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Installation and Maintenance Manual 

 

18 

5.

 

OPERATIONS 

Start

‐

up Procedures 

 

CAUTION 

Start-up to be conducted by qualified service engineers familiar with equipment. 

 

 

Ensure that drain lines are fitted to both the dump outlet as well as the overflow outlet (if 

necessary). 

 

Ensure drain lines have been charged with water. 

 

Check all duct work connections are clean, and clear of any obstruction. Ensure all relevant 

dampers and fire dampers are open or at the correct setting. 

 

Check if there are any signs of excessive vibration on fans. 

 

Ensure filters have been fitted in the outdoor air inlet. 

 

Check that sufficient electrical power is available. 

Unit Air Flows 

 

The Supply airflow quantity set point has been pre-set in the factory, allowing the fan to 

automatically adjust the speed to meet the required airflow. The airflow setpoint can still be 

adjusted using the air volume controller (UNIcon CPG). Please contact the Air Change technical 

support team for instructions. 

 

Cooke Industries - Phone: +64 9 579 2185    Email: [email protected]    Web: www.cookeindustries.co.nz

Summary of Contents for PCU

Page 1: ...rd Avenue Milperra 02 8774 1400 sales airchange com au April 2019 INSTALLATION AND MAINTENANCE MANUAL Air Change Precise Control Unit PCU Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 2: ...ase Rotation 9 Miswiring of 3 phase Power 9 Filters 10 Electrical Electronic Connections 10 Mains Power Supply and Fusing 10 Electrical Connection and Supply Size Precaution 10 Ducting 11 3 REFRIGERATION PIPING 12 General 12 Piping 12 Charging 12 4 SYSTEM COMPONENTS 13 Requirement 13 System Components 13 Cabinet 13 Fans 14 Scroll Compressors 15 Electrical 16 Coils 16 Control System 16 Optional Fir...

Page 3: ...at exchangers 27 Air Change Sensible Heat Exchangers 27 Maintenance Schedule 27 General 27 Monthly Maintenance Schedules 28 Three Monthly Checks 28 Annual Maintenance 28 9 TROUBLESHOOTING GUIDE 29 10 TECHNICAL DATA TABLES 30 Heat Exchanger Data 30 Sandwich Panel Data 30 11 WARRANTY INFORMATION TERMS CONDITIONS 31 Warranty Claim Form 32 Details of Servicing 33 12 WARRANTY POLICY 34 Cooke Industries...

Page 4: ...r conditions which may cause personal injury or property damage and will void the warranty Check with Air Change or your nearest Air Change dealer for any information required on this equipment DANGER Electrical shock can cause personal injury or death Before performing any work on this equipment the electrical supply must be turned off at the electrical service box to avoid the possibility of sho...

Page 5: ...bly constructed for the purpose all safety precautions have been applied prior to installation and all preparation work has been constructed and suitably sized for its purpose Inspection and Unpacking The unit should be inspected upon delivery for possible external damage incurred during transport If damage is evident it should be noted on the freight docket and the Air Change sales office contact...

Page 6: ...porting the unit Lifting with a Crane NOTE All units should be lifted into position using slings Where units have to be lifted into position installers must check the unit weight is within tolerance of the safe working capacity of the lifting equipment When preparing to move the unit always determine the unit s centre of gravity in order to equally distribute the weight Spreader bars must be used ...

Page 7: ...upport the unit and minimise the transmission of vibration to the building Suspending the Unit Before suspending the unit check the supporting beams to be used and verify that it has sufficient load carrying capacity to support the weight of the unit Access for Maintenance The unit must be mounted so maintenance personnel can gain access to all parts of the unit and with sufficient room to remove ...

Page 8: ... transmitted into the building structure We recommend wafer pads be used under the frame We also recommend flexible couplings be fitted to the supply and return ducts to reduce vibration transfer Drainage IMPORTANT Installation of a P Trap is mandatory for all drainage points Air Change will not accept any liability for any water damage resulting from incorrect installation A minimum of 50 mm elev...

