FREECOOL.OD.PCK.36F2 · 2016-08-11 · Page 7 of 52 Product Overview Unit Operating Modes The air conditioning system has three modes of operation: I. The free cooling mode (see figure

Item code: 1170103020 Version number: V1.0-20130222

Before installation and startup of the unit, carefully read this manual.

FREECOOL.OD.PCK.36F2.48

INSTALLATION AND OPERATION INSTRUCTIONS

AirSys Refrigeration Engineering Technology (Beijing) Co.,Ltd

No.28 LuGu East Street Beijing 100040

Phone：010-68656161

Fax：010-68652453

http://www.air-sys.com

Page 1 of 52

Contents

CHAPTER 1: OVERVIEW ................................................................................................................................. 4

Using this Manual ........................................................................................................................................... 4 Documentation Conventions........................................................................................................................... 4 Unit Identification ........................................................................................................................................... 5 Acronyms and Abbreviations.......................................................................................................................... 6

Product Overview ............................................................................................................................................... 7 Unit Operating Modes .................................................................................................................................... 7

CHAPTER 2: INSTALLATION ........................................................................................................................ 10

Installation Preparation ..................................................................................................................................... 10 Delivery ........................................................................................................................................................ 10 Warranty ....................................................................................................................................................... 10 Moving the Unit ............................................................................................................................................. 11 General Safety Rules ..................................................................................................................................... 11

Required Materials ............................................................................................................................................. 11 AIRSYS Supplied Materials .......................................................................................................................... 11 Installer Supplied Material............................................................................................................................. 11

FCB Dimensions ............................................................................................................................................... 13 Physical Location of the FCB ....................................................................................................................... 14 Select the Wall for Installing the Unit ........................................................................................................... 14 Make Openings and Holes ............................................................................................................................ 15 Install Weather Stripping .............................................................................................................................. 15 Position the Unit ........................................................................................................................................... 16 Seal the Opening between Units and Wall .................................................................................................... 17 Attach the Supply Air Grill and the Return Air Grill to the Wall .................................................................. 18

Complete Electrical Connections ...................................................................................................................... 19 Cautions ........................................................................................................................................................ 19 Electrical Connection List ............................................................................................................................ 19 Electrical Connection to Controller Box ....................................................................................................... 20 Field Wiring Power & Control ................................................................................................................. 25 Field Wiring Alarm Connections ............................................................................................................. 26

Complete the Installation Check list ................................................................................................................. 27 Turn On Component Breakers .......................................................................................................................... 27 Verify the Installation ........................................................................................................................................ 27

Turn on 48VDC Power ................................................................................................................................. 27 Turn the FCB System On (or Off) ................................................................................................................ 28 System Test ................................................................................................................................................... 29 Complete the Registration Card .................................................................................................................... 30

CHAPTER 3: SYSTEM OPERATION ............................................................................................................. 32

User Interface Introduction ............................................................................................................................... 32 Navigating the Main Menu ............................................................................................................................... 32

Turning the HVAC System On or Off ........................................................................................................... 33 Executing the start test .................................................................................................................................. 33

Alarms............................................................................................................................................................... 34 Viewing Alarm History ................................................................................................................................. 34 Clearing Alarm History ................................................................................................................................. 34 6.2 Alarm Descriptions ................................................................................................................................. 35

System Diagnostics ........................................................................................................................................... 37 Port Definitions ............................................................................................................................................. 37 System Parameters and Default Values ......................................................................................................... 38

CHAPTER4: PREVENTIVE MAINTENANCE ............................................................................................. 44

Preventive Maintenance Schedule .................................................................................................................... 44 General Operation Check ............................................................................................................................. 44 Replace Air Filter .......................................................................................................................................... 45 Check Air Damper ........................................................................................................................................ 45

Spare Parts ........................................................................................................................................................ 46

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Order Form ................................................................................................................................................... 46

APPENDIX 1: DRAWINGS ............................................................................................................................... 48

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Page 4 of 52

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 economizer, described as “free

cooling.” This feature combines with a powerful controller and can provide 100% cooling capacity. This Free

Cooling function is accomplished consuming less than 500 Watts and provides cooling benefit whenever the

outdoor temperature is just a few degrees lower than the inside temperature. This feature alone can save telecom

operators significant utility dollars, 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:

Simple unobstructed access to all key components for PM and servicing

Selectable alarm relays (NC or NO) to enable the system to adapt to the customer rather than the other

way around

Since the FCB is powered directly from the DC plant, it will continue to operate in the event of prime power

loss. Even if the outside temperature is higher than the temperature set point, the FCB is programmed to

recognize the need for emergency ventilation when the existing HVAC systems are unable to cool the site.

With a suite of best in class components from around the globe, the AIRSYS FCB delivers quality and reliability

while substantially reducing cost of operation.

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

How to install the system, including preparation, installing the wall units, installing the pLD user

interface, and verifying the installation

How to access the functions via the pLD user interface, understand system alarms, and perform

advanced troubleshooting

Preventive maintenance and repair

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. Indicate 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.

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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.

PROTECT AGAINST RAIN:

The packaged unit must be stored in a dry place.

DO NOT STACK

Unit Identification

Each unit is identified by a model number, such as FREECOOL.OD.PCK36F2.48.XXX. The elements in the

number are explained in Table 2.

Table 2: Model Number

Element Meaning

FREECOOL Production series name. In this example, FREECOOL-Free Cooling Box is abbreviated FCB

OD Installed type. OD: Outdoor mount; ID: Indoor mount

PCK Structure type. PCK is Packaged Unit abbreviation; SPL is Split Unit abbreviation

36 Nominal air volume. In this example, 36 means 3600m3/h (1800CFM). Also the air volume can be Custom-made.

F2 Fan quantity. F2 means 2 fans assembled; F1 means 1 fan assembled.

