compressor for a minimum of 10 minutes, shut down the compressor and drain excess oil from the Schrader valve until the oil level is at one-half of the sight-glass level. This should be repeated twice to make sure the proper oil has been achieved.

Expansion Valve Service & Maintenance >

POE must be handled carefully and the proper protective equipment (gloves, eye protection, etc.) must be used when handling POE lubricant. POE must not come into contact with any surface or material that might be harmed by POE, including without limitation, certain polymers (e.g. PVC/ CPVC and polycarbonate).

Warning: DisDisposal of filter drier cores, compressor oil and system components should be handled according to local laws.

Access Valve

Expansion valve is responsible for allowing the proper amount of refrigerant to enter the evaporator regardless of cooling load. It does this by maintaining a constant superheat. Typically, superheat should run in the range of 8°F to 12°F (4.4°C to 6.6°C). Maintaining correct superheat to the compressor is an important element in extending compressor life.

Liquid line filter drier should be replaced whenever there is a motor burn out.

Expansion Valve Overfeeding Note:- Do not use excessive water pressure. Excessive water pressure can bend the fans and tubing of the coil and lead to inadequate unit performance. Be careful not to splash water excessively into unit.

Overfeeding of the evaporator results in high suction pressure, low superheat and possible liquid carryover. This set of conditions is usually remedied by readjusting the valve superheat. If this falls to correct the condition, the valve should be replaced.

Expansion Valve Underfeeding CAUTION Chemical reaction! Compressor destruction! Do not mix up ester oils with mineral oil and/or alkyl benzene when used with chlorine-free (HFC) refrigerants.

Compressor Oil level check When the compressor is running under stabilised conditions the oil level must be visible in the sight glass. The presence of foam filling in the sight glass indicates large concentration of refrigerant in the oil and / or presence of liquid returning to the compressor. The oil level can also be checked a few minutes after the compressor stops, the level must be between 1/4” and 3/4” of sight glass.

Underfeeding of the evaporator results in low suction pressure and high superheat. It may be caused by improper super heat adjustment, restricted solenoid valve or drier or an inoperative expansion valve power element. Test the power element in the following manner:

1.

Stop the unit and allow it to warm to ambient temperature.

2.

Remove remote bulb from suction line and place it in container of ice water.

3.

Start system.

4.

Remove the bulb from the ice water and warm in hand. At the same time feel the suction line for a drop in temperature. If liquid refrigerant floods through the valve, the power element is operating properly. If there is no change in the suction line temperature, the power element is defective. Replace it.

Dismantling & Disposal • Removing oil and refrigerant • Do not disperse in the environment • • •

38 |

Use the correct equipment and method of removal Dispose of oil and refrigerant properly Dispose of compressor properly

System pressures: Installation or Removal Figure 23.

MAINTENANCE

Warning: Don’t place open flame near or on bulb Figure 24.

Bulb locations Figure 27.

Valve Orientation Figure 25.

Solder techniques Figure 28.

Bulb and external equalizer locations Figure 26.

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MAINTENANCE

•

Hot Gas Bypass On many air conditioning and refrigeration systems it is desirable to limit the minimum evaporating pressure during periods of low load either to prevent coil icing or to avoid operating the compressor at a lower suction pressure than it was designed to operate. Hot gas bypass is a method of maintaining compressor suction pressure (creating a false load) during low loads. This has the affect of modulating compressor capacity below the minimum unloading point without cycling the compressor. It is accomplished by introducing the hot (discharge) gas from the leaving side of the compressor back to a point on the lowpressure side of the refrigeration circuit.

Introduction of the bypassed gas between the thermostatic expansion valve and the distributor is not generally recommended because of the large pressure drop caused by the hot gas flowing through the distributor nozzle, or throat, and the tube circuits, which have been sized for normal cooling flow rates. Careful evaluation and testing should precede any application where hot gas is bypassed between the TEV and the distributor.

Brazing Procedures Any of the commonly used brazing alloys for high side usage are satisfactory. However, when soldering or brazing, it is very important that the internal parts be protected by wrapping the valve with a WET cloth to keep the body temperature below 300°F. While the ADRS (E)-2, ADRP (E)-3 have metal to metal seating material, the ADRH (E)-6 valves use synthetic-to-metal seating material and must be protected from overheating. SHGB (E) valves use synthetic material in the piston ring and seating surface that must be protected from overheating. The pilot valve diaphragm and springs are also susceptible to damage from overheating and must be protected. The extended fittings will adequately protect the synthetic material under normal conditions. However, when using high temperature solders, the torch tip should be large enough to avoid prolonged heating of the copper connections. Always direct the flame away from the valve body.

Discharge bypass Valves Setting The minimum allowable evaporating temperature that will avoid coil icing depends on the evaporator design and the amount of air passing over the coil. The refrigerant temperature may be below 32 oF but coil icing will not usually occur with high air velocities since the external surface temperature of tube will be above 32 oF. Discharge bypass valves can be set so they would be at their rated capacity at 26 oF evaporating temperature. (Pressure setting for R-134a is 28 psig).

Pilot Operated Valves:

Location •

The Valve should be always installed at the condensing unit rather than at the evaporator section. Not only will this ensure the rated the bypass capacity of the valve but it will eliminate the possibility of hot gas condensing the bypass line.

•

HGBP valve can be installed in horizontal or vertical lines which ever best suits the application and permits easy accessibility of the valves.

•

When externally equalized valves are used, the equalizer connection must be connected to the suction line where it will sense the desired operating pressure.

•

In all cases it is important that some precautions be taken in mounting the valves. It is suggested that they be adequately supported to prevent excessive stress on the connections.

•

Consideration should be given to locate these valves so they do not act as oil traps and so solder cannot run into the internal parts during brazing.

Spare parts

Figure 29.

40 |

MAINTENANCE

Service Tips: MALFUNCTION - FAILURE TO OPEN POSSIBLE CAUSE

REMEDY

1. Pilot solenoid coil de-energized.

1. Energize solenoid coil.

2. Pilot solenoid coil failure.

2. Replace solenoid coil.

3. External equalizer line pinched shut, plugged or not connected.

3. Connect or replace external equalizer line.

4. Main piston sticking due to foreign material

4. Disassemble valve and clean. Replace piston if necessary

5. Pilot solenoid port blocked with foreign material. (SHGB(E) models only) 5. Remove enclosing tube and clean pilot solenoid port. 6. Pilot valve port blocked with foreign material

6. Disassemble pilot valve and clean.

MALFUNCTION - FAILURE TO CLOSE 1. Main piston sticking due to foreign material.

1. Disassemble valve and clean. Replace piston if necessary.

2. Pilot valve port not closing due to foreign material.

2. Disassemble pilot valve and clean.

If solenoid coils is de-energized (SHGB(E) models only) 3. Solenoid plunger not closing solenoid pilot due to foreign material or 3. Remove enclosing tube and clean or replace if necessary. damaged enclosing tube. 4. Solenoid pilot port worn or damaged due to foreign material.

4. Inspect and replace pilot assembly if necessary. Table 10.

Direct Acting Valves:

Figure 30.

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MAINTENANCE

Service Tips: VALVE TYPE

MALFUNCTION

ADRI-1-1/4 ADRIE-1-1/4 ADRS-2 ADRSE-2 ADRP-3 ADRPE-3

ADRH-6 ADRHE-6

CAUSE

REMEDY

Failure to open

1. Dirt or foreign material in valve

1. Disassemble valve and clean

Failure to close

1. Dirt or foreign material in valve 2. Diaphragm failure 3. Equalizer passageway plugged 4. External equalizer not connected or equalizer line pinched shut 5. Internal spring overhead

1. Disassemble valve and clean 2. Replace element only 3. Disassemble valve and clean 4. Connect or replace equalizer line 5. Replace valve

Failure to open

1. Dirt or foreign material in valve 2. Equalizer passageway plugged 3. External equalizer not connected or equalizer line pinched shut

1. Disassemble valve and clean 2. Disassemble valve and clean 3. Connect or replace equalizer line

Failure to close

1., Dirt or foreign material in valve 2. Diaphragm failure

1. Disassemble valve and clean 2. Replace element only

Figure 31.

Keys To Successful Implementation

•

Dispose of oil and refrigerant properly

1.

•

Dispose of compressor properly

Position the HGBP valve above the discharge line, near the compressor. If the system includes Pump-down provide a means to shut off refrigerant flow.

2.

Pitch the line upstream of the HGBP valve to drain oil back into the discharge line.

3.

Pitch the line downstream of the HGBP valve toward the evaporator, away from the valve.

4.

For disassembly and disposal the unit must be consigned to an authorised disposal centre.

Insulate the entire length of the HGBP line

Dismantling & Disposal

42 |

Warning: Disposal of filter drier cores, compressor oil and system components should be handled according to local laws.

•

Removing oil and refrigerant

•

Do not disperse in the environment

•

Use the correct equipment and method of removal

• • •

During disassembly the fan, motor and coils, if in working order may be recycled or reused. All materials should be recycled or disposed of according to local bylaws. Electrical and electronic components must not be disposed off as domestic waste. Current local laws for disposal of electronic waste are to be observed.

MAINTENANCE

Voltage Check the voltage across incoming power terminals when the system is operating. Voltage requirements are: 1.

Voltage should not to exceed voltage utilization range. See table below.

2.

Voltage imbalance between phases not to exceed 2%.

