Air PreciseAIR PPW Series Installation and operating instructions

Installation, Operation,
and Maintenance
IOM-PreciseAIR
Release Date: 11-12-20
PreciseAIR
7.5 to 60 tons
Series PPW
Packaged Water Cooled DX Unit
Series PCA
Split System Air Cooled DX Unit
Series PPA
Packaged Air Cooled DX Unit
Series PHW
Chilled Water Air Handling Unit

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Table of Contents
1. General...................................................................................................................................................4
1.1. Resources ........................................................................................................................................................................ 4
2. Installation..............................................................................................................................................5
2.1. Safety considerations ...................................................................................................................................................... 5
2.2. Receiving ......................................................................................................................................................................... 5
2.3. Handling .......................................................................................................................................................................... 5
2.4. Lifting............................................................................................................................................................................... 6
2.5. Storage ............................................................................................................................................................................ 8
2.6. Room Considerations ...................................................................................................................................................... 8
2.7. Ductwork Connections .................................................................................................................................................... 9
2.8. Condenser Water or Chilled Water Piping .................................................................................................................... 11
2.9. Piping Hook-up Components......................................................................................................................................... 11
2.10. Series PCA - Split System Field Refrigerant Piping......................................................................................................... 13
2.11. Condensate Drain Piping ............................................................................................................................................... 13
2.12. Electrical Drawings and Connections............................................................................................................................. 13
2.13. Main Control Panel Layout and Components................................................................................................................ 15
2.14. Smoke Detector............................................................................................................................................................. 16
2.15. Duct Mounted Sensors.................................................................................................................................................. 16
2.16. Room Mounted Sensors................................................................................................................................................ 16
3. Operation .............................................................................................................................................16
3.1. System Components...................................................................................................................................................... 16
3.2. Sequence of Operation.................................................................................................................................................. 23
3.3. Allen-Bradley CompactLogix PLC with PanelView Touch............................................................................................... 25
3.4. Main .............................................................................................................................................................................. 25
3.5. Compressors.................................................................................................................................................................. 26
3.6. Setpoint Screens:........................................................................................................................................................... 27
3.7. Active Alarm / Alarm History......................................................................................................................................... 29
3.8. Carel PCO5+ with pGD1................................................................................................................................................. 30
3.8.1.HMI................................................................................................................................................................................ 30
3.8.2.Main Loop...................................................................................................................................................................... 31
3.8.3.On/Off Unit.................................................................................................................................................................... 33
3.8.4.Setpoints ....................................................................................................................................................................... 33
3.8.5.Alarms ........................................................................................................................................................................... 34
3.8.6.Alarm History................................................................................................................................................................. 36
3.9. List of Alarms................................................................................................................................................................. 37
4. Maintenance.........................................................................................................................................38
4.1. Troubleshooting Charts ................................................................................................................................................. 38

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4.2. Compressors.................................................................................................................................................................. 40
4.3. Air Cooled Condensers .................................................................................................................................................. 40
4.4. Water Cooled Condensers............................................................................................................................................. 41
4.5. Filters............................................................................................................................................................................. 42
4.6. Drives (sheaves and belts)............................................................................................................................................. 42
4.7. Blower Bearings............................................................................................................................................................. 43
4.8. Blower Wheel and Shaft Maintenance.......................................................................................................................... 44
4.9. Evaporator Coil.............................................................................................................................................................. 45
4.10. Maintenance Checklists................................................................................................................................................. 45
4.11. Maintenance Logs ......................................................................................................................................................... 49