48 Voltage. 48 means 48VDC, range:36VDC~57VDC

XXX Custom number for special customer requested identification.

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Acronyms and Abbreviations

Table 3 lists acronyms and abbreviations used in this book.

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 Communication

DC Direct Current

DG Diesel Generator

FC Free Cooling

FCB Free Cooling Box

HVAC Heating, Ventilation, and Air Conditioning

Humid Humidity

I/O Input/Output

IPU Indoor Packaged Unit

kW Kilowatt

LED Light Emitting Diode

NC Normally Closed

NO Normally Open

PLD Programmable LED Display

PWM Pulse width modulation

R Read

RoHS Restriction of Hazardous Substances Directive

R/W Read/Write

Temp Temperature

VAC Voltage in Alternating Current

VDC Voltage in Direct Current

WPU Wall Pack Unit

Page 7 of 52

Product Overview

Unit Operating Modes The air conditioning system has three modes of operation:

I. The free cooling mode (see figure 1)

II. The mechanical cooling assist mode

III. The emergency cooling /ventilation mode

The control system determines the unit’s mode of operation based on the temperature and humidity sensor

readings.

Figure 1: Free Cooling Mode

Free Cooling Mode 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. The existing third party HVAC units are “off” in this

mode.

Mechanical Cooling Assist Mode

The lower the T (T = Temp inside – Temp outside) the less cooling capacity the FCB has. There is a point for

every shelter when that T is small enough where the FCB can no longer maintain the inside temp to the

designated set-points. When this occurs the FCB will ask the existing HVAC systems to engage to provide

additional cooling capacity in order to maintain the site temperature.

NOTE: As long as T ≥ 3.6°F the FCB will provide cooling benefit and will continue to operate to minimize

compressor run time. It is normal for the FCB to be providing this benefit during Mechanical Cooling Assist

Mode.

Emergency Cooling/Ventilation Mode If the mechanical cooling assist mode fails to keep the site cool enough whereby the site temp exceeds the upper

set point by a few degrees then the FCB will shift into Emergency/Ventilation mode. In this mode the FCB will

continue to monitor outside and inside temperature and will provide Free Cooling as long as Tinside-Toutside >

0ºF. This will typically only occur when the system would need Mechanical Cooling Assist Mode and the

Mechanical Cooling fails to work. This emergency mode can occur whenever there is a loss of prime power or

there is complete failure of either HVAC system to cool the site to within a few degrees of the upper set point.

FCB

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Ease of Control and Configuration

The FCB controller has a convenient Programmable LED Display (PLD). This three-button PLD is the user

interface by which an operator can do the following:

Check current status of the system such as sensor readings and operating mode

Change factory set points

Review alarms and alarm history

Many of these same functions can be accessed remotely via an RS485 communication interface built into the

controller.

FCB Electronics Compartment Accessible outside the shelter by removing

front cover of FCB and then panel covering

electronics compartment.

Houses FCB controller and other critical

electronics

FCB Controller Board

Inside

Shelter

Outside

Shelter

Page 9 of 52

Page 10 of 52

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 11 for the complete list of material shipped with each unit.

Check that:

The supply voltage meets the requirements as designated, 36V DC~57V DC.

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 9.

Installation and startup must be performed by an AIRSYS Authorized Service Technician (AAST).

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

Avertissement. Utilisation à l’extérieur. Risque de chocs électriques peut causer des blessures et même

entraîner la mort. Couper les sources d’alimentation à distance avant le dépannage.

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.

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 from losses.

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.

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 US distributor, Tempest

Telecom Solutions LLC.

Note: Warranty assumes that an AAST performed the installation and submitted 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, as date of installation

cannot be confirmed.

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

Page 11 of 52

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.

. 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, wearing gloves, and wearing 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:

[email protected]

Phone: (855)-874-5380 Table 4: Material Supplied by AIRSYS

Item Model # or Part # Qty Item Description Comments

1 5100007560 1 FREECCOL.OD.PCK36F2 FCB Free Cooling Box

2 2030100280 1 Supply air grill

3 2030100270 1 Return air grill

4 8553703300 24 Self tapping screw ST4.2*25 For the supply and return air grill installation

5 8554504600 6 Pan head screw with washer M5*16

For PLD installation

6 2040303110 1 Controller Assembled in electric box

7 8452001058 1 Indoor temp. sensor (ST1) One end connected inside the electric box

8 8452001058 1 Outdoor temp. sensor (ST2) One end connected inside the electric box

9 8452001040 1 Supply air temp. sensor (ST3) One end connected inside the electric box

10 8454020720 1 Humid. sensor (SH) One end connected inside the electric box

11 1170103020 1 Installation and Operation Manual

12 8453500390 1 PLD Cable From user terminal to FCB controller

Installer Supplied Material Table 5 lists items required for installation that must be supplied by an AIRSYS Authorized Service Technician

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(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 WPU communication cable “R” to FCB electric box

2 1 set of cable From WPU to FCB electric box; Max current capacity, recommended gauge: 5 Amps, 16 gauge recommended

2 48VDC power plant cable to FCB

1 1 set of three-wire cable To terminals 1+,2-,PE in electric box; Max current capacity, recommended gauge: 11 Amps, 10 gauge recommended

3 Fire/Smoke alarm input harness

1 1 cable with 2 wires, length as needed Alarm panel to FCB controller ID4 & IDC1

4 DG run status input harness (optional)

1 1 cable with 2 wires, length as needed Alarm panel to FCB controller ID1 & IDC1

5 Supply air frame 1 Refer to Appendix 1 for size details for each model.

Built inside wall to facilitate air flow

6 Return air frame 2 Refer to Appendix 1 for size details for each model.

Built inside wall to facilitate air flow

7 Tin-coated paper

As needed

With single-sided adhesive Used to line the return and supply air frames

8 Silicone sealant

As needed

Commercial grade outdoor silicone sealant

9 Weather stripping As needed

Commercial grade neoprene weather stripping or equivalent Recommend a minimum of 25 mm (~1”) wide and 20 mm (~0.8”) thick