Rated power supply

Operating Limits (Volts)

V/Ph/Hz

Minimum

Maximum

380-415/ 3 /50 440/ 3 /50 380/ 3 /60 460/ 3 /60 220/ 3 /60

360 396 342 414 198

440 462 418 506 242 Table 11

% Voltage imbalance = 100 * (Max. Voltage deviation from average voltage of three phases / Average voltage of three phases) As an example, nominal 440V, 3Ph power source produces following voltages between the terminals.

are no blockages. •

Inspect the evaporator and condenser coils for dirt, bent fins, etc. If the coils appear dirty, clean them according to the instructions described under “Coil Cleaning”.

•

Inspect the F/A-R/A damper hinges and pins to ensure that all moving parts are securely mounted. Keep the blades clean.

•

Manually rotate the condenser fans to ensure free movement and check motor bearings for wear. Verify that all of the fan mounting hardware is tight.

Refrigerant Recovery, Recycling, and Reclamation There are many environmental and economic benefits to be gained from recovery, recycling and reclamation efforts worldwide. The major benefits include: • Minimized atmospheric emissions and reduced environmental impact; • Expanded market opportunity for used refrigerant; • Reduced environmental compliance costs; • Reduced need for new refrigerant; • Increased lifetime of refrigeration equipment due to contaminant removal The following describes the specific differences between refrigerant recovery, recycling and reclamation:

L1 – L2 = 430V, L1 – L3 = 436V, L2 – L3 = 445V Average Voltage = (430 + 436 + 445)= 437V 3 Max. Deviation = 445 – 437 = 8V % Voltage Imbalance = (100 * 8) = 1.83% 437

WARNING! Hazardous Voltage Disconnect all electric power including remote disconnect switch before servicing or maintenance. Proper lockout procedures to be followed so that power cannot be energized. Failure to disconnect power before servicing could result in serious injury or death.

Lifting Point

Fork Lifting

Refrigerant RECOVERY involves the removal of a refrigerant from a system and the placement of that refrigerant into a container. The recovery process: •

Is conducted whenever technicians need to open or dispose of air conditioning or refrigeration equipment.

•

Includes removal of refrigerant vapor (heels) to established vacuum levels to maximize the amount of refrigerant captured and minimize releases. Performance specifications are included in Air Conditioning and Refrigeration Institute (AHRI) 740.

•

Involves service technicians, equipment operators, appliance disposal facilities, equipment and refrigerant manufacturers.

Contactor 1.

Inspect the contacts. If they appear pitted or burned, replace the contacts or contactor.

2.

Using an ohmmeter, test continuity of the contactor holding coil. If the coil does not test continuous, replace it.

Cooling Season •

Check the unit’s drain pans and condensate piping to ensure that there

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MAINTENANCE

•

Is conducted whenever technicians need to open or dispose of air conditioning or refrigeration equipment.

•

Includes removal of refrigerant vapor (heels) to established vacuum levels to maximize the amount of refrigerant captured and minimize releases. Performance specifications are included in Air Conditioning and Refrigeration Institute (AHRI) 740.

•

inlet port) is clean before starting every job. This screen prevents damage to the unit from debris that may get past the inline filter. When pumping dirty refrigerant, this screen may quickly clog and slow the process when used without an inline filter. 1. Setup the machine as shown in the diagram below. Make sure that all the connections are tight. A. Connect the AC system High side to the Manifold High side.

Involves service technicians, equipment operators, appliance disposal facilities, equipment and refrigerant manufacturers.

B.

Refrigerant RECYCLING involves processing used refrigerants to reduce contaminants, then reusing the refrigerant. •

Recycling is recommended only when recharging to the same owner’s equipment.

•

Recycling involves removal of some contaminants prior to reuse. Contaminants can result in early system failure. Contaminants include oil, moisture, acid, chlorides, particulates, and noncondensable gases.

•

•

The Industry Recycling Guide (IRG-2) published by AHRI describes maximum recommended levels of impurities. International Organization for Standards (ISO) 11650 or AHRI 740 standards may be used to measure recovery/recycling equipment performance.

Refrigerant RECLAMATION involves purifying used refrigerant to meet industry product specifications. •

Reclamation identifies bad or mixed refrigerants which could result in equipment damage or leakage. Chemical analysis also is required to verify specification values to meet or exceed product standards. (e.g. ISO 12810, AHRI 700).

•

Reclamation may include filtering, separation, distillation, dilution, or reformulation of the recovered refrigerant.

•

Reclamation is recommended when used refrigerants will be charged into equipment other than the equipment it was removed from, or into equipment owned by a different company.

•

Reclamation facilities and processes should be designed to minimize emissions.

•

Non-reclaimable refrigerants should be disposed of in an environmentally acceptable manner, and in accordance with applicable regulations.

C. Connect the Manifold center port to the Recovery Unit input port. D. Connect the Recovery Unit output to the Recovery Cylinder liquid port. 2.

Connect the recovery unit to a 230V outlet using a 12PSivG cord (minimum) and not more than 15 feet long.

3.

Make sure the input valve on the recovery unit is closed, this will make it easier for the compressor to start when the power is turned on.

4.

Open the liquid port of the Recovery Cylinder and the output valve of the recovery unit.

5.

Open the liquid port on the Manifold Gauge Set. Removing the liquid first will keep the recovery time to a minimum.

6.

Turn on the recovery unit with the On/Off switch on the front panel. The compressor and fan should start.

7.

Slowly open the input valve of the recovery unit.

8.

When all the liquid has been removed, slowly open the vapor port on the Manifold Gauge Set. Both valves to system should now be fully open to maximize vapor flow.

9.

Run the unit until the vacuum required by the EPA is achieved.

10. Close both valves on the Manifold Gauge Set and on the recovery unit. 11. Shut off machine. 12. Close the valves on the Recovery Cylinder and disconnect the hoses.

Figure 32

Self Purging The Recovery Unit 1.

Close all the ports on the system you are servicing that are connected to the recovery unit.

2.

Close the input valve on the recovery unit.

3.

Turn off the recovery unit to prevent high pressure shutoff.

4.

Turn the Purge/Recover knob to the Purge Setting.

Note: A scale must be used to avoid overfilling the storage tank.

5.

Turn on the recovery unit and run the machine until you achieve the desired vacuum.

Note: Use an inline filter when you are pumping dirty refrigerant.

6.

Close all valves on the recovery unit and the recovery tank.

7.

Turn off the recovery unit and return IN the Purge/Recover knob to the Recover setting.

Refrigerant Recovery Techniques Standard Recovery Procedure

Note: Check that the debris screen (on

44 |

Connect the AC system Low side to the Manifold Low side.

MAINTENANCE

Figure 33

Push/Pull Recovery Procedure (for Bulk Liquid Refrigerant)

Figure 34

Tank Cooling Procedure (Optional) Note: A scale must be used to avoid overfilling the storage tank.

In order for this procedure to work, you must have at least 2.3 kgs. of liquid refrigerant in the storage tank. 1. Connect the hoses as shown. A. Connect the Recovery Unit input to the Recovery Cylinder vapor port.

The Push/Pull method is useful for recovering large amounts of liquid from a system. This will only work on large systems where the liquid can be accessed easily. Do not attempt this on systems that contain less than 15 Ibs of refrigerant unless it has a receiver tank or it may not work correctly.

Once the siphoning starts, it can continue to fill the tank even when the machine has been shut off. To avoid overfilling, you must be sure to close all valves on the tank and system when you are finished.

1. Setup the machine as shown in the figure 35. Make sure that all the connections are tight.

B.

Connect the Recovery Unit output to the Recovery Cylinder liquid port.

2.

Open all valves.

3.

Start Machine.

4.

Throttle the output valve so that the output pressure is at least 100psi greater (but never greater than psi) than the input pressure.

5.

Run until the tank is cold.

Alternative Cooling Setup (Optional) By setting up your equipment as shown here, it is possible to cool the tank during the recovery procedure if necessary. Normal Recovery:

A. Connect the System Vapour side to the Recovery Unit output port.

A. Tank vapor valve - Closed.

B.

Tank Cooling:

Connect the System Liquid side to the Recovery Tank liquid port.

C. Connect the Recovery Unit input port to the Recovery Tank vapor port.

Note: Keep valves on tank and system closed at this time. 2.

Slowly open valves on the Recovery Unit.

3.

Switch on the power to the Recovery Unit.

4.

Slowly open the valves on the tank and system. The liquid should now begin to be pulled out of the system. You can monitor the progress with an Inline sight glass.

5.

When all the liquid has been siphoned off, turn off the Recovery Unit and close all the valves.

6.

You can now proceed to remove the remaining vapor using the standard recovery procedure.

Figure 35

A. Tank vapor valve- Open. B.

Manifold Gauge Set- 80th Closed.

C. Follow steps 3-5 above to cool tank.

Figure 36

Purging Non-Condensables from Storage Tanks • • •

•

The tank must be left undisturbed for at least 24 hours so that all of the air will rise to the top. Connect a Manifold Gauge Set to the tank and check the pressure at the vapour port. Look up the refrigerant you are using on a Refrigerant Temperature/Pressure chart and use the ambient air temperature to determine what the tank pressure should be. If the tank pressure is higher than the pressure on the chart. Slowly open the vapour port and let the excess pressure bleed off until it is about 5psi above the pressure on the chart. Close the valves and let the tank stand still for 10 minutes. Repeat if necessary.

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MAINTENANCE

Trouble Shooting Problem: Compressor is Noisy Symptoms Possible Cause Recommended Action

• • •

Symptoms Possible Cause Recommended Action

• • •

Abnormally cold suction line. Liquid “Flood back.” Check and adjust superheat. Check if remote bulb is loosen suction line and refix. Abnormally cold suction line. Compressor knocks. Expansion valve stuck in open position. Repair or replace valve.

