A_c Unit (Air Innovations).PDF

CH APTER 4: PO W ER D ISTRIBUTIO N

CTX 9000 DSi Training M anual GE InVision, Inc. Com pany Confidential66 of 378 M arch 10, 2005

A/C U N IT (AIR IN N OVATION S)

OVERVIEW

Figure 4-16 A/C Unit (Air Innovations)

The Air Innovations H VAC unit (P/N 2603-0006) is a heating and air-conditioning system that is designed to m aintain the air tem perature and hum idity w ithin the x-ray generating environm ent.

The Air Innovations H VAC unit is a closed loop system , m eaning that all the air supplied to the unit is then returned for reconditioning. This m inim izes the heat load on the H VAC system and also m inim izes contam ination of the electronics by dust and particulates from the am bient air. This closed air loop passes through a filter located in the H VAC unit w ith each pass. The H VAC system is intended to operate continuously, even w hen the CTX 9000 DSi is in idle or off m ode.

NOTE: Although all supporting documentation on the Air Innovations A/C unit indicates a

measured voltage of 350 VD C, the actual measured voltage is 330 VD C.

O utput M odule

Condensor

Evaparator

CHAPTER 4: POWER DISTRIBUTION

GE InVision, Inc. Company Confidential CTX 9000 DSi Training ManualMarch 10, 2005 67 of 378

DESCRIPTION

The HVAC system has two separate refrigeration circuits (situated in series with respect to each other), which allows for greater load shedding when 50% or less of the total cooling power is required (i.e. days when ambient temperatures are approximately 70 F and below). In addition, the two separate refrigeration circuits provide a level of redundancy if one of the circuits should fail.

NOTE: At temperatures above 70 F, both circuits are required to maintain setpoint.

Q Environm ental Specifications: The system is designed to operate in environments ranging from 15 F to 120 F and with either 60 Hz or 50 Hz power supplies.

NOTE: Even w hen the A/C unit is optimally functional, there is no guaranteed temperature

setpoint. Indeed, system limits are determined by the follow ing factors: ambient

temperature, humidity and pow er specif ications (i.e. w hether the system is operating at 50

H z or 60 H z).

Q Tem perature Control: Temperature control is achieved by modulating an electronic EPR (Evaporator Pressure, Regulating) valve installed on circuit #1 (the primary circuit).

Circuit #2 operates in an ON/OFF mode controlled by the controller. The controller uses its alarm contacts to turn each compressor on or off.

NOTE: If the ambient temperature is very low , the unit may sw itch over to a heating mode. Should

this occur, both compressors are automatically locked out of operation and the heater is

pulsed to maintain setpoint.

Q System Indicators: The LEDs and Digital Temperature Controller, mounted on the front of the electric panel, will indicate system status and any faults while the system is powered (even if the ON/OFF switch is turned to OFF).

NOTE: The LEDs and Digital Temperature Controller can only be shut dow n via the main pow er

breaker located on the front of the electric panel.


CTX 9000 DSi Training Manual GE InVision, Inc. Company Confidential68 of 378 March 10, 2005

COM PONENTS

Figure 4-17 A/C Unit (Air Innovations)

The system is physically comprised of three separate main assemblies and one sub-assembly (see Figure 4-17):

Q Evaporator (for more information, see Evaporator on page 68.)

Q Condenser (for more information, see Condenser on page 69.)

Q Electric Panel (for more information, see Electrical Panel on page 71.)

Q Drain Tube Assembly (for more information, see Drain Tube Assembly on page 75.)

Each of these components is installed individually in the CTX 9000 DSi and then connected together with quick connects for refrigerant piping and electrical connections.

EVAPORATOR

Main Components:

Q Evaporator fan (draw-thru impeller).

Q Evaporator coil (divided into two circuits in series).



Q Pre-filter.

NOTE: The evaporator f ilter is a 14" x 16" x 1", medium eff iciency pleated type U.L. Class 2 f ilter.

The average eff iciency is 25 - 30% with an arrestance of 90 - 92% on ASHRAE Standard

52-76. The f ilter media is high density glass micro f ibers laminated to an all glass woven

mesh backing.

Q Two TXV valves.

Q Two filter driers.

Q Two sight glasses.

Q EPR valve (circuit #1).

Q Two air proving switches for filter monitoring and fan safety.

Q Three electric heater elements.

Q Temperature sensor in supply air stream.

Q Four flexible refrigerant hoses for connection to condenser section.

Q Electrical harness for connecting sensors, safeties and power to electrical panel.

Two openings in the evaporator provide for return air and supply air connections to the baffle plate.

Return air first passes through the pre-filter and then enters the evaporator coil. It then flows through the rows dedicated to circuit #2 and then those rows dedicated to circuit #1. After leaving the evaporator coil, the air passes over the electric heater elements and then through the fan. Once the return air has left the fan, the air passes over the temperature sensor and then out the supply air opening.

CONDENSER

Main Components:

Q Two condenser fans.

Q Two compressors.

Q Two condenser coils.

Q Two combination High/Low pressure switches.