Used to frame the WPU outlet and inlet to create a weather tight seal

10 Terminals As needed

Recommended for ease of terminal block installation; however, not required

11 Crimping pliers If needed

Only needed when using terminals

12 Nylon zip-tie As needed

Small nylon zip tie For securing humidity sensor to humidity sensor box

Optional connections

13 RS485 communication cable

1 1 cable with 2 wires From electric box to customer defined location; 16 gauge recommended

14 24 VDC power plant cable to inverter

1 1 cables with 3 wires From 24 VDC power plant to 24 to 48VDC inverter; Max current capacity, recommended gauge: 22 Amps, 8 gauge recommended

15 FCB alarm output cable 1 1 cables with 2 wires To monitor the alarm; 12 gauge recommended

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FCB Dimensions 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 6: External Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal)

Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal) NOTE: Dimensional tolerance ± 1/16” (2 mm)

MODEL UNIT WIDTH (W/W’)

DEPTH (D)

HEIGHT (H)

SUPPLY RETURN

A B C B E F G I J K L M N

36F2C0 MM 830/750 635 1620 438 615 240 615 828 50 790 630 169 131 107 50 1600

IN 32.68/29.53 25 63.78 17.24 24.21 9.45 24.21 32.6 1.97 31.1 24.8 6.65 5.16 4.23 1.97 62.99

Page 14 of 52

Physical Location of the FCB

FCB location is best if it can be located according to the drawing below:

Mounted on short side of the shelter so there is maximum Air flow

Centered on the wall to facilitate good air flow

With a minimum of 24“ clearance between supply vent and any partial or complete blockage

Do not place directly behind complete supply blockage suck as a battery bank.

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: Leave at least:

1200 mm (47.24”) free space in front of the unit;

Recommended 500 mm (19.68”) free space at the bottom of the unit; Figure 2: Working Space

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.

24” clearance

Equipment

Shelter

Good

Rack1 Rack2

Rack3 Rack4 Rack5

BEST BEST

OK

OK Good

Good

Good

OK OK

FCB OK OK

Least

desirable

Least

desirable

Least

desirable

Least

desirable

Page 15 of 52

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 6 on page 13 for dimensions.

Figure 3: Left Side View

Figure 4: Openings and Holes in the Wall

Install Weather Stripping Before mounting the unit on the outside wall, fix the neoprene weather stripping (installer provided) around the

Page 16 of 52

openings of the air supply and the air return to ensure an airtight closure, as shown in Figure 5.

Figure 5: Install Sealing Strips

Position the Unit

Important. The unit is heavy. Exercise caution while putting the unit in place to prevent damage to the

FCB or personnel.

The unit must be installed in a level position. (refer to Figure 6).

Figure 6: Inclination of Mounted FCB

Lift the unit from below with lifting equipment or tools, and then move the unit to the wall. Use the screws

(installer supplied) to fix the unit on the wall. Generally this is done by following these steps:

Position the unit next to the wall using a forklift or leveling system.

Figure 7: Position the Unit

Attach a single mounting screw and adjust to ensure the unit is level.

Weather stripping (Table 5, item 10)

Use either a level system or a forklift to position the unit.

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Figure 8: Verify the Unit is Level

After the unit is level, attach the remaining mounting screws (a quantity of 6 total for one FCB).

Seal the Opening between Units and Wall In order to prevent rain from entering the gap, 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 8) as shown in Figure .

Figure 9: Seal the Opening between Holes and Wall

Page 18 of 52

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 9.

Figure 9: Install the Supply and Return Air Grills

Note the following:

Install the supply and return air frames into their respective cutouts.

Use aluminum tape to tape down the edges of the return and supply air frames on the WPU side.

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 Appendix 1 for the dimensions of the supply and return air frames for each model.

Return air grill (Table 4, item 2)

Return air frame (Table 5, item 6) and supply air frame (Table 5, item 6)

Tin-coated paper

(Table 5, item 7)

Supply air grill

(Table 4, item 3)

FCB

Product Information

Page 19 of 52

Complete Electrical Connections

Cautions

Danger. Only a certified service technician should make the electrical connections to the existing 3rd

party

HVAC system.

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 FCB. 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.

Electrical Connection List

# Connection Description

1 *HVAC1 Control Prevents operation of HVAC 1 when FCB relay KA1 is open

(Breaks command for Compressor (Y) and Supply Fan (G))

2 *HVAC2 Control Prevents operation of HVAC 2 when FCB relay KA2 is open

(Breaks command for Compressor (Y) and Supply Fan (G))

3 48 VDC Supplies operating power to FCB (10 Amps MAX)

4 Earth Ground Should meet local electrical codes

5 Smoke/Fire Alarm Input SignalForm C contact relay that can be NO or NC

(6) FCB Alarm (Optional) Output Signal Indicates FCB has a fault (NO or NC)

(7) Diesel Generator run (Optional) Input Signal Indicates generator is running (NO or NC)

* This connection is made as an interrupt in the low voltage control line from the HVAC controller to each HVAC.

Consult the HVAC controller manual for details on choosing a low voltage line for HVAC 1 and HVAC 2

HVAC1 HVAC2

FCB

HVAC controller

48 VDC Rectifier

Smoke/Fire detector

HVAC1 Control

Break In HVAC2 Control

Break In

-48 VDC In -48 VDC Rtn

Smoke/Fire

alarm signal

Earth

Ground

1 2

3

4

5

FCB

Product Information

Page 20 of 52

Electrical Connection to Controller Box Refer to ‘field wiring diagram’ on page 44 for all electrical connections.

