TC Manual Air Conditioners

8/14/2019 TC Manual Air Conditioners

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Prepared By: Justin Day

Temperature Control ManualAir Condi tioners

Engineering Department

TC Manual Air Conditioners.doc Aggreko Australia Pacific

Temperature Control Manual

AIR CONDITIONERS


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TABLE OF CONTENTS

Section Page

1 INTRODUCTION........................................ ............................................ ............................ 31.1 Description............................. ........................................... ........................................... ..... 31.2 Equipment......... ........................................... ........................................... .......................... 31.2.1 Compressor............. ........................................... .............................................. ............ 31.2.2 Condenser ............................................... .............................................. ....................... 41.2.3 RMD or Thermal Expansion Valve (TxV)..................................................................41.2.4 Evaporator .......................................... ........................................... .............................. 51.2 Applications .......................................... ........................................... ................................. 51.3.1 C................................................................................ Error! Bookmark not defined.

2 TECHNICAL DATA......................................... ........................................... ....................... 6

3 INSTALLATION, OPERATION AND MAINTENANCE (IOM) ............................... 20

3.1 Introduction................................... ............................................ ...................................... 203.2 Installation ........................................ .......................................... .................................... 203.3 Commissioning and Testing ............................................. .............................................. 203.3.1 Cooling mode ......................................... ............................................... .................... 203.3.2 Hot Gas Injection............................................... ........................................... ............. 213.3.3 Outdoor Fan Speed Control ............................................. .......................................... 213.4 Operation .......................................... ........................................... ................................... 213.4.1 Ventilation .......................................... ........................................... ............................ 223.4.2 Cooling ............................................ .............................................. ............................ 223.4.3 Heating............................................. ........................................... ............................... 233.4.4 Defrost ............................................. ........................................... ............................... 233.4.5 Fault Lockout........................ ........................................... .......................................... 233.5 Decommissioning......................................... ........................................... ........................ 23

3.6 Maintenance.................... ............................................ ........................................... ......... 233.6.1 Heating / Cooling Coil............. ........................................... ....................................... 243.6.2 Liquid line sight glass............................................... ........................................... ...... 243.6.3 Monthly / Site Visits......... ........................................... ........................................... ... 253.6.4 Annual Checks.................. ........................................... ........................................... ... 25

4 ELECTRICAL ............................................ ........................................... ............................ 27


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1 INTRODUCTION

1.1 Description

Aggrekos air-conditioning units are a packaged system that is specifically designed forhigh ambient conditions with energy conservation and reliability of operation being amajor design consideration.

These units are of the air-cooled type and have a maximum designed temperature of43deg C.

1.2 Equipment

1.2.1 Compressor

The compressors in the Aggreko range of ACs are hermetically sealed scroll type units

that utilise R22 refrigerant. The compressors come pre-filled from the factory with the

following types of oil, depending on the type;

a. SM Series with mineral oil (ref 160P)

b. SZ Series with polyester oil (ref 160SZ)

c. SY Series with polyester oil (ref 320SZ).

These lubricants are not to be mixed with one another.

The compressor in an air-conditioning/refrigeration system maintains the pressure drop

between the High pressure side and Low Pressure side along with the RefrigeratedMeasuring Device (or Thermal Expansion Device).

The compressor also raises the temperature of the refrigerant from the evaporator

(cooling coil) so the absorbed heat can be removed by ambient conditions (especially air-

cooled) by passing over the condenser coil.

NOTE:Avoid contact with the discharge line from the compressors, as the copper linescan become very hot.


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1.2.2 Condenser

The condensers are manufactured utilising copper tubing along with aluminium fins,

which provide the best method of heat transfer.

The purpose of the condenser is to reject the absorbed heat from the evaporator and the

added heat from the pressure and temperature increase from the compressor.

The high temperature high pressure superheated vapour (refrigerant) discharges from thecompressor enters the condenser, where it is cooled and changes state from a vapour to a

medium temperature high pressure liquid. The temperature that usually exists from the

discharge side of the compressor is around 45 55degC.

From here the MTHPL is piped to the Refrigerated Measuring Device (RMD).

1.2.3 RMD or Thermal Expansion Valve (TxV)

This valve is attached into the liquid refrigerant line as near as possible to the inlet to the

evaporator and controls the rate at which the liquid is released into the evaporator.