Figure 4-18 Pressure Switches

Q Two push button high pressure switches for alarm indication.

Q Two head pressure control valves.

Q Two refrigerant receivers (welded on top of each other).

Q Q uench valve (circuit #1).

Q Electrical harness for connecting sensors, safeties and power to electrical panel.

Ambient air is drawn into the A/C unit through the evaporators louvered covers found on both sides of the Input module. A replaceable mesh filter in installed in each louvered cover.

The ambient air is drawn through the condenser coils and is then exhausted from the A/C unit through louvered deflector covers on both sides of the Input module.

NOTE: The evaporator section is pie shaped to provide air paths to these coils.

Hot condenser air exits the unit via the louvers installed in the base section on the condenser side. Circuit #1 exhausts on the left side and circuit #2 on the right side.

Each compressor is dedicated to one circuit. Compressors are turned on and off based on the inputs from the controller. Circuit #1 comes on first (and only as required) to maintain setpoint and, if necessary, circuit #2 comes on for additional cooling capacity.

NOTE: The nominal capacity of each circuit is 2 tons.



ELECTRICAL PANEL

Figure 4-19 Electric Panel

Main Components:

Q Temperature controller.

Q All LED indicators.



Figure 4-20 Temperature Controller and Control LEDs

Q All breakers.

Figure 4-21 Breakers

Q All relays.

Q All switches.

Q Siemens LOGO for discreet controls.



Figure 4-22 Siemens LOGO

Q Quad I/O.

Figure 4-23 Quad I/O (Air Innovations Air Conditioner)

Q Mitsubishi FR-S540-0.4K-NA Variable Frequency Drive (VFD) to control the evaporator fan.



Figure 4-24 Mitsubishi FR-S540-0.4K-NA Variable Frequency Drive (VFD)

Q Cables for connecting to evaporator and condenser sections (quad I/O cable for connecting the A/C unit to the CTX 9000 DSi main computer).

Figure 4-25 Controller Cables



The electrical panel controls all functions of the HVAC system as well as provides power and electrical circuit protection to all components.

DRAIN TUBE ASSEMBLY

Main Components:

Q Pre-formed PVC piping.

Q Kazoo assembly.

Figure 4-26 Drain Tube Assembly

The drain assembly removes the condensate from the evaporator coil and is connected to an external drain or condensate pump. The kazoo allows the system to be self-priming, meaning that condensate will flow properly even if the unit runs with no water in the trap.

OPERATING RANG ES

The HVAC system is designed to operate continuously across a wide variety of ambient environments. The supply air setpoint to achieve these ranges is 60 F (with an allowable control range of +/- 10 F). When the supply air temperature is above 70 F, an alarm signal is sent to the quad I/O. Nonetheless, the A/C unit will continue to operate until manually shut down (if so desired).



SYSTEM SPECIFICATIONS

Ambient Dry Bulb Maximum

Ambient Relative H umidity @ Maximum F

Ambient Temp Minimum

Supply Air Temp Minimum/Maximum

Pow er Supply

120 F 50% RH 14 F 50 / 70 F 480 VAC 3 PHASE /

60 Hz

105 F 50% RH 14 F 50 / 70 F 380 VAC 3 PHASE /

50 Hz

System Specifications

Construction

Weight 500 lbs.

Construction External Painted Galvanized and Aluminum Components

Construction Internal Galvanized and Stainless Steel

Hardware Stainless Steel Metric Fasteners

Condensate Drain Gravity Drain

Condenser Coils 5 RowCopper TubesAluminum fins Coated with Mt. Holly Gold (or equivalent)

Evaporator Coil 6 Row (Circuited 3 and 3 in a Series)Copper TubesAluminum fins Coated with Mt. Holly Gold (or equivalent)

Fans Direct Drive Motorized Impellers

Filter 30/30 Filter on Evaporator Inlet

Controller Digital PID Controller

Performance

Supply Air Volume 800 CFM @ 1.0" wg External Maximum Pressure

Nominal Capacity Circuit #1 = 2 tonsCircuit #2 = 2 tons

Electrical Heating Coils 3 - 2000 W Solid Rod Type



THEORY OF OPERATION

The following topics are reviewed in this section:

Q Startup Sequence on page 78.

Q Normal Running Sequence on page 78.

Q Cooling Control Logic on page 79.

Q Heating Control Logic on page 80.

Q PID Control Functions on page 80.

Refrigerant R-134a

Noise (maximum) 85 dB A-weighted

Supply Voltage 480 / 3 / 60 Hz VAC or380 / 3 / 50 Hz VAC

Amperage 11.4 FLA @ 480V / 60Hz

Status LED Indicators

Control Circuit Green

Circuit #1 Cooling Green

Circuit #2 Cooling Green

Heater Yellow

Evaporator Filter Replacement Red

Circuit #1 Low Pressure Red

Circuit #2 Low Pressure Red

Circuit #1 High Pressure Red

Circuit #2 High Pressure Red

Agency Approvals

North America UL recognized to UL1995 / C22.2 no. 236

European Union (CE / LVD EMC) EN60335-1, 60335-2-24, 55014-1, 61000-3-2, 61000-3-3, 55014-2

System Specifications



STARTUP SEQ UENCE

Figure 4-27 Startup Sequence

Q Legend

Q TEMPTemperature reading of the RKC controller.