Page 9: ...uilding wall Where drain lines are likely to be exposed to freezing temperatures or when they are subject to the formation of condensation the lines should be insulated Phase Rotation Applicable to PCU D models only Correct phasing Phase sequencing the scroll compressor is designed to operate with the motor in only one direction Miswiring of 3 phase Power Miswiring of 3 phase power phase reversal ...

Page 10: ...d cabinet Mains Power Supply and Fusing A power supply rated at 415 V 10 3 phase or 240 V 10 1 phase 50 Hz is required to operate the machine within manufacturer s tolerances Mains cables are to be connected as per the wiring diagram Field wiring on the sensor and HLI communication to the controller if any need to be done on site The units require a mains circuit breaker or HRC fusing capable of h...

Page 11: ... To reduce losses due to fan system effect adequate length of straight duct between elbow and fan inlet should be provided or turning vanes used in the elbow Poor fan outlet conditions can affect the fan performance particularly the effective duct length For 100 recovery the duct must meet requirements for 100 effective duct length Ducts should be sized to accommodate a maximum airflow velocity of...

Page 12: ... into the compressor during off cycle and to ensure return of oil to the compressor Piping Pipe diameters vary with unit capacity Use only clean sealed refrigeration grade piping and cut only with a pipe cutter Insulate the gas line and seal all insulation joints Charging Evacuate the indoor unit and interconnecting pipe work to a standard pressure of 500 microns which is to be held for minimum of...

Page 13: ...0 outside air and comprises of the following components Cabinet Prefabricated wall and ceiling panels are made of stressed skin insulated sandwich construction consisting of metal internal parts and external skins bonded under pressure with thermosetting adhesive to a core of rigid cellular insulation Insulation is a single layer of rigid Polyisocyanurate sheet to AS1366 3 Class SL continuous with...

Page 14: ...h airstream are of equal volume flowrate IMPORTANT DO NOT ATTEMPT TO CHANGE THE LENGTH OF THE HEAT EXCHANGER BY REMOVING END PLATES AND PLASTIC PLATES This can cause the media between the plates to dislodge from its position resulting in a lack of performance because of an increased pressure drop through the heat exchanger or damage to the Sensible media Any tampering with the heat exchanger may i...

Page 15: ...veral hours for them to reset or longer on very hot days Accompanied with the scroll compressor are characteristic sounds that do not affect reliability or indicate that the compressor is defective At start up Under conditions of low refrigerant flows low suction pressures such as start up a rattling sound may emanate from the compressor This will be heard until the head pressure is great enough t...

Page 16: ...s is designed at around 2 0 m s for a low pressure drop and high efficiency Control System All controllers are installed on the main electrical board inside the unit Outdoor Air Air Off Coil and Supply Air sensors are pre fitted inside the unit The controller is designed to automatically energise the unit by receiving a start signal from an external digital input or from the LCD touch screen on th...

Page 17: ...l Board In case of fire the 24 V DC circuit will be de activated causing the unit to switch off shutting down the system completely except for the exhaust fans which act independently for smoke exhaust The 24 V DC circuit can only be reset by the Fire Department Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 18: ...s are open or at the correct setting Check if there are any signs of excessive vibration on fans Ensure filters have been fitted in the outdoor air inlet Check that sufficient electrical power is available Unit Air Flows The Supply airflow quantity set point has been pre set in the factory allowing the fan to automatically adjust the speed to meet the required airflow The airflow setpoint can stil...

Page 19: ...re program and result in fans not delivering accurate air volume 1 Press and simultaneously to enter the Main Menu 2 Press or to find Setting and press P to enter 3 Under Setpoint 1 press P button until the value flashes and press or to change 4 Press P to save the new value 5 Press and again to return to main menu 6 The Info menu is read only and displays key running parameters such as actual air...

Page 20: ... humidity readings 2 Temperature and or humidity set points Adjust using up and down arrows 3 The serial number and name for the unit 4 The mode the unit is running in The number refers to the number of compressors running ie COOLING 2 means the unit is in cooling mode with 2 compressors running 5 Alarm status will display NORMAL when there are no faults and ALARM when there are faults For more in...

Page 21: ...ys the job number and the IP address of the HMI 