Example: biology

Wall Mounted Packaged Air Conditioners

Wall Mounted Packaged Air Conditioners Models 3R1C1 9E1C2 5R1C1 13E1C3 17E1C20.E1C2 18.E1C418E1C4 INSTALLATION AND OPERATION MANUAL AIRSYS Refrigeration Engineering Technology (Beijing) Co.,Ltd

Tags:

  Wall, Mounted, Conditioners, Packaged, Wall mounted packaged air conditioners

Information

Domain:

Source:

Link to this page:

Please notify us if you found a problem with this document:

Other abuse

Text of Wall Mounted Packaged Air Conditioners

Wall Mounted Packaged Air Conditioners Models 3R1C1 9E1C2 5R1C1 13E1C3 INSTALLATION AND OPERATION MANUAL AIRSYS Refrigeration Engineering Technology (Beijing) Co.,Ltd This document contains proprietary information that is protected by copyright and other intellectual property laws. No part of this document may be reproduced, translated, or modified without the prior written consent of AIRSYS. The information contained in this document is subject to change without notice. AIRSYS provides this material as is and makes no warranty of any kind, expressed or implied, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. AIRSYS shall not be liable for errors contained herein or for incidental or consequential damages (including lost profits) in connection with the furnishing, performance, or use of this material whether based on warranty, contract, or other legal theory. Designations used by other companies to distinguish their products are often claimed as trademarks. In this document, the product names appear in initial capital or all capital letters. Contact the appropriate companies for more information regarding trademarks and registration. Copyright 2012 by AIRSYS AIRSYS Refrigeration Engineering Technology (Beijing) Co. Ltd LuGu East Street Shijingshan Beijing, China 100040 Phone: 010-68656161 Fax: 010-68652453 Item Code: 1170104800 Version Number: Page i Contents Chapter 1: Overview ........................................ ........................................ ........................................ ............. 1 Using this Manual ........................................ ........................................ ........................................ .............. 2 Documentation Conventions ........................................ ........................................ .................................. 2 Model Identification ........................................ ........................................ ........................................ ........ 3 Acronyms and Abbreviations ........................................ ........................................ ................................. 4 Product Overview ........................................ ........................................ ........................................ .............. 5 Unit Operation ........................................ ........................................ ........................................ ................ 5 The Control System (Controller Box) ........................................ ........................................ ..................... 6 Chapter 2: Installation ........................................ ........................................ ........................................ ........... 7 Installation Preparation ........................................ ........................................ ........................................ ...... 7 Delivery ........................................ ........................................ ........................................ .......................... 7 Warranty ........................................ ........................................ ........................................ ........................ 8 Moving the Unit ........................................ ........................................ ........................................ .............. 8 General Safety Rules ........................................ ........................................ ........................................ ..... 8 Required Materials ........................................ ........................................ ........................................ ............ 9 AIRSYS Supplied Materials ........................................ ........................................ ................................... 9 Installer Supplied Material ........................................ ........................................ ................................... 10 Summary Electrical Ratings (Wire Sizing) ........................................ ........................................ ........... 11 Physical Installation ........................................ ........................................ ........................................ ......... 12 Select the Wall for Installing the Unit ........................................ ........................................ ................... 13 Make Openings and Holes ........................................ ........................................ .................................. 14 Install Weather Stripping ........................................ ........................................ ...................................... 15 Position the Unit ........................................ ........................................ ........................................ ........... 15 Remove Wooden Pallet from WPU ........................................ ........................................ ..................... 16 Seal the Joints between WPUs and Wall ........................................ ........................................ ............ 17 Attach the Supply Air Grill and the Return Air Grill to the Wall ........................................ .................... 17 Remove the Compressor Brackets ........................................ ........................................ ...................... 18 Controller Box 19 Install Outdoor Temperature Sensor ........................................ ........................................ ................... 21 Position the Humidity Sensor ........................................ ........................................ ............................... 24 Position Indoor Temperature Sensors and Supply Air Temperature Sensors .................................... 24 Complete Electrical Connections ........................................ ........................................ ............................ 26 Cautions ........................................ ........................................ ........................................ ....................... 26 Overview of Wiring ........................................ ........................................ ........................................ ....... 26 Electrical Connection to Controller Box ........................................ ........................................ ............... 29 Electrical Connection to WPUs ........................................ ........................................ ............................ 30 Complete the Installation Checklist ........................................ ........................................ ......................... 33 Verify System Operation ........................................ ........................................ ........................................ .. 34 Turn On Component Breakers ........................................ ........................................ ............................. 34 Turn on Primary Power ........................................ ........................................ ........................................ 34 Execute the Step-Test ........................................ ........................................ ........................................ . 35 Turn the HVAC System On ........................................ ........................................ .................................. 36 Set System Time ........................................ ........................................ ........................................ .......... 37 Verify the sensor readings ........................................ ........................................ ................................... 38 Verify Input and Output Alarms ........................................ ........................................ ............................ 38 Complete the Registration Card ........................................ ........................................ .......................... 39 Chapter 3: System Operation ........................................ ........................................ ..................................... 44 User Interface Introduction ........................................ ........................................ .................................. 44 Page ii Navigating the Main Menu ........................................ ........................................ ....................................... 45 Turning the HVAC System On or Off ........................................ ........................................ ................... 46 Using Comfort Mode ........................................ ........................................ ........................................ .... 47 Sequence of Operation ........................................ ........................................ ........................................ .... 48 Compressor and Heater Operation ........................................ ........................................ ...................... 48 Free Cooling (Economizer) Operation ........................................ ........................................ ................. 48 Executing the Step-Test ........................................ ........................................ ........................................ .. 49 Alarms ........................................ ........................................ ........................................ .............................. 50 Viewing Alarm History ........................................ ........................................ ........................................ .. 51 Clearing Alarm History ........................................ ........................................ ........................................ . 51 Alarm Descriptions ........................................ ........................................ ........................................ ....... 52 System Diagnostics ........................................ ........................................ ........................................ ......... 57 Port Definitions ........................................ ........................................ ........................................ ............. 57 System Parameters and Default Values ........................................ ........................................ .............. 58 Chapter 4: Preventive Maintenance ........................................ ........................................ ............................ 67 Preventive Maintenance Schedule ........................................ ........................................ .......................... 67 General Operation Check ........................................ ........................................ .................................... 67 Replace Air Filter ........................................ ........................................ ........................................ ......... 69 Clean the Preliminary Air Filter ........................................ ........................................ ............................ 69 Inspect and Clean Condenser Coils ........................................ ........................................ .................... 70 Inspect and Clean the Drain Pipe ........................................ ........................................ ........................ 70 Physical Inspection of the Damper ........................................ ........................................ ...................... 70 Operation Checklist ........................................ ........................................ ........................................ ......... 71 Spare Parts ........................................ ........................................ ........................................ ...................... 72 Appendix 1:Drawings ........................................ ........................................ ........................................ .......... 73 Appendix 2:Reference Tables ........................................ ........................................ ..................................... 73 Appendix 3:List of Tables ........................................ ........................................ ........................................ .... 75 Appendix 4:List of 76 Chapter 1: Overview Page 1 Chapter 1: Overview Thank you for choosing a unit manufactured by AIRSYS REFRIGERATION ENGINEERING TECHNOLOGY (BEIJING) CO., LTD. The AIRSYS line of wall mounted HVAC systems is optimized for energy efficiency. These systems are uniquely designed for the efficient removal of heat generated by electronics from enclosed shelters. The supply air of the AIRSYS system is delivered from the bottom of the machine and the exhaust is at the top, the opposite of a traditional HVAC system. This bottom throw is designed to take full advantage of the fact that hotter air rises. With the exhaust located higher within the shelter, every rotation of the fan removes more heat. The cooler air supplied at the bottom accelerates this natural process. This is just one of many design features that makes the AIRSYS HVAC systems among the most energy efficient in the world. Another feature that promotes energy efficiency is the robustly designed integrated economizer, described as free cooling . This feature combines with the powerful controller to provide 100% cooling capacity of the wall pack unit (WPU), consuming ~ 1kW or less whenever the outdoor temperature is a few degrees lower than a predetermined set point. This feature alone can save telecom operators significant utility cost, especially in cool weather climates. Along with the energy efficiency, these systems are simple to operate, maintain, and service. The AIRSYS design team is committed to listening and responding to the customer community. As a result, these systems have continuously evolved with customer-defined features that have improved the overall quality and the user experience. Usability features include: A functional step test that facilitates complete operational verification in less than 5 minutes Simple unobstructed access to all key components for Preventive Maintenance (PM) and servicing No need to define compressor orientation as the units can be easily serviced with as little as an 8 inch clearance on either side A high level of redundancy in the precision lead/lag controller to enhance reliability Completely selectable alarm relays (NC or NO) to enable the system to adapt to the customer s requirements The AIRSYS WPUs are available in cooling capacities from ton through ton; however, the sensible cooling