AIRSYS 3R1C1 User manual

Wall Mounted Packaged Air
Conditioners
Models
3R1C1 9E1C2
5R1C1 13E1C3
17E1C20.E1C2 18.E1C418E1C4
INSTALLATION AND OPERATION MANUAL
AIRSYS Refrigeration Engineering Technology (Beijing) Co.,Ltd

This document contains proprietary information that is protected by copyright and other intellectual property laws.
No part of this document may be reproduced, translated, or modified without the prior written consent of AIRSYS.
The information contained in this document is subject to change without notice.
AIRSYS provides this material as is and makes no warranty of any kind, expressed or implied, including, but not
limited to, the implied warranties of merchantability and fitness for a particular purpose. AIRSYS shall not be liable
for errors contained herein or for incidental or consequential damages (including lost profits) in connection with the
furnishing, performance, or use of this material whether based on warranty, contract, or other legal theory.
Designations used by other companies to distinguish their products are often claimed as trademarks. In this
document, the product names appear in initial capital or all capital letters. Contact the appropriate companies for
more information regarding trademarks and registration.
Copyright ©2012 by AIRSYS
AIRSYS Refrigeration Engineering Technology (Beijing) Co. Ltd
No.28 LuGu East Street
Shijingshan Beijing, China 100040
Phone: [phone]
Fax: [phone]
http://www.air-sys.com
Item Code: 1170104800
Version Number: 2.2.4

Page i
Contents
Chapter 1: Overview................................................................................................................................1
Using this Manual ................................................................................................................................2
Documentation Conventions.............................................................................................................2
Model Identification...........................................................................................................................3
Acronyms and Abbreviations ............................................................................................................4
Product Overview.................................................................................................................................5
Unit Operation..................................................................................................................................5
The Control System (Controller Box).................................................................................................6
Chapter 2: Installation..............................................................................................................................7
Installation Preparation.........................................................................................................................7
Delivery............................................................................................................................................7
Warranty...........................................................................................................................................8
Moving the Unit.................................................................................................................................8
General Safety Rules........................................................................................................................8
Required Materials...............................................................................................................................9
AIRSYS Supplied Materials ..............................................................................................................9
Installer Supplied Material...............................................................................................................10
Summary Electrical Ratings (Wire Sizing).......................................................................................11
Physical Installation............................................................................................................................12
Select the Wall for Installing the Unit...............................................................................................13
Make Openings and Holes..............................................................................................................14
Install Weather Stripping.................................................................................................................15
Position the Unit .............................................................................................................................15
Remove Wooden Pallet from WPU.................................................................................................16
Seal the Joints between WPUs and Wall ........................................................................................17
Attach the Supply Air Grill and the Return Air Grill to the Wall .........................................................17
Remove the Compressor Brackets..................................................................................................18
Controller Box Installation ..................................................................................................................19
Install Outdoor Temperature Sensor ...............................................................................................21
Position the Humidity Sensor..........................................................................................................24
Position Indoor Temperature Sensors and Supply Air Temperature Sensors...................................24
Complete Electrical Connections........................................................................................................26
Cautions.........................................................................................................................................26
Overview of Wiring .........................................................................................................................26
Electrical Connection to Controller Box...........................................................................................29
Electrical Connection to WPUs .......................................................................................................30
Complete the Installation Checklist.....................................................................................................33
Verify System Operation ....................................................................................................................34
Turn On Component Breakers........................................................................................................34
Turn on Primary Power...................................................................................................................34
Execute the Step-Test....................................................................................................................35
Turn the HVAC System On.............................................................................................................36
Set System Time............................................................................................................................37
Verify the sensor readings..............................................................................................................38
Verify Input and Output Alarms.......................................................................................................38
Complete the Registration Card......................................................................................................39
Chapter 3: System Operation.................................................................................................................44
User Interface Introduction.............................................................................................................44

Page ii
Navigating the Main Menu..................................................................................................................45
Turning the HVAC System On or Off...............................................................................................46
Using Comfort Mode.......................................................................................................................47
Sequence of Operation......................................................................................................................48
Compressor and Heater Operation .................................................................................................48
Free Cooling (Economizer) Operation.............................................................................................48
Executing the Step-Test.....................................................................................................................49
Alarms...............................................................................................................................................50
Viewing Alarm History.....................................................................................................................51
Clearing Alarm History....................................................................................................................51
Alarm Descriptions .........................................................................................................................52
System Diagnostics............................................................................................................................57
Port Definitions...............................................................................................................................57
System Parameters and Default Values..........................................................................................58
Chapter 4: Preventive Maintenance.......................................................................................................67
Preventive Maintenance Schedule .....................................................................................................67
General Operation Check...............................................................................................................67
Replace Air Filter............................................................................................................................69
Clean the Preliminary Air Filter........................................................................................................69
Inspect and Clean Condenser Coils................................................................................................70
Inspect and Clean the Drain Pipe....................................................................................................70
Physical Inspection of the Damper..................................................................................................70
Operation Checklist............................................................................................................................71
Spare Parts........................................................................................................................................72
Appendix 1:Drawings.............................................................................................................................73
Appendix 2:Reference Tables................................................................................................................73
Appendix 3:List of Tables.......................................................................................................................75
Appendix 4:List of Figures .....................................................................................................................76