Problem: Compressor Short cycles Symptoms Possible Cause Recommended Action

• • •

Normal Operation, except very frequent stopping and starting. Intermittent contact in electrical control circuit. Repair or replace faulty controls.

Symptoms

•

Possible Cause Recommended Action

• •

Normal Operation, except very frequent stopping and starting on low pressure control. Lack of refrigerant. Repair refrigerant leak and recharge.

Symptoms

•

Possible Cause Recommended Action

• •

Temperature change in refrigerant line through drier or solenoid valve. Clogged liquid line or filter drier. Repair/replace solenoid valve or replace drier core.

Symptoms Possible Cause Recommended Action

• • •

No flow of refrigerant through valve. Expansion valve power assembly has lost charge. Repair expansion valve assembly.

Symptoms Possible Cause Recommended Action

• • •

Loss of capacity. Obstructed expansion valve. Clean valve or replace if necessary.

Problem: Discharge pressure Too Low Symptoms Possible Cause Recommended Action

• • •

Bubbles in sight glass. Lack of refrigerant. Repair leak and charge.

Problem: Discharge pressure Too High

46 |

Symptoms

•

Possible Cause

•

Recommended Action

•

Excessively warm air leaving condenser cuts out on high pressure control. Too little or too warm condenser air or restricted condenser air flow/ obstruction to air flow. Clean coil, check fan and motors for proper operation.

Symptoms Possible Cause Recommended Action

• • •

Exceptionally hot condenser and excessive discharge pressure. Air or noncondensible gas in system. Remove air or non condensibles.

Symptoms Possible Cause Recommended Action

• • •

Exceptionally hot condenser and excessive discharge pressure. Overcharge refrigerant. Remove excess refrigerant gradually, normal subcooling is 12 ºF (6.7 ºC).

Symptoms Possible Cause Recommended Action

• • •

Abnormally cold suction line. Liquid “Flood back.” Check and adjust superheat. Check if remote bulb is loosen suction line and refix.

MAINTENANCE

Trouble Shooting Problem: Suction pressure Too High Symptoms Possible Cause Recommended Action

• • •

Compressor runs continuously. Excessive load on unit. Check unit sizing & selection. Investigate system design & install additional air conditioning if required.

Symptoms Possible Cause Recommended Action

• • •

Abnormally cold suction line. Liquid flooding back to compressor. Expansion valve stuck in open position, air filter blocked. Repair or replace valve. Change filter.

Problem: Suction pressure Too low Symptoms Possible Cause Recommended Action

• • •

Loss of capacity. Obstruction in the liquid line or low air flow or under charging. Check for dirty filter drier, inoperative expansion valve, choked compressor.

Symptoms Possible Cause

• •

Recommended Action

•

Icing on suction line. Fan not running, thermostat setting too low, ambient temperature too low/blocked air filter. Check thermostat setting and investigate system design &/or unit sizing selection/clean filter. Check fan motor, overload &belt.

Symptoms Possible Cause Recommended Action

• • •

Loss of capacity or bubbles in sight glass. Gas leakage. Repair leak and charge.

| 47

Trouble Shooting Problem: Supply Fan does not Start Symptoms Possible Cause

• •

Recommended Action

•

Symptoms Possible Cause

• •

Recommended Action

•

Symptoms Possible Cause Recommended Action

• • •

Supply Fan Does not start even if unit controller is ON. Schedule in the controller is off. Correct the schedule.

Symptoms Possible Cause

• •

Recommended Action

•

Supply Fan Does not start even if unit controller is ON. Fan mode in the room unit is Auto and there is no cooling or heating Demand. Change the Fan mode to On or adjust the temperature set point.

Supply Fan Does not start even if unit controller is ON. Supply fan switched off by unit controller due to motor overload trip, or voltage monitor trip, or room unit communication loss. Reset the motor overload, Check the incoming power supply and voltage monitor, Check the communication between unit controller and room unit. Supply Fan Does not start even if unit controller is ON. Run/Stop switch in the unit control panel is off, Room unit power button is off. Switch on the Run/Stop switch, Turn on the power button in room unit

Problem: Compressor does not start

4 48 8 |

Symptoms

•

Possible Cause Recommended Action

• •

Symptoms

•

Possible Cause Recommended Action

• •

Symptoms

•

Possible Cause

•

Recommended Action

•

Compressor does not start even if there is cooling demand and supply fan is running. Circuit tripped on high discharge pressure or Low suction pressure or compressor motor protector. Correct the cause for the trip and reset the alarm if necessary.

Symptoms Possible Cause Recommended Action

• • •

Compressor does not start even if supply fan is running. No cooling demand. Adjust the temperature set point in room unit.

Compressor does not start even if there is cooling demand and supply fan is running. Room unit’s operating mode is in ‘Ventilation’. Change the room unit operating mode to Cool or Auto (Auto only in units with heater). Compressor does not start even if there is cooling demand and supply fan is running. Circuit enable/display selection in the controller display is disabled. Enable the circuit from the controller display.

APPENDIX- I

Loading Points PACV51008-S 51010-S 51014-S 52015-S 51017-S 52017-S 52020-S 52023-S 52026-S 52030-S 52032-S 52038-S 52045-S

UNIT Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg

A1 214 97 242 110 462 209 503 228 494 224 513 233 549 249 576 261 699 317 736 334 737 334 822 373 969 439

LOADING POINTS A2 A3 215 97 243 110 461 209 493 224 493 223 504 229 536 243 553 251 689 312 722 328 725 329 807 366 934 424

309 140 334 152 578 262 607 275 608 276 622 282 657 298 732 332 873 396 889 403 894 405 1011 459 1283 582

A4

TOTAL WEIGHT

311 141 336 152 550 249 605 274 580 263 615 279 654 297 693 314 871 395 882 400 891 404 1008 457 1207 547

1049 476 1154 524 2050 930 2208 1001 2175 987 2254 1023 2395 1086 2553 1158 3133 1421 3228 1464 3248 1473 3648 1655 4392 1992

Table 12

MODEL PACV61009-S 61012-S 61018-S 62018-S 61020-S 62020-S 62024-S 62028-S 62033-S 62036-S 62037-S 62046-S 62055-S

UNIT Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg

A1 221 100 256 116 472 214 513 233 505 229 523 237 563 255 591 268 720 327 760 345 791 359 850 386 1088 494

Load at Each Point lbs. [Kg.] A2 A3 A4 221 100 256 116 472 214 503 228 503 228 515 233 551 250 568 258 710 322 747 339 776 352 835 379 1054 478

312 141 338 153 581 263 610 277 612 278 625 284 663 301 756 343 883 401 899 408 909 412 1021 463 1350 612

313 142 340 154 553 251 608 276 584 265 618 280 661 300 718 326 881 400 891 404 906 411 1018 462 1274 578

TOTAL WEIGHT 1067 484 1190 540 2078 942 2235 1014 2204 1000 2282 1035 2438 1106 2634 1195 3195 1449 3297 1495 3383 1534 3723 1689 4767 2162 Table 13

| 49

Loading Points

PACV52050-S 52055-S 52065-S 53070-S 53075-S 53080-S 53085-S 53090-S 53095-S 54100-S 54110-S 54115-S 54125-S

UNIT Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg

A1

A2

A3

A4

A5

1004 456 1153 523 960 435 683 310 687 312 719 326 752 341 770 349 808 366 954 433 974 442 993 451 1028 466

987 448 1134 514 1026 465 467 212 471 213 478 217 503 228 509 231 529 240 665 302 675 306 680 308 694 315

1360 617 1391 631 566 257 777 353 781 354 813 369 882 400 908 412 937 425 1119 507 1139 516 1158 525 1189 539

1357 615 1378 625 633 287 661 300 665 302 673 305 755 343 766 347 777 353 943 428 953 432 957 434 968 439

983 446 604 274 607 275 640 290 673 305 691 313 716 325 865 392 885 401 904 410 929 422

LOADING POINTS A6 A7 983 446 397 180 401 182 408 185 435 197 436 198 444 201 582 264 591 268 596 270 602 273

1284 583 600 272 626 284 634 288 676 307 682 310 693 314 917 416 956 433 962 436 976 443

A8

A9

A10

A11

A12

TOTAL WEIGHT

1284 583 824 374 894 406 902 409 944 428 950 431 967 439 1298 589 1336 606 1345 610 1375 624

1046 475 1148 521 1156 524 1210 549 1241 563 1249 567 1505 683 1584 719 1603 727 1613 732

876 397 944 428 952 432 1009 458 1023 464 1033 469 1513 686 1587 720 1604 728 1622 736

793 360 821 372 828 376 879 399 885 401 893 405 1097 497 1144 519 1151 522 1157 525

1030 467 1105 501 1112 505 1176 533 1182 536 1190 540 1339 607 1399 635 1404 637 1410 640

4708 2135 5056 2294 7720 3502 8758 3973 9149 4150 9316 4226 9895 4488 10045 4556 10236 4643 12796 5804 13222 5998 13357 6059 13564 6153

Table 14 MODEL PACV62060-S 62066-S 62076-S 63085-S 63090-S 63095-S 63100-S 63105-S 63110-S 64120-S 64130-S 64136-S 64145-S

UNIT Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg Ib Kg

A1

A2

A3

A4

A5

1152 522 1226 556 1019 462 729 331 732 332 770 349 804 365 826 374 867 393 1014 460 1036 470 1058 480 1098 498

1133 514 1205 546 1086 492 468 212 472 214 480 218 505 229 511 232 530 241 667 302 677 307 681 309 696 316

1501 681 1526 692 568 258 822 373 826 375 863 392 934 424 964 437 996 452 1179 535 1201 545 1223 555 1259 571

1497 679 1513 686 634 288 662 300 666 302 674 306 757 343 767 348 779 353 944 428 954 433 959 435 970 440

