TC Manual Air Conditioners

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Temperature Control Manual Air Conditioners
Version 0.1 Date: 1/02/2007 Prepared By: Justin Day Engineering Department
Temperature Control Manual
AIR CONDITIONERS
TC Manual Air Conditioners.doc
Aggreko Australia Pacific
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TABLE OF CONTENTS
Section
1 1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2 1.3.1 2 3 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.5 3.6 3.6.1 3.6.2 3.6.3 3.6.4 4
Page
INTRODUCTION................................................................................................................ 3 Description........................................................................................................................ 3 Equipment......................................................................................................................... 3 Compressor.................................................................................................................. 3 Condenser .................................................................................................................... 4 RMD or Thermal Expansion Valve (TxV) .................................................................. 4 Evaporator ................................................................................................................... 5 Applications ...................................................................................................................... 5 C ................................................................................ Error! Bookmark not defined. TECHNICAL DATA ........................................................................................................... 6 INSTALLATION, OPERATION AND MAINTENANCE (IOM) ............................... 20 Introduction..................................................................................................................... 20 Installation ...................................................................................................................... 20 Commissioning and Testing ........................................................................................... 20 Cooling mode ............................................................................................................ 20 Hot Gas Injection....................................................................................................... 21 Outdoor Fan Speed Control ....................................................................................... 21 Operation ........................................................................................................................ 21 Ventilation ................................................................................................................. 22 Cooling ...................................................................................................................... 22 Heating....................................................................................................................... 23 Defrost ....................................................................................................................... 23 Fault Lockout............................................................................................................. 23 Decommissioning ............................................................................................................ 23 Maintenance.................................................................................................................... 23 Heating / Cooling Coil............................................................................................... 24 Liquid line sight glass................................................................................................ 24 Monthly / Site Visits.................................................................................................. 25 Annual Checks........................................................................................................... 25 ELECTRICAL ................................................................................................................... 27
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1 1.1 INTRODUCTION Description
Aggrekos air-conditioning units are a packaged system that is specifically designed for high ambient conditions with energy conservation and reliability of operation being a major design consideration. These units are of the air-cooled type and have a maximum designed temperature of 43deg C.
1.2 1.2.1
Equipment 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. b. c. SM Series with mineral oil (ref 160P) SZ Series with polyester oil (ref 160SZ) 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 Refrigerated Measuring 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 aircooled) by passing over the condenser coil. NOTE: Avoid contact with the discharge line from the compressors, as the copper lines can 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 the compressor 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 temperature is 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 below 4oC.
1.2
Applications
The Aggreko dehumidifiers can be used in various applications as shown:
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2 TECHNICAL DATA
aggreko
Prepared by: Discipline: Section:
Adam Hentschel
Date:
14.04.1999
Revision:
Page
6 of 27
Air Conditioners
Document number
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 intensive installation. 2. KEY-DATA
Cooling Capacity 17 kW @ 1.1 m3/s, 35oC ambient 3 o Heating Capacity 17 kW @ 1.1 m /s, 15 C ambient Absorbed Power 6.1kW Control Temperature Range 6oC - 43oC Maximum ambient temp. 50C Dimensions length 1.76 metres width 1.13 metres height 1.97 metres Weight 3. LAYOUT 580 kg
Page 7 of 27
aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page
7 of 27
Air Conditioners
Document number
REVERSE CYCLE PACKAGED AC17

