Download 7.Installation,Operation & Maintenance(IOM) PDF

Title7.Installation,Operation & Maintenance(IOM)
TagsGas Compressor Capacitor Air Conditioning Personal Protective Equipment Mechanical Fan
File Size4.5 MB
Total Pages65
Document Text Contents
Page 1

Installation,Operation&Maintenanceanual

PACV-S

Packaged Air Conditioners

Page 2

2 | 2 |

Table of Contents
1 Introduction 4

Nomenclature . . . . . . . . . . . . . . . . . . . . 5

Safety Instructions . . . . . . . . . . . . . . . . . . 5

Specifi c Hazards. . . . . . . . . . . . . . . . . . . . 5

Points To Remember. . . . . . . . . . . . . . . . . . 6

Component Features . . . . . . . . . . . . . . . . . 7

Liquid Line Controls . . . . . . . . . . . . . . . . . . 9

Electrical Control panel . . . . . . . . . . . . . . . 10

Room Unit . . . . . . . . . . . . . . . . . . . . . 11

2 Installation

Receiving of Equipment . . . . . . . . . . . . . . . 13

Rigging . . . . . . . . . . . . . . . . . . . . . . 13

Handling . . . . . . . . . . . . . . . . . . . . . . 13

Storage . . . . . . . . . . . . . . . . . . . . . . 14

Location & Space Requirements . . . . . . . . . . . 14

Pre-Installation Checkup. . . . . . . . . . . . . . . 15

Preparation For Installation . . . . . . . . . . . . . 16

Carrying Out Installation . . . . . . . . . . . . . . . 16

Condensate Draining . . . . . . . . . . . . . . . . 16

3 Operation

Pre-Startup Checklist . . . . . . . . . . . . . . . . 17

Pre-Startup Procedure . . . . . . . . . . . . . . . . 17

Service Record . . . . . . . . . . . . . . . . . . . 18

Unit Startup . . . . . . . . . . . . . . . . . . . . 19

Display & Keypad Operation . . . . . . . . . . . . . 20

Alarms . . . . . . . . . . . . . . . . . . . . . . . 21

List of alarms in the unit controller . . . . . . . . . . 21

Operation of the Room Unit . . . . . . . . . . . . . 22

Setting the address of the room unit . . . . . . . . . 22

switching in and switching off the unit . . . . . . . . 22

Commissioning Test Report . . . . . . . . . . . . . 25

4 Maintenance

Periodic Maintenance . . . . . . . . . . . . . . . . 26

Leak Testing, Evacuation &

Charging Procedures . . . . . . . . . . . . . . . . 28

Fan . . . . . . . . . . . . . . . . . . . . . . . . 32

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MAINTENANCE

• Remove protection screws and protection
rings out of the bearings. Remove protection
rings out of the shaft. Using appropriate
tools, hold the shaft in an appropriate
position in order not to damage the rotors
wheel.

• Remove nuts and bolts from cross bars and
separate assembly from shaft and bearing.
Replace the old rubber rings and bearings
and assemble the new ones onto the cross
bars.

• Install protection rings onto the bearings
clamping them according to the fan’s
rotations direction and secure them with
fi xing screws. Turn the wheel several times
in order to check if it rotates correctly.
Assemble cross bars on side panels and
make sure to preserve coaxiality of the rotor.
Tighten the nuts and bolts on cross belts to
the side panels.

Replacement instruction of fan
bearings assembled on Cross bars

1. Check bearing for sound, a normal bearing
generates a smooth uniform sound, while
a damage bearing generates a loud and
irregular sound.

2. Excess vibrations or temperature are often
a sign of possible damages Check the
bearing locking and seals periodically.

3. Check for excessive grease leakage from
the bearing. Leakage of small quantity from
the bearing is normal.

Bearing

Cross bars

Protection ringsProtection screw

Cross bars

Fan Motor

Checking the insulation
If the unit has been stored for long time or if it has been kept
in a damp atmosphere, insulation resistance test for the motor
should be carried out. This measurement must be carried out
using a megohmmeter at 500V D.C. (do not use a magneto
electric system).

Draining off condensation water
Temperature variations cause condensation to form inside the
motor, which must be removed before it adversely affects motor
operation. Condensation drain holes, located at the bottom of
the motors (bearing in mind their operating position) are sealed
with plugs which must be removed and then replaced every
six months (if they were not replaced, the motor degree of
protection would no longer be maintained). Clean the orifi ces
and plugs before reassembling them.

Cast iron separate casing

Cover

Fan
For smooth operation fan must be serviced
regularly. The most important maintenance
measures to be made at least twice a year are:
1. Vibration and sound level to be checked.

Anomalous values indicate a problem on the
unit.

2. Check the presence of corrosion on the fan
especially on the rotating path to prevent
breaking.

3. Check if there are any objects within the
range of the fan which might be sucked into
the rotor once the fan is running.

