Air Change PCU Manual
Air Change Australia Pty Ltd
2 Ashford Avenue, Milperra
(02) 8774 1400
April 2019
INSTALLATION AND
MAINTENANCE MANUAL
Air Change Precise Control Unit (PCU)
Installation and Maintenance Manual 2
Table of Contents
1. INTRODUCTION.............................................................................................................................. 4
Inspection and Unpacking ............................................................................................................................... 5
Unit Handling ................................................................................................................................................... 5
Lifting with a Forklift......................................................................................................................................... 6
Lifting with a Crane.......................................................................................................................................... 6
2. INSTALLATION ............................................................................................................................... 7
Location ........................................................................................................................................................... 7
General.................................................................................................................................................... 7
Level and Suitable Base.......................................................................................................................... 7
Suspending the Unit ................................................................................................................................ 7
Access for Maintenance .......................................................................................................................... 7
Ductwork Considerations................................................................................................................................. 7
Fresh Air Inlet Precautions .............................................................................................................................. 7
Noise Levels .................................................................................................................................................... 8
Drainage .......................................................................................................................................................... 8
Phase Rotation ................................................................................................................................................ 9
Miswiring of 3-phase Power............................................................................................................................. 9
Filters............................................................................................................................................................. 10
Electrical/Electronic Connections................................................................................................................... 10
Mains Power Supply and Fusing ................................................................................................................... 10
Electrical Connection and Supply Size Precaution ........................................................................................ 10
Ducting .......................................................................................................................................................... 11
3. REFRIGERATION PIPING ............................................................................................................ 12
General.......................................................................................................................................................... 12
Piping............................................................................................................................................................. 12
Charging ........................................................................................................................................................ 12
4. SYSTEM COMPONENTS.............................................................................................................. 13
Requirement .................................................................................................................................................. 13
System Components ..................................................................................................................................... 13
Cabinet .................................................................................................................................................. 13
Fans ...................................................................................................................................................... 14
Scroll Compressors ............................................................................................................................... 15
Electrical................................................................................................................................................ 16
Coils ...................................................................................................................................................... 16
Control System ...................................................................................................................................... 16
Optional Fire Control Circuitry ............................................................................................................... 17
5. OPERATIONS................................................................................................................................ 18
Start‐up Procedures....................................................................................................................................... 18
Installation and Maintenance Manual 3
Unit Air Flows ................................................................................................................................................ 18
6. EC PLUG FAN AIR VOLUME CONTROLLER SETPOINT CHANGE PROCEDURE ................. 19
7. CLIMASYNC™ CONTROLLER .................................................................................................... 20
Home Page.................................................................................................................................................... 20
Service Page ................................................................................................................................................. 21
Settings Page 1 ............................................................................................................................................. 22
Settings Page 2 ............................................................................................................................................. 23
Status Page ................................................................................................................................................... 24
Alarm History ................................................................................................................................................. 25
Trends ........................................................................................................................................................... 26
8. SERVICE & MAINTENANCE ........................................................................................................ 27
Heat exchangers............................................................................................................................................ 27
Air Change Sensible Heat Exchangers.................................................................................................. 27
Maintenance Schedule .................................................................................................................................. 27
General.......................................................................................................................................................... 27
Monthly Maintenance Schedules................................................................................................................... 28
Three‐Monthly Checks................................................................................................................................... 28
Annual Maintenance...................................................................................................................................... 28
9. TROUBLESHOOTING GUIDE ...................................................................................................... 29
10. TECHNICAL DATA ‐
‐‐
‐TABLES ...................................................................................................... 30
Heat Exchanger Data .................................................................................................................................... 30
Sandwich Panel Data .................................................................................................................................... 30
11. WARRANTY INFORMATION, TERMS & CONDITIONS.............................................................. 31
Warranty Claim Form..................................................................................................................................... 32
Details of Servicing........................................................................................................................................ 33
12. WARRANTY POLICY .................................................................................................................... 34
Installation and Maintenance Manual 4
Air Change PCU
1. INTRODUCTION
SAFETY CONSIDERATIONS
IMPORTANT
DO NOT LEAVE HEAT EXCHANGERS EXPOSED TO DIRECT SUNLIGHT.