Before wiring to the FCB, manually open air damper by holding the black button with one hand and opening the

air damper with the other hand.

Note: When the Air Damper is open, the installer can look upward through the FCB and see the FCB exhaust

cut-out in the shelter wall.

Figure 10: The status of air valve open or close

Hold the black button, and

open the air damper

Outside Air Damper

Damper Closed Damper Open

FCB

Product Information

Page 21 of 52

Then, do the connections with following procedures.

1) Take the cables through the holes which are in the wall and built-in the unit. Connect the 48VDC power

plant cable from the DC plant to the FCB electric box.(refer to ‘field wiring diagram’)

!!!Caution: DC power plant breaker must be in the off position.

2) Connect the PLD cable from PLD to the FCB.

a. Take the cables through the holes which are in the wall and built-in the unit.

b. Tie the communication cable and power cables together and tightened by zip tie.

c. Tie communication cable at the middle of the bar and through the holes which at the right side of the FCB.

Take the PLD cable through the holes

Tie the PLD cable and power cables together

Tie the PLD cable

Take the PLD cable through the holes

FCB

Product Information

Page 22 of 52

d. Put the communication cable through the hole under the electric box and plug the communication cable

terminal to controller board ‘J7’ terminal as shown below.

3) Fix the user terminal on the wall

a. Take the cover of the user terminal away by small screw driver.

b. Using the screw driver to loosen the screw and turn around the yellow block, then tighten the screw, fix the

user terminal on the install bar.

PLD cable to J7 terminal

Through the hole

Take the cover away

Fix the PLD user terminal on the install bar

Put the PLD cable through the holes

FCB

Product Information

Page 23 of 52

c. After fix the user terminal on the install bar, put the user terminal cover back.

d. Put the other side terminal of communication cable to user terminal.

e. Fixed the PLD terminal install bar on the wall, make sure the PLD cable hide behind.

4) Relocate the indoor temperature sensor (ST1) and humidity sensor (RH) near PLD user terminal.

Fix the PLD user terminal on the install bar

FCB

Product Information

Page 24 of 52

Sensor Locations at time of FCB Shipment:

Re-locate Room Temperature sensor (ST1) as show in picture above.

Re-locate Humidity sensor (RH) as shown in picture above

ST1, indoor temperature sensor

ST3, supply air temperature sensor

ST2, outdoor temperature sensor

RH, humidity sensor

FCB

Product Information

Page 25 of 52

Field Wiring Power & Control

Connection to Existing

HVAC, should be

Normally Closed (NC).

Refer to below information

about KA1&KA2:

1&8 is coil;

6&7 is Normally Closed;

6&8 is Normally Open;

3&2 is Normally Closed;

3&4 is Normally Open.

6

5

3

4

7

8

2

1

KA1/2

IMPORTANT -48 Vdc Polarity (1+) to (- 48 rtrn)

(2-) to (- 48 Vdc)

FCB

Product Information

Page 26 of 52

Field Wiring Alarm Connections

5 Required: o NAME: Fire/Smoke Alarm Input

o CONFIG: NC or NO via software (NC default)

o CONNECT: J4 ID4 & IDC1

Shuts down outside Air damper and HVACs

6 Optional: o NAME: FCB Alarm Output

o CONFIG: NC via NC5 or NO via NO5

o CONNECT: J11 C5 and NC5 or NO5

Provides signal to NOC that maintenance is needed

7 Optional: o NAME: DG Run Alarm

o CONFIG: NC or NO via software (NC default)

o CONNECT: J4 ID1 & IDC1

Shuts outside Air damper when DG is running

5

7

6

FCB Alarm

Output

J11

Smoke/Fire Alarm

Input

J4: ID4 & IDC1

DG Run

Input

J4: ID1 & IDC1

Page 27 of 52

Complete the Installation Check list You should now have completed all of the physical installation steps. Before starting the system, ensure that no

steps have been omitted by completing this installation and wiring checklist.

Date: ___________________Unit Factory Number:__________________(refer to the FCB name plate)

INSTALLATION √ or Χ

Commercial grade weather stripping is fastened around both supply and exhaust holes in FCB

FCB is securely mounted to the wall

Silicone sealant has been applied to seal FCB to wall with NO gaps

Indoor temperature sensor is mounted near the PLD.

Humidity sensor is mounted near the PLD.

The aluminum grills are fastened.

WIRING

The connections must be secure from FCB to 48VDC power panel.

The connections must be secure from 24VDC to 48VDC convertor to 24VDC power panel. (OPTIONAL)

The connections must be secure from 24VDC to 48VDC convertor to FCB. (OPTIONAL)

Verify air damper moves freely without interfere from cables.

Turn On Component Breakers After completing the checklist, turn all breakers to the on position. Then reattach all covers and panels before

turning on the breakers in the prime power panel.

Verify the Installation To verify the installation, you will complete these steps:

Turn on the switches at the main power supply.

Execute the test to verify the equipment is functioning correctly.

Turn the system on.

Fill out the registration card and mail it to the address on the back of the card so the warranty period

can be properly established.

Three of these steps require using the PLD interface. Additional details on using the PLD to perform operational

functions can be found in Chapter 3 starting on page 32. The steps that require using the PLD in this section are

in summary form.

Turn on 48VDC Power Turn on the 48VDC input breaker in DC power plant.

Note: The PLD display should light up and after a brief delay should display the inside temperature. If any

alarms are registered, use the information in chapter 3, Table 7: Troubleshooting Alarms to diagnose the

problem. Chapter 3 includes detailed information on PLD operation and how to understand and respond to

alarms.

Page 28 of 52

Turn the FCB System On (or Off)

There are two methods for turning the FCB system ON/OFF. For either method you must get to the main

menu by pressing the Up and Down buttons together to show the room temperature displayed on the pLD

Press the Up and Down buttons together to enter the main screen.