UNITS kW C / C C C / C C / C C / C
au.4.3
4.
TECHNICAL SPECIFICATIONS
ITEM Performance Data Design Capacity heat / cool Design Indoor Air Temperature Design Outdoor Ambient Temperature Minimum / Maximum Indoor air temperature Minimum / Maximum Ambient Temperature Compressor Compressor Type Number Of Compressors Number Of Capacity Steps Indoor Side Design Air Volume Maximum external pressure at design flow Minimum Air volume at free outlet Maximum Air Volume at free outlet Fan Power Fan Type Fan Speed Air Volume Control Number of outlets at 500mm dia Outdoor Side Number of outdoor fans Fan Motor Size External pressure at design flow Refrigerant Data Refrigerant type Number of circuits Refrigerant mass Lubricant type Electrical Data Design Electrical Voltage Design Electrical Rating Nominal Current Starting Current Recommended Generator Size Connection type Noise Data Sound Pressure Level at 10m Lp(A) Sound Power Level Lw(A) Physical Data Overall Length Overall Width Overall Height Weight
3
VALUE 17 23 35 8 / 35 -5 / 50
Hermetic Reciprocating 1 Single stage plus hot gas bypass m /s Pa m3/s 3 m /s kW 1.1 500 0.5 2.0 1.5 Centrifugal Forward Curved 680 - 2295 Variable Speed Drive 1 1 0.17 0 R22 1 5.8
Rpm
kW Pa
kg / kg
Volts kVA / kW Ampere Ampere kVA mm dB(A) dB(A) metres metres metres kg
415 3ph / 50 hz 10 kVA 13.6 A 65.0 A 15 kVA 32A Clipsal Lead
73 1.76 1.13 1.97 580
NOTE: Contact Technical Department If application conditions differ from design conditions
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aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 8
of 27
Air Conditioner
Document number
Reverse Cycle Packaged AC64
a4.1
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 intensive installation.
2.
KEY-DATA
Cooling Capacity 66 kW @ 3.5 m3/s, 35oC ambient Heating Capacity 72 kW @ 3.5 m3/s, 15oC ambient Absorbed Power 26 kW Temperature Range 8oC - 45oC Maximum ambient temp. 45C Dimensions length 2.69 metres width 2.44 metres height 1.76 metres Weight 1800 kg *NOTE: AC-138 to AC-141 have been built to smaller dimensions to fit in a 20sea container they are the same dims as the 100kW AC units
3.
LAYOUT
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aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 9
of 27
Air Conditioner
Document number
Reverse Cycle Packaged AC64

TECHNICAL SPECIFICATIONS UNITS
kW C / C C C / C C / C C / C
a4.1
4. ITEM
VALUE
64 12 / 6 -12 / +15 3.5 / 10.2 35 3 / +43 Hermetic Reciprocating 2 Single stage plus hot gas bypass
Performance Data Design Capacity heat / cool Design Indoor Air Temperature Design Outdoor Ambient Temperature Minimum / Maximum Indoor air temperature Minimum / Maximum Outdoor air temperature Minimum / Maximum Ambient Temperature Compressor Compressor Type Number Of Compressors Number Of Capacity Steps Indoor Side Design Air Volume Maximum external pressure at design flow Minimum Air volume at free outlet Maximum Air Volume at free outlet Fan Power Fan Type
m /s Pa m3/s m3/s kW
Fan Speed Rpm Air Volume Control Number of outlets at 500mm dia Outdoor Side 2 Number of outdoor fans 1.2 kW Fan Motor Size 16.2 m/s Design Air Volume 0 Pa External pressure at design flow Refrigerant Data R22 Refrigerant type 2 Number of circuits kg / kg 6.5/6.5 Refrigerant mass 025E Lubricant type Electrical Data 415 3ph / 50 Hz Volts Design Electrical Voltage kVA / kW Design Electrical Rating 56.2 Ampere Nominal Current 247 Ampere Starting Current 60 kVA Recommended Generator Size 20 mm Minimum Cable Size Noise Data Sound Pressure Level at 10m Lp(A) dB(A) 63 Sound Power Level Lw(A) dB(A) 91 Physical Data Overall Length metres 2.69 Overall Width metres 2.44 Overall Height metres 1.76 Weight kg 1800 NOTE: Contact Technical Department If application conditions differ from design conditions
3.5 1500 1.5 6.0 7.5 Centrifugal Backward Curve 680 - 2295 Variable Speed Drive 1
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aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 10
of 27
Air Conditioner
Document number
AC64 DIGITAL CONTROLLER
a4.1.1
1. AIR CONDITIONER CONTROLLER This document outlines the customised software installed on aggreko air conditioners. The digital controller allows setup for various climates and applications via preset software parameters. The control of the indoor fan Variable Frequency Drive allows for automatic control of air flow to provide exact air off temperatures and allow the unit to vary indoor fan speed to avoid HP LP faults in extreme conditions. Four preset modes of operation are available. 1) Heating and Cooling to a preset return air temperature. For example controlling a building temperature 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 general heating / 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 increased by a maximum of 15% of full speed. 3) Cooling the air to a preset temperature. Does not require return air. May be used for general cooling applications where an air off temperature of no less than 8 degC is required. Constant preset fan speed unless HP point is approached upon which fan speed will be dropped in increments 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 is required. Fan speed will vary to deliver specified temperature. Other features include the ability to schedule operation, remote control and monitor operation and maintenance history.
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aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 11
of 27
Air Conditioner
Document number
a4.1.1
2. BASIC LID USAGE

