OYL MANUFACTURING COMPANY AC040 User manual

AIR COOLED MINI CHILLER
INSTALLATION MANUAL
IM-AC-0501 (Cover) 21/1/03, 9:20 AM3

i
OUTLINE AND DIMENSIONS
AC040 /050 /058
AC075 /100 /125
UNIT INSTALLATION
AC040 /050 /058 AC075 /100 /125
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ii
Model A B C
AC075 – 125 950 mm 900 mm 900 mm
Model A B C
AC040 – 058 950 mm 900 mm 900 mm
Per preservarsi da eventuali ferite, evitare di toccare gli spigoli affilati e la superficie
dei serpentini.
!Cautela
Острые края и поверхности змеевиков являются потенциальными
местами нанесения травм. Остерегайтесь контакта с этими местами.
!Осторожно
Sharp edges and coil surfaces are potential locations which may cause injury
hazards. Avoid from being in contact with these places.
!Caution
Les bords coupants et les surfaces du refroidisseur tubulaire présentent
un risque de blessure. Mieux vaut éviter le contact avec ces endroits.
! Avertissement
Scharfe Kanten undWärmetauscherflächen stellen eine Gefahrenquelle dar. Jeglicher
Kontakt mit diesen Stellen ist zu vermeiden.
!Vorsicht
Los Bordes afilados y la superficie del serpentín pueden producir lesiones. Evite
tocarlos.
!Cuidado
NOTE: “Standard Marking on the cover applicable to specific models; check with label data on the unit.”
REMARQUE: “Le marquage standard qui se trouve sur la couverture s’applique à des modèles spécifiques;
vérifiez avec les données de l’étiquette placée sur l’appareil.”
HINWEIS: “Die Standardkennzeichnung auf der Abdeckhaube gilt für spezielle Modelle, daher mit
Etikettdaten auf der Einheit überprüfen.”
NOTA: “Marchio Standard in copertina riferente a modelli specifici; verificare i dati dell’etichetta check
sull’unità.”
NOTA: “Marcado estándar en la tapa aplicable a modelos específicos; comprobar la información de la etiqueta
en la unidad.”
ПРИМЕЧАНИЕ: “Стандартная маркировка на крышке применима к конкретным моделям;
сверяйтесь с та личкой на аппарате.”
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1-1
English
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ARABIC Deutsch
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Русский Español
This manual provides the procedures of installation to ensure a safe and good standard of operation for the air
conditioner unit.
Special adjustment may be necessary to suit local requirements.
Before using your air conditioner, please read this instruction manual carefully and keep it for future reference.
INSTALLATION MANUAL
AIR COOLED MINI CHILLER
MODEL
Part No.: A08019013021
COOLING UNIT
AC040A / AMAC040A / MAC040A
AC050A / AMAC050A / MAC050A
AC058A / AMAC058A / MAC058A
4AC040A /A4AC040A / M4AC040A
4AC050A /A4AC050A / M4AC050A
4AC058A /A4AC058A / M4AC058A
4AC040AE /A4AC040AE / M4AC040AE
4AC050AE /A4AC050AE / M4AC050AE
4AC058AE /A4AC058AE / M4AC058AE
AC075B / AMAC075B / M4AC075B
AC100B / AMAC100B / M4AC100B
AC125B / AMAC125B / M4AC125B
4AC075B /A4AC075B / M4AC075B
4AC100B /A4AC100B / M4AC100B
4AC125B /A4AC125B / M4AC125B
4AC075BE /A4AC075BE / M4AC075BE
4AC100BE /A4AC100BE / M4AC100BE
4AC125BE /A4AC125BE / M4AC125BE
HEAT PUMP
AC040AR / AMAC040AR / MAC040AR
AC050AR / AMAC050AR / MAC050AR
AC058AR / AMAC058AR / MAC058AR
4AC040AR / A4AC040AR / M4AC040AR
4AC050AR / A4AC050AR / M4AC050AR
4AC058AR / A4AC058AR / M4AC058AR
4AC040ARE / A4AC040ARE / M4AC040ARE
4AC050ARE / A4AC050ARE / M4AC050ARE
4AC058ARE / A4AC058ARE / M4AC058ARE
AC075BR / AMAC075BR / MAC075BR
AC100BR / AMAC100BR / MAC100BR
AC125BR / AMAC125BR / MAC125BR
4AC075BR / A4AC075BR / M4AC075BR
4AC100BR / A4AC100BR / M4AC100BR
4AC125BR / A4AC125BR / M4AC125BR
4AC075BRE / A4AC075BRE / M4AC075BRE
4AC100BRE / A4AC100BRE / M4AC100BRE
4AC125BRE / A4AC125BRE / M4AC125BRE
IM-AC-0501
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1-2
CONTENTS
Before installing the air conditioner unit, please read the following safety precautions carefully.