995 451 649 294 652 296 690 313 725 329 746 339 775 351 925 420 947 429 969 440 999 453

Load at Each Point lbs. [Kg.] A6 A7 A8 995 451 398 181 402 182 410 186 436 198 438 199 445 202 583 264 593 269 598 271 604 274

1365 619 609 276 635 288 643 292 685 311 691 314 702 318 928 421 971 440 973 441 988 448

1365 619 832 378 903 410 911 413 953 432 959 435 976 443 1309 594 1358 616 1356 615 1386 629

A9

A10

A11

A12

TOTAL WEIGHT

1059 481 1161 527 1169 530 1224 555 1254 569 1263 573 1526 692 1605 728 1624 737 1634 741

889 403 957 434 965 438 1022 464 1036 470 1047 475 1534 696 1608 729 1625 737 1643 745

804 365 832 377 840 381 890 404 896 406 904 410 1108 503 1152 523 1162 527 1168 530

1040 472 1116 506 1124 510 1187 538 1193 541 1201 545 1350 613 1400 635 1416 642 1422 645

5282 2396 5470 2481 8027 3641 8963 4066 9354 4243 9538 4327 10122 4592 10282 4664 10485 4756 13069 5928 13502 6124 13645 6189 13867 6290

Table 15

50 |

Dimensional Data

APPENDIX- II

PACV Models: 51008 S, 51010 S & 61009 S, 61012 S 10 [254]

A1

A3

10 [254]

L EGEND 7 6 5 4

-CONDENSER FAN -CONTROL PANEL -CONDENSER COIL -COMPRESSOR

3 -FAN MOTOR 2 -EVAPORATOR FAN 1 -EVAPORATOR COIL

ACCESS

CERTIFIED DRAWINGS ARE AVAILABLE ON REQUEST A2

A4 DRAIN Ø1[25] x2Nos. L

1 [25]

1.5 [38]

68 [1727] C

45 [1143]

7

6

F

3.94 [100]

H

I

FILTERED VENTILLATION ON BOTH SIDES

51.65 [1312]

J

G

A

2 [51]

CABLE ENTRY RIGGING HOLES Ø.79 [20] 4Nos.

1 15 [381]

2

3

4

5

ACCESS PANEL

DIMENSIONS

MODEL PACV-

H

L

A

C

F

J

G

I

51008 S 61009 S

52.44 [1332]

81 [2057]

36 [914]

40 [1016]

24 [610]

13.43 [341]

15.55 [395]

7.56 [192]

51010 S 61012 S

61.91 [1572]

85 [2159]

40 [1016]

44 [1118]

30 [762]

15.91 [404]

18.54 [471]

8.54 [217]

Figure 37.

PACV Models: 51014 S to 52023 S & 61018 S to 62028 S DIMENSIONS H

W

H1

L

A

B

C

I

F

J

G

D

* 51014 S * 61018 S

5 9.41 [15 09]

74 [1880]

52.63 [1 337]

92 [2337]

36 [914]

56 [1422 ]

60 [ 1524]

7.56 [192]

30 [76 2]

13.43 [341]

15.55 [ 395]

43.67 [ 1109]

52015 S 62018 S

5 9.41 [15 09]

74 [1880]

52.63 [1 337]

92 [2337]

36 [914]

56 [1422 ]

60 [ 1524]

7.56 [192]

30 [76 2]

13.43 [341]

15.55 [ 395]

43.67 [ 1109]

* 51017 S * 61020 S

5 9.41 [15 09]

76 [1930]

52.63 [1 337]

92 [2337]

36 [914]

56 [1422 ]

65.4 [ 1661]

7.56 [192]

30 [76 2]

13.43 [341]

15.55 [ 395]

43.67 [ 1109]

52017 S 62020 S

5 9.41 [15 09]

76 [1930]

52.63 [1 337]

92 [2337]

36 [914]

56 [1422 ]

65.4 [ 1661]

7.56 [192]

30 [76 2]

13.43 [341]

15.55 [ 395]

43.67 [ 1109]

52020 S 62024 S

6 2.87 [15 97]

84 [2134]

60.63 [1 540]

96 [2438]

40 [ 1016]

56 [1422 ]

72 [ 1829]

8.54 [217]

30 [76 2]

15.91 [404]

18.54 [ 471]

52.28 [ 1328]

52023 S 62028 S

6 8.87 [17 49]

84 [2134]

60.63 [1 540]

98 [2489]

40 [ 1016]

58 [1473 ]

72 [ 1829]

8.54 [217]

36 [91 4]

15.91 [404]

18.54 [ 471]

52.28 [ 1328]

*MODEL WITH 1-COMPRESSOR

A3

ACCESS

CERTIFIED DRAWINGS ARE AVAILABLE ON REQUEST A2

DRAIN Ø1 [25]x2Nos. L

W C 1.5 [38]

D G

1 [25]

A

A4 5

B 6

7

F

H

FILTERED VENTILLATION ON BOTH SIDES

H1

I

J

G

10 [254]

10 [254]

A1

W

MODEL PACV-

1

RIGGING HOLES Ø.79 [20]4Nos.

2 [51]

4.92 [125]

CABLE ENTRY 15 [381]

2

3 ACCESS PANEL BOTH SIDES

4

Figure 38.

| 51

Dimensional Data PACV Models: 52026 S to 52038 S & 62033 S to 62046 S H

DIMENSIONS ARE IN INCHES [mm] H1 A F J

L

10 [254] G

D

I

52026 S 72.87 116 62033 S [1851] [2946]

40 40 [1016] [1016]

60.63 [1540]

15.91 [404]

18.54 [471]

52.28 [1328]

8.54 [217]

52030 S 80.87 116 62036 S [2054] [2946]

40 48 [1016] [1219]

60.63 [1540]

15.91 [404]

18.54 [471]

52.28 [1328]

8.54 [217]

52032 S 80.87 116 40 48 62037 S [2054] [2946] [1016] [1219]

60.63 [1540]

15.91 [404]

18.54 [471]

52.28 [1328]

8.54 [217]

77.63 [1972]

18.82 [478]

21.93 [557]

61.85 [1571]

10.75 [273]

* 52038 S * 62046 S

93.99 [2387]

119 [3023]

43 56 [1092] [1422]

A3

A1

10 [254]

88 [2235]

MODEL PACV-

ACCESS

* MODEL WITH TANDEM COMPRESSORS FROM THE MODELS 52038S/62046S, USING TANDEM COMPRESSORS

A4

A2 CERTIFIED DRAWINGS ARE AVAILABLE ON REQUEST

DRAIN Ø1[25]x2Nos.

88 [2235] 75 [1905] D

L

1.5 [38]

G

5

G

1 [25]

A

76 [1930] 6

FILTERED VENTILLATION ON BOTH SIDES F

H

L EG E ND

1

3 -FAN MOTOR

RIGGING HOLES Ø.79[20] x 4 Nos.

2 -EVA PORATOR FA N 1 -EVA PORATOR COIL

CABLE ENTRY

2 [51]

5 -CON DEN SER COIL 4 -COMP RESSOR

15 [381]

2

4

3 ACCESS PANEL BOTH SIDES

4.92 [125]

7 -CON DEN SER FA N 6 -CON TROL P ANEL

Figure 39.

PACV Models: 52045 S to 52055 S & 62055 S to 62066 S 10 [254]

10 [254] A1

A3

DIMENSIONS ARE IN INCHES [mm] W H1 C F

MODEL PACV-

H

52045 S 62055 S

99.24 [2521]

88 [2235]

77.63 [1972]

75 [1905]

66 [1676]

6 [152]

52050 S 62060 S

103.24 [2622]

88 [2235]

85.63 [2175]

75 [1905]

72 [1829]

4 [102]

52055 S 62066 S

103.24 [2622]

92 [2337]

85.63 [2175]

80 [2032]

72 [1829]

4 [102]

W

CERTIFIED DRAWINGS ARE AVAILABLE ON REQUEST

I

ACCESS

A4

A2 5

DRAIN Ø1 1/4 [32]x2Nos.

** TANDEM COMPRESSOR

127 [3226]

W C 1 [25]

61.85 [1571]

43 [1092]

84 [2134]

1.5 [38]

21.93 [557]

18.82 [478]

21.93 [557]

6

I

7

H1

F

H

FILTERED VENTILLATION ON BOTH SIDES

2 [51]

4.92 [125]

CABLE ENTRY

RIGGING HOLES Ø.79 [20]x 4 Nos.

52 |

H1

I

J

7

1

15 [381]

2

3 ACCESS PANEL BOTH SIDES

** 4

Figure 40.

Dimensional Data PACV Models: 52065 S & 62076 S 108.5 [2756]

2.8 [70]

2.8 [70] A5

A3

A1

A7

CERTIFIED DRAWINGS ARE AVAILABLE ON REQUEST

ACCESS

A4

A6

10 [254] 2 [51]

S/A

R/A 10

114 [2896] 35.35 [898]

39.31 [999]

10 [254]

198 [5029]

84 [2134]

39.31 [999]

7

6

FILTERED VENTILLATION ON BOTH SIDES

84 [2134]

78.49 [1994]

1

35.35 [898]

6 [153]

9

89.91 [2284]

20 [508]

2 [51]

88 [2235]

A8

86.61 [2200]

A2

CABLE ENTRY

ACCESS

3

DRAIN Ø 1 1/2"[38]

8

4

RIGGING HOLES Ø7/8[22]4 Nos.

5.91 [150]

2 5

Figure 41.

