Komatsu Breathesafe WA900-3EO Installation guide

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WA900
 
Manufacturer KOMATSU
Type WHEEL LOAD E R
Model WA900-3EO
Site ROBE RIVER IRON ASSOCIATES
Serial Number 60348
Cabin Pressure Max 253Pa
Set Auto Cabin Pressure 50
Key Modules High Capacity Pressuriser - HEPA H13 FRESH AIR INTAKE
INPRESS Cabin Pressure Monitoring & Display
HEPA Return Air lter - RECIRCULATION AIR INTAKE
HVAC SYSTEM UPGRADE

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WA900-3EO
SAFETY FIRST
Warning, Safety First!
The air conditioning system described in this manual has the following
areas, which may be dangerous if not treated with great care.
Wear correct personal protective equipment when cleaning and
servicing this unit due to hazardous bres which may be caught by all
stages of ltration during regular unit operation.
The electrical power system is supplied by 12v dc or 24v dc. no work
should be carried out on the system without the correct electrical safety
measures being taken and all relevant circuit breakers opened to isolate
the circuit.
The air conditioning system has various types of rotating equipment
installed. Ensure all safety guards are in place while the system is
running.
The refrigeration system, components, and copper pipework used in
the air conditioning unit are under high pressure and can cause serious
injury if the system is opened without following correct procedures.
The refrigeration system, components, and copper pipework contain
liquid or vapour mixtures under pressure, which can freeze and cold-
burn human body tissue resulting in permanent damage if the system is
opened without following the correct procedures. This damage can
occur within one second when running; the equipment has several hot
(>60⁰) and cold (>-5⁰) areas.
While servicing the equipment, be well aware of these areas to avoid
injury.

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OVERVIEW
5
DUST-FREE
PRESSURISED
AIR TO HVAC
1. Dirty, hazardous air enters the lter assembly
through angled veins.
2. The veins cause the air ow to spin and move.
3. The spinning air ow is accelerated further by the
integrated pre-cleaner rotor. Centrifugal force throws
the heavier than air dirt and dust particles to the
outside walls ejector ports.
4. 90% + of the coarse dust and hazardous debris is
ejected safely away as this process extends the
lifecycle of the lter media.
5. An inner vortex is formed and only precleaned air
is drawn down into the lter chamber.
6. The pre-cleaned air is pushed through the easily
serviceable lter media rated for submicron dust
particle ltration. HEPA (High-eciency Particulate
Air) media complies with OH&S guidance for
respirable silica, coal dust and mineral bres down to
0.3-micron particles.
7. A variable speed centrifugal air pump generates
powerful pressurised air.
8. Clean, hazard free, pressurised air is delivered to
the operator’s cabin.
9. The pressurised air is mixed with the HVAC
systems return air.
HEPA Return Air Filter isolates HVAC system
thus provides highest protection factor for the
operator.
In essence, this part of the system controls dust
from shoes and clothes.
10. The air passes through the HVAC system and into
the cab.
11. Positive cabin pressure ensures a safe work
environment. Positive internal pressure repels
harmful, hazardous dust.
1
2
3
HEPA
RETURN
AIR
FILTER
SAFE
BREATHING
ZONE
OPTION:
HEPA AIR
SCRUBBER
PRE-CLEANER
HEPA
FILTRATION
12. The Breathesafe INPRESS unit monitors the
cabin pressure as measured through its built-in
pressure transducer and calculates the error based on
the pressure set-point. This value is applied to an
algorithm and the controller calculates a proportional
output which adjusts the speed of the pressuriser
motor.
13. If the cabin pressure drops below the set point a
visual and if tted, an audible alarm is activated.
14. A backlit LCD, displays actual cabin pressure in
pascals on the top line and the time and date or any
alarms present, on the bottom line.
15. The digital interface allows the operator to easily
adjust the pressure set point and access additional
features.
CabinPressureDataLog
9
10
11
CabinPressureDataLog
12
12 13 15
16. Typically the processor can save up to 3.5 months
of data including date, time, pressure readings and
alarm instances. Data logs are easily downloadable
via a standard RS232 cable.
17. If required, remote data log access, report
analysis and management are available using the
4G network and customer support.
14
16 17
4
7
6
PRESSURISED
AIR
50 pascals
8