1. Use the Up or Down buttons until display shows STa then press the Sel & Down buttons together.

This will change the state of the FCB from On to Off or from Off to On.

OR

2. When the display shows OFF/ON hold the Sel button down for three (3) seconds. This which

change the state of the FCB from On to Off or from Off to On.

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.

Main menu

Main screen (Press “ Up” and “Down” button at the same time)

Parameter Displayed Description

Room temperature 73.6 Current room temperature

Unit Condition Sta

Unit status

Refer to “Fig.4: Operation flow chart on PLD ”to enter the next menu.

Description of the displayed number: 0.Unit on; 1. OFF by alarms; 2. OFF by monitor;

3. OFF by time–schedule control; 4. OFF by digital input; 5. OFF by keyboard ;6.

Manual operation;7.Standby status

Unit type TYP Unit type, See section “5.Unit type definition” .Read-only.

Unit Status ON (or OFF) Unit status in on or Unit status is off

Humidity HU Humidity measurement

Outside temperature ET External Ambient (outside) temperature measurement

Supply temperature ST Supply Air temperature measurement

Enter into other menu Enter into other menu

Press Sel and Down buttons together

Press both buttons together to enter the main screen

Hold the Sel button for 3 secs

Page 29 of 52

System Test

I. Verify all sensor readings are accurate

Room Temp sensor

Outside Temp Sensor

Supply Air Temp Sensor

Humidity sensor

II. Verify Free Cooling Mode of Operation:

CONDITIONS: Room temperature – Outside temperature =ΔT > 3.6º

Indoor Temp > 73ºF

RH < 85%

RESULTS: Fan Speed and damper position should reflect logic diagrams below

III. Verify Emergency Mode of Operation:

CONDITIONS: Room temperature > U19 (Factory Default 84.9°F) AND Room Temp > Outside Temp

RESULTS: Supply Fan speed at 100%, damper open

IV. Verify Mechanical Cooling Mode of Operation: CONDITIONS: Room temperature > U06/U08 (Factory Default 78.9°F)

RESULTS: HVACs will be released to operate “normally” under their own controller until Room Temp

cools down to U07/U09

NOTE: Verify turning off the

DC Power to the FCB also places

HVACs in “normal” operation

Page 30 of 52

V. Alarm Verification Testing:

a. Trigger FIRE/SMOKE alarm:

i. FCB Damper should close and fan shuts off

ii. HVACs should shut down (Closed to outside air and fans off)

b. Trigger DG Run Alarm (optional): FCB Damper should close.

c. Trigger FCB Fail Alarm (optional): If connected alarm signal should be

received by the NOC.

Complete the Registration Card The information on the registration card is critical for establishing the warranty start point.

Unit #1

Unit #2

Unit #3

Page 31 of 52

Page 32 of 52

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 11: PLD User Interface

Button actions are described in Table 8. Table 8: PLD Button Actions

Button and LED Function Description

Sel

Confirm or review the value.

When the LED is on, indicates that an alarm has been triggered.

Up Increase value or go back to previous display.

Down Decrease value or go to next display.

+

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.

Navigating the Main Menu Pressing the Up and Down buttons at the same time displays the PLD Main Menu. The default display is the

current room temperature. You use the Up or Down buttons to access the other options on the main menu, listed

in Table 9.

Some of the options on the main menu let you view a sensor measurement (humidity, outdoor temperature,

supply air temperature). Press the Sel button to display the measurement value; press the Up and Down buttons

to return to the Main Menu.

Other options let you perform actions: turn the system on and off, start comfort mode and set the comfort mode

temperature, access other menu options. These options are described in the following sections.

Note: Option A-8 (Set) 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” on page 38.

In the table, the following abbreviations are used:

S.N Serial number

R The parameter can only be viewed, not changed.

R/W The parameter can be both viewed and updated.

Page 33 of 52

Table 9: Parameters on Main Menu (A)

S.N Display R/W Description

A-1 Room temperature 20.8 Current room temperature

A-2 Unit status Sta

Unit status Description of the displayed number: 0.Unit on; 1. OFF by alarms; 2. OFF by monitor; 3. OFF by time–schedule control; 4. OFF by digital input; 5. OFF by keyboard ;6. Manual operation;7.Standby status

A-3 Unit type TYP Unit type, Read-only.

Turning the HVAC System On or Off Press the Up and Down buttons together to enter the main screen.

Press Down or Up until the screen displays STa.

If the screen displays STa, press the Sel and Down buttons together. The up and down LED lights will be on or

off, if the up and down LED lights are 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: 0 means on, 5 means off. 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.

Executing the start test This set of steps verifies that the system is operating as expected. Note the following considerations:

Before you begin this process, the FCB system must be turned on. Refer to “Turning the HVAC System On or Off” section above.

The system will display the main menu (indoor temperature) automatically after ten minutes when there has

been no input from the technician.

If any alarms are triggered during the test, refer to “

Press until screen

displays STa

Press Sel and Down buttons together

Press both buttons together to enter the main screen

Page 34 of 52

Alarms” on page 34 for details.

Complete the test:

Step.1 Make sure the indoor temperature higher than 73˚F.

Step.2 Make sure the ∆T=Tindoor –Toutdoor > 3.6F

Check if the supply fan runs normally, if OK, means the FCB installation and wiring are OK.

When you finished the check, replace the electric box cover and front cover.

Page 35 of 52

Alarms When a problem occurs during operation of the unit, the controller records the related information and sounds an

alarm signal. The code identifying the malfunction displays on the screen of the user terminal. Depending on the

severity of the alarm, various devices 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.

When an alarm occurs, press the Sel and Up buttons to terminate the alarm sound. Press the Down button to

review details of the latest alarm. The system also lets you review alarm history through a separate menu.