Default Screen Figure F-1 shows a LID displaying the default screen. This screen provides you with the 24 character controller name and the controllers current time, date and alarm status. This screen first appears when the LID is powered up and communicating with the Comfort Controller or there is no keyboard activity for ten minutes. Figure F-1 Local Interface Device (LID)
Keyboard and Display The LID (local interface device) consists of a keypad with 8 function keys, 4 operative keys, 12 numeric keys (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++ custom programming. Before anything can be modified a password must be entered. By pressing 3 (SET) then ENTER; the password table can be accessed. Under curtain conditions the EXPN/EDIT key may have to be pushed if the LID was previously in the maintenance mode, (this key switches between the maintenance & edit modes). The default login password is 1111.
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aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 12
of 27
Air Conditioner
Document number
a4.1.1
If a password is not entered, all items in the 1600 & 6400 can be accessed but not modified. The quick reference chart on the back of the LID is used to reference all items in the controllers. By keying the number on the left hand side then the appropriate function key, the associated parameter can be accessed. Main Menu Shortcut Key 1 STAT then ENTER 2 STAT then ENTER 1 HIST then ENTER 1 SCHD then ENTER 2 SCHD then ENTER 3 SCHD then ENTER 3 SET then ENTER 2 SET then ENTER 1 SET then ENTER

Hardware Points Display Software Points Display Alarm History Occupancy Schedules Setpoint Schedules Holiday Schedules Password Daylight Saving Time Set Clock
For example to display all hardware (connected) points you would key in 1 (STAT) then ENTER and use the up/down arrows to scroll through the listing of points in the system. Hardware Points (instrumentation and system status)

Supply Air Temperature Return Air Temperature Unit Fault Status Fan Run Status from VSD Suction pressure circuit 1 Discharge pressure circuit 1 Suction pressure circuit 2 Discharge pressure circuit 2 Supply fan control to VSD. Compressor 1 control Reversing valve control Compressor 2 control Fan Control signal to VSD
oC oC Alarm / Normal On / Off kPA kPA kPA kPA On / Off On / Off Heat / Cool On / Off 0 - 100%
If a point is not configured the LID will display DECONFIGURED I/O which represents that the channel has not been configured and is not in use. If at any time information cannot be displayed or entered as usual, 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-STAT for software points, the item can be accessed directly without having to go through each separate menu.
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aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 13
of 27
Air Conditioner
Document number
a4.1.1
Software Points (Control and set points)

Unit control ( 0N / OFF) Maximum fan speed. ( 30-100%) Minimum fan speed. ( 30 - 100%) Preheat timer over ride Preheat time remaining Mode Selection. (1,2,3 or 4) Mode 1 Set point. R/A (16C to 30C) Mode 2 Set point. S/A (16C to 45C) Mode 3 Set point. S/A (8C to 30C) Mode 4 Set point. S/A (8C to 30C) Compressor 1 run hours Compressor 2 run hours Compressor allowed to run ? HP / LP alarm circuit 1 HP / LP alarm circuit 1 Program mode VSD local / remote
Switch Set Point Set Point Switch Display Switch Set Point Set Point Set Point Set Point Display Display Switch Display Display Switch Switch
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aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 14
of 27
Air Conditioner
Document number
a4.1.1
Operation and Software Set points After the unit is powered up and the keypad display is active. 1) Key in 3 SET then ENTER (slowly). Log in to Controller Enter Password should be displayed, if not press the EXPN/EDIT key to change from maintenance mode to edit mode. 1) Enter 1111 for the password then press the ENTER key. 1) The display should read Log in to Controller Logged In. 1) Next press 2 STAT then ENTER to access Software Points. 1) Unit Control Point is the 1st point to be accessed. 1) Using the up/down arrow keys move down the list of points and set the following highlighted points to the desired value.

Unit control ( 0N / OFF) Maximum fan speed. ( 30-100%) Minimum fan speed. ( 30 - 100%) Preheat timer over ride Preheat time remaining Mode Selection. (1,2,3 or 4) Mode 1 Set point. R/A (16C to 30C) Mode 2 Set point. S/A (16C to 45C) Mode 3 Set point. S/A (8C to 30C) Mode 4 Set point. S/A (8C to 30C)
1) If the main power supply has been off for any reason the unit will run in preheat mode for 2 hours to activate the crankcase heaters before running and compressors. (NO COMPRESSORS ALLOWED TO RUN) 1) If this requires over riding select the Preheat Timer Over Ride point and press 1 ENTER to activate the over ride. (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 ENTER to turn it on (1=On/0=Off). 1) Once the unit is not required the Unit Control Point should be turned off so when the unit is next run it wont start up instantly. ## NOTE - The display will log off automatically if the keypad is not touched for 10 minutes.
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aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Page 15
of 27
Air Conditioner
Document number
a4.1.1
Appendix A-1 - Local Interface Device (LID) Quick Access Functions

