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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

2 |
Bearing . . . . . . . . . . . . . . . . . . . . . . 32
Fan Belt Adjustment. . . . . . . . . . . . . . . . . 33
Fan Pulley Adjustment
(For variable pitch pulleys only) . . . . . . . . . . . 35
Alignment of Shafts & Sheaves . . . . . . . . . . . . 35
Mold In And Around Drain Pans . . . . . . . . . . . . 36
Coil . . . . . . . . . . . . . . . . . . . . . . . . 37
Coil Cleaning . . . . . . . . . . . . . . . . . . . . 37
Compressor Oil . . . . . . . . . . . . . . . . . . . 37
Adding Oil . . . . . . . . . . . . . . . . . . . . . 37
Dismantling & Disposal . . . . . . . . . . . . . . . 38
Expansion valve service & maintenance . . . . . . . . 38
Hot gas by pass . . . . . . . . . . . . . . . . . . . 40
Refrigerant Recovery, Recycling &
Reclamation . . . . . . . . . . . . . . . . . . . . 43
Trouble Shooting . . . . . . . . . . . . . . . . . . 46

5 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 Note:- It is not the intention of this manual
order to avoid unnecessary/dangerous conditions in the to cover all possible variations in systems
machine and to guarantee the safety of the equipment. that may occur or to provide comprehensive
The contents in this manual are mainly the installation and information concerning every possible
operating instructions of your Package Air Conditioning contingence that may be encountered during an installation,
unit. The precautions mentioned through out this manual operation and maintenance. If additional information is
should be taken seriously to derive maximum safety for required or if specific problems arise that are not fully
all. Installation, service and start up of any air-conditioning discussed in this manual, contact your local office.
equipment should be done only by a qualified personnel or
service technician. Always observe precautions in the manual Always heed all WARNING and SAFETY
and be familiar of all the symbols / labels attached in the unit INSTRUCTION boxes. Always read and heed all
when dealing or working with the equipment. instructions in this manual carefully. Failure to
follow WARNING, SAFETY INSTRUCTIONS and all
Unit Description other instructions could result in severe personal
The PACV-S series is a modern, diversified and environment injuries and death.
friendly series of packaged air conditioners which use R - 134a
as the refrigerant.
The complete PACV-S package provides an extremely rugged, For the representation and understanding of the points
heavy duty, long-life, energy efficient and self-contained package of caution, attention, danger, and information. Following
air conditioner that will provide cooling at higher efficiency over symbols are used throughout the manual.
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 General Warning
compressor.
Totally enclosed, Class F insulated, IP55 CAUTION
protected condenser and evaporator fan
motors.
Heavy duty condenser and evaporator coils Take special attention
optimised in design for long-life maintenance and points to be
free operation. noted.
Cabinet construction specifically designed ATTENTION
for Gulf climates.
IP 54 Electrical panel.
Indicates dangers
Factory installed, advanced and user friendly through electrical
microprocessor based control system. shock, system
Interface capability with major BMS protocols pressure, and
(option). DANGER location.
The SKM PACV-S series packaged air
conditioning units are durable, dependable,
strong, reliable, versatile, quiet and energy
efficient. Wherever a heavy duty packaged General Information.
air-conditioner is required, the PACV-S series
should be an automatic choice. INFORMATION

Unit Name Plate Indicates dangers by


Typical SKM Air Cooled Packaged Unit high voltage
nameplate is as shown.
Check the nameplate data with the P.O/ HIGH VOLTAGE
Submittal when receiving the unit.

Indicates dangers
MODEL ITEM CODE by moving/rotating
POWER SUPPLY (V/Ph/Hz)
CONTROL VOLTAGE(V/Ph/Hz)
parts
COMPRESSOR MODEL Qty LRA RLA

MOVING/ROTATING PARTS
CONDENSER MOTOR Qty KW FLA
EVAPORATOR MOTOR Qty KW FLA
MIN.CIR AMPS/MAX. FUSE AMPS
HEATER KW/NO. OF STAGES
R-134A CHARGE(KGS) Factory/Field
Indicates dangers by
MANUFACTURING SERIAL NO hot pipes
MANUFACTURED IN SHARJAH,UNITED ARAB EMIRATES HOT PIPES

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INSTALLATION, OPERATION & MAINTENANCE

Nomenclature 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.
PAC V - 5 1 008 S Y
It is the responsibility of the user or the person installing
Packaged Air Power Supply Code the equipment to provide proper grounding and branch
Y: 380-415V/3Ph/50Hz
Conditioner circuit protection according to NEC, Local & National
P: 440V/3Ph/50Hz
V-shaped condenser R: 380V/3Ph/60Hz safety regulations.
construction E: 460V/3Ph/60Hz
T: 220V/3Ph/60Hz This Air Conditioning equipment must be disconnected
Power supply frequency from the mains if any repair work is to be carried out.
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 The control ON/OFF switch in the control panel does not
Nominal Scroll Compressor disconnect the equipment from the mains and thus it is
Capacity (TR) (R-134a) not to be used as a safety switch.
Do not attempt to repair, move, alter or reinstall the unit. If
performed by an unauthorized personal, these operations
SKM reserves the right to change, in part
may cause electrical shock or fires.
or in whole the specifications of its Air
Conditioning Equipment at any time in Always remember to inspect the units, refrigerant tubes
order to add the latest technology. Therefore, and protection regularly. These operations should be
the enclosed information may change without performed by a qualified personnel only.
any prior notice. 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 Noise Emission
conditioning equipment. For maximum
safety installers should always follow The sound emission expected in normal use of the fan
the list of warnings. During the should be duly taken into account.
installation process care should be
taken to avoid any accidents related to:
1. High voltage Wear ear defenders when
working near to or on the running
2. High pressure in the system fan!
3. Hot pipes due to discharge
temperature
4. Moving/Rotating parts
Heavy Loads
The heavy weight of fans
and their components entail
This manual explains how to install,
the following risks during
operate and maintain SKM PACV-S
maintenance:
series, Air cooled packaged unit. The
manufacturer shall not be responsible Risk of being trapped,
for damages arising from wrong crushed or cut by moving or toppling
p
practices used. So SKM recommends machinery.
to do the installation including the Danger of falling components.
connection of electricity, operation and maintenance
by a person qualified for the air- conditioning and Do not stand or work under suspended loads.
refrigeration work only.
Wear a hard hat, safety shoes and gloves.
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 Rotating Shafts and Impellers
manual. Also this shall invalidate the warranty. Objects fixed to rotating shafts and impellers can fly
The air conditioning equipment should be used off at an angle and cause serious injury.
only for the applications for which it has been
Articles of clothing and hair can get caught in rotating
designed.
shafts and impellers.

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INSTALLATION, OPERATION & MAINTENANCE

Do not remove guards


during operation. Points To Remember
Do not wear loose-fitting
clothing when working Being an electromechanical machine, the unit may fail or
near rotating shafts and cause difficulties. Remembering the following few points will
impellers. ensure correct and prompt rectification and continued optimal
performance.
Wear goggles.

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. A correct installation ensuring proper clearances for
When the condenser fan has correct condenser air flow and maintenance as per the
stopped wait until the motor drawings shown for recommended clearances
has cooled down.
Wear protective gloves. 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.
Electrical Shock Hazards
If power fuse is blown off, be sure to replace the same
All power must with a new fuse having pre designed Amperage. Do
be disconnected not use a steel wire or copper wire instead of proper
prior to installation fuse. Genuine fuse ensures safety and proper protection.
and servicing this Incorrect fusing may cause fire or trouble with your equipment.
equipment. More
than one source of
Before replacing any fuse or opening any electrical
power may be present. Disconnect
panel door, make sure the main switch is OFF.
all power sources to avoid
electrocution or shock injuries.
Do not spray or sprinkle water directly over or into
the air conditioning equipment for cleaning because
Fiber glass Insulation! electric insulations and terminal of the components
This Product contains fiber glass wool. Disturbing are opened.
the insulation in this product during installation, The microprocessor controller is programmed to stop
maintenance or repair will expose you to airborne functioning the Air conditioning equipment including
particles of glass wool fibers and ceramic fibers. the compressor in the event of a safety device trips. The
All necessary Personal Protective Equipment problem should be investigated and repaired or rectified as per
(PPE) including gloves, eye protection, mask, trouble shooting instruction in this manual before attempting to
long sleeves and pants must be worn when reset and restarting the machine.
working with products containing fibreglass
wool. Exposition to glass wool fibers without Following a power supply interruption during operation,
all necessary PPE equipment could result in the microprocessor is programmed to restart the unit
cancer, respiratory, skin or eye irritation, which automatically when power supply has returned to normal.
could result in death or serious injury.
Avoid breathing fiber glass dust. This Air conditioning equipment is meant to be installed
Use a NIOSH approved dust/mist respirator. out doors and suitable to normal environment elements.
Avoid contact with the skin or eyes. Wear Do not try to cover or block any inlets or discharge openings
long-sleeved, loose-fitting clothing, gloves, to condenser.
and eye protection.
Wash clothes separately from other Periodical maintenance of the unit will give better
clothing: rinse washer thoroughly. performance in the long run than only break down
maintenance.
Operations such as sawing, blowing,
tear-out, and spraying may generate
fibre concentrations requiring additional Insist on maintenance from a reputable maintenance
respiratory protection. Use the appropriate contractor to ensure a trouble free operation.
NIOSH approved respiration in these
situations.

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INSTALLATION, OPERATION & MAINTENANCE

Component Features
NOT covered under the manufacturers limited
Compressor warranty.
Compressors used in PACV-S packaged unit series are
hermetically sealed, compact scroll with the following features:
High Efficiency. Parallel Operation
Quite operation, Low Sound levels. A parallel compressors installation, with common suction line
Compact and light . and common discharge line, gives a reduced operating cost
through greater control of capacity and power consumption. This
Limited wear.
is achieved by staggering compressor switch-on sequences that
70% fewer moving parts than comparably sized allow the parallel system to match its power with the capacity
reciprocating compressors needed. By switching-off individual compressor from parallel
Unique ability to handle liquid refrigerant. installation, while other compressor is operating 100%, the
improved part load efficiency can be achieved. The specially
Suction gas motor cooling. developed and adopted oil equalization system ensures correct
Centrifugal oil pumps with filter and magnet. compressors operation, oil balancing between compressors and
Brazed fittings or Rotalock as options. reliability.

Multiple refrigerant circuits on larger units provides


efficient part load.
Condensers
Vacuum operation!
Condenser coils are manufactured of seamless copper tubes
Compressor damage! mechanically bonded to aluminum
fins to ensure optimum heat transfer.
Scroll compressors should never be
All coils are tested against leakage by
used to evacuate a refrigeration or air pressure of 450 psig (3100 kPa)
air-conditioning system. under water. All standard coils are
2,3 or 4 rows/14 FPI, 3/8 (9.5 mm)
O.D. tubes. An integral subcooling
Do not pump down the scroll circuit is provided to increase the
compressor into a vacuum! cooling capacity, without additional
operating cost.
For different application requirements,
Three phase compressors other optional condenser fin materials
only: On initial startup, if are available:
the compressor sound is Copper fins.
abnormally high and the readings Electrotinned Copper Fins.
of suction and discharge pressures
Copper finned coils with electro-tinned after manufacturing.
are outside normal range, there is
a possibility that the compressor Precoated Aluminum fins
The pre-coated is hydrophobic polyurethane resin. This option
rotation is in the reverse direction.
provides substantial corrosion protection beyond standard
In this case, interchange any coil construction.
two legs of the power supply
Aeris Guard Coil Coating
and attempt to restart. Running
The Aeris Guard Coil is a self etching high performance
a scroll compressor in reverse modified epoxy finish that is specifically designed to coat
direction for an extended period and protect Aluminum and Copper surfaces. In addition, the
of time will cause damage to the coating is ideal for the protection of ferrous and non ferrous
compressor. such damage is not materials.
covered under manufacturers
SKM PACV-S series, all models, are restricted to a 14FPI (1.8
limited warranty.
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
Reverse rotation for 5 to free operation with the least possibility operational blockage on
15 minutes will result in the condenser. Ample condenser surface and sensible air flow
the overheating of motor across the condenser ensures a low temperature differential
windings. In this case, the thermostat between condensing temperature and the high Gulf ambients
in the motor windings open and making the PACV-S packaged unit perform efficiently and durably.
result in stopping of the compressor.
Continued reverse operation of scroll
compressor will result in failure of scroll
compressors. Such failures are

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INSTALLATION, OPERATION & MAINTENANCE

Condenser Fans Fan Section


Condenser fans are Fans in the PACV-S units are selected for the best sound
propeller type, aluminium characteristics based on maximum fan efficiency. More than one
alloy blades, directly driven arrangement of evaporator fans are used in the PACV-S series
by electric motors. Motors packaged units due to the wide range of air flow rates.
are Totally Enclosed Air Over Commonly, all fans are double inlet, double width, centrifugal
(TEAO) six pole with class F type with forward curved impellers provide the combination of
insulation and minimum IP55 efficiency and quietness of operation. All fans are statically and
protection. The TEAO and class F insulation features ensure dynamically balanced, belt driven by motor sizes up to 15 kW are
long life and are unique for SKM. provided with adjustable pitch pulleys as standard.
The motors are factory wired, using wires specially selected for Above 15 kW motor sizes are equipped with fixed pitch pulleys
high ambients operation, to unit control panel where the motor s standard and adjustable pitch pulleys are option. Specify PP.
contactors are located to control the operation of these motors. Single fan is used for PACV-51008S, PACV-51010S, PACV-
The condenser fans are individually statically and dynamically 61009S & PACV-61012S models. Models PACV-51014S~PACV-
balanced at the factory. 52055S & PACV- 61018S~PACV- 62066S are equipped with two
fans. These fans are mounted on a single heavy duty shaft driven
Complete fan assembly is provided with suitable acrylic coated by a single electric motor. Shaft end insert into over sized, tapered
fan guard. lock self aligning long life bearings. The motor is mounted on
an adjustable base, so that belt tension can be easily adjusted.
Evaporator Models PACV-52065S and PACV-62076S onwards, use single
fan assembly, which has maximum strength, high performance,
Evaporator coils are manufactured of seamless copper tubes
quietness and reliability. These fans use self aligned ball or pillow
mechanically bonded to aluminium fins to ensure optimum
block bearings that are greased for life. Pillow block bearings
heat transfer. All evaporator coils are tested against leakage
are provided with re-greasing fittings. The motor is mounted on
by air pressure of 300 psig (2068 kPa) under water. The DX
an adjustable base, so that belt tension can be easily adjusted.
evaporator coils are complete with headers of seamless
copper tubing. Supply headers incorporate a correctly sized The complete fan-motor drive assembly is mounted on a floating
distributor. For different application requirements, other sub-base. In order to limit transmission of noise and vibration,
evaporator coil material and/or treatment are available the complete fan motor sub-base assembly is mounted on anti-
on request. vibration mounts. Flexible connection is provided between fan
Copper fins. discharge and casing panel to avoid transmission of vibration to
the connecting duct.
Electrotinned Copper fins.
The optional modular construction units for models PACV-
Copper finned coils with electro-tinned after 51008S~PACV-52055S & PACV-61009S~62066S are also using
manufacturing. the same fan specifications as mentioned above.
Precoated Aluminum fins. The electric motors are foot mounted, 4 pole, totally enclosed fan
The pre-coated is hydrophobic polyurethane cooled (TEFC), IP-55 protected, Class F insulation with Class
resin. This option provides substantial B temperature rise.
corrosion protection beyond standard coil Drive package is factory selected for the medium air flow rate as
construction. shown in the capacity ratings. Alternative drive packages to meet
Aeris Guard Coil Coating. specific job or client requirements can be provided.
The Aeris Guard Coil is a self etching high
performance modified epoxy finish that is
specifically designed to coat and protect Refrigerant Circuit
Aluminum and Copper surfaces. In addition, PACV-S series comes complete, as standard, with correctly
the coating is ideal for the protection of sized and piped refrigerant lines including sight glass, filter drier,
ferrous and non ferrous materials. 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
Evaporator coil supplied with suitable size insulated with (12 mm) wall thickness closed cell pipe insulation.
thermostatic expansion valve(s) and multi-
circuited distributors providing capacity
modulation to match the compressors. The cross Filter Section
wave fins and staggered tubes design uses the PACV-S series can be with a range of filter sections and filters
evaporator surface effectively by creating uniform to meet requirements for the most demanding applications.
air turbulence and optimum heat transfer over the Flat or vee filter sections to accommodate 1 or 2
entire finned surface. Requirements for higher cleanable aluminium media filters can be provided.
face velocities can be handled by use of moisture A bag filter section to house 22, 30 or 36 deep
eliminators to avoid carryover. 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.

