OYL MANUFACTURING COMPANY AC040A User manual

INSTALLATION
MANUAL
INSTALLATION
MANUAL
AIR COOLED MINI CHILLER
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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 yourair conditioner, please read this instruction manual carefully and keep it for future reference.
INSTALLATIONMANUAL
AIR COOLED MINI CHILLER
MODEL
Part No.:08019008612
Reference Model
AC040A
AC050A
AC058A
AC040AR
AC050AR
AC058AR
AC075B
AC100B
AC125B
AC075BR
AC100BR
AC125BR
Models
AMAC040A / MAC040A
AMAC050A / MAC050A
AMAC058A / MAC058A
AMAC040AR / MAC040AR
AMAC050AR / MAC050AR
AMAC058AR / MAC058AR
AMAC075B / MAC075B
AMAC100B / MAC100B
AMAC125B / MAC125B
AMAC075BR / MAC075BR
AMAC100BR / MAC100BR
AMAC125BR / MAC125BR
IM-AC-1099L
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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.
IMPORTANT
DO NOT INSTALLOR USE THEAIR CONDITIONER UNIT INA LAUNDRY ROOM.
- Safety Precautions page 2
- Outline And Dimensions page 3
- Unit Installation page 4
- Refrigerant Circuit page 6
- Water Filling page 6
- Electrical Wiring Connection page 6
- Chiller Control Operation Guide page 8
- Trouble Shooting page 9
!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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AC075/100/125
OUTLINEAND DIMENSIONS
AC040/050/058
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UNIT INSTALLATION
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MODEL A B C
AC040 – 058A 950mm 900mm 900mm
AC040AR – 058AR
MODEL A B C
AC075 – 125B 950mm 900mm 900mm
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REFRIGERANT CIRCUIT
All mini chiller series is precharged with refrigerant R22, 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 R22 in AC040A/AR ~ 058A/AR 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).
ELECTRICALWIRING CONNECTION
MODEL AC040A/AR ~AC058A/AR AC075B/BR AC100B/BR AC125BR
Voltage Range 380 – 420V/3ph / 50Hz +
Power Supply Cable Size 4 6 10 16
Number of conductor
Interconnection Cable Size (mm2) 2.5 2.5 2.5 2.5
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
Presure
Differential Valve
Three Way Valve
Good Controlling Bad Controlling
Worst Controlling
Gate Valve
Gate Valve
Two Way Valve
Gate Valve
Gate Valve
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FCU
FCUFCU
Gate Valve
Gate Valve
Thermometer
Flexible
Thermometer
Flexible
Strainer
Gate Valve
Gate Valve
Gate Valve
Gate Valve
Presure
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
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AC 040AR ~ 058AR
12NA AL1 AL2 12V 12V COOL HEAT TNRS Of 4WVcomp
Remote Switch
or ON/OFF Switch
Indoor Unit 12V DC or
230V AC
Power Supply 415V/3ø/50Hz
AC 040A ~ 058A
AC 040A ~ 058A
12 N AL1 AL2 12V 12V TNRS comp
Remote Switch
or ON/OFF Switch LED
Indoor Unit
12V DC or
230V AC
Power Supply 415V/3ø/50Hz
AC 075B ~ 125B
AC 075B ~ 125B (EXPORT SPEC)
12N AL1 FS LP HP
AL2
C.OL P.OL 12V 12V HEAT COOL TNRS
Remote Switch or
ON/OFF Switch
Indoor Unit
12V DC or
230V AC
Power Supply 415V/3ø/50Hz
AC 075BR ~ 125BR
AC 075BR ~ 125BR (EXPORT SPEC)
12N AL1 FS LP HP
AL2
C.OL P.OL 12V 12V HEAT COOL TNRS
Remote Switch or
ON/OFF Switch
Indoor Unit
12V DC or
230V AC
Power Supply 415V/3ø/50Hz
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CHILLER CONTROLOPERATION 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 : 2°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 resitor (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
requiredwater entering temperature which(35°C ~ 50°C)
for heating mode.
• To prevent water from freezing in the system, adjust the
variable resistor VR2.The setting range is between +3°C
to -4°C.
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
OUTDOORDEFROSTSENSORSOCKET. (LENGTH 1.0M)
OUTDOORAIR TEMP. SENSOR. (LENGTH 0.6M)
LEAVING WATER /ANTIFREEZE SENSOR. (LENGTH 1.0M)
ENTERING WATER SENSOR. (LENGTH 0.6M)
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TROUBLESHOOTING
If any malfunction occurrs, immediately switch off the power supply to the unit, and contact a local dealer if necessary. Some
simple trouble shooting tips are given below.
SYMTOMS POSSIBLE CAUSES REMEDIALACTION
1. Compressor does
not start.
2. Fan does not work.
3. Air cooled mini
chiller does work,
but cools
unsuffuciently.
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 cir-
cuit breakers when the fault has been cor-
rected. 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.
* Resetthepressure switch and observe theunits
operation when it is restarted.
* Contact local dealer.
* Clean the coil with chemical detergent.
* Contact local dealer.
* Replace it.
* Resetthepressure switch and observe theunits
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.
CK20AN-ENG 20/07/2000, 14:529

OYLMANUFACTURING COMPANY SDN. BHD.
JALAN PENGAPIT 15/19, P.O. BOX 7072, 40702 SHAHALAM, SELANGOR DARUL EHSAN, MALAYSIA.
CK20AN-Cover 20/07/2000, 14:492