capacity of these machines is as much as 40% higher than a traditional machine. An available ordering guide helps to properly match the capacity of the HVAC system to the heat load in the shelter. Heating elements can also be included per customer requirements in a range from kW through kW. With a suite of best in class components from around the globe, the AIRSYS WPU delivers quality and reliability while substantially reducing cost of operation. Chapter 1: Overview Using this Manual Page 2 Using this Manual Before attempting to install or start the unit, you should read this manual carefully. Retain this manual for reference for the entire operational life of the unit. This manual provides information on the following general topics: Product overview System installation including preparation, physical and electrical installation of WPUs and the controller box, and commissioning the system System operation, including system alarms, program menus, and advanced troubleshooting Preventive maintenance Documentation Conventions For safety and to achieve the highest levels of performance, always follow the warnings and cautions in this manual when handling and operating the AIRSYS unit. Danger. Emphasizes hazardous conditions that could cause personal injury or death. Warning. Indicates where the operator must proceed with caution to avoid personal injury or damage to property. Important. Indicates technical information critical for proper installation or operation. Table 1 lists symbols and their meaning that may appear on the external packaging. Table 1: Packaging Symbols Symbol Meaning Symbol Meaning THIS SIDE UP Shows the orientation of the unit. NO HOOKS Do not use hooks to lift the packed unit. FRAGILE Handle with care. KEEP AWAY FROM HEAT The unit must be kept away from heat sources. PROTECTAGAINST RAIN: The packaged unit must be stored in a dry place. DO NOT STACK Chapter 1: Overview Using this Manual Page 3 Model Identification Each unit is identified by a model number, such as The elements in the number are explained in Table 2. Table 2: Model Number Nomenclature 1M-OD2133E14C35D6R4107230/1 s eri es name: M-OD = MOBILECOOL-OUTDOOR Packaged ai r condi ti oner wi th fres h ai r free cool i t nomi nal total cool i ng capaci ty i n kWCompres s or type & number: E1 = Hermeti c s crol l compres s or qty 1; R1= Rotary compres s or qty 1Cabi net s i ze code: There are 4 cabi net s i zes : C1, C2, C3 & confi gurati on: D = Uni t i s des i gned to operate i n a Dual control envi ronment (aka Lead/Lag operati on)Refri gerant: R410 = source: Voltage/Phase/Frequency; 230V/1 /60Hz, 230V/3 /60Hz, 460V/3 y Fan confi gurati on: DC = DC EC fan; AC = AC EC fan. (EC = El ectroni cal l y commutated vari abl e s peed fan)Speci al code: Uti l i zed to des i gnate uni t cus tomi zati on (non-s tandard confi gurati on)135724689Chapter 1: Overview Using this Manual Page 4 Acronyms and Abbreviations Table 3 lists acronyms and abbreviations used in this manual. Table 3: Acronyms and Abbreviations Term Meaning AIRSYS AIRSYS Refrigeration Engineering Technology (Beijing) Co., Ltd AAST AIRSYS Authorized Service Technician Amp Ampere, unit of electric current, or rate of flow of electricity AUT/MAN Automatic/Manual BMS Building Monitoring System CFM Cubic Feet per Minute Com Common Comp Compressor Cond Condenser DC Direct Current Gen Run Generator Run Signal EC Electronically Commutated (Referes to variable speed evaporator/supply fan) Evap Evaporator FC Free Cooling HVAC Heating, Ventilation, and Air Conditioning Humid Humidity I/O Input/Output IPU Indoor Packaged Unit kW Kilowatt LED Light Emitting Diode MC Mechanical Cooling Normally Closed Normally Open pLAN PCO controller Local Area Network PLD Programmable LED Display PSI Pounds per Square Inch PWM Pulse Width Modulation R Read Only RoHS Restriction of Hazardous Substances Directive R/W Read/Write Temp Temperature VAC Voltage in Alternating Current VDC Voltage in Direct Current WPU Wall Packaged Unit Chapter 1: Overview Product Overview Page 5 Product Overview Unit Operation The air conditioning system has three key components: 1. The free cooling system 2. The mechanical cooling system 3. The control system The control system determines the unit s mode of operation: free or mechanical, as shown in Figure 1. Figure 1: Basic Operating Modes Free Cooling System When the operating conditions for free cooling are met, the control system switches the air damper to the free cooling position. Cooler air from outside is delivered to the shelter by the supply air fan. At the same time, hot air in the shelter is discharged to the outdoor environment. Mechanical Cooling System When the operating conditions for mechanical cooling are met, the control system switches the air damper to the mechanical cooling position. The compressor compresses the refrigerant gas and sends it to the condenser. The condenser is a heat exchanger, removing heat from the hot compressed gas and allowing it to condense into a liquid. The liquid refrigerant is then routed to the thermal expansion valve, which acts as a restriction device by forcing the refrigerant to go through a small hole. This causes the pressure to drop. Then the liquid refrigerant is routed to the evaporator. The evaporator is also a heat exchanger, absorbing heat from the indoor hot air causing the liquid refrigerant to change back into gas. The refrigerant gas is then routed back to the compressor to complete the cycle. Free Cooling Mode Mechanical Cooling Mode Chapter 1: Overview Product Overview Page 6 The refrigerant is used over and over again, absorbing heat from the indoor environment and discharging the condenser heat to the outdoor environment. The Control System (Controller Box) The AIRSYS controller box is designed to operate a fully or partially redundant air conditioning system for equipment shelters or enclosures. Two variations of the AIRSYS Lead Lag Controller are available: & is standard for HVAC equipped with an AC EC evaporator fan. is standard for HVAC equipped with a DC EC evaporator fan. The controller box is factory programmed with standard industry set points but can be configured on-site to meet specific needs. Settings are retained indefinitely in the event of a power loss. Ease of Control and Configuration The controller box has a convenient Programmable LED Display (PLD). The PLD and button actions are explained in more detail in Chapter 3 starting on page 48. This three-button PLD is the user interface by which an operator can do the following: Check current status of the HVAC system, such as sensor readings and operating mode Change factory set points Place the system temporarily into comfort mode Review alarms and alarm history Labeling on the outside of the controller box provides a convenient guide on how to access the most common functions. Many of these same functions can be accessed remotely via an RS485 communication interface built into the controller. Lead and Lag Roles When mechanical cooling (MC) is required to maintain site temperature, only one unit is called upon to provide the cooling. The unit that has this primary role during MC is referred to as the lead unit. The unit functioning in a backup role during periods of MC is referred to as the lag unit. After a set period of time, the lead and lag units switch roles. This scheduled change of roles ensures an extended and balanced operational life for each unit. The factory default for the scheduled switch of roles is 168 hours (seven days); however, this can be adjusted using the PLD (1 to 999 hours). The lag unit will provide MC if the lead unit is unable to maintain site temperature on its own. This MC assistance will occur if the heat load at the site is higher than the cooling capacity of a single WPU or if the system in the lead role is functioning at a reduced capacity. A system in this state should be serviced as soon as possible. During periods of free cooling (FC), both the lead and the lag units work together. This ensures longer periods of FC which minimizes compressor run time. This design extends the life of the system and reduces energy consumption. Chapter 2: Installation Installation Preparation Page 7 Chapter 2: Installation Installation Preparation Unpack the unit carefully. A number of parts are packed loosely and will be free moving as the packaging is opened. Before discarding the box, check the packaging carefully for any parts or documents inside. Refer to Table 4 on page 9 for the complete list of material shipped with each unit. Check that: The supply voltage meets the requirements as designated: AC part: 230 VAC 15%; (DC Supply fan only) DC part: 36VDC~57VDC. The shelter to be conditioned is clean on the inside, and free of excess dirt and dust. A minimum clearance of 61 cm (24 ) between supply air and any equipment/rack or other obstruction is recommended since any interference with the airflow will adversely affect the efficiency of the machine. Also verify that you have all of the items that the installer must provide, listed in Table 5 on page 10. Installation and startup must be performed by an AIRSYS Authorized Service Technician (AAST). For more information about the AAST program, please contact: Tempest Telecom Solutions w. ph. 805-879-5432 e. 136 W. Canon Perdido Street, Suite 100 Santa Barbara CA 93101 Danger. All the installation work must be done by a skilled professional. Installation that does not comply with the instructions herein can result in the loss of warranty coverage. AIRSYS shall not be held liable for any damage caused to persons or objects due to incorrect installation or incorrect operational use of the units. Warning. All the wiring installation must comply with the local compulsory safety standards and building codes under all circumstances. Warning. Outdoor use. Risk of electric shock can cause injury or death: disconnect all remote electric power supplies before servicing When no longer in use, disposal of equipment and materials must be compliant with the local relevant laws and standards. Delivery When your units are delivered, be sure to inspect them to verify that they have not been damaged during transport. Also verify that all requested accessories listed on the purchase order have been included. Chapter 2: Installation Installation Preparation Page 8 Important. If packages show any signs of shipping damage or potential shipping damage, it is very important to annotate shipping damage on the Bill of Lading prior to signing for the freight. In order to recover for any damage, please take detailed photographs of all the packaging before the external packaging is removed. Once detailed photos of the external packaging have been taken, then the external packaging may be removed so the items can be inspected further. Please document with photos any damage to the equipment that relates directly to the damage observed to the external packaging. Without the detailed photos, it will be very difficult to recover equipment loss. Warranty The warranty duration is 12 months from the date of installation. AIRSYS warrants that its products will be free from defects in materials and workmanship for a period of 12 months after installation. The compressor is to be free from defect in material or workmanship for a period of 60 months from date of installation. Important. For sites equipped with a generator, when the generator switches to the primary source of power, the instantaneous voltage may become lower. At this time, the compressor may run at a lower voltage which may decrease the compressor s working life. Make sure the wiring of Gen-Run signal input is connected which can protect the compressor. The warranty does not cover damage to the compressor caused by repetitive out of specification condition of the supply voltage during compressor operation. AIRSYS will furnish free of charge replacement parts for any component failures that occur within the warranty period. Customer is responsible for the cost of shipment of replacement material from the US distributor, Tempest Telecom Solutions LLC. Note: Warranty assumes that an AAST performs the installation and submits the warranty registration card that accompanied the units in shipment. If the warranty registration card was not filled out and returned to the supplier, then the warranty will be assumed to expire 12 months from the date of shipment for all components except the compressor, which will be assumed to expire 60 months from date of shipment. This warranty does not cover damage to the systems caused by misuse or abuse of the systems such as physical damage due to mishandling. The warranty does not cover damage caused by force majeure. Important. Any mishandling of the equipment or modifications to the equipment, unless agreed upon in writing by AIRSYS, will void the warranty. Moving the Unit Forklifts are recommended for moving, loading, unloading, and positioning the WPU for installation. If bands or ropes are used to create a sling, make sure that excessive force is not applied to the upper edges of the machines or the package to avoid cosmetic or material damage. When using spacing bars, protective materials are required around the units to prevent damage. To avoid damage to the units while moving or transporting, ensure the units always remain in the upright position. General Safety Rules Danger. Do not carry out any operation on the machines if you do not have sufficient knowledge of the operating principles and have not taken all the precautions that permit the system to operate in safe conditions. Chapter 2: Installation Required Materials Page 9 Warning. Work on the electric board only after verifying prime power is disconnected. Do not apply power to the machine with the covers removed. Important. Before carrying out inspections, maintenance operations, and safety checks, follow all accident-prevention standards such as wearing goggles, gloves, and an appropriate uniform. Required Materials AIRSYS Supplied Materials Table 4 lists all the material supplied by AIRSYS. After opening the package, verify that all items are accounted for. If any material is missing, please contact an AIRSYS distribution center using the following information: Tempest Telecom Solutions, LLC Web: Email: Phone: 805-879-5432 Table 4: Material Supplied by AIRSYS Item Model # or Part # Qty Item Description Comments Wall Pack Unit Assembly: Two per Shelter 1 Example: 1 Wall pack unit refer to Table 2: Model Number Nomenclature 2 2030104200 1 Return air grill Only included for models 3/5R1C1 2030104190 1 Supply air grill 2 8255504110 1 Return air grill Only included for models 7/9E1C2 8255504120 1 Supply air grill 2 8255503240 1 Return air grill Only included for models 13E1C3 8255503230 1 Supply air grill 2 8255504090 1 Return air grill Only included for models 18E1C4 8255504100 1 Supply air grill 3 8553703300 24 Self-tapping screw *25 For the supply and return air grill installation Controller Box Assembly: One per Shelter 4 2040303110 or 2040307640 1 Controller box Model: or 5 9000000357 1 Indoor temperature sensor One end connected inside the controller box 6 9000000357 1 Backup Indoor temperature sensor One end connected inside the controller box 7 9000000357 1 Outdoor temperature sensor One end connected inside the controller box 8 8454020720 1 Humidity sensor One end connected inside the controller box 9 8458716820 1 Sensor box For housing outdoor temperature sensor and mounting on outside wall 10 1170104040 1 Installation and Operation Manual 11 1110212510 1 Registration card Must be returned according to instructions on page 39 Chapter 2: Installation Required Materials Page 10 Item Model # or Part # Qty Item Description Comments 12 1110212560 2 Compressor removing bracket sticker To remind the service technician to remove the compressor bracket before turning on the HVAC unit. 13 9000000357 2 Supply air temperature sensor 14 8458716650 4 Temp sensor hold connector 15 1050500720 2 Right angle supply air temp sensor mounting bracket Installer Supplied Material Table 5 lists items required for installation that must be supplied by an AIRSYS Authorized Service Technician (AAST). The wire length and gauge depends on site-specific conditions. However, recommendations are provided. Table 5: Materials Supplied by the Installer No. Item Qty Description Comments 1 AC power supply cable to two WPUs 2 2 cables for two WPUs, AC part (compressor & heater) Refer to Summary Electrical Ratings 2 DC power supply cable to two WPUs (If the HVAC is equipped with DC EC supply fan ) 2 2 sets of three wire cable for two WPUs DC part (supply fan). Refer to Summary Electrical Ratings 3 DC power supply cable to controller box 1 A set of two-wire cable for WPU controller box Max current capacity Amps; 18 gauge recommended 4 Control harness from controller box to WPU 2 Control harnesses with 13 wires from controller box to each WPU Terminals recommended but not required. 