It senses the temperature of the refrigerant gas leaving the evaporator, if this temperatureis high it indicates that heat absorption is high and the valve opens wider to allow more

refrigerant into the evaporator and absorb more heat.

However, if the sensed temperature is low, the valve reduces the refrigerant flow to the

evaporator because there is little heat to be absorbed.


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1.2.4 Evaporator

The evaporator is responsible for the transfer of the heat from the application air to the

refrigerant in order to remove it from the application being cooled.

This is achieved when the refrigerant, as a liquid, is released into the evaporator and

absorbs heat as it changes from a liquid into a gas. The evaporator may be fitted with a

system to automatically defrost (de-ice) the coil when operating at temperatures below4oC.

1.2 Applications

The Aggreko dehumidifiers can be used in various applications as shown:


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2 TECHNICAL DATA

aggrekoPrepared by: Adam Hentschel Date: 14.04.1999 Revision: A Page 6 of 27Discipline: Air Conditioners Document number

Section: REVERSE CYCLE PACKAGED AC17 au.4.3

1. INTRODUCTION

Air Conditioners (AC) units cover a wide range of applications, from tent cooling to dense air injection.

An air conditioning installation will not only cool down the air but also take care of heating,dehumidification, humidification and filtering of the air to ensure an ideal climate for humans or storage.The Aggreko AC units will cool down the air, and as a natural side effect, remove moisture from the air.

An AC unit is at is best at high temperatures, the nature of control is such that at low temperatures

commute of the compressor unloading stages is hard to avoid, therefore a combination of fluid chiller,pumps and air handlers is preferred above the use of an AC unit, in spite off the more labour intensiveinstallation.

2. KEY-DATA

Cooling Capacity 17 kW @ 1.1 m3/s, 35

oC ambient

Heating Capacity 17 kW @ 1.1 m3/s, 15

oC ambient

Absorbed Power 6.1kWControl Temperature Range 6

oC - 43

oC

Maximum ambient temp. 50CDimensions

length 1.76 metreswidth 1.13 metres

height 1.97 metresWeight 580 kg

3. LAYOUT


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aggrekoPrepared by: Adam Hentschel Date: 14.04.1999 Revision: A Page 7 of 27

Discipline: Air Conditioners Document number

Section: REVERSE CYCLE PACKAGED AC17 au.4.3

4. TECHNICAL SPECIFICATIONS

ITEM UNITS VALUEPerformance DataDesign Capacity heat / coolDesign Indoor Air TemperatureDesign Outdoor Ambient TemperatureMinimum / Maximum Indoor air temperatureMinimum / Maximum Ambient Temperature

kWC / C

CC / CC / CC / C

172335

8 / 35-5 / 50

Compressor

Compressor Type

Number Of CompressorsNumber Of Capacity Steps

HermeticReciprocating1

Single stage plus hotgas bypass

Indoor SideDesign Air VolumeMaximum external pressure at design flowMinimum Air volume at free outletMaximum Air Volume at free outletFan PowerFan Type

Fan SpeedAir Volume ControlNumber of outlets at 500mm dia

m3/s

Pam

3/s

m3/s

kW

Rpm

1.15000.52.01.5

Centrifugal ForwardCurved

680 - 2295Variable Speed Drive

1

Outdoor SideNumber of outdoor fansFan Motor SizeExternal pressure at design flow

kWPa

1

0.170

Refrigerant DataRefrigerant typeNumber of circuitsRefrigerant massLubricant type

kg / kg

R221

5.8

Electrical DataDesign Electrical VoltageDesign Electrical RatingNominal CurrentStarting CurrentRecommended Generator SizeConnection type

VoltskVA / kWAmpereAmpere

kVAmm

415 3ph / 50 hz10 kVA13.6 A65.0 A15 kVA

32A Clipsal LeadNoise Data

Sound Pressure Level at 10m Lp(A)Sound Power Level Lw(A)

dB(A)dB(A) 73

Physical DataOverall LengthOverall WidthOverall HeightWeight

metresmetresmetres

kg

1.761.131.97580

NOTE: Contact Technical Department If application conditions differ from design conditions


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Discipline: Air Conditioner Document numberSection: Reverse Cycle Packaged AC64 a4.1

1. INTRODUCTION



An AC unit is at is best at high temperatures, the nature of control is such that at low temperaturescommute of the compressor unloading stages is hard to avoid, therefore a combination of fluid chiller,

pumps and air handlers is preferred above the use of an AC unit, in spite off the more labour intensiveinstallation.