Q AL1Alarm Setting for circuit #1 (62.5 F).


Q AH1Alarm #1 Hysteresis (differential gap) compressor #1 (Shut off point is 55.0 F).


NORMAL RUNNING SEQ UENCE

Figure 4-28 Normal Running Sequence

Q Legend

Q TEMPTemperature reading of the RKC controller.

TEMP > AL1 Circuit #1 TEMP > AL2 Circuit #2

1 Minute "ON" 2 Minutes "ON"

ON/OFF Switch Evap Fan TEMP > AH1 & TEMP < AL1 Other

"ON" "ON" "No action"

TEMP < AH1 Heater

"ON"

TEMP > AL1 Circuit #1 TEMP > AL2 Circuit #2

If compressor has been off for 1 minute

"ON"If compressor has been

off for 2 minutes "ON"

Evap Fan TEMP > AH1 & TEMP < AL1 Other

"Running" "No

action"

TEMP < AH1 Heater

"ON"







COOLING CONTROL LOGIC

Consisting of two 2 ton circuits, the cooling control system is a redundant system so that in the event that one of the circuits fails, the other circuit can act as a backup.

NOTE: Should the one evaporator fan fail, the system cannot operate.

Q Circuit Specifications:

Q Circuit #1 has a capacity control valve that will allow the circuit to throttle back should the entire 2 or 4 tons not be necessary.

Q Circuit #2 does not have capacity control; it provides a full 2 tons of capacity.

Q Cooling Control System Operation:

Q The cooling system will control at or about the setpoint of 60 F.

Q When the temperature rises to 62.5 F, alarm # 1 of the temperature controller will close and start compressor circuit #1. When the temperature drops to 55 F, circuit #1 will shut off.

Q Should the temperature continue to rise to 65 F, alarm #2 of the controller will close and start circuit #2. When the temperature drops to 57.5 F, circuit #2 will shut off.

NOTE: There is a one minute time delay for circuit #1 and a two minute time delay for circuit #2.

Q The timers start timing when the compressor has been shut down. As long as circuit #1 has been off for one minute and circuit #2 has been off for two minutes, the compressors will start once the alarm has been activated.

Q Electronic Evaporator Pressure RegulatorThe electronic evaporator pressure regulator (capacity control valveSporlan CDS-9) is a stepper motor controlled valve. The electronic evaporator pressure regulator allows the A/C unit to match the heat load requirements of the CTX 9000 DSi, the ambient temperature as well as any leakage air that may be present.

Receiving control signals (5.5 - 20mA) from the temperature controller, the electronic evaporator pressure regulator reduces or increases the amount of suction return gas to compressor circuit #1. When the supply air temperature is at or below 60 F, the valve will begin to close which will reduce the capacity of circuit #1.

NOTE: This valve also modulates while circuit #2 is running.



Finally, the temperature controller provides a current (5.5 - 20mA) PID control output to allow the valve to precisely position itself. The output is proportional to the amount of deviation between the temperature and the setpoint and also the rate at which the temperature is either rising or falling and the PID settings programmed into the controller. For more information, see PID Control Functions on page 80.

HEATING CONTROL LOGIC

The heating control system is designed to bring the system up to temperature before the CTX 9000 DSi system is started.

Q Heating Control System Operation:

Q The heating control system will control at or about the setpoint of 60 F.

Q If the temperature is below 60 F, and neither compressor is running, the heater will be energized.

Q If the temperature rises to 62.5 F, compressor circuit #1 will come on and automatically disable the heater output circuit.

The three 2 kW heaters (Output #1) are controlled by the RKC temperature controller.

The controller outputs a time-proportioned PID (proportional, integral, derivative) on/off DCV control signal which is applied to the 2 Solid State Relays (SSRs). When the control signal is applied to the SSRs, the high voltage (AC) is allowed to pass through to the heater elements.

NOTE: The control signal and high voltage circuit are optically isolated from each other.

When the control signal is removed, the SSRs drop out. The amount of on and off time is regulated by:

Q The amount of deviation between the temperature and the setpoint.

Q The rate at which the temperature is either rising or falling.

Q The cycle time and PID settings programmed into the controller.

NOTE: For more information, see PID Control Functions on page 80.

PID CONTROL FUNCTIONS

Q Proportional Band (P)

The proportional band parameter regulates the effect of the proportional action. This setting causes the output to change continuously in proportion to the input deviation magnitude. A small proportional band value will (with a small deviation in input) cause a large change in output, and visa versa.

Q A small proportional band setting will cause control fluctuations or oscillations.



Q A large proportional band setting will cause a control offset. The smaller the value, the small the offset.

Q If the proportional band value is set to zero, an ON/OFF control will result .

Q When manually setting the proportional band, keep the following in mind.

