Zamil MAC-240 Instruction manual

MOBILE AIR CONDITIONING SYSTEM
Model: MAC-240
INSTALLATION,
OPERATION
&
MAINTENANCE
MANUAL

1
Contents Page
GENERAL ................................................................................................................................................................... 3
1. FOREWORD ........................................................................................................................................................... 4
2. STANDARD SPECIFICATION ............................................................................................................................... 4
2.1 BASE CHASSIS AND CONSTRUCTION ...........................................................................................................4-6
2.2 DIESEL ENGINE GENERATOR .........................................................................................................................6-8
2.3 UNIT PHYSICAL DATA ......................................................................................................................................... 9
2.3.1 UNIT SPECIFICATION SUMMARY .................................................................................................................. 10
2.4 AIR CONDITIONING SECTION ........................................................................................................................... 11
2.5 ELECTRICAL ENCLOSURE ASSEMBLY ........................................................................................................... 12
2.6 OPERATING FROM EXTERNAL POWER SOURCE.......................................................................................... 13
3. REFRIGERATION SYSTEM ................................................................................................................................. 13
3.1 GENERAL DESCRIPTION .................................................................................................................................. 13
3.2 REFRIGERATION CYCLE..............................................................................................................................13-14
3.3 MAJOR REFRIGERATION COMPONENTS ....................................................................................................... 15
3.3.1 SCROLL COMPRESSORS .........................................................................................................................15-17
3.3.2 CONDENSER COIL .......................................................................................................................................... 17
3.3.3 CONDENSER FAN ........................................................................................................................................... 17
3.3.4 CONDENSER FAN MOTOR............................................................................................................................. 17
3.3.5 EVAPORATOR COIL ........................................................................................................................................ 17
3.3.6 EVAPORATOR FAN ......................................................................................................................................... 17
3.3.7 HOT GAS BY PASS CONTROL ....................................................................................................................... 18
3.3.8 CRANKCASE HEATER .................................................................................................................................... 18
3.3.9 REPLACEABLE CORE FILTER DRIER ........................................................................................................... 18
3.3.10 SIGHT GLASS ................................................................................................................................................ 18
3.3.11 FAN CYCLE HEAD PRESSURE CONTROL.................................................................................................. 18
3.3.12 CONDENSER COIL GUARD .......................................................................................................................... 18
3.3.13 DISCHARGE LINE MUFFLER ........................................................................................................................ 18
3.3.14 VIBRATION ELIMINATOR .............................................................................................................................. 18
3.3.15 SAFETY VALVE.............................................................................................................................................. 18
3.4 REFRIGERATION SYSTEM ASSEMBLY........................................................................................................... 19
4. CONTROL SYSTEM ............................................................................................................................................. 20
4.1 GENERAL DESCRIPTION .................................................................................................................................. 20
4.2 COOLING CONTROL .......................................................................................................................................... 20
4.2.1 TEMPERATURE SETTINGS ............................................................................................................................ 20
4.2.2 COOLING MODES............................................................................................................................................ 20
4.2.2a LOW COOL .................................................................................................................................................... 21
4.2.2b MEDIUM COOL .............................................................................................................................................. 21
4.2.2c HIGH COOL .................................................................................................................................................... 21
4.3 SUPPLY FAN SPEED CONTROL ....................................................................................................................... 22
4.3.1 GENERAL DESCRIPTION ............................................................................................................................... 22
4.3.2 VARIABLE FREQUENCY DRIVE ..................................................................................................................... 22
4.4 CONTROL PANEL DESCRIPTION & FUNCTION .............................................................................................. 22
4.4.1 MAIN CONTROL PANEL .............................................................................................................................22-24
4.4.2 GENERATOR SET CONTROL PANEL .......................................................................................................24-25
4.4.3 SENSORS....................................................................................................................................................25-26
INDEX