2. KEY-DATA

Cooling Capacity 66 kW @ 3.5 m3/s, 35

oC ambient

Heating Capacity 72 kW @ 3.5 m3/s, 15

oC ambient

Absorbed Power 26 kWTemperature Range 8

oC - 45

oC

Maximum ambient temp. 45CDimensions length 2.69 metres

width 2.44 metresheight 1.76 metresWeight 1800 kg

*NOTE: AC-138 to AC-141 have been built to smaller dimensions to fit in a 20sea container they are thesame dims as the 100kW AC units

3. LAYOUT


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Discipline: Air Conditioner Document numberSection: Reverse Cycle Packaged AC64 a4.1


ITEM UNITS VALUEPerformance DataDesign Capacity heat / coolDesign Indoor Air TemperatureDesign Outdoor Ambient TemperatureMinimum / Maximum Indoor air temperatureMinimum / Maximum Outdoor air temperatureMinimum / Maximum Ambient Temperature

kWC / C

CC / CC / CC / C

6412 / 6

-12 / +153.5 / 10.2

353 / +43

CompressorCompressor TypeNumber Of CompressorsNumber Of Capacity Steps

HermeticReciprocating

2 Single stage plushot gas bypass



m3/s

Pam

3/s

m3/s

kW

Rpm

3.515001.56.07.5

Centrifugal BackwardCurve

680 - 2295Variable Speed Drive

1

Outdoor SideNumber of outdoor fansFan Motor SizeDesign Air VolumeExternal pressure at design flow

kWm/sPa

21.216.2

0


kg / kg

R222

6.5/6.5025E

Electrical DataDesign Electrical VoltageDesign Electrical RatingNominal CurrentStarting CurrentRecommended Generator SizeMinimum Cable Size


kVAmm

415 3ph / 50 Hz

56.22476020

Noise DataSound Pressure Level at 10m Lp(A)Sound Power Level Lw(A)

dB(A)dB(A)

6391

Physical DataOverall LengthOverall WidthOverall HeightWeight

metresmetresmetres

kg

2.692.441.761800

NOTE:Contact Technical Department If application conditions differ from design conditions


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Discipline: Air Conditioner Document numberSection: AC64 DIGITAL CONTROLLER a4.1.1

1. AIR CONDITIONER CONTROLLERThis document outlines the customised software installed on aggreko air conditioners. The digitalcontroller allows setup for various climates and applications via preset software parameters. Thecontrol of the indoor fan Variable Frequency Drive allows for automatic control of air flow to provideexact air off temperatures and allow the unit to vary indoor fan speed to avoid HP LP faults inextreme conditions.

Four preset modes of operation are available.

1) Heating and Cooling to a preset return air temperature. For example controlling a buildingtemperature to 22 degC where return air is ducted back to the unit.

2) Heating the air to a preset temperature. Does not require return air, May be used for generalheating / drying applications where an air off temperature of no more than 45 degC is required.Constant preset fan speed unless LP point is approached upon which fan speed will be increasedby a maximum of 15% of full speed.

3) Cooling the air to a preset temperature. Does not require return air. May be used for generalcooling applications where an air off temperature of no less than 8 degC is required. Constantpreset fan speed unless HP point is approached upon which fan speed will be dropped inincrements to a minimum (minimum fan speed 30% of full speed).

4) Cooling the air to a preset temperature. Does not require return air. May be used for specific

cooling / dehumidification applications where an air off temperature of no less than 8 deg C isrequired. Fan speed will vary to deliver specified temperature.

Other features include the ability to schedule operation, remote control and monitor operation andmaintenance history.


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2. BASIC LID USAGE

Default Screen

Figure F-1 shows a LID displaying the default screen. This screen provides you with the 24 charactercontroller name and the controllers current time, date and alarm status. This screen first appears whenthe LID is powered up and communicating with the Comfort Controller or there is no keyboard activity forten minutes.