Prolonged exposure to UV light can cause severe damage to the structure of the heat
exchanger, and will void the warranty.
WARNING
Improper installation, service, maintenance or use can cause explosions, fire, electrical
shocks or other conditions which may cause personal injury or property damage and
will void the warranty. Check with Air Change or your nearest Air Change dealer for
any information required on this equipment.
DANGER
Electrical shock can cause personal injury or death. Before performing any work on
this equipment, the electrical supply must be turned off at the electrical service box to
avoid the possibility of shock, injury or damage to equipment.
Note: There may be more than one power supply circuit.
Installation and Maintenance Manual 5
NOTE TO INSTALLER
Only trained and qualified personnel should install, repair or service air conditioning equipment.
Untrained supervised operatives can perform basic maintenance functions such as cleaning or
replacing filters. Service personnel must perform all other operations.
Installing and servicing air conditioning equipment can be hazardous due to electrical and
mechanical components.
When working on air conditioning equipment, observe precautions in all literature, tags and labels
attached to or shipped with unit. Follow all safety codes and guidelines. Wear safety goggles, work
gloves and any protective clothing.
All work must comply with relevant Australian Standard wiring rules and local authority codes.
Installers must ensure that all statutory regulations and by-laws have been addressed, and that all
relevant codes regarding the handling and recovery of refrigerants have been observed.
Installers must ensure that the structures built to take the units have been suitably constructed for
the purpose, all safety precautions have been applied prior to installation, and all preparation work
has been constructed and suitably sized for its purpose.
Inspection and Unpacking
The unit should be inspected upon delivery for possible external damage incurred during transport.
If damage is evident it should be noted on the freight docket and the Air Change sales office
contacted. A claim should be lodged with shipping company within three (3) days if shipment is
damaged or incomplete.
If major damage is apparent, do not lift unit on to site without prior approval from Air Change. All
units are tested and inspected prior to packing and leave Air Change premises in perfect condition.
Check unit rating plate to ensure the correct unit matches the job specifications.
Unit Handling
Do not remove the skids, or any protective crating or packaging, until the unit is at the point of
installation. When removing packaging or crating, be careful not to damage, scratch, or dent the
unit.
After the removal of packaging or crating, all removable access panels should be opened to inspect
for unit internal damage.
Installation and Maintenance Manual 6
Lifting with a Forklift
Exercise extreme caution when lifting with a forklift. Do not exceed the height limit of the forklift and
never allow fork to lift against the bottom panel of the unit.
Make careful consideration of the unit’s centre of gravity and distribute the weight equally on both
forks. Test load to see if the weight is equally distributed. Do this by lifting the unit a few
centimetres off the floor and holding it there before lifting any further or before transporting the unit.
Lifting with a Crane
NOTE: All units should be lifted into position using slings.
Where units have to be lifted into position, installers must check the unit weight is within tolerance
of the safe working capacity of the lifting equipment.
When preparing to move the unit, always determine the unit's centre of gravity in order to equally
distribute the weight.
Spreader bars must be used between slings to prevent crushing the frame or panels. Spreader
bars and/or pipe are not supplied with units.
Spreaders whose length exceeds the largest dimension across the unit should be across the top of
the unit.
Installation and Maintenance Manual 7
. INSTALLATION
Location
General
The PCU unit is marked with stickers “SA” (Supply Air), and “OA” (Outdoor Air), showing the air
path through the unit.
The Fresh Air supply inlet should be clear of any polluted air from other units, exhaust fans, etc.
Level and Suita le Base
These units are primarily designed to be fitted on a suitably reinforced support base of sufficient
strength to adequately take the full operating weight of the equipment.
The unit must be mounted on a level base and any slope should not exceed +25 mm over the unit's
dimensions to ensure proper condensate drainage.
On rooftop applications, the unit must sit at least 152 mm above the roof surface. Place the unit
above a load bearing wall. Arrange supporting members to adequately support the unit and
minimise the transmission of vibration to the building.
Suspending the Unit
Before suspending the unit, check the supporting beams to be used and verify that it has sufficient
load carrying capacity to support the weight of the unit.