PACV Models: 53070 S to 53095 S & 63085 S to 63110 S 2.8 [70]

LEGEND 10 -FLEXIBLE CONNECTION 9 -WEATHER PROOF CANOPY 8 -ANTI VIB. MOUNTS 7 -CONDENSER FAN 6 -CONTROL PANEL 5 -CONDENSER COIL 4 -TANDEM COMPRESSOR 3 -FAN MOTOR 2 -EVAPORATOR FAN 1 -EVAPORATOR COIL

2 [51]

B A1

A3

2.8 [70] A7

A9

A11 6

A2

A8 A6 20 [508] L

A4

10 [254] 2 [51]

88 [2235]

A5

A

6 [152]

9

F

A10

10 [254] 88.6 [2250] 7

47.05 [1195]

G

A12

5

F

PARTITION

FILTERED VENTILATION BOTH SIDE

J

1

95.28 [2420] 106.89 [2715]

E

C

R/A

DETACHABLE PLATE FOR CABLE ENTRY

10

29.5 [750]

106.9 [2715] H

S/A

2

ACCESS

MODEL PACVL 53070 S 249.6 63085 S [6341] 53075 S 249.6 63090 S [6341]

8

5.91 [150]

3 DRAIN Ø 1 1/2"[38]

A 114 [2896]

RIGGING HOLES Ø7/8[22] 4 Nos.

4

DIMENSIONS ARE IN INCHES [MM] B F E H 93 108.5 37.17 98.94 [2362] [2756] [944] [2513]

J 39.65 [1007]

G

C

39.65 [1007]

87.5 [2222]

114 [2896]

108.5 [2756]

93 [2362]

37.17 [944]

98.94 [2513]

39.65 [1007]

39.65 [1007]

87.5 [2222]

53080 S 249.6 63095 S [6341] 53085 S 253.6 63100 S [6441]

114 [2896]

108.5 [2756]

102 [2591]

37.17 [944]

107.91 [2741]

39.65 [1007]

39.65 [1007]

96.5 [2451]

118 [2997]

112.5 [2857]

102 [2591]

36.76 [934]

107.91 [2741]

44.49 [1130]

44.49 [1130]

96.5 [2451]

53090 S 259.6 63105 S [6594] 53095 S 266.6 63110 S [6772]

124 [3150]

118.5 [3010]

102 [2591]

39.76 [1010]

107.91 [2741]

44.49 [1130]

44.49 [1130]

96.5 [2451]

131 [3327]

125.5 [3188]

102 [2591]

43.26 [1099]

107.91 [2741]

44.49 [1130]

44.49 [1130]

96.5 [2451]

Figure 42.

| 53

PACV Models: 54100 S to 54125 S & 64120 S to 64145 S 2.8 [70]

MODEL DIMENSIONS ARE IN INCHES[mm] PACVA B F L 54100 S 311.2 134 128.5 44.76 64120 S [7904] [3404] [3264] [1137] 54110 S 315.2 64130 S [8006] 54115 S 321.2 64136 S [8158]

138 [3505]

132.5 [3365]

46.76 [1188]

144 [3658]

138.5 [3518]

49.76 [1264]

54125 S 329.2 64145 S [8362]

152 [3861

146.5 [3721]

53.76 [1365]

2.8 [70]

B A1

A5

A3

A2

A4

A8

A6

10 [254]

A9

A7

6

A11

LEGEND 10 -FLEXIBLE CONNECTION 9 -WEATHER PROOF CANOPY 8 -ANTI VIB. MOUNTS 7 -CONDENSER FAN 6 -CONTROL PANEL 5 -CONDENSER COIL 4 -COMPRESSOR 3 -FAN MOTOR 2 -EVAPORATOR FAN 1 -EVAPORATOR COIL

A12

A10

20 [508]

10 [254]

CERTIFIED DRAWINGS ARE AVAILABLE ON REQUEST 88 [2235]

2 [51]

2 [51]

L 88.6 [2250]

6 [152]

A 9

F

44.49 [1130]

F

PARTITION

88.6 [2250] 7

5

12 [305] PARTITION

10

DETACHABLE PLATE FOR CABLE ENTRY

ACCESS 3

5.91 [150]

DRAIN Ø 1 1/2"[38]

29.5 [750]

2

95.27 [2420] 106.88 [2715]

R/A

FILTERED VENTILATION BOTH SIDE 102 [2591]

107.91 [2741] 96.49 [2451]

S/A

44.49 [1130]

1

8

RIGGING HOLES Ø7/8[22] 4 Nos.

4

Figure 43.

54 |

APPENDIX- III

Refrigerant Piping Layout This section presents the unit refrigerant piping diagrams for different available configurations.

Figure 45

Figure 44

APPENDIX- IV Typical Piping Layout Typical Liquid Line Piping

Figure 46.

| 55

Typical Suction & Discharge Line Piping for Individual Compressor

Figure 47

Typical Suction & Discharge Line Piping for Tandem Compressor

Figure 48

56 |

APPENDIX- V

Filter te Dimensions e s o s & S es FLAT FILTER 1 [25]

F

MODEL PACV-S

F

G

SIZE H x L

VEE FILTER

5.6 [142]

BAG FILTER

26 [660]

FLAT FILTER QTY. SIZE H x L

QTY.

*

1 [25]

F

1 [25]

26 [660]

F

G

VEE FILTER QTY. SIZE H x L

SIZE H x L

BAG FILTER QTY. SIZE H x L

QTY.

51008 S 24 40 61009 S (610) (1016) 25x20(635x508)

2

-

20x20 (508x508)

4

24x20 (610x508)

2

44 16x25 (406x635) 51010 S 30 61012 S (762) (1118) 16x20 (406x508)

2 2

-

25x20 (635x508) 25x25 (635x635)

2 2

12x24 (305x610) 12x20 (305x508)

1 1

20x24 (508x610) 20x20 (508x508)

1 1

51014 S 30 60 61018 S (762) (1524) 16x20(406x508)

6

-

25x20 (635x508)

6

12x20 (305x508)

3

20x20(508x508)

3

52015 S 30 60 62018 S (762) (1524) 16x20 (406x508)

6

-

25x20 (635x508)

6

12x20(305x508)

3

20x20(508x508)

3

51017 S 30 65 16x25 (406x635) 61020 S (762) (1661) 16x20 (406x508)

2 4

-

25x16 (635x406) 25x25 (635x635)

2 4

12x24 (305x610) 12x20 (305x508)

1 2

20x24(508x610) 20x20 (508x508)

1 2

65 16x25 (406x635) 52017 S 30 62020 S (762) (1661) 16x20(406x508)

2 4

-

25x16 (635x406) 25x25 (635x635)

2 4

12x24 (305x610) 12x20(305x508)

1 2

20x24 (508x610) 20x20 (508x508)

1 2

16x16 (406x406) 52020 S 30 72 62024 S (762) (1829) 16x20 (406x508)

4 4

-

25x20 (635x508) 25x25(635x635)

2 4

12x24 (305x610) 20x24 (508x610)

3 3

52023 S 36 72 16x16 (406x406) 62028 S (914) (1829) 16x20(406x508)

2 2

20x16 (508x406) 20x20(508x508)

6 6

52026 S 40 75 62033 S (1016) (1905) 20x25 (508x635)

6

-

20x25 (508x635)

9

75 52030 S 48 25x25 (635x635) 62036 S (1219) (1905)

6

-

25x25 (635x635)

9

75 52032 S 48 25x25 (635x635) 62037 S (1219) (1905)

6

-

25x25 (635x635)

9

12x24 (305x610) 24x24 (610x610) 20x20 (508x508) 20x24 (508x610) 20x12 (508x305) 24x20 (610x508) 24x24 (610x610) 24x12 (610x305) 24x20 (610x508) 24x24 (610x610) 24x12 (610x305) 12x12 (305x305) 12x20 (305x508) 12x24 (305x610) 20x24 (508x610) 24x20 (610x508) 24x24 (610x610) 24x12 (610x305) 24x20 (610x508) 24x24 (610x610) 24x12 (610x305)

3 3 4 2 2 4 2 2 4 2 2 1 2 1 1 4 2 2 6 3 3

20x16(508x406) 20x20 (508x508)

2 2

-

20x20 (508x508) 20x12 (508x305) 24x24 (610x610) 24x20(610x508) 24x12(610x305) 20x20 (508x508) 20x24 (508x610) 20x12 (508x305)

2 1 1 2 1 2 1 1

16x25 (406x635) 75 52038 S 56 62046 S (1422) (1905) 20x25(508x635)

3 6

-

25x25 (635x635)

9

25x25 (635x635) 75 52045 S 66 62055 S (1676) (1905) 20x25 (508x635)

3 6

-

25x25 (635x635)

12

75 16x25(406x635) 52050 S 72 62060 S (1829) (1905) 20x25 (508x635)

6 6

-

25x25(635x635)

12

80 16x20 (406x508) 52055 S 72 62066 S (1829) (2032) 20x20 (508x508)

8 8

-

25x20 (635x508)

16

24x20 (610x508)

12

-

16x25 (406x635) 98 52065 S 72 62076 S (1829) (2489) 20x25 (508x635)

8 8

-

25x25 (635x635)

16

24x24(610x610)

12

-

16x25 (406x635) 98 53070 S 81 63085 S (2057) (2489) 25x25(635x635)

8 8

-

25x25 (635x635)

20

20x24 (508x610)

16

-

98 16x25 (406x635) 53075 S 81 63090 S (2057) (2489) 25x25 (635x635)

8 8

-

25x25 (635x635)

20

20x24 (508x610)