Figure F-1Local Interface Device (LID)

Keyboard and Display

The LID(local interface device) consists of a keypad with 8 function keys, 4 operative keys, 12 numerickeys (0 to 9, and -) and a two line, alphanumeric liquid crystal display (LCD). Each line on the LCD can

display 24 characters.

The LID can be used to access all parameters of the 1600 & 6400 controllers, accept for BEST++ customprogramming. Before anything can be modified a password must be entered. By pressing 3 (SET)thenENTER;the password table can be accessed. Under curtain conditions the EXPN/EDIT key may have tobe pushed if the LID was previously in the maintenance mode, (this key switches between themaintenance & edit modes).

The default login password is 1111.


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If a password is not entered, all items in the 1600 & 6400 can be accessed but not modified. The quickreference chart on the back of the LIDis used to reference all items in the controllers. By keying thenumber on the left hand side then the appropriate function key, the associated parameter can beaccessed.

Main Menu Shortcut Key

Hardware Points Display 1 STAT then ENTER Software Points Display 2 STAT then ENTER Alarm History 1 HIST then ENTER

Occupancy Schedules 1 SCHD then ENTER Setpoint Schedules 2 SCHD then ENTER Holiday Schedules 3 SCHD then ENTER Password 3 SET then ENTER Daylight Saving Time 2 SET then ENTER Set Clock 1 SET then ENTER

For example to display all hardware (connected) points you would key in 1 (STAT) then ENTERand usethe up/down arrows to scroll through the listing of points in the system.

Hardware Points (instrumentation and system status)

Supply Air Temperature oC

Return Air Temperature oC

Unit Fault Status Alarm / Normal Fan Run Status from VSD On / Off Suction pressure circuit 1 kPA Discharge pressure circuit 1 kPA Suction pressure circuit 2 kPA Discharge pressure circuit 2 kPA Supply fan control to VSD. On / Off Compressor 1 control On / Off Reversing valve control Heat / Cool Compressor 2 control On / Off Fan Control signal to VSD 0 - 100%

If a point is not configured the LID will display DECONFIGURED I/O which represents that the channelhas not been configured and is not in use. If at any time information cannot be displayed or entered asusual, depressing the EXPN/EDIT key will change the LID from maintenance to edit modes.

Appendix A-1shows the quick reference chart that is used to access all items in the Comfort Controller.By keying in the appropriate key number then cross referencing to the desired item E.G. 2-STATforsoftware points, the item can be accessed directly without having to go through each separate menu.


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Software Points (Control and set points)

Unit control ( 0N / OFF) Switch Maximum fan speed. ( 30-100%) Set Point Minimum fan speed. ( 30 - 100%) Set Point Preheat timer over ride Switch Preheat time remaining Display Mode Selection. (1,2,3 or 4) Switch Mode 1 Set point. R/A (16C to 30C) Set Point

Mode 2 Set point. S/A (16C to 45C) Set Point Mode 3 Set point. S/A (8C to 30C) Set Point Mode 4 Set point. S/A (8C to 30C) Set Point Compressor 1 run hours Display Compressor 2 run hours Display Compressor allowed to run ? Switch HP / LP alarm circuit 1 Display HP / LP alarm circuit 1 Display Program mode Switch VSD local / remote Switch


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Operation and Software Set points

After the unit is powered up and the keypad display is active.

1) Key in 3 SETthen ENTER(slowly). Log in to Controller Enter Passwordshould be displayed, if not pressthe EXPN/EDITkey to change from maintenance mode to edit mode.

1) Enter 1111for the password then press the ENTERkey.

1) The display should read Log in to Controller Logged In.

1) Next press 2 STATthen ENTERto access Software Points.

1) Unit Control Pointis the 1stpoint to be accessed.

1) Using the up/down arrow keys move down the list of points and set the following highlightedpoints to thedesired value.

Unit control ( 0N / OFF)Maximum fan speed. ( 30-100%)

Minimum fan speed. ( 30 - 100%)

Preheat timer over ride

Preheat time remainingMode Selection. (1,2,3 or 4)Mode 1 Set point. R/A (16C to 30C)

Mode 2 Set point. S/A (16C to 45C)



1) If the main power supply has been off for any reason the unit will run in preheat mode for 2 hours to activatethe crankcase heaters before running and compressors. (NO COMPRESSORS ALLOWED TO RUN)

1) If this requires over riding select the Preheat Timer Over Ridepoint and press 1 ENTERto activate the override. (Note the point will automatically go back to off when the over ride has been done).