Access for Maintenance
The unit must be mounted so maintenance personnel can gain access to all parts of the unit and
with sufficient room to remove fans, compressors, coils or heat exchangers as required.
Minimum space requirements:
600 mm for electrical access;
1000 mm from Fresh Air inlet;
1000 mm from all access doors on the unit in accordance with the design and construction to
allow servicing or removal of parts.
Ductwork Considerations
The unit must be situated close to the point of use to prevent unnecessary long runs of ductwork.
Fresh Air Inlet Precautions
The location of the Fresh Air inlets should adhere to AS1668.2.
Installation and Maintenance Manual 8
The Fresh Air intake should be positioned clear of any objects which could obstruct the airflow and
be away from any exhaust discharge ducts from the unit or any adjacent equipment.
The Fresh Air inlet should be fitted with a weather shelter and inlet and exhaust points should be
minimum 6 m apart.
Noise Levels
Do not sit unit adjacent to sleeping quarters unless background noise levels have been checked
and permitted by the appropriate authority.
It is recommended that rubber supporting or vibration absorbing pads are used to support the unit
to minimise any vibration being transmitted into the building structure. We recommend wafer pads
be used under the frame. We also recommend flexible couplings be fitted to the supply and return
ducts to reduce vibration transfer.
Drainage
IMPORTANT
Installation of a “P” Trap is mandatory for all drainage points. Air Change will not
accept any liability for any water damage resulting from incorrect installation. A
minimum of 50 mm elevation difference between three levels are required. Schematics
are as follows.
All drainage needs to be trapped (standard “P” trap). Prior to start up, charge the external “P” trap by
pouring several litres of water into the drip tray, allowing run off to seal the drain outlets to prevent
outside air being drawn into the unit.
Installation and Maintenance Manual 9
IMPORTANT
External drip trays are mandatory for units installed in plant rooms or inside roof
space. Drainage from the unit and external drip tray is the responsibility of the
installing contractor. A separate safety tray must be fitted under the unit and drained
separately.
Air Change will not accept any liability for any water damage resulting from incorrect
installation.
The unit should be installed with a positive fall to ensure water drains away freely through drain
holes provided. Drain lines must be as large as or larger than the fitting to which the line is being
connected. Ensure that drain lines are fitted to both the dump outlet as well as the overflow outlet
(if necessary). Drain lines should have a minimum fall of 20 mm per m length.
If drain lines are to be extended from the inside to the outside of the building, they must be
extended beyond the walls of the building to eliminate the possibility of damage caused by drain
water running down the exterior surface of the building wall.
Where drain lines are likely to be exposed to freezing temperatures or when they are subject to the
formation of condensation, the lines should be insulated.
Phase Rotation
(Applicable to PCU-D models only)
Correct phasing:
Phase sequencing: the scroll compressor is designed to operate with the motor in only one
direction.
Miswiring of 3-phase Power
Miswiring of 3-phase power (phase reversal) will cause the compressor to operate in the wrong
rotation. The compressor will damage itself if the phasing is incorrect, will not pump refrigerant and
will draw minimal current. As a result, the discharge line and pressures will be well below normal.
The unit is fitted with a PPR (Phase Protection Relay). If there is a phase reverse or phase loss,
the PPR will shut down all fans and compressor.
All 3-phase motors are phase connected and sequence tested in the factory. If fan motors are
3-phase, run the condenser fans. If they run in the correct direction, then compressors will have
correct rotation. If running backwards, the current 3-phase connection is incorrect.
IMPORTANT
Do not change phases at compressor terminal or contactor.
Installation and Maintenance Manual 10
Filters
IMPORTANT
Never operate the unit without filters fitted to the Return and Fresh Air intakes with
blower access panels removed.
Make-up air quantity (if any) is to be incorporated into outdoor air filtered airflow.
G4 panel and bag filters are included in standard units.
NOTE: If these units are being used during construction when adhesive or sealants are in use, and
if ducts and carpets are being installed or removed, make sure all equipment is fitted and
adequately protected. We recommend using disposable or temporary filters during commissioning
and during pre‐hand over running.