4. Check whether the fans rotor rotates freely,
without any friction against the casing body.

5. Check the fan design speed as it must not
exceed the rotary speed.

6. Check whether the supply cables in the fan
section are fi rmly fi xed.

Replacement instructions of fan bearings
assembled on Cast iron pillow blocks
• Unlock the casing cover easing screws at both sides. Using

appropriate tools, hold the shaft in an appropriate position
in order not to damage the inlet funnel or rotors wheel.

• Remove protection rings from the bearing side (only
one bearing is equipped with it). After removing grease,
remove sealing half-rings from the upper and lower port of
the block casing.

• Slide down the bearings, straightening the screwed ring
tongue located on the sleeve, ease at each side screwed
rings with a centre pouch and hammer. Install the bearings,
tighten up the sleeves with the screwed ring bend the rings
tongue. Install a new sealing sleeve into grooves located
in the lower part of the block. Install the lubricated shaft
assembly with a bearing on the block basis. Assemble
fi xing ring (or more fi xing rings) at a side of one bearing
only (the other bearing is not adjustable). Insert the other
sealing ring onto the upper block side. Put the upper block
part onto the lower one and tighten up the screws. Fill the
bearing with suitable grease. Turn the wheel several times
in order to check if it rotates correctly.

Page 33

| 33

MAINTENANCE

• Disconnect and lock-out power
before installation and maintenance.

• Working on or near energized equipment
can result in severe injury or death.

• Do not operate equipment without guards
in place. Exposed equipment can result in
severe injury or death.

• Periodic inspections should be performed.
Failure to perform proper maintenance
can result in premature product failure and
personal injury.

• To avoid damage, supporting structure
including shafts and bearings must be
designed to handle transmitted loads and
belt tension(s).

V-Belt Installation Check List

1
Turn off and lock out power
source

( ) Yes ( ) No

2 Observe all other safety procedures ( ) Yes ( ) No

3 Select proper replacement belts ( ) Yes ( ) No

4 Remove belt guard ( ) Yes ( ) No

5
Inspect drive elements–bearings,
shaft, etc.

( ) Yes ( ) No

6 Inspect sheave grooves for wear ( ) Yes ( ) No

7 Check sheave alignment ( ) Yes ( ) No

8 Install new belts ( ) Yes ( ) No

9 Tension belts ( ) Yes ( ) No

10 Check sheave alignment (fi nal) ( ) Yes ( ) No

11 Replace guard ( ) Yes ( ) No

12 Start drive (look & listen) ( ) Yes ( ) No

13
Re adjust the tension after fi rst 24
hours of operation

( ) Yes ( ) No

Cleaning
To ensure the motor operates correctly, remove
any dust or foreign bodies which might clog the
cover grille and the housing fi ns. Before carrying
out any cleaning operation check that the motor is
completely sealed (terminal box, drain holes, etc).
Dry cleaning (vacuuming or compressed air) is
always motor preferable to wet cleaning.

Always clean at reduced pressure from the centre
of the motor towards the extremities to avoid
introducing dust and particles under the seals.

Bearing

As soon as any abnormal noise or vibration is
noted on the motor or abnormal temperature
rise is noted in the bearing, the condition of the
bearings must be checked. Damaged bearings
must be replaced as soon as possible to prevent
worse damage to the motor and the fan. It
is also recommended to change the bearing
after 100,000 hours of operation under normal
operating conditions. If one bearing needs to be
replaced, the other bearing must also be replaced.
The seals should be changed routinely when the
bearings are changed.

Fan Belt Adjustment

The supply fan belts must be inspected periodically
to ensure proper unit operation. Replacement
is necessary if the belts appear frayed or worn.
Units with dual belts require a matched set of belts
to ensure equal belt lengths.

Periodic inspections should
be performed. Failure to

perform proper maintenance can
result in premature product failure
and personal injury.

Maintenance of the fan
equipment should only be

carried out by skilled and adequately
trained staff. To ensure complete
safety do not start any maintenance
procedure or inspection without
disconnecting the unit from the
power supply and before the fan
and motor have completely stopped
rotating.

Close any inlet or outlet
damper to avoid a rotation of
the impeller due to induced

airfl ow.

When installing new belts or during replacement, do not stretch
them over the sheaves; Instead loosen the adjustable motor
mounting base. Once the new belts are installed, adjust the belt
tension using tension gauge.

Table 8.

Page 64

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ºF ºC R-22 R-410A R-407C R134a ºF ºC R-22 R-410A R-407C R134a ºF ºC R-22 R-410A R-407C R134a