1) Select the Unit Control Point and press 1 ENTERto turn it on (1=On/0=Off).

1) Once the unit is not required the Unit Control Pointshould be turned off so when the unit is next run it wontstart up instantly.

## NOTE - The display will log off automatically if the keypad is not touched for 10 minutes.


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Appendix A-1- Local Interface Device (LID) Quick Access Functions

LID Function Keys

LID

Num. Algorithms Status History Service Alarm Setup Schedules

Key (ALGO) (STAT) (HIST) (SRVC) (ALRM) (SET) (SCHD)

1 AO-Adaptive Control Hardware Points Alarm History Function Definition Limit Set Clock Occupancy

2 AO-Cooling CV Software Points Analog Point Trace Channel Definition Setpoint Real Time Clk Setpoint

3 AO-Cooling VAV Temperature Input Discrete Point Trace System Definition Discrete Password Holiday

4 AO-Fan Tracking Milliamp Input Consumable Channel Setpoint Definition First Out S/W Setpoint

5 AO-Heating CV Custom mA Input Internal Consumable Database Control Runtime Network Time

6 AO-Heating VAV Voltage Input Runtime Channel Comfort Controller No of Starts

7 AO-Hum idity Control Custom Voltage Input CCN Control

8 AO-Mixed Air CV w/IAQ Sensed Discrete Input LID Preferences

9 AO-Mixed Air VAV w/IAQ Latched Discrete Input

10 AO-Permissive Interlock Pulsed Discrete Input

11 AO-Reset Milliamp Output

12 AO-Shared Transducer Custom mA Output

13 AO-Static Pr essure Voltage Output

14 DO-Analog Custom Voltage Output

15 D O- DX- Stagi ng VAV D iscr ete Output

16 D O-Elec tr ic Heat C V Stepper Motor Output

17 DO-Electr ic Heat VAV Discrete Software Point

18 DO-Enthalpy Comparison Analog Software Point

19 DO-Interlock Network Data Out

20 DO- Lighting Control Network Data In

21 DO-Permissive Interlock

22 DO-Pump Control

23 DO-Prop Thermostat

24 DO-Prop Thermo 2 Pipe

25 DO-Prop Thermo 4 Pipe

26 DO-Staged Thermostat

27 DO-Staging Control

28 DO-Time Clock Control

29 DO-Time Clock w/Check

30 AOSS Schedule

31 Network Broadcast

32 Linkage/AOSS Schedule

33 NTFC w/Enthalpy Check

34 Sensor Group

35 WSM Air Source

36 WSM Cool Source

37 Custom Program


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Discipline: Air Conditioners Document numberSection: REVERSE CYCLEPACKAGED AC100 au4.5

1. INTRODUCTION

Air Conditioners (AC) units cover a wide range of applications, from tent cooling to dense airinjection.

An air conditioning installation will not only cool down the air but also take care of heating,dehumidification, humidification and filtering of the air to ensure an ideal climate for humans orstorage. The Aggreko AC units will cool down the air, and as a natural side effect, removemoisture from the air.

An AC unit is at is best at high temperatures, the nature of control is such that at lowtemperatures commute of the compressor unloading stages is hard to avoid, therefore acombination of fluid chiller, pumps and air handlers is preferred above the use of an AC unit, inspite off the more labour intensive installation.

2. KEY-DATA

Cooling Capacity 96 kW @ 5.3 m3/s, 38oC ambientHeating Capacity 74 kW @ 5.3 m3/s, 4oC ambientAbsorbed Power XX kWTemperature Range 8oC - 45oC

Maximum ambient temp. 45CDimensionslength 2.93 metreswidth 2.30 metresheight 1.94 metresWeight 1904 kg

3. LAYOUT


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Section: INDUSTRIAL PACKAGED AC176 au4.2

1. INTRODUCTION



An AC unit is at is best at high temperatures, the nature of control is such that at low temperaturescommute of the compressor unloading stages is hard to avoid, therefore a combination of fluid chiller,pumps and air handlers is preferred above the use of an AC unit, in spite off the more labour intensive

installation.