Q As a rule, adjust for larger numeric values rather than smaller ones.

Q If cycling or oscillating occurs, the value is too small.

Q Oscillations will likely go above and below setpoint.

Q The longer the derivative time, the stronger the corrective action, and the more likely it is that oscillations will occur.

Q The derivative is OFF when set to zero. For control of fast-response input such as flow and pressure, or of input that fluctuates rapidly, set the derivative to zero.

Q When manually setting the derivative time, keep the following in mind:

Q As a rule, adjust from smaller numeric values to larger ones.

Q If the derivative is too large, very short-period oscillations will result.

NOTE: These oscillations will be much smaller than those caused by the proportional band or

integral time and are unlikely to cross the setpoint, but will instead fluctuate above or

below it .

Q Normal offset cannot be corrected by a proportional band change.

Q Integral Time (I)

Integral time (I) can be defined as the time required to develop an output change due to integral action that is equal to the change due to proportional action. The integral time (I) will automatically diminish the offset or normal deviation (offset) that cannot be prevented by adjusting the proportional band. The integral time will continuously increase or decrease the output in proportion to the time integral of the deviation from setpoint.

Q The smaller or shorter the integral time, the faster the output changes, and visa versa.

Q Shortening the integral time, like lowering the proportional band setting, will cause output to oscillate. However, such oscillations will have a longer period than those caused by a small proportional band.

Q When manually setting the integral time, keep the following in mind:

Q As a rule, adjust from larger numeric values to smaller ones.

Q If the integral time is too small, long-period oscillations will result. These oscillations are likely to go above and below setpoint with a long period.

Q Derivative Time (D)

The derivative action is the action that changes the output in proportion to the deviation derivative or rate of change. Just as the proportional and integral action cause the controlled object to approach the setpoint, the derivative time (D) slows this approach to prevent over-shoot.



EVAPORATOR COIL CAPACITY CONTROL

The electronic evaporator pressure regulator (capacity control valveSporlan CDS-9) is a stepper motor controlled valve. This valve controls the evaporator coil capacity from the RKC controller. When cooling output LED (Output 5) on the front of the controller is illuminated, the valve is active. The controller applies a minimum of 5.5 mA output so that the valve will not close completely. (4 mA would close the valve completely.)

Its maximum output (fully open, full capacity) is 20 mA and is automatic. The output to the valve is based on the difference between the process value (supply air temperature) and the setpoint. It is a PID controlled output (PID2) and no adjustment or calibration of this valve is required. For more information, see PID Control Functions on page 80.

PRESSURE TEST POINTS

Pressure test points (shrader valves) for a manifold gauge set are located at the end of the compressor/condenser section (on the side of the CTX 9000 DSi opposite the control box).

OPERATING PROCEDURES

W Uncrating the A/C UnitQ The evaporator, condenser and control box are all shipped on separate skids.

Q Each section is banded to its skidno screws or bolts are used to mount the sections.

Q A heavy tri-wall cardboard covering is installed over each section which is then banded to a skid.

1. To remove the units from their containers, cut the banding and remove the cardboard.

2. Discard the banding and cardboard.

3. Confirm with the site personnel on where to store or dispose of the A/C unit skids.

W Inspecting the A/C Unit

1. After uncrating the three sections of the A/C unit , inspect for any visible damage that may have occurred during shipping.

2. Report any damage to the carrier and file a written damage claim.

3. Check for any concealed irregularities by removing all access panels.

4. Check for loose hardware.

5. Ensure that no components inside the A/C unit shifted due to extreme force during shipping.

6. Rotate the three A/C fans to be sure that they spin freely.

7. Check the compressor(s) mounts to be sure they are securely attached.



NOTE: While shaking the compressor back and forth, ensure that there is no noise. Should you

hear any noise, ensure that the compressor(s) mounting are secure.

8. Inspect the refrigerant flex hoses for signs of damage, kinks or cracks.

NOTE: If the insulation on either suction flex line is torn, inspect the line carefully for damage.

9. Check all other tubing and valves for signs of stress or damage.

10. Inspect the wiring and wiring connectors on the evaporator and condenser section for signs of any damage that may have occurred.

NOTE: The male-female spade connectors are very diff icult to pull apart. As such, it is highly

unlikely that any of these will come apart.

11. Check the interior or exterior of the control box for any signs of damage to the cables, connectors, EMI filter, controller, LED's etc.

12. Remove the return air filter access panel to ensure the filter is installed properly.

13. Check the entire system for any refrigerant leaks that may have occurred during shipping.

W Installing the A/C UnitQ The CTX 9000 DSi HVAC system consists of 4 individually shipped components: the evaporator

section, condenser section, control (electronic) box and condensate drain assembly.

1. To install the condensate drain assembly, mount the drain assembly to the top of the forklift pocket below the control box.

2. Attach the tubing to the right side of the kazoo-mounting bracket.

This tubing section runs over to the left end of the CTX 9000 DSi where it is attached to the drain nipple.