16

-

98 20x25 (508x635) 53080 S 90 63095 S (2286) (2489) 25x25 (635x635) 25x16 53085 S 90 102 25x20 (635x406) (635x508) 63100 S (2286) (2591) 20x25 (508x635) 108 20x16 (508x406) 53090 S 90 63105 S (2286) (2743) 20x20 (508x508)

8 8 4 2 4 6 6

25x25 (635x635)

20

25x25 (635x635) 20x16 (508x406) 20x20 (508x508) 25x16 (635x406) 25x20 (635x508)

4 4 2 6 6

12 4 3 9 3 12 3

20x20 (508x508) 20x24 (508x610) 20x12(508x305) 20x24(508x610) 20x12(508x305)

1 3 1 4 1

115 25x25 (635x635) 53095 S 90 63110 S (2286) (2921) 25x16 (635x406)

8 2

20x25 (508x635) 20x16 (508x406)

1 4

118 25x25 (635x635) 54100 S 90 64120 S (2286) (2997) 25x20 (635x508) (635x635) 122 25x25 54110 S 90 25x20 (635x508) 64130 S (2286) (3099) 25x16 (635x406) 128 20x16 (508x406) 54115 S 90 64136 S (2286) (3251) 25x16 (635x406) (635x635) 136 25x25 54125 S 90 25x20 (635x508) 64145 S (2286) (3454) 25x16 (635x406)

8 2 4 4 4 16 16 8 2 2

20x25 (508x635) 20x20 (508x508) 20x25 (508x635) 20x20(508x508) 20x16 (508x406)

* BAG FILTER IS APPLICABLE FOR 22" DEPTH

25x25 (635x635)

20

25x16 (635x406) 25x20 (635x508)

15 15

24x24 (610x610) 20x24(508x610) 24x20(610x508) 24x24(610x610) 24x12(610x305) 24x24 (610x610) 24x12 (610x305)

8 2

25x25 (635x635) 25x16 (635x406)

20 5

24x20 (610x508) 24x24 (610x610)

3 12

20x20 (508x508) 20x24(508x610)

8 2 4 4 4

25x25(635x635) 25x20 (635x508)

20 5

24x24(610x610) 20x24(508x610)

15 5

-

25x25 (635x635)

25

24x24 (610x610) 20x24 (508x610) 24x20 (610x508) 24x24 (610x610) 24x12 (610x305) 24x20 (610x508) 24x24 (610x610) 24x12 (610x305)

15 5 3 12 3 15 3 3

20x20 (508x508) 20x24 (508x610) 20x12 (508x305) 20x20 (508x508) 20x24 (508x610) 20x12 (508x305)

-

20x25 (508x635) 20x20 (508x508) 20x16 (508x406)

-

8 2 2

25x25 (635x635)

30

25x25(635x635) 25x20 (635x508) 25x16(635x406)

20 5 5

ALL DIMENSIONS ARE IN INCHES (MM)

-

1 4 1 5 1 1

Table 16

| 57

1

AIR FLOW

58 |

8

9

10

3

6

37

36

10 11 12 13 14 15 16

FAN PULLEY BEARINGS FAN SHAFT EVAPORATOR FAN COMPRESSOR EVAPORATOR FAN MOTOR

3 4 5 6 7 8

9

EXPANSION VALVE

EVAPORATOR COIL

2

1

CONDENSER FAN BLADE

CONDENSER FAN MOTOR

24

23

22

21

SHUT OFF VALVE CONDENSER COIL

20

19

SOLENOID VALVE FILTER DRIER

18

17

BELT

MOTOR PULLEY

42

POWER TERMINAL BLOCK

COMPRESSOR CONTACTORS

EFM CONTACTORS

6

4

5

37

CONTROL SWITCH / PUMP DOWN SWITCH 13A SOCKET 31

39

38

36

EXPANSION MODULE

35

MASTER BOARD

32 34

10

9

8

POWER SUPPLY MODULE

3

2

1

33

4

7

CONTROL TERMINAL BLOCK

TOUCH PANEL

7

41

14

CF

SIMATIC PANEL

LOGO!

SIEMENS

S7-200

CR1

CTB

CR2

CR3

EM 235

CR4

S1 & S2

CR5

S3 & CS Plug For PC

23

11

33

CF

S1 & S2

26

CR2

12

CR1

LOGO POWER

CTB

7

39

CS

OK

18

Esc

13

OL

COMP.CONTACTOR 1

WEATHER PROOF CANOPY

ANTI VIBRATION MOUNTS

SIGHT GLASS

OVER LOAD RELAY

CONTROL FUSE / MCB

FILTER CORE

BALL VALVE

MS-32

MS-32

COMP.CONTACTOR 2

C2

OL

C9

COMP.CONTACTOR 2

MS-32

OL

C5

EFM CONTACTOR

F2

C4

F2

MS-32

OL

C12

COMP.CONTACTOR 4

OL

C11

42

41

40

C5

MS-32

MS-32

24

F4

PTB

[120SQMM]

34 24

17

14

15

16

Spare Parts Figure 49

LOW PRESSURE SWITCH

HIGH PRESSURE SWITCH

CONTROL FUSE/MCB

[120SQMM]

PTB

C6

C15

COMP.CONTACTOR 6

C14

EFM CONTACTORS

F3

COMP.CONTACTOR 5

OL

C13

22

34 20 22

OL

C4

CFM CONTACTORS

OL

C3

F1

C3

COMP.CONTACTOR 3

OL

C10

CFM CONTACTORS

F1

21

19 27 28 29 23 21

TIME DELAY RELAY

35

30

C1

OL

C8

COMP.CONTACTOR 1

OL

C7

20

TYPICAL CONTROL PANELS

40 25 26 27 28 29 30 31 32

30

29

28

CFM CONTACTORS POWER CIRCUIT FUSE

27

CONTROL RELAY

25 26

38

CONTROL PANEL

CONDENSER FAN GUARD

35

11

12

18

19

APPENDIX- VI

APPENDIX- VII

Electrical Data

POWER SUPPLY 380-415V/3Ph/50Hz

Unit Characteristic

Compressor

Model PACV-S

MFA

MCA

ICF

51008 51010 51014 52015 51017 52017 52020 52023 52026 52030 52032 52038 52045 52050 52055 52065 53070 53075 53080 53085 53090 53095 54100 54110 54115 54125

63 80 100 100 125 125 125 160 160 200 200 200 250 250 315 315 315 400 400 400 400 400 500 500 500 500

33 43 59 61 68 73 84 94 109 121 127 155 184 200 214 234 269 293 293 306 318 330 383 402 414 438

127 183 243 158 292 216 234 285 300 351 357 305 375 391 444 465 473 497 497 550 562 574 587 646 658 682

QTY 1 1 1 1+1 1 1+1 1+1 1+1 1+1 1+1 1+1 2+2 2+2 2+2 2+2 2+2 3+3 3+3 3+3 2+4 4+2 5+1 4+4 3+5 5+3 4+4

RLA 22 30 38 22 + 22 44 30 + 22 30 + 30 38 + 30 38 + 38 44 + 38 44 + 44 30 + 30 38 + 30 38 + 38 44 + 38 44 + 44 38 + 30 38 + 38 38 + 38 44 + 38 44 + 38 44 + 38 38 + 38 44 + 38 44 + 38 44 + 44

Condenser Fan Motor LRA 118 174 225 118 + 118 272 174 + 118 174 + 174 225 + 174 225 + 225 272 + 225 272 + 272 174 + 174 225 + 174 225 + 225 272 + 225 272 + 272 225 + 174 225 + 225 225 + 225 272 + 225 272 + 225 272 + 225 225 + 225 272 + 225 272 + 225 272 + 272

QTY 2 2 2 2 2 2 2 2 3 3 3 3 4 4 4 4 6 6 6 6 6 6 8 8 8 8

FLA 1.1 1.1 2.4 2.4 2.4 2.4 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9

Evaporator Fan Motor LRA 3.9 3.9 8.9 8.9 8.9 8.9 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2 17.2

QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FLA 3.6 3.6 6.6 6.6 8.6 8.6 8.6 8.6 11.8 16 16 16 23.2 23.2 23.2 31.6 31.6 31.6 31.6 31.6 31.6 37.9 37.9 37.9 37.9 44.2

LRA 19.2 19.2 35.6 35.6 45.6 45.6 45.6 45.6 67.3 105.6 105.6 105.6 148.5 148.5 148.5 221.2 221.2 221.2 221.2 221.2 221.2 284.2 284.2 284.2 284.2 331.6

Table 17

POWER SUPPLY 440V/3Ph/50Hz Unit Characteristic Model 51008 51010 51014 52015 51017 52017 52020 52023 52026 52030 52032 52038 52045 52050 52055 52065 53070 53075 53080 53085 53090 53095 54100 54110 54115 54125

Compressor

MFA

MCA

ICF

63 80 100 100 125 125 125 160 160 200 200 200 250 250 315 315 315 400 400 400 400 400 500 500 500 500

33 43 59 61 68 73 84 94 109 120 126 154 183 199 212 232 267 291 291 304 316 328 381 400 412 436

126 182 243 158 291 215 233 284 299 350 356 304 374 390 443 462 471 495 495 548 560 571 585 644 656 679

QTY 1 1 1 1+1 1 1+1 1+1 1+1 1+1 1+1 1+1 2+2 2+2 2+2 2+2 2+2 3+3 3+3 3+3 2+4 4+2 5+1 4+4 3+5 5+3 4+4

RLA 22 30 38 22 + 22 44 30 + 22 30 + 30 38 + 30 38 + 38 44 + 38 44 + 44 30 + 30 38 + 30 38 + 38 44 + 38 44 + 44 38 + 30 38 + 38 38 + 38 44 + 38 44 + 38 44 + 38 38 + 38 44 + 38 44 + 38 44 + 44