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WA900-3EO
INPRESS TL PRESSURISER 24V
Item Part Number Qty. Descrip�on Service Interval
1TLF700EN 1Fresh Air HEPA H13 Filter TESTED AS PER EN1822 500 - 1000 Hours
500 - 1000 Hours
2
TL4M
2
Brushless Blower motor - INPRESS TL 7500 Hours
3
4
TQ47010320H
TQUCPM INPRESS
1
Cabin HEPA RETURN AIR FILTER
BREATHE SAFE DIGITAL DISPLAY - DATA RECORDER 10000 Hours
Refer to page 16
INPRESS TL ACTIVATED CARBON PHASE
Item Part Number Qty. Descrip�on Service Interval
1TQ47055400SCSO2
TQ4706300EN
1MK2 & MK3 FILTER MODULE: ACTIVATED CARBON 500 - 1000 HOURS
Includes: 1 x HEPA nal lter
1 x Solid Core Ac�vated Carbon Module
2TQUCPH405Z 1MK3 CASE STAINLESS STEEL 10000 HOURS
1
5 TQ530061 1 Air Condi�oning - Receiver drier
PRESSURISER CRITICAL PARTS

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AIR CONDITIONING SYSTEM
Cases are fabricated fro m
hea vy gaug e zinc plated
steel. 100% Pow der coat
finish as standard.
All w etted s urfaces
are lined w i t h a c o mbination sound d e a d ening and
con densa te preventative comp ound.
CONSTRUCTION
Heat exchangers are
of heavy gauge copper o r
a l u m i n i u m t u b e
an d a l um i n iu m f i n
constru c t i o n.
They have been sized and
designed to maintain
reasonable pressures at a
wide rang e o f c o n ditions and loads
COILS
A combination HP/LP switch
pro vides f or safety cut-o ut and is
connected in series with a defrost
typ e therm ostat in the compresso r
clutch circuit
AUTOMATIC CONTROLS
The universal electronic thermostat has been selected f o r
its reliability and functionality.
It has be e n p r e -progra m m e d t o p rovide t h e o p t i mum
tempe r a t u r e contro l f o r t h e o perator s c o m f ort.
The r eturn a ir prob e is located in the return a ir. The
return ai r t e m p erature is adjust a b l e v ia the digital
con trol pa nel and has a nomin al set- point r ange between
15oC to 32 oC.
Inc orpor ated into the electric al circ uit are f our cir cuit
breakers which protect all fan motors, compressor, an d
var ious ot her electronic compo nents a nd wiri ng. In
circumstances of tripping, they can be easily accessed and
reset through return air.
ELECTRICAL CONTROLS
Our f an and bl owers are totally
enclosed and come equipped with
fully sealed shafts,
hea vy duty b earin gs and non-
replacable bushes.
FANS & BLOWERS

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AIR CONDITIONING TECHNICAL DATA
PERFORMANCE SPECIFICATIONS
Cooling Capacity 7.0 kW
Evaporator Air On Temperature 29oC DB / 19oC WB
Suction Temperature -2oC
Ambient Temperature 30oC
Refrigerant R134a
Total Refrigerant Charge 2.2kgs
THERMOSTAT
The electronic thermostat controls re turn air temperature and coil
temperat u re.
Power Supply 24V DC
Selectable Return Air Temperature 18oC - 28oC
Dead Band 0.5oC (Either side of set point)
De-ice cut out temperature 2oC
De-ice cut in temperature 8oC

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An air conditioning unit operates on a num-
ber of dierent principles. Following is a brief
discussion of each of these principles and how
they are used in an air conditioner unit.
TRANSFER OF HEAT
To understand the principle of heat transfer, we
must rst understand that cold is de- ned as the
lack of heat. Like water, which always ows,
downhill heat always ows down a temperature
scale from a warm level to a colder one. When
we hold a cold glass of drink, heat always ows
from our warm hands to the colder glass.
LATENT HEAT
Latent heat is the hidden heat that cannot
be found with a thermometer. If we were
to put a kettle full of water on a burner and
measure the water temperature with a ther-
mometer, the temperature would rise until the
water starts to boil.
At this point the temperature will read 100oC
and stop rising. Even if the ame were to be
turned up the temperature of the water would
remain at 100oC.
Where does the heat go? The water ab- sorbs the
heat as it changes to steam. The heat just
described is called the latent heat of
vaporisation. There is one other instance where
heat seems to disappear. This second
kind of latent heat is known as the la- tent heat
of fusion (which means melting). Whenever we
think of something boiling we
instinctively think of it being very hot. However
this is not true in every case. Some substances
will boil violently while sitting on a block of ice.
Any liquid will absorb large quantities of heat at
its boiling point temperature without get- ting
any warmer.
It should be noted that the boiling point of water
is 100oC only if it is subjected to the air pressure
at sea level. The boiling point temperature will
actually decrease at higher elevations.
TEMPERATURE AND PRESSURE
It has already been pointed out that the boiling
temperature of water decreases as elevation
increases. This is because atmo- spheric pressure
decreases with an increase
in elevation. Conversely an increase in pressure
raises the boiling temperature of water.
It is also true that if we apply pressure to
compress steam we increase its tempera- ture
without increasing the heat it contains. It is
useful to think of temperature as a mea- sure of
heat intensity. Temperature is not a measure of
heat quantity.
So far we have discussed steam but the
same principle applies to all vapours.
If we apply pressure to compress vapour we
increase its temperature.
BASIC AIR CONDITIONER OPERATION
There are four basic components in every air
conditioner system -
» Evaporator
» Compressor
» Condenser and
» Expansion Valve
The refrigerant in the evaporator boils into a
vapour at a temperature well below the air
temperature of the compartment.
As it does, it soaks up a lot of heat without
getting any hotter. The compressor then ap-
plies pressure to the vapour to increase its
temperature.
Heat is now transferred from the warm high-
pressure vapour in the condenser to the cooler
surrounding air. As the vapour cool, it
condenses into a liquid at high pressure; the
high-pressure liquid refrigerant passes to the
expansion valve at the entrance to the evaporator.
At the valve orice the pressure is lowered and
the refrigerant enters the evaporator as a low-
pressure liquid. The cycle then starts all over
again.
PRINCIPALS OF AIR CONDITIONING
OVERVIEW

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The components, which combine to make up
the air conditioning system, are in four dierent
circuits as under:
» Air Circuit
» Refrigeration Circuit
» Heating Circuit
» Electrical Circuit
AIR CIRCUIT
The evaporator section has a basic air
recirculation circuit provided by two forward
curved fans in parallel. These blow air through
the evaporator and deliver the conditioned air
into the cab.
Average cab temperature is controlled by a
thermostat, the capillary of which senses the
temperature of the coil.
A second circuit is created by the addition of a
lter / pressuriser. If tted this consists of two
stages of ltering, followed by a single stage
pressurising fan with the ltered fresh air being
mixed with cab return air before passing over the
heat exchange coils.
Depending on the model of condenser, the
condenser air is provided by either one axial
(propeller) ow fan and drawn through the
bottom of the condenser coil and discharged
through the top of the condenser. Or the
condenser air is provided by three axial fans
and drawn through the top of the condenser and
discharged over the condenser coil.
REFRIGERATION CIRCUIT
To illustrate the change of state of the
refrigerant as it travels through the system, the
descriptions of the refrigeration components
have been listed in the order which coincides
with refrigerant ow.
1. Condenser Coil
Condensing of the refrigerant is the change
of state of the refrigerant from a vapour to a
liquid. The condenser
receives the high pressure, high
temperature refrigerant vapour from the
compressor and condenses it to a high
temperature liquid. The liquid refrigerant
then ows to the receiver drier.
2. Receiver Drier
The receiver drier utilised in these units is
of fully welded construction, tted with an
integral sight glass. The receiver drier
serves as a reservoir for the storage of high
pressure liquid produced in the condenser.
It also functions as a lter/drier by means
of a dehydrating agent combined with
ltration system to trap minute particles of
moisture and foreign material which may
have entered the refrigeration system.
3. Thermostatic Expansion Valve
The expansion valve is located on the
evaporator inlet line and provides the
functions of throttling and controlling the
ow of liquid refrigerant to the evaporator
coil. This refrigerant ow is restricted
creating a pressure drop across the valve.
Thus, the refrigerant that enters the valve
as a hot high pressure liquid exits it as a
cold low pressure liquid.
The ow rate will vary according to the
heat load, sensed by the diaphragm
capillary, and the suction pressure at the
evaporator.
PRINCIPALS OF AIR CONDITIONING
OVERVIEW

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4. Evaporator Coil
The evaporator coil is constructed from
copper tubing, through which passes
the R134a refrigerant, and aluminium
ns for optimum heat transfer. The
refrigerant evaporates as it passes
through the copper tubes due to heat,
which it absorbs from the hot air owing
over and around the ns and tubes.
This absorption of heat reduces the
temperature of the air passing through
the coil, thus cooling the cab. The
refrigerant boils o becoming a low
pressure gas.
5. Compressor
The function of the compressor is to
compress the refrigerant in the system,
thus concentrating the resultant rise in
temperature. At the compressor, the
low pressure gas is changed to a high
pressure, high temperature gas. This
pressure build-up is accomplished by
having a restriction in the high pressure
side of the system. This restriction
occurs at the metered orice in the T.X.
valve.
The compressor is normally belt
driven from the engine PTO. An
electromagnetic clutch is typically
used to provide a means of stopping
the compressor from pumping when
refrigerant ow is not desired or when a
malfunction develops within the system.
6. Compressor Service Valves
Two service valves are located on the
top of the compressor cylinder head.
The valves enable the connecting
of system test gauges and also to
isolate the compressor from the rest of
the system to facilitate compressor
replacement. The high (discharge) side
service valve is quickly identied by the
smaller discharge hose routed to the
condenser, while the low (suction) side
has a larger hose coming from the
evaporator.
The valve is normally back-seated,
closing o the gauge port allowing
normal system operation. The valve
should be in this position before
disconnecting any service equipment.
The valve should be in the mid position
when the system is operating and any
service equipment is connected. Loss
of refrigerant gas will occur if the valve
is opened to this position without rst
connecting the service equipment.
The front-seated position of the valve
shuts o ow to both the gauge port
and compressor. This position is used
when isolation of the compressor
from the rest of the system is desired.
Operation of the compressor with the
valve in this position will result in severe
compressor damage due to excessive
build-up.
HEATING CIRCUIT
The heater coil (if available), is supplied with
hot water from the main engine cooling
system.
Control is via a manually operated valve in
the supply line or via the electronic
thermostat (if available), which can be
operated whilst in cooling mode to provide
some humidity control and rapid demisting.
ELECTRICAL CIRCUIT
Battery power is circuited through a circuit
breaker to the main four-position switch or
electronic thermostat (if available) which
provides for control of the three-speed
recirculating (supply) air fan.
The compressor clutch is in series with the
High Pressure / Low Pressure safety switch
and thermostat protecting the system.
A circuit breaker operates through a relay to
supply full voltage to the condenser fan
motors.
PRINCIPALS OF AIR CONDITIONING
OVERVIEW

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BREATHESAFE AIR CONDITIONING CONTROL - TQ6301-4
1. Controller Appearance
IMPORTANT
:The air conditioning system must be run for a minimum of ve minutes each
week regardless of the season to lubricate the system and prevent damage to the seals.
   
  
Item Description
1 Power switch
2 Power indicator
3 Fan motor indicator
4 Cooling indicator
5 PET cover
6 Fan speed regulation
7 Temp setting regulation
OPERATING INSTRUCTIONS

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OPERATING INSTRUCTIONS
2. Plugging & Unplugging
IMPORTANT
:The electrical power system is supplied by 12v
dc or 24v dc. No work should be carried out on the system
without the correct electrical safety measures being taken
and all relevant circuit breakers opened to isolate the circuit.
Make sure the power is o while plugging and unplugging the
controller.
To remove the controller, please press in the middle of the panel
and with two screwdrivers, gently pry the controller free. Once
started it will eject automatically.
To install the controller again, please push it rmly from the right
hole and ensure the controller secularly fastening.
Make sure the power o while plugging and unplugging the
controller.
3. Wiring
Connector A
1. Brown 0.75: GND
2. Purple 0.75: control wire of compressor
3. White 0.75: control wire of fan speed regula�on
Connector B
1. Yellow/green 0.75: interior temp sensor
2. Brown 0.75: GND
3. Green 0.75: defrost temp sensor
4. Brown 0.75: GND
Connector C
1. Red 0.75: +24V
ACC power
2. Black 0.75: GND
OPERATING INSTRUCTIONS

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OPERATING INSTRUCTIONS
4. Technical Specication
Rated Voltage : DC24V (DC19V~ DC32V)
Ambient temperature : - 30oC / +80oC
: 5% / 95%RH non-condensing
Basic Input : (1) (25oC, Rb=5K, B=3274)
Interior temp. sensor (at 25C ,Rb=5K, B=3274)
: (2) (25oC, Rb=5K, B=3274)
Defrost temp. sensor (at 25C ,Rb=5K, B=3274)
: (3) ACC Battery
Basic Output : (1) 1.6~10V
Fan speed Signal 1.6~10V
: (2) 1A
Cooling (Max 1A)
NOTES
These outputs are eective at high level (positive).
Setting temp. range : 15~32oC, ±1oC
Cooling Mode : 15~32oC, precision ±1oC
Protection : IP54
EMC Level : ISO7637-2
Weight : 255g
OPERATING INSTRUCTIONS

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OPERATING INSTRUCTIONS
5. Operation Instruction
AIR VOLUME REGULATION
Turning the knob to MIN,
decreases the air volume to
15%. The voltage output is 1.6V
and the fan motor runs at
600RPM,
Turning the knob to MAX,
increases the air volume to
100%. The voltage output is
10V and thefan motor runs at
full speed.
TEMPERATURE SETTING
Turn the Temperature Knob to
set the temperature value in the
range of 15~32oC.
POWER SWITCH
Pressing the switch to “ON”,
turns the controller and system
on.
Pressing the switch to “OFF”,
turns the controller and system
o.
IMPORTANT
:The air conditioning system
must be run for a minimum of ve minutes each
week regardless of the season to lubricate
the system and prevent damage to the seals.
OPERATING INSTRUCTIONS

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OPERATING INSTRUCTIONS
6. Start up Procedure
With the engine running, pressing the Power Switch (1) to the “ON”
position starts the Air Conditioning System.
Adjust the Temperature (7) and Fan (6) control knobs to set the
temperature and air ow as required.
7. Cooling Function
The Controller regulates the cabin temperature as follows -
If the interior temperature ≤ setting temp 2oC, the compressor
is turned o.
If the interior temperature ≥ setting temp 2oC, the compressor
is turned on.
8. Defrost Function
The Controllers defrost sensor value operates as follows -
If the Defrost sensor temperature measures ≤ 2oC, the
compressor is turn o and the defrost system is turned on.
If the Defrost sensor temperature measures ≥ 8oC, the
compressor is turn on and the defrost system is turned o.
9. Shut o Procedure
Pressing the Power Switch (1) to the “OFF” position, shuts down
the Air Conditioning System.
   
  
OPERATING INSTRUCTIONS

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SERVICE INTERVALS
MAINTENANCE SCHEDULE
Air conditioning
IMPORTANT
The air conditioning system must be run for a minimum of
ve minutes each week regardless of the season to
lubricate the system and prevent damage to the seals.
Ensure a qualied technician is employed for any
repairs required.
To ensure dependable ecient operation, all air conditioning units
require a certain amount of Preventative Maintenance to be carried
out at regular intervals between services.
These regular inspections will ensure that the unit is always
operating at peak eciency and will provide early warning of
potential problems, which if left unattended, may incur costly
machine down-time.
It is strongly recommended that an annual service programme be
implemented. This full unit service should be carried out once a
year, generally just prior to the beginning of the warmer season.
This service should only be carried out by a qualied refrigeration
mechanic and should involve a full function test of the complete
system, as well as checking of component settings.
The following tables show are our suggested maintenance schedule
for all units .
DAILY INSPECTION
Component / System Inspection Required
Return air lters Check for cleanliness and deterioration.
Refrigeration hoses. Check for damage or deterioration.
Fresh air ltration. Check pre-cleaner for damage or deterioration.
MONTHLY INSPECTION
Component / System Inspection Required
Condenser coil. Check for cleanliness.
Evaporator coil. Check for cleanliness.
Condenser fan motors. Clean motors with dry compressed air.
OPERATING INSTRUCTIONS

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SERVICE INTERVALS
THREE MONTHLY INSPECTION
Component / System Inspection Required
Condenser coil. Check refrigeration connections against leakage.
Check coil support bolts.
Condenser fan motor. Check motor support clamps and screws. Check shaft
bearings and brushes for wear. Check electrical con-
nections.
Condenser fan. Check for excessive noise during operation. Check for
blade damage. Check securing screws.
Compressor. Check refrigeration connections against leakage.
Check securing bolts. Check anti vibration mounts.
Check for excessive noise during operation.
Receiver drier. Check refrigeration connections against leakage.
Check securing bolts. Check for system charge in
sight glass during operation.
High/Low pressure control. Check electrical connections.
Evaporator coil. Check for refrigerant leakage. Check coil securing
screws.
Evaporator fan motor. Check motor support clamps and screws. Check shaft
bearings and brushes for wear. Check electrical con-
nections.
Evaporator fan. Check for excessive noise during operation. Check for
blade damage. Check securing screws.
Thermal expansion valve. Check refrigerant connections against leakage.
Thermostat. Check electrical connections.
Control switches. Check electrical connections. Check operation.
Supply air louvres. Check for damage and cleanliness.
Condensate drip tray. Check for cleanliness. Check for drain pipe blockage.
Main frame and panels.
Unit mounting.
Check securing screws and catches.
Check securing screws. Check plenum seal for leaks.
Refrigeration lines.
Fresh air fan motor.
Check for excessive noise during operation. Check
motor support clamps and screws. Check shaft bear-
ings and brushes for wear. Check electrical connec-
tions.
TWELVE MONTHLY OR 2000 HOURS INSPECTION
Component / System Inspection Required
Compressor Check compressor belts for wear, tightness and align-
ment. Replace and adjust as necessary.
Check Oil Level.
Condenser Coil Hose condenser coil clean being careful not to use
excess pressure, which can damage coil nning.
(More frequent service may be required in dusty
applications.)
Evaporator Coil Check and if necessary clean.
Performance Test Carry out full components and system performance
test using a Gauge Manifold Set.
4000 HOURS INSPECTION
Component / System Inspection Required
Evaporator Coil Remove evaporator coil and thoroughly clean being
careful not to use excess pressure, which can dam-
age coil nning. Straighten nning.
Receiver Drier Replace receiver drier. (Indicative only, always
replace receiver drier when the system has been
opened.)
Supply Air Fan Remove and clean fan assemblies and check for
bearing wear and noise.
Condenser Fans Remove and clean fan assemblies and check for
bearing wear and noise.
Evaporator Fans Remove and clean fan assemblies and check for
bearing wear and noise.
Compressor Check compressor oil level and bearings.
Evaporator Drain Tray Check for blockage of condensate drains.
OPERATING INSTRUCTIONS

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SERVICE INTERVALS
MAINTENANCE SCHEDULE -
Pressuriser
DAILY INSPECTION
Component / System Inspection Required
Pre-cleaner - Dust Bowl If tted with a Dust Bowl Pre-cleaner, remove
from the pressuriser unit, clean and ret.
MONTHLY INSPECTION
Component / System Inspection Required
Pre-cleaner - Turbo If tted, check operation of Turbo pre cleaner.
Filter Element Remove internal lter element and while up-
side down, hit rmly on a at surface. Repeat
procedure several times or replace element as
required.
Filter Housing Check the lid seals and all bolt and screws are
secure.
THREE MONTHLY INSPECTION
Component / System Inspection Required
Filter Element Replace the lter element.
Fan Check the fan wheel is operating correctly.
Filter Housing Vacuum out and clean all internal surfaces of
dust.
4000 HOURS INSPECTION
Component / System Inspection Required
Filter Element Replace the lter element.
Fan Replace Pressuriser Fans
Filter Housing Vacuum out and clean all internal surfaces of
dust.
Mounting Check all mountings.
safe
Breathe
OPERATING INSTRUCTIONS

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COMPONENT MAINTENANCE
1. REPLENISHING REFRIGERANT
“Flashing” in the liquid line sight glass of a previously charged
system indicates an inadequate charge of refrigerant and
replenishment is accomplished with the plant running.
Before replenishing a thorough leak test with a halogen leak detector
is required so that the oending leak can be located and rectied.
To replenish proceed as follows:-
1. Loosely connect the charging line from the cylinder of refrigerant
to the suction service valve situated on the compressor. Purge
the charging line.
2. Ensure that the charging line connection to the cylinder is fully
secure and that the cylinder is vertical.
3. Tighten the charging valve/charging line connection.
4. Open the charging valve slowly.
5. Add refrigerant until a steady liquid ow in the sight glass indi -
cates a fully charged condition. This can be accomplished by
adding a small mount of refrigerant at a time.
CAUTION: Particular care should be taken when
adding refrigerant as an overcharge of refrigerant
causes excessive head pressures which in turn can
cause considerable damage.
6. Backseat the suction service valve, but do not disconnect the
cylinder at this stage.
7. Allow running conditions to stabilise and check the sight glass
and discharge pressure. Add more refrigerant should ashing
occur.
8. On completion of the replenishment, tightly backseat the suction
service valve and remove the charging line. Fit a sealing cap to
the line before storing.
2. COILS
“Flashing” in the liquid line sight glass of a previously charged
system indicates an inadequate charge of refrigerant and
replenishment is accomplished with the plant running.
If cleaning is required wash with low pressure, mains temperature
water in the reverse direction to the air ow. For evaporator coil
ensure a bae is used to prevent any water from entering cabin
through the return air plenum.
WARNING: DO NOT brush coil ns with a wire brush as
irreparable damage may occur. If ns are bent, use only
the correct n comb to straighten them.
3. FAN MOTORS
Check the motors for excessive shaft end-play. Brushes are
accessible by removing the two plastic brush caps on each motor.
Note: Before removing brush caps thoroughly clean the
motors using water-free compressed air.
OPERATING INSTRUCTIONS

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COMPONENT MAINTENANCE
4. FAN BLADES
Check the fan blades for wear or damage. Check that blades are
tight on motor shaft.
Any damaged/worn blades should be replaced - DO NOT repair.
5.FRESHAIR FILTER (Pressuriser)
The fresh air pressurising lter is located inside the lter housing of
the pressuriser unit. The fresh air ltration system is comprised of a
pre-cleaner plus a lter element.
Both of these items should be checked at regular intervals for signs
of damage or deterioration. To service fresh air ltration systems
proceed as follows -
1. Remove pre-cleaner bowl (if tted) from top of lter housing.
Clean out accumulated dust and ret bowl.
Note: Take care not to over-tighten knurled knob on top
of pre-cleaner bowl cover.
2. Unclip or unscrew the lter housing and remove the cover.
3. Remove and clean the lter element by gently tapping on a
rm surface - DO NOT wash.
4. Check the rubber seals at the base of the lter element for
damage or deterioration.
5. Remove accumulated dust from lter housing.
6. Ret the lter element, ensuring that it seats correctly and
replace cover.
6. RECEIVER DRIER / INLINE DRIER
This is a fully sealed, non-serviceable component which should be
renewed whenever the refrigerant system is ‘opened’. After renewal
of the receiver drier the system must be evacuated and recharged.
The drier is isolated to minimise gas loss on replacement.
To remove:
1. Shut o line valve at condenser coil outlet
2. Run compressor and pump down liquid line.
3. Shut o line valve upstream of drier.
4. Remove and replace.
Note: Ensure both line valves are reopened once drier is
replaced. An access port is provided to evacuate this
section prior to re-opening.
7. PRESSURE CONTROL SWITCH
This is a fully sealed, pre-set, non-serviceable component.
It should be noted that this is tted on Schraeder valves and can be
replaced without loss of gas.
8. ELECTRONIC THERMOSTAT
This item is fully sealed and a non-serviceable item.
Please refer to FAULT DIAGNOSIS section to ensure correct
operation if required.
OPERATING INSTRUCTIONS

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COMPONENT MAINTENANCE
9. THERMAL EXPANSION VALVE
This valve is factory set to provide the correct balance of pressure
and temperature at the evaporator.
Service on this valve is limited to the removal and cleaning of the
wire gauze lter at the valve inlet.
To remove the lter proceed as follows -
1. Shut o line valve upstream of TX valve.
2. Run compressor and pump down evaporator coil and suction
line.
3. Close compressor suction service valve.
4. Remove the lagging compound from around the valve.
5. Remove the valve assembly from the refrigeration system.
6. Using a sharp instrument carefully prise out the conical
shaped strainer from the inlet port.
Note: Care must be taken not to tear the wire gauze.
7. Carefully wash the gauze in a suitable solvent.
8. Installation is a reversal of the above procedure.
9. Ensure line and service valves are reopened once complete.
WARNING: If the lter blockage is due to a
concentration of small white balls it is possible that the
desiccant has become dislodged within the receiver
drier.
If this is the case, the entire system will have to be
ushed out and a new receiver drier installed.
10. COMPRESSOR
For compressor service refer to relevant manufactures service
manuals.
11. RETURN AIR FILTER
The return air lter should be removed and washed as required,
under cleaned running water, as noted on the Maintenance Schedule
Chart.
OPERATING INSTRUCTIONS