18 gauge recommended 5 Alarm wiring harness 5 1 cable with 2 wires, length as needed Alarm connection to controller box, 3 alarm inputs and 4 alarm outputs; all alarm connections are optional 6 Supply air frame 2 Refer to Figure 23: Frame Dimensions on page 73 for size details for each model Built inside wall to facilitate air flow 7 Return air frame 2 Refer to Figure 23: Frame Dimensions on page 73 for size details for each model Built inside wall to facilitate air flow 8 Adhesive tape A/R With single-sided adhesive Used to line the return and supply air frames 9 Silicone sealant A/R Commercial grade outdoor silicone sealant 10 Weather stripping A/R Commercial grade neoprene weather stripping or equivalent Recommend a minimum of 25 mm (~1 ) wide and 20 mm (~ ) thick Used to frame the WPU outlet and inlet to create a weather tight seal 11 Terminals 52 Recommended for ease of terminal block installation; however, not required 12 Crimping pliers A/R Only needed when using terminals 13 Nylon zip-tie 1 Small nylon zip tie For properly dressing cables and harnesses Chapter 2: Installation Required Materials Page 11 No. Item Qty Description Comments 14 Breakers for AC power panel 3 One 10 amp circuit breaker for ; One circuit breakers each for the two WPUs AC part, amperage based on model number Refer to Table 6: WPU Electrical Ratings on page 11 15 Breakers for DC power panel (only if is chosen and the HVAC is equipped with DC EC supply fan) 3 One 10 amp circuit breaker for ; One circuit breaker each for two WPUs DC part, amperage based on model number Refer to Table 6: WPU Electrical Ratings on page 11 Summary Electrical Ratings (Wire Sizing) Table 6: WPU Electrical Ratings ELECT. HEAT KW 5 KW AC 48VDC AC 48VDC AC 48VDC Model MCA MFS MCA MFS MCA MFS MCA MFS MCA MFS MCA MFS AC Supply Fan, Single Phase AC Power Supply M-OD 10 15 -- -- 15 20 -- -- -- -- -- -- 11 15 -- -- 15 20 -- -- -- -- -- -- -- -- -- -- 17 25 -- -- 31 35 -- -- -- -- -- -- -- -- -- -- 31 35 -- -- -- -- -- -- -- -- -- -- 32 40 -- -- -- -- -- -- -- -- -- -- 37 55 -- -- DC Supply Fan, Single Phase AC Power Supply M-OD -- -- -- -- 18 30 7 10 28 35 7 10 -- -- -- -- -- -- -- -- 28 40 14 20 DC Supply Fan, Three Phase AC Power Supply M-OD -- -- -- -- -- -- -- -- 17 25 14 20 Note: This chart should be used as a general guideline for estimating the conductor size and over-current protection. Always refer to the data label on the unit for sizing the conductors and over-current protection. MCA = Minimum Circuit Ampacity (Wire Size Amps). MFS = Maximum Fuse Size or HACR circuit breaker. Chapter 2: Installation Physical Installation Page 12 Physical Installation To assist in the installation process, the following figure and table provide the schematic dimensions of the units using a dimensional tolerance of 1/16 (2 mm). Table 7: External Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal) Cabinet Size C1 C2 C3 C4 Unit of measurement mm in mm in mm in mm in Width (W) 700 1010 1160 1360 Depth (D) 620 700 700 700 Height (H) 1930 2130 2130 2130 Supply A 200 268 268 268 B 450 708 759 880 Return C 300 356 356 356 B 450 708 759 880 E 1000 1104 1104 1104 F 133 101 101 101 G 660 970 1120 1320 I 350 400 400 400 J 226 178 178 178 K 101 101 101 101 L 87 87 112 112 M 80 80 80 80 N 1800 1999 1999 1999 O 1815 2017 2017 2017 Chapter 2: Installation Physical Installation Page 13 Select the Wall for Installing the Unit Select the wall where the unit will be installed. Be certain that the wall can support the weight of the unit and that sufficient space is available for easy operation and installation, both inside and outside the mounting location. Refer to Table 7 on page 12 and Table 8 below for dimensions and weights by model number. Leave at least: 1200mm ( ) free space in front of the unit 400mm ( ) free space at the side of the unit (minimum of 205 mm (8 ) If any protrusions will hang over the unit covering any portion of the exhaust fans, you must leave a minimum of 1000mm ( ) free space above the unit. Figure 2: Working Space Table 8: Dimensions and Weight by model number 1 Ton Ton 2 Ton Ton Ton 5 Ton Model 3R1C1 5R1C1 7E1C2 9E1C2 13E1C3 18E1C4 Dimensions & Weight Width in Depth in Height in Weight lbs 355 370 515 530 615/635* 712 * Ton (13E1C3) AC WPU = 615 lbs / Ton (13E1C3) AC WPU = 635 lbs Important. The wall selected for the unit must be strong enough to support both the static weight of the unit and the vibration of a unit under operation. Allow spacing as noted if any physical structure will significantly reduce air flow. Minor obstructions, such as a chain linked fence, will not impact the HVAC system. Chapter 2: Installation Physical Installation Page 14 Make Openings and Holes Make openings for supply and return air and cable and bolt holes in the installation wall as shown in Figure 3 and Figure 4; refer to Table 7 on page 12 for dimensions. Figure 3: Left Side View Figure 4: Openings and Holes in the Wall Note: You may use template printed on the shipping carton to create wall cuts. Chapter 2: Installation Physical Installation Page 15 Install Weather Stripping Before mounting the unit on the outside wall, fix the neoprene weather stripping (installer provided) around the openings of the air supply and the air return to ensure an airtight closure, as shown in Figure 5. Figure 5: Install Weather Stripping Position the Unit Important. The unit is heavy. Exercise caution while putting the unit in place to prevent damage to the WPU or personnel. The unit must be installed in a level position. An inclination of more than 6-7 mm ( 1 ) could cause the condensation tray to overflow (refer to Figure 6). Figure 6: Inclination of Mounted WPU Weather stripping (Table 5, item 5) Weather stripping (Table 5, item 5) Chapter 2: Installation Physical Installation Page 16 Lift the unit from below with lifting equipment or tools, and then move the unit to the wall. Use the screws (installer supplied) to affix the unit on the wall. Generally this is done by following these steps: 1. Position the unit next to the wall using a forklift or leveling system. Figure 7: Position the Unit 2. Attach a single mounting screw and adjust to ensure the unit is level. Figure 8: Verify the Unit is Level 3. After the unit is level, attach the remaining mounting screws (a quantity of 10 total for each WPU). Remove Wooden Pallet from WPU The WPU is bolted to a wooden pallet to facilitate safe lifting and transport of the unit. Four bolts attach the pallet to the unit, as show in Figure 9. The pallet frame is recessed under the WPU to allow for easy installation while using a forklift. Before completing the mounting of the unit to the wall, remove the pallet by removing the four bolts. Figure 9: Remove Wooden Pallet Use either a level system or a forklift to position the unit. Remove the 4 bolts under the unit to remove the pallet Chapter 2: Installation Physical Installation Page 17 Seal the Joints between WPUs and Wall In order to prevent moisture from getting in and air leaking out, coat the joint between the rear panel of the unit and the wall with a layer of silicone sealant (installer provided, see Table 5, item 9) as shown in Figure 10. Figure 10: Seal the Joints between WPUs and Wall Attach the Supply Air Grill and the Return Air Grill to the Wall The supply air grill and the return air grill should be installed at the holes inside the shelter as shown in Figure 11. Figure 11: Install the Supply and Return Air Grills Silicone Sealant Silicone Sealant Silicone Sealant Chapter 2: Installation Physical Installation Page 18 Note the following: 1. Install the supply and return air frames into their respective cutouts. 2. Use an adhesive tape to tape down the edges of the return and supply air frames on the WPU side. 3. After installing the supply air grill, adjust the angle of the fins to direct airflow away from adjacent equipment and prevent bounce-back of supply air. Adjust the fins first up and down; then, left and right. Refer to Figure 23: Frame Dimensions on page 73 and Table 31 on page 74 for each model. Remove the Compressor Brackets Open the front, bottom panel on the WPU to locate the compressor. The two brackets at the base of the compressor are required for transport only. Loosen the four bolts, remove the two brackets, and then tighten the four bolts back down to the base of the compressor. Figure 12: Remove Compressor Brackets Tin-coated paper (Table 5) Return air frame and supply air frame (Table 5) Return air grill (Table 4) Supply air grill (Table 4) Remove the two brackets; then refasten the bolts Remove the two brackets; then refasten the bolts Chapter 2: Installation Controller Box Installation Page 19 Controller Box Installation Find a suitable location inside the shelter between the two WPUs to mount the controller box. Mount the controller box so that the PLD is near eye level of the intented operator. Figure 13: Controller Box Dimensions Table 9: Key Components in the Controller Box Assembly Mounting controller for PLD to be at eye level Indoor temp sensor Outdoor temp sensor Humidity sensor PLD Cable Backup indoor temp sensor Supply air temp sensor Chapter 2: Installation Controller Box Installation Page 20 Figure 14: System Block Diagram illustrates the basic arrangement of two WPUs and the controller box. Note: The power feed to all three components should be in parallel. Each unit should have a unique breaker/fuse connection to the main power service. WPU with AC Supply Fan WPU with DC Supply Fan Figure 14: System Block Diagram Backup Indoor Temperature Sensor Indoor Temp Sensor Humidity Sensor Power supply *Refer to the unit nameplate Power Supply *Refer to the unit nameplate Power Supply *Refer to the unit nameplate Chapter 2: Installation Controller Box Installation Page 21 Figure 15: System Schematic Diagram Install Outdoor Temperature Sensor The outdoor temperature sensor that is connected to the controller box must be installed outside the shelter. Use the following steps to complete this task. 1. Select the wall where the WPU is mounted. Power Supply *Refer to the unit nameplate Power Supply *Refer to the unit nameplate Chapter 2: Installation Controller Box Installation Page 22 2. Drill a inch diameter hole for the outdoor temperature sensor through the shelter wall. 3. Open the controller box assembly and locate the outdoor temperature sensor (ST2) assembly. 4. Thread the outdoor temperature sensor through the right-hand port at the bottom of the controller box. 5. Punch out all holes on the bottom and both sides of the white sensor box to allow for proper airflow and drainage. 6. Thread the outdoor temperature sensor from the controller box through the hole in the bottom of the box. 7. Secure the sensor to the bottom of the box with a nylon zip-tie. 8. Secure the box to the outside wall. Snap the sensor box cover in place and use sealant along the seam between the box and the wall. Outdoor Temperature Sensor (ST2) Chapter 2: Installation Controller Box Installation Page 23 Figure 16 illustrates the relationship of the sensor to the installed WPUs Figure 16: Location of Outdoor Temperature Sensor Note: punching out the holes on the sides and the bottom of the sensor box is critical to allow proper airflow and to facilitate drainage from rain and dew. Important. Ensure no air leakage exists from inside the shelter to the box housing the outdoor temperature sensor. Any path whereby air could exit the shelter and arrive in the sensor box will adversely affect the outdoor temperature sensor reading. The hole in the shelter wall where the outdoor temperature sensor has passed through must be 100% sealed so no air can leak out of the shelter. Figure 17: Ensure No Leakage Controller Box (Inside Shelter) Indoor Temp Sensor Humidity Sensor Backup Indoor Temperature Sensor Chapter 2: Installation Controller Box Installation Page 24 Position the Humidity Sensor Follow these steps to install the humidity sensor that is connected to the controller box: 1. Open the controller box assembly and locate the humidity sensor (SH) assembly. 2. Remove the cover of the humidity sensor, and then unfasten the harness from the sensor. 