Condenser Fan Motor LRA 118 174 225 118 + 118 272 174 + 118 174 + 174 225 + 174 225 + 225 272 + 225 272 + 272 174 + 174 225 + 174 225 + 225 272 + 225 272 + 272 225 + 174 225 + 225 225 + 225 272 + 225 272 + 225 272 + 225 225 + 225 272 + 225 272 + 225 272 + 272

QTY 2 2 2 2 2 2 2 2 3 3 3 3 4 4 4 4 6 6 6 6 6 6 8 8 8 8

FLA 1.1 1.1 2.8 2.8 2.8 2.8 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3 4.3

LRA 3.9 3.9 9.2 9.2 9.2 9.2 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6 17.6

Evaporator Fan Motor QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FLA 3.1 3.1 5.7 5.7 7.4 7.4 7.4 7.4 10.2 13.8 13.8 13.8 20 20 20 27.3 27.3 27.3 27.3 27.3 27.3 32.7 32.7 32.7 32.7 38.2

LRA 16.6 16.6 30.8 30.8 39.3 39.3 39.3 39.3 58 91.1 91.1 91.1 128.1 128.1 128.1 190.9 190.9 190.9 190.9 190.9 190.9 245.2 245.2 245.2 245.2 286.1

Table 18

| 59

Electrical Data

POWER SUPPLY 380V/3Ph/60Hz

Unit Characteristic Model 61009 61012 61018 62018 61020 62020 62024 62028 62033 62036 62037 62046 62055 62060 62066 62076 63085 63090 63095 63100 63105 63110 64120 64130 64136 64145

Compressor

MFA

MCA

ICF

63 100 125 100 160 125 160 160 200 200 250 250 315 315 400 400 400 400 400 500 500 500 500 630 630 630

37 54 65 67 85 85 102 109 122 143 157 189 213 231 262 290 310 325 325 357 385 405 426 472 500 548

155 207 299 188 374 241 264 348 362 439 453 351 452 470 557 585 562 577 577 664 692 713 678 779 807 855

QTY 1 1 1 1+1 1 1+1 1+1 1+1 1+1 1+1 1+1 2+2 2+2 2+2 2+2 2+2 3+3 3+3 3+3 2+4 4+2 5+1 4+4 3+5 5+3 4+4

RLA 24 37 42 24 + 24 56 37 + 24 37 + 37 42 + 37 42 + 42 56 + 42 56 + 56 37 + 37 42 + 37 42 + 42 56 + 42 56 + 56 42 + 37 42 + 42 42 + 42 56 + 42 56 + 42 56 + 42 42 + 42 56 + 42 56 + 42 56 + 56

Condenser Fan Motor LRA 145 196 280 145 + 145 353 196 + 145 196 + 196 280 + 196 280 + 280 353 + 280 353 + 353 196 + 196 280 + 196 280 + 280 353 + 280 353 + 353 280 + 196 280 + 280 280 + 280 353 + 280 353 + 280 353 + 280 280 + 280 353 + 280 353 + 280 353 + 353

QTY 2 2 2 2 2 2 2 2 3 3 3 3 4 4 4 4 6 6 6 6 6 6 8 8 8 8

FLA 1.5 1.5 3.1 3.1 3.1 3.1 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3

LRA 4.5 4.5 9.6 9.6 9.6 9.6 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5

Evaporator Fan Motor QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FLA 3.6 4.9 6.3 6.3 8.4 8.4 8.4 8.4 11.5 15.5 15.5 15.5 23 30.9 30.9 30.9 30.9 30.9 30.9 30.9 30.9 37.5 37.5 37.5 37.5 43.6

LRA 18.9 25 34 34 44.3 44.3 44.3 44.3 65.5 102.3 102.3 102.3 147.1 216 216 216 216 216 216 216 216 281.3 281.3 281.3 281.3 326.7

Table 19

POWER SUPPLY 460V/3Ph/60Hz Unit Characteristic Model 61009 61012 61018 62018 61020 62020 62024 62028 62033 62036 62037 62046 62055 62060 62066 62076 63085 63090 63095 63100 63105 63110 64120 64130 64136 64145

Compressor

MFA

MCA

ICF

63 80 100 100 125 100 125 160 160 200 200 200 250 250 315 315 315 400 400 400 400 400 500 500 500 500

32 42 59 59 68 69 80 92 110 121 127 147 181 207 221 233 263 293 293 307 319 330 385 404 416 439

135 190 245 166 294 222 240 286 304 354 360 307 374 401 454 466 473 503 503 556 568 579 594 653 665 688

QTY 1 1 1 1+1 1 1+1 1+1 1+1 1+1 1+1 1+1 2+2 2+2 2+2 2+2 2+2 3+3 3+3 3+3 2+4 4+2 5+1 4+4 3+5 5+3 4+4

RLA 21 28 38 21 + 21 44 28 + 21 28 + 28 38 + 28 38 + 38 44 + 38 44 + 44 28 + 28 38 + 28 38 + 38 44 + 38 44 + 44 38 + 28 38 + 38 38 + 38 44 + 38 44 + 38 44 + 38 38 + 38 44 + 38 44 + 38 44 + 44

Condenser Fan Motor LRA 125 179 225 125 + 125 272 179 + 125 179 + 179 225 + 179 225 + 225 272 + 225 272 + 272 179 + 179 225 + 179 225 + 225 272 + 225 272 + 272 225 + 179 225 + 225 225 + 225 272 + 225 272 + 225 272 + 225 225 + 225 272 + 225 272 + 225 272 + 272

QTY 2 2 2 2 2 2 2 2 3 3 3 3 4 4 4 4 6 6 6 6 6 6 8 8 8 8

FLA 1.3 1.3 3.1 3.1 3.1 3.1 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

LRA 5.2 5.2 11.8 11.8 11.8 11.8 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0 21.0

Evaporator Fan Motor QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FLA 3 4.1 5.2 5.2 6.9 6.9 6.9 6.9 9.5 12.8 12.8 12.8 19 25.5 25.5 25.5 25.5 25.5 25.5 25.5 25.5 31 31 31 31 36

LRA 15.6 20.7 28.1 28.1 36.6 36.6 36.6 36.6 54.1 84.5 84.5 84.5 121.6 178.5 178.5 178.5 178.5 178.5 178.5 178.5 178.5 232.5 232.5 232.5 232.5 270

Table 20

60 |

Electrical Data

POWER SUPPLY 220V/3Ph/60Hz

Unit Characteristic Model 61009 61012 61018 62018 61020 62020 62024 62028 62033 62036 62037 62046 62055 62060 62066 62076 63085 63090 63095 63100 63105 63110 64120 64130 64136 64145

Compressor

MFA

MCA

ICF

125 160 250 200 250 250 250 315 315 400 400 400 500 630 630 630 800 800 800 800 800 800 1000 1000 1000 1000

70 89 123 127 134 147 167 194 229 244 250 309 378 434 447 459 551 614 614 627 639 657 805 825 837 865

261 359 538 325 642 424 453 618 654 761 767 595 802 858 964 976 996 1059 1059 1165 1177 1194 1250 1362 1374 1403

QTY 1 1 1 1+1 1 1+1 1+1 1+1 1+1 1+1 1+1 2+2 2+2 2+2 2+2 2+2 3+3 3+3 3+3 2+4 4+2 5+1 4+4 3+5 5+3 4+4

RLA 47 60 81 47 + 47 87 60 + 47 60 + 60 81 + 60 81 + 81 87 + 81 87 + 87 60 + 60 81 + 60 81 + 81 87 + 81 87 + 87 81 + 60 81 + 81 81 + 81 87 + 81 87 + 81 87 + 81 81 + 81 87 + 81 87 + 81 87 + 87

Condenser Fan Motor LRA 245 340 505 245 + 245 605 340 + 245 340 + 340 505 + 340 505 + 505 605 + 505 605 + 605 340 + 340 505 + 340 505 + 505 605 + 505 605 + 605 505 + 340 505 + 505 505 + 505 605 + 505 605 + 505 605 + 505 505 + 505 605 + 505 605 + 505 605 + 605

QTY 2 2 2 2 2 2 2 2 3 3 3 3 4 4 4 4 6 6 6 6 6 6 8 8 8 8

FLA 2.5 2.5 5.4 5.4 5.4 5.4 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9

LRA 7.5 7.5 16.7 16.7 16.7 16.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7 29.7

Evaporator Fan Motor QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FLA 6.2 8.5 10.9 10.9 14.4 14.4 14.4 14.4 19.9 26.8 26.8 26.8 39.7 53.3 53.3 53.3 53.3 53.3 53.3 53.3 53.3 64.8 64.8 64.8 64.8 75.2

LRA 32.6 43.3 58.7 58.7 76.5 76.5 76.5 76.5 113.1 176.6 176.6 176.6 254.1 373.1 373.1 373.1 373.1 373.1 373.1 373.1 373.1 485.9 485.9 485.9 485.9 564.3

Table 21

Voltage imbalance between phases to be < 2%

Legend MFA Maximum Fuse Amps (for fuse sizing), complies with NEC Article 440-22 & 430-52. MCA Minimum Circuit Amps.(for wire sizing), complies with NEC article 440-33. ICF

