Air Change PCU Manual

Air Change Australia Pty Ltd
2 Ashford Avenue, Milperra
[phone]
[email protected]
April 2019
INSTALLATION AND
MAINTENANCE MANUAL
Air Change Precise Control Unit (PCU)
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz

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
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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
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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.
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Installation and Maintenance Manual 5
NOTE TO INSTALLER

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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.

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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.

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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.

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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

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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.

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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.

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Check unit rating plate to ensure the correct unit matches the job specifications.
Unit Handling

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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.
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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.

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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.

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When preparing to move the unit, always determine the unit's centre of gravity in order to equally
distribute the weight.

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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.
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Installation and Maintenance Manual 7
. INSTALLATION
Location
General
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The PCU unit is marked with stickers “SA” (Supply Air), and “OA” (Outdoor Air), showing the air
path through the unit.
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The Fresh Air supply inlet should be clear of any polluted air from other units, exhaust fans, etc.
Level and Suita le Base
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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.
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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.
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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

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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

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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.

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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.
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Installation and Maintenance Manual 8

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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.

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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.
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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.

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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.

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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.

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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.
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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.

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G4 panel and bag filters are included in standard units.

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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

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For power requirements and voltages, see the unit specifications.

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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.

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Mains cables are to be connected as per the wiring diagram.

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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.
Cooke Industries - Phone: [phone] Email: [email protected] Web: www.cookeindustries.co.nz