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1. GENERAL
Advance Industrial Refrigeration, Inc. reserves the right to make changes and/or improvements
in designs, features, options, and procedures without notice or obligation.
1.1. Resources
The following information is available for download: https://www.air-eng.com/resources
Product Catalog and IOM Manual
•Catalog-PreciseAIR, “Product Catalog - PreciseAIR”.
•IOM-PreciseAIR, “Installation, Operation, and Maintenance Manual - PreciseAIR”.
Drawings
•PreciseAIR Dimensional Drawings
Model Designations
•Series PPW
•Series PCA
•Series PPA
•Series PHW
Guide Specifications
•Series PPW
•Series PCA
•Series PPA
•Series PHW
Technical Bulletins
oTB-14, “Piping Recommendation for Refrigerant Systems” (Series PCA only).
oTB-15, “Condensate Trapping”.
oTB-33, “Blowers Maintenance”.
oTB-60, “Mechanical Water Regulating Valve Hose Installation”.
oTB-52, “A0002238 Installation Instructions (Wall Mounted Temp/RH Sensor)”.
oTB-54, “A0007416 Installation Instructions (Temp/RH Sensor)”.
oTB-60, “Mechanical Water Regulating Valve Hose Installation”.
oTB-61, “A0003701 Installation Instructions (Temp/RH Sensor)”.
oTB-64, “Torque Bolts Generic Assembly”.
Technical Reports
oTR-01, “Pre-startup Checklist”.

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oTR-02, “A/C Unit Start-up Report”.
Miscellaneous
•AIR Standard Warranty Policy.
2. INSTALLATION
2.1. Safety considerations
Installation and servicing of air-conditioning and process cooling equipment can be hazardous due
to system pressure and electrical components. Only trained and qualified service personnel
should install, repair, or service the equipment. Observe precautions in the literature, tags and
labels attached to the unit. Follow all safety codes. Wear personal protective equipment and put
safety as the priority item during work.
WARNING - ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury and/or death.
Before performing service or maintenance operations on a unit, turn off the main power switch.
Tag disconnect switch with a suitable warning label.
2.2. Receiving
This unit has been factory run-tested and has gone through a comprehensive inspection prior to
its packaging and shipment. However, shipping damage can occur and an inspection of the unit
should be performed immediately upon delivery. Note and photograph any external damage or
other damage due transportation on the freight carrier’s forms. Inspect the unit itself for internal
damage. File a claim with the shipping company if the equipment is damaged or incomplete.
2.3. Handling
Move the unit in its upright position to the installation site. The unit contains one or two lifting
access points for forklift and four brackets in the frame for hoist rings. If the air handler section
frame is used for lifting, caution must be taken to ensure that the bolts connected to both frames
are tightened when moving the compressor section and air handler section together.
Damage may occur during unit handling for installation. Extreme caution must be taken to prevent
any damage to the refrigerant system, especially when handling the unit with forklifts. This unit
may contain a system that is pressurized with refrigerant and if it is damaged, the refrigerant
could leak to the atmosphere or cause bodily harm due to the extreme cold nature of the
substance. Protective equipment such as gloves and safety glasses to minimize or prevent injury
in case of a system leak during installation must be used.

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2.4. Lifting
1. Before lifting the unit, be sure that all the shipping
material has been removed from the unit.
2. To assist in determining rigging requirements, weights
are provided in the unit mechanical submittal.
3. Unit must be lifted by all lifting points using the brackets
for the hoist ring provided in the unit.
4. Spreader bar(s) must span the unit to prevent damage
to the cabinet by lifting cables.
5. Always test-lift the unit to check for proper balance and
rigging before hoisting to desired location.
6. Do’s and don’ts:
Do
•Tight the hoist rings screw to the recommended torque value.
•Make sure that the hoist ring is free to pivot and swivel in all the directions.
•Always choose a hoist ring with the proper load rating.
•When installing a hoist ring, make sure to use a Grade 8 nut that has full thread
engagement.
Don’t
•NEVER EXCEED RATED LOAD.
•NEVER APPLY SHOCK LOAD.
•Never use a hoist ring that you believe is damaged.
•Never use a hoist ring that is not tightened to the recommended torque.
•Never shim or use washers between the hoist ring and surface of the object
being lifted.
Figure 1: Unit with 4 Lifting Points