2. KEY-DATA

Cooling Capacity 176 kW @ 50 hzAbsorbed Power 58 kWTemperature Range 10 C - 30 CMaximum ambient temp. 40CDimensions

length 3.96 metreswidth 2.33 metresheight 2.33 metresWeight 3864 kg

3. LAYOUT


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Section: INDUSTRIAL PACKAGED AC176 au4.2


ITEM UNITS VALUE

Performance Data

Design Capacity Cooling OnlyDesign Evaporator Air TemperatureDesign Condenser TemperatureMinimum evaporator outlet air temperatureMaximum Ambient Temperature

hzkWCCCC

50 / 60176 / 211

10301040

CompressorCompressor TypeNumber Of CompressorsNumber Of Capacity Steps

Open Reciprocating1

4 stage plus hot gasbypass



m3/s

Pam

3/s

m3/s

kW

Rpm

4.55001.74.57.4

Centrifugal BackwardCurve

1Inlet Guide Vane

1

Outdoor SideNumber of outdoor fansFan Motor SizeExternal pressure at design flow

kWPa

41.50


kg

R221

45

Electrical DataDesign Electrical VoltageDesign Electrical RatingNominal CurrentStarting CurrentRecommended Generator Size

Minimum Cable Size


kVA

mm

460 3ph / 60 hz86 / 69

120520175

35Noise DataSound Pressure Level at 1m Lp(A) dB(A) 87Physical DataOverall LengthOverall WidthOverall HeightWeight

metresmetresmetres

kg

3.962.332.333864

NOTE: Contact Technical Department If application conditions differ from design conditions.


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3 INSTALLATION, OPERATION AND MAINTENANCE (IOM)

3.1 Introduction

Installation of the Air-conditioners is of utmost importance. The operating life of theseunits will be greatly determined on how the equipment is positioned.

The following section will outline the correct procedures for installation of Aggrekos

air-conditioners.

3.2 Installation

The unit must be installed on a solid, level ground/mounting pad which also ensures

service access.

No items should be placed on-top of the condenser fans for the discharge of rejected air

from the condenser. If items are placed in front of the inlet or on top as previously

mentioned, a safety shutdown of the equipment will occur (High Condensing Pressure).

An adequate drain-line trap must be provided outside the inside coil for condensate run-

off. The drain pipe should be installed with a continuous downward grade away from the

unit. The gradient should not be less than 1:50.

Outdoor units operating on the reverse cycle will release water from the outdoor coilduring defrost. Where appropriate, water should be drained to waste

3.3 Commissioning and Testing

Prior to commissioning any type of Air-conditioning unit, filters should be fitted (where

applicable).

Align belt drive fan and motor pulleys with a straight edge. For variable speed pulleys,

ensure that the centre lines of both pulleys are in line and parallel to fan casing. Adequatespace should be left for the ability to service the equipment.

3.3.1 Cooling mode

When in cooling mode, the following steps should be followed;

a. Switch the unit on in cooling mode with the thermostat set to minimumtemperature set point.

b. Measure the compressor suction pressure and convert to a compressor saturatedsuction temperature using the R22 refrigerant pressure/temperature chart.

c. Measure the suction line temperature approximately 100mm before thecompressor.

d. Calculate the superheat = Suction line temperature Compressor Saturated SuctionTemperature.

e. Measure the outdoor ambient air temperature.

f. Measure the indoor return and supply air dry bulb and wet bulb temperatures, bothbefore and after the indoor coil.


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g. Measure the indoor air quantity ensuring it falls within the fan limits.

h. Allow system pressure to stabilise for a minimum of 20 minutes.

i. Measure and record all operating pressures, motor currents and temperatures as

noted for start up.j. Adjust fan speed tapping or pulley to suit the static pressure and air quantity

requirements.

3.3.2 Hot Gas Injection

The injection valve, which is operated from suction pressure, will modulate and inject hot

gas into the indoor coil to maintain a minimum suction pressure of 400kPa. The systemis protected by a suction temperature sensor which will close the gas injection solenoid

valve if the temperature exceeds 12deg C.

