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.

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•Provide a minimum 12” of straight duct on the discharge outlets.
•Provide an access door at each backdraft damper (in discharge outlet) for future
maintenance.
2.8. Condenser Water or Chilled Water Piping
All piping connecting to the unit must be aligned and supported as to not impart stress on the unit
connections.
The required field installed water pipe sizes may or may not be the same as the connection sizes
at the unit. This will depend on the length of the pipe and the calculated pressure drop of
peripheral components.
Water connections on the unit are dimensioned and labeled on the unit’s mechanical submittal
and labeled on the unit itself.
The Customer should provide isolation valves for the condenser water lines should be installed
upstream and downstream of the heat exchangers, located to also provide practical service
isolation for flow sensing devices, field thermometers, flexible connectors, and any removable
pipe spools.
Air vents must be installed in various locations in the piping system to purge the air and avoid
problems due to the presence of air in the water loop.
If the unit will remain operational at subfreezing ambient temperatures, the water system must
be protected from freezing, by one of the following measures:
1. Insulate or install heat tape on the unit heat exchanger, water piping, pumps, and other
components to protect from freezing in low ambient temperatures. Heat tape must be
designed for low ambient temperature applications. Heat tape selection should be based
on the lowest expected ambient temperature.
2. Add a non-freezing, low temperature, corrosion inhibiting, heat transfer fluid to the
chilled water system. The solution must be strong enough to provide protection against
ice formation at the lowest anticipated ambient temperature.
NOTE: Use of glycol type antifreeze reduces the cooling capacity of the unit and must be considered
in the design of the system specifications.
2.9. Piping Hook-up Components
Piping components include all devices and controls used to provide proper water system operation
and unit safety. These components Include the following:
Entering Water Piping
•Isolation valve (located upstream from all components listed below).

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•Pipe strainer
oMesh no larger than 0.9 mm recommended for cooling coils/evaporators.
o0.5 to 1.5 mm mesh recommended for condensers.
•Water pressure gauge with shutoff valves.
•Water temperature gauge.
•Low point drain.
•Relief valve (required if water pressure may exceed 125 psig at any time, including upset
conditions. Customer to review shut off pressure of system pumps).
•Flexible hose connection to unit.
Leaving Water Piping
•Isolation valve (located downstream from all components listed below).
•Water pressure gauge with shutoff valves.
•Water temperature gauge.
•High point vent.
•Flexible hose connection to unit.
•Balancing Valve.
CAUTION
Use Piping Strainers!
To prevent condenser damage, pipe strainers must be installed in the water supplies
to protect components from water borne debris. AIR is not responsible for equipment
damage caused by water borne debris. 0.5 to 1.5 mm mesh recommended.
Proper Water Treatment!
The use of untreated or improperly treated water may result in inefficient operation and tube
damage due to scaling, erosion, corrosion, algae or slime. It is recommended that the services of
a qualified water treatment specialist be engaged to determine what water treatment is required.
AIR assumes no responsibility for equipment failures which result from untreated or
improperly treated water, or saline or brackish water.
Condenser or Water Coil Damage!
To prevent damage to water components, do not allow pressure
(maximum working pressure) to exceed 125 psig @ 150°F.

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2.10. Series PCA - Split System Field Refrigerant Piping
Refrigerant Piping
AIR does not assume responsibility for the line size selection. The ultimate responsibility for the
refrigerant piping sizing is for the installing contractor or Customer’s engineer.
Field discharge, liquid or suction lines will not necessarily be the same as the field pipe size
required. In some cases, these will vary significantly.
Special care must be taken to ensure proper oil return and efficient operation. Lines must be
designed and installed by a qualified refrigeration engineer and mechanic.
Refer to technical bulletin TB-14 for more instructions.
2.11. Condensate Drain Piping
All cooling coil drain pans have a connection for condensate removal.
A P-trap should be built into the drain line to prevent air from backing up into the unit. Refer to
technical bulletin TB-15.
2.12. Electrical Drawings and Connections
All electrical connections must be performed by a qualified electrical technician and must follow
all local electrical and safety regulations. Failure to do so may cause death, serious personal injury
or property damage and will void the warranty of the equipment. AIR is not responsible for any
damage caused by not following the instructions present in this document.
The Customer’s electrical installer will make holes in the enclosure to attach electrical fittings and
pass wires and cables. Make sure to protect the components (with tape or cardboard, for
example) to ensure that no debris or metal shavings fall through any component opening.
After drilling holes, make sure that the panel is clean and no metal shavings or other materials are
left inside it. If the panel is not cleaned up, those pieces can cause a catastrophic failure and the
warranty will be voided.
All electrical connections are depicted in the unit’s electrical submittal. The electrical submittal
includes the following drawings:
EF (Electrical Field)
Shows the power connection, the field devices (sensors) installed by the end user, and the
equipment nameplate. The equipment nameplate contains the minimum circuit ampacity data
which is used to size the conductors feeding power to the equipment and the maximum
overcurrent protection data which is used to select the protective device size (breaker of fuses).