3. Thread the harness through the hole at the bottom or top of the controller box and reattach the sensor and then the cover. Note: If further shipping is required after mounting the controller, secure the humidity sensor under the controller box with tape to protect the sensor from vibration). Position Indoor Temperature Sensors and Supply Air Temperature Sensors An indoor temperature sensor is located at the bottom of the controller box and a backup temperature sensor at the top of the controller box. The sensor monitors the shelter temperature to control the WPU operation. Slide the sensor through the port on the bottom left side of the controller box. Tighten the port cover to hold the sensor cable in place. Follow the same steps to position the backup sensor at the top of the box. Figure 18: Position Indoor Temperature Sensor Chapter 2: Installation Controller Box Installation Page 25 The supply air temperature sensors should be installed at the middle-front of the supply air grill as shown in Figure 19. Figure 19: Position Supply Air Temperature Sensors Two screws should be used for fixing the supply air temperature sensor mounting hardware. Supply air temperature sensor location Chapter 2: Installation Complete Electrical Connections Page 26 Complete Electrical Connections Cautions Danger. Only an authorized service technician should make the electrical connections to the WPUs and the controller box. Important. The electrical wiring of the unit must be in compliance with IEC standards or with appropriate national standards. Danger. The power supply must be disconnected or turned off before working on the unit. Important. Noncompliance with these instructions may cause damage to the WPU or the controller box. Not following instructions can void the warranty. Important. No modification to the unit s electric circuit is allowed. If a change is required, it must be authorized by AIRSYS in writing. Overview of Wiring Figure 20 illustrates the wiring terminals in the control box. Each unit has an identical set of terminals. The terminal numbers for HVAC #2 are distinguished with a single quote ( ) after the number. Figure 20: Field Wiring Terminals 2 Control Harnesses 13 wires from controller box to each WPU Chapter 2: Installation Complete Electrical Connections Page 27 Table 10: Alarm Connections Alarm Name Alarm Type (Input/Output) Severity Default (NC or NO) Adjustability (S=software via PLD) (HW= Hard wired) Connections To Related Alarm codes: Comments Form C Contact Alarm INPUTS Fire/Smoke alarm Input Critical NC S --> parameter SFt 41 and 5 A05 Only Remove factory jumper prior to connecting alarm input Generator Run Input None NO S --> parameter DGT 42 and 5 A28 Only Connected to Gen-Run signal from Automatic Transfer Switch or generator Prime Power Outage Input Major NO NA 60 and 5 A09 Only Only when using DC Fail-Over Box: Form C Contact Alarm OUTPUTS High/low temperature alarm Output Critical NC S --> parameter HTT 43 and 44 A07 Can connect in series for NC or in parallel (NO) with analog High/low Temp thermostats in many sites. HVAC1 alarms Output Major NO HW 45 and 46 A02, A03, A10, A29, A31 Indicates Mechanical Cooling disabled until problem addressed on site NC 46 and 47 HVAC2 alarms Output Major NO HW 48 and 49 A04, A06, A11, A30, A32 Indicates Mechanical Cooling disabled until problem addressed on site NC 50 and 49 Two compressor run Output Minor NC S parameter 2CT 51 and 52 A23 Indicates compressors running in both Lead & Lag WPUs simultaneously Alarm Input/Output detail Inputs: 1. Smoke/Fire Alarm: When the Smoke/Fire alarm is active all fans will shut down and the dampers will close. This is to prevent air circulation and minimize the spread of fire. 2. Generator Run Signal: When the generator signal is active, the outside air dampers will close and only one HVAC system will be allowed to engage in Mechanical Cooling. The dampers close to prevent the free cooling function from potentially pulling diesel fumes into the shelter. The second HVAC system is prevented from engaging in mechanical cooling to reduce power consumption while generator is running. 3. Prime Power Outage: This signal is ONLY relevant when a DC Fail-over box ( ) is part of the configuration. This signal comes from the DC fail-over system and wires directly into the controller. When this signal is received, the system will go into a low power, Supply Fan-only mode. If cool enough outside, the system will continue to cool the site with outside air. Outputs: 1. Temp Alarm: Factory set to trigger 18 F above set point (77 + 18 = 95 F) OR 32 F below set point. Set point (StP) can be changed via the PLD user interface 2. HVAC 1/2 Alarm: Indicates WPU Mechanical Cooling will not come on without an on-site service visit. Acknowledging the alarm via the pLD will clear the lockout condition. Reset the breaker to the controller will also clear the lockout condition. 3. Second Compressor Run Alarm: Triggers whenever both the Lead & Lag units are engaged in Mechanical cooling, Chapter 2: Installation Complete Electrical Connections Page 28 Table 11: Control harness terminal identification of AC power part Terminal 1 MC, compressor The voltage between terminal 1 & terminal 4 is 240Vac Terminal 2 MF2, supply fan The voltage between terminal 2 & terminal 4 is 240Vac Terminal 3 EH1-3, electrical heater The voltage between terminal 3 & terminal 4 is 240Vac Terminal 4 L, L of line voltage Line voltage Alarm part Terminal 5 Common terminal Common terminals for alarms Terminal 6 LP, low pressure switch Between terminal 6 & terminal 5 is NC Terminal 7 HP, high pressure switch Between terminal 7 & terminal 5 is NC Terminal 8 PF, air pressure differential switch Between terminal 8 & terminal 5 is NC Terminal 9 MF2, output the operating status of supply fan to controller Internal overload protection, it is NC. DC power part Terminal 10 YE, input signal to air damper actuator The signal voltage for damper actuator, 0~10Vdc Terminal 11 MF2, input signal to supply fan The signal voltage for supply fan, 0~10Vdc Terminal 12 DC Ground Reference For DC power supply and signal voltage Terminal 13 24 Vdc Power supply for Damper actuator, the voltage between terminal 12 & terminal 13 is 24Vdc. Table 12: Control harness terminal identification of 48 VDC power part Terminal 1 MC, compressor The voltage between terminal 1 & terminal 12 is 48Vdc Terminal 2 HVAC prime power power alarm Between terminal 2 & terminal 12 is NC Terminal 3 EH1-3, electric heater The voltage between terminal 3 & terminal 12 is 48Vdc Terminal 4 None Alarm part Terminal 5 Common terminal Common terminals for alarms Terminal 6 LP, low pressure switch Between terminal 6 & terminal 5 is NC Terminal 7 HP, high pressure switch Between terminal 7 & terminal 5 is NC Terminal 8 PF1, air pressure differential switch Between terminal 8 & terminal 5 is NC Terminal 9 PF2 or PF2&3, output the operating status of supply fans to controller Between terminal 9 & terminal 5 is NC (The system which installed two DC fans need PF2 &PF3) 24 VDC power part Terminal 10 YE, input signal to air damper actuator The signal voltage for damper actuator, 0~10Vdc Terminal 11 MF2, input signal to supply fan The signal voltage for supply fan, 0~10Vdc Terminal 12 Ground Power supply for Damper actuator Terminal 13 24 VDC Power supply for Damper actuator, the voltage between terminal 12 & terminal 13 is 24Vdc. Refer to Figure 15: System Schematic Diagram on page 21. Chapter 2: Installation Complete Electrical Connections Page 29 Electrical Connection to Controller Box Follow these steps to complete the connections: 1. Open the controller box. 2. Ensure the PLD cable is FIRMLY plugged into the user interface terminal located on the inside of the controller box cover. 3. Ensure the other side of the PLD cable is FIRMLY plugged into the HVAC1 controller board terminal J7 as shown below. 4. Connect the WPU 1 control harness in the controller box. When this is complete, do the same for the WPU 2 control harness. Refer to Fig 15. System Schematic Diagram on page 21. Chapter 2: Installation Complete Electrical Connections Page 30 5. Connect the power cable from power plant to the controller box as shown below. Electrical Connection to WPUs Depending on which controller you are installing, either two or three wire harnesses are passed through the shelter wall into the WPUs: Control harness Prime power 48VDC power - ONLY if is installed and the HVAC is equipped with DC EC supply fan 1. There are two options for bringing the control harness and the power cables into the WPU. a. Make the connections from side panel. Connect the 48VDC power Connect the prime power (L1&L2, 230Vac) Righthand wiring holes (when looking at installed units from inside the shelter) Lefthand wiring holes (when looking at installed units from inside the shelter) 3 wiring holes Important. Ensure the wiring harnesses are dressed inside the machine in such a way that they will not interfere with the movement of the air damper. Lefthand wiring holes (when looking at installed units from inside the shelter) Chapter 2: Installation Complete Electrical Connections Page 31 b. Make the connection from the back panel From: here routing through mid-plate To here. Or here here Chapter 2: Installation Complete Electrical Connections Page 32 2. Bring the control harness (item 4 in Table 5 on page 10) from the controller box to the WPU by passing it through the hole in the shelter. Make the thirteen wire connections inside the WPU. 3. Connect the power cables from the power plant to each WPU. Note: If the is chosen and the HVAC is equipped with DC EC supply fan, connect the power cables as shown in the picture below. the connections. Control harness connections in the WPU Prime power connections to WPU 48VDC power connections to WPU Prime power connections to WPU Chapter 2: Installation Complete the Installation Checklist Page 33 Complete the Installation Checklist You should now have completed all of the physical installation steps. Prior to starting the system, ensure that no steps have been omitted by completing this installation and wiring checklist. Date: _____________________ Unit Factory Number:_______________________(refer to the unit name plate) Verify Physical Installation or Weather stripping has been attached to the air inlet and outlet of the WPU at the room side. The entire machine is fastened. All the leaks are sealed with gel. The indoor temperature sensor, backup indoor temperature sensor, and humidity sensor have been mounted around the controller box inside the shelter. The aluminum grills are fastened. The brackets at the bottom of the compressor have been removed and the screws refastened. The outdoor temperature sensor is inside the sensor box and mounted outside the shelter. Sensor box drain holes are facing downward and the through hole in the shelter wall has been sealed. Verify Electrical Installation A one-to-one correspondence exists between the 1 to 13 connections from WPU to controller box. The 1 to 13 connections are secured. The main voltage connections between each WPU and the prime power panel are secured. The power connections between the controller box and power plant panel are secured. Proper clearance is allowed between the cables and air damper in the WPU to avoid interference. Chapter 2: Installation Verify System Operation Page 34 Verify System Operation A complete system operation verification is vital to ensure all components are operating correctly after the installation. A system commissioning checklist is available on page 41. Follow instructions in this section to complete the checklist and leave a copy on site. Turn On Component Breakers After completing the checklist, turn all three breakers to the on position: one in each WPU and one in the controller box. Then reattach all covers and panels before turning on the breakers in the prime power panel. Turn on Primary Power Turn on the primary power breakers at the breaker panel in this order; first the two WPU breakers, then the controller box. Note: The PLD display should light up and after a brief delay will display the inside temperature. If all instructions were followed correctly, you are still likely to get a Prime Power (A09) alarm. This is normal. Press Sel to clear the alarm. Any other alarm should be investigated, with the most common cause being a mistake in the wiring. Note: Use the information in Alarm Descriptions on page 52 to understand the meaning of any alarms. Detailed information on PLD operation and how to understand and respond to alarms is covered in Chapter 3. WPU Breakers breaker Chapter 2: Installation Verify System Operation Page 35 Execute the Step-Test The step-test systematically verifies that key components of the system are operating as expected. Note the following considerations: The steps in the test can be executed in any order; they do not need to be sequential. The test must be completed within 30 minutes. If you cannot complete it in that time, you will need to re-enter the step-test mode. The system will display the main menu (indoor temperature) automatically after ten minutes when there has been no input from the technician. PLD button actions are listed in more detail on page 41. If any alarms are triggered during the test, refer to Alarms on page 50 for details. Warning. Once a compressor has been turned on, it must be allowed to run for at least one minute before the next step to prevent compressor damage. To complete the test, follow these steps: 1. Press Up and Down together to enter the main screen. The screen will display the indoor temperature. If the indoor temperature does not display, press both buttons again and repeat as needed. 2. When the system is on, press and hold Up and Sel together for 3 seconds. The user terminal will display Sft. Press Up until COD displays. When the system is off, press Up and Sel together for 3 seconds and the user terminal will display COD. 3. With COD displayed on screen press Sel to confirm. The screen will display 0. Press Up to select appropriate step (1-8; see Table 13: Step-Test below). Press Sel to confirm selection. The user terminal returns to COD and the component will be engaged. Repeat these steps as needed. 4. When the step-test is complete, return to the main menu and turn the HVAC system on. Table 13: Step-Test Cod Value ACTION WPU #1 WPU #2 NOTES Turns on Supply Fan 1 5 Turns on Heater 2 6 May take a few minutes before you feel warm air Turns on Compressor 3 7 IMPORTANT: Let compressor run for at least one minute before going to next step Opens Fresh Air Damper 4 8 HINT: With the lights off in the shelter, you can see indirect daylight via opening behind exhaust grill Chapter 2: Installation Verify System Operation Page 36 Turn the HVAC System On 1. Press Up and Down together to enter the main screen (current room temperature will be displayed). 2. Press Down or Up until the screen displays OFF. 3. Hold Sel for 3 seconds. The screen will display ON, indicating that the system is turned on. Press Down and Up together again to return to the main screen and display the indoor temperature. Note: When the system is On both the Up and Down LEDs will be lit. When the system is Off both the Up or Down LEDs will be dark. Warning. Never leave the site with the HVAC system in the off state (Up and Down LEDs dark). Your site will have no cooling, which likely will result in a high temperature alarm requiring an urgent site visit to correct. When the HVAC system is on, the PLD will display the current temperature. Press until screen displays OFF Press both buttons together to enter the main screen Press the button for 3 seconds Chapter 2: Installation Verify System Operation Page 37 Set System Time The system time parameters are listed in Table 14. R/W indicates that the code can be viewed and updated. Note: System time is based on a 24 hour clock. Table 14: System Time Parameters Display R/W Description Range N15 R/W Display and set the current time/date hour 0~23 N16 R/W Display and set the current time/date minute 0~59 N17 R/W Display and set the current time/date year 0~99 N18 R/W Display and set the current time/date month 0~12 N19 R/W Display and set the current time/date day 0~31 1. Press Up and Down together to enter the main menu. The screen will display the indoor temperature. If the indoor temperature does not display, press both buttons again and repeat as needed. 