3.3.3 Outdoor Fan Speed Control

The controller, which has a 3 bar operating band, starts to decrease the motor speed whenthe pressure falls below 16 bar. The motor will continue to operate on low speed when the

pressure falls below 13 bar.

3.4 Operation

The operation of the Aggreko Air conditioners is best illustrated in the following

diagram.

The sequence of operation includes the ventilation, cooling, heating, defrost and fault

lockout

Compressor

RMD

Condenser

Evaporator

Heat Absorption Heat Rejection


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3.4.1 Ventilation

Set the thermostat for continuous fan operation. The indoor fan will start and runcontinuously.

3.4.2 Cooling

On a call for cooling, the lead compressor and outdoor fan will start. The lag compressor

and outdoor fan will start on further cooling demand and cycle the unit in response to the

thermostat to maintain desired room conditions.

Short cycle protection, built into the electronic controller prevents the compressors fromrestarting for at least 5 minutes after they have been switched off. The electronic

controller provides a 5 second time delay before starting the compressor and outdoor fan

on both stages; 5 minutes initial time delay for stage 1 compressor at initial start of thesystem and a 1 minute time delay between stages during operation.

If indoor fan operation mode auto is selected there is a 10 second time delay betweenlead compressor and indoor fan activation.

Refrigerant Vapour

Liquid

Refrigerant

Refrigerant Flow

Air Flow


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3.4.3 Heating

The reversing valves are energised with the compressor and outdoor fans. Sequence of

operation is as described for cooling.

3.4.4 Defrost

The defrost control is independent reverse cycle. It is activated when the temperature of

the outdoor coil sensor falls below -3 deg C, provided that the accumulated compressorrun time exceeds 30 minutes (factory set) or 5 minutes at initial start of the system.

The defrost cycle is terminated when the coil is temperature sensor exceeds 10degC or

when the defrost time exceeds 10 minutes. Typical defrost time is usually 2 to 4 minutes.

When defrost is initiated, the stage which required defrost de-energises the reversing

valve and outdoor fan, whilst the other stage continues to operate or is forced to operate 1minute before defrost is initiated to provide heating. The indoor fan continues to operate

during defrost. The LP switch is bypassed during defrost and for a further 2.5 minutesafter the termination of defrost. When defrost is terminated, the second stage can then

defrost if required. When defrost/s is pending or in progress the thermostat contacts areoverridden until defrost/s has been completed.

3.4.5 Fault Lockout

When any of the operating faults are exceeded, the safety limits trip and disables the

compressor and outdoor fan of the relevant stage of the unit.

The compressor and the outdoor fan will remain off after the limit switches re-close untilthe Stage 1 input terminal is de-energised and energised via the thermostat or on/off

switch. The control is independent. If one stage is in fault, the other stage will continue

to respond to the thermostat,

If the indoor fan overload trips, the system is locked out until the overload resets and the

fan input terminal is de-energised and energised via thermostat or on/off switch.

Single-phase fan motors have internal overloads, which reset automatically. The defrost

sensor open circuit will lock out the relevant stage.

3.5 Decommissioning

3.6 Maintenance

To ensure continued high performance and minimisation of premature equipment failure,

periodic maintenance must be performed on the air-conditioning equipment. The unit

should be inspected at least once a year by a QUALIFIED refrigeration technician.

The minimum maintenance requirements for this equipment are as follows;


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3.6.1 Heating / Cooling Coil

The coils must be maintained, and this can be achieved by cleaning the indoor and

outdoor coils. Also the fins should be straightened wherever possible.

All of the joints on the refrigerant slide should be leak tested with electronic leak detector

or soapy water

3.6.2 Liquid line sight glass

The liquid sight glass indicates if there is moisture present in the line.

Indoor coils

Refrigerant slide

Indicating Moisture Free

Yellow/ Pink.

Moisture Present

Green/ Blue

Moisture Free


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3.6.3 Monthly / Site Visits

a. Inspect indoor coil. Replace throw away type filters when they become cloggedwith dust and lint or clean cleanable filters when necessary.

b. Check moisture indictors in the liquid line for moisture in the refrigerant.

c. Conduct a leak test on entire refrigerant system.