SAFETY PRECAUTIONS
!Warning
• Installation and maintenance should be performed by qualified persons who are familiar with local code and
regulation, and experienced with this type of appliance.
• All field wiring must be installed in accordance with the national wiring regulation.
• Ensure that the rated voltage of the unit corresponds to that of the name plate before commencing wiring work
according to the wiring diagram.
• The unit must be GROUNDED to prevent possible hazards due to insulation failure.
• All electrical wiring must not touch the refrigerant piping, compressor or any moving parts of the fan motors.
• Confirm that the unit has been switched OFF before installing or servicing the unit.
• Do not touch the compressor or refrigerant piping without wearing gloves.
IMPORTANT
DO NOT INSTALL OR USE THEAIR CONDITIONER UNIT IN A LAUNDRY ROOM.
- Outline And Dimensions page i
- Unit Installation page i-ii
- Safety Precautions page 2
- Refrigerant Circuit page 3
- Water Filling page 3
- Electrical Wiring Connection page 3
- Chiller Control Operation Guide page 5
- Carel Controller Operation Guide page 6
- Trouble Shooting page 7
- Trouble Shooting (Carel Controller) page 8
!Caution
Please take note of the following important points when installing.
• Do not install the unit where leakage of flammable gas may occur.
If gas leaks and accumulates around the unit, it may cause fire ignition.
• Ensure that the drainage piping is connected properly.
If the drainage piping is not connected properly, it may cause water leakage which will dampen the
furniture.
• Do not overcharge the unit.
This unit is factory pre-charged. Overcharge will cause over-current or damage to the compressor.
• Ensure that the units panel is closed after service or installation.
Unsecured panels will cause unit to operate noisily.
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REFRIGERANT CIRCUIT
All mini chiller series is precharged with refrigerant R22 or R407C, the only pipe work that needs to be done is to connect the
water piping between the mini chiller (outdoor unit) and the fan coil (indoor unit).
Purging of the refrigerant in AC 040 - 058 A/AR, 4AC 040 - 058A/AR or 4AC 040 - 058 AE/ ARE series is only required if
the unit is installed separately with hydraulic kit.
WATER FILLING
In this close water system, the pump can cater for longer piping compared to normal direct expansion units.
After connecting all the pipes and equipments, filling water in the circuit, perform leak check for all the connections and
joints. Do not start the unit when the system is leaking.
To optimize the capacity of the system, ensure that the system is free of air bubbles or air-traps. Air traps in the system
seriously unbalance the whole system. It is very important to check the whole water system especially ensuring that the water
tank is not full of water. This protection step is not only to prevent tank & piping corrosion but also to ensure optimum
performance of the unit. This can be done by releasing the air trap from the auto-air-vent (water tank) and manual air vent
(installed in the highest place of the water system).
ELECTRICAL WIRING CONNECTION
IMPORTANT : These values are for information only. They should be checked and selected to comply with local and/or
national codes of regulations. Which is also subject to the type of installation and size of conductors used.
