McLean SPECTRACOOL G57 User manual

© 2012 Pentair Technical Products 89055585
Rev. I P/N 10-1008-243
Protecting Electronics.
Exceeding Expectations.™
McLean Parts
5736 N Michigan Road
Indianapolis, IN 46228 USA
+1.317.257.6811
+1.317.257.1590
[email protected]
McLeanParts.com
INSTRUCTION MANUAL
SPECTRACOOL™
Air Conditioner
G57

© 2012 Pentair Technical Products 89055585 - 2 -
TABLE OF CONTENTS
RECEIVING THE AIR CONDITIONER ......................................................................................................................................................................................................................................................................... 3
HANDLING AND TESTING THE AIR CONDITIONER ............................................................................................................................................................................................................................................ 3
HOW TO READ MODEL NUMBERS .......................................................................................................................................................................................................................................................................... 3
TECHNICAL INFORMATION........................................................................................................................................................................................................................................................................................ 4
Sequence of Operation ...................................................................................................................................................................................................................................................................................4
Heating ......................................................................................................................................................................................................................................................................................................4
Cooling ...................................................................................................................................................................................................................................................................................................... 4
Standard and Optional Component Operation .....................................................................................................................................................................................................................................4
Thermostat .............................................................................................................................................................................................................................................................................................. 4
Remote Access Control (optional) ...................................................................................................................................................................................................................................................4
Head Pressure Control ......................................................................................................................................................................................................................................................................... 4
Contactor..................................................................................................................................................................................................................................................................................................4
Freezestat ................................................................................................................................................................................................................................................................................................. 4
Time Delay Relay ................................................................................................................................................................................................................................................................................... 5
200 V to 230 V Transformer (G572026G2XX only) ...................................................................................................................................................................................................................... 5
Phase Monitor (G572046GXXX only) .............................................................................................................................................................................................................................................. 5
460 V to 230 V Transformer (G572046GXXX only) .....................................................................................................................................................................................................................5
230V to 10V Transformer (optional) ................................................................................................................................................................................................................................................5
230V to 24V Transformer and Relay (optional) ........................................................................................................................................................................................................................... 5
Schematics and Wiring Diagrams for Thermostat Control .................................................................................................................................................................................................................5
G57 208V 1-Phase Generic Schematic (actual unit options may vary) ..............................................................................................................................................................................5
G57 230V 1-Phase Generic Schematic (actual unit options may vary) ..............................................................................................................................................................................6
G57 400/460V 3-Phase Generic Schematic (actual unit options may vary) ..................................................................................................................................................................... 6
G57 208V 1-Phase Generic Wire Diagram (actual unit options may vary) ........................................................................................................................................................................7
G57 230V 1-Phase Generic Wire Diagram (actual unit options may vary) ........................................................................................................................................................................8
G57 400/460V 3-Phase Generic Wire Diagram (actual unit options may vary) ............................................................................................................................................................... 9
DIMENSIONAL DRAWINGS ......................................................................................................................................................................................................................................................................................10
20000 BTU/Hr. (G572026GXXX, G572026G2XX) With Thermostats ..............................................................................................................................................................................................10
20000 BTU/Hr. (G572046G15X) With Thermostats ..............................................................................................................................................................................................................................10
INSTALLATION INSTRUCTIONS ...............................................................................................................................................................................................................................................................................11
REMOTE ACCESS CONTROL (optional) ................................................................................................................................................................................................................................................................13
INTRODUCTION ...............................................................................................................................................................................................................................................................................................13
ENERGIZING THE CONTROLLER .................................................................................................................................................................................................................................................................13
CONTROL STATUS INDICATION ..................................................................................................................................................................................................................................................................13
DISPLAYING AND CHANGING PROGRAM VARIABLES ........................................................................................................................................................................................................................14
OPERATING PARAMETERS ............................................................................................................................................................................................................................................................................14
ALARM PARAMETERS .....................................................................................................................................................................................................................................................................................14
DISPLAYING TEMPERATURE SENSOR #2 ..................................................................................................................................................................................................................................................14
COMPRESSOR RESTART TIME DELAY ........................................................................................................................................................................................................................................................14
ALARM OUTPUT CONTACT ..........................................................................................................................................................................................................................................................................14