3.6.4 Annual Checks

a. Inspect indoor coil, drain pan and condensate drain. Clean where necessary.

b. Inspect indoor fan motor and wheel for cleanliness and alignment. Clean, lubricateand align the motor assembly where applicable. Replace worn belts whereapplicable.

c. Inspect outdoor coil. Clean where necessary.

d. Inspect outdoor fans and motors. Ensure that fan blades are clean and adequatelybalanced.

e. Inspect the unit cabinet and insulation for damage and corrosion. Repair wherenecessary. Check for vibration and excessive noise. Correct where necessary.

f. Inspect refrigerant tubing and coils for oil accumulations. If oil is detected, conducta leak test. Preferred method is the Electronic leak detector or Soapy water.

g. Check refrigerant charge by measurement of superheat and subcooling. Wherenecessary, adjust the Tx Valve to achieve optimum performance.

h. Check the tightness of all electrical connections.

Maintenance Schedule for Aggreko's Package Air-Cooled Reverse Cycle Condition ers AC4.5, AC17, AC64, and AC100:

ItemNo.

Installation, Start-up, Servicing, and Maintenance InstructionsOn Hire andInstallation

Monthlyor at 750

Hours

6-Monthlyor at 4300

Hours

Completionof Hiring

andDecomm.

Installation, Safety, Initial Start-up, Commissioning, and Follow-up in General:

1 Read all instructions before proceeding with installation and start up. X

2Follow the safety procedures titled 'SAFETY CONSIDERATIONS' providedin the respective sections of this manual by Carrier Apac for units AC64(P064AHR9AD) and AC100 (P096AHR9AD).

X X

3Follow 'START-UP AND COMMISSIONING PROCEDURES' provided inthe respective sections of this manual by Carrier Apac for AC17 (S17HP/BV), AC64 (P064AHR9AD), and AC100 (P096AHR9AD), as applicable.

X

4Check all the components for possible transport damage. Reportdamage(s) to the local Aggreko Depot and seek remedial help for on-sitediagnostic assessment of the problem(s) and possible repairs.

X

5All on-site or off-site work involving refrigeration circuitry at any stage of thehiring process should be carried out in accordance with the RefrigerationCode of Practice SAA HB 40.

X X X

6 Check and ensure that all components are secure. X X


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7 Check and ensure that thermal insulation is secure. X X

8Check and ensure that all service doors/ panels and locks are operableand permitting inspection and service access.

X X

9 Carry out thorough check on the electrical components. X X

10 Check all electrical wiring and terminals. X X

11Check and ensure that air filters are placed having correct type, model, andsize specifications.

X X

12 Check the condition of the air filters and replace them if necessary X X

13Check the alignment of belt-driven motor and fan pulleys with a straightedge. Align them as necessary.

X X

14 Check motor-fan belt tension. Replace belts if necessary. X X X

15 Check and clean condensate drip trays and drains from any debris. X X X

16 Check and test thermostat, as applicable. X X

17 Lubricate parts in accordance with manufacturer's recommendations. X X

18 Lubricate fan motors. X X

19 Check compressor oil levels. X X X

20Check refrigerant gas charge through sight glass and adjust refrigerantcharge. Record readings.

X X X

21 Check refrigerant system for any leaks. X X

22 Check and record system operating pressures. X

23 Check operation of crankcase heaters. X X

ItemNo.

Maintenance and Servicing InstructionsOn Hire andInstallation

Monthlyor at 750

Hours

6-Monthlyor at 4300

Hours

Completionof Hiring

andDecomm.

24

Measure and record AIR-ON and AIR-OFF DB and WB temperatureswith an electronic hygrometer. Measure, by traversing, AIR-OFF side airvelocity with a hot wire type or vane type anemometer and calculate the AirFlow Rate = Velocity x Discharge Area in cum/ sec or Lt/sec, and check allmeasured data against the intended design conditions and operatingparameters, as a part of the commissioning works.

X

25 Check all motor operating temperatures and current and record result. X X

26 Check incoming volts. X X

27 Check operation of Hi-Limit thermostats and air switches, as applicable. X X

28 Check and test all safety circuits and set points. X X

29Clean inlet side of the evaporator coils. Examine for damage, comb the

fins as necessary.X

30Check all coils and cabinet, etc. for corrosion or damage. Repair and

paint.X


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4 ELECTRICAL

Documents

TC Manual Air Conditioners