Table 10 lists the alarm codes that may display with a brief description. Table 10 on page 28 provides more

detail on troubleshooting alarms should they occur during operation of the system. Table 10: Summary of System Alarms

Code Description Output Delay

Devices Switched Off

A01 Dirty air filter1 10s

A03 Smoke/fire alarm Free cooling function off

A04 Fan 1 overload Free cooling function off

A05 Fan 2 overload Free cooling function off

A06 High temperature alarm 60s

A07 Low temperature alarm 60s

A08 Indoor temp sensor defective 60s Free cooling function off

A09 Humidity sensor defective 60s Free cooling function off

A10 Outdoor temperature sensor defective 60s Free cooling function off

A11 Supply air temperature sensor defective 60s

A16 Air damper alarm 195m

A17 Prime power outage

Viewing Alarm History To review the history of alarm codes, follow these steps:

From the main menu, press the Sel and Down buttons at the same time, the screen displays L01. Press Down

button until the screen displays L05.

Press the Sel button to confirm, the screen displaysH01. Press Sel to confirm.

Then press Up or Down to review the history.

Clearing Alarm History To clear the history of alarm codes, follow these steps:

From the main menu, press the Sel and Down buttons at the same time, the screen displays L01. Press Down

button until the screen displays L05.

Press the Sel button to confirm, the screen displaysH01. Press Down button the screen displays H02, press Sel

to confirm. The screen displays NO.

Then press Up or Down to clear the history.

Page 36 of 52

6.2 Alarm Descriptions

Table 11: Troubleshooting Alarms

Code Signal Description Possible cause Components to check Recommend actions

Device Actions

Fan Damper HVAC

A01 Dirty air filter1 Alarm sounds, after deal with the problem, it can reset automatically.

Filter clogging. Check if the filter is dirty. Clean filter and after clean 2times, replace filter

Corresponding input digital (DI2) is disconnected or controller board broken

Check if the DI2 is disconnected or loose, review the DI2 status through L04 replay.

Re-connect the DI2 or replace controller board

Air pressure switch setting value is too low

Check the air pressure switch setting value (defaut:250)

Adjust the alarm value to standard value.

A03 Smoke/fire alarm Free cooling function stop, HVAC stop, alarm sounds. It can reset automatically.

The fire alarm is generated Check if the fire alarm is generated Replace fire alarm equipment

Off Off Off



Re-connect the DI4 or replace controller board

A04 Fan 1 overload

Alarm sounds, it can reset automatically.

If the A05 start at the same time, Free cooling stop, HVAC start to work.

Fan 1 is blocked or fan broken Check if the fan speed can work normally.

Remove the blocked object or replace the fan



Re-connect the DI5 or replace controller board.

A05 Fan 2 overload


If the A04 start at the same time, Free cooling stop, HVAC start to work

Fan 2 blocked or fan broken Check if the fan speed can work normally

Remove the blocked object or replace the fan



Re-connect the DI6 or replace controller board.

A06 High temp. (HT) alarm


FCB broken, if HVAC installed, HVAC broken.

Check if FCB broken or filter clogged;

Check if HVAC work broken.

Remedy FCB; Remedy HVAC.

The alarm setting value unreasonable

Check the HT alarm value L01-U15 Change the value to reasonable value.

A07 Low temp. (LT) alarm


Leak Check if there are some leaks between wall and FCB

Seal the leaks

Page 37 of 52

Code Signal Description Possible cause Components to check Recommend actions

Device Actions

Fan Damper HVAC

The alarm setting value unreasonable

Check the HT alarm value L01-U16 Change the value to reasonable value.

A08 Indoor temperature defective

Free cooling function stop, HVAC start to work. It can reset automatically.

Indoor temp. sensor (B1) broken Check if the senor is shorted or broken

Replace the sensor Off Off ON

A09 Humidity sensor defective


Ambient Humidity. sensor (B2) broken

Check if the senor is shorted or broken


A10 Outdoor temperature sensor defective


Ambient temp. sensor (B3) broken



A11 Supply air temperature senor defective


Supply air temp. sensor (B3) broken


Replace the sensor

A16 Air damper defective


Air valve hindered Check if the valve can work normally

Remove the hindered object

Air damper actuator broken Check if the damper can work normally

Replace the air damper actuator

Page 38 of 52

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 of factory settings and how they can be viewed and possibly modified

Port Definitions Figure 12 is a schematic drawing of the controller box ports.

G0

G

B1

B2

B3

B4

SYNC

GND

+5VREF

+24VDC

Y1

Y2

Y3

GND

ID1

ID2

ID3

ID4

ID5

ID6

IDC1

J1

J2

J3

J4

J8

J9

J10

J11

J5

J6

J7

RXTX+

RXTX-

GND

GND

TLAN

C1

NO1

NO2

NO3

C4

NO4

NO5

C5

NC5

PLD00SF400AIR-SYS GROUP

Sel

pLD user interface

prg

power

anologue input

anologue output

RS485 seriel com（optional）

digital inputdigital output

communication

clock card

（optional）

Plan net

Figure 12: pCOxs Controller Hardware Structure

Table 12 lists the input and output ports of the unit.

Note: The supply air temperature is a calculated value; the unit does not have a supply temperature sensor. This

temperature is used only when the unit is operating in free cooling mode.

Table 12: Port Values

Digital inputs Analog Inputs Digital Outputs Analog Outputs

ID1 DG Status (Close =Run)

B1 Indoor temperature DO1 HVAC 1 Y1 Fan1/Fan2

ID2 Filter clogged alarm B2 Humidity DO2 HVAC 2 Y2 Air damper

ID3 Prime power outage alarm B3 Outdoor temperature DO3 Y3

ID4 Smoke/fire, default:L02-F05=9(NC);

If F05=10 (NO).