ALARM INPUT CONNECTION ......................................................................................................................................................................................................................................................................15
ALARM CONDITION DISPLAY ......................................................................................................................................................................................................................................................................15
AIR CONDITIONER UNIT COMMUNICATION FEATURES .....................................................................................................................................................................................................................15
USB Communication ..........................................................................................................................................................................................................................................................................15
Ethernet Communication .................................................................................................................................................................................................................................................................15
Software and MIB File Downloads ................................................................................................................................................................................................................................................15
Using the McLean PC Interface Tool .............................................................................................................................................................................................................................................15
USB COMMUNICATION MODE ...................................................................................................................................................................................................................................................................16
Viewing Air Conditioner Unit Values ............................................................................................................................................................................................................................................16
Changing Air Conditioner Unit Values .........................................................................................................................................................................................................................................16
Viewing and Changing Ethernet Information ...........................................................................................................................................................................................................................16
ETHERNET COMMUNICATION MODE .......................................................................................................................................................................................................................................................17
Viewing Air Conditioner Unit Values ............................................................................................................................................................................................................................................17
Changing Air Conditioner Unit Values .........................................................................................................................................................................................................................................17
Viewing and Changing Ethernet Information ...........................................................................................................................................................................................................................17
Alarm Log Accessible with SNMP ..................................................................................................................................................................................................................................................17
Remote Access Control Pin-out .................................................................................................................................................................................................................................................................18
Schematic and Wiring Diagram for Remote Access Control ...........................................................................................................................................................................................................19
G57 1-Phase Generic Schematic (actual unit options may vary) .......................................................................................................................................................................................19
G57 3-Phase Generic Schematic (actual unit options may vary) .......................................................................................................................................................................................20
G57 1-Phase Generic Wire Diagram for Remote Access Control (actual unit options may vary) ...........................................................................................................................21
G57 3-Phase Generic Wire Diagram for Remote Access Control (actual unit options may vary) ...........................................................................................................................22
DIMENSIONAL DRAWINGS ......................................................................................................................................................................................................................................................................................23
G57 Generic Model Drawing With Remote Access Control .............................................................................................................................................................................................................23
INSTALLATION INSTRUCTIONS WITH REMOTE ACCESS CONTROL ............................................................................................................................................................................................................24
MAINTENANCE ............................................................................................................................................................................................................................................................................................................25
Compressor .......................................................................................................................................................................................................................................................................................................25
Inlet Air Filter ....................................................................................................................................................................................................................................................................................................25
How To Remove, Clean or Install a New Inlet Air Filter ......................................................................................................................................................................................................................25
Condenser and Evaporator Air Movers ...................................................................................................................................................................................................................................................26
Refrigerant Loss ...............................................................................................................................................................................................................................................................................................26
Refrigerant Properties Chart (R407c) .......................................................................................................................................................................................................................................................27
Functional Data ...............................................................................................................................................................................................................................................................................................27
Unit Characteristics ........................................................................................................................................................................................................................................................................................28
SERVICE DATA...............................................................................................................................................................................................................................................................................................................29
Components List .............................................................................................................................................................................................................................................................................................29
TROUBLE SHOOTING .................................................................................................................................................................................................................................................................................................30
Basic Air Conditioning Trouble Shooting Check List - Thermostat Version................................................................................................................................................................................30
Symptoms and Possible Causes - Thermostat Version ......................................................................................................................................................................................................................31
Basic Air Conditioning Trouble Shooting Check List - Remote Access Control Version ........................................................................................................................................................32
Symptoms and Possible Causes - Remote Access Control Version ...............................................................................................................................................................................................33