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INSTALLATION, OPERATION & MAINTENANCE

On 100% fresh air applications an initial sand Solenoid Valve


trap louvre can effectively minimize entrance It is used to stop the flow of refrigerant within
of sand into the air stream. the refrigeration system.
High efficiency mini pleat panel filters are The valve is typically a normally-closed type of
available as an alternative for bag filter where valve so that it is closed when it is energized
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 Shut Off Valve/Ball Valve
size with option ASL.
Usually used so that portions of refrigeration system can be
Casing/Structure 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 95F (35C) and 95% relative humidity as per ASTM
B117. The entire casing panels are designed to be leak proof Sight glass
against rain and ensure rain cannot enter the PACV-S series
Used to observe the flow of liquid refrigerant. Bubbles or
packaged air conditioner interior. Evaporator section sealed
foaming in the sight glass indicate a shortage of refrigerant or
by the use of vinyl gasketing material.
restriction in the liquid line that can adversely affect system
The evaporator section is insulated from all sides with black- operation. Sight glasses are widely used as a means of
neoprene faced heavy density 1 thick fiber glass insulation determining if the system is adequately charged.
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 Filter Driers
section, option DSE provides 0.7 mm galvanized inner
skin. Suitable isolation to ensure no cold-bridges Driers are mounted in the refrigerant liquid line to ensure that
and no condensation on the exterior of the units all the refrigerant in circulation passes through the drier each
is provided. The condensate drain pan is heavily time it circulates through the system so as to remove any
insulated to ensure that condensation may not moisture or foreign matter from the refrigerant stream.
occur. Stainless steel condensate drain pans are
available on request.

Liquid Line Controls

Thermostatic Expansion Valve


For controlling the flow of liquid refrigerant into Low Pressure Switch
the evaporator, an orifice in the valve meters This switch is fitted in the suction side of each refrigerant circuit
the flow into the evaporator, the rate of being and is wired to the unit controller digital input. Its function is to
modulated as required by needle type plunger protect the compressors against low suction pressure. If the
and seat, which varies the orifice opening. 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 The unit mounted control panel enclosure is fabricated out of heavy
refrigerant circuit and is wired to the unit controller gauge sheet steel in phosphatized powder coated baked finish.
digital input. Its function is to protect the compressors The enclosure conforms to IP54 as per guidelines in IEC 529. A
against high discharge pressure. If this switch hinged access door and key-fastener is provided for easy access
remains open for one second, then the unit controller and security. The panel is factory wired in accordance with NEC
will switch off the corresponding refrigerant circuit 430 & 440, labelled, tagged and features 220V/240v controls.
and generate High Discharge pressure alarm. 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.
Discharge Pressure Transducer 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 Microprocessor Controller


switches and Fan cycling 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
Factory Switch Settings fan, compressors and condenser fans. The controller comes
Cut Out Cut In with a built in keypad and display for simple but meaningful man
Description machine interface. This controller provides complete operational
(PSIG) (PSIG)
control for the unit and has built-in auto diagnostic capability
Low Pressure
14.5 29 that can signal normal operation or alarm conditions as well as
Switch
shutting down the unit or system if necessary.
High Pressure .The Main Features of the controller are as follows:
300 200
Switch
Built in LCD display with back light.
Table 1 Roll & push knob and 3 function buttons.
Battery backed up built in real time clock.
Factory Fan Cycling Settings Multiple authorization level to provide tight security
in Unit Controller for the control system.
(Units with 4 fans)
Capacity control based on room temperature or
Description On (PSIG) Off (PSIG) return air temperature.
Fan Cycling Alarm history.
180 130
Stage- 1 A sleek & elegant design room unit.
Fan Cycling
200 150
Stage- 2
Fan Cycling
220 170
Stage- 3
Fan Cycling
240 190
Stage- 4
Table 2

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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 A brief description of each button in the room unit is shown in
The intelligent microprocessor based controller table below:
monitors all the safeties related to the unit and
Button for unit power on or unit
makes the necessary protections,by shutting ON/OFF
power off
down the entire unit or the effected circuit. The
protection includes Button for Time scheduler, pressing
Low suction pressure. this button allows date/time setting,
Program
High discharge pressure. while holding it allows schedule
High compressor motor temperature. (For programming
compressors with internal motor protector). Button for set-point adjustment,
Compressor short cycling. each operation of the Minus (-)
Evaporator fan motor overload Minus button reduces the set point by
differential which is defined in
BMS Connectivity (Optional) controllers setting
Volt free contacts for run status, common fault Button for set-point adjustment,
status, auto mode status and provision for remote each operation of the Plus (+)
on/off shall be provided as option if required. Plus button increases the set point by
In addition, the PACVS microprocessor can differential which is defined in
support the major BMS protocols such as BACnet, controllers setting
Modbus & LON. Extra hardware may be required Button for confirmation of date/time
depending on the protocol. and scheduler settings. Long press
OK
of this button can toggle between
measurement units -oC and oF
Room Unit Button for fan mode either
Fan
The controller comes with a loose supplied sleek continuous mode or auto mode
and elegant design room unit for installing in the
Button for unit mode: Cool, heat,
conditioned space. Communication between
ventilation and or cool-heat
unit controller and room unit is through two
Mode auto changeover (*Cool-Heat
wire interface. The communication cable
is available only if heat mode is
should be 2 core, twisted pair, unscreened
applicable)
with stranded conductors, as per KNX
specification. Maximum distance between room Table 3
unit and controller can be 700 meters. The room
unit has a built in sensor for measuring the room
temperature. It transmits room temperature, Control or data communication
set point, unit operating mode etc. to the unit cables should not be routed along
controller. Control of the compressors is based with power cables. Sufficient distance
on room temperature and the set point, as is to be maintained while routing the cables
standard. If unit control needs to be based between Power and data communication cables
on duct temperature, please specify during (If any).
time of order.

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

The microprocessor controller & room


unit include electrical and electronic
Figure 1 components and must not be disposed
off as domestic waste. Current local laws on
disposal of electronic waste are to be observed.

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 |
INSTALLATION,

Receiving of Equipment Handling


Rigging holes are provided on the sides of the unit.
Responsibility should be assigned to a
dependable individual at the job site to Avoid twisting or uneven lifting of the unit
receive material. Each The cable length from bracket to the hook should always
shipment should be be longer than the distance between the outer lifting points.
carefully checked against the bill of If the unit is stored at the construction site for an intermediate
lading. The shipping receipt should period, follow these additional precautions:
not be signed until all items listed on a. Support the unit well along the length of the base rail
the bill of lading have been accounted
b. Level the unit (no twists uneven ground surface)
for.
c. Provide proper draining around the unit to prevent
When uncrating, care should flooding of the equipment
be taken to prevent damage. d. Provide adequate protection from vandalism,
Heavy equipment should be mechanical contact, etc.
left on its shipping base until it has been e. Securely close the doors
moved to the final location.
f. Cover the supply and return air openings an limits
without isolation dampers.
Check carefully for concealed damage. Any
shortage or damages should be reported to the Use all lifting points. Improper lifting can
delivering carrier. Damaged material becomes the cause severe personal injury and property
delivering carriers responsibility, and should not be damage.
returned to the manufacturer unless prior approval is given HOOK

to do so.

The packing list included with each shipment SLING

should be carefully checked to determine if


all parts and equipment have been received.
Any accessories such as starters, contactors SPREADER

or controls should be fastened to the basic unit to avoid


loss and prevent possible interchanging with other
units.

Make sure that wiring diagrams and


IOM manuals are available within the
equipment control panel.
WOODEN PIECE

Rigging

Regardless of the packaging


SHACKLE
used in transporting of the units, it WOODEN PIECE

Figure 3
should preferably be lifted with a fork
lift truck or a crane and belts. The HOOK

units should be unpacked as close


as possible to its final installation position. The
unit should always be left standing upright.
4No.EQUAL SLING

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 SHACKLE

customer on site.
Figure 4

| 13
INSTALLATION,

Storage 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 B

measures are required:


Units must be stored in a protected area and

A
safe from construction debris. Do not remove the
wooden coil guard.

DUCT
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

A
Sales Office or SKM sales representative.
Keep the liquid line Shut Off valve closed. PACV- 51008 S TO 52055 S
PACV- 61009 S TO 62066 S
When selecting a location for the unit, the following Figure 5
points should be considered:
There should be enough space for air movement
beside the condenser coils which should be SPACING FOR AIR FLOW
approximately equal to the height of the coils.
The discharged air from the condenser fan should
DUCT

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

A
B

78
[1981]
PACV- 52065 S
Location and Space Requirements PACV- 62076 S
Figure 6
PACV-S A B C
51008-S 61009-S
50

A*
DUCT
51010-S 61012-S
51014-S 61018-S
66 60
52015-S 62018-S 52
51017-S 61020-S
72
52017-S 62020-S
DUCT
52020-S 62024-S 46

A*
78 [1165]

52023-S 62028-S 54 B

52026-S 62033-S 72 PACV- 53070 S TO 54125 S


*

PACV- 63085 S TO 64145 S SPACING FOR BOTH AIR FLOW AND SERVICE
52030-S 62036-S
66 Figure 7
52032-S 62037-S p
82
52038-S 62046-S Multiple Unit Installation
96
52045-S 62055-S
52050-S 62060-S 78 SPACING FOR SERVICE SPACING FOR AIR FLOW
108
52055-S 62066-S 86
52065-S 62076-S 78
53070-S 63085-S
104
53075-S 63090-S
B

53080-S 63095-S
53085-S 63100-S 108
53090-S 63105-S 114 -
84
53095-S 63110-S 121
54100-S 64120-S 124
54110-S 64130-S 128
54115-S 64136-S 134
54125-S 64145-S 142 DUCT DUCT
ALL DIMENSIONS ARE IN INCHES C
Table 4 PACV- 51008 S TO 52055 S
PACV- 61009 S TO 62066 S
Figure 8

14 |
INSTALLATION,

Multiple Units Installation (Modular If there are walls on one or two adjacent sides of the unit.
Construction) B 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.
DUCT

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.
DUCT

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


PACV- 51008 S TO 52055 S vibration isolators of rubber-in-shear or spring type be
PACV- 61009 S TO 62066 S installed under the base refer to loading points (Page 49).
t. Figure 9

Foundation
Recommendations A flat level concrete foundation which can support the weight of
the equipment must be provided.
It is a necessity that the units are installed with adequate
free space around them to ensure proper circulation of Where units are to be located, over steel trusses or on a steel
air that is rejected by the condensers and to provide platform, careful analysis to ensure proper distribution of weight
adequate space for unit access for servicing and onto the structural members should be ensured. The steel platform
maintenance. There is a possibility of recycling of air should be strong enough to hold the operating weight.
if the rejected air from condenser encounters any
obstacles leading to an increase in the ambient air
temperature surrounding the units.
Pre-Installation Check-Up
Air distribution across the entire heat exchange
Electrical
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 IMPORTANT: When installing the unit, always
an increase in discharge pressure of the disconnect the electric supply.
compressors. This leads to a loss of capacity &
increase in compressor power input
Make sure that the power supply is compliant with current
safety standards. Always install the air conditioner in
Units should not be compliance with current local safety standards.
completely shrouded
with higher uninterrupted Verify that suitable grounding connection is available.
wind shield in order to prevent
reversing of air flow. In case, such Verify that the voltage and frequency of the power supply
a configuration cannot be avoided, comply with the specifications and that the installed power
a properly designed exhaust duct is sufficient to ensure the operation of any other domestic
or hood that does not influence appliance connected to the same electric lines.
any additional pressure a properly
designed exhaust duct or hood that Verify that the air conditioner is connected to the power
does not influence any additional supply in accordance with the instructions provided in the
pressure on the fans and which of the wiring diagram included in the manual.
same hight as surrounding shield to be
installed. 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 Carrying Out Installation

1. Unpack the unit carefully.


When deciding on the location of the unit with the
owner, the following restrictions must be taken into 2. Unfasten or dismantle transport locks.
consideration:
3. Packing material to be fully removed and disposed.
4. The unit base frame must be fixed without stresses to the
The discharge air from the condenser fan supporting structure.
should not be obstructed by any roofing, 5. AVM to be regularly placed around centre of gravity and
shelter, ducting etc. Any obstruction will firmly fixed. Check whether AVM is balanced under load.
cause short circuiting of condenser fans leading
6. No forces or vibrations may be transferred from other plant
to reduction in capacity or nuisance tripping of
parts.
the PACV-S package unit from the high pressure
control and sometimes in motor burnout . 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.
General 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 Condensate Draining
following elements :
Combustible gases It is mandatory to install a properly sized drain trap in order to
ensure proper draining of condensate collected in the drain pan.
Saline air
Below mentioned are recommendations for sizing a drain trap.
Machine oil
Sulphide gas Measure the maximum negative static pressure upstream from
Special environment conditions, the fan. The height H1 shown in below figures must be greater
if you must install the unit in such than or equal to the negative static pressure at design conditions.
conditions, first consult SKM. 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


Avoid installing the equipment in the H2= H1/2
following: H= H1 + H2+ Pipe Diameter + Insulation

Condensate traps serving the cooling coils should be of sufficient


In areas where it is exposed to
height to be effective.
direct sunlight. Close to any heat
The unit should be located on a suitable base to provide adequate
source.
height from the ground in order to accommodate the drain trap.
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 Figure 10
is running.

16 |
OPERATION

the oil charge has been properly adjusted to maintain the oil level
Pre Startup Checklist at the center of the sight glass.
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 PACV-S unit is factory charged
with the installation instruction and applicable codes.
Check all electrical connections in unit control panel;
tighten them as required. Please make sure to open supply air
dampers fully (if any) before starting the
Make sure the compressor oil level is within the fan motor. Otherwise, blower fan can be
sight glass range.
damaged due to back pressure and warranty
Check the power supply phase sequence for proper will be void.
direction of rotation of motors.
Make sure all system hand valves are in fully open
position and system contains an operating charge
of refrigerant. Precaution: Carry out a fan test run
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.
Risk of injury from rotating impeller!

Pre-Startup Procedure Never reach into the impeller when the fan
After the installation has been completed, the following points is in operation.
should be covered before the system is placed in operation.
a. Check electrical connections. Be sure they
are all tight. Take measures to prevent centrifugal fan
from being switched on accidentally.
b. Observe compressor oil level before start-up. Clear the ducting system and fan of all foreign
The oil level should be at or slightly above the bodies (tools, small parts, construction
center of the sight glass. Use only oil approved waste, etc.).
by compressor manufacturer.
Close all the inspection openings.
c. Remove or loosen shipping retainers under Switch on fan and check direction of rotation
motor- compressors. Make sure hold down of impeller by comparing it with the arrow on
nuts on spring mounted compressors are not the fan indicating the direction of rotation.
touching the compressor feet.
If the direction of rotation is wrong, reverse
d. Check high and low pressure controls, the polarity of the motor having due regard to
pressure regulating valves and all other safety the safety instructions.
controls, and adjust if necessary. Once operating speed has been reached
e. Check refrigerant used in the system. measure the current consumption and
compare it with the nominal motor current on
f. Wiring diagrams, instruction bulletins, etc the fan type plate or motor rating plate.
attached to PACV-S units should be read
and filed for future reference. If there is continuous overload switch the
centrifugal fan off immediately.
g. Make the proper refrigerant connections Check that the fan runs smoothly and quietly.
and charge the unit with the refrigerant to Ensure that there are no unusual oscillations
be used. Weigh the refrigerant drum before or vibrations.
charging so an accurate record can be kept
of the weight of refrigerant put in the system. Check the motor for any abnormal noises.

h. Observe system pressures during charging


and initial operation. Do not add oil while the If the state of the fan does not allow adapted
system is short of refrigerant, unless oil level
action for repair it has to be put out of
is dangerously low.
order immediately and to be replaced if
i. Continue charging until system has sufficient required.
refrigerant for proper operation. Do not over-
charge. Remember that bubbles in a sight
glass may be caused by a restriction as well
Prior to starting up the unit, we
as a shortage of refrigerant.
recommend checking if the following
j. Do not leave unit unattended until the system steps have been carried out:
has reached normal operating conditions and

| 17
OPERATION

Operational Check-Out Service Record


A permanent data sheet should be prepared on each
After the system has been charged and has operated for installation, with a copy for the owner and the original for the
at least two hours at normal operating conditions without installing contractors files. If any other firms are to handle
any indication of malfunction, it should be allowed to operate service and maintenance, additional copies should be prepared
over-night on automatic controls. Then a thorough recheck as necessary.
of the entire system operation should be made as follows:
The form of the data sheet may vary, but a complete record
a. Check compressor head and suction of sizes and identification of all components used in the
pressures. If not within system design limits, installation, together with any pertinent information should be
determine why and take corrective action. included. Following is suggested check-off list:

b. Check liquid line sight glass and expansion a. Compressor manufacturer model and serial number.
valve operation. If there are indications that
more refrigerant is required, leak test all b. Equipment manufacturer model and serial number.
connections and system components and
repair any leaks before adding refrigerant. c. Design operating temperatures.
c. When applicable, observe oil level in d. Refrigerant and weight of charge.
compressor crankcase sight glass, and add
oil as necessary to bring level to center of e. Electrical service, volts, cycles, phase, wire size.
the sight glass.
f. Control circuit, voltage, breaker size.
d. Thermostatic expansion valves must be
checked for proper superheat settings. g. Contactor or starter, manufacturer, model, size, part
Sensing bulbs must be in positive contact with number.
the suction line. Valves with high superheat
settings produce little refrigeration and poor h. Compressor motor protection(if available), type, size,
oil return. Too little superheat causes low part number.
refrigeration capacity and promotes liquid
i. Data on relays or other electrical components.
slugging and compressor bearing washout.
Liquid refrigerant must be prevented from j. Pressure control, type, size, model number, setting.
reaching the crankcase. If proper control
cannot be achieved with the system in normal k. Data on miscellaneous components such as pressure
operation, a suction accumulator must be controls, crankcase heaters, solenoids, valves, etc.
installed in the suction line just a head of the
compressor to prevent liquid refrigerant from l. Liquid line drier, manufacturer, size, model number,
reaching the compressor. connections.

e. Using suitable instruments, carefully m. Schematic diagram of refrigerant piping.


check line voltage and amperage at the
compressor terminals. If high or low voltage n. Final settings on all pressure, regulating and safety
indicated, notify the power company. The controls.
current normally should not exceed 120%
of the nameplate rating. If amperage draw o. Microprocessor details
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.
f. 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.