LID Function Keys LID Num. Algorithms Key (ALGO) 1 AO-Adaptive Control 2 AO-Cooling CV 3 AO-Cooling VAV 4 AO-Fan Tracking 5 AO-Heating CV 6 AO-Heating VAV 7 AO-Humidity Control 8 AO-Mixed Air CV w/IAQ 9 AO-Mixed Air VAV w/IAQ 10 AO-Permissive Interlock 11 AO-Reset 12 AO-Shared Transducer 13 AO-Static Pressure 14 DO-Analog 15 DO-DX-Staging VAV 16 DO-Electric Heat CV 17 DO-Electric Heat VAV 18 DO-Enthalpy Comparison 19 DO-Interlock 20 DO-Lighting Control 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 Status (STAT) Hardware Points Software Points Temperature Input Milliamp Input Custom mA Input Voltage Input Custom Voltage Input Sensed Discrete Input Latched Discrete Input Pulsed Discrete Input Milliamp Output Custom mA Output Voltage Output Custom Voltage Output Discrete Output Stepper Motor Output Discrete Software Point Analog Software Point Network Data Out Network Data In History (HIST) Alarm History Analog Point Trace Discrete Point Trace Consumable Channel Internal Consumable Runtime Channel Service (SRVC) Function Definition Channel Definition System Definition Setpoint Definition Database Control Comfort Controller CCN Control LID Preferences Alarm (ALRM) Limit Setpoint Discrete First Out Runtime No of Starts Setup (SET) Set Clock Real Time Clk Password Schedules (SCHD) Occupancy Setpoint Holiday S/W Setpoint Network Time
Page 16 of 27
aggreko
Adam Hentschel
Date:
19.12.2002
Revision:
Page 16 of 27 Document number
Air Conditioners
REVERSE CYCLEPACKAGED AC100
au4.5
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 intensive installation. 2. KEY-DATA 96 kW @ 5.3 m3/s, 38oC ambient 74 kW @ 5.3 m3/s, 4oC ambient XX kW 8oC - 45oC 45C 2.93 metres 2.30 metres 1.94 metres 1904 kg
Cooling Capacity Heating Capacity Absorbed Power Temperature Range Maximum ambient temp. Dimensions length width height Weight 3. LAYOUT
Page 17 of 27
aggreko
Adam Hentschel
Date:
19.12.2002
Revision:
Air Conditioners
REVERSE CYCLEPACKAGED AC100

UNITS
kW C / C C C / C C / C C / C
au4.5
VALUE
96/74 12 / 6 -12 / +15 3.5 / 10.2 35 3 / +43
4.
TECHNICAL SPECIFICATIONS ITEM