3. Slide the evaporator and condenser section into their respective locations within the CTX 9000 DSi.

4. To secure the evaporator section to the mounting rails, install one bolt on the side toward the control box and two bolts on the opposite side.

5. To secure the condenser section to its mounting rails, only one bolt can be installed on each side.

NOTE: The mounting holes on the condenser section will be somewhat diff icult to reach due to

obstructions.

6. Before proceeding, ensure that all bolts have been tightened.



7. Attach the pre-formed p-trap tubing to the copper drain pipe on the evaporator section and attach the other end to the kazoo mounting bracket with hose clamps.

8. While installing the four refrigerant lines, consider the following:

NOTE: The refrigerant lines are marked so that they cannot be connected improperly.

Q It is crucial that the two suction and two liquid refrigerant lines are mated to their corresponding circuits or the system will not function properly. (The suction lines are insulated.)

Q Be careful not to bend any of the fins on the condenser coil when positioning the suction lines or the liquid lines.

a. Apply some refrigerant oil (POE oil) to the quick connects.

b. While installing the refrigerant lines, ensure that there is some oil visible on the threads.

c. After identifying the proper connection points, use the appropriate wrench to tighten each connection.

d. Tighten each connection until it stops.

CAUTION: Do not overtighten the connections. There should be no threads visible on the male

end after properly tightening the f ittings.

e. Once you have tightened the fittings, install the two small pieces of pipe insulation on the suction lines.

9. Install the control box to the mounting brackets on the CTX 9000 DSi.

10. To install the four electrical cables (one 24-pin, one 16-pin, one 9-pin and the quad I/O cable), feed the 24-pin, 16-pin and 9-pin cables through the two holes in the Input module located to the right of the control box.

NOTE: There are also two 4-pin connectors located on the bottom of the control box. The one

located on the right side of the control box is the remote start connection. The one located

on the left side of the control box is for RS-485 communication from the temperature

controller.

11. Attach the 24-pin cable connector to the condenser section.

NOTE: The connector is keyed so that it cannot be installed incorrectly.

12. Attach the 16-pin and 9-pin cable connectors to the evaporator section.

NOTE: The connectors are keyed so that they cannot be installed incorrectly.



13. Once you have each individual connector lined up, push it together and tighten the threaded collar.

14. Hook the quad I/O cable to its appropriate connector.

15. Install the two brackets (shipped loose) to attach the supply/return air plenum to the evaporator.

NOTE: The brackets will help to eliminate any leakage that may occur around the felt gasket area

of the plenum.

W Starting Up the A/C Unit

CAUTION: High voltage may be present at the line side of the circuit breaker.

1. Ensure that the main cable (3-phase power) is disconnected from the control box.

2. Ensure that the main breaker (visible from the outside of the control box) is in the OFF position (switched down).

3. Ensure that the start/stop (black and red) rocker switch is in the OFF position.

4. Open the right hand side control box door.

5. Ensure that all the circuit breakers are in the ON position (switched to the left).

6. Close the control box door.

7. Attach the 3-phase power cable to the flanged inlet at the bottom of the control box.

CAUTION: This is a twist lock-style connector. O nce it is seated, twist the connector to the right to

lock it in place. O nce it is connected, pull the connector downward to ensure that it is

securely attached.

8. Switch the main breaker to the ON position to energize the control circuit of the HVAC unit. The controller will display the temperature and the green control circuit LED will illuminate.

Should no LEDs illuminate after switching the breaker on, one of the following conditions may need to be rectified:

Q The main power feeding the CTX system has not been switched on.

Q The breaker feeding the HVAC unit has not been switched on.

Q The twist lock connector has not been connected properly.

9. Either:

Q Push the system start/stop rocker switch to the ON position for manual operation.

~OR~



Q Leave the switch in the OFF position for remote start operation.

10. Once the switch is activated, the evaporator (supply air) fan will ramp up to speed (40 Hz for 460-480/3/60; 45 Hz for 380-400/3/50).

11. The setpoint of the controller is 60 F. The system will automatically start to control around this setpoint.

NOTE: There is a one minute time delay for compressor/condenser circuit #1 (the timer starts

timing when the compressor shuts off).There is a two minute time delay for compressor/condenser circuit #2 (the timer starts

timing when the compressor shuts off).

W Shutting Down the A/C Unit

1. Either:

Q For manual operation, turn the system start/stop switch to the OFF position.

~OR~

Q For remote operation, activate the shutdown command from the motion control computer system.

This will shut down the fan and de-energize any compressor/condenser circuits and the heater control.

NOTE: The temperature controller will remain energized as will the green control circuit indicating

LED.

2. Turn the main breaker to the OFF position to de-energize the HVAC system.

CAUTION: High voltage is still present on the line side of the breaker until the power cable is

disconnected or the CTX 9000 DSi breaker is turned off.

3. Should any A/C maintenance or troubleshooting be necessary, disconnect the power cable attached to the bottom of the control box to de-energize all remaining circuits.

4. Press the Set key on the RKC controller.

5. Once SV illuminates on the upper display (the set valueit actually looks like an S and an upside down A), push the R/S key to move the brightly lit digit to the position that needs to be changed.