18 |
OPERATION

module (if available in compressor) are healthy.


Unit Start Up If above are satisfied, solenoid valve will be opened
Switch on the three phase power supply to the unit.
and when the low pressure switch closes, compressor
Switch on the control circuit breakers. Unit controller will be started.
will start up.
A typical two compressor control is as shown below:
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.

Sequence of Operation Condenser fans


The unit may be enabled or disabled through the Run/ Condenser fans will switch on with associated compressor(s)
Stop toggle switch in the unit mounted control panel or and cycle based on discharge pressure.
from the room unit on/off button. Control is based on room
For single compressor units or units with circuits having
temperature sensed by room unit(for units with duct sensor
independent condenser fans, condenser fans will be
,control is based on duct temp). Evaporator fan motor
switched on based on the discharge pressure of that
starts first. Compressors will be staged based on the set
circuit. Each fan will switch on if pressure is above the
point and actual room temperature. On an increase in
stage on value and will switch of if the pressure is below
room temperature, cooling stages will be added and
stage off value.
on a decrease in room temperature, cooling stages
will be removed from the system. Sequence for the For units with more than one compressor sharing the
compressors and motors are as given below: condenser fans, the highest pressure among the circuits
will be taken to cycle the fans.
Supply Fan
Supply fan will be switched on if the below
conditions are satisfied. Unit Controller Display and Keypad
Controller start up is finished. The keypad/display of the controller consists of a 64 x 144 screen
Run/Stop switch in the unit control resolution 5 line 22 character display screen,3 buttons and a push
panel is ON. & turn knob for navigation.
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
Supply fan has two modes; ON (continuously where the SKM Unit model & serial number can be viewed.
ON) or AUTO (ON when there is cooling or Alarm button: This is used to enter directly the alarm screen for
heating demand). viewing the alarm details & to reset them manually if required.
Esc button: This is a back button to move back to the previous
Compressor screen or to the home screen.
Compressor will switch on if the below conditions
are satisfied.
Compressor minimum OFF time
Push & Turn Knob
completed. This is a navigation wheel that can be rotated as well as pushed.
Supply fan runs for 30 seconds. Rotating the wheel navigates between the lines of the screen
Circuit enable (from controller display) and also to change/edit the changeable values on the screen.
is enabled. Clockwise rotation increases the values and anti-clockwise rotation
Unit is in cool mode. decreases the value. Pushing the wheel acts as an Enter button
Demand for compressor is present. to acknowledge the changed value.
Discharge pressure and motor protector
| 19
OPERATION

Display and Keypad operation


The main display screen consists of a 5 line display, with If supply fan is not starting, navigate to these screens to find out
the first line displaying the page title and a numeric display the reason. In order for the supply fan to start, the Run/Stop input
of the number of alarms along with the e symbol if any should be Run, Room Unit should be On, Schedule Status
alarms are present. Second & third lines display the date & should be On in case the schedule is enabled, Motor over load
time respectively. There are three sub menus in the display should be healthy and Voltage monitor should be healthy.
namely, SYSTEM OVERVIEW, PASSWORD & ALARMS.
Every page can consist of data fields, either changeable or with
Circuit Screen
information only. As the cursor moves over each line, the text Each circuit screen will show the status of all the inputs and
in the line is highlighted with a black box around it and the text outputs related to that circuit.
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.
These will show the status of supply fan motor (On or Off), Circuit
Figure: Rotation of the navigation wheel 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).
Figure: Pushing the navigation wheel
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.
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 Condenser fans
including safeties and status of compressors, motors These screens will show the discharge pressures of each circuit
and set points. Different screens of the controller are and status of the condenser fans.
as given below.

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

Schedule
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.
System Overview
Selecting the system overview will lead to below
screens

Set points
This screen will show the temperature set point and actual indoor
From the above two screens, further navigation temperature (or duct
ct temperature if optional duct sensor
s is used).
is possible to different screens which will give
information about supply fan, each refrigerant
circuit, condenser fans, schedule and set points.
Supply fan
The below screens will give information about all If factory password is entered, then set points screen will show
the inputs and outputs related to supply fan. access to factory parameters as well.

20 |
OPERATION

Factory parameters will show Compressor Minimum off


time, Compressor Minimum On time, Low pressure alarm Below Screen will appear.
pp
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.

Rotate the Navigation wheel and then screen will show


Exe...

Press the navigation wheel and all the alarms which are
Note that factory parameters should be changed only by SKM. 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,
Alarms entire unit will be switched off. This alarm is auto reset as standard.
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 This alarm occurs when the unit controller looses communication
alarms. All alarms will be with date & time and will with the room unit. When this alarm happens, entire unit will be
be in easily readable English language. switched off. This alarm is auto reset as standard.
Circuit-# Suction Pressure: Trip
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 doesnt close for a specific time (low
Note that some of the alarms (like high pressure alarm delay set point). When this happens, corresponding
discharge pressure) are manual reset. In order circuit will be switched off and alarm will be generated. This alarm
to acknowledge the manual reset alarms, follow is automatic reset as standard.
below steps. Circuit-# Discharge Pressure: Trip
Enter the user password 1234 (Refer This alarm occurs when the high pressure switch senses a
Passwords) high discharge pressure in the refrigerant circuit. This alarm
Go to alarm list screen and press will be generated, if the high pressure switch remains open for
acknowledge 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 Operation of the Room Unit
circuit will be switched off and alarm will be generated. The room unit displays indoor temperature (duct temperature if
This alarm is automatic reset as standard. optional duct sensor is used), temperature set point, unit on/off
status, unit operating mode, fan mode, day of the week, time of
Passwords the day and schedule. Room unit will let the user to make the
In order to enter the password, use Password screen. unit on/off, change the operating mode, change the fan mode,
Follow the below steps. adjust the set point, change the temperature measurement unit,
Go to the Password screen in the Main Menu. change date & time and operating schedule.

Use the navigation wheel to enter password


passw
(Rotate to change and Press to select.). If user
password is required, enter 1234. Setting the address in Room Unit

Adjust the set point, change the temperature measurement unit,


change date & time and operating schedule.

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.

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.

Press mode button; room unit will display parameter 001


as below, with 001 blinking

22 |
OPERATION

Press plus button multiple times to reach


parameter 005. At this stage parameter 005 Switching on and switching off the unit
will be blinking. On pressing mode button;
Press the button to make the unit on and off. When the unit is
parameter value will start blinking. Use plus
on, will be shown on the display.
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, Changing the Unit operating mode
then parameter 005 will start blinking.
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


Operating mode of the fan can be changed by pressing the button.
Press plus button to reach parameter 006. There are two modes for the fan which are Auto ( ) and On ( )).
At this stage parameter 006 will be blinking. Auto means the supply fan will run only when there is cooling or
Press mode button and then use plus heating demand. On means supply fan will run continuously. In
button or minus button to make the value the units where there is much changes in temperature, always
0002 (if it is already 0002, no need to do use On mode.
this step). Press mode button again, then
g
parameter 006 will start blinking.
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 Alarm Indication
mode button and then use plus button or
minus button to make the value 0003 (if it is In case if there is any alarm present in the unit, will blink on
already 0003, no need to do this step). Press the room unit display. Once the alarms are cleared from the unit
mode button again, then parameter 007 will controller, then the alarm symbol will disappear.
start blinking.
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 Time and Date Setting
to parameter 001. Then press power button,
By pressing the button, user will enter time and date setting.
the version screen will be displayed.
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:

Press power button again, then room unit


p y as below.
will show normal display

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

| 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:

After the time format is confirmed, HMI-SG will jump


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

SUPPLY FAN
RUN/STOP INPUT : STOP
ROOM UNIT : ON
ON/OFF SCHEDULE : ENABLE
An Overview Of Menu Structure SCHEDULE STATUS : ON
FAN MODE : ON
MOTOR OVERLOAD : TRIP
VOLTAGE MONITOR : TRIP
SUPPLY FAN MOTOR : OFF

CIRCUIT-1
SUPPLYFAN MOTOR : OFF
CIRCUIT1 ENABLE : ENABLE
UNIT MODE : VENT
DISCH.PRES.-1 : TRIP
SUCT.PRES-1 : HEALTHY
COMPRESSOR-1 : OFF
SOL.VALVE-1 : CLOSED

CIRCUIT-2
SYSTEM OVERVIEW
SUPPLYFAN MOTOR : OFF
SUPPLY FAN
CIRCUIT2 ENABLE : ENABLE
CIRCUIT-1
UNIT MODE : VENT
MAIN MENU CIRCUIT-2
DISCH.PRES.-2 : TRIP
DATE CONDENSER FANS
SUCT.PRES-2 : HEALTHY
TIME SCHEDULE
SYSTEM OVERVIEW SETPOINTS COMPRESSOR-2 : OFF
PASSWORD SOL.VALVE-2 : CLOSED
ALARMS

CONDENSER FANS
DISCH.PRES.-1 : XX.X PSI
DISCH.PRES.-2 : XX.X PSI
HMI PASSWORD ENTER PASSWORD _____________________________
ENTER PASSWORD FAN-1 : OFF
CLOSE ACCOUNT ENTRY **** FAN-2 : OFF
FAN-3 : OFF
FAN-4 : OFF
ALARMS
ALARMLIST
ALARMHISTORY 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 : XX.X C
INDOOR TEMP : XX.X C
FACTORY SETTINGS

FACTORY SETTINGS
COMP.MIN.OFF TIME : XXX s
COMP.MIN.ON TIME : XXX s
LP ALARM DELAY : XXX s
COOLING STEP : XX.X C
COOLING DIFF. : XX.X C
COND.STG1 ON : XXX PSI
COND.STG1 OFF : XXX PSI
COND.DIFF.ON : XXX PSI
COND.DIFF.OFF : XXX PSI
CLEAR ALM HIST : Enable
ON/OFF SCHEDULE : PASSIVE
BSP VERSION : X.XX

24 |
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 Checklist Weekly Monthly Half Yearly Annually


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

Superheat at Compressor Yes


Operation Level
Crank Case Heater
Maintenance Yes
Operation
Refrigerant Sub cooling in
Yes
Liquid Line
Operating Pressures Yes
Dust & Debris on Power
Terminals/ Contactors Yes
/Loose Cable Lugs
Check for correct voltage
Control Panel Yes
at unit (Unit operating)
Check Unit Operation Yes
Check for alarms in Unit
Yes
Microprocessor
Check for Vibrations &
Yes
Noise
Check unbalance of the
Yes
Fan
Condenser Fan
Motor Bearings to be
& Motor Yes
checked
Corrosion Yes
Fan Blades to be checked
Yes
/Balancing
Check connecting lines ,
joints & coil for evidence Yes
Condenser Coil of oil leaks
Section Clean & inspect outdoor
coil , wash with water if Yes
necessary
Table 6

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

Maintenance 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
The maintenance of this equipment shall be in accordance
soon as a complete fillet is formed to avoid possible restriction
with the regulation of authorities having jurisdiction and
in the line.
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
7 . Visually inspect the connection after brazing to locate any
pin holes or crevices in the joint .

control of the condenser fans which should provide adequate


head pressure control down to 50 F (10 C) provided the
unit is not exposed to windy conditions. The system design is
responsible for assuring the condensing section is not exposed Never use oxygen for pressurizing a
to excessive wind or air recirculation. system; an explosion may occur if oil
is present in the system. Always use
a gauge equipped pressure regulator
Procedures on the high pressure back-up gas, and never
It is quite probable that a majority of operating failures can be interconnect the refrigerant cylinder and the
traced to careless or inadequate maintenance procedures. The inert gas cylinder through a gauge manifold.
following instructions have been prepared to help the service Nitrogen and carbon dioxide cylinder pressures
engineer systematically cover the many points which must can rupture a refrigerant cylinder.
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: Never solder, braze or weld on
refrigerant lines or any unit
Brazing Procedures components with pressures that are
above atmospheric pressure or where
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
refrigerant may be present. Always remove
refrigerant by following the local guidelines.
should be passed through the line at low pressure After refrigerant removal, use dry nitrogen to
to prevent scaling and oxidation inside the tubing. bring system back to atmospheric pressure
Dry nitrogen is preferred. Nitrogen displaces air before opening system for repairs. Mixtures of
in the tubing and prevents oxidation of the interior refrigerants and air under pressure may become
surfaces. A pressure regulating valve is to be used combustible in the presence of an ignition source
to control the flow. leading to an explosion. Excessive heat from
soldering, brazing or welding with refrigerant
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
vapours present can form highly toxic gases
Failure to follow all proper safe refrigerant
surface even. 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 Leak Testing, Evacuation & Charging
brazing: Procedures:
All pipe work shall be cut square with a proprietary pipe The below mentioned procedures are to be followed whenever
cutter to give a clean cut, without copper fragmentation. any major repair or replacement is done on the system. These
Hacksaws must not be used. When brazing, all pipe work procedures of Leak Testing, Evacuation & Charging are required to
shall be purged with low-pressure oxygen-free nitrogen, be made in order to bring the system back to its original operating
above atmospheric pressure (to provide a positive pressure condition after any major repair or replacement.
in the pipe) to prevent the formation of copper oxides and
scale, and to prevent moisture from the surrounding air MANIFOLD GAUGE
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 pipe work should be flushed with oxygen free, high-


pressure 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 Figure 11
directives.
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
Use only dry nitrogen
a sight glass. These sight glasses have been
with a pressure regulator
known to fail and risk causing serious injury to
for pressurizing unit. Do
the engineer carrying out the test. The manifold
not use acetylene, oxygen
gauges and service lines must be in good
or compressed air or mixtures of
condition. Manifolds with sight glasses are only
a hydrogen containing refrigerant
suitable for refrigerant recovery.
and air above atmospheric
pressure containing them for
pressure testing as they may Handling of nitrogen cylinders: When
become flammable and could the cylinder is not being used ensure
result in an explosion. Refrigerant, the valve is closed. Never transport or store the
when used as a trace gas should cylinder with the regulator fitted.
only be mixed with dry nitrogen
for pressurizing units.Failure
to follow these recommendations
could result in death or serious Dangers of Use of Nitrogen: You will
injury or equipment ! 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.

28 |
MAINTENANCE

Pressurise the system using Nitrogen to the below mentioned


Leak testing procedure pressures based on the refrigerant being used in the system.
If there is any residual refrigerant left in the system this
must be recovered prior to follow this procedure.
Maximum Maximum
1. Ensure the nitrogen cylinder is either secured Refrigerant Suitable Regulator
Pressure, bar g Pressure, psig
or located in a position so that it cannot fall
over. R 22 23.6 342 Maximum output of 33 Bar
2. Ensure the regulator valve is wound fully out R 134 a 13.7 200 Maximum output of 26 Bar
(counter clockwise / anti clockwise).
R 407 C 23.6 342 Maximum output of 33 Bar
3. Fit the regulator to the cylinder.
R 410 A 33 478 Maximum output of 40 Bar
4. Fit gauges to the system and ensure there
are no isolated sections within the part of the Table 7
system to be pressure tested.
LEAK TESTING
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 in
(clockwise) to pressurise the system:

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;

9. When the maximum system allowable Figure 12


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 Evacuation
gauge.
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 Vacuum Pump
system pressurised.
Whenever there is a replacement of system components like
15. Slowly vent the remaining nitrogen. compressor, filter drier, expansion valve etc, the refrigerant
16. Repair any leaks found and then repeat the system should be evacuated in order to remove moisture from
test procedure using OFN. the system.

17. When it is established that the system is safe Moisture affects the proper functioning of the system. Air being
and leak tight the OFN can be evacuated and a non-condensable will exist in the top of the condenser and
the system can be recharged with refrigerant. the receiver.

| 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 ( ID minimum).
If the compressor has service valves, they should be opened.