Electrical/Electronic Connections
For power requirements and voltages, see the unit specifications.
The electrical diagram is attached on the wall of the electrical board cabinet.
Mains Power Supply and Fusing
A power supply rated at 415 V +/‐10% 3-phase or 240 V +/‐10% 1-phase, 50 Hz is required to
operate the machine within manufacturer's tolerances.
Mains cables are to be connected as per the wiring diagram.
Field wiring on the sensor and HLI communication to the controller (if any) need to be done on site.
The units require a mains circuit breaker or HRC fusing capable of handling the full load of the unit
and selected in accordance with SAA Wiring Rules to be fixed external to the unit.
A mains switch is fitted to the electrical board inside unit.
Electrical Connection and Supply Size Precaution
We recommend an isolator be mounted externally to the unit (not supplied) and a suitably sized
fuse mounted back at the distribution board to provide local isolation during service and
maintenance periods. The unit has a 3‐phase switch internally on the electrical board.
Installation and Maintenance Manual 11
Ducting
Flexiduct ducting is recommended for use with all Air Change systems. See image below.
Ducts should be insulated in accordance with ASHRAE Standard 90.1.
Fan inlet conditions can affect the fan performance, particularly ducting elbows which can cause
non‐uniform inlet flow and swirl at the inlet. To reduce losses due to fan system effect, adequate
length of straight duct between elbow and fan inlet should be provided or turning vanes used in the
elbow.
Poor fan outlet conditions can affect the fan performance, particularly the effective duct length. For
100% recovery, the duct must meet requirements for 100% effective duct length.
Ducts should be sized to accommodate a maximum airflow velocity of no greater than 6 m/s
through the duct.
Installation and Maintenance Manual 12
3. REFRIGERATION PIPING
(Applicable to PCU-D Systems only)
IMPORTANT
The unit is designed for use with specific refrigerants (R-410A or R-407C). Check
serial number plate for type of refrigerant. The use of other refrigerants is not
authorised or approved by Air Change, and may cause operational problems such as
poor performance and efficiency, loss of capacity, degradation of materials, and
refrigerant leaks.
DANGER
The use of flammable or explosive materials as a refrigerant creates the additional
risks of fire and explosion which may result in property damage, personal injury or
death.
General
Design pipe work to prevent drainage of liquid refrigerant into the compressor during off cycle, and
to ensure return of oil to the compressor.
Piping
Pipe diameters vary with unit capacity.
Use only clean sealed refrigeration grade piping and cut only with a pipe cutter.
Insulate the gas line and seal all insulation joints.
Charging
Evacuate the indoor unit and interconnecting pipe work to a standard pressure of 500 microns
which is to be held for minimum of 15 minutes.
Open the service valve at both the indoor and outdoor unit to allow refrigerant to flow through the
system.
Start by altering the refrigerant charge to match the nominal amount specified for the total line
length installed.
Check the superheat on the suction line is in the 3°C – 5°C range under the following conditions:
21°C – 27°C (indoor temperature)
24°C – 35°C (outdoor temperature).
Installation and Maintenance Manual 13
4. SYSTEM COMPONENTS
Requirement
The PCU has been developed by Air Change to dehumidify outdoor air and maintain the supply air
temperature. The PCU incorporates a series of sensible heat exchangers that transfer temperature
only.
These units are manufactured to meet the design criteria. The system is professionally assembled,
and internally wired throughout, with large access panels where required for service and
maintenance.
If specified, for corrosive air applications, the required components are coated with corrosion
resistant materials selected by Air Change. Upon request, specifications of the treatments used
can be supplied.
System Components
The unit employs 100% outside air and comprises of the following components:
Ca inet
Prefabricated wall and ceiling panels are made of stressed skin insulated sandwich construction,
consisting of metal internal parts and external skins bonded under pressure with thermosetting
adhesive to a core of rigid cellular insulation.
Insulation is a single layer of rigid Polyisocyanurate sheet to AS1366.3 Class SL continuous
without voids, free of line faults through or across the sheet.