6. Use the up or down arrow key to make the new change.

7. Once the correct setpoint is displayed, press the Set key to save the new setpoint.



W Adjusting the Frequency Drive Parameters

NOTE: For more information on the Mitsubishi FR-S frequency drive, review the OEM documentation.The only parameters shown are the ones that change from the default settings.

W Adjusting the Frequency Drive Speed

NOTE: For more information on the Mitsubishi FR-S frequency drive, review the OEM documentation.

The Mitsubishi frequency drive speed is adjusted with the dial on the front of the unit.

1. Turn the dial to the desired speed (40 Hz for 480 VAC systems, 45 Hz for 380 VAC systems).

2. The flickering frequency is the set frequency. Press Enter to store the new speed.

W Adjusting the RKC Temperature Controller Setpoint

NOTE: For more information on the RKC temperature controller, review the following OEM documentation:Specifications: http://www.rkcinst.co.jp/english/pdf/ma900_02e.pdfInstructional Manual: http://www.rkcinst.co.jp/english/pdf_manual/imr01h01e4.pdfCommunications Instructional Manual: http://www.rkcinst.co.jp/english/pdf_manual/imr01h02e3.pdf

Parameter Number

Parameters Settings

P7 ACCELERATION TIME 10

P8 DECELERATION TIME 15

P9 ELECTRONIC THERMAL OVERLOAD RELAY 1.1

P14 LOAD PATTERN SELECTION 1

P65 A, B, C TERMINAL FUNCTION SELECTION 0

P67 NUMBER OF RETRIES 10

P68 RETRY WAITING TIME 5

P72 PWM FREQUENCY SELECTION 3

P79 OPERATION MODE SELECTION 3



The RKC temperature controller setpoint is changed by using the set key.

1. Press the Set key.

2. Once SV illuminates on the upper display (the set valueit actually looks like an S and an upside down A), push the R/S key to move the brightly lit digit to the position that needs to be changed.

3. Use the up or down arrow key to make the new change.

4. Once the correct setpoint is displayed, press the Set key to save the new setpoint.

TROUBLESHOOTING THE AIR INNOVATIONS A/C UNIT

SUPPLY AIR CONDITIONS TROUBLESHOOTING

1. Supply Air Temperature Too Low.

NOTE: There is no LED or Quad I/O indicator for this condition.

2. Supply Air Temperature Too High (above 70 FQuad I/O Indicator).

Symptom Possible Cause Recommended Action

Supply air

temperature

remains below

setpoint.

The temperature

controller setpoint

has been lowered.

Check controller setpoint setting (the normal setting is 60 F.)

Same Compressor(s)

running when it/

they should not.

Check controller alarm and hysteresis (differential gap) settings.

Same Heater control

system not

functioning

properly.

Check amperage to heaters. If necessary, raise setpoint(Output 1

LED on controller will be on). Check heater Amp draw (it should be ~

7.2 A at 480 VAC and ~ 5.5 at 380-400 VAC).Check DC control voltage to SSRs. If there is no DC signal at the

SSRs, and there is amperage to the heaters, the SSRs are defective.

When SSRs fail, they normally fail closed. Replace defective SSR(s).

Same Temperature sensor

is defective.

Check sensor against an accurate hand held device. If in error,

temporarily offset the input to the controller until a new sensor can

be obtained.



AIR CONDITIONING TROUBLESHOOTING

1. Compressor Fails To Start (LED Indicator #1,# 2, #3, #8 or #9; Quad I/O High Pressure Indicator).


Supply air

temperature

remains above

setpoint.

Temperature

controller is

defective.

Check programming parameters.

Same Defective heater

control system.

Check DC control voltage to SSRs. If there is no DC signal at the

SSRs, and there is amperage to the heaters, the SSRs are defective.

When SSRs fail, they normally fail closed. Replace defective SSR(s).

Low airflow in

evaporator

section.

Defective fan motor,

frequency drive,

breaker or wiring.

Contact Air Innovations.

Same Dirty evaporator coil

filter.

Replace filter.

Supply air

temperature

remains above

setpoint.

Temperature sensor

is defective.

Check sensor against an accurate hand held device. If in error,

temporarily offset the input to the controller until a new sensor can

be obtained.

No air

conditioning.

Compressor(s) not

running.

Check controls, switches, and wiring using OEM schematic.

Insufficient

cooling.

Unit being operated

in an excessively hot

and humid

condition.

Be sure both compressors are running. If the high temperature

alarm (activates at 70 F) is triggered (quad I/O pin 4-1), shut the

CTX 9000 DSi system down.


Electric circuit test Power failure. Check for blown line fuse or breaker.Check main circuit breaker.

Same Disconnect switch is

open.

Determine why the switch was opened. If the

system is in working order, close the switch.

Electric circuit test shows power

on line side but not on the load

side of compressor.

Circuit breaker is

tripped or defective.

Reset or replace breaker if defective.



2. Compressor Rapid Cycles (#1 or #2 Low Pressure LED Indicator; Quad I/O Indicator).

Full voltage at motor terminals

but compressor will not run.