RLA LRA FLA

Rated Load Amps. (at worst operating condition) Locked Rotor Amps Full Load Amps

Maximum Instantaneous Current Flow

Note : Voltage imbalance not to exceed ± 2 % of the rated voltage

| 61

E

TFR

CR2

I

G

T2 T1 M 1 M2 S1 S2

CM2

MICROPROCESSOR CONTROLLER

C1

COMP.-1

T8 24~_ G0

MCB2

CR1

CM1

L1 L2 L3

I

G

C3

CFM1

I> I> I>

MPCB1

LSV-1

C2

COMP.-2

MCB1

T2 T1 M 1 M2 S1 S2

DISC. PRESSURE-1

L1 L2 L3

DISC. PRESSURE-2

* C4

MPCB2

LPS-1

MPM2

CFM2

I> I> I>

C5

CFM3

I> I> I>

MPCB3

LPS-2

LSV-2

C3

CFM1

*

C4

CFM2

MPM1

CR2

C6

EFM

I> I> I>

MPCB4

CR1

C5

CFM3

L1

MP-1

CS

OL VMM

VMM A B C NC Com NO

F 2A

24~_

ESC

INFO

C6

T-IP

N

MP-2

C2

EFM

220~ 240V

RUN/STOP

C1

HPS-1

T9 Q12 Q11 Q14 T10 Q22 Q21 Q24 Q33 Q34 Q43 Q44 T11 Q53 Q54 Q64 Q73 Q74 Q84 T12 C D01 D02 T13 DL1 DN DL2

24V

MPCB4

POWER SUPPLY

RS485

2CORE UNSCREENED TWISTED PAIR CABLE AS PER KNX SPECIFICATION (BY OTHERS)

+

PB

-

ROOMUNIT (LOOSESUPPLY)

OK

POL 687/STD

L1 L2 L3 N

T-HI

T1 B1 M B2 M B3 T2 X1 M X2 5V= 24V= X3 M X4 T3 X5 M X6 5V= 24V= X7 M X8 T4 D1 M D2 T5 DU1 DG DU2 T6 A+ BREF T7 CE+ CEHPS-2

NOTE:-

TRANSFORMER CONTROL SWITCH CONTACTOR

L EG EN D

C2

C1

Figure 50

** Provide Overcurrent, short circuit, earth fault protec on & disconnect means as required by local and na

VMM VOLTAGEMONITORINGMODULE MOTOR PROTECTOR MODULE MPM MPCB MOTOR PROTECTOR CIRCUT BREAKER OL OVERLOAD RELAY CCH CRANKCASEHEATER LIQUID LINESOLENOID VALVE MCB MINIATURECIRCUIT BREAKER LSV EVAPORATOR FAN MOTOR EFM CFM CONDENSER FAN MOTOR CONTROL RELAY COMPRESSOR MOTOR CR CM LPS LOW PRESSURESWITCH FIELD WIRING HPS HIGH PRESSURESWITCH

TFR CS C

* MPM Module is not available in some small compressors.

CXT option is amust.

* For 440/3/50 or 460/3/60 or power supplies without neutral,

power supplies areavailableonrequest.

* Wiring diagrams for 440/3/50, 220/3/60 or 460/3/60

380/3/60, 4 wire power supplies.

* Typical wiring diagram given here is for units with 380~ 415/3/50 or

CCH1

62 | CCH2

**

APPENDIX- VIII

Typical Wiring Diagram

APPENDIX- IX

Instructions For Downloading/Upgrading The Software For Microprocessor •

Switch off the controller

•

Insert the SD-Card in the slot

•

Push the Service-Button

•

Use a paper clip (feel the click)

•

Don’t press too strong, you could damage the button

•

Switch on the power supply

•

Keep the Service-Push-Button pressed until start BSPLED flash red/green of controller

•

The BSP-LED on the Controller shows the progress

BSP-LED yellow BSP-LED flash red/green BSP-LEDs yellow BSP-LEDs yellow flashing all LEDs off

}

 

Startup Phase



Download finished

Load Firmware in Flash (15.....50 sec, avoid power interruption)

Note: The behaviour of the LED-Signalization depends on the BSP, which was loaded on the controller before the overload.

| 63

APPENDIX- X

P-T Chart ºF

ºC

R-22

R-410A R-407C R134a

ºF

ºC

R-22

-60

-51.1

*11.9

*0.9

*16.0

-55

-48.3

*9.2

1.8

-50

-45.6

*6.1

-45

-42.8

-40

R-410A R-407C R134a

ºF

ºC

R-22

R-410A R-407C R134a

*21.6

12

-11.1

34.8

65.4

29.0

13.2

42.0

5.6

71.5

123.6

64.6

37.0

*13.7

*20.2

13

-10.6

35.8

67.0

29.9

13.8

43.0

6.1

73.0

125.9

66.1

38.0

4.3

*11.1

*18.6

14

-10.0

36.8

68.6

30.9

14.4

44.0

6.7

74.5

128.3

67.6

39.0

*2.7

7.0

*8.1

*16.7

15

-9.4

37.8

70.2

31.8

15.1

45.0

7.2

76.1

130.7

69.1

40.0

-40.0

0.6

10.1

*4.8

*14.7

16

-8.9

38.8

71.9

32.8

15.7

46.0

7.8

77.6

133.2

70.6

41.1

-35

-37.2

2.6

13.5

*1.1

*12.3

17

-8.3

39.9

73.5

33.8

16.4

47.0

8.3

79.2

135.6

72.2

42.2

-30

-34.4

4.9

17.2

1.5

*9.7

18

-7.8

40.9

75.2

34.8

17.1

48.0

8.9

80.8

138.2

73.8

43.2

-25

-31.7

7.5

21.4

3.7

*6.8

19

-7.2

42.0

77.0

35.9

17.7

49.0

9.4

82.4

140.7

75.4

44.3

-20

-28.9

10.2

25.9

6.2

*3.6

20

-6.7

43.1

78.7

36.9

18.4

50.0

10.0

84.1

143.3

77.1

45.4

-18

-27.8

11.4

27.8

7.2

*2.2

21

-6.1

44.2

80.5

38.0

19.2

55.0

12.8

92.6

156.6

106.0

51.2

-16

-26.7

12.6

29.7

8.4

*0.7

22

-5.6

45.3

82.3

39.1

19.9

60.0

15.6

101.6

170.7

116.2

57.4

-14

-25.6

13.9

31.8

9.5

0.4

23

-5.0

46.5

84.1

40.2

20.6

65.0

18.3

111.3

185.7

127.0

64.0

-12

-24.4

15.2

33.9

10.7

1.2

24

-4.4

47.6

85.9

41.3

21.4

70.0

21.1

121.5

201.5

138.5

71.1

-10

-23.3

16.5

36.1

11.9

2.0

25

-3.9

48.8

87.8

42.4

22.1

75.0

23.9

132.2

218.2

150.6

78.6

-8

-22.2

17.9

38.4

13.2

2.8

26

-3.3

50.0

89.7

43.6

22.9

80.0

26.7

143.7

235.9

163.5

86.7

-6

-21.1

19.4

40.7

14.6

3.7

27

-2.8

51.2

91.6

44.7

23.7

85.0

29.4

155.7

254.6

177.0

95.2

-4

-20.0

20.9

43.1

15.9

4.6

28

-2.2

52.4

93.5

45.9

24.5

90.0

32.2

168.4

274.3

191.3

104.3

-2

-18.9

22.4

45.6

17.4

5.5

29

-1.7

53.7

95.5

47.1

25.3

95.0

35.0

181.9

295.0

206.4

113.9

0

-17.8

24.0

48.2

18.9

6.5

30

-1.1

54.9

97.5

48.4

26.1

100.0

37.8

196.0

316.9

222.3

124.1

1

-17.2

24.8

49.5

19.6

7.0

31

-0.6

56.2

99.5

49.6

26.9

105.0

40.6

210.8

339.9

239.0

134.9

2

-16.7

25.7

50.9

20.4

7.5

32

0.0

57.5

101.6

50.9

27.8

110.0

43.3

226.4

364.1

256.5

146.3

3

-16.1

26.5

52.2

21.2

8.0

33

0.6

58.8

103.6

52.1

28.6

115.0

46.1

242.8

389.6

274.9

158.4

4

-15.6

27.4

53.6

22.0

8.6

34

1.1

60.2

105.7

53.4

29.5

120.0

48.9

260.0

416.4

294.2

171.1

5

-15.0

28.3

55.0

22.8

9.1

35

1.7

61.5

107.9

54.8

30.4

125.0

51.7

278.1

444.5

314.5

184.5

6

-14.4

29.1

56.4

23.7

9.7

36

2.2

62.9

110.0

56.1

31.3

130.0

54.4

297.0

474.0

335.7

198.7

7

-13.9

30.0

57.9

24.5

10.2

37

2.8

64.3

112.2

57.5

32.2

135.0

57.2

316.7

505.0

357.8

213.5

8

-13.3

31.0

59.3

25.4

10.8

38

3.3

65.7

114.4

58.9

33.1

140.0

60.0

337.4

537.6

380.9

229.2

9

-12.8

31.9

60.8

26.2

11.4

39

3.9

67.1

116.7

60.3

34.1

145.0

62.8

359.1

571.7

405.1

245.6

10

-12.2

32.8

62.3

27.1

12.0

40

4.4

68.6

118.9

61.7

35.0

150.0

65.6

381.7

607.6

430.3

262.8

11

-11.7

33.8

63.9

28.0

12.6

41

5.0

70.0

121.2

63.1

36.0

155.0

68.3

405.4

645.2

456.6

281.0

All temperatures and pressures are shown at sea level. Pressures are listed as psig, except (*) indicates inches in mercury vacuum.

Table 22

Note:

•

To determine subcooling for R-407C, use bubble point values (temperatures above 50 oF, shown with shaded gray background).

•

To determine superheat for R-407C, use dew point values (temperature 50 oF and below)

64 |

Manual# : 088- IOM- 2014

Supersedes Manual# : 088- IOM- 2012