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The load in each hoist ring is not simply the total weight divided by the number of hoist rings.
The resultant force can be significantly greater at shallow lifting angles and with unevenly
distributed loads.
L = Load experienced by each hoist ring
N = Number of hoist rings = 4
W = Total weight
A = Lifting Angle
L = W / (N*sine(A))
Figure 2: Hoist Rings

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2.5. Storage
If required, store the equipment in a dry area, out of the weather, protected from damage by
other equipment in storage or transportation equipment. Never stack equipment and avoid
frequent relocation.
For split systems, the air handler section and compressor section are each shipped charged and
sealed with low pressure (1 –5 psig) inert gas, such as nitrogen. This will prevent contaminants
from entering the coil. If the coils are not charged and sealed, condensation mixes with air
pollutants forming a weak acid and over time it can cause pinhole leaks to develop in the coil
tubes. If the equipment is stored longer than 30 days, the Customer should check that each
section is still charged to avoid coil damage. Refer to the unit’s mechanical submittal.
Prior to long term storage, fan bearings and motor bearings are to be greased per the
manufacturer’s specifications. On belt driven blowers, the belt tension should be reduced to less
than half the specified value for the fan’s design to prevent a sag/set from forming in the shaft
and belts.
On a monthly interval, the blower should be checked to ensure that it has remained in an
acceptable stored condition. The blower and motors should be rotated several times by hand
while adding enough grease to replenish the bearing surfaces with fresh grease and to maintain
a full bearing cavity.
When equipment is installed after being stored, caution should be taken to inspect and replace,
if required, belts and gaskets. All moving parts, such as blowersand motors, should be hand tested
to ensure that they are free and clean prior to start-up. Finally verify that all lubrication is fresh
and full.
2.6. Room Considerations
This unit is designed to control the room temperature within close tolerances. However, the room
must be built with a proper vapor barrier to prevent diffusion of moisture through wall, ceiling
and floor. Failure to provide a vapor barrier can compromise space conditions.
Proper room sealing is required to prevent excessive infiltration of humid air into the space. Unit
sizing must consider the impact of infiltration air or pressurization air on the sensible and latent
cooling load capacity required by the unit.
Unless the unit was specified to be installed outdoors by the Customer at the time of purchase,
the unit should be installed indoors or under a roof to protect from weather.

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2.7. Ductwork Connections
The discharge and return opening dimensions are provided in the chart below. For proper fan
performance, match the duct size to the dimensions indicated.
Discharge Sizes
Unit size
Unit Discharge
Opening Size (H X W)
Recommended Duct
Size (H X W)
090
11-¼” X 13”
13-¼” X 16”
120
13-⅜” X 15-½”
16-⅜” X 18-½”
180
13-⅜” X 15-½”
16-⅜” X 18-½”
240
11-¼” X 13”
13-¼” X 16”
300
13-⅜” X 15-½”
16-⅜” X 17-½”
360
13-⅜” X 15-½”
16-⅜” X 17-½”
Return Sizes
Unit size
Recommended Duct Connection
at Filter Rack (H1 X W1)
090
34-½” X 44-⅞”
120
34-½” X 44-⅞”
180
34-½” X 56-⅞””
240
46-½” X 56-⅞”
300
46-½” X 68-⅞”
360
58-½” X 68-⅞”

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Figure 3: Discharge and Return Connections
Unit sizes 090, 120, and 180 have only 1 discharge connection.
Duct connections to unit should be flanged connect flush to the supply fan outlet (on top) or to
the filter rack inlet (rear of unit) using self-tapping screws. Flanges should be gasketed with either
full faced 1/8” thick DURO 60 neoprene gasket or Tremco Butyl Sealant.
•Installation of all ducts should be done in accordance with Best Practices and SMACNA.
•Recommended Ductwork to Unit connection screws:
oSelf-tapping screws for metals with one piece hex washer head with a wide flat
bearing surface, used in materials such as steel and stainless steel, fully threaded, no
longer than 1”. Screws longer than 1” may cause damage to internal components.
oStainless steel screws are recommended.
•HVAC duct sealant is recommended to seal all possible leaks.