Compressor burned

out.


Test for burned-out contactor coil

or broken contacts.

Inoperative

compressor

contactor.

Replace contactor.

Contactor coil is not energized. Open control circuit

for:

Q Start/Stop

switch.

Q Pressure

switches.

Q Frequency

drive switch.

Q Airflow

switches.

Locate open control circuit and determine its

cause.

Condenser fan is not starting

which causes the compressor to

shut off on high pressure.

Motor winding

protector is open.Motor is defective.

The motor winding protector will reset itself

when the A/C unit temperature drops. If the

motor does not restart, replace the A/C motor.


Compressor cuts out

intermittently from its low

pressure cut-out switch.

(Caution: Rapid cycling can

damage the compressor if

allowed to continue for an

extended period.)

Lack of refrigerant. Certified technician should perform the following:

1. Shut off breaker to the affected compressor circuit.

2. Isolate refrigerant leak.

3. Repair and recharge system.

Same System being

operated in a low

ambient condition.

System should not be operated in an ambient

condition below 25 F. If condition is above 25 F, the

refrigerant charge may be low.

Same Return air filter

clogged.

Clean or replace filter.




4. Compressor is Noisy.


5. System Short of Capacity (LED Indicator #6 or #7; Quad I/O Low Pressure Indicator).

6. Discharge Pressure Too High (LED Indicator #8 or #9; Quad I/O High Pressure Indicator).


Compressor

knocks.

Compressor running in

opposite direction.

Reverse direction of compressor

Abnormally

cold suction

line.Compressor

knocks.

Liquid flood back. Certified technician should check and adjust the superheat

setting. (Note: Setting may be too low or the remote bulb is

loose on suctionthe normal superheat setting is 10 - 12 F.)

Same Expansion valve stuck in

open position.

Certified technician should repair or replace valve.

Same Check evaporator coil for

ice.

De-ice coil.


Bubbles in sight

glass.

Lack of refrigerant (Note: Some

flashing in low ambient conditions

is acceptable, at least to of

the sight glass should appear to

have refrigerant flowing through

it).

Certified technician should add refrigerant (if so

recommended by Air innovations).

Temperature

change in

refrigerant line

through dryer.

Plugged filter drier. Certified technician should replace the filter drier.

Short cycling. Expansion valve stuck or

obstructed.

Certified technician should repair or replace valve.

Superheat too

high.

Improper superheat adjustment. Certified technician should adjust TXV to maintain a

minimum 10 F superheat.



7. Discharge Pressure Too Low (LED Indicator #6 or #7; Quad I/O Low Pressure Indicator).

8. Suction Pressure Too High.



Exceptionally hot

condenser and

excessive

discharge

pressure.

System operating in an

excessively hot and humid

environment.

If system operates at 350 PSI, the high pressure

switch will open and shut down the compressor. Once

the temperature rises above 70 F, the quad I/O is

triggered and an indicator will display with a warning

to shut down the CTX 9000 DSi or internal damage

could occur.

Same Air or non-condensable gas in

system.

Certified technician should purge non-condensable

gas.

Same Overcharge of refrigerant. Certified technician should remove excess

refrigerant. (Note: Sight glass will start flashing at

around 8 lbs.).

Same Defective condenser fan motor

or controls.

Repair or replace defective parts.


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

Excessively cold liquid

returning from

condenser.

Faulty low ambient control valve. (Note: This valve

should maintain a head pressure of 125 PSI.)



Abnormally cold

suction line. Liquid flooding back

to compressor.

Overfeeding of expansion valve. Certified technician should modify the

superheat setting of the expansion valve and

check to see that remote bulb is properly

attached to the suction line.

Same Expansion valve stuck in open

position.

Certified technician should repair or replace

valve.



9. Suction Pressure Too Low (If Pressure is Below 2 - 4 PSI, LED Indicator #6 or #7; Quad I/O Low Pressure Indicator).

SPARE PARTS LIST FOR THE AIR INNOVATIONS A/C UNIT

Table 4-3 Spare Parts List for the Air Innovations A/C Unit


Bubbles in sight glass. Lack of refrigerant (Note: Some

flashing in low ambient

conditions is acceptable, at

least to of the sight glass

should appear to have

refrigerant flowing through it).

Certified technician should repair leak and

charge.

Evaporator discharge air

is too low.

Frequency drive setting not at

40 Hz or 45 Hz.

Adjust drive.

Temperature change in

refrigerant line through

dryer.

Clogged filter drier. Certified technician should replace the filter

drier.

No flow of refrigerant

through valve.Unit short cycles.

Expansion valve power element

has lost charge.

Certified technician should replace expansion

valve power element.

Loss of capacity. Obstructed expansion valve. Certified technician should clean valve or

replace as necessary.