Purpose built UV treated polymer joiners are used to insulate against heat loss through the body of
the unit. The cabinet is fully weatherproof and designed for outdoor use.
Galvanised steel RHS construction on base.
Air Change units are designed with extremely large access doors to ensure that all parts are
accessible for servicing and replacement.
Installation and Maintenance Manual 14
Fans
Supply fans in standard units are aerofoil single
inlet backward inclined centrifugal impellers
with three dimensional profiled blades made
from one cast, without welds.
The fan is directly driven by high efficiency
variable speed EC (electronically commutated)
motor and controlled via 0-10 V through
constant volume air controller
The fan motor is fitted with sealed-for-life ball bearings with in-built diagnostic/service LEDs.
Heat Exchanger
The sensible heat exchanger uses counter flow with
transfer media between moulded plastic air guiding
frames for a very high efficiency and long life.
There is no cross contamination between the air paths.
The Heat Reclaim (sensible) counter flow heat
exchanger incorporated into the unit has efficiency of
80% when both airstream are of equal volume flowrate.
IMPORTANT
DO NOT ATTEMPT TO CHANGE THE LENGTH OF THE HEAT EXCHANGER BY
REMOVING END PLATES AND PLASTIC PLATES.
This can cause the media between the plates to dislodge from its position, resulting in
a lack of performance because of an increased pressure drop through the heat
exchanger or damage to the Sensible media. Any tampering with the heat exchanger
may invalidate our warranty and Air Change will not be held responsible for
compromised performance or a pressure drop.
If the heat exchanger is the incorrect length, please return to Air Change for a
replacement unit.
Heat Exchangers are constructed of plastic moulded plates with media between each plate. The
heat exchanger has been secured by end plates under pressure. Sensible heat exchanger has end
plates and corner/middle fixings of powder coated aluminium with sensible Mylar media between
the plates.
Installation and Maintenance Manual 15
Scroll Compressors
(Not applicable in PCU-D Systems only)
Air Change units employ Scroll compressors.
Scroll compressors and all electrical components are housed in their own separate compartment,
together with reversing valves, other refrigerant parts and pipe work.
Compressors are suitable for condensing temperatures of not greater than 55°C at design ambient.
Scroll compressors are of rigid design with limited number of moving parts. They provide constant
and stable compression at variable speed.
If there is a need to detect a leak in the refrigerant system, never subject the compressor to a
pressure greater than 1400 kPa.
Should a compressor fail and burn out, follow the guidelines for correct replacement and properly
clean out the system including the liquid line drier (where fitted) and fit a suction line drier to
remove contaminants from the system. The suction line drier must be checked and replaced before
returning the system to normal operating condition.
All compressors are fitted with internal line break overloads. Should there be a problem such that
the internal overloads trip, it may take several hours for them to reset (or longer on very hot days).
Accompanied with the scroll compressor are characteristic sounds that do not affect reliability or
indicate that the compressor is defective.
At start up: Under conditions of low refrigerant flows (low suction pressures) such as start-up, a
rattling sound may emanate from the compressor. This will be heard until the head pressure is
great enough to allow the thermal expansion valve to flow sufficient refrigerant and increase the
suction pressure.
At shut down: The gas within the scrolls expands and causes momentary reverse rotation,
resulting in a ‘flutter’ type noise.
Refrigerant flooding: If the compressor experiences severe liquid slugging during operation,
the compressor will make a loud rattling sound. This is normal because of the separation of the
scrolls which allow the liquid refrigerant to pass through the compressor without damage.
IMPORTANT
The compressor can only cycle a maximum of 12 times per hour. The controller will
optimize the starting time by making sure the minimum time delay between each start-
up is 5 min. Never disconnect the compressor contractor from the controller.
Do not condemn a compressor until time has been allowed for reset of internal
line break overloads.
Installation and Maintenance Manual 16
Electrical
An electrical diagram is attached to the inside of the access door.
The electrical switchboard incorporated in the unit is fully internally wired and housed within the
compressor enclosure. It is of industrial standard and conforms to Australian Standards and
specific state electrical authorities.
All wiring is independently colour coded.