B4 Supply temperature DO4

ID5 Fan2 overload DO5 General alarms

ID6 Fan1 overload

Page 39 of 52

System Parameters and Default Values This section describes the menus used for completing operations and displaying information. This section

describes the menus that let an authorized technician access factory default settings. Table 13: Control Menus

ID Purpose Description

A Main Menu Review the current indoor temperature, software version and turn on/off FCB.

L01 User Menu Password protected values that can only be changed by an AIRSYS Certified Service Technician. To change the FCB working settings.

L02 Factory Menu Password protected values that can only be changed by an AIRSYS Certified Service Technician. FCB factory configuration.

L03 Maintenance Menu

Don’t need password. Manual mode to operate the FCB and review the FCB run time.

L04 I/O menu Don’t need password. Review the current indoor temperature, outdoor temperature, supply air temperature and humidity.

L05 Initialization & Version

Review software version and reset the whole unit.

L06 History alarm menu

Review history alarm and clear the history alarm

To review or modify a parameter, follow these general steps:

Press the Up or Down button to find the code you want in main menu.

Then press the Sel button to review the value.

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.

To review L01~L05 menu, press the Sel and Down buttons together.

Then press the Sel button to review the value.

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.

The following four tables display the parameters for the “L” menus. In the tables, the following abbreviations are

used:

S.N Serial number

R The parameter can only be viewed, not changed.

R/W The parameter can be both viewed and updated.

NOTE: Fahrenheit is used as the default temperature unit although it can be set locally to Centigrade.

Main menu

Main screen (Press “ Up” and “Down” button at the same time)

Displayed Meaning

Room temperature 20.8 Current room temperature

Unit status Sta

Unit status

Refer to “Fig.4: Operation flow chart on PLD ”to enter the next menu.

Description of the displayed number: 0.Unit on; 1. OFF by alarms; 2. OFF by monitor;

3. OFF by time–schedule control; 4. OFF by digital input; 5. OFF by keyboard ;6.

Manual operation;7.Standby status

Unit type TYP Unit type, See section “5.Unit type definition” .Read-only.

ON Unit status in on

HU Humidity

ET Ambient temperature

ST Supply temperature

Enter into other menu

OFF Unit status in off

Page 40 of 52

Parameters of L01~L05

Parameter Read/ Write

Screen Code

Description Unit Range Default Value

L01 – User menu

User password R/W PS1 Input user password 0~999 123

Temp. set point of min. fan speed

R/W U01

˚F

U16~U02 72.8

Temp. set point of max. fan speed

R/W U02 U01~U15 78.9

Fan starting temp. diff. R/W U03

Temp. diff.= Room temperature- Ambient temperature. If outdoor temperature is selected, the screen appears.

˚F -70~99.9 2/3.6

Humidity limited set point R/W U04 When F22=YES, Display

% U05~99.9 90.0

No humidity limited set point R/W U05 % 0~U04 85.0

A/C1 start set point temp. R/W U06 If A/C1 is selected, the screen appears.

˚F

U07~U15 78.9

A/C1 stop set point temp. R/W U07 U01~U06 74.8

A/C2 start set point temp. R/W U08 If A/C2 is selected, the screen appears.

˚F U09~U15 78.9

A/C2 stop set point temp. R/W U09 U01~U08 74.8

A/C Min running time R/W U12 If A/C is selected, the screen appears.

M 0~500 8

High temp. set point temp. R/W U15

˚F

U06~999 95.0

Low temp. set point temp. R/W U16 -70~U13 41.0

High/low temp. delay R/W U17 Sec. 0~999 60

Enable emergency mode R/W U18 No humidity limited in this mode.

Yes/No Yes

Emergency mode set point R/W U19

˚F

0~999 84.9

Emergency mode fall-back deviation

R/W U20 0~99.9 4.8

Enable temperature difference limited

R/W U21 Yes/No Yes

Fan running time in emergency mode

R/W U22 (Judge whether the linkage to A/C default is recovered or not)

M 1~500 15

Temperature difference judgment time in emergency mode

R/W U23 M 1~500 3

Temperature difference for judgment in emergency mode

R/W U24 ˚F 0~99.9 3.6

Temperature difference in emergency mode

R/W U25 ˚F 0~99.9 0

Whether humidity limit function is valid or not in emergency mode

R/W U26 Yes/No No

Air supply limited R/W U27

Temperature of air supply and air fresh valve is necessary.

˚F -70~999 35.6

Air supply difference limited R/W U28 0~99.9 7.2

Fresh air valve is off difference R/W U29 0~99.9 90

Alarm of fresh air valve is valid. R/W U30 Yes/No No

L02 – Factory menu

Factory password R/W PS2 Input factory password 0~999 123

Unit type R/W F01 Port selection 0-10 8

Page 41 of 52


Screen Code


Digital input 1 select R/W F02 0






Analog input 1 select R/W F08 4




Analog output 1 select R/W F12 2

Analog output 2 select R/W F13 3

Analog output 3 select（PWM） R/W F14 0

Digital output 1 select R/W F15 4





Fan min. output voltage R/W F20 Select the analog supply fan.

V 0~10 3.0

Fan max. output voltage R/W F21 V 0~10 10.0

Enable humidity limit function R/W F22 Yes: humidity limit control enabled.

Yes/No

Yes

Enable A/C and fan running at the same time

R/W F24 If F24=NO, when A/C starts, fan stops.

Yes/No

Yes

Enable clock card R/W F25 Need corresponding options.