Air Innovations Part Number

Description QuantityManufacturing Part

Number

34C0072-00 BREAKER, 1 POLE 1 5SX2104-7

34C0072-01 BREAKER, 2 POLE 1 5SX2203-7

34C0072-02 BREAKER, 3 POLE 1 5SX2303-7

34C0072-03 BREAKER, 3 POLE 2 5SX2308-8

34C0072-04 BREAKER, 3 POLE 1 5SX2310-7

34C0072-05 BREAKER, 3 POLE 1 5SX2316-8

51C0028-00 COMPRESSOR 2 ZB21KCE-TFD-230

33C0056-00 CONTACTOR, 24 VDC COIL, 20 AMP 2 3RT1016-1B B42



39C0054-00 CONTROL BOARD FOR SPORLAN ELECTRONIC EPR

(TCB BOARD)

1 952660

35C0056-00 CONTROLLER, TEMPERATURE 1 MA900-4ADA1-V8-

3*AAH-N6/1/Y

54C0029-00 COUPLING, FEMALE, 3/8 ODS 1 5505-06B-06

54C0029-01 COUPLING, FEMALE, 5/8 ODS 1 5505-10S-08

54C0030-00 COUPLING, MALE, 3/8 ODS 1 55006B-06

54C0030-01 COUPLING, MALE, 5/8 ODS 1 55010S-08

73C0077-00 FAN, CONTROL BOX COOLING 1 CR0924HB-A70GL

(P/N 032768)

30C0017-00 FILTER, EMI (CORCOM) 1 16FCD10

50A0009-00 FILTER DRIER, 3/8 C x C 1 C-053-S

36C0119-00 FLANGED INLET, TWIST LOCK, GROUNDING, 4

CONDUCTOR

1 L1620-FL

35C0057-00 FREQUENCY DRIVE 1 FR-S540-0.4K-NA

37C0048-00 HEATER ELEMENT 3 L17A-7239

54C0035-00 DRAIN TUBE (KAZOO), 6" LONG 1

54C0033-00 DRAIN TUBE, EVAPORATOR PRE-FORMED 1

71C0046-00 DRAIN TUBE (KAZOO) MOUNTING BRACKET 1

32C0019-00 LED, GREEN, 24 VDC 1 1904X351

32C0019-01 LED, RED, 24 VDC 5 1904X353

32C0019-02 LED, YELLOW, 24 VDC 1 1904X352

50C0029-00 MOISTURE INDICATOR, 3/8 F x S 1 SA-K202

73C0075-00 MOTORIZED IMPELLER 3 TMK280-2-34

39C0104-00 POWER SUPPLY, 24VDC, 5A 1 6EP1333-3BA00

74C0053-00 PREFILTER, 30%, 14" x 16" x 1", CLASS 2 1 54862001

33C0058-00 QUAD I/O, PCB 1 SDS-C2SUB-4

50C0030-00 RECEIVER, SPECIAL 2 CIRCUIT 1 X9499

33C0053-00 RELAY, SOLID STATE 2 W6425DSX-1



Number



UPS

The CTX 9000 DSi uses UNIX, DOS and Windows operating systems for different system operation functions.

Q DOS is used for system control functions.

Q The GUI (Graphical User Interface) runs on Windows.

Q UNIX is utilized for image reconstruction and inspection functions.

39C0101-00 SENSOR, RTD, 100 OHM, STAINLESS STEEL SHEATH 1 RBJB0TA080AB020

32A0010-00 SWITCH, AIR PRESSURE (.1 to .5" WC) 1 PSF100A-0.5

32A0010-01 SWITCH, AIR PRESSURE (.4 - .6" WC) 1 PSF100A-20929

32A0032-01 SWITCH, HIGH PRESSURE 2 29PSL012-389 343R02

32A0041-00 SWITCH, HIGH / LOW PRESSURE 2 P70SA-1

36F0004-00 SWITCH, ROCKER, SPST 1 RSCA701-VB-B-1-V

32H0006-00 SWITCH, SNAP ACTION, 135-175 DEG F 1 3L05-1

32H0007-00 SWITCH, SNAP ACTION, MAN., 160 DEG F 1 3L02-161

33C0057-01 TIMER/RELAY EXPANSION MODULE 1 6ED1055-1HB00-0BA0

33C0057-00 TIMER/RELAY MODULE 1 6ED1052-1MD00-

0BA3

52C0063-00 VALVE, ELECTRONIC EPR 1 CDS-9-10'-S

52C0061-00 VALVE, EXPANSION 2 Y-1017-FJE-C

52C0064-00 VALVE, HEAD PRESS.CONTROL 1 LAC-4 125

52C0062-00 VALVE, QUENCH TEV, 3/8 IN x 1/2 OUT 1 Y-1253-EFJ-1/2

54C0032-00 VIBRA-SORBER, 3/8 x 24 2 VAF3 X 30

54C0032-01 VIBRA-SORBER, 5/8 x 24 2 VAF5 X 30

36C0116-00 WIRE HARNESS, CONDENSER, 24-PIN 1

36C0117-00 WIRE HARNESS, EVAPORATOR, 16-PIN 1

36C0118-00 WIRE HARNESS, EVAPORATOR, 9-PIN 1



Number

Documents

A_c Unit (Air Innovations).PDF