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EW (Electrical Power)
Shows the wiring schematic for the high voltage components.
EP (Electrical Panel)
Shows the wiring schematic for the low voltage components.
ED (Electrical Detailed)
Shows the connections between the electrical boxes and devices.
EI (Electrical Instruction)
Shows information about network communication, addressing, cables colors conventions, and
any other information that is particular to the design.
Refer to electrical drawings for specific connections made inside each block or box.
The main power feeding the equipment is connected to the MCP (Main Control Panel, also
referred in this manual as Electrical Enclosure), which is the largest electrical box supplied
mounted to the machine or separated from the unit for wall mounting.
With the remote electrical enclosure option, the connections between the junction boxes, block
and the MCP may require field wiring by the Customer.

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2.13. Main Control Panel Layout and Components
Figure 4: Main Control Panel Layout

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2.14. Smoke Detector
When mounting the smoke detector, always refer to the respective device mechanical installation
manual for detailed explanation.
2.15. Duct Mounted Sensors
When mounting duct mounted sensors, always refer to the respective device mechanical
installation manual for detailed explanation. Refer to technical bulletins TB-54 and TB-61.
2.16. Room Mounted Sensors
The room mounted temperature/humidity sensor is a critical part of the system. It measures the
controlled variables and therefore it must be properly installed and located. Select a mounting
location which is the best representation of a typical temperature and relative humidity inside the
room. Keep in mind that some rooms have cold and hot spots. Locating the devices in those
locations can affect the system ability to maintain proper control.
The location of the sensors should consider the following:
•Mount sensors 5’-0” above finished floor.
•Do not locate wall mounted sensor in the direct path of supply air from the supply grilles.
•Do not locate wall mounted sensor adjacent to high heat producing electrical equipment.
•Avoid mounting directly on exterior walls, especially if exposed to solar load. If this is the
only option, mount thermostat on a mounting bracket at least 3” from the wall surface.
•Consider mounting the wall mounted sensor near the return grille to measure the average
space temperature.
Refer to technical bulletin TB-52 and the respective device installation manual for detailed
explanation.
3. OPERATION
3.1. System Components
Blowers
Units equipped with one or two forward curved double width, double inlet blowers. All blowers
equipped with high quality cast iron pillow block bearings and welded steel frame.
Coils
Series PPW, PCA, and PPA units are equipped with a single DX evaporator coil. For two cooling
circuits, the DX coil will have an interlaced design. Furnishing coils with a corrosion resistance
coating is an option.

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Series PHW chilled water units are equipped with a single chilled water cooling coil. Furnishing
coils with a corrosion resistance coating is an option.
Compressors
DX systems are provided with scroll compressors with R-410a refrigerant. The lead compressor is
provided with a VFD for capacity modulation.
Condensers
Series PPW units will be equipped with water cooled shell and tube condenser(s).
Series PCA and PPA units will be equipped with an air cooled condenser with vertical air flow.
Expansion Valves
DX units are equipped with one externally adjustable thermostatic expansion valve per refrigerant
circuit. The expansion valve controls the flow of liquid refrigerant entering the coil by maintaining
a constant superheat of the refrigerant vapor at the outlet of the coil.
Filter Driers
Each refrigeration circuit is equipped with a filter drier with replaceable drier core for durability
in the most aggressive environmental applications.
High and Low Pressure Cutout Switches
Each refrigerant circuit is equipped with a high and low pressure cutout switch for safety control.
The compressor motor is de-energized when the discharge or suction pressure of the compressor
becomes excessive. This prevents possible compressor damage.
Relief Valves
Each refrigerant circuit is equipped with a pressure relief valve to limit the pressure in the circuit
to a safe level. The pressure is relieved by allowing the refrigerant to flow through an auxiliary
passage out of the system.
Sight Glasses
Each refrigerant circuit is equipped with a sight glass to provide accurate identification and better
visibility of system conditions through a large viewing window with indicator.
Water Regulating Valves
Each water cooled condenser is equipped with a pressure actuated valve, which is used for
regulating the flow of water in the condenser. The water regulating valves modulate to maintain
constant condensing pressure during operation.

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Item
Description
1
AHU Section
2
Compressor Section
3
Filter rack
4
Electrical enclosure
5
Air Filter
Figure 5: Components Location

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Item
Description
1
Flex duct connection
2
Centrifugal blower
3
Blower motor with adjustable base (one per blower)
4
Thermal or electronic expansion valve
5
DX Evaporator coil
6
Drain pan
Figure 6: AHU Section Internal Components

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Item
Description
1
Compressor
2
Sight glass (moisture indicator)
3
Solenoid valve
4
Filter drier
1
2
3
4
Figure 7: Compressor Section Internal Components
Figure 8: Air Cooled Condenser (may have 1 or 2 fans)