2. Press Down until displays. Then press Sel, the user terminal will display STP. 3. Press Down until the screen displays N15; then press Sel to confirm. Set the current hour; then press Sel to confirm. 4. Press Down until the screen displaysN16; then press Sel to confirm. Set the current minute; then press Sel to confirm. 5. Press Down until the screen displays N17; then press Sel to confirm. Set the current year; then press Sel to confirm. 6. Press Down until the screen displays N18; then press Sel to confirm. Set the current month; then press Sel to confirm. 7. Press Down until the screen displays N19; then press Sel to confirm. Set the current day; then press Sel to confirm. 8. Press Up and Down together to return to the main menu. Note: 24 Hour Clock , 15 = 3pm Chapter 2: Installation Verify System Operation Page 38 Verify the sensor readings All the sensors are factory calibrated before shipping. However, it is essential to verify that all sensors are properly connected. 1. Press Up and Down together to return to the default display (indoor temperature)Press Up or Down to scroll through the main menu 2. Press Sel to display reading for Humidity, Outdoor Temp, and Supply Air Temp 3. Scroll to and Press Sel The pLD will display StP (temperature setpoint) 4. Press Down until rt2 (Room temp 2) is displayed, press Sel to display backup temp sensor reading Table 15: ASLLC Main Menu Note: Sensors can be calibrated in the C menu. See section Accessing the C Menu on page 59 for detail. Verify Input and Output Alarms 1. Verify Generator Signal (A28 alarm) Important: Incorrect signal from generator will prevent the 2nd unit from cooling a. From rt2 press Down until D5A is displayed, Press Sel to display generator status b. If the generator is not running or generator signal is not wired, your screen should display OFF c. Press the Sel button to return to D5A 2. Verify Smoke/Fire Alarm Signal (A05 alarm) a. Press the test bottom on the smoke/fire detector. The system should completely shut down (Fans and compressors off, damper closed, A05 alarm code will be displayed). b. The Smoke/fire Alarm is connected to 41 and 5 on the controller terminal. If the smoke/fire detector does not have a test bottom, disconnect the jumper on 41; the system should shut down. Sensor Display R/W Description Comments ST1 R Current indoor temperature; default display Press UP and DOWN together to get to the indoor temp. Press DOWN to access other menus. COF R/W Comfort mode ON/OFF CFT R/W Comfort mode run time SP2 R/W Set comfort mode indoor temperature SH Hu R Indoor Humidity Hint: use the Huff Test ST2 Et R Outdoor temperature ST3 Su R Unit 1 Supply air temperature Important: Wrap hand around supply air sensor to verify unit 1 sensor is mounted on unit 1 and vice versa ST3 SU2 R Unit 2 Supply air temperature Access other menus for viewing and modifying preconfigured system parameters ON R/W System On/Off Chapter 2: Installation Verify System Operation Page 39 3. Verify HVAC Alarm a. HVAC1: Turn off the HVAC1 prime power breaker at panel or unit b. Verify NC terminal 46 and 47 is Open c. HVAC2: Turn off the HVAC2 prime power breaker at panel or unit d. Verify NC terminal 49 and 50 is Open Complete the Registration Card The information on the registration card is critical for establishing the warranty start point. The following pictures show serial number locations for the WPU and control box. These must be recorded on the AIRSYS Product Warranty Registration Card. WPU serial number Control box serial number AIRSYS PRODUCT WARRANTY REGISTRATION CARD PRODUCT INFORMATION Controller Model #: ____________________ Serial #: ____________________ WPU #1 ( left of controller ) Model #: ____________________ Serial #: ____________________ WPU #2 ( right of controller ) Model #: ____________________ Serial #: ____________________ INSTALLATION INFORMATION Site #: ________________________________ Site Name: _________________________________ Street address: _________________________ City: _____________ State: _____________ Zip: _____________ Date Install Completed: ____/_____/_____ Installation Company: ________________________________________ ______ Installer Name: _______________________ Phone #: _______________________ Email: _______________________ OWNERSHIP INFORMATION Company: ________________________________________ _______________ Site Supervisor Name: _______________________ Phone #: _______________________ Email: _______________________ REGISTRATION ONLINE: BY EMAIL: Scan and send By MAIL: AIRSYS Product Registration Tempest Telecom Solutions, LLC, 136 W. Canon Perdido Street, Suite 100 Santa Barbara CA 93101 Chapter 3: System Operation User Interface Introduction Page 44 Chapter 3: System Operation This chapter describes how to use the PLD interface to execute the functions needed during standard operation. In addition, reference information is supplied on all of the factory default settings. This information may be useful during troubleshooting and in conversations with technical support. The following topics are covered: Using the Main Menu to execute basic functions Understanding alarms that may occur and clearing alarm history Additional system diagnostic information User Interface Introduction The units are controlled using a simple interface with an LED display and three buttons. Figure 21: PLD User Interface Button actions are described in Table 16: PLD Button Actions. Table 16: PLD Button Actions Button and LED Function Description Sel Confirm selection or display value. When the LED is on, indicates that an alarm has been triggered. Up Increase value or go back to previous parameter. When flashing (slow flash), there is no Mechanical Cooling on HVAC 1 (aka Lockout) Down Decrease value or go to next paramter. When flashing (slow flash), there is no Mechanical Cooling on HVAC 2. (aka Lockout) + Up + Down Press together to return to the main menu. When both of these buttons are lit, the system is on. When both are dark, the system is off. + Up + Down When both of these buttons are flashing once every second, the system is in comfort mode. or Up or Down When Up and Down buttons are flashing once every 2 seconds and the alarm button is red, this indicates the HVAC1 & HVAC2 are in lockout. This requires manual reset. Note: Power cycling the controller will clear the lockout condition Note: Please check that the system is not in comfort mode (Up and Down button are both flashing every second). Chapter 3: System Operation Navigating the Main Menu Page 45 Navigating the Main Menu Pressing Up and Down at the same time displays the PLD Main Menu. The default display is the current room temperature. Use Up or Down to scroll through the main menu. The order of the options varies depending on whether the HVAC system is currently on or off. Table 17: Main Menu (A) with System Off lists the options on the main menu when the system is off; Table 18: Main Menu (A) with System On lists them when the system is on. Note: Option A-10 () lets an AAST access all of the preconfigured system parameters. Typically, only a few are ever needed during normal operation. These are described here. The remaining menus are described in System Parameters and Default Values starting on page 58. In the table, the following abbreviations are used: Ref Reference number for the code R The parameter can only be viewed, not changed. R/W The parameter can be both viewed and updated. Table 17: Main Menu (A) with System Off Ref Display R/W Description Unit Range Default A-1 R Current indoor temperature; default display F ~ 104 A-2 OFF R/W Turn the system on at the terminal On/Off A-3 COF R/W Comfort mode ON/OFF On/Off Off A-4 CFT R/W Comfort mode run time Hrs 1~9 1 A-5 SP2 R/W Set comfort mode indoor temperature F 100 A-6 Hu R Humidity (Default: indoor) A-7 Et R Outdoor temperature F A-8 Su R Supply air temperature F A-9 SU2 R Supply air temperature 2 F A-10 Access other menus for viewing and modifying preconfigured system parameters Table 18: Main Menu (A) with System On Ref Display R/W Description Unit Range Default A-1 R Current indoor temperature; default display F ~ 104 A-3 COF R/W Comfort mode ON/OFF On/Off Off A-4 CFT R/W Comfort mode run time Hrs 1~9 1 A-5 SP2 R/W Set comfort mode indoor temperature F 100 A-6 Hu R Humidity (Default: indoor) A-7 Et R Outdoor temperature F A-8 Su R Supply air temperature F A-9 Su2 R Supply air temperature 2 F A-10 Access other menus for viewing and modifying preconfigured system parameters A-2 On R/W Turn the system off at the terminal On/Off Chapter 3: System Operation Navigating the Main Menu Page 46 Some of the options on the main menu let you view a sensor measurement (humidity, outdoor temperature, supply air temperature). Press Sel to display the value; press Up and Down together to return to the main menu. Other options let you perform the following actions: Turn the system on and off. Start comfort mode. Set the comfort mode temperature. Access other menus. These options are described in the following sections. Turning the HVAC System On or Off 1. Press Up and Down together to enter the main screen. 2. Press Down or Up until the screen displays either On or Off. On indicates the system has been turned on. 3. If the screen displays OFF, hold Sel for 3 seconds. The screen will display ON, indicating that the system is turned on. Press Down and Up together again to return to the main screen and display the indoor temperature. If you want to turn the system off, repeat steps 1 and 2 and then press Sel for 3 seconds to change the On to OFF. Press Down and Up together again to return to the main screen and display the indoor temperature. Note: When the system is On both the Up and Down LEDs will be lit. When the system is Off both the Up and Down LEDs will be dark. Warning. Never leave the site with the HVAC system in the off state (Up and Down LEDs dark). Your site will have no temperature control, which likely will result in an urgent site visit to correct. Press until screen displays OFF or On hold Sel for 3 seconds Press both buttons together to enter the main screen Chapter 3: System Operation Navigating the Main Menu Page 47 Using Comfort Mode The settings on the HVAC system are optimized primarily for operating efficiency and not for the comfort of people. When you need to work inside the shelter for an extended period of time, you can temporarily adjust the site temperature to your personal preference. This temporary adjustment of site temperature is referred to as the comfort mode. Important. The HVAC system must be On to enter comfort mode. To turn comfort mode ON (if it is currently off) or OFF (if it is currently on), press Sel and Down together for 3 seconds. Both the Down and Up LEDs will flash once every second to indicate the system is in comfort mode. Note: When comfort mode has been turned on, the system will remain in comfort mode for one hour or until the operator turns comfort mode off. To turn comfort mode on or off, press the Sel and Down buttons together for 3 seconds. (Default run time: 1 hour) To change the comfort mode run time and temperature set point: 1. From the main menu, press Down until the screen displays CFT. 2. Press Sel to display the comfort mode run time set point, the default is 1 (range: 1~9 hours) 3. Change the run time setting using Down or Up and then press Sel to confirm the new set point. 4. From the main menu, press Down until the screen displays SP2. 5. Press Sel to display the comfort mode temperature set point; the factory default is 72 F. 6. Change the temperature setting using Down or Up and then press Sel to confirm the new set point. Important. If the HVAC system needs to cool aggressively to reach the comfort mode set point, both WPUs may go into mechanical cooling mode which will trigger an A23 alarm. Chapter 3: System Operation Sequence of Operation Page 48 Sequence of Operation Compressor and Heater Operation Note: Diagrams based on Main Setpoint (Stp) = 77 F. For details on changing trigger points, please refer to System Parameters and Default Values on page 58 for detail. Lead Compressor The lead compressor turns on at main setpoint +2 (configurable at C02 under E Menu). The lead compressor turns off at 6 degrees beblow its turn on point (configurable at C01 under E Menu). Note: Compressor engages a 3 min delay when the units are powered to prevent rapid compressor cycling. Note 2: When outdoor temp is lower than indoor temp, the lead compressor will have a delayed start ranging from 10s to 300s to gives the system a chance to use FC before turning on the compressor. Lag Compressor The lag compressor turns on at main setpoint + with 1 min delay (configurable at F38 under L05 Menu). The lag compressor turns off at degrees below its turn on point (configurable at F39 under L05 Menu) Lead Heater The lead heater turns on at setpoint -27 (configurable at H02 under E Menu). The lead heater turns off 3 degrees above its turn on point (configurable at H01 under E Menu). Lag Heater The lag heater turns on at setpoint -27 with 1 minute delay (configurable at F36 under L05 Menu). The lag heater turns off 3 degrees above its turn on point (configurable at F37 under L05 Menu). Free Cooling (Economizer) Operation When the Free Cooling is engaged, the damper opens to introduce cooler air from outside to be delivered to the shelter. The top exhaust design cause the exhaust air to be significantly hotter than the indoor temperature. This allows small temperature difference between indoor and outdoor temperature (minimum , connfigurable at U06 under L04 Menu) to deliver large cooling capacity. FC starts at low fan speed when indoor temperature reaches above the lead compressor turn off point. As the indoor temperature rises, the fan speed increases to maintain the indoor temperature within 1 degree F of the main temp setpoint. If the indoor temperature cannot be maintained below the lead compressor turn on point, the compressor will start to assist FC. Note : For shelters without a secondary pressure relief ( a barometric louvre), FC can be disabled when the compressor is running. (configurable at F04 under L05 Menu). During cold weather, the outdoor damper modulates to keep mixed air temperature above (configurable at U54 under L04 Menu) Chapter 3: System Operation Executing the Step-Test Page 49 Executing the Step-Test The step-test systematically verifies that key components of the system are operating as expected. Note the following considerations: The steps in the test can be executed in any order; they do not need to be sequential. The test must be completed within 30 minutes. If you cannot complete it in that time, you will need to re-enter the step-test mode. The system will display the main menu (indoor temperature) automatically after ten minutes when there has been no input from the technician. PLD button actions are listed in more detail on page 41. If any alarms are triggered during the test, refer to Alarms on page 50 for details. Warning. Once a compressor has been turned on, it must be allowed to run for at least one minute before the next step to prevent compressor damage. To complete the test, follow these steps: 7. Press Up and Down together to enter the main screen. The screen will display the indoor temperature. If the indoor temperature does not display, press both buttons again and repeat as needed. 