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.
Figure 13
5. Repeat steps 1- 4 again, i.e. evacuate for a second time
down to 1500 microns.
Increase in pressure depends on the amount of air in the
6. The triple evacuation method is completed by final
system. Any time a system is running with abnormally high
operation of the pump to bring down the system pressure
head pressure, air in the system is a prime suspect.
to 500 microns.
The presence of air reduces the lubricating properties of
the oils especially POEs which are Hygroscopic in nature. 7. Close all service valves on the gauge and shut off the
Air in the system increases the risk of Acid formation vacuum pump.
thus damaging the Copper Plating and Motor insulation,
thus leading to electrical and mechanical failure of 8. Maintain Vacuum at 500 microns for minimum of 30
the compressor. In order to avoid these, system minutes.
vacuum should be done according to the procedures 9. Connect the cylinder of the refrigerant that is to be used in
mentioned: the system using gauges and open until system pressure
is 10 psig or proceed to refrigerant charging procedures.
System Evacuation Procedures
10. The triple evacuation method to a pressure of 500 microns
Equipment Required: is practical under field conditions, and represents a
specification that can be met.
Vacuum Pump- Two stage type with Gas
Ballast and a capacity matching the system
volume (Using a vacuum pump larger than the To evacuate a system properly
system volume increases the risk of freezing requires time and care. Any slight
the moisture in the system. carelessness in protecting the sealed
Connection lines ( in for Small Systems system can undo all the precautions taken
& in for larger systems are recommended) previously. But the slight extra effort required
to make an evacuation properly and completely
A Manifold Gauge or a Micron gauge capable will pay big dividends in reduced maintenance
of measuring vacuum down to 200 microns is and trouble free operation.
to be installed between the System and the
vacuum pump to allow the system pressure
to be checked after evacuation
Under no conditions is the motor/
Nitrogen Cylinder with regulator and hose kit. 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
Do not turn off vacuum dielectric strength of the atmosphere within the
pump when connected motor chamber.
to an evacuated system
before closing shut off valve/
Manifold Gauge. Never use a Meghommeter to apply
power to compressor while it is under
vacuum, doing so will cause motor
winding damage.

30 |
MAINTENANCE

and connect it to the low side. Now with the compressor running,
Refrigerant charging
open the cylinder valve, purge the refrigerant and charge the
The proper performance of air conditioning system is system until the weight of
dependent on the proper refrigerant charge. An under- refrigerant charged is equal to
charged system will starve the evaporator, resulting that mentioned on the name
in excessively low compressor suction pressures, loss plate of the unit.
of capacity, and possible compressor overheating.
Overcharging can flood the condenser resulting in high Once the charging has been
discharge pressures, liquid refrigerant flooding, and potential done as per the weight of
compressor damage. refrigerant mentioned on the
Each system must be considered separately, since systems nameplate, it is necessary to
with the same capacity or horsepower rating may not check whether the refrigerant
necessarily require the same refrigerant or the same amount charge is sufficient. This can
of charge. Therefore it is important to first determine the type be done in the following ways.
of refrigerant required for the system, the unit nameplate
normally identifying both the type of refrigerant and the weight Figure 15
of refrigerant required.

Checking the Sight Glass: A sight glass in the liquid line


Liquid charging is one of the easiest ways to determine whether a system
is optimally charged, provided there is no sudden change
Liquid refrigerant charging is much faster than vapour charging
in the operating conditions while observing e.g. Cycling of
and it is commonly used in large capacity systems.
condenser fans, High Evaporator load etc. Even a small
For initial charge, the following important notes should be obstruction before the sight glass could cause flashing of
taken into consideration. refrigerant in the liquid line and cause bubbles in the sight
The compressor should not be running and any glass even though there will be sufficient sub cooling
compressor service valves should be closed. available from the condenser.
Charging should be done through filter drier Measuring the Refrigerant Sub cooling: This is best
access valve to prevent any contaminants being method provided the proper instrumentation is available.
inadvertently introduced into the system. Check the discharge pressure and the liquid line temperature
Check the compressor oil level and make sure and check the saturated condensing temperature
crank case heater is energized at least 24 Hours corresponding to the discharge pressure (Available on
prior to startup. 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.
The entire system
should be pulled
to a deep vacuum
(See evacuation
procedures)
prior to liquid
charging. Place
Figure 16
refrigerant
cylinder in WARNING: Never charge Liquid
a scale to
refrigerant to Low side of the system
measure the
amount of
when the system is in the Off state
refrigerant
charge. Attach Measuring the Refrigerant Superheat : Measure the
the charging Figure 14 suction pressure and obtain the saturated suction temperature
line from the cylinder to the filter drier service from the P-T Chart. Measure the Actual Suction temperature.
valve ports. Purge the charging line and open The difference between the two temperatures gives the
the cylinder liquid valve and the charging measure of Superheat entering the compressor. The optimum
valve. The initial vacuum in the system will value for superheat is 8-12 oF.
cause liquid to flow through the charging line
until the system pressure and the refrigerant
cylinder is equalized.
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 Figure 17
valve and remove the charging line from the high side

| 31
MAINTENANCE

Replacement instructions of fan bearings


Fan
assembled on Cast iron pillow blocks
For smooth operation fan must be serviced
regularly. The most important maintenance Unlock the casing cover easing screws at both sides. Using
measures to be made at least twice a year are: appropriate tools, hold the shaft in an appropriate position
1. Vibration and sound level to be checked. in order not to damage the inlet funnel or rotors wheel.
Anomalous values indicate a problem on the Remove protection rings from the bearing side (only
unit. one bearing is equipped with it). After removing grease,
2. Check the presence of corrosion on the fan remove sealing half-rings from the upper and lower port of
especially on the rotating path to prevent the block casing.
breaking. Slide down the bearings, straightening the screwed ring
3. Check if there are any objects within the tongue located on the sleeve, ease at each side screwed
range of the fan which might be sucked into rings with a centre pouch and hammer. Install the bearings,
the rotor once the fan is running. tighten up the sleeves with the screwed ring bend the rings
4. Check whether the fans rotor rotates freely, tongue. Install a new sealing sleeve into grooves located
without any friction against the casing body. in the lower part of the block. Install the lubricated shaft
5. Check the fan design speed as it must not assembly with a bearing on the block basis. Assemble
exceed the rotary speed. fixing ring (or more fixing rings) at a side of one bearing
6. Check whether the supply cables in the fan only (the other bearing is not adjustable). Insert the other
section are firmly fixed. sealing ring onto the upper block side. Put the upper block
part onto the lower one and tighten up the screws. Fill the
Bearing bearing with suitable grease. Turn the wheel several times
1. Check bearing for sound, a normal bearing in order to check if it rotates correctly.
generates a smooth uniform sound, while
a damage bearing generates a loud and
irregular sound.
2. Excess vibrations or temperature are often
a sign of possible damages Check the
bearing locking and seals periodically. Cover
3. Check for excessive grease leakage from
the bearing. Leakage of small quantity from
the bearing is normal.

Replacement instruction of fan


bearings assembled on Cross bars
Remove protection screws and protection Cast iron separate casing
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 Fan Motor
separate assembly from shaft and bearing.
Replace the old rubber rings and bearings
and assemble the new ones onto the cross
Checking the insulation
bars. If the unit has been stored for long time or if it has been kept
Install protection rings onto the bearings in a damp atmosphere, insulation resistance test for the motor
clamping them according to the fans should be carried out. This measurement must be carried out
rotations direction and secure them with using a megohmmeter at 500V D.C. (do not use a magneto
fixing screws. Turn the wheel several times electric system).
in order to check if it rotates correctly.
Assemble cross bars on side panels and Draining off condensation water
make sure to preserve coaxiality of the rotor. Temperature variations cause condensation to form inside the
Tighten the nuts and bolts on cross belts to motor, which must be removed before it adversely affects motor
the side panels. operation. Condensation drain holes, located at the bottom of
Cross bars
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
Protection rings
Protection screw and plugs before reassembling them.

Cross bars

32 |
MAINTENANCE

When installing new belts or during replacement, do not stretch


Cleaning them over the sheaves; Instead loosen the adjustable motor
To ensure the motor operates correctly, remove mounting base. Once the new belts are installed, adjust the belt
any dust or foreign bodies which might clog the tension using tension gauge.
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 Disconnect and lock-out power
always motor preferable to wet cleaning. before installation and maintenance.
Always clean at reduced pressure from the centre
of the motor towards the extremities to avoid Working on or near energized equipment
introducing dust and particles under the seals. can result in severe injury or death.

Bearing Do not operate equipment without guards


As soon as any abnormal noise or vibration is in place. Exposed equipment can result in
noted on the motor or abnormal temperature severe injury or death.
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 Periodic inspections should be performed.
worse damage to the motor and the fan. It Failure to perform proper maintenance
is also recommended to change the bearing can result in premature product failure and
after 100,000 hours of operation under normal personal injury.
operating conditions. If one bearing needs to be
replaced, the other bearing must also be replaced.
The seals should be changed routinely when the To avoid damage, supporting structure
bearings are changed. including shafts and bearings must be
designed to handle transmitted loads and
belt tension(s).

Fan Belt Adjustment


The supply fan belts must be inspected periodically
to ensure proper unit operation. Replacement V-Belt Installation Check List
is necessary if the belts appear frayed or worn.
Units with dual belts require a matched set of belts
to ensure equal belt lengths. Turn off and lock out power
1 ( ) Yes ( ) No
source
2 Observe all other safety procedures ( ) Yes ( ) No
Periodic inspections should 3 Select proper replacement belts ( ) Yes ( ) No
be performed. Failure to 4 Remove belt guard ( ) Yes ( ) No
perform proper maintenance can Inspect drive elementsbearings,
result in premature product failure 5 ( ) Yes ( ) No
shaft, etc.
and personal injury. 6 Inspect sheave grooves for wear ( ) Yes ( ) No
7 Check sheave alignment ( ) Yes ( ) No
Maintenance of the fan 8 Install new belts ( ) Yes ( ) No
equipment should only be
9 Tension belts ( ) Yes ( ) No
carried out by skilled and adequately
trained staff. To ensure complete 10 Check sheave alignment (final) ( ) Yes ( ) No
safety do not start any maintenance 11 Replace guard ( ) Yes ( ) No
procedure or inspection without 12 Start drive (look & listen) ( ) Yes ( ) No
disconnecting the unit from the
Re adjust the tension after first 24
power supply and before the fan 13 ( ) Yes ( ) No
hours of operation
and motor have completely stopped
rotating. 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 Excessive belt tension shortens belt
drive. life and may cause bearing & shaft
damage
Never mix belts from more than one
manufacturer.
Note: When new belts are installed on a drive,
Always replace with the right type
the tension will drop rapidly during the first few
of V-belt.
hours. Thus, for new belts, tighten to the initial
Always observe V-belt matching installation defection force shown in the tables
limits. below. Check tension frequently during the first
24 hours of operation. Subsequent re tensioning
should fall between the minimum and maximum
Belt Tensioning Instructions forces shown in the tables.

Ideal tension is the lowest tension at which the


belt will not slip under peak load conditions. Note: The proper tension for V-belt drive is the
lowest tension at which the belts wont slip
Check tension frequently during the first 24 hours
under peak load conditions.
of operation. Check after jog start or 1-3 minutes
of operation, at 8 hours, 24 hours, 100 hours
and periodically thereafter are recommended.
Belt Deflection Force, lb
Over tensioning shortens belt and bearing life. Smallest
Belt Sheave Super
RPM Gripnotch Belts
Keep belts free of foreign material which may Cross Diameter Gripbelts
cause slip. Range
Section Range
Used New Used New
Make v-drive inspection on a periodic basis. (inches)
Belt Belt Belt Belt
Under-tensioned belt drives often produce
audible squeal noise. Tension when slipping.
860-2500 - 4.9 7.2
3.4 - 4.2
2501-4000 - 4.2 6.2

Before doing maintenance or B, BX


860-2500 5.3 7.9 7.1 10.5
4.4 - 5.6
tensioning on belt drives, turn 2501-4000 4.5 6.7 6.1 9.1
equipment off and lock out the 860-2500 6.3 9.4 8.5 12.6
5.8 - 8.6
power source. 2501-4000 6.0 8.9 7.3 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 Figure 18
Deflection = (Belt span)/64

Solution
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 Figure 19
first operating day. Re adjust the tension
until the tension is maintained within the
recommended range.

34 |
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:
In order to check the location of adjustable sheave on shafts,
Figure 20 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
Figure 21
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.

Fan Pulley Adjustment (For variable pitch


pulleys only) NOTE: At or before start-up check the wiring of
the three phase fan motor to assure proper shaft
Blower speeds are factory adjusted by default as rotation. Incorrect fan rotation may loosen the
per the fan selection data. The required airflow locking collar resulting in pre-mature bearing
rate and the total static pressure adjustment failure.
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
Figure 22.
the fixed flange.

| 35
MAINTENANCE

Solution
Mold In And Around Drain Pans 1. There must be a drain line, and it must be connected through
Drain pans under cooling coils are a common a trap to the drain pan.
source of mold and mildew problems. If the drain 2. The trap stem height should be greater than the pressure of
pan does not actually drain water for whatever the fan. (The stem height is the vertical distance between the
reasonmold and mildew will certainly grow in outlet of the trap and the bottom of the drain pan.
the pan and spread through the duct work to the
3. The contractor must be certain that the drain line actually
occupied spaces. Also, if water leaks or spills out
connects to a drain.
of the drain pan, mold and mildew will grow in the
soaked food source.
Failure to provide adequate condensate
The problems fall into three categories:
piping to the drain trap may result in wa-
maintenance, pan design and drain line installation.
ter damage to the equipment or building.

Maintenance:
Problem
1. Dirt collects in the line .
Duct Connections
2. Drain line is clogged. Connections of supply and return ducting to the PACV-S series
3. Pan can over flow. packaged units should be by means of flexible duct connections
4. Possibility of mold growing. 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.
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.

36 |
MAINTENANCE

to the manufacturers instructions. If desired, heat the


Coil solution to 150 F maximum to improve its cleaning
If the coil is to deliver its full cooling or heating capacity capability.
both its internal and external surfaces must be clean. 6. Pour the cleaning solution into the sprayer. If a high-
1. Periodic verification of the coil cleanliness pressure sprayer is used:
is required. Dirty coil increases air pressure
drop and reduces heat transfer potential, a. The minimum nozzle spray angle is 15 degrees.
thus unbalancing the system. b. Do not allow sprayer pressure to exceed 600
2. Examine finned surface for accumulation psi.
of dirt or lent. If necessary wash down the
c. Spray the solution perpendicular (at 90 degrees)
affected areas with a mild detergent solution
to the coil face.
and a soft brush. (Take care of the fin surface
while cleaning). d. Maintain a minimum clearance of 6 between
3. Compressed air line may be used to blow out the sprayer nozzle and the coil.
any solids between the fans. Do not probe
7. Spray the leaving-airflow side of the coil first; then spray
the coils with a metal scraper as any damage
the opposite side of the coil. Allow the cleaning solution to
may cause tube leaks. Clean refrigerant
stand on the coil for five minutes.
coils with cold water and detergent or one
of the commercially available chemical coil 8. Rinse both sides of the coil with cool, clean water.
cleaners. 9. Inspect both sides of the coil; if it still appears to be dirty,
4. Inspect the drain pan and condensate repeat Steps 7 and 8.
drain at the same time the evaporator coil 10. Reinstall all of the components and panels removed in
is checked. Clean the drain pan by flushing Step 2; then restore power to the unit.
with water and removing any matters of 11. With a fin comb, straighten any coil fins which were
obstructions which may be present. inadvertently bent during the cleaning process.