Performance Data Design Capacity heat / cool Design Indoor Air Temperature Design Outdoor Ambient Temperature Minimum / Maximum Indoor air temperature Minimum / Maximum Outdoor air temperature Minimum / Maximum Ambient Temperature Compressor Compressor Type Number Of Compressors Number Of Capacity Steps Indoor Side Design Air Volume Maximum external pressure at design flow Minimum Air volume at free outlet Maximum Air Volume at free outlet Fan Power Fan Type
Hermetic Reciprocating 2 Single stage plus hot gas bypass m /s Pa m3/s m3/s kW
3
Fan Speed Rpm Air Volume Control Number of outlets at 500mm dia Outdoor Side 2 Number of outdoor fans 1.1 kW Fan Motor Size 5.8/6.6 m/s Design Air Volume 50/60 Hz 0 Pa External pressure at design flow Refrigerant Data R22 Refrigerant type 2 Number of circuits kg / kg 10.5/10.5 Refrigerant mass Maneurop 160P* Lubricant type Electrical Data 380-460v//50-60 Hz Volts Design Electrical Voltage 37/29.9 kVA / kW Design Electrical Rating 56.2 Ampere Nominal Current 247 Ampere Starting Current 100 kVA Recommended Generator Size 35 mm Minimum Cable Size Noise Data Sound Pressure Level at 10m Lp(A) dB(A) 63 Sound Power Level Lw(A) dB(A) 91 Physical Data 2.93 metres Overall Length 2.30 metres Overall Width 1.94 metres Overall Height 1904 kg Weight NOTE: Contact Technical Department If application conditions differ from design conditions
5.3 1500 1.5 6.0 7.5 Centrifugal Backward Curve 680 - 2295 Variable Speed Drive 1
* Top up with Carrier 3GS permitted
Page 18 of 27
aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Air Conditioners
INDUSTRIAL PACKAGED AC176
au4.2
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 intensive installation. 2. KEY-DATA 176 kW @ 50 hz 58 kW 10 C - 30 C 40C 3.96 metres 2.33 metres 2.33 metres 3864 kg
Cooling Capacity Absorbed Power Temperature Range Maximum ambient temp. Dimensions length width height Weight 3. LAYOUT
Page 19 of 27
aggreko
Adam Hentschel
Date:
14.04.1999
Revision:
Air Conditioners
INDUSTRIAL PACKAGED AC176
au4.2
4.
TECHNICAL SPECIFICATIONS
ITEM Performance Data Design Capacity Cooling Only Design Evaporator Air Temperature Design Condenser Temperature Minimum evaporator outlet air temperature Maximum Ambient Temperature Compressor Compressor Type Number Of Compressors Number Of Capacity Steps Indoor Side Design Air Volume Maximum external pressure at design flow Minimum Air volume at free outlet Maximum Air Volume at free outlet Fan Power Fan Type Fan Speed Air Volume Control Number of outlets at 500mm dia Outdoor Side Number of outdoor fans Fan Motor Size External pressure at design flow Refrigerant Data Refrigerant type Number of circuits Refrigerant mass Lubricant type Electrical Data Design Electrical Voltage Design Electrical Rating Nominal Current Starting Current Recommended Generator Size Minimum Cable Size Noise Data Sound Pressure Level at 1m Lp(A) Physical Data Overall Length Overall Width Overall Height Weight hz kW C C C C 50 / 60 176 / 211 10 30 10 40 Open Reciprocating 1 4 stage plus hot gas bypass m /s Pa m3/s m3/s kW
3
UNITS
VALUE
Rpm
4.5 500 1.7 4.5 7.4 Centrifugal Backward Curve 1 Inlet Guide Vane 1 4 1.5 0 R22 1 45
kW Pa
kg
Volts kVA / kW Ampere Ampere kVA mm dB(A) metres metres metres kg
460 3ph / 60 hz 86 / 69 120 520 175 35 87 3.96 2.33 2.33 3864
NOTE: Contact Technical Department If application conditions differ from design conditions.
Page 20 of 27

3 3.1
INSTALLATION, OPERATION AND MAINTENANCE (IOM) Introduction

Installation of the Air-conditioners is of utmost importance. The operating life of these units 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 runoff. 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 coil during 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. Adequate space 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. b. c. d. e. f. Switch the unit on in cooling mode with the thermostat set to minimum temperature set point. Measure the compressor suction pressure and convert to a compressor saturated suction temperature using the R22 refrigerant pressure/temperature chart. Measure the suction line temperature approximately 100mm before the compressor. Calculate the superheat = Suction line temperature Compressor Saturated Suction Temperature. Measure the outdoor ambient air temperature. Measure the indoor return and supply air dry bulb and wet bulb temperatures, both before and after the indoor coil.
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g. h. i. j.
Measure the indoor air quantity ensuring it falls within the fan limits. Allow system pressure to stabilise for a minimum of 20 minutes. Measure and record all operating pressures, motor currents and temperatures as noted for start up. 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 system is 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 when the 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.
Compressor
Condenser
Heat Absorption
Heat Rejection
Evaporator
RMD
The sequence of operation includes the ventilation, cooling, heating, defrost and fault lockout
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Air Flow
Refrigerant Vapour
Liquid Refrigerant
Refrigerant Flow
3.4.1
Ventilation
Set the thermostat for continuous fan operation. The indoor fan will start and run continuously.
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 from restarting 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 the system 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 between lead compressor and indoor fan activation.
Page 23 of 27

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 compressor run 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 1 minute 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 minutes after 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 are overridden 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 until the 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;
Page 24 of 27

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
Indoor coils
Refrigerant slide
3.6.2
Liquid line sight glass