8. When the system is on, press and hold Up and Sel together for 3 seconds. The user terminal will display Sft. Press Up until COD displays. When the system is off, press Up and Sel together for 3 seconds and the user terminal will display COD. 9. With COD displayed on screen press Sel to confirm. The screen will display 0. Press Up to select appropriate step (1-8; see Table 13: Step-Test below). Press Sel to confirm selection. The user terminal returns to COD and the component will be engaged. Repeat these steps as needed. 10. When the step-test is complete, return to the main menu and turn the HVAC system on. Table 19: Step-Test Cod Value ACTION WPU #1 WPU #2 NOTES Turns on Supply Fan 1 5 Turns on Heater 2 6 May take a few minutes before you feel warm air Turns on Compressor 3 7 IMPORTANT: Let compressor run for at least one minute before going to next step Opens Fresh Air Damper 4 8 HINT: With the lights off in the shelter, you can see indirect daylight via opening behind exhaust grill Chapter 3: System Operation Alarms Page 50 Alarms When a problem occurs during operation of the unit, the controller records the related information and the Sel button will be lit. Depending on the severity of the alarm, various components are automatically shut down. The system will restart most of these devices without human intervention after a defined delay period. However, manual reset is required when high or low pressure alarms occur three times within an hour. If the Sel button is illuminated, press the Sel button when the screen displays indoor temperature. The code identifying the malfunction displays on the screen of the user terminal. Press Up to scroll through any other active alarms. You can review alarm history through a separate menu and this will be covered in the following section. Table 20 lists the alarm codes that may display with a brief description. Table 22 on page 52 provides more detail on troubleshooting alarms should they occur during operation of the system. Table 20: Summary of System Alarms Code1 Description Output Delay Alarm Contact Reporting PLD display High/low temp. Alarm HVAC 1 Major Alarm HVAC 2 Major Alarm 2nd Comp. Run A025 Low pressure 15 60/10s X X A035 High pressure 15 2s X X A045 Low pressure 25 60/10s X X A05 Smoke/Fire None X A065 High pressure 25 2s X X A07 High temperature 300s X X A08 Low temperature 300s X X A092 Prime power outage (Only if DC Failover is used) 40s X X X A102 Supply fan overload 1 0s X X A112 Supply fan overload 2 0s X X A15 Dirty air filter1 10s X A16 Dirty air filter2 10s X A17 pLAN alarm 30s X X A18 Clock card alarm 60s X A19 Humidity alarm 60s X A20 Indoor temperature sensor defective 60s X A21 Backup indoor temp. sensor defective 60s X A20&A21 Indoor & backup indoor temp. sensors defective 60s X X X A22 Outdoor temp. sensor defective 60s X A23 2nd compressor run 5s X X A24 Damper Failure 1 60m X A25 Damper Failure 2 60m X A26 HVAC 1 supply air temp. sensor defective 60s X A27 HVAC 2 supply air temp. sensor defective 60s X A28 Generator run 5s X A293 HVAC1 air flow defective or DC part powered off 30s X X A303 HVAC2 air flow defective or DC part powered off 30s X X A313 HVAC1 AC part powered off alarm 30s X X A323 HVAC2 AC part powered off alarm 30s X X 1. Alarm codes listed in the table above will result in an audible tone and a red alarm light presented on the PLD. 2. A09, A10&A11 will not display if the HVAC is equipped with DC EC supply fan and is chosen. 3. A29, A30, A31& A32 will not display if the HVAC is equipped with AC EC supply fan and is chosen. 4. HVAC major alarm will not be cleared until manually reset or the components can work normally at the next working time. 5. If a Low pressure or High pressure alarm is triggered 3 times in one hour, the corresponding unit will LOCKOUT. This means only the supply fan will operatate with no compressor function. There are two ways to clear the alarm: a. Power cycle the controller or b. Access the parameters in the table: L04-U2L (Manual reset if low pressure) or U2E (Manual reset if high pressure). Chapter 3: System Operation Alarms Page 51 Viewing Alarm History To review the history of alarm codes, follow these steps: 1. From the main menu, press Up until the screen displays . Press Sel to confirm. This will display the Stp. 2. Press Up until ALn displays. Press Sel to confirm. This will display the most recent alarm code. 3. Then press Up to review the history. When you find an alarm number you want to review, press Sel to select it. This should display N1P, the first display in the alarm history menu. 4. Press Sel to display the code s value, for example when N1P displays, press Sel to display the alarm sequence such as 4. 5. After viewing the value, press Sel again to return to the Display code (such as N1P). 6. Use Up and Down to review the additional details listed in Table 21 and follow the same steps to view the value and return to the code display. 7. Press Up and Down together to return to the alarm code display. Table 21: Alarm History Ref Display R/W Description C-40-1-1 N1P R Sequence number of the alarm (for example, 4 for the fourth alarm to be recorded) C-40-1-2 N1C R Year of the alarm C-40-1-3 N1L R Month of the alarm C-40-1-4 N1E R Day of the alarm C-40-1-5 N1F R Hour of the alarm C-40-1-6 N20 R Minute of the alarm Clearing Alarm History At significant points such as during yearly preventive maintenance you may want to clear the alarm history. Warning. Alarm history is collected because it can be very helpful in identifying a problem with the system. The alarm history should never be arbitrarily cleared by an operator. Only an AIRSYS authorized service technician should clear the alarm history after all the alarms stored in history have been recorded. To clear the alarm history, you need to supply a password to access the L05 menu. Follow these steps to enter the L05menu and erase alarm history: 1. Press Down and Up simultaneously to display the main screen. 2. Press Up until the screen displays . 3. Then press Down and Sel simultaneously. The user terminal will display 0. 4. Enter the supplied password. The user terminal will display L01. 5. Press Up to display L05. Press the Sel button and the terminal will display F01. 6. Press the Up button to displayF3A; press the Sel button to display No on the PLD. 7. Use the Up button to flash Yes on the PLD and erase the alarm history. Page 52 Alarm Descriptions Table 22: Troubleshooting System Alarms Code Signal Description Possible Cause Component to Check Recommended Action Device Actions Supply Fan Compressor/ Cond Fan Heat Damper A02 A04 Low pressure alarm If the alarm is triggered once or twice in an hour, it is reset automatically. If it occurs three times in an hour, the compressor and condenser fan are locked. Lack of refrigerant Run the unit and check if the low pressure value is in the normal range. Reset manually using the L04 menu, U2L parameter, or restart the unit to remove the alarm. Charge appropriate amount of refrigerant. Off The switch is defective Check if the low pressure switch is OK. If it is defective, replace it. Check if the connection to the corresponding input terminal (ID3) is ok or if the controller board is defective. Check if the connection is OK. Check if the controller board is OK. Reconnect the cables. If the controller board is defective, replace it. A03 A06 High pressure alarm If the alarm is triggered once or twice in an hour, it can be reset automatically. If it occurs three times in an hour, the compressor and condenser fan are locked. Reduced condenser heat exchange Run the unit and check if the high pressure value is in the normal range. Reset manually using the L04 menu U2E parameter or restart the unit to remove the alarm. Discharge appropriate amount of the refrigerant. Clean the condenser. Off Condenser fan has failed. The condenser fan speed controller has failed. Check the condenser fan status while the high pressure is outside the normal setting. Replace the condenser fan. Replace the condenser fan speed controller. The switch is defective Check if the high pressure switch is OK. If it is defective, replace it. Check if the connection to the corresponding input terminal (ID4) is ok or if the controller board is defective. Check if the connection is OK. Check if the controller board is OK. Reconnect the cables. If the controller board is defective, replace it. A05 Smoke/Fire alarm The entire unit stops working. The alarm resets automatically. Fire/Smoke detector is triggered. Check the external Fire/Smoke detector WPU 1. Replace the external Fire/Smoke detector Off Off Off Closed Page 53 Code Signal Description Possible Cause Component to Check Recommended Action Device Actions Supply Fan Compressor/ Cond Fan Heat Damper Check if the connection to the corresponding input terminal (ID1) is ok or if the controller board is defective. Check if the connection is OK. Reconnect the cable. If the controller board is defective, replace it. A07 High temperature alarm Alarm is reset automatically. Occurs when the current indoor temperature is greater than the indoor temperature set point value plus the temperature alarm offset. The default is F with 5 minutes delay. The cooling capacity loss or heat load is too great. Check for leakages in the refrigerant circuit. Check if heat load exceeds the design range. Patch the leak. Increase the cooling capacity. Compressor circuit failure Check if components connected to the compressor are OK; Check if the compressor is OK. Check if the electric connection is OK. Replace the defective components. Replace the compressor. Reconnect the cables. Indoor temperature sensor (B1) failure. Check if the sensor is shorted or has failed. Replace the indoor temperature sensor. Incorrect value set for the high temperature alarm. Check if the value is correct. Correct the value. A08 Low temperature alarm Alarm can be reset automatically. Occurs when the current indoor temperature is less than the indoor temperature set point value minus the temperature alarm offset. The default is 59 F with 5 minutes delay. Heating capacity loss. Check if the heaters are OK. Check for leaks around the unit. If heaters have failed, replace them. Seal the leaks. Indoor temperature sensor (port B2) failure. Check for a short in the sensor or if it has failed. Replace the indoor temperature sensor Incorrect value set for the high temp alarm Check if the value is correct. Correct the value. A09 Prime power outage Alarm is reset automatically Primary power is or was turned off. Off Off Off Closed A10 A11 Supply fan overload The unit will stop working. Alarm is reset automatically. The fan is blocked. Check if the fan speed and operating current are normal. Remove the blockage. If the fan is defective, replace it. Off Off Off Closed Page 54 Code Signal Description Possible Cause Component to Check Recommended Action Device Actions Supply Fan Compressor/ Cond Fan Heat Damper Main power has been lost. Check if the main power is OK. Turn main power on. The current to the fan is higher than normal. Check if the switch, relay or built-in fan protection is disconnected. Close the switch, and check. If the fan is defective, replace it. Check if the connection to the corresponding input terminal (ID6) is ok or if the controller board is defective. Check if the connection is ok. Reconnect the cable. If the controller board is defective, replace it. A15 A16 Dirty air filter Alarm is reset automatically. The alarm is a warning to the replace the filter. Filter is clogged. Check if the filter is dirty. Clean or replace the filter Check if the connection to the corresponding input terminal (ID5) is ok or if the controller board is defective. Check if the connection is ok. Reconnect the cable. If the controller board is defective, replace it. The value set for the air pressure diff. switch is too low. Check the air pressure diff switch value. Correct the value of the switch to standard value. A17 pLAN alarm Each unit continues to work separately. It can be reset automatically. The pLAN cable is disconnected. Check if the cable is connected or shorted. Reconnect the cable. A18 Clock card alarm The clock function is not available. Both time display function and history alarm record function are disabled. It can be reset automatically. Clock card is loose. Fix the clock card on the controller board After the clock card is fixed, check if the alarm is removed. The clock card has failed. After fixing the clock card, the alarm still exists. Replace it. A19 Humidity alarm The free cooling damper will be closed. It can be reset automatically. Humidity sensor (port J2-B3 on unit 1 controller) failure. Check if the cable is connected or shorted. Replace it. Closed The humidity is higher than standard value. Dry the sensor, and then check if the alarm is cleared. Relocate the sensor. A20 Indoor temp. sensor defective It can be reset automatically. Indoor temperature sensor (port J2-B2 on unit1 controller) failure. Check if the cable is connected or shorted. Replace it. Page 55 Code Signal Description Possible Cause Component to Check Recommended Action Device Actions Supply Fan Compressor/ Cond Fan Heat Damper A21 Backup indoor temperature sensor defective Both units stop working. It can be reset automatically. Indoor temperature sensor (port J2-B2 on unit 2 controller) failure. Check if the cable is connected or shorted. Replace it. A20 AND A21 Indoor and backup indoor temperature sensors are both defective Both units stop working. It can be reset automatically. Both Indoor temperature sensors have failed. Check if the cable is connected or shorted. Replace it. Off Off Off Closed A22 Outdoor temperature sensor defective The free cooling damper will be closed. It can be reset automatically. Temperature sensor (port J2-B3 on unit 1 controller) failure. Check if the cable is connected or shorted. Replace it. Closed A23 Second compressor run alarm Both compressors are running at the same time. Heat load at the site exceeds single HVAC capacity. Check if the heat load of cell site exceeds the nominal heat load. None Check if refrigerant quantity is low. Check for leakages in the refrigerant system. A24 A25 HVAC Damper failure The alarm can be automatically reset once the alarm is removed. HVAC damper is broken or blocked or loosen Check if the damper actuator is broken or loose. If loose, tighten. If the damper actuator is broken, replace it. None None None None Check if the damper is blocked. If the damper is blocked, clear blockage. A26 A27 Supply air temp. sensor defective Damper will stop working. It can be reset automatically. HVAC Supply air temp. sensor failure Check if the cable is connected to (B1&GND) or shorted. Replace it. Closed A28 Generator run signal This indicates that the generator is running. Lag compressor will be prevented from running by default. A29 A30 HVAC air flow defective The PLD will display A29/ A30 The supply fan doesn t work. The 48VDC power is powered off or no 48VDC power input The pressure switches Check the supply fan. If the supply fan is blocked or broken, please remove the object or replace the fan. Off Off