FCU
FCUFCU
Gate Valve
Gate Valve
Expansion
Tank
Thermometer
Flexible
Thermometer
Flexible
Strainer
Gate Valve
Gate Valve
Gate Valve
Gate Valve
Pressure
Differential Valve
Three Way Valve
Good Controlling Bad Controlling
Worst Controlling
Gate Valve
Gate Valve
Two Way Valve
Gate Valve
Gate Valve
FCU
FCUFCU
Gate Valve
Gate Valve
Thermometer
Flexible
Thermometer
Flexible
Strainer
Gate Valve
Gate Valve
Gate Valve
Gate Valve
Pressure
Differential Valve
Three Way Valve
Good Controlling Bad Controlling
Worst Controlling
Gate Valve
Gate Valve
Two Way Valve
Gate Valve
Gate Valve
Gate Valve
Water Feeding / Drainage
AC040 - 058A/AR AC075 B/BR AC100 B/BR AC125 B/BR
Model 4AC040 - 058A/AR 4AC075 B/BR 4AC100 B/BR 4AC125 B/BR
4AC040 - 058AE/ARE 4AC075 BE/BRE 4AC100 BE/BRE 4AC125 BE/BRE
Voltage Range 380 – 420V /3Ph /50Hz + N + !
Power Supply Cable Size (mm2)4 6 10 16
Number of Conductor 5 5 5 5
Interconnection Cable Size (mm2) 2.5 2.5 2.5 2.5
AC 040 / 050 / 058
AC 075 / 100 / 125
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1-4
AC 040AR ~ 058AR
AC 075BR ~ 125BR
AC 075B ~ 125B
AC 040A ~ 058A
4AC 075 - 125 BE/ 4AC 075 - 125 BRE
4AC 040 - 058 AE/ 4AC 040 - 058 ARE
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S1
COMP
L
RL 1 RL 2
NEUTRAL
RL 3
RL 6 RL 5 RL 7 RL 4 RL 8
PCB
AHTR
OF
PUMP
4WV
TH4 TH3 TH2 TH1
AL 1
AL 2
S 2 S 3
S 4
+ 12V
+ 12V
COOL
HEAT
HP
LP
FL
SW 1
VR 1
VR 3
VR 2
OV
S5
S6
PUMP O/L
COMP O/L
SW 2
L
CHILLER CONTROL OPERATION GUIDE
1. ON/OFF Toggle switch
• Push up to start the chiller.
• Push down to switch off the chiller for servicing and maintenance.
2. Water Entering Temperature °C (Factory Setting)
• Cooling Mode, setting : 12°C
• Heating Mode, setting : 40°C
3. Antifreeze Protection for Cooling Mode
• Setting : 3°C
4. Temperature Setting
• For cooling mode, press the SW1 button switch once. The green LED will blink for a few seconds. Adjust the small
variable resistor (VR3) to the required water entering temperature of between (10°C - 15°C) by using a suitable tool.
• For extremely low water temperature (obtained by adding glycol), set the water entering temperature to between 3°C to
9°C by adjusting the DIP switch (SW2).
Set SW2
Temperature °C SW 2-3 SW2-2 SW2-1
Set by VR3 0 0 0
3001
4010
5011
6100
7101
8110
9111
1 = ON
0 = OFF
If the DIP switch is set to (0,0,0), the setting temperature
will be determined by the VR3 setting. Otherwise,
• For heating mode, press the SW1 button switch twice
and then the red LED will blink for a few seconds.
Adjust the variable resistor (VR1) by setting it to the
requiredwaterentering temperature which (35°C ~ 50°C)
for heating mode.
• To prevent water from freezing in the system, adjust the
variable resistorVR2. The setting range is between +3°C
to -4°C.
OUTDOORDEFROSTSENSORSOCKET. (LENGTH 1.0M)
OUTDOOR AIR TEMP. SENSOR. (LENGTH 0.6M)
LEAVING WATER / ANTIFREEZE SENSOR. (LENGTH 1.0M)
ENTERING WATER SENSOR. (LENGTH 0.6M)
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1-6
CAREL CONTROLLER OPERATION GUIDE
1.1 The user is informed of the status of the unit by means of four LEDs on the display.
1.1.1 The display value is the entering water temperature.
1.2 Keypad
1.2.1 Enabling/ disabling of COOLING operation mode
The cooling operating mode can be ended/ disabled by pressing the 9 button for more than 5 seconds. It is impossible
to directly change from the heating to the cooling operating mode; if the unit is actually operating in the heating mode,
pressing the 8 button will not swap the current mode.