The liquid sight glass indicates if there is moisture present in the line.
Green/ Blue Moisture Free
Indicating Moisture Free
Yellow/ Pink. Moisture Present
Page 25 of 27
3.6.3
Monthly / Site Visits

a. b. c. Inspect indoor coil. Replace throw away type filters when they become clogged with dust and lint or clean cleanable filters when necessary. Check moisture indictors in the liquid line for moisture in the refrigerant. Conduct a leak test on entire refrigerant system.
3.6.4
Annual Checks
a. b. Inspect indoor coil, drain pan and condensate drain. Clean where necessary. Inspect indoor fan motor and wheel for cleanliness and alignment. Clean, lubricate and align the motor assembly where applicable. Replace worn belts where applicable. Inspect outdoor coil. Clean where necessary. Inspect outdoor fans and motors. Ensure that fan blades are clean and adequately balanced. Inspect the unit cabinet and insulation for damage and corrosion. Repair where necessary. Check for vibration and excessive noise. Correct where necessary. Inspect refrigerant tubing and coils for oil accumulations. If oil is detected, conduct a leak test. Preferred method is the Electronic leak detector or Soapy water. Check refrigerant charge by measurement of superheat and subcooling. Where necessary, adjust the Tx Valve to achieve optimum performance. Check the tightness of all electrical connections.
c. d. e. f. g. h.
Maintenance Schedule for Aggreko's Package Air-Cooled Reverse Cycle Conditioners AC4.5, AC17, AC64, and AC100:
Completion of Hiring and Decomm.
Item No.
Installation, Start-up, Servicing, and Maintenance Instructions
On Hire and Installation
Monthly or at 750 Hours
6-Monthly or at 4300 Hours
Installation, Safety, Initial Start-up, Commissioning, and Follow-up in General: 1 Read all instructions before proceeding with installation and start up. Follow the safety procedures titled 'SAFETY CONSIDERATIONS' provided in the respective sections of this manual by Carrier Apac for units AC64 (P064AHR9AD) and AC100 (P096AHR9AD). Follow 'START-UP AND COMMISSIONING PROCEDURES' provided in the respective sections of this manual by Carrier Apac for AC17 (S17 HP/BV), AC64 (P064AHR9AD), and AC100 (P096AHR9AD), as applicable. Check all the components for possible transport damage. Report damage(s) to the local Aggreko Depot and seek remedial help for on-site diagnostic assessment of the problem(s) and possible repairs. All on-site or off-site work involving refrigeration circuitry at any stage of the hiring process should be carried out in accordance with the Refrigeration Code of Practice SAA HB 40. Check and ensure that all components are secure. X
5 6
X X
X X
Page 26 of 27

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Item No. Check and ensure that thermal insulation is secure. Check and ensure that all service doors/ panels and locks are operable and permitting inspection and service access. Carry out thorough check on the electrical components. Check all electrical wiring and terminals. Check and ensure that air filters are placed having correct type, model, and size specifications. Check the condition of the air filters and replace them if necessary Check the alignment of belt-driven motor and fan pulleys with a straight edge. Align them as necessary. Check motor-fan belt tension. Replace belts if necessary. Check and clean condensate drip trays and drains from any debris. Check and test thermostat, as applicable. Lubricate parts in accordance with manufacturer's recommendations. Lubricate fan motors. Check compressor oil levels. Check refrigerant gas charge through sight glass and adjust refrigerant charge. Record readings. Check refrigerant system for any leaks. Check and record system operating pressures. Check operation of crankcase heaters. X X X X X X X X X X X X X X X X X
Monthly or at 750 Hours
Version 0.1 Date: 1/02/2007 Prepared By: Justin Day Engineering Department X X X X X X X X X X X X X X X X X X X
X
6-Monthly or at 4300 Hours Completion of Hiring and Decomm.
Maintenance and Servicing Instructions
On Hire and Installation
24
Measure and record AIR-ON and AIR-OFF DB and WB temperatures with an electronic hygrometer. Measure, by traversing, AIR-OFF side air velocity with a hot wire type or vane type anemometer and calculate the Air Flow Rate = Velocity x Discharge Area in cum/ sec or Lt/sec, and check all measured data against the intended design conditions and operating parameters, as a part of the commissioning works. Check all motor operating temperatures and current and record result. Check incoming volts. Check operation of Hi-Limit thermostats and air switches, as applicable. Check and test all safety circuits and set points. Clean inlet side of the evaporator coils. Examine for damage, comb the fins as necessary. Check all coils and cabinet, etc. for corrosion or damage. Repair and paint.
25 26 27 28 29 30
X X X X
X X X X X X
Page 27 of 27

4 ELECTRICAL

TC Manual Air Conditioners

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Temperature Control Manual Air Conditioners

Temperature Control Manual