Yes/No

No

PC permit start and stop unit R/W F26 Yes/No

No

Enable auto restart R/W F27 Yes: auto restart enabled No: auto restart disabled

Yes/No

Yes

Filter alarm delay R/W F28 Filter alarm occurs delay times

Sec. 0~999 10

Whether temperature check function is valid or not

R/W F30

No: disable temperature check when fan idle status Yes: enable temperature check when fan idle status

Yes/No No

Communication protocol type R/W F33 0: Carel 1: Modbus 2: YDT

CAR/MDB/YDT

MDB

Communication Protocol address

R/W F34 1~207 1

Communication protocol Speed R/W F35 0-1200, 1-2400, 2-4800, 3-9600, 4-19200

Bps 0~4 3

Use British Imperial Units R/W F36 Yes/No Yes

Minimum control voltage of damper

R/W F38 0~10v damper valve V 0~10 0

Maximum control voltage of damper

R/W F39 0~10v damper valve V 0~10 10

Page 42 of 52


Screen Code


One fan overload for alarm, two fans are serious alarm

R/W F40 one output controls 2 fans Yes/No Yes

New factory password R/W PSF 123

L03 – Maintenance menu

Room temp. offset R/W M01 ˚C/˚F -99~999 0

Ambient humidity offset R/W M02 % -99~999 0

Ambient temp. offset R/W M03 ˚C/˚F -99~999 0

Supply temp. offset R/W N04 ˚C/˚F -99~999 0

Enable manual control R/W M05 Manually operate the unit when the system is OFF.

˚C/˚F AUT/NAN AUT

Fan 1 manual voltage output R/W M06

If N05= NAN, the screen appears.

V 0~10 0

Valve manual voltage output R/W M9A V 0~10 0

A/C1 manual control R/W M11 On/Off Off

A/C2 manual control R/W M12 On/Off Off

Fan1 run time high value R M15 1000Hour

0~999

Fan1 run time low value R/W M16 Hour 0~999

Fan1 time reset R M17 Yes/No NO

Fan1 start times R M18

Fan1 start times reset R/W M19 No/Yes NO

A/C1 run time high value R M25 A/C1 run time 1000Hour

0~999

A/C1 run time low value R M26 Hour 0~999

A/C1 time reset R/W M27 Yes/No NO

A/C1 start times R M28

A/C1 start times reset R/W M29 No/Yes NO

A/C2 run time high value R M30 A/C2 run time 1000Hour

0~999

A/C2 run time low value R M31 Hour 0~999

A/C2 time reset R/W M32 Yes/No No

A/C2 start times R M33

A/C2 start times reset R/W M34 No/Yes No

Filter1 clogged times R/W M45

Filter1 clogged times reset R/W M46 No/Yes No

L04 – Input and output menu

Room temperature R I01 ˚C/˚F -99~999

Ambient humidity R I02 % -99~999

Ambient temp. R I03

˚C/˚F

-99~999

Supply temp. R I04 Need corresponding options.

-99~999

Page 43 of 52


Screen Code


Digital input 1 R I05 C: Close, O: Open C/O






Digital output 1 R O01 C: Close, O: Open C/O





Analog output 1 R y1 V 0~10

Analog output 2 R Y2 V 0~10

Analog output 3 (PWM) R Y3 PWM 0~10

L05 – Initialization and version menu

Version R FC.B 1.4

BIOS R BIO 430=4.30

BOOT R BOO 403=4.03

Input initialization password R/W PS3 123

Initialization R/W DEF After unit type is changed, press “Sel.” to initialize.

Modify initialization password R/W PSD 123

Software version R E07

L06 – History alarm menu

History alarm R H01

Reset history alarm R/W H02 Yes/No No

Page 43 of 52

Page 44 of 52

Chapter4: 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 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 a will help to avoid serious damage to components and

expensive repairs by skilled personnel. Table 14: Preventive Maintenance Schedule

Task Recommended Frequency Comments

Check general operations 12 months Perform the start test

Preliminary air filter inspection/cleaning and replace if needed

Based on local conditions Depends on the amount and frequency of airborne particulates in the area

Inspect the two supply fans 12 months Working normally

Check air damper 12 months

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

Inspect all hardware for “snug” connection 12 months Make note of any loose hardware so it can be checked again at next scheduled PM

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 always 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.

Wiring and Components For wiring and components, perform a preliminary check and a white test.:

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.

Page 45 of 52

Perform a Functional Test

The purpose of this operation is to simulate real operation without damaging components due to incorrect

operation or protection failures.

Use the start test to check that the relays, breakers, and components work normally. For details on executing this

test, see “Executing the start test” on page 33.

When the supply fan turns on, the relay KA1 is triggered. If not, check the wiring.

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, you should increase the frequency of checks and maintenance.

Check Air 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:

Check if the damper can open and close normally.

Check if the damper actuator is OK (no damage).

Check if the damper rotor is OK (no damage).

Check if the nuts are properly tightened, as shown in the following figure.

Remove

panel

Replace air

filter

Page 46 of 52

Spare Parts Most of the important spare parts of the system can be provided by AIRSYS. Visit the AIRSYS Web site for

ordering information and to download a copy of the Spare Parts Brochure:

www.air-sys.com

Request spare parts from the nearest AIRSYS Authorized Service Center by providing the system series, model,

and serial number of the machine and the code of the component requested.

Order Form If you need to replace damaged components, complete the following order form. Some information of the

required information can be found on the name plate attached to the FCB.

Address: ___________________ Site No.: ___________________________ Date: _____________________

Unit model

Unit factory number

Replacement part name and number

(List all required components)

Description of issues

Root cause of the issues

http://www.air-sys.com/

Page 47 of 52

Page 48 of 52

Appendix 1: Drawings

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Tempest Telecom Solutions, LLC Phone:(805) 879-5432 136 W. Canon Perdido Street Phone (855) 874-5380 Suite 100

Santa Barbara CA 93101 [email protected]

Version number: V1.0-20130809

Documents

FREECOOL.OD.PCK.36F2 · 2016-08-11 · Page 7 of 52 Product Overview Unit Operating Modes The air conditioning system has three modes of operation: I. The free cooling mode (see figure