Coil Cleaning 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
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
Regular coil maintenance, including annual has exceeded the limit if a burn out occurred.
cleaning enhances the units operating If a motor burn out has occurred, change the oil in both
efficiency by minimizing: compressors in a tandem set. This will require that the oil
1. Compressor head pressure and equalizer tube be removed to suck the oil out of the oil sump. A
amperage draw catch pan must be used to catch the oil when the compressor
2. Fan brake horsepower and oil equalizer line is loosened.
3. Static pressure losses. Note: Refrigerant oil is detrimental to some roofing
materials. Care must be taken to protect the roof from oil
At least once each yearor more often if the leaks or spills.
unit is located in a dirty environmentclean Charge the new oil into the Schrader valve on the shell of the
the condenser coils using the instructions compressor.
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
Adding Oil
sprayer.
2. Remove enough panels from the unit to Schrader- The oil fill connection and gauge port is a 1/4 male
gain safe access to coils. flare connector incorporating a schrader valve.
3. Straighten any bent coil fins with a fin For compressor with access valve port oil should be added by
comb. schrader connection, for other compressor oil should be added
through the suction lines.
4. Remove loose dirt and debris from both
sides of the coil with a soft brush. To remove this excess oil an access valve port has been added to
the lower shell of the service compressor replacement compressor
5. Mix the detergent with water according

| 37
MAINTENANCE

. After running the replacement


compressor for a minimum of 10 minutes, Warning: Dis-
shut down the compressor and drain excess Disposal of filter drier cores, compressor
oil from the Schrader valve until the oil level oil and system components should be
is at one-half of the sight-glass level. This handled according to local laws.
should be repeated twice to make sure the
proper oil has been achieved.
POE must be handled carefully and the proper
protective equipment (gloves, eye protection, Expansion Valve Service & Maintenance
etc.) must be used when handling POE lubricant.
Expansion valve is responsible for allowing the proper amount
POE must not come into contact with any surface
of refrigerant to enter the evaporator regardless of cooling load.
or material that might be harmed by POE, including

>
Access Valve It does this by maintaining a constant superheat. Typically,
without limitation, certain polymers (e.g. PVC/
superheat should run in the range of 8F to 12F (4.4C to 6.6C).
CPVC and polycarbonate).
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. Overfeeding of the evaporator results in high suction pressure, low
Excessive water pressure can bend superheat and possible liquid carryover. This set of conditions is
the fans and tubing of the coil and lead usually remedied by readjusting the valve superheat. If this falls
to inadequate unit performance. Be to correct the condition, the valve should be replaced.
careful not to splash water excessively
into unit.

Expansion Valve Underfeeding


Underfeeding of the evaporator results in low suction pressure
CAUTION and high superheat. It may be caused by improper super heat
Chemical reaction! adjustment, restricted solenoid valve or drier or an inoperative
Compressor destruction! Do expansion valve power element. Test the power element in the
not mix up ester oils with mineral following manner:
oil and/or alkyl benzene when
used with chlorine-free (HFC) refrigerants.

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


2. Remove remote bulb from suction line and place it in
Compressor Oil level check container of ice water.
3. Start system.
When the compressor is running under stabilised
conditions the oil level must be visible in the sight 4. Remove the bulb from the ice water and warm in hand. At the
glass. The presence of foam filling in the sight same time feel the suction line for a drop in temperature. If
glass indicates large concentration of refrigerant in liquid refrigerant floods through the valve, the power element
the oil and / or presence of liquid returning to the is operating properly. If there is no change in the suction line
compressor. The oil level can also be checked a temperature, the power element is defective. Replace it.
few minutes after the compressor stops, the level
must be between 1/4 and 3/4 of sight glass.

Dismantling & Disposal


Removing oil and refrigerant
Do not disperse in the environment
Use the correct equipment and method of removal
Dispose of oil and refrigerant properly
System pressures: Installation
Dispose of compressor properly or Removal
Figure 23.

38 |
MAINTENANCE

Warning: Dont place open flame


near or on bulb

Figure 24. Bulb locations

Figure 27.

Valve Orientation
Solder techniques
Figure 25.
Figure 28.

Bulb and external equalizer


locations

Figure 26.

| 39
MAINTENANCE


Hot Gas Bypass
On many air conditioning and refrigeration systems it
is desirable to limit the minimum evaporating pressure
Brazing Procedures
during periods of low load either to prevent coil icing or Any of the commonly used brazing alloys for high side usage
to avoid operating the compressor at a lower suction are satisfactory. However, when soldering or brazing, it is very
pressure than it was designed to operate. important that the internal parts be protected by wrapping the
valve with a WET cloth to keep the body temperature below
Hot gas bypass is a method of maintaining compressor 300F. While the ADRS (E)-2, ADRP (E)-3 have metal to metal
suction pressure (creating a false load) during low seating material, the ADRH (E)-6 valves use synthetic-to-metal
loads. This has the affect of modulating compressor seating material and must be protected from overheating. SHGB
capacity below the minimum unloading point without (E) valves use synthetic material in the piston ring and seating
cycling the compressor. It is accomplished by surface that must be protected from overheating. The pilot
introducing the hot (discharge) gas from the leaving valve diaphragm and springs are also susceptible to damage
side of the compressor back to a point on the low- from overheating and must be protected. The extended fittings
pressure side of the refrigeration circuit. 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.
Introduction of the bypassed gas
between the thermostatic expansion
valve and the distributor is not generally Discharge bypass Valves Setting
recommended because of the large The minimum allowable evaporating temperature that will avoid
pressure drop caused by the hot gas coil icing depends on the evaporator design and the amount
flowing through the distributor nozzle, of air passing over the coil. The refrigerant temperature may
or throat, and the tube circuits, which be below 32 oF but coil icing will not usually occur with high air
have been sized for normal cooling flow velocities since the external surface temperature of tube will be
rates. Careful evaluation and testing above 32 oF. Discharge bypass valves can be set so they would
should precede any application where be at their rated capacity at 26 oF evaporating temperature.
hot gas is bypassed between the TEV (Pressure setting for R-134a is 28 psig).
and the distributor.

Pilot Operated Valves:


Location Spare parts
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.

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.

| 41
MAINTENANCE

Service Tips:
VALVE
MALFUNCTION CAUSE REMEDY
TYPE
ADRI-1-1/4 Failure to open 1. Dirt or foreign material in valve 1. Disassemble valve and clean
ADRIE-1-1/4 1. Dirt or foreign material in valve 1. Disassemble valve and clean
ADRS-2 2. Diaphragm failure 2. Replace element only
ADRSE-2 Failure to close 3. Equalizer passageway plugged 3. Disassemble valve and clean
ADRP-3 4. External equalizer not connected or equalizer line pinched shut 4. Connect or replace equalizer line
ADRPE-3 5. Internal spring overhead 5. Replace valve
1. Dirt or foreign material in valve 1. Disassemble valve and clean
Failure to open 2. Equalizer passageway plugged 2. Disassemble valve and clean
ADRH-6 3. External equalizer not connected or equalizer line pinched shut 3. Connect or replace equalizer line
ADRHE-6
1., Dirt or foreign material in valve 1. Disassemble valve and clean
Failure to close
2. Diaphragm failure 2. Replace element only

Figure 31.

Keys To Successful Implementation Dispose of oil and refrigerant properly


1. Position the HGBP valve above the Dispose of compressor properly
discharge line, near the compressor. If the
system includes Pump-down provide a
Warning:
means to shut off refrigerant flow. Disposal of filter drier cores, compres-
sor oil and system components should
2. Pitch the line upstream of the HGBP valve be handled according to local laws.
to drain oil back into the discharge line.
3. Pitch the line downstream of the HGBP
valve toward the evaporator, away from the For disassembly and disposal the unit
valve. must be consigned to an authorised
4. Insulate the entire length of the HGBP line disposal centre.

During disassembly the fan, motor and coils, if in working


Dismantling & Disposal order may be recycled or reused.
All materials should be recycled or disposed of according
Removing oil and refrigerant
to local bylaws.
Do not disperse in the environment Electrical and electronic components must not be disposed
Use the correct equipment and method of off as domestic waste. Current local laws for disposal of
removal electronic waste are to be observed.

42 |
MAINTENANCE

Voltage

Check the voltage across incoming power terminals when are no blockages.
the system is operating. Voltage requirements are: Inspect the evaporator and condenser coils for dirt, bent
fins, etc. If the coils appear dirty, clean them according to
1. Voltage should not to exceed voltage utilization the instructions described under Coil Cleaning.
range. See table below. Inspect the F/A-R/A damper hinges and pins to ensure that
2. Voltage imbalance between phases not to exceed all moving parts are securely mounted. Keep the blades
2%. clean.
Manually rotate the condenser fans to ensure free
movement and check motor bearings for wear. Verify that
Operating Limits
Rated power supply all of the fan mounting hardware is tight.
(Volts)

V/Ph/Hz Minimum Maximum


Refrigerant Recovery, Recycling, and
Reclamation
380-415/ 3 /50 360 440
There are many environmental and economic benefits to
440/ 3 /50 396 462 be gained from recovery, recycling and reclamation efforts
380/ 3 /60 342 418 worldwide. The major benefits include:
460/ 3 /60 414 506 Minimized atmospheric emissions and reduced
220/ 3 /60 198 242 environmental impact;
Table 11 Expanded market opportunity for used refrigerant;
Reduced environmental compliance costs;
% Voltage imbalance = 100 * (Max. Voltage deviation Reduced need for new refrigerant;
from average voltage of three Increased lifetime of refrigeration equipment due to
phases / Average voltage of contaminant removal
three phases)
The following describes the specific differences between
refrigerant recovery, recycling and reclamation:
As an example, nominal 440V, 3Ph power source
produces following voltages between the terminals.

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 Lifting Point

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. Fork Lifting
Failure to disconnect power before
servicing could result in serious injury Refrigerant RECOVERY involves the removal of a refrigerant
or death. from a system and the placement of that refrigerant into a
container. The recovery process:
Is conducted whenever technicians need to open
Contactor or dispose of air conditioning or refrigeration
1. Inspect the contacts. If they appear pitted equipment.
or burned, replace the contacts or contactor.
Includes removal of refrigerant vapor (heels) to
2. Using an ohmmeter, test continuity of the established vacuum levels to maximize the amount
contactor holding coil. If the coil does not of refrigerant captured and minimize releases.
test continuous, replace it. Performance specifications are included in Air
Conditioning and Refrigeration Institute (AHRI)
Cooling Season 740.
Check the units drain pans and Involves service technicians, equipment operators,
condensate piping to ensure that there appliance disposal facilities, equipment and
refrigerant manufacturers.

| 43
MAINTENANCE

Is conducted whenever technicians need


to open or dispose of air conditioning or
refrigeration equipment. inlet port) is clean before starting every job. This screen
prevents damage to the unit from debris that may get past
Includes removal of refrigerant vapor
the inline filter. When pumping dirty refrigerant, this screen
(heels) to established vacuum levels
may quickly clog and slow the process when used without
to maximize the amount of refrigerant
an inline filter.
captured and minimize releases.
Performance specifications are included 1. Setup the machine as shown in the diagram below.
in Air Conditioning and Refrigeration Make sure that all the connections are tight.
Institute (AHRI) 740.
A. Connect the AC system High side to the Manifold
Involves service technicians, equipment
High side.
operators, appliance disposal facilities,
equipment and refrigerant manufacturers. B. Connect the AC system Low side to the Manifold
Low side.
Refrigerant RECYCLING involves processing used refrigerants
to reduce contaminants, then reusing the refrigerant. C. Connect the Manifold center port to the Recovery
Recycling is recommended only when Unit input port.
recharging to the same owners equipment. D. Connect the Recovery Unit output to the Recovery
Recycling involves removal of some Cylinder liquid port.
contaminants prior to reuse. Contaminants
2. Connect the recovery unit to a 230V outlet using a 12PSivG
can result in early system failure.
cord (minimum) and not more than 15 feet long.
Contaminants include oil, moisture,
acid, chlorides, particulates, and non- 3. Make sure the input valve on the recovery unit is closed,
condensable gases. this will make it easier for the compressor to start when the
power is turned on.
The Industry Recycling Guide (IRG-2)
published by AHRI describes maximum 4. Open the liquid port of the Recovery Cylinder and the
recommended levels of impurities. output valve of the recovery unit.
International Organization for Standards 5. Open the liquid port on the Manifold Gauge Set. Removing
(ISO) 11650 or AHRI 740 standards may the liquid first will keep the recovery time to a minimum.
be used to measure recovery/recycling 6. Turn on the recovery unit with the On/Off switch on the
equipment performance. front panel. The compressor and fan should start.
Refrigerant RECLAMATION involves purifying used 7. Slowly open the input valve of the recovery unit.
refrigerant to meet industry product specifications. 8. When all the liquid has been removed, slowly open the
vapor port on the Manifold Gauge Set. Both valves to
Reclamation identifies bad or mixed system should now be fully open to maximize vapor flow.
refrigerants which could result in
equipment damage or leakage. Chemical 9. Run the unit until the vacuum required by the EPA is
analysis also is required to verify achieved.
specification values to meet or exceed 10. Close both
product standards. (e.g. ISO 12810, AHRI valves on the
700). Manifold Gauge
Reclamation may include filtering, Set and on the
separation, distillation, dilution, or recovery unit.
reformulation of the recovered refrigerant. 11. Shut off machine.
Reclamation is recommended when used 12. Close the valves
refrigerants will be charged into equipment on the Recovery
other than the equipment it was removed Cylinder and
from, or into equipment owned by a disconnect the Figure 32
different company. hoses.
Reclamation facilities and processes
should be designed to minimize emissions.
Self Purging The Recovery Unit
Non-reclaimable refrigerants should
be disposed of in an environmentally 1. Close all the ports on the system you are servicing that are
acceptable manner, and in accordance connected to the recovery unit.
with applicable regulations.
2. Close the input valve on the recovery unit.
Refrigerant Recovery Techniques 3. Turn off the recovery unit to prevent high pressure shutoff.
Standard Recovery Procedure
4. Turn the Purge/Recover knob to the Purge Setting.
Note: A scale must be used to avoid overfilling 5. Turn on the recovery unit and run the machine until you
the storage tank. achieve the desired vacuum.
Note: Use an inline filter when you are pumping 6. Close all valves on the recovery unit and the recovery tank.
dirty refrigerant.
7. Turn off the recovery unit and return IN the Purge/Recover
Note: Check that the debris screen (on
knob to the Recover setting.

44 |
MAINTENANCE

Figure 33
Push/Pull Recovery Procedure (for Bulk Liquid
Figure 34
Refrigerant)
Tank Cooling Procedure (Optional)
Note: A scale must be In order for this procedure to work, you must have at least 2.3
used to avoid kgs. of liquid refrigerant in the storage tank.
overfilling the storage
tank. 1. Connect the hoses as shown.
A. Connect the Recovery
The Push/Pull method is useful for recovering Unit input to the
large amounts of liquid from a system. This will Recovery Cylinder
only work on large systems where the liquid vapor port.
can be accessed easily. Do not attempt this B. Connect the Recovery
on systems that contain less than 15 Ibs of Unit output to the
refrigerant unless it has a receiver tank or it may Recovery Cylinder
not work correctly. liquid port.
2. Open all valves.
Once the siphoning Figure 35
3. Start Machine.
starts, it can continue to
fill the tank even when 4. Throttle the output valve so that
the machine has been shut off. To the output pressure is at least 100psi greater (but never
avoid overfilling, you must be sure greater than psi) than the input pressure.
to close all valves on the tank and 5. Run until the tank is cold.
system when you are finished.
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.
1. Setup the machine as shown in the figure 35.
Make sure that all the connections are tight. Normal Recovery:
A. Connect the System Vapour side to A. Tank vapor valve
the Recovery Unit output port. - Closed.

B. Connect the System Liquid side to the Tank Cooling:


Recovery Tank liquid port. A. Tank vapor
valve- Open.
C. Connect the Recovery Unit input port
to the Recovery Tank vapor port. B. Manifold Gauge
Set- 80th
Closed.
Note: Keep valves on tank and
system closed at this time. C. Follow steps
3-5 above to Figure 36
cool tank.
2. Slowly open valves on the Recovery Unit.
Purging Non-Condensables from Storage Tanks
3. Switch on the power to the Recovery Unit.
The tank must be left undisturbed for at least 24 hours so
4. Slowly open the valves on the tank and that all of the air will rise to the top.
system. The liquid should now begin to be Connect a Manifold Gauge Set to the tank and check the
pulled out of the system. You can monitor pressure at the vapour port.
the progress with an Inline sight glass. Look up the refrigerant you are using on a Refrigerant
5. When all the liquid has been siphoned off, Temperature/Pressure chart and use the ambient air
turn off the Recovery Unit and close all the temperature to determine what the tank pressure should
valves. be. If the tank pressure is higher than the pressure on
the chart. Slowly open the vapour port and let the excess
6. You can now proceed to remove the pressure bleed off until it is about 5psi above the pressure
remaining vapor using the standard on the chart.
recovery procedure. Close the valves and let the tank stand still for 10 minutes.
Repeat if necessary.
| 45
MAINTENANCE

Trouble Shooting

Problem: Compressor is Noisy


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

Problem: Compressor Short cycles


Symptoms Normal Operation, except very frequent stopping and starting.
Possible Cause Intermittent contact in electrical control circuit.
Recommended Action Repair or replace faulty controls.
Symptoms Normal Operation, except very frequent stopping and starting on
low pressure control.
Possible Cause Lack of refrigerant.
Recommended Action Repair refrigerant leak and recharge.
Symptoms Temperature change in refrigerant line through drier or solenoid
valve.
Possible Cause Clogged liquid line or filter drier.
Recommended Action Repair/replace solenoid valve or replace drier core.

Symptoms No flow of refrigerant through valve.


Possible Cause Expansion valve power assembly has lost charge.
Recommended Action Repair expansion valve assembly.

Symptoms Loss of capacity.


Possible Cause Obstructed expansion valve.
Recommended Action Clean valve or replace if necessary.