Chapter 1: Overview
Page 1
Chapter 1: Overview
Thank you for choosing a unit manufactured by AIRSYS REFRIGERATION ENGINEERING TECHNOLOGY
(BEIJING) CO., LTD.
The AIRSYS line of wall mounted HVAC systems is optimized for energy efficiency. These systems are uniquely
designed for the efficient removal of heat generated by electronics from enclosed shelters. The supply air of the
AIRSYS system is delivered from the bottom of the machine and the exhaust is at the top, the opposite of a
traditional HVAC system. This “bottom throw” is designed to take full advantage of the fact that hotter air rises.
With the exhaust located higher within the shelter, every rotation of the fan removes more heat. The cooler air
supplied at the bottom accelerates this natural process. This is just one of many design features that makes the
AIRSYS HVAC systems among the most energy efficient in the world.
Another feature that promotes energy efficiency is the robustly designed integrated economizer, described as “free
cooling”. This feature combines with the powerful controller to provide 100% cooling capacity of the wall pack unit
(WPU), consuming ~ 1kW or less whenever the outdoor temperature is a few degrees lower than a predetermined
set point. This feature alone can save telecom operators significant utility cost, especially in cool weather climates.
Along with the energy efficiency, these systems are simple to operate, maintain, and service. The AIRSYS design
team is committed to listening and responding to the customer community. As a result, these systems have
continuously evolved with customer-defined features that have improved the overall quality and the user experience.
Usability features include:
A functional step test that facilitates complete operational verification in less than 5 minutes
Simple unobstructed access to all key components for Preventive Maintenance (PM) and servicing
No need to define compressor orientation as the units can be easily serviced with as little as an 8 inch clearance
on either side
A high level of redundancy in the precision lead/lag controller to enhance reliability
Completely selectable alarm relays (NC or NO) to enable the system to adapt to the customer’s requirements
The AIRSYS WPUs are available in cooling capacities from 1.0 ton through 5.0 ton; however, the sensible cooling
capacity of these machines is as much as 40% higher than a traditional machine. An available ordering guide helps
to properly match the capacity of the HVAC system to the heat load in the shelter.
Heating elements can also be included per customer requirements in a range from 1.5 kW through 5.0 kW.
With a suite of best in class components from around the globe, the AIRSYS WPU delivers quality and reliability
while substantially reducing cost of operation.

Chapter 1: Overview
Using this Manual
Page 2
Using this Manual
Before attempting to install or start the unit, you should read this manual carefully. Retain this manual for reference
for the entire operational life of the unit. This manual provides information on the following general topics:
Product overview
System installation including preparation, physical and electrical installation of WPUs and the controller box,
and commissioning the system
System operation, including system alarms, program menus, and advanced troubleshooting
Preventive maintenance
Documentation Conventions
For safety and to achieve the highest levels of performance, always follow the warnings and cautions in this manual
when handling and operating the AIRSYS unit.
Danger. Emphasizes hazardous conditions that could cause personal injury or death.
Warning. Indicates where the operator must proceed with caution to avoid personal injury or damage to
property.
Important. Indicates technical information critical for proper installation or operation.
Table 1 lists symbols and their meaning that may appear on the external packaging.
Table 1: Packaging Symbols
Symbol
Meaning
Symbol
Meaning
THIS SIDE UP
Shows the orientation of the unit.
NO HOOKS
Do not use hooks to lift the packed unit.
FRAGILE
Handle with care.
KEEP AWAY FROM HEAT
The unit must be kept away from heat
sources.
PROTECTAGAINST RAIN:
The packaged unit must be stored in a dry
place.
DO NOT STACK

Chapter 1: Overview
Using this Manual
Page 3
Model Identification
Each unit is identified by a model number, such as M-OD.13E1C3DR410.230/1/60.DC. The elements in the number
are explained in
Table 2.
Table 2: Model Number Nomenclature
1 M-OD
213
3E1
4C3
5 D
6 R410
7 230/1/60
8AC
9
M-OD.13E1C3DR410.230/1/60.AC
Product series name: M-OD = MOBILECOOL-OUTDOOR：Packaged air conditioner with fresh air free cooling.
Unit nominal total cooling capacity in kW
Compressor type & number: E1 = Hermetic scroll compressor qty 1; R1= Rotary compressor qty 1
Cabinet size code: There are 4 cabinet sizes: C1, C2, C3 & C4.
Control configuration: D = Unit is designed to operate in a Dual control environment (aka Lead/Lag operation)
Refrigerant: R410 = R410a.
Power source: Voltage/Phase/Frequency; 230V/1φ/60Hz, 230V/3φ/60Hz, 460V/3φ/60Hz.
Supply Fan configuration: DC = DC EC fan; AC = AC EC fan. (EC = Electronically commutated variable speed fan)
Special code: Utilized to designate unit customization (non-standard configuration)
1
3
5
7
2
4
6
8
9