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Contents Page
5. START-UP & SHUTTING DOWN SEQUENCE .................................................................................................... 26
5.1 VISUAL INSPECTION OF EQUIPMENT (CHECK LIST)................................................................................26-27
5.2 STARTING THE GENERATOR ENGINE ............................................................................................................ 28
5.3 STARTING THE ACU (AIR CONDITIONING UNIT) ............................................................................................ 28
5.4 MACHINE SHUT DOWN...................................................................................................................................... 29
6. ALARM AND TROUBLE SHOOTING GUIDE ...................................................................................................... 30
6.1 DESCRIPTION OF ALARM ................................................................................................................................. 30
6.2 TROUBLE SHOOTING GUIDE.......................................................................................................................31-32
7. PROTECTION DEVICES ...................................................................................................................................... 32
7.1 VOLTAGE MONITORING RELAY ....................................................................................................................... 32
7.2 THERMAL OVERLOAD RELAYS........................................................................................................................ 32
7.3 CIRCUIT BREAKERS .......................................................................................................................................... 32
7.4 DISCHARGE PRESSURE SWITCH .................................................................................................................... 32
8. ACCESSORIES ..................................................................................................................................................... 33
8.1 FUEL FILL STATION ASSEMBLY ....................................................................................................................... 33
8.2 SERVICE LAMPS ................................................................................................................................................ 33
8.3 ROTARY (BEACON ) LAMPS.............................................................................................................................. 33
9. MAINTENANCE & SERVICING ........................................................................................................................... 34
9.1 GENERAL MAINTENANCE................................................................................................................................. 34
9.2 INSPECTION & PREVENTIVE MAINTENANCE ............................................................................................34-36
9.3 AIR CONDITIONING SYSTEM ............................................................................................................................ 37
9.4 MOISTURE IN A REFRIGERANT SYSTEM ...................................................................................................38-39
9.5 EVACUATING THE REFRIGERANT SYSTEM ................................................................................................... 40
9.6 REFRIGERANT LEAK TESTING....................................................................................................................40-41
9.7 REFRIGERANT LEAK REPAIR ........................................................................................................................... 41
9.8 REFRIGERANT CHARGING & PRESSURE LIMITS........................................................................................... 42
10. EQUIPMENT DIMENSIONAL DETAILS ............................................................................................................ 43
11. COMPONENT LAYOUT (MAIN CONTROL PANEL) ......................................................................................... 44
12. COMPONENT PARTS LIST (MAIN CONTROL PANEL) .................................................................................. 45
13. PARTS LIST ................................................................................................................................................... 46-51
14. WIRING DIAGRAM ........................................................................................................................................ 52-53
15. SYMBOLS AND LEGENDS ................................................................................................................................ 54
16. PHOTO GALLERY ......................................................................................................................................... 55-66
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.
THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

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GENERAL
GENERAL STATEMENT
The Zamil Mobile Air Conditioning units are designed & built for the optimum performance. However, it is required that
you become well acquainted with good practices for the proper installation/operation/and maintenance procedures in
order to ensure a safe trouble free operation, year after year.
Please read through the whole manual contents before you attempt to install/operate/ and maintain the unit.
Most of the procedures described in this manual require certain skills and experience. The installation and other mainte-
nance procedures should be performed only by highly skilled and experienced technicians. The end user’s role should be
limited to the cleaning of the filter.
SAFETY ISSUES
There are three degrees of safety hazards that are identified throughout this manual as WARNING (where the situation
will result in personal injury), CAUTION (where personal injury might occur), and ATTENTION (where minor personal
injury and/or property damage could happen). Please understand and respect those identifications.
WARNING: These units operate on a high voltage with moving parts (at high speed) which can lead to serious
injuries and/or damage to the unit. Never attempt to service the unit unless the main electrical power supply has
been disconnected.
CAUTION: Extra care should be observed when installing, test running, adjusting, servicing, or maintaining the
unit as the hazard of explosion, fire, electrical shock, and potential personal injury and property damage are
present.
Whenperforming any task pertaining tothe installation and maintenance ofthe unit, the skilled technicianshould observe
all the applicable safety measures (wear of safety helmet, boots, gloves, and goggles. Use of proper handling materials
for brazing and use of wet cloth for quenching. A fire extinguisher should be easily accessible etc.). He should also read
all the instructions and information in this Manual prior to attempting to perform any installation or servicing of the unit.
All applicable local codes should also be observed during installation and servicing.

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1. FOREWORD
The purpose of this document is to give a brief description of the MAC240 mobile Air Conditioning equipment, its speci-
fication and other relevant information related to maintenance and safe operation of the equipment.
2. STANDARD SPECIFICATION
The Zamil MAC240 mobile air-conditioning equipment consisting of a dual system refrigeration section (condensing
unit), air handling section, and a power generation unit encased in one complete enclosure. The power generator in the
unit is a diesel fed engine which provides power of 460V-3PH-60HZ to the motors in the equipment. The equipment is
mounted on a trailer for the purpose of movements in any area or at any position proper for its safe operation during
installation.
UNIT LEFT SIDE VIEW
2.1 BASE CHASSIS and CONSTRUCTION
The MAC240 Chassis is ruggedly constructed with mild steel base frame and consists of overall system enclosures as
well as trolley’s components and accessories. The enclosure made of double skin heavy gauge (G-90) zinc coated and
galvanized steel by the hot dip process of lock-forming quality conforming to ASTM A 653 commercial weight G-90
followed by baked on electrostatic polyester dry powder coat. Posts and insulated Aluminum outer panels covered
internally by perforated galvanized steel panels filled with standard fiber glass insulation (25mm thick density: 48 kg/m)
as per NEPA 90A standards. The enclosure is constructed of posts and panels.
The MAC240’s enclosure is provided with inner lighting system in various areas to ease the troubleshooting activities
especially in the emergency cases. In addition, it is designed to have the maximum accessibility using access doors as
well as all the enclosure’s panels and posts are removable incase unusual accessibility is needed.
All the service doors are Hinge mounted with air tight turn buckle lock. These light weight aluminum construction doors
allow easy access to components for service and inspection. The main access doors provided are as follow.