Off closed Check the 48VDC power plant. If the 48VDC power plant has no power, check the power source. Page 56 Code Signal Description Possible Cause Component to Check Recommended Action Device Actions Supply Fan Compressor/ Cond Fan Heat Damper PF2 or 3 or both for HVAC supply fan are broken. The pressure switches PF2 or 3 or both for HVAC are disconnected. Check the 48VDC power breaker (QF2). If the 48VDC power breaker is broken, please replace it. Check the air pressure differential switch. If the cable is loosen, secure the cable. If the air pressure differential switch is broken, replace it. Check the set point of the air pressure differential switch. If the set point is not near 50 Pa, change it back. A31 A32 HVAC AC power powered off alarm The PLD will display A31/A32 The AC power is powered off Check the breaker. If the breaker is broken, replace it. Off Off Check the AC power source. If the AC power plant has no power, check the power source. Check the ports B3 & B4 of HVAC 2. If the B3 or B4 or both are broken, replace the controller. If the cables connected to B3 or B4 or both are loose, secure them. Chapter 3: System Operation System Diagnostics Page 57 System Diagnostics The information provided in this section may be useful during the troubleshooting of issues that arise during operation of the system. Two types of information are provided: A description of the input and output ports of the controller A description of all factory settings and how they can be viewed and modified Port Definitions Figure 22 is a schematic drawing of the controller module (PLC) ports. Figure 22: pCOxs Controller Hardware Structure Table 23 lists the input and output ports of the unit. Table 23: Port Values Digital Input Analog Input Digital Output Analog Output pCOxs-1 (Main, Address 1: WPU 1) ID1 Smoke/Fire (NC) B1 Supply temperature NO1 Compressor Y1 Supply fan ID2 Gen run (NO) B2 Indoor temperature NO2 Supply fan Y2 Free cooling ID3 Low pressure (LP) B3 Humidity NO3 Electrical heater Y3 ID4 High pressure (HP) B4 Outdoor temperature NO4 High/low temperature alarm (NC) ID5 Filter flow NO5 HVAC1 alarms (NC/NO) ID6 Supply fan overload Chapter 3: System Operation System Diagnostics Page 58 Digital Input Analog Input Digital Output Analog Output pCOxs-2 (Extension, Address2: WPU 2) ID1 Prime power outage B1 Supply temperature NO1 Compressor Y1 Supply fan ID2 Smoke/Fire (NC) B2 Backup indoor temperature NO2 Supply fan Y2 Free cooling ID3 Low pressure (LP) B3 HVAC1 AC power powered off alarm (If is chosen) NO3 Electrical heater Y3 ID4 High pressure (HP) B4 HVAC2 AC power powered off alarm (If is chosen) NO4 2nd compressor run alarm (NC) ID5 Filter flow NO5 HVAC2 alarms (NC/NO) ID6 Supply fan overload System Parameters and Default Values This section describes the controller menus used for completing operations and displaying information. Using the main menu is described in Navigating the Main Menu on page 45. The main menu is not described here. This section describes the additional menus that let an authorized technician access factory default settings. Table 24: Menu Overview ID Purpose Description A Main Menu View current sensor readings: indoor temperature, indoor humidty, outside temperature, supply air temperature Comfort mode setting Turn system on/off Launch into other menu () C Maintenance Main Temperature Setpoint Rotate lead/lag unit immediately Sensor Calibration Component Status Software Revsion System Clock D Installation Step Test Alarm input/output settings E Factory Defaults High/low temperature alarm setpoints Compressor/heater turn on/off setpoints Reset to factory default L Software Parameters Run time/start counters Controller board input/output status Free cooling settings Communication settings Advanced alarm configuration Erase Alarm History Chapter 3: System Operation System Diagnostics Page 59 To review or modify a parameter, follow these general steps: 1. Press the Up or Down button to find the code you want. 2. Then press the Sel button to review the value. 3. If the parameter can be modified (R/W), press the Up or Down button to modify the value. Then press Sel to confirm the change. 4. To review another parameter, press the Up or Down button to find its code, and repeat these steps. Press the Up or Down button together to return to the main screen. Accessing the C Menu When the PLD displays , press the Sel button to enter the C menu. Then press the Down button to display the parameters in the order listed in Table 25. Table 25: Parameters on Maintenance Menu (C) Ref Display R/W Description Unit Range Default C-1 STp R/W Main temperature setpoint F ~104 C-2 Ht R High temp. alarm difference. High temp alarm occurs at Main temp. setpoint + high temp. alarm difference F C-3 Lt R Low temp. alarm difference. Low temp alarm occurs at Main temp. setpoint - low temp. alarm difference F C-4 R0t R/W Lead/lag rotation. Rotates Lead/Lag once after Yes is selected nO/YES nO C-5 rt2 R Backup room temperature sensor reading F C-6 AC1 R Unit 1 AC power status (DC EC Fan Only) -C-/-O- C-7 AC2 R Unit 2 AC power status (DC EC Fan Only) -C-/-O- C-8 DS1 R Unit 1 Supply fan status On/off C-9 DS2 R Unit 1 Compressor status On/off C-10 DS3 R Unit 1 Heater status On/off C-11 DS4 R Unit 1 Free cooling status On/off C-12 D5A R Generator status On/off C-13 DS6 R Unit 2 Supply fan status On/off C-13 DS7 R Unit 2 Compressor status On/off C-14 DS8 R Unit 2 Heater status On/off C-15 DS9 R Unit 2 Free cooling status On/off *C-16 U1T R Unit 1 System Status 0~7 *C-17 U2T R Unit 2 System Status 0~7 C-18 bIO R Bios version C-19 bOO R Boot version C-20 VE1 R Software version 1 C-21 VE2 R Software version 2 C-22 N15 R/W Display and set the current time/date - hour 0~23 C-23 N16 R/W Display and set the current time/date - minute 0~59 C-24 N17 R/W Display and set the current time/date - year 0~99 Chapter 3: System Operation System Diagnostics Page 60 Ref Display R/W Description Unit Range Default C-25 N18 R/W Display and set the current time/date - month 0~12 C-26 N19 R/W Display and set the current time/date - day 0~31 C-27 STA R System working status 1~7 7 The following parameters with gray highlight are displayed after the system is turned off using the PLD C-28 N21 R/W Unit 1 Supply fan manual mode On/off Off C-29 N2Y R/W Unit 1 Supply fan manual mode to change the input voltage V 0-10 0 C-30 N29 R/W Unit 1 Free cooling manual mode On/off Off C-31 N4y R/W Unit 1 Free cooling manual mode to change the input voltage V 0-10 0 C-32 N26 R/W Unit 1 Compressor manual mode On/off Off C-33 N23 R/W Unit 1 Heater manual mode On/off Off C-34 N41 R/W Unit 2 Supply fan manual mode On/off Off C-35 N5Y R/W Unit 2 Supply fan manual mode to change the input voltage V 0-10 0 C-36 N40 R/W Unit 2 Free cooling manual mode On/off Off C-37 N6Y R/W Unit 2 Free cooling manual mode to change the input voltage V 0-10 0 C-38 N3F R/W Unit 2 Compressor manual mode On/off Off C-39 N3E R/W Unit 2 Heater manual mode On/off Off C-40 N2A R/W Indoor temperature calibration F ~ 0 C-41 N2P R/W Outdoor temperature calibration F ~ 0 C-42 N2C R/W Supply air temperature calibration F ~ 0 C-43 N2L R/W Humidity sensor calibration % ~ 0 C-44 N42 R/W Backup indoor temperature calibration F ~ 0 C-45 N43 R/W Supply temperature sensor 2 calibration F ~ 0 C-46 ALN R View history of alarm code, date, and time --- *Note: The range of parameters U1T & U2T are 0-7. The identification of the numbers is listed in the table below. The two parameters are used to check the system status. Note: If you want to rotate the lead and lag units, please change the parameter ROT from NO to YES, and then check the either U1T & U2T to confirm that the lead and lag units have rotated successfully. Table 26: U1T & U2T Parameter Range Value Unit status 0 Unit ON 1 OFF by Alarms 2 OFF by Supervisory 3 OFF by Time zones 4 OFF by Digital Input 5 OFF by Keyboard, 6 Manual Procedure 7 Unit Stand-by Chapter 3: System Operation System Diagnostics Page 61 Accessing the D Menu After the terminal displays , press the Up and Sel buttons at the same time to enter into the D menu. Then press the Down button to display the parameters in Table 27 in the listed order. *Note: 1. The parameters TES and COD will display on PLD when the system is off. 2. After the parameter TES is changed from off to on, press Sel button to confirm. The parameter COD will display on the PLD. Note: If the has been reset to factory default, the parameter SF1 shall be changed from 1 to 0. Table 27: Installation Menu (D) Ref Display R/W Description Unit Range Default *D-1 tES R/W Device test, displays when the unit has been turned off using the PLD interface On/off Off *D-2 COD R Device test code, displays when the unit has been turned off using the PLD interface 0-8 0 D-3 sft R/W Fire/Smoke alarm input D-4 DGT R/W Generator run status input D-5 2CT R/W Second compressor run status output D-6 PUT R/W HVAC1/HVAC2 lockout output D-7 HTT R/W High/low temperature alarm output D-8 CST R/W Generator on, compressor stop time, or Power on compressor turns on with a delay time. S 0-999 180 D-9 E2C R/W Generator on, enable second compressor turn-on. no/YES no D-10 SF1 R/W Supply fan configuration; 0 means DC drive supply fan; 1 means AC drive supply fan 0/1 1 Accessing the E Menu After the terminal displays , press the Down and Sel buttons at the same time to enter the E menu. Then press the Down button to display the parameters in Table 28 in the listed order. Table 28: Protected Factory Defaults (E) Ref Display R/W Description Unit Range Default E-1 0 R/W Input user password 0~999 000 Input Password, Press Sel button, the following parameters will display. E-2 Stp R/W Temperature setting F ~ E-3 Ht R/W High temp. alarm difference. High temp alarm occurs at Main temp. setpoint + high temp. alarm difference F ~ E-4 Lt R/W Low temp. alarm difference. Low temp alarm occurs at Main temp. setpoint - low temp. alarm difference F ~ E-5 C01 R/W Lead compressor turn off difference F ~100 E-6 C02 R/W Lead compressor turn on difference F ~ E-7 H01 R/W Lead heater turn off difference F ~100 E-8 H02 R/W Lead heater turn on difference F ~ E-9 C03 R/W Not used -- -- 0 E-10 CAD R/W Controller address 1/2 1 Chapter 3: System Operation System Diagnostics Page 62 Ref Display R/W Description Unit Range Default E-11 TS1 R/W Allow adjustment of supply fan speed as PI no/ YES YES E-12 TS2 R/W Allow 1st compressor to start with a variable delay time no/ YES YES E-13 ET2 R/W Enable pCOxs-2 temperature sensor failure alarm and temperature sensor backup no/ YES YES E-14 SYS R/W Number of units 1/2 2 E-15 FC1 R/W Enable FC damper alarm no/ YES YES E-16 FC2 R/W Check T (close) F ~ E-17 FC3 R/W Check T (open) F ~ E-18 FC4 R/W FC damper alarm delay s 1~999 300 E-19 FC5 R/W FC damper alarm restart time M 1~540 60 E-20 FC6 R/W Damper Lockout counters 1~10 3 E-21 FC7 R/W Lockout time M 1~540 540 E-22 DEF R/W Reset the system to factory default E-23 PSUW R/W Set password 0 Accessing the L Menus The L menus allow authorized technical personnel access to all of the factory default settings. Accessing these parameters requires the technician to supply a password. The parameters are divided into five menus: L01 Temperature, humidity, and working status L02 Component run time and start counters, sensor calibration, manual mode, and alarm history L03 Input and output configuration L04 Cooling and heating set points, alarm delay time, free cooling damper set point L05 WPU factory configuration Follow these steps to enter these menus: 1. From the main menu s temperature display, press the Down button until the screen displays . 1. Then press Down and Sel simultaneously. The user terminal will display 0. 2. Enter the supplied password. The user terminal will display L01. 3. Press Sel to review the L01 menu. Press Down and Up simultaneously to return to the L01 screen 4. When the terminal displays L01, press Down to display L02, L03, L04, and L05. Follow the same steps to select and view the parameters. Table 29: L Parameters Display R/W Description Unit Range Default L01 Main Screen ADD R Unit Address 1 DS1 R Unit 1 supply fan status On/Off Off DS2 R Unit 1 compressor status On/Off Off DS3 R Unit 1 heater status On/Off Off DS4 R Unit 1 free cooling status On/Off Off Chapter 3: System Operation System Diagnostics Page 63 Display R/W Description Unit Range Default DSA R Generator status On/Off Off DS6 R Unit 2 supply fan status On/Off Off Ds7 R Unit 2 compressor status On/Off Off Ds8 R Unit 2 heater status On/Off Off Ds9W R Unit 2 free cooling status On/Off Off Ds5W R Supply air limit On/Off Off L02 Maintenance Menu ALN R Not used N01 R Free cooling running hours *1000 Hrs 0~999 0 N02 R Free cooling running hours *1 Hrs 0~999 0 R01 R/W Free cooling running hours reset no/YES no N03 R Free cooling 1 start counters 0~999 0 R03 R/W Free cooling 1 start counters reset no/YES no N31 R Free cooling 2 running hours *1000 Hrs 0~999 0 N32 R Free cooling 2 running hours *1 Hrs 0~999 0 R31 R/W Free cooling 2 running hours reset no/YES no N33 R Free cooling 2 start counters 0~999 0 R33 R/W Free cooling 2 start counters reset no/YES no N09 R Compressor 1 running hours *1000 Hrs 0~999 0 N0A R Compressor 1 running hours *1 Hrs 0~999 0 R09 R/W Compressor 1 running hours reset no/YES no N0P R Compressor 1 start counters 0~999 0 R0P R/W Compressor 1 start counters reset no/YES no N34 R Compressor 2 running hours *1000 Hrs 0~999 0 N35 R Compressor 2 running hours *1 Hrs 0~999 0 R34 R/W Compressor 2 running hours reset no/YES no N36 R Compressor 2 start counters 0~999 0 R36 R/W Compressor 2 start counters reset no/YES no N0L R Heater 1 running hours *1000 Hrs 0~999 0 NOE R Heater 1 running hours *1 Hrs 0~999 0 R0L R/W Heater 1 running hours reset no/YES no N0F R Heater 1 start counters 0~999 0 R0F R/W Heater 1 start counters reset no/YES no N37 R Heater 2 running hours *1000 Hrs 0~999 0 N38 R Heater 2 running hours *1 Hrs 0~999 0 R37 R/W Heater 2 running hours reset no/YES no N39 R Heater 2 start counters 0~999 0 R39 R/W Heater 2 start counters reset no/YES no Chapter 3: System Operation System Diagnostics Page 64 Display R/W Description Unit Range Default N11 R Supply fan 1 start counters 0~999 o R11 R/W Supply fan 1 start counters reset no/YES no N13 R Supply fan 1 running hours *1000 Hrs 0~999 0 N14 R Supply fan 1 running hours*1 Hrs 0~999 0 R13 R/W Supply fan 1 running hours reset no/YES no N3A R Supply fan 2 start counters 0~999 0 R3A R/W Supply fan 2 start counters reset no/YES no N3P R Supply fan 2 running hours *1000 Hrs 0~999 0 N3C R Supply fan 2 running hours *1 Hrs 0~999 0 R3C R/W Supply fan 2 running hours reset no/YES no N15 R/W Hour N16 R/W Minute N17 R/W Year N18 R/W Month N19 R/W Date N1A R/W Day (Monday, Tuesday, ..., Sunday) Mon~Sun N2A R/W Indoor temperature calibration F ~ N2P R/W Outdoor temperature calibration F ~ N2C R/W Supply air temperature sensor 1 calibration F ~ N2L R/W Humidity sensor calibration % ~ N42 R/W Backup Indoor temperature calibration F ~ N43 R/W Supply air temperature sensor 2 calibration F ~ L03 Controller Board Input/Output 110 R ID1:Fire/smoke alarm output -C or O- 111 R ID2:Generator status signal -C or O- 112 R ID3:Low pressure -C or O- 113 R ID4:High pressure -C or O- 114 R ID5:Dirty filter -C or O- 115 R ID6: Supply fan overload -C or O- 120 R 2 ID1: Prime Power Outage 121 R 2 ID2: Smoke/Fire 122 R 2 ID3:Low pressure 2 -C or O- 123 R 2 ID4:High pressure 2 -C or O- 124 R 2 ID5:Dirty Filter 2 -C or O- 125 R 2 ID6: Supply fan 2 overload -C or O- 118 R Y1: Supply fan speed ~ 119 R Y2: Free cooling damper opening ~ 126 R 2 Y1: Supply fan speed 2 ~ Chapter 3: System Operation System Diagnostics Page 65 Display R/W Description Unit Range Default 127 R 2 Y2: Free cooling damper opening 2 ~ 11p R NO1: Compressor (MC) -C or O- 11C R NO2: Supply fan (MF2) -C or O- 11L R NO3: Heater (EH1-3) -C or O- 11E R NO4: High/low temp alarm -C or O- 11F R NO5: HVAC1 Fail -C or O- 128 R 2 NO1: Compressor (MC) -C or O- 129 R 2 NO2: Supply fan (MF2) -C or O- 12A R 2 NO3: Heater (EH1-3) -C or O- 12P R 2 NO4: 2nd compressor run -C or O- 12C R 2 NO5: HVAC2 Fail -C or O- L04 User Menu U01 R/W Minimum temperature setting F ~ U02 R/W Maximum temperature setting F ~ 104 U49 R/W Allow adjustment of temperature as PI logic no/YES no U03 R/W Free cooling humidity limit no/YES YES U04 R/W Free cooling humidity setting % ~ U05 R/W Free cooling humidity difference % ~ U06 R/W Free cooling temperature difference of indoor and outdoor temperatures F ~ U08 R/W Auto-start after power on no/YES YES U09 R/W Turn the unit on or off by software no/YES YES U0A R/W Delay time of high/low temperature alarm output S 0~999 60 U0P R/W Supply air temperature limit no/YES no U0C R/W Not used F ~ U0L R/W Not used F ~ U2L R/W Manual reset for low pressure lockout no/YES no U2E R/W Manual reset for high pressure lockout no/YES no U30 R/W Monitor system address 1 U31 R/W Communication baud rate:1 means 2400; 2 means 4800; 3 means 9600; 4 means 19200. 