Problem: Discharge pressure Too Low

Symptoms Bubbles in sight glass.


Possible Cause Lack of refrigerant.
Recommended Action Repair leak and charge.

Problem: Discharge pressure Too High


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

Symptoms Exceptionally hot condenser and excessive discharge pressure.


Possible Cause Air or noncondensible gas in system.
Recommended Action Remove air or non condensibles.

Symptoms Exceptionally hot condenser and excessive discharge pressure.


Possible Cause Overcharge refrigerant.
Recommended Action Remove excess refrigerant gradually, normal subcooling is 12 F
(6.7 C).

Symptoms Abnormally cold suction line.


Possible Cause Liquid Flood back.
Recommended Action Check and adjust superheat. Check if remote bulb is loosen suction
line and refix.

46 |
MAINTENANCE

Trouble Shooting
Problem: Suction pressure Too High
Symptoms Compressor runs continuously.
Possible Cause Excessive load on unit.
Recommended Action Check unit sizing & selection. Investigate system design & install
additional air conditioning if required.
Symptoms Abnormally cold suction line. Liquid flooding back to compressor.
Possible Cause Expansion valve stuck in open position, air filter blocked.
Recommended Action Repair or replace valve. Change filter.

Problem: Suction pressure Too low


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

Symptoms Icing on suction line.


Possible Cause Fan not running, thermostat setting too low, ambient temperature
too low/blocked air filter.
Recommended Action Check thermostat setting and investigate system design &/or unit
sizing selection/clean filter. Check fan motor, overload &belt.
Symptoms Loss of capacity or bubbles in sight glass.
Possible Cause Gas leakage.
Recommended Action Repair leak and charge.

| 47
Trouble Shooting

Problem: Supply Fan does not Start


Symptoms Supply Fan Does not start even if unit controller is ON.
Possible Cause Supply fan switched off by unit controller due to motor overload
trip, or voltage monitor trip, or room unit communication loss.
Recommended Action Reset the motor overload, Check the incoming power supply and
voltage monitor, Check the communication between unit controller
and room unit.

Symptoms Supply Fan Does not start even if unit controller is ON.
Possible Cause Run/Stop switch in the unit control panel is off, Room unit power
button is off.
Recommended Action Switch on the Run/Stop switch, Turn on the power button in room
unit

Symptoms Supply Fan Does not start even if unit controller is ON.
Possible Cause Schedule in the controller is off.
Recommended Action Correct the schedule.

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

Problem: Compressor does not start


Symptoms Compressor does not start even if there is cooling demand and
supply fan is running.
Possible Cause Room units operating mode is in Ventilation.
Recommended Action Change the room unit operating mode to Cool or Auto (Auto only
in units with heater).

Symptoms Compressor does not start even if there is cooling demand and
supply fan is running.
Possible Cause Circuit enable/display selection in the controller display is disabled.
Recommended Action Enable the circuit from the controller display.

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

Symptoms Compressor does not start even if supply fan is running.


Possible Cause No cooling demand.
Recommended Action Adjust the temperature set point in room unit.

4
488 |
APPENDIX- I

Loading Points
LOADING POINTS TOTAL
PACV- UNIT
A1 A2 A3 A4 WEIGHT
Ib 214 215 309 311 1049
51008-S
Kg 97 97 140 141 476
Ib 242 243 334 336 1154
51010-S
Kg 110 110 152 152 524
Ib 462 461 578 550 2050
51014-S
Kg 209 209 262 249 930
Ib 503 493 607 605 2208
52015-S
Kg 228 224 275 274 1001
Ib 494 493 608 580 2175
51017-S
Kg 224 223 276 263 987
Ib 513 504 622 615 2254
52017-S
Kg 233 229 282 279 1023
Ib 549 536 657 654 2395
52020-S
Kg 249 243 298 297 1086
Ib 576 553 732 693 2553
52023-S
Kg 261 251 332 314 1158
Ib 699 689 873 871 3133
52026-S
Kg 317 312 396 395 1421
Ib 736 722 889 882 3228
52030-S
Kg 334 328 403 400 1464
Ib 737 725 894 891 3248
52032-S
Kg 334 329 405 404 1473
Ib 822 807 1011 1008 3648
52038-S
Kg 373 366 459 457 1655
Ib 969 934 1283 1207 4392
52045-S
Kg 439 424 582 547 1992
Table 12

MODEL Load at Each Point lbs. [Kg.] TOTAL


UNIT
PACV- A1 A2 A3 A4 WEIGHT
Ib 221 221 312 313 1067
61009-S
Kg 100 100 141 142 484
Ib 256 256 338 340 1190
61012-S
Kg 116 116 153 154 540
Ib 472 472 581 553 2078
61018-S
Kg 214 214 263 251 942
Ib 513 503 610 608 2235
62018-S
Kg 233 228 277 276 1014
Ib 505 503 612 584 2204
61020-S
Kg 229 228 278 265 1000
Ib 523 515 625 618 2282
62020-S
Kg 237 233 284 280 1035
Ib 563 551 663 661 2438
62024-S
Kg 255 250 301 300 1106
Ib 591 568 756 718 2634
62028-S
Kg 268 258 343 326 1195
Ib 720 710 883 881 3195
62033-S
Kg 327 322 401 400 1449
Ib 760 747 899 891 3297
62036-S
Kg 345 339 408 404 1495
Ib 791 776 909 906 3383
62037-S
Kg 359 352 412 411 1534
Ib 850 835 1021 1018 3723
62046-S
Kg 386 379 463 462 1689
Ib 1088 1054 1350 1274 4767
62055-S
Kg 494 478 612 578 2162
Table 13

| 49
Loading Points

LOADING POINTS TOTAL


PACV- UNIT
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 WEIGHT
Ib 1004 987 1360 1357 - - - - - - - - 4708
52050-S
Kg 456 448 617 615 - - - - - - - - 2135
Ib 1153 1134 1391 1378 - - - - - - - - 5056
52055-S
Kg 523 514 631 625 - - - - - - - - 2294
Ib 960 1026 566 633 983 983 1284 1284 - - - - 7720
52065-S
Kg 435 465 257 287 446 446 583 583 - - - - 3502
Ib 683 467 777 661 604 397 600 824 1046 876 793 1030 8758
53070-S
Kg 310 212 353 300 274 180 272 374 475 397 360 467 3973
Ib 687 471 781 665 607 401 626 894 1148 944 821 1105 9149
53075-S
Kg 312 213 354 302 275 182 284 406 521 428 372 501 4150
Ib 719 478 813 673 640 408 634 902 1156 952 828 1112 9316
53080-S
Kg 326 217 369 305 290 185 288 409 524 432 376 505 4226
Ib 752 503 882 755 673 435 676 944 1210 1009 879 1176 9895
53085-S
Kg 341 228 400 343 305 197 307 428 549 458 399 533 4488
Ib 770 509 908 766 691 436 682 950 1241 1023 885 1182 10045
53090-S
Kg 349 231 412 347 313 198 310 431 563 464 401 536 4556
Ib 808 529 937 777 716 444 693 967 1249 1033 893 1190 10236
53095-S
Kg 366 240 425 353 325 201 314 439 567 469 405 540 4643
Ib 954 665 1119 943 865 582 917 1298 1505 1513 1097 1339 12796
54100-S
Kg 433 302 507 428 392 264 416 589 683 686 497 607 5804
Ib 974 675 1139 953 885 591 956 1336 1584 1587 1144 1399 13222
54110-S
Kg 442 306 516 432 401 268 433 606 719 720 519 635 5998
Ib 993 680 1158 957 904 596 962 1345 1603 1604 1151 1404 13357
54115-S
Kg 451 308 525 434 410 270 436 610 727 728 522 637 6059
Ib 1028 694 1189 968 929 602 976 1375 1613 1622 1157 1410 13564
54125-S
Kg 466 315 539 439 422 273 443 624 732 736 525 640 6153
Table 14

MODEL Load at Each Point lbs. [Kg.] TOTAL


UNIT
PACV- A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 WEIGHT
Ib 1152 1133 1501 1497 - - - - - - - - 5282
62060-S
Kg 522 514 681 679 - - - - - - - - 2396
Ib 1226 1205 1526 1513 - - - - - - - - 5470
62066-S
Kg 556 546 692 686 - - - - - - - - 2481
Ib 1019 1086 568 634 995 995 1365 1365 - - - - 8027
62076-S
Kg 462 492 258 288 451 451 619 619 - - - - 3641
Ib 729 468 822 662 649 398 609 832 1059 889 804 1040 8963
63085-S
Kg 331 212 373 300 294 181 276 378 481 403 365 472 4066
Ib 732 472 826 666 652 402 635 903 1161 957 832 1116 9354
63090-S
Kg 332 214 375 302 296 182 288 410 527 434 377 506 4243
Ib 770 480 863 674 690 410 643 911 1169 965 840 1124 9538
63095-S
Kg 349 218 392 306 313 186 292 413 530 438 381 510 4327
Ib 804 505 934 757 725 436 685 953 1224 1022 890 1187 10122
63100-S
Kg 365 229 424 343 329 198 311 432 555 464 404 538 4592
Ib 826 511 964 767 746 438 691 959 1254 1036 896 1193 10282
63105-S
Kg 374 232 437 348 339 199 314 435 569 470 406 541 4664
Ib 867 530 996 779 775 445 702 976 1263 1047 904 1201 10485
63110-S
Kg 393 241 452 353 351 202 318 443 573 475 410 545 4756
Ib 1014 667 1179 944 925 583 928 1309 1526 1534 1108 1350 13069
64120-S
Kg 460 302 535 428 420 264 421 594 692 696 503 613 5928
Ib 1036 677 1201 954 947 593 971 1358 1605 1608 1152 1400 13502
64130-S
Kg 470 307 545 433 429 269 440 616 728 729 523 635 6124
Ib 1058 681 1223 959 969 598 973 1356 1624 1625 1162 1416 13645
64136-S
Kg 480 309 555 435 440 271 441 615 737 737 527 642 6189
Ib 1098 696 1259 970 999 604 988 1386 1634 1643 1168 1422 13867
64145-S
Kg 498 316 571 440 453 274 448 629 741 745 530 645 6290
Table 15

50 |
Dimensional Data
APPENDIX- II
PACV Models: 51008 S, 51010 S & 61009 S, 61012 S
10 10
[254] A1 A3 [254]
L EGEND
7 -CONDENSER FAN
6 -CONTROL PANEL
5 -CONDENSER COIL
4 -COMPRESSOR
3 -FAN MOTOR
2 -EVAPORATOR FAN
1 -EVAPORATOR COIL ACCESS

CERTIFIED DRAWINGS ARE


AVAILABLE ON REQUEST

A2 A4
DRAIN 1[25] x2Nos.
68 L
[1727]
1 A 45
C
[25]

[38]
[1143]

1.5
G 7 6
J

FILTERED
I

VENTILLATION

[1312]
51.65
ON BOTH SIDES
H

[100]
3.94

CABLE ENTRY
[51]

1 2 3 4
2

RIGGING HOLES 5
.79 [20] 4Nos. 15
ACCESS PANEL
[381]

MODEL DIMENSIONS
PACV- H L A C F J G I
51008 S 52.44 81 36 40 24 13.43 15.55 7.56
61009 S [1332] [2057] [914] [1016] [610] [341] [395] [192]
51010 S 61.91 85 40 44 30 15.91 18.54 8.54
61012 S [1572] [2159] [1016] [1118] [762] [404] [471] [217]
Figure 37.

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

MODEL DIMENSIONS
10 10
PACV- H W H1 L A B C I F J G D
[254] [254]
* 51014 S 5 9.41 74 52.63 92 36 56 60 7.56 30 13.43 15.55 43.67
A1 A3
* 61018 S [15 09] [1880] [1 337] [2337] [914] [1422 ] [ 1524] [192] [76 2] [341] [ 395] [ 1109]

52015 S 5 9.41 74 52.63 92 36 56 60 7.56 30 13.43 15.55 43.67


62018 S [15 09] [1880] [1 337] [2337] [914] [1422 ] [ 1524] [192] [76 2] [341] [ 395] [ 1109]

* 51017 S 5 9.41 76 52.63 92 36 56 65.4 7.56 30 13.43 15.55 43.67


* 61020 S [15 09] [1930] [1 337] [2337] [914] [1422 ] [ 1661] [192] [76 2] [341] [ 395] [ 1109]

52017 S 5 9.41 76 52.63 92 36 56 65.4 7.56 30 13.43 15.55 43.67


62020 S [15 09] [1930] [1 337] [2337] [914] [1422 ] [ 1661] [192] [76 2] [341] [ 395] [ 1109]

52020 S
W

6 2.87 84 60.63 96 40 56 72 8.54 30 15.91 18.54 52.28


62024 S [15 97] [2134] [1 540] [2438] [ 1016] [1422 ] [ 1829] [217] [76 2] [404] [ 471] [ 1328]

52023 S ACCESS
6 8.87 84 60.63 98 40 58 72 8.54 36 15.91 18.54 52.28
62028 S [17 49] [2134] [1 540] [2489] [ 1016] [1473 ] [ 1829] [217] [91 4] [404] [ 471] [ 1328]

*MODEL WITH 1-COMPRESSOR CERTIFIED DRAWINGS ARE


AVAILABLE ON REQUEST

A2 A4
DRAIN 1 [25]x2Nos. 5
W L
C
1 A B
D
[38]

[25]
1.5

G G 7 6
J
I

FILTERED
VENTILLATION
H

ON BOTH SIDES
H1
F

CABLE ENTRY
[51]

15
2

2 3 4
[125]
4.92

RIGGING HOLES [381]


ACCESS PANEL Figure 38.
.79 [20]4Nos.
BOTH SIDES

| 51
Dimensional Data

PACV Models: 52026 S to 52038 S & 62033 S to 62046 S


10 10
MODEL DIMENSIONS ARE IN INCHES [mm] [254] [254]
A1 A3
PACV- H L A F H1 J G D I
52026 S 72.87 116 40 40 60.63 15.91 18.54 52.28 8.54
62033 S [1851] [2946] [1016] [1016] [1540] [404] [471] [1328] [217]

52030 S 80.87 116 40 48 60.63 15.91 18.54 52.28 8.54


62036 S [2054] [2946] [1016] [1219] [1540] [404] [471] [1328] [217]

52032 S 80.87 116 40 48 60.63 15.91 18.54 52.28 8.54

[2235]
88
62037 S [2054] [2946] [1016] [1219] [1540] [404] [471] [1328] [217]
ACCESS
* 52038 S 93.99
[2387]
119
[3023]
43 56
[1092] [1422]
77.63
[1972]
18.82
[478]
21.93
[557]
61.85
[1571]
10.75
[273]
* 62046 S
* MODEL WITH TANDEM COMPRESSORS
FROM THE MODELS 52038S/62046S, USING TANDEM COMPRESSORS
A2 A4
CERTIFIED DRAWINGS ARE
AVAILABLE ON REQUEST 88 DRAIN 1[25]x2Nos. 5
[2235] L
75
[1905]
D 1 A 76

[38]
1.5
G G [25] [1930]

7 6

J
I

FILTERED
L EG E ND VENTILLATION
H

ON BOTH SIDES

H1
F

7 -CON DEN SER FA N


6 -CON TROL P ANEL
1
5 -CON DEN SER COIL CABLE ENTRY
4 -COMP RESSOR
3 -FAN MOTOR
[51]

RIGGING HOLES 4
2

15 2 3

[125]
4.92
2 -EVA PORATOR FA N .79[20] x 4 Nos.
[381] ACCESS PANEL
1 -EVA PORATOR COIL BOTH SIDES
Figure 39.

PACV Models: 52045 S to 52055 S & 62055 S to 62066 S


10 10
[254] [254]

A1 A3

CERTIFIED DRAWINGS ARE


AVAILABLE ON REQUEST

MODEL DIMENSIONS ARE IN INCHES [mm]


W

PACV- H W H1 C F I
52045 S 99.24 88 77.63 75 66 6 ACCESS
62055 S [2521] [2235] [1972] [1905] [1676] [152]
52050 S 103.24 88 85.63 75 72 4
62060 S [2622] [2235] [2175] [1905] [1829] [102]

52055 S 103.24 92 85.63 80 72 4


62066 S [2622] [2337] [2175] [2032] [1829] [102] A2 A4

DRAIN 1 1/4 [32]x2Nos. 5


** TANDEM COMPRESSOR
127
W [3226]

C
61.85 1 43 84
[1571] [25] [1092] [2134]
21.93 21.93
[38]
1.5

[557] [557]
18.82
[478]

7 6
I

FILTERED
VENTILLATION
ON BOTH SIDES
H

H1

CABLE ENTRY
[125]
4.92
[51]

1 ** 4
2

2 3
15
RIGGING HOLES [381]
.79 [20]x 4 Nos.
ACCESS PANEL Figure 40.
BOTH SIDES

52 |
Dimensional Data

PACV Models: 52065 S & 62076 S


2.8 108.5 2.8
[70] [2756] [70]
A1 A3 A5 A7

CERTIFIED DRAWINGS ARE


AVAILABLE ON REQUEST
ACCESS

A2 A4 A6 A8

10 20 10
[254] [508] [254]
2 88 2 198
[51] [2235] [51] [5029]
114 84
[2896] [2134]
9
[153]

39.31 35.35 39.31


6

[999] [898] [999] 7 6

1
35.35
[898]

S/A FILTERED
VENTILLATION
ON BOTH SIDES
[1994]

[2134]
78.49
[2284]
89.91

[2200]
86.61
84

R/A
10
CABLE ENTRY
2

ACCESS

[150]
4 5

5.91
3 8 RIGGING HOLES
DRAIN 1 1/2"[38]
7/8[22]4 Nos.
Figure 41.