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UNIT TOP VIEW & ACCESS DOOR LOCATION
•Complete back side access is provided with two easy open lockable latched hinged doors to access the power genera-
tor and its components. The first one is to access the genset’s control panel and provided with outer sight glass
allowing quick visual monitoring to genset operation without the need of opening the access door.
•Air Conditioning discharge side access is provide with two easy open lockable latched hinged doors; the first to reach
the cooling system, the fuel injection’s air filter and belts area of power generator’s engine while the other access door
which is provided with outer sight glass allowing quick visual monitoring is the main maintenance access for the whole
system designed to reach the following components/systems:
!The back side of the power generator and its components.
!The A/C system blower and blower motor.
!The variable frequency dive control box control.
•The front side of the MAC240 is provided with one safe hinged door which can be opened by Allen key to prevent
unnecessary opening to the compressor compartment while the system on operation which result safety cutoff to the
compressors due to the high pressure in the condenser side. (refer to the operation part of the manual for more
information).
•The control box side is having only the access door to the control panel user interface and the control box door allowing
the access to all the electrical and control components. While the fuel filling/monitoring is exposed allowing easer
access.
This type of enclosure’s design provides overall system strength as well as reduces the noise level transmitted to the
outer environment from the internal components of the system especially from the power generator side. Moreover, the
components used are enhancing the enclosure noise damping performance like the heavy duty low noise type con-
denser/outer gen-set cooling fans for quieter operation in addition to the Scroll type compressors equipped.
On the other hand, the enclosure is mounted on a heavy duty trolley system and bolted at four points for each side of the
system. This trolley system is consists of rigid steel structure mounted on two heavy duty axles with total four heavy
machinery wheels; each can carry 2.4 tons while the total trolley system is designed to carry up to 8 Tons.

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The trolley system is designed with front turnable axle by means of swivel bearing and both front and rear axles are
mounted on heavy duty leaf springs allowing the required vibration damping to the upper components. This design allows
towing the MAC240 from the front side of the trolley toward the swivel bearing by means of rigid heavy duty beak
supported towing bar as well as it can be lifted by forklift safely. For more towing operation the system is provided with tail
light as well as side reflection lights.
1. Cooling fan
2. V-Belts (fan)
3. Optional attachment of hydraulic pumps
4. V-belt washer
5. Tension roller
6. Oil filler neck
7. Fuel pump
8. Fuel change filter
9. Injection pump
10. Oil dipstick
11. Shut-off magnet
12. SAE housing
13. Lube oil filter
14. Air duct hood
15. Cylinder head cove
2.2 DIESEL ENGINE GENERATOR
The diesel engine generator supplies electrical power to compressors, condenser motor, blower motors and controls
respectively. The generator set mounted across the rear of the unit base. The service accessibility of components is
within easy reach through hinged sight glass doors. The generator is fully self-contained including all controls, alarm
indications, and other operating parameters for the engine and generator. The low emission gas generator set is comply-
ing with international safety protection standards. Exhaust muffler mounted on top of the unit is rigidly connected with
spark arrestor silencer.
A. GENERAL Description:
The power generator used in MAC240 is air cooled “DEUTZ” diesel type which consists of 6-cylinder naturally aspirated
enginesequipped with advanced injection and combustion system, mechanical governor. And connectedto an alternator
to produce 460 Volts 3 phase 60 Hz with a rating of 85.0 KVA running @ NTP (refer to the specification section for more
details). Both the engine and the alternator are controlled by “mecc alte spa” regulator and “DEEP SEA ELECTRONICS”
control system (refer to the components’ appendix and components’ manuals for more information) and located on back
side of the enclosure in top of and to the side alternator respectively.
The power generator of the MAC240 consists of the following components:
It is very important that the riggers and movers should use designated forklift channels
provided under the trolley. MAC unit can be lifted by a minimum 5 ton load forklift vehicle
using proper forklift channels to handle the complete unit weight.