3 U32 R/W Communication protocol, Ca means Carel; Nod means MODBUS Ca/Nod Nod U54 R/W Free cooling supply air temperature limit F ~ U55 R/W Free cooling supply air temperature modulating range F ~ U56 R/W Free cooling cycle time S ~ Chapter 3: System Operation System Diagnostics Page 66 L05 Manufacturer Menu F01 R/W BMS network no/YES YES F02 R/W Allow clock card no/YES YES F03 R/W Allow free cooling no/YES YES F04 R/W Allow free cooling and compressor to work simultaneously no/YES YES F48 R/W Enable audible buzzer (Rev 13B64 and after) no/Yes no F47 R/W Allow free cooling ONLY in emergency ventilation mode no/YES no F44 R/W Not used no/YES YES F06 R/W Enable Major alarms output no/YES YES F07 R/W Type of Major alarm output F3p R/W Unit of temperature, C means Celsius. F means Fahrenheit. -F-/-C- - F - F16 R/W Minimum speed setting of supply fan V ~ F17 R/W Maximum speed setting of supply fan V ~ F46 R/W Fan speed change during the DC-failover on V ~ F18 R/W Free cooling speed V ~ F19 R/W Startup delay time of supply fan S 0~999 5 F1A R/W Stop delay time of supply fan S 0~999 60 F3C R/W Startup delay time of supply fan overload S 0~999 0 F3L R/W Recovery delay time of supply fan overload S 0~999 120 F1P R/W Startup delay time of low pressure alarm S 0~999 60 F1C R/W Recovery delay time of low pressure alarm S 0~999 10 F1L R/W Low pressure alarms allowed before system (per hour) 3 F1E R/W High pressure alarms allowed before system (per hour) 3 F20 R/W Minimum stop time of compressor S 0~999 180 F21 R/W Minimum run time of compressor S 0~999 60 F22 R/W Supply fan air flow defective if the supply fan is DC fan S 30 F23 R/W Delay time of filter alarm output S 0~999 10 F24 R/W Shut off free cooling due to dirty filter alarm no/YES no F27 R/W Minimum voltage input of free cooling V ~ 2 F31 R/W Number of backup units for unit rotation 1 F32 R/W Unit rotation time hr 0~999 168 F33 R/W Force startup of the backup unit no/YES YES F34 R/W Delay time of low temperature M 0/1 1 F35 R/W Delay time of high temperature M 0/1 1 F36 R/W Lag heater turn on difference F ~ F37 R/W Lag heater turn off difference F ~ F38 R/W Lag compressor turn on difference F ~ F39 R/W Lag compressor turn off difference F ~ F3A R/W Erase alarm history no/YES no Chapter 4: Preventive Maintenance Preventive Maintenance Schedule Page 67 Chapter 4: Preventive Maintenance Important. The AIRSYS WPUs are designed to be among the highest performing in the world for both energy efficiency and reliability. Good preventive maintenance (PM) techniques are a crucial part of maintaining that high level of energy efficiency and reliability. It is also important to keep track of findings during each PM event so that trends can be established for future reference. Preventive Maintenance Schedule This section provides guidelines for the owner of an AIRSYS unit to ensure that the equipment continues to perform well. Following these guidelines for regular care will help avoid serious damage to components and expensive repairs by skilled personnel. Table 30: Preventive Maintenance Schedule Task Recommended Frequency Comments Inspect all wiring for signs of wear Based on local conditions More frequently in areas with active rodent or insect populations that can damage wiring Check general operations 12 months Perform the Step-Test Inspect all hardware for snug connection 12 months Make note of any loose hardware so it can be checked again at next scheduled PM Air filter inspection/cleaning and replacement if needed Based on local conditions Depends on the amount and frequency of airborne particulates in the area Inspect and clean condenser coil 12 months More frequently in areas that experience excessive airborne particulates that will collect on the condenser coil Inspect drain pipe 12 months Physical Inspection of Air Damper 12 months Danger. Stop the machine and remove the power supply from the equipment before performing maintenance operations. Important. All PM should be performed by an AIRSYS Authorized Service Technician (AAST) to ensure the manufacturer s warranty is preserved. General Operation Check It is a good idea to compare the operation of the equipment with the results of the previous inspection. Any differences in operating characteristics can then be easily identified. A detailed and periodic visual inspection of the equipment and a general cleaning are both important to ensure good operation. Before beginning the PM steps, you should verify the general system status by looking at the areas outlined in this section. Chapter 4: Preventive Maintenance Preventive Maintenance Schedule Page 68 Check Main Voltage For the main voltage, check: The main voltage is ranging within 10% of the rated voltage required by the machine (230V, 60Hz). The DC voltage is in normal range, if applicable. (36VDC~ 57VDC) The main electrical supply cable and the terminals, including the user terminal cable, are correctly hooked up. All cables are secured to the system. Check Wiring and Components For wiring and components, perform a preliminary check to verify the system is functional: Check that the system has been installed correctly. Check that the wiring cable sections meet current capacity. Report any incorrect mounting and setting to the AAST who installed the system so that the necessary modifications can be made. Check that the grounding cables have been installed in the controller box and unit as shown in the graphic. Perform the Step-Test The purpose of this test is to simulate real operation without damaging components due to incorrect operation or protection failures. Use the step-test to check that the relays, breakers, and components work normally. For details on executing this test, see Executing the Step Test on page 48. Refer to Alarms on page 50 if any alarm occurs during the step test. Refer to wiring diagram included in the controller shipment for possible mechanical/electrical issues. Wiring diagram is also available on cable Chapter 4: Preventive Maintenance Preventive Maintenance Schedule Page 69 Replace Air Filter A dirty air filter reduces the air volume and the system capacity. This problem can be avoided by periodically and regularly cleaning or replacing filters. The frequency at which filters must be checked depends on the amount of dust in the environment. If during inspection, the filters are frequently very dirty, the frequency of checks and maintenance should be increased. Clean the Preliminary Air Filter The preliminary air filter can become clogged with dust and leaves or other debris after a period of use, and should be cleaned with water or blown air. Remove bottom-front panel Take off the filter Clean the filter Remove middle-front panel Replace the filter Chapter 4: Preventive Maintenance Preventive Maintenance Schedule Page 70 Inspect and Clean Condenser Coils During times of peak usage, the condensing coils must be able to offer maximum thermal exchange. Debris such as paper, dead leaves, and dust can be sucked in around the coils, reducing the thermal exchange rate. Remove any objects from the coil which may have accumulated and wash the system with water and commercial coil cleaner. Dirty condenser coils may trigger the high pressure switch and cause system lockout. You should check the coil condition more frequently if your environment experiences seasons of high dust or falling leaves. Inspect and Clean the Drain Pipe To avoid water overflow, ensure that the system has proper drainage for condensation discharges. The pipe and outflow should be completely free of any obstructions. If necessary, clean the drain and outflow area. Physical Inspection of the Damper The air damper is a critical element in the WPU. If it does not function normally, the free cooling function will fail. This can be avoided by periodically and regularly checking the following: 1. Check if the damper can fully open and close via the manual override 2. Check if the nuts are properly tightened, as shown in the following images. Chapter 4: Preventive Maintenance Operation Checklist Page 71 Operation Checklist If you experience a problem with the system, use this checklist to verify the system and determine the root cause. Keep these records for future inspections. Address: ___________________Site No.: ___________________________ Date: _____________________ Unit Factory Number:_____________________________ (refer to the unit name plate) Check Items or Step-Test or Manual Operation Verify WPU 1 supply fan is working(1) Verify WPU1 heater works normally (2) Verify WPU 1 compressor works normally (3) At the same time, check if the WPU 1 condenser fan works normally. Verify WPU 1 free cooling is working (4) Verify WPU 2 supply fan works normally(5) Verify WPU 2 heater works normally (6) Verify WPU 2 compressor works normally(7) At the same time, check if the WPU 2 condenser fan works normally. Verify WPU 2 free cooling works normally (8) Record these values using pressure gauges or multi-meter readings Outdoor Temperature: _______________________Indoor Temperature: _______________________________ The WPU 1 low pressure value R410a system, normal range:8~12Bar/116~174PSI R407c system, normal range: 4-7 Bar/PSI The WPU 1 high pressure value R410a system normal range:25~30 ~435PSI R407c system normal range, 16-20Bar/232-290PSI Bar/PSI The WPU 1 current of the compressor (refer to nameplate) Amp The WPU 1 current of the supply fan (refer to nameplate) Amp The WPU 2 low pressure value R410a normal range:8~12Bar/116~174PSI R407c normal range:4-7 Bar/PSI The WPU 2 high pressure value R410a normal range:25~30 ~435PSI R407c normal range:16-20Bar/232-290PSI Bar/PSI The WPU 2 current of the compressor (refer to nameplate) Amp The WPU 2 current of the supply fan (refer to nameplate) Amp Chapter 4: Preventive Maintenance Spare Parts Page 72 Spare Parts For all part requests, please contact: Tempest Telecom Solutions LLC Web: Email: Phone: 805-879-5432 Address: 136 W. Canon Perdido St, Suite 100, Santa Barbara CA 93101 Appendix 1:Drawings Page 73 Appendix 1:Drawings Figure 23: Frame Dimensions Technical Notes: 1. Use two holes provided for fastening the sheet metal together. 2. Remove the burrs. 3. Use stainless steel sheet metal that is mm (.031 in) thick. Appendix 2:Reference Tables Page 74 Appendix 2:Reference Tables Table 31: Supply and Return Air Frame Dimensions Model 3R1C1,5R1C1 7E1C2, 9E1C2 13E1C3 18E1C4 Frame Type Supply Return Supply Return Supply Return Supply Return Unit mm in mm in mm in mm in mm in mm in mm in mm in A 435 435 693 693 744 744 864 864 A 467 467 725 725 776 746 896 896 B 200 300 254 344 254 344 254 344 B 232 332 286 376 286 376 286 376 C 100 100 100 100 100 100 100 100 D 90 90 90 90 90 90 90 90 E 30 30 30 30 30 30 30 30 F 9 9 9 9 9 9 9 9 Table 32: WPU Filter Sizes Model Filter Qty Nominal Size (in) Exact Size (in) 3R1C1,5R1C1 1 16 x 16 x 2 15 x 15 x 1 7E1C2, 9E1C2 1 25 x 18 x 2 24 x 17 x 1 13E1C3 2 16 x 16 x 2 15 x 15 x 1 18E1C4 2 20 x 16 x 2 19 x 15 x 1 Appendix 3:List of Tables Page 75 Appendix 3:List of Tables TABLE 1: PACKAGING SYMBOLS 2 TABLE 2: MODEL NUMBER NOMENCLATURE 3 TABLE 3: ACRONYMS AND ABBREVIATIONS 4 TABLE 4: MATERIAL SUPPLIED BY AIRSYS 9 TABLE 5: MATERIALS SUPPLIED BY THE INSTALLER 10 TABLE 6: WPU ELECTRICAL RATINGS 11 TABLE 7: EXTERNAL DIMENSIONS OF BASIC UNIT FOR ARCHITECTURAL AND INSTALLATION REQUIREMENTS 12 TABLE 8: DIMENSIONS AND WEIGHT BY MODEL NUMBER 13 TABLE 9: KEY COMPONENTS IN THE CONTROLLER BOX ASSEMBLY 19 TABLE 10: ALARM CONNECTIONS 27 TABLE 11: THE CONTROL HARNESS TERMINAL IDENTIFICATION OF 28 TABLE 12: THE CONTROL HARNESS TERMINAL IDENTIFICATION OF 28 TABLE 13: STEP-TEST 35 TABLE 14: SYSTEM TIME PARAMETERS 37 TABLE 15: ASLLC MAIN MENU 38 TABLE 16: PLD BUTTON ACTIONS 44 TABLE 17: MAIN MENU (A) WITH SYSTEM OFF 45 TABLE 18: MAIN MENU (A) WITH SYSTEM ON 45 TABLE 19: STEP-TEST 49 TABLE 20: SUMMARY OF SYSTEM ALARMS 50 TABLE 21: ALARM HISTORY 51 TABLE 22: TROUBLESHOOTING SYSTEM ALARMS 52 TABLE 23: PORT VALUES 57 TABLE 24: MENU OVERVIEW 58 TABLE 25: PARAMETERS ON MAINTENANCE MENU (C) 59 TABLE 26: U1T & U2T PARAMETER RANGE 60 TABLE 27: INSTALLATION MENU (D) 61 TABLE 28: PROTECTED FACTORY DEFAULTS (E) 61 TABLE 29: L PARAMETERS 62 TABLE 30: PREVENTIVE MAINTENANCE SCHEDULE 67 TABLE 31: SUPPLY AND RETURN AIR FRAME DIMENSIONS 74 TABLE 32: WPU FILTER SIZES 74 Appendix 4:List of Figures Page 76 Appendix 4:List of Figures FIGURE 1: BASIC OPERATING MODES 5 FIGURE 2: WORKING SPACE 13 FIGURE 3: LEFT SIDE VIEW 14 FIGURE 4: OPENINGS AND HOLES IN THE WALL 14 FIGURE 5: INSTALL WEATHER STRIPPING 15 FIGURE 6: INCLINATION OF MOUNTED WPU 15 FIGURE 7: POSITION THE UNIT 16 FIGURE 8: VERIFY THE UNIT IS LEVEL 16 FIGURE 9: REMOVE WOODEN PALLET 16 FIGURE 10: SEAL THE JOINTS BETWEEN WPUS AND WALL 17 FIGURE 11: INSTALL THE SUPPLY AND RETURN AIR GRILLS 17 FIGURE 12: REMOVE COMPRESSOR BRACKETS 18 FIGURE 13: CONTROLLER BOX DIMENSIONS 19 FIGURE 14: SYSTEM BLOCK DIAGRAM 20 FIGURE 15: SYSTEM SCHEMATIC DIAGRAM 21 FIGURE 16: LOCATION OF OUTDOOR TEMPERATURE SENSOR 23 FIGURE 17: ENSURE NO LEAKAGE 23 FIGURE 18: POSITION INDOOR TEMPERATURE SENSOR 24 FIGURE 19: POSITION SUPPLY AIR TEMPERATURE SENSORS 25 FIGURE 20: FIELD WIRING TERMINALS 26 FIGURE 21: PLD USER INTERFACE 44 FIGURE 22: PCOXS CONTROLLER HARDWARE STRUCTURE 57 FIGURE 23: FRAME DIMENSIONS 73 Version Number: Tempest Telecom Solutions, LLC 136 West Canon Perdido Suite 100 Santa Barbara, CA 93101 Phone: 805-879-5432

Related search queries