PACV Models: 53070 S to 53095 S & 63085 S to 63110 S


2.8 B 2.8
LEGEND [70] [70]
A1 A3 A5 A7 A9 A11
10 -FLEXIBLE CONNECTION
9 -WEATHER PROOF CANOPY 6
8 -ANTI VIB. MOUNTS
7 -CONDENSER FAN
6 -CONTROL PANEL
5 -CONDENSER COIL
4 -TANDEM COMPRESSOR
3 -FAN MOTOR
2 -EVAPORATOR FAN A2 A4 A6 A8 A10 A12
1 -EVAPORATOR COIL 20
10 10
[254] [508] [254]
L
2 88 2
[51] [2235] [51] A 47.05 88.6
[1195] [2250]
9
[152]

F G F 5 7
PARTITION
6

1 FILTERED
VENTILATION
BOTH SIDE
J

S/A
106.89
[2420]
[2715]

[2715]
95.28
106.9

E
H

R/A 10 DETACHABLE
PLATE FOR
CABLE ENTRY
[750]
29.5

3 ACCESS
8 RIGGING HOLES
[150]
5.91

DRAIN 1 1/2"[38] 4
7/8[22] 4 Nos.

MODEL DIMENSIONS ARE IN INCHES [MM]


PACV- L A B E F H J G C
53070 S 249.6 114 108.5 93 37.17 98.94 39.65 39.65 87.5
63085 S [6341] [2896] [2756] [2362] [944] [2513] [1007] [1007] [2222]
53075 S 249.6 114 108.5 93 37.17 98.94 39.65 39.65 87.5
63090 S [6341] [2896] [2756] [2362] [944] [2513] [1007] [1007] [2222]
53080 S 249.6 114 108.5 102 37.17 107.91 39.65 39.65 96.5
63095 S [6341] [2896] [2756] [2591] [944] [2741] [1007] [1007] [2451]
53085 S 253.6 118 112.5 102 36.76 107.91 44.49 44.49 96.5
63100 S [6441] [2997] [2857] [2591] [934] [2741] [1130] [1130] [2451]
53090 S 259.6 124 118.5 102 39.76 107.91 44.49 44.49 96.5
63105 S [6594] [3150] [3010] [2591] [1010] [2741] [1130] [1130] [2451]
53095 S 266.6
63110 S [6772]
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 B 2.8
[70] [70]
MODEL DIMENSIONS ARE IN INCHES[mm] A1 A3 A5 A9
PACV- A7 A11 6
L A B F LEGEND
54100 S 311.2 134 128.5 44.76
64120 S [7904] 10 -FLEXIBLE CONNECTION
[3404] [3264] [1137]
9 -WEATHER PROOF CANOPY
54110 S 315.2 138 132.5 46.76
64130 S [8006] 8 -ANTI VIB. MOUNTS
[3505] [3365] [1188]
7 -CONDENSER FAN
54115 S 321.2 144 138.5 49.76
64136 S [8158] 6 -CONTROL PANEL
[3658] [3518] [1264]
5 -CONDENSER COIL
54125 S 329.2 152 146.5 53.76 4 -COMPRESSOR
64145 S [8362] [3861 [3721] [1365]
A2 A4 A6 A8 A10 A12 3 -FAN MOTOR
2 -EVAPORATOR FAN
10 20 10 1 -EVAPORATOR COIL
[254] [508] [254]
CERTIFIED DRAWINGS ARE
AVAILABLE ON REQUEST
2 88 2 L
[51] [2235] [51]
A 88.6 88.6 12
[2250] [2250] [305]
[152]

9 F 44.49 F
6

PARTITION 7 5 PARTITION
[1130]

1
[1130]
44.49

FILTERED
S/A VENTILATION
BOTH SIDE
[2451]

[2591]
96.49
107.91
[2741]

106.88
[2420]

[2715]
102

95.27
R/A DETACHABLE
10
PLATE FOR
CABLE ENTRY
2

[750]
29.5
ACCESS
DRAIN 1 1/2"[38] 4
[150]

8
5.91

3 RIGGING HOLES
7/8[22] 4 Nos.

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 VEE FILTER BAG FILTER
G 1
[25]
5.6
[142]
1
[25]
26
[660]
1
[25]
26
*
[660]

F
MODEL FLAT FILTER VEE FILTER BAG FILTER
PACV-S F G
SIZE H x L QTY. SIZE H x L QTY. SIZE H x L QTY. SIZE H x L QTY. SIZE H x L QTY.
51008 S 24 40
61009 S (610) (1016) 25x20(635x508) 2 - 20x20 (508x508) 4 24x20 (610x508) 2 -

51010 S 30 44 16x25 (406x635) 2


-
25x20 (635x508) 2 12x24 (305x610) 1 20x24 (508x610) 1
61012 S (762) (1118) 16x20 (406x508) 2 25x25 (635x635) 2 12x20 (305x508) 1 20x20 (508x508) 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) 2 25x16 (635x406) 2 12x24 (305x610) 1 20x24(508x610) 1


61020 S (762) (1661) 16x20 (406x508) -
4 25x25 (635x635) 4 12x20 (305x508) 2 20x20 (508x508) 2
52017 S 30 65 16x25 (406x635) 2
-
25x16 (635x406) 2 12x24 (305x610) 1 20x24 (508x610) 1
62020 S (762) (1661) 16x20(406x508) 4 25x25 (635x635) 4 12x20(305x508) 2 20x20 (508x508) 2
52020 S 30 72 16x16 (406x406) 4 25x20 (635x508) 2 12x24 (305x610) 3
62024 S (762) (1829) 16x20 (406x508) - -
4 25x25(635x635) 4 20x24 (508x610) 3
52023 S 36 72 16x16 (406x406) 2 20x16(508x406) 2 20x16 (508x406) 6 12x24 (305x610) 3
-
62028 S (914) (1829) 16x20(406x508) 2 20x20 (508x508) 2 20x20(508x508) 6 24x24 (610x610) 3
52026 S 40 75 20x20 (508x508) 4
62033 S (1016) (1905) 20x25 (508x635) 6 - 20x25 (508x635) 9 20x24 (508x610) 2 -
20x12 (508x305) 2
52030 S 48 75 24x20 (610x508) 4
25x25 (635x635) 6 - 25x25 (635x635) 9 24x24 (610x610) 2 -
62036 S (1219) (1905) 24x12 (610x305) 2
52032 S 48 75 24x20 (610x508) 4
25x25 (635x635) 6 - 25x25 (635x635) 9 24x24 (610x610) 2 -
62037 S (1219) (1905) 24x12 (610x305) 2
12x12 (305x305) 1 20x20 (508x508) 2
52038 S 56 75 16x25 (406x635) 3 12x20 (305x508) 2 20x12 (508x305) 1
- 25x25 (635x635) 9 24x24 (610x610) 1
62046 S (1422) (1905) 20x25(508x635) 6 12x24 (305x610) 1 24x20(610x508)
1 2
20x24 (508x610) 24x12(610x305) 1
52045 S 66 75 25x25 (635x635) 3 24x20 (610x508) 4 20x20 (508x508) 2
- 25x25 (635x635) 12 24x24 (610x610) 2 20x24 (508x610) 1
62055 S (1676) (1905) 20x25 (508x635) 6 24x12 (610x305) 2 20x12 (508x305) 1
52050 S 72 75 16x25(406x635) 6 24x20 (610x508) 6
- 25x25(635x635) 12 24x24 (610x610) 3 -
62060 S (1829) (1905) 20x25 (508x635) 6 24x12 (610x305) 3
52055 S 72 80 16x20 (406x508) 8
- 25x20 (635x508) 16 24x20 (610x508) 12
62066 S (1829) (2032) 20x20 (508x508) 8 -

52065 S 72 98 16x25 (406x635) 8


- 25x25 (635x635) 16 24x24(610x610) 12 -
62076 S (1829) (2489) 20x25 (508x635) 8
53070 S 81 98 16x25 (406x635) 8
- 25x25 (635x635) 20 20x24 (508x610) 16 -
63085 S (2057) (2489) 25x25(635x635) 8
53075 S 81 98 16x25 (406x635) 8
63090 S (2057) (2489) 25x25 (635x635) - 25x25 (635x635) 20 20x24 (508x610) 16 -
8
53080 S 90 98 20x25 (508x635) 8 - 25x25 (635x635) 20 24x24 (610x610) 12
-
63095 S (2286) (2489) 25x25 (635x635) 8 20x24(508x610) 4
53085 S 90 102 25x20 (635x406)
25x16 4 25x25 (635x635) 4 24x20(610x508) 3 20x20 (508x508) 1
(635x508) 2 20x16 (508x406) 4 25x25 (635x635) 20 24x24(610x610) 9 20x24 (508x610) 3
63100 S (2286) (2591) 20x25 (508x635) 4 20x20 (508x508) 2 24x12(610x305) 3 20x12(508x305) 1
53090 S 90 108 20x16 (508x406) 6 25x16 (635x406) 6 25x16 (635x406) 15 24x24 (610x610) 12 20x24(508x610) 4
63105 S (2286) (2743) 20x20 (508x508) 6 25x20 (635x508) 6 25x20 (635x508) 15 24x12 (610x305) 3 20x12(508x305) 1
53095 S 90 115 25x25 (635x635) 8 20x25 (508x635) 8 25x25 (635x635) 20 24x20 (610x508) 3 20x20 (508x508) 1
63110 S (2286) (2921) 25x16 (635x406) 2 20x16 (508x406) 2 25x16 (635x406) 5 24x24 (610x610) 12 20x24(508x610) 4
54100 S 90 118 25x25 (635x635) 8 20x25 (508x635) 8 25x25(635x635) 20 24x24(610x610) 15
64120 S (2286) (2997) 25x20 (635x508) 2 20x20 (508x508) 2 25x20 (635x508) 5 20x24(508x610) 5 -

54110 S 90 122 25x25 (635x635) 4 20x25 (508x635) 4


25x20 (635x508) 4 20x20(508x508) 4 25x25 (635x635) 25 24x24 (610x610) 15
64130 S (2286) (3099) 25x16 (635x406) 20x24 (508x610) 5 -
4 20x16 (508x406) 4
54115 S 90 128 20x16 (508x406) 16 24x20 (610x508) 3 20x20 (508x508) 1
- 25x25 (635x635) 30 24x24 (610x610) 12 20x24 (508x610) 4
64136 S (2286) (3251) 25x16 (635x406) 16 24x12 (610x305) 3 20x12 (508x305) 1
54125 S 90 136 25x25 (635x635) 8 20x25 (508x635) 8 25x25(635x635) 20 24x20 (610x508) 15 20x20 (508x508) 5
25x20 (635x508) 2 20x20 (508x508) 2 25x20 (635x508) 5 24x24 (610x610) 3 20x24 (508x610) 1
64145 S (2286) (3454) 25x16 (635x406) 2 20x16 (508x406) 2 25x16(635x406) 5 24x12 (610x305) 3 20x12 (508x305) 1

* BAG FILTER IS APPLICABLE FOR 22" DEPTH ALL DIMENSIONS ARE IN INCHES (MM)
Table 16

| 57
58 |
19 23 20 21 22 34 24
Spare Parts

18 F1 F2 F3 F4

CR1 CR2 CR3 CR4 CR5

CFM CONTACTORS EFM CONTACTORS

C7 C8 C9 C10 C11 C12 C13 C14 C15

SIMATIC PANEL OL OL OL OL OL OL OL
S1 & S2 S3 & CS

Plug For PC

SIEMENS S7-200 EM 235


PTB
[120SQMM]

LOGO!

MS-32 MS-32 MS-32 MS-32 MS-32 MS-32

C1 C2 C3 C4 C5 C6

CF
COMP.CONTACTOR 1 COMP.CONTACTOR 2 COMP.CONTACTOR 3 COMP.CONTACTOR 4 COMP.CONTACTOR 5 COMP.CONTACTOR 6

CTB

40 25 26 27 28 29 30 31 32
TYPICAL CONTROL PANELS

37
19 27 28 29 23 21 24

14
LOGO F1 F2
CR1 CR2 POWER

Esc OK

30
COMP.CONTACTOR COMP.CONTACTOR
1 2
S1 & S2 CS

CFM EFM
CONTACTORS CONTACTOR

PTB
OL C3 C4 C5 [120SQMM]

CF

CTB OL OL OL

41
33 26 34 20 22

18
AIR FLOW 17
1
7
16
2
15
7
42
APPENDIX- VI

38 3
12 4
5
11 6

7 14
35 35
11
6

4 12
39 13
3
8
9
10
10
1 EVAPORATOR COIL 9 MOTOR PULLEY 17 CONDENSER FAN GUARD 25 TOUCH PANEL 32 TIME DELAY RELAY 40 CONTROL FUSE/MCB
9 2 EXPANSION VALVE 10 BELT 18 CONTROL PANEL 26 CONTROL TERMINAL BLOCK 33 CONTROL FUSE / MCB 41 HIGH PRESSURE SWITCH
3 FAN PULLEY 11 SOLENOID VALVE 19 CONTROL RELAY 27 POWER SUPPLY MODULE 34 OVER LOAD RELAY 42 LOW PRESSURE SWITCH
4 BEARINGS 12 FILTER DRIER 20 CFM CONTACTORS 28 MASTER BOARD 35 SIGHT GLASS
5 FAN SHAFT 13 SHUT OFF VALVE 21 POWER CIRCUIT FUSE 29 EXPANSION MODULE 36 ANTI VIBRATION MOUNTS
8 36
6 EVAPORATOR FAN 14 CONDENSER COIL 22 EFM CONTACTORS 30 CONTROL SWITCH / 37 WEATHER PROOF CANOPY
PUMP DOWN SWITCH
7 COMPRESSOR 15 CONDENSER FAN MOTOR 23 COMPRESSOR CONTACTORS 38 BALL VALVE
EVAPORATOR FAN MOTOR CONDENSER FAN BLADE POWER TERMINAL BLOCK 31 13A SOCKET
8 16 24 39 FILTER CORE

Figure 49
APPENDIX- VII

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


Unit Characteristic
Model Compressor Condenser Fan Motor Evaporator Fan Motor
PACV-S MFA MCA ICF
QTY RLA LRA QTY FLA LRA QTY FLA LRA
51008 63 33 127 1 22 118 2 1.1 3.9 1 3.6 19.2
51010 80 43 183 1 30 174 2 1.1 3.9 1 3.6 19.2
51014 100 59 243 1 38 225 2 2.4 8.9 1 6.6 35.6
52015 100 61 158 1+1 22 + 22 118 + 118 2 2.4 8.9 1 6.6 35.6
51017 125 68 292 1 44 272 2 2.4 8.9 1 8.6 45.6
52017 125 73 216 1+1 30 + 22 174 + 118 2 2.4 8.9 1 8.6 45.6
52020 125 84 234 1+1 30 + 30 174 + 174 2 3.9 17.2 1 8.6 45.6
52023 160 94 285 1+1 38 + 30 225 + 174 2 3.9 17.2 1 8.6 45.6
52026 160 109 300 1+1 38 + 38 225 + 225 3 3.9 17.2 1 11.8 67.3
52030 200 121 351 1+1 44 + 38 272 + 225 3 3.9 17.2 1 16 105.6
52032 200 127 357 1+1 44 + 44 272 + 272 3 3.9 17.2 1 16 105.6
52038 200 155 305 2+2 30 + 30 174 + 174 3 3.9 17.2 1 16 105.6
52045 250 184 375 2+2 38 + 30 225 + 174 4 3.9 17.2 1 23.2 148.5
52050 250 200 391 2+2 38 + 38 225 + 225 4 3.9 17.2 1 23.2 148.5
52055 315 214 444 2+2 44 + 38 272 + 225 4 3.9 17.2 1 23.2 148.5
52065 315 234 465 2+2 44 + 44 272 + 272 4 3.9 17.2 1 31.6 221.2
53070 315 269 473 3+3 38 + 30 225 + 174 6 3.9 17.2 1 31.6 221.2
53075 400 293 497 3+3 38 + 38 225 + 225 6 3.9 17.2 1 31.6 221.2
53080 400 293 497 3+3 38 + 38 225 + 225 6 3.9 17.2 1 31.6 221.2
53085 400 306 550 2+4 44 + 38 272 + 225 6 3.9 17.2 1 31.6 221.2
53090 400 318 562 4+2 44 + 38 272 + 225 6 3.9 17.2 1 31.6 221.2
53095 400 330 574 5+1 44 + 38 272 + 225 6 3.9 17.2 1 37.9 284.2
54100 500 383 587 4+4 38 + 38 225 + 225 8 3.9 17.2 1 37.9 284.2
54110 500 402 646 3+5 44 + 38 272 + 225 8 3.9 17.2 1 37.9 284.2
54115 500 414 658 5+3 44 + 38 272 + 225 8 3.9 17.2 1 37.9 284.2
54125 500 438 682 4+4 44 + 44 272 + 272 8 3.9 17.2 1 44.2 331.6
Table 17