Chapter 1: Overview
Using this Manual
Page 4
Acronyms and Abbreviations
Table 3 lists acronyms and abbreviations used in this manual.
Table 3: Acronyms and Abbreviations
Term
Meaning
AIRSYS
AIRSYS Refrigeration Engineering Technology (Beijing) Co., Ltd
AAST
AIRSYS Authorized Service Technician
Amp
Ampere, unit of electric current, or rate of flow of electricity
AUT/MAN
Automatic/Manual
BMS
Building Monitoring System
CFM
Cubic Feet per Minute
Com
Common
Comp
Compressor
Cond
Condenser
DC
Direct Current
Gen Run
Generator Run Signal
EC
Electronically Commutated (Referes to variable speed evaporator/supply fan)
Evap
Evaporator
FC
Free Cooling
HVAC
Heating, Ventilation, and Air Conditioning
Humid
Humidity
I/O
Input/Output
IPU
Indoor Packaged Unit
kW
Kilowatt
LED
Light Emitting Diode
MC
Mechanical Cooling
N.C.
Normally Closed
N.O.
Normally Open
pLAN
PCO controller Local Area Network
PLD
Programmable LED Display
PSI
Pounds per Square Inch
PWM
Pulse Width Modulation
R
Read Only
RoHS
Restriction of Hazardous Substances Directive
R/W
Read/Write
Temp
Temperature
VAC
Voltage in Alternating Current
VDC
Voltage in Direct Current
WPU
Wall Packaged Unit

Chapter 1: Overview
Product Overview
Page 5
Product Overview
Unit Operation
The air conditioning system has three key components:
1. The free cooling system
2. The mechanical cooling system
3. The control system
The control system determines the unit’s mode of operation: free or mechanical, as shown in Figure 1.
Figure 1: Basic Operating Modes
Free Cooling System
When the operating conditions for free cooling are met, the control system switches the air damper to the free
cooling position. Cooler air from outside is delivered to the shelter by the supply air fan. At the same time, hot air in
the shelter is discharged to the outdoor environment.
Mechanical Cooling System
When the operating conditions for mechanical cooling are met, the control system switches the air damper to the
mechanical cooling position. The compressor compresses the refrigerant gas and sends it to the condenser. The
condenser is a heat exchanger, removing heat from the hot compressed gas and allowing it to condense into a liquid.
The liquid refrigerant is then routed to the thermal expansion valve, which acts as a restriction device by forcing the
refrigerant to go through a small hole. This causes the pressure to drop. Then the liquid refrigerant is routed to the
evaporator. The evaporator is also a heat exchanger, absorbing heat from the indoor hot air causing the liquid
refrigerant to change back into gas. The refrigerant gas is then routed back to the compressor to complete the cycle.
Free Cooling Mode
Mechanical Cooling Mode

Chapter 1: Overview
Product Overview
Page 6
The refrigerant is used over and over again, absorbing heat from the indoor environment and discharging the
condenser heat to the outdoor environment.
The Control System (Controller Box)
The AIRSYS controller box is designed to operate a fully or partially redundant air conditioning system for
equipment shelters or enclosures. Two variations of the AIRSYS Lead Lag Controller are available: ASLLC.2 &
ASLLC.2.48.
ASLLC.2 is standard for HVAC equipped with an AC EC evaporator fan.
ASLLC.2.48 is standard for HVAC equipped with a DC EC evaporator fan.
The controller box is factory programmed with standard industry set points but can be configured on-site to meet
specific needs. Settings are retained indefinitely in the event of a power loss.
Ease of Control and Configuration
The controller box has a convenient Programmable LED Display (PLD). The PLD and button actions are explained
in more detail in Chapter 3 starting on page 48. This three-button PLD is the user interface by which an operator
can do the following:
Check current status of the HVAC system, such as sensor readings and operating mode
Change factory set points
Place the system temporarily into comfort mode
Review alarms and alarm history
Labeling on the outside of the controller box provides a convenient guide on how to access the most common
functions.
Many of these same functions can be accessed remotely via an RS485 communication interface built into the
controller.
Lead and Lag Roles
When mechanical cooling (MC) is required to maintain site temperature, only one unit is called upon to provide the
cooling. The unit that has this primary role during MC is referred to as the lead unit. The unit functioning in a
backup role during periods of MC is referred to as the lag unit. After a set period of time, the lead and lag units
switch roles. This scheduled change of roles ensures an extended and balanced operational life for each unit. The
factory default for the scheduled switch of roles is 168 hours (seven days); however, this can be adjusted using the
PLD (1 to 999 hours).
The lag unit will provide MC if the lead unit is unable to maintain site temperature on its own. This MC assistance
will occur if the heat load at the site is higher than the cooling capacity of a single WPU or if the system in the lead
role is functioning at a reduced capacity. A system in this state should be serviced as soon as possible.
During periods of free cooling (FC), both the lead and the lag units work together. This ensures longer periods of FC
which minimizes compressor run time. This design extends the life of the system and reduces energy consumption.