1.2.2 Enabling/ disabling of HEATING operating mode
The heating operating mode can be enabled/ disabled by pressing the 8 button for more than 5 seconds. It is impossible
to directly change from the cooling to the heating operating mode; if the unit is actually operating in the cooling mode,
pressing the 9 button will not swap the current mode, it is necessary to inhibit the cooling mode.
1.3 ParameterAdjustment
Setting and displaying the entering water Set-Point
Press SEL for more than 5 seconds to display the cooling and heating Set-Point and the other main parameters (user
are inhibited to adjust the other parameters).
Pressing 8 and 9 buttons allow to scroll all parameters.
Press SEL again to display the require parameter and modify its value with the 8 and 9 buttons.
Press PRG to store the modified parameters and exit the procedure, while the SEL button allows to return to the
parameter menu again.
The display will automatically blink after a few seconds if no button is pressed.
Blinking will continue until the unit return to normal operation without storing the values of the modified parameters.
1.4 Reset Alarms
Press 8 and 9for more than 5 seconds to reset any alarm condition (manual reset). The relative LED light will turn
OFF and the alarm relay will de-energize.
Description Parameter Setting (˚C)
Cool entering water temperature r1 10 - 20
Heat entering water temperature r3 30 - 50
LED LED Blinking LED ON
COMP Request for compress Compressor ON
- Heating Mode
- Cooling Mode
x 100 - Visualized value x 100
LED
Parameter Value Keypad
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TROUBLE SHOOTING
If any malfunction occurs, immediately switch off the power supply to the unit, and contact a local dealer if necessary. Some
simple trouble shooting tips are given below.
SYMPTOMS POSSIBLE CAUSES REMEDIAL ACTION
1. Compressor does
not start.
2. Fan does not work.
3. Air cooled mini
chiller does work,
but cools
insufficiently.
4. PCB display ‘CO’.
5. PCB display ‘PO’.
6. PCB display ‘FL’.
7. PCB, display ‘HP’.
8. PCB display ‘LP’.
9. PCB display ‘E3’.
* No power supply.
* Fuses blown or automatic circuit break-
down open.
* Thermal relay tripped.
* Defective contactor or coil.
* Unit is stopped because safety device has
tripped.
* Loose wires.
* Compressor faulty.
* No power supply.
* Fan motor faulty.
* Thermostat setting too high.
* Condenser coil dirty.
* Obstacle blocking air inlet or outlet of the
unit.
* Insufficient refrigerant in the system.
* Improper water flow rate.
* Water source contains contamination.
* Compressor thermal relay tripped.
* Terminal loose.
* Pump thermal relay tripped.
* Terminal loose.
* Flow switch connection loose.
* Wrong terminal in flow switch.
* Water volume not enough.
* Flow switch blade too short or too long.
* Discharged pressure too high.
* Overcharge.
* Coil dirty.
* Condenser Fan does not work.
* Expansion valve stuck in open position.
* Suction pressure too low.
* Undercharge.
* Gas Leak.
* Water flow rate too low.
* Antifreeze protection activated.
* Water flow rate too low.
* Bubble in the heat exchanger.
* Check power supply.
* Look for short circuit or grounded wires in
motor windings. Replace fuses and reset
circuit breakers when the fault has been
corrected. Check tightness and soundness of
all electrical connections.
* Reset the thermal relay and carefully monitor
units operation when it is restarted.
* Repair or replace.
* Determine the type of safety shut down and
correct the default before the unit is restarted.
* Check wire connections and tighten terminal
screws.
* Contact local dealer.
* Check power supply.
* Contact local dealer.
* Reset thermostat.
* Contact local dealer.
* Remove the obstacle.
* Contact local dealer.
* Contact local dealer.
* Contact local dealer.
* Reset the thermal relay and carefully monitor
units operation when it is restarted.
* Tighten terminal screws.
* Reset the thermal relay and carefully monitor
units operation when it is restarted.
* Tighten terminal screws.
* Tighten terminal screws.
* Change the terminal.
* Add water into the system.
* Replace flow switch.
* Resetthe pressure switch andobserve the units
operation when it is restarted.
* Contact local dealer.