-60 -51.1 *11.9 *0.9 *16.0 *21.6 12 -11.1 34.8 65.4 29.0 13.2 42.0 5.6 71.5 123.6 64.6 37.0
-55 -48.3 *9.2 1.8 *13.7 *20.2 13 -10.6 35.8 67.0 29.9 13.8 43.0 6.1 73.0 125.9 66.1 38.0
-50 -45.6 *6.1 4.3 *11.1 *18.6 14 -10.0 36.8 68.6 30.9 14.4 44.0 6.7 74.5 128.3 67.6 39.0
-45 -42.8 *2.7 7.0 *8.1 *16.7 15 -9.4 37.8 70.2 31.8 15.1 45.0 7.2 76.1 130.7 69.1 40.0
-40 -40.0 0.6 10.1 *4.8 *14.7 16 -8.9 38.8 71.9 32.8 15.7 46.0 7.8 77.6 133.2 70.6 41.1
-35 -37.2 2.6 13.5 *1.1 *12.3 17 -8.3 39.9 73.5 33.8 16.4 47.0 8.3 79.2 135.6 72.2 42.2
-30 -34.4 4.9 17.2 1.5 *9.7 18 -7.8 40.9 75.2 34.8 17.1 48.0 8.9 80.8 138.2 73.8 43.2
-25 -31.7 7.5 21.4 3.7 *6.8 19 -7.2 42.0 77.0 35.9 17.7 49.0 9.4 82.4 140.7 75.4 44.3
-20 -28.9 10.2 25.9 6.2 *3.6 20 -6.7 43.1 78.7 36.9 18.4 50.0 10.0 84.1 143.3 77.1 45.4
-18 -27.8 11.4 27.8 7.2 *2.2 21 -6.1 44.2 80.5 38.0 19.2 55.0 12.8 92.6 156.6 106.0 51.2
-16 -26.7 12.6 29.7 8.4 *0.7 22 -5.6 45.3 82.3 39.1 19.9 60.0 15.6 101.6 170.7 116.2 57.4
-14 -25.6 13.9 31.8 9.5 0.4 23 -5.0 46.5 84.1 40.2 20.6 65.0 18.3 111.3 185.7 127.0 64.0
-12 -24.4 15.2 33.9 10.7 1.2 24 -4.4 47.6 85.9 41.3 21.4 70.0 21.1 121.5 201.5 138.5 71.1
-10 -23.3 16.5 36.1 11.9 2.0 25 -3.9 48.8 87.8 42.4 22.1 75.0 23.9 132.2 218.2 150.6 78.6
-8 -22.2 17.9 38.4 13.2 2.8 26 -3.3 50.0 89.7 43.6 22.9 80.0 26.7 143.7 235.9 163.5 86.7
-6 -21.1 19.4 40.7 14.6 3.7 27 -2.8 51.2 91.6 44.7 23.7 85.0 29.4 155.7 254.6 177.0 95.2
-4 -20.0 20.9 43.1 15.9 4.6 28 -2.2 52.4 93.5 45.9 24.5 90.0 32.2 168.4 274.3 191.3 104.3
-2 -18.9 22.4 45.6 17.4 5.5 29 -1.7 53.7 95.5 47.1 25.3 95.0 35.0 181.9 295.0 206.4 113.9
0 -17.8 24.0 48.2 18.9 6.5 30 -1.1 54.9 97.5 48.4 26.1 100.0 37.8 196.0 316.9 222.3 124.1
1 -17.2 24.8 49.5 19.6 7.0 31 -0.6 56.2 99.5 49.6 26.9 105.0 40.6 210.8 339.9 239.0 134.9
2 -16.7 25.7 50.9 20.4 7.5 32 0.0 57.5 101.6 50.9 27.8 110.0 43.3 226.4 364.1 256.5 146.3
3 -16.1 26.5 52.2 21.2 8.0 33 0.6 58.8 103.6 52.1 28.6 115.0 46.1 242.8 389.6 274.9 158.4
4 -15.6 27.4 53.6 22.0 8.6 34 1.1 60.2 105.7 53.4 29.5 120.0 48.9 260.0 416.4 294.2 171.1
5 -15.0 28.3 55.0 22.8 9.1 35 1.7 61.5 107.9 54.8 30.4 125.0 51.7 278.1 444.5 314.5 184.5
6 -14.4 29.1 56.4 23.7 9.7 36 2.2 62.9 110.0 56.1 31.3 130.0 54.4 297.0 474.0 335.7 198.7
7 -13.9 30.0 57.9 24.5 10.2 37 2.8 64.3 112.2 57.5 32.2 135.0 57.2 316.7 505.0 357.8 213.5
8 -13.3 31.0 59.3 25.4 10.8 38 3.3 65.7 114.4 58.9 33.1 140.0 60.0 337.4 537.6 380.9 229.2
9 -12.8 31.9 60.8 26.2 11.4 39 3.9 67.1 116.7 60.3 34.1 145.0 62.8 359.1 571.7 405.1 245.6
10 -12.2 32.8 62.3 27.1 12.0 40 4.4 68.6 118.9 61.7 35.0 150.0 65.6 381.7 607.6 430.3 262.8
11 -11.7 33.8 63.9 28.0 12.6 41 5.0 70.0 121.2 63.1 36.0 155.0 68.3 405.4 645.2 456.6 281.0

P-T Chart

Note:

• To determine subcooling for R-407C, use bubble point values (temperatures above 50 oF, shown with
shaded gray background).

• To determine superheat for R-407C, use dew point values (temperature 50 oF and below)

All temperatures and pressures are shown at sea level.
Pressures are listed as psig, except (*) indicates inches in mercury vacuum.

APPENDIX- X

Table 22

Page 65

Manual# : 088- IOM- 2014
Supersedes Manual# : 088- IOM- 2012

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