POWER SUPPLY 440V/3Ph/50Hz


Unit Characteristic
Compressor Condenser Fan Motor Evaporator Fan Motor
Model
MFA MCA ICF
QTY RLA LRA QTY FLA LRA QTY FLA LRA
51008 63 33 126 1 22 118 2 1.1 3.9 1 3.1 16.6
51010 80 43 182 1 30 174 2 1.1 3.9 1 3.1 16.6
51014 100 59 243 1 38 225 2 2.8 9.2 1 5.7 30.8
52015 100 61 158 1+1 22 + 22 118 + 118 2 2.8 9.2 1 5.7 30.8
51017 125 68 291 1 44 272 2 2.8 9.2 1 7.4 39.3
52017 125 73 215 1+1 30 + 22 174 + 118 2 2.8 9.2 1 7.4 39.3
52020 125 84 233 1+1 30 + 30 174 + 174 2 4.3 17.6 1 7.4 39.3
52023 160 94 284 1+1 38 + 30 225 + 174 2 4.3 17.6 1 7.4 39.3
52026 160 109 299 1+1 38 + 38 225 + 225 3 4.3 17.6 1 10.2 58
52030 200 120 350 1+1 44 + 38 272 + 225 3 4.3 17.6 1 13.8 91.1
52032 200 126 356 1+1 44 + 44 272 + 272 3 4.3 17.6 1 13.8 91.1
52038 200 154 304 2+2 30 + 30 174 + 174 3 4.3 17.6 1 13.8 91.1
52045 250 183 374 2+2 38 + 30 225 + 174 4 4.3 17.6 1 20 128.1
52050 250 199 390 2+2 38 + 38 225 + 225 4 4.3 17.6 1 20 128.1
52055 315 212 443 2+2 44 + 38 272 + 225 4 4.3 17.6 1 20 128.1
52065 315 232 462 2+2 44 + 44 272 + 272 4 4.3 17.6 1 27.3 190.9
53070 315 267 471 3+3 38 + 30 225 + 174 6 4.3 17.6 1 27.3 190.9
53075 400 291 495 3+3 38 + 38 225 + 225 6 4.3 17.6 1 27.3 190.9
53080 400 291 495 3+3 38 + 38 225 + 225 6 4.3 17.6 1 27.3 190.9
53085 400 304 548 2+4 44 + 38 272 + 225 6 4.3 17.6 1 27.3 190.9
53090 400 316 560 4+2 44 + 38 272 + 225 6 4.3 17.6 1 27.3 190.9
53095 400 328 571 5+1 44 + 38 272 + 225 6 4.3 17.6 1 32.7 245.2
54100 500 381 585 4+4 38 + 38 225 + 225 8 4.3 17.6 1 32.7 245.2
54110 500 400 644 3+5 44 + 38 272 + 225 8 4.3 17.6 1 32.7 245.2
54115 500 412 656 5+3 44 + 38 272 + 225 8 4.3 17.6 1 32.7 245.2
54125 500 436 679 4+4 44 + 44 272 + 272 8 4.3 17.6 1 38.2 286.1
Table 18

| 59
Electrical Data POWER SUPPLY 380V/3Ph/60Hz
Unit Characteristic
Compressor Condenser Fan Motor Evaporator Fan Motor
Model
MFA MCA ICF
QTY RLA LRA QTY FLA LRA QTY FLA LRA
61009 63 37 155 1 24 145 2 1.5 4.5 1 3.6 18.9
61012 100 54 207 1 37 196 2 1.5 4.5 1 4.9 25
61018 125 65 299 1 42 280 2 3.1 9.6 1 6.3 34
62018 100 67 188 1+1 24 + 24 145 + 145 2 3.1 9.6 1 6.3 34
61020 160 85 374 1 56 353 2 3.1 9.6 1 8.4 44.3
62020 125 85 241 1+1 37 + 24 196 + 145 2 3.1 9.6 1 8.4 44.3
62024 160 102 264 1+1 37 + 37 196 + 196 2 5.3 17.5 1 8.4 44.3
62028 160 109 348 1+1 42 + 37 280 + 196 2 5.3 17.5 1 8.4 44.3
62033 200 122 362 1+1 42 + 42 280 + 280 3 5.3 17.5 1 11.5 65.5
62036 200 143 439 1+1 56 + 42 353 + 280 3 5.3 17.5 1 15.5 102.3
62037 250 157 453 1+1 56 + 56 353 + 353 3 5.3 17.5 1 15.5 102.3
62046 250 189 351 2+2 37 + 37 196 + 196 3 5.3 17.5 1 15.5 102.3
62055 315 213 452 2+2 42 + 37 280 + 196 4 5.3 17.5 1 23 147.1
62060 315 231 470 2+2 42 + 42 280 + 280 4 5.3 17.5 1 30.9 216
62066 400 262 557 2+2 56 + 42 353 + 280 4 5.3 17.5 1 30.9 216
62076 400 290 585 2+2 56 + 56 353 + 353 4 5.3 17.5 1 30.9 216
63085 400 310 562 3+3 42 + 37 280 + 196 6 5.3 17.5 1 30.9 216
63090 400 325 577 3+3 42 + 42 280 + 280 6 5.3 17.5 1 30.9 216
63095 400 325 577 3+3 42 + 42 280 + 280 6 5.3 17.5 1 30.9 216
63100 500 357 664 2+4 56 + 42 353 + 280 6 5.3 17.5 1 30.9 216
63105 500 385 692 4+2 56 + 42 353 + 280 6 5.3 17.5 1 30.9 216
63110 500 405 713 5+1 56 + 42 353 + 280 6 5.3 17.5 1 37.5 281.3
64120 500 426 678 4+4 42 + 42 280 + 280 8 5.3 17.5 1 37.5 281.3
64130 630 472 779 3+5 56 + 42 353 + 280 8 5.3 17.5 1 37.5 281.3
64136 630 500 807 5+3 56 + 42 353 + 280 8 5.3 17.5 1 37.5 281.3
64145 630 548 855 4+4 56 + 56 353 + 353 8 5.3 17.5 1 43.6 326.7
Table 19
POWER SUPPLY 460V/3Ph/60Hz
Unit Characteristic
Compressor Condenser Fan Motor Evaporator Fan Motor
Model
MFA MCA ICF
QTY RLA LRA QTY FLA LRA QTY FLA LRA
61009 63 32 135 1 21 125 2 1.3 5.2 1 3 15.6
61012 80 42 190 1 28 179 2 1.3 5.2 1 4.1 20.7
61018 100 59 245 1 38 225 2 3.1 11.8 1 5.2 28.1
62018 100 59 166 1+1 21 + 21 125 + 125 2 3.1 11.8 1 5.2 28.1
61020 125 68 294 1 44 272 2 3.1 11.8 1 6.9 36.6
62020 100 69 222 1+1 28 + 21 179 + 125 2 3.1 11.8 1 6.9 36.6
62024 125 80 240 1+1 28 + 28 179 + 179 2 5 21.0 1 6.9 36.6
62028 160 92 286 1+1 38 + 28 225 + 179 2 5 21.0 1 6.9 36.6
62033 160 110 304 1+1 38 + 38 225 + 225 3 5 21.0 1 9.5 54.1
62036 200 121 354 1+1 44 + 38 272 + 225 3 5 21.0 1 12.8 84.5
62037 200 127 360 1+1 44 + 44 272 + 272 3 5 21.0 1 12.8 84.5
62046 200 147 307 2+2 28 + 28 179 + 179 3 5 21.0 1 12.8 84.5
62055 250 181 374 2+2 38 + 28 225 + 179 4 5 21.0 1 19 121.6
62060 250 207 401 2+2 38 + 38 225 + 225 4 5 21.0 1 25.5 178.5
62066 315 221 454 2+2 44 + 38 272 + 225 4 5 21.0 1 25.5 178.5
62076 315 233 466 2+2 44 + 44 272 + 272 4 5 21.0 1 25.5 178.5
63085 315 263 473 3+3 38 + 28 225 + 179 6 5 21.0 1 25.5 178.5
63090 400 293 503 3+3 38 + 38 225 + 225 6 5 21.0 1 25.5 178.5
63095 400 293 503 3+3 38 + 38 225 + 225 6 5 21.0 1 25.5 178.5
63100 400 307 556 2+4 44 + 38 272 + 225 6 5 21.0 1 25.5 178.5
63105 400 319 568 4+2 44 + 38 272 + 225 6 5 21.0 1 25.5 178.5
63110 400 330 579 5+1 44 + 38 272 + 225 6 5 21.0 1 31 232.5
64120 500 385 594 4+4 38 + 38 225 + 225 8 5 21.0 1 31 232.5
64130 500 404 653 3+5 44 + 38 272 + 225 8 5 21.0 1 31 232.5
64136 500 416 665 5+3 44 + 38 272 + 225 8 5 21.0 1 31 232.5
64145 500 439 688 4+4 44 + 44 272 + 272 8 5 21.0 1 36 270
Table 20

60 |
Electrical Data POWER SUPPLY 220V/3Ph/60Hz
Unit Characteristic
Compressor Condenser Fan Motor Evaporator Fan Motor
Model
MFA MCA ICF
QTY RLA LRA QTY FLA LRA QTY FLA LRA
61009 125 70 261 1 47 245 2 2.5 7.5 1 6.2 32.6
61012 160 89 359 1 60 340 2 2.5 7.5 1 8.5 43.3
61018 250 123 538 1 81 505 2 5.4 16.7 1 10.9 58.7
62018 200 127 325 1+1 47 + 47 245 + 245 2 5.4 16.7 1 10.9 58.7
61020 250 134 642 1 87 605 2 5.4 16.7 1 14.4 76.5
62020 250 147 424 1+1 60 + 47 340 + 245 2 5.4 16.7 1 14.4 76.5
62024 250 167 453 1+1 60 + 60 340 + 340 2 9 29.7 1 14.4 76.5
62028 315 194 618 1+1 81 + 60 505 + 340 2 9 29.7 1 14.4 76.5
62033 315 229 654 1+1 81 + 81 505 + 505 3 9 29.7 1 19.9 113.1
62036 400 244 761 1+1 87 + 81 605 + 505 3 9 29.7 1 26.8 176.6
62037 400 250 767 1+1 87 + 87 605 + 605 3 9 29.7 1 26.8 176.6
62046 400 309 595 2+2 60 + 60 340 + 340 3 9 29.7 1 26.8 176.6
62055 500 378 802 2+2 81 + 60 505 + 340 4 9 29.7 1 39.7 254.1
62060 630 434 858 2+2 81 + 81 505 + 505 4 9 29.7 1 53.3 373.1
62066 630 447 964 2+2 87 + 81 605 + 505 4 9 29.7 1 53.3 373.1
62076 630 459 976 2+2 87 + 87 605 + 605 4 9 29.7 1 53.3 373.1
63085 800 551 996 3+3 81 + 60 505 + 340 6 9 29.7 1 53.3 373.1
63090 800 614 1059 3+3 81 + 81 505 + 505 6 9 29.7 1 53.3 373.1
63095 800 614 1059 3+3 81 + 81 505 + 505 6 9 29.7 1 53.3 373.1
63100 800 627 1165 2+4 87 + 81 605 + 505 6 9 29.7 1 53.3 373.1
63105 800 639 1177 4+2 87 + 81 605 + 505 6 9 29.7 1 53.3 373.1
63110 800 657 1194 5+1 87 + 81 605 + 505 6 9 29.7 1 64.8 485.9
64120 1000 805 1250 4+4 81 + 81 505 + 505 8 9 29.7 1 64.8 485.9
64130 1000 825 1362 3+5 87 + 81 605 + 505 8 9 29.7 1 64.8 485.9
64136 1000 837 1374 5+3 87 + 81 605 + 505 8 9 29.7 1 64.8 485.9
64145 1000 865 1403 4+4 87 + 87 605 + 605 8 9 29.7 1 75.2 564.3
Table 21
Voltage imbalance between phases to be < 2%

Legend
MFA Maximum Fuse Amps (for fuse sizing), complies with RLA Rated Load Amps. (at worst operating condition)
NEC Article 440-22 & 430-52. LRA Locked Rotor Amps
MCA Minimum Circuit Amps.(for wire sizing), complies with FLA Full Load Amps
NEC article 440-33.
ICF Maximum Instantaneous Current Flow

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

| 61
62 |
POWER SUPPLY
L1
** L2
L3
N
F
2A

C1 C2 MPCB1 MPCB2 MPCB3 MPCB4

I> I> I> I> I> I> I> I> I> I> I> I>
N L1 MPM1 * MPM2
L1 L2 L3
* L1 L2 L3
C3 C4 C5 C6
T2 T1 M 1 M2 S1 S2 T2 T1 M 1 M2 S1 S2 VMM
CM1 CM2
A B C
NC Com NO
CFM1 CFM2 CFM3 EFM
MCB1

CR1 CR2

ROOMUNIT NOTE:-
(LOOSESUPPLY) * Typical wiring diagram given here is for units with 380~ 415/3/50 or
380/3/60, 4 wire power supplies.
Typical Wiring Diagram

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


power supplies areavailableonrequest.

G G
* For 440/3/50 or 460/3/60 or power supplies without neutral,
OL + - CXT option is amust.
I I CR1 CR2 CS

MPCB4
VMM
* MPM Module is not available in some small compressors.

MP-1
MP-2

LPS-1
LPS-2
2CORE UNSCREENED

RUN/STOP
TWISTED PAIR CABLE
AS PER KNX SPECIFICATION L EG EN D
(BY OTHERS)
TFR TRANSFORMER VMM VOLTAGEMONITORINGMODULE

DISC. PRESSURE-1
DISC. PRESSURE-2
CS CONTROL SWITCH MPM MOTOR PROTECTOR MODULE
C CONTACTOR MPCB MOTOR PROTECTOR CIRCUT BREAKER
CCH CRANKCASEHEATER OL OVERLOAD RELAY
MCB MINIATURECIRCUIT BREAKER LSV LIQUID LINESOLENOID VALVE
CFM CONDENSER FAN MOTOR EFM EVAPORATOR FAN MOTOR
CM COMPRESSOR MOTOR CR CONTROL RELAY
LPS LOW PRESSURESWITCH
FIELD WIRING
HPS HIGH PRESSURESWITCH
24~_ RS485 PB
** Provide Overcurrent, short circuit, earth fault protec on &

M
M
M
M
M
M
M
B-
MCB2

X1
X2
X3
X4
X5
X6
X7
X8

B1
B2
B3
A+

D1
D2
DG
CE-

REF
CE+

5V=
5V=
DU1
DU2

T1
T2
T3
T4
T5
T6
T7
disconnect means as required by local and na

24V=
24V=
INFO
APPENDIX- VIII

MICROPROCESSOR
CONTROLLER OK
TFR

24V

220~ 240V
ESC
POL 687/STD

C1 C2

T8
T9

24~_
G0
Q12
Q11
Q14
Q22
Q21
Q24
Q33
Q34
Q43
Q44
Q53
Q54
Q64
Q73
Q74
Q84
C
D01
D02
DL1
DN
DL2

T10
T11
T12
T13
T-IP
T-HI
CCH1
CCH2

HPS-1
HPS-2

E
LSV-1 LSV-2

COMP.-1
COMP.-2
CFM1
CFM2
CFM3
EFM

C1 C2 C3 C4 C5 C6

Figure 50
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)
Dont press too strong, you could damage the button
Switch on the power supply

Keep the Service-Push-Button pressed until start BSP-


LED flash red/green of controller

The BSP-LED on the Controller shows the progress


BSP-LED yellow Startup Phase
BSP-LED flash red/green Load Firmware in Flash (15.....50 sec, avoid power interruption)
BSP-LEDs yellow
BSP-LEDs yellow flashing
all LEDs off
} Download finished

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
F C R-22 R-410A R-407C R134a F C R-22 R-410A R-407C R134a F C R-22 R-410A R-407C R134a

-60 -51.1 *11.9 *0.9 *16.0 *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
-55 -48.3 *9.2 1.8 *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
-50 -45.6 *6.1 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
-45 -42.8 *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 -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. Table 22
Pressures are listed as psig, except (*) indicates inches in mercury vacuum.
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