* Clean the coil with chemical detergent.
* Contact local dealer.
* Replace it.
* Resetthe pressure switch andobserve the units
operation when it is restarted.
* Contact local dealer.
* Contact local dealer.
* Adjust the flow rate.
* Check the temperature setting.
* Adjust the flow rate.
* Increase the water volume.
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1-8
TROUBLE SHOOTING (CAREL CONTROLLER)
If any malfunction occurs, immediately switch off the power supply to the unit, and contact a local dealer if necessary. Some
simple trouble shooting tips are given below.
SYMPTOMS POSSIBLE CAUSES REMEDIALACTION
Compressor does
not start.
Fan does not work.
Air cooled mini
chiller does work, but
cools insufficiently.
Controller display
‘FL’.
Controller display
‘H1’.
Controller display
‘L1’.
Controller display
‘A1’.
Controller display
‘r1’.
Controller display
‘EU’.
Controller display
‘EO’.
Controller display
‘E1’, ‘E2’ or ‘E3’.
• No power supply.
• Fuses blown or automatic circuit break-
down open.
• Thermal relay tripped.
• Defective contactor or coil.
• Unit is stopped because safety device has
tripped.
• Loose wires.
• Compressor faulty.
• No power supply.
• Fan motor faulty.
• Thermostat setting too high.
• Condenser coil dirty.
• Obstacle blocking air inlet or outlet of
the unit.
• Insufficient refrigerant in the system.
• Improper water flow rate.
• Water source contains contamination.
• Flow switch connection loose.
• Wrong terminal in flow switch.
• Water volume not enough.
• Flow switch blade too short or too long.
• Discharged pressure too high.
• Overcharge.
• Coil dirty.
• Condenser fan does not work.
• Expansion valve stuck in open position.
• Suction pressure too low.
• Undercharge.
• Gas Leak.
• Water flow rate too low.
• Antifreeze protection activated.
• Water flow rate too low.
• Bubble in the heat exchanger.
• Defrost error.
• Long defrost duration.
• Low voltage supply.
• High voltage supply.
• Sensor bulb faulty.
• Sensor bulb mixing.
• Check power supply.
• Look for short circuit or grounded wires in
motor windings. Replace fuses and reset
circuit breakers when the fault has been
corrected. Check tightness and soundness of
all electrical connections.
• Reset the thermal relay and carefully monitor
units operation when it is restarted.
• Repair or replace.
• Determine the type of safety shut down and
correct the default before the unit is restarted.
• Check wire connections and tighten terminal
screws.
• Contact local dealer.
• Check power supply.
• Contact local dealer.
• Reset thermostat.
• Contact local dealer.
• Remove the obstacle.
• Contact local dealer.
• Contact local dealer.
• Contact local dealer.
• Tighten terminal screws.
• Change the terminal.
• Add water into the system.
• Replace flow switch.
• Reset the controller and observe the units
operation when it is restarted.
• Contact local dealer.
• Clean the coil with chemical detergent.
• Contact local dealer.
• Replace it.
• Reset the controller and observe the units
operation when it is restarted.
• Contact local dealer.
• Contact local dealer.
• Adjust the flow rate.
• Check the temperature setting.
• Adjust the flow rate.
• Increase the water volume.
• Reset controller.
• Adjust defrost duration parameter.
• Check the power supply.
• Check the power supply.
• Check sensor & its location.
• Replacement.
IM-AC-050A (En) 6/21/02, 10:358

IMPORTANT: * These values are for information only, they should be checked and selected to comply with the local and/or national
codes and regulations. They are also subjected to the type of installation and size of conductors.
** The appropriate voltage range should be checked with data label on the unit. ETL listed is only applicable to 60Hz
power supply only.
OUTDOOR UNIT : SL 30 BR OUTDOOR UNIT : SL 30 CR
The electrical power must be provided
with protection devices (circuit breaker
or fuse) with double pole separation
system (phase + neutral) with minimum
contact gap of 3 mm.
!
The electrical power must be provided
with protection devices (circuit breaker
or fuse) with double pole separation
system (phase + neutral) with minimum
contact gap of 3 mm.
!