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B. Alternator
This type alternators are brushless, self-regulating and incorporate a rotating inductor with damper cage winding and a
fixed stator with skewed slots. The stator windings have a shortened pitch to reduce the harmonic content of the output
waveform. The alternators are made in compliance with the 98/37, 73/23, 89/336 CEE directives and their amendments,
and the CEI 2-3, EN 60034-1, IEC 34-1, VDE 0530, BS4999-5000, CAN/CSA-C22.2 N°14-95 - N°100-95 regulations.
C. Power Generator Control System:
Thepower generator control system is anAutomatic Mains Failure Control Module. The module is used tomonitor amains
supply and automatically start a standby generator set. The module also provides indication of operational status and fault
conditions, automatically shutting down the genset and indicating failures by means of an LCD display, and appropriate
flashing LED on the front panel.
Selected timers and alarms can be altered by the customer from the front panel. Alterations to the system are made using
the 810 interface and a PC. This interface also provides real time diagnostic facilities.
Easy push-button control
Operation of the module is via push-button controls (with security locking facility) mounted on the front panel with STOP/
RESET, AUTO, MANUAL and START push-button. The first three push-buttons feature LED ‘selected’ indications. Fur-
ther push-buttons provide LCD DISPLAY SCROLL and EVENT LOG VIEW functions.
Microprocessor control
Themodulefeatures16-Bitmicroprocessorcontrol and a comprehensive list of timers and pre-configured sequences. This
allows demanding specifications to be achieved.
Event Log
The instrumentation displays are supplemented further by EVENT LOG VIEW, which shows the last 15 shutdown events
along with date and time of shutdown.
LED indication
‘Hid-‘til-lit’ icons are used to show the presence of alarm conditions detected by the module.
In addition 4 uncommitted LCD segments allow the user to configure the module to provide other status indications from
either internal states or from external digital inputs.
Digital Inputs
The module accepts the following digital inputs:
•Emergency Stop Input - A N/C DC positive input
•Fully configurable warning or shutdown inputs
With the exception of the Emergency Stop Input, these are configurable to be either N/C or N/O contacts connected to the -
Ve DC. The 6 fully configurable auxiliary inputs can be selected to be indication, warning or shutdown inputs either immedi-
ate or held off during start up to allow for use as protection expansion inputs. Alternatively they may be configured to
control extra functions such as Lamp Test or Remote Start input, and many others - refer to appropriate manuals for
details.

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D. Alarms & Shutdowns:

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2.3 UNIT PHYSICAL DATA
MODEL NUMBER MAC240
NOMINAL CAPACITY (TONS) @ 950F AMBIENT 24
CAPACITY (TONS) @ 1150F AMBIENT 21
APPLICATION INDUSTRIAL, 100% FRESH AIR
POWER SUPPLY (V-PH-HZ) 460-3-60
COMPRESSOR Type SCROLL
Part # (Qty.) 800-674-19 (2)
Refrigerant R-22
Operating charge per system, oz 450
RLA/LRA,Amps 19.6/125
CONDENSER FAN & MOTOR Type PROPELLER
Part # (Qty.) 800-226-01 (2)
NominalCFM 15000
Dia. (mm) 700
POWER SUPPLY (V-PH-HZ) 460-3-60
Motor kW - RPM - FLA - LRA 1.5 - 1000- 2.6- 10
EXHAUST FAN Size (mm) 700
Part # (Qty.) 800-237-03 (1)
kW - RPM - FLA - LRA 1.5 - 1000- 2.6- 17.4
MINIMUMCIRCUITAMPACITY Amps 74
MAX. FUSE SIZE/CIRCUIT BREAKER Amps 90
UNIT KVA Amps 54.6
CONDENSER COIL Type Inner grooved tubes and enhanced fins
Tube Dia.- Rows - Fins per inch 3/8-5-14
Total face area (Sq. ft.) 25
EVAPORATORBLOWER Type BACKWARDCURVED
Size (inch) DP/500
Drive type DIRECT DRIVE
NominalCFM 2400
EVAPORATOR BLOWER MOTOR Motor KW 13.2
FLA/LRA 21 /111
Motor frame IEC
EVAPORATORCOIL Type CORRUGATED FIN & TUBE
Tube Dia.- Rows - Fins per inch 1/2-12-10
Total face area (Sq. ft.) 6
HIGH PRESSURE SETTING OPEN - PSIG 450 ± 10
CLOSE - PSIG 360 ± 15
LOW PRESSURE SETTING OPEN - PSIG 25 ± 5
CLOSE - PSIG 50 ± 5
AIR COOLED DIESEL ENGINE GENERATOR / WESTAC ( DEUTZ) WPDZ72/F6L914 (85KVA / 68KW )
UNIT DIMENSIONS TRAILER MOUNTED - L x B x H (meters) 3.6 x 2.2 x 2.6
UNIT WEIGHT ( WITHOUT FUEL), KG 4000
TRAILERSPEEDLIMIT 15 KM / H