The main power entering the system is protected by an isolation switch inside the unit. Circuit
breakers, contactors and overloads are used on the three-phase fan motors to ensure maximum
protection at all times.
Internal controls are 24VAC.
Coils
Condenser and evaporator coils are constructed of inner groove copper tubing and aluminium fins.
If specified by the client, coils can be treated against corrosion using coil saver epoxy.
Hot water coils in the PCU can be designed into units according to the client’s requirements.
Velocity through coils is designed at around 2.0 m/s for a low pressure drop and high efficiency.
Control System
All controllers are installed on the main electrical board inside the unit.
Outdoor Air, Air Off Coil and Supply Air sensors are pre-fitted inside the unit.
The controller is designed to automatically energise the unit by receiving a start signal from an
external digital input or from the LCD touch screen on the field controller or from HLI (optional).
The controller will automatically turn off some components when a fault occurs. The fault code,
name, time and date are traceable from the controller
The controller has a built-in function to short cycling of compressors and reversing valve (if
applicable)
The controller is powered by a 240/24VAC transformer on the electrical board. No external power
is needed for the controller.
Please refer to control system manual for operation detail.
IMPORTANT
Under no circumstances should the any unit electrical compartment bypass the
controller. Failure in this may damage the unit and void the warranty.
Installation and Maintenance Manual 17
Optional Fire Control Circuitry
Units can be supplied with a 24 V DC circuit supplied by the Fire Department’s Fire Control Board. In
case of fire, the 24 V DC circuit will be de‐activated, causing the unit to switch off, shutting down the
system completely except for the exhaust fans which act independently for smoke exhaust.
The 24 V DC circuit can only be reset by the Fire Department.
Installation and Maintenance Manual 18
5. OPERATIONS
Start‐up Procedures
CAUTION
Start-up to be conducted by qualified service engineers familiar with equipment.
Ensure that drain lines are fitted to both the dump outlet as well as the overflow outlet (if
necessary).
Ensure drain lines have been charged with water.
Check all duct work connections are clean, and clear of any obstruction. Ensure all relevant
dampers and fire dampers are open or at the correct setting.
Check if there are any signs of excessive vibration on fans.
Ensure filters have been fitted in the outdoor air inlet.
Check that sufficient electrical power is available.
Unit Air Flows
The Supply airflow quantity set point has been pre-set in the factory, allowing the fan to
automatically adjust the speed to meet the required airflow. The airflow setpoint can still be
adjusted using the air volume controller (UNIcon CPG). Please contact the Air Change technical
support team for instructions.
Installation and Maintenance Manual 19
6. EC PLUG FAN AIR VOLUME CONTROLLER
SETPOINT CHANGE PROCEDURE
EC Plug Fans employ a UNIcon CPG Controller from Ziehl‐Abegg to deliver the correct amount of air
volume.
IMPORTANT
Do NOT change any parameters under the BASE SETUP menu. Alteration of any
parameter under this menu will reset the entire program and result in fans not
delivering accurate air volume.
1 Press ▼and ▲simultaneously to enter the Main Menu.
Press ▼or ▲to find “Setting” and press Pto enter.
3 Under Setpoint 1 press Pbutton until the value flashes and press ▼or ▲to change.
4 Press Pto save the new value.
5 Press ▼and ▲again to return to main menu.
6 The “Info” menu is read‐only, and displays key running parameters such as actual airflow, and
control voltage reference.
Installation and Maintenance Manual 20
7. CLIMASYNC™ CONTROLLER
The following is a general guide for the use of Air Change units which have the Climasync™ Control
option with touch screen interface (ABB CP620 HMI). Please be advised that Air Change units and the
accompanying Climasync™ controls package ips custom made, and may differ from this guide.
Home Page
1. Displays the main temperature and humidity readings;
2. Temperature and/or humidity set points. Adjust using up and down arrows;
3. The serial number and name for the unit;
4. The mode the unit is running in. The number refers to the number of compressors
running ie COOLING 2 means the unit is in cooling mode with 2 compressors running;
5. Alarm status will display “NORMAL” when there are no faults and “ALARM” when there
are faults. For more information on faults go to SERVICE page then press STATUS;
6. Service page button.
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