Power Supply Cable
Terminal Strip
Outdoor unit
Terminal Strip
Indoor unit L
COMP
!
!
N
N
OF
4WV
COMP
OF
4WV
N
!
Outdoor Coil Sensor
Power Supply Cable
Terminal Strip
Outdoor unit
Terminal Strip
Indoor unit L
COMP
!
!
N
N
OF
4WV
Outdoor Coil Sensor
L
!
N
L
COMP
N
OF
4WV
!
A
Indoor unit CK30AR, CK30BR, CE30DR, CC28CR, CC30CR
Outdoor unit SL30BR SL30CR
Voltage range** 220V–240V / 1Ph / 50Hz + !or 208V–230V / 1Ph / 60Hz + !
Recommended fuse* A 25 25
Power supply cable size* mm22.5 4.0
Number of conductors 33
Interconnection cable size* mm22.5 1.5
Number of conductors 56
Heat Pump Units
OUTDOOR UNIT : SL 30 B
Power Supply
Cable
Terminal Strip
Outdoor unit
Terminal Strip
Indoor unit
L
COMP
N
N
!
!
N
!
L
N
N
!
COMP
COMP
!
!
!
L
COMP
N
S
R
L
NTerminal Strip
Outdoor unit
Terminal Strip
Indoor unit
Power Supply
Cable
OUTDOOR UNIT : SL 30 C
The electrical power must be provided
with protection devices (circuit breaker
or fuse) with double pole separation
system (phase + neutral) with minimum
contact gap of 3 mm.
!
The electrical power must be provided
with protection devices (circuit breaker
or fuse) with double pole separation
system (phase + neutral) with minimum
contact gap of 3 mm.
!
Indoor unit CK30A, CK30B, CE30D, CC28C, CC30C
Outdoor unit SL30B SL30C
Voltage range** 220V–240V / 1Ph / 50Hz + !or 208V–230V / 1Ph / 60Hz + !
Recommended fuse* A 25 25
Power supply cable size* mm22.5 4.0
Number of conductors 33
Interconnection cable size* mm22.5 1.5
Number of conductors 34
Cooling Only Units
TECHNICAL CORRECTION
IM-AC-050A technical(En) 6/21/02, 10:451

OYL MANUFACTURING COMPANY SDN. BHD.
JALAN PENGAPIT 15/19, P.O. BOX 7072, 40702 SHAH ALAM, SELANGOR DARUL EHSAN, MALAYSIA.
• In the event that there is any conflict in the interpretation of this manual and any translation of the same in any language,
the English version of this manual shall prevail.
• The manufacturer reserves the right to revise any of the specification and design contain herein at any time without prior
notification.
• En cas de désaccord sur l’interprétation de ce manuel ou une de ses traductions, la version anglaise fera autorité.
• Le fabriquant se réserve le droit de modifier à tout moment et sans préavis la conception et les caractéristiques techniques
des appareils présentés dans ce manuel.
• Im Falle einer widersprüchlichenAuslegung der vorliegendenAnleitung bzw. einer ihrer Übersetzungen gilt dieAusführung
in Englisch.
• Änderungen von Design und technischen Merkmalen der in dieserAnleitung beschriebenen Geräte bleiben dem Hersteller
jederzeit vorbehalten.
• Nel caso ci fossero conflitti nell’interpretazione di questo manuale o delle sue stesse traduzioni in altre lingue, la versione
in lingua inglese prevale.
• Il fabbricante mantiene il diritto di cambiare qualsiasi specificazione e disegno contenuti qui senza precedente notifica.
• En caso de conflicto en la interpretación de este manual, y en su traducción a cualquier idioma, prevalecerá la versión
inglesa.
• El fabricante se reserva el derecho a modificar cualquiera de las especificaciones y diseños contenidos en el presente
manual en cualquier momento y sin notificación previa.
•В случае противоречия перевода данного руководства с другими переводами одного и того же текста,
английский вариант рассматривается как приоритетный.
•Завод-изготовитель оставляет за собой право изменять характеристики и конструк ию в любое время
без предварительного уведомления.
IM-AC-0501 (Cover) 21/1/03, 9:20 AM2