© 2012 Pentair Technical Products89055585 - 3 -
RECEIVING THE AIR CONDITIONER
Inspect the air conditioner. Check for concealed damage that may have occurred during shipment. Look for dents,
scratches, loose assemblies, evidence of oil, etc. Damage evident upon receipt should be noted on the freight bill.
Damage should be brought to the attention of the delivering carrier -- NOT to McLean Parts -- within 15
days of delivery. Save the carton and packing material and request an inspection. Then le a claim with the delivering
carrier.
McLean Parts cannot accept responsibility for freight damages; however, we will assist you in any way
possible.
HANDLING AND TESTING THE AIR CONDITIONER
If the air conditioner has been in a horizontal position, be certain it is placed in an upright, vertical or mounting
position for a minimum of ve (5) minutes before operating.
Do not attempt to operate the air conditioner while it is horizontal
or on its side, back or front. The refrigeration compressor is lled
with lubricating oil. This will cause permanent damage to the air
conditioner and also voids the warranty.
CAUTION
TEST FOR FUNCTIONALITY BEFORE MOUNTING THE AIR CONDITIONER TO THE ENCLOSURE.
Refer to the nameplate for proper electrical current requirements, and then connect the power cord to a properly
grounded power supply. Minimum circuit ampacity should be at least 125% of the amperage shown in the design
data section for the appropriate model. No other equipment should be connected to this circuit to prevent
overloading.
Immediately after applying power, the evaporator blower (enclosure air) should start running. Operate the air
conditioner with the compressor running for ve (5) to ten (10) minutes. You will need to set the cooling thermostat or
controller setpoint below the ambient temperature to operate the compressor.
Condenser air temperatures should be warmer than normal room temperatures within a few minutes after the
condenser impellers start.
See Sequence of Operation on page 4 for specics on how the unit operates when powered up.
HOW TO READ MODEL NUMBERS
G57 20 2 6 G150
12345
1. Identies the type/family of air conditioner and the approximate height (i.e. G57 = Global family about 57
inch high).
2. This is the air conditioner’s listed capacity in BTU/Hr. at rated conditions. (i.e. 20 = 20,000 BTU/Hr. at
131/131 F)
3. 2 = 208 or 230 Volt, 4 = 460 Volt.
4. 6 = 50/60 Hz or 60 Hz only.
5. Unique set of numbers for each air conditioner which identies the accessories on a model. All G2XX
models are 208 Volt 60 Hz.

© 2012 Pentair Technical Products 89055585 - 4 -
TECHNICAL INFORMATION
Sequence of Operation
The air conditioner comes standard with two internally mounted thermostats. There are two modes of operation;
heating and cooling. During heating and cooling modes, the evaporator fan will be running.
Heating
When the enclosure temperature is below the heating thermostat setpoint, power is applied to the heaters.
When the enclosure temperature is 10 degrees above the setpoint, the heater is powered o.
Cooling
When the enclosure temperature is above the cooling thermostat setpoint, power is applied through the
thermostat. The compressor is then energized either directly or through a contactor if unit requires one. The
condenser impellers will start immediately if the unit is not equipped with an optional head pressure control
switch. If the unit is equipped with an optional head pressure control switch, the condenser impellers will
start once the refrigerant pressure reaches the setting of the switch. Component specic information is listed
below.
Operating the air conditioner below the minimum ambient temperature or above the maximum ambient
temperatures indicated on the nameplate voids all warranties. DO NOT set the enclosure thermostat to a
temperature lower than 70 F. Doing so can increase the likelihood of frost buildup on the evaporator coil.
The moisture that the enclosure air can contain is limited. If moisture ows from the drain tube continuously
this can only mean that ambient air is entering the enclosure. Be aware that frequent opening of the
enclosure’s door admits humid air that the air conditioner must then dehumidify.
Standard and Optional Component Operation
Thermostat
The G57 air conditioner uses our standard 10-1061-16 thermostat. The thermostat setpoint equals the
temperature that the air conditioner turns o. The thermostat has a 10 F dierential from setpoint until it calls
for cooling or heating. An example of operation is shown below.
For cooling (75-100 F range):
• Thermostat setpoint = 80 F
• Cooling turns on at 90 F
• Cooling turns o at 80 F
For heating (55-65 F range):
• Thermostat setpoint = 55 F
• Heating turns on at 55 F
• Heating turns o at 65 F
NOTE: For testing purposes only, the thermostat stop screw may be removed (on units so
equipped) to allow settings below 70 F. After testing, replace the stop screw and verify that the
thermostat cannot be set below 70 F. Extended operation below 70 F can cause coil freeze ups
resulting in reduced load and/or unit damage.
Remote Access Control (optional)
See REMOTE ACCESS CONTROL (optional) on page 13
Head Pressure Control
Unit is set at the factory, no adjustment necessary.
At a saturated condenser temperature of 82 F (170 psig), the condenser fans will power o. At a saturated
condenser temperature of 104 F (246 psig), the condenser fans will power on.
Contactor
The contactor on this model uses a 230V coil.
Freezestat
The freezestat shuts down the compressor during a frozen evaporator coil condition. The freezestat will
automatically reset when the frozen coil has thawed suciently.

© 2012 Pentair Technical Products89055585 - 5 -
Time Delay Relay
The time delay relay keeps the unit from short cycling after the freezestat resets following a frozen evaporator
coil condition.
200 V to 230 V Transformer (G572026G2XX only)
The 230 V from this transformer powers the compressor, fans, contactor and optional transformers.
Phase Monitor (G572046GXXX only)
The phase monitor protects the compressor from reverse operation. When both lights on the monitor are lit
constant, the power to the unit has been wired correctly and the compressor will operate as designed.
If both lights on the monitor are not lit constant, the unit is out of phase. Swap the power leads at the terminal
block until both lights are lit constant.
Factory Settings:
Top dial set at 480 V for 60 Hz operation (Reset to 440 V for 50 Hz operation)
Middle dial set at 5 seconds
Bottom dial set at -20%
460 V to 230 V Transformer (G572046GXXX only)
The 230 V from this transformer powers the fans, contactor and optional transformers. 460 V is only used to
run the compressor.
230V to 10V Transformer (optional)
This transformer powers the thermal display only.
230V to 24V Transformer and Relay (optional)
This transformer and relay are used to start/stop the unit thru a customer supplied, remote mounted door
switch.
Schematics and Wiring Diagrams for Thermostat Control
G57 208V 1-Phase Generic Schematic (actual unit options may vary)
89044386

© 2012 Pentair Technical Products 89055585 - 6 -
G57 230V 1-Phase Generic Schematic (actual unit options may vary)
89047070
G57 400/460V 3-Phase Generic Schematic (actual unit options may vary)
MTR
MTR
MTR
MTR
CIRCUIT
BREAKER
CONTACTOR
MONITOR
PHASE
R
L1 L2
S
L3
T
AUTO-TRANSFORMER
COMPRESSOR
CLG CONTACTOR
CLG TSTAT
PHASE MONITOR
EVAPORATOR
CONDENSER
CONDENSER
IMPELLER 2
IMPELLER 1
IMPELLER
CAP
CAP
CAP
GRND
RELAY
HPC
COOLING CONTACTOR
HEATING
LIMIT SWT'S
AUTO & MAN
HEATERS
HTG TSTAT
HTG CONTACTOR
FREEZE STAT
VARISTOR
TRANSFORMER W/
TEMP. DISPLAY
(OPTIONAL)
DOOR SWITCH
TRANSFORMER
RELAY (OPTION)
TDR
24V
RSWT.
CUST.
R
89060233

© 2012 Pentair Technical Products89055585 - 7 -
G57 208V 1-Phase Generic Wire Diagram (actual unit options may vary)

© 2012 Pentair Technical Products 89055585 - 8 -
G57 230V 1-Phase Generic Wire Diagram (actual unit options may vary)

© 2012 Pentair Technical Products89055585 - 9 -
G57 400/460V 3-Phase Generic Wire Diagram (actual unit options may vary)

© 2012 Pentair Technical Products 89055585 - 10 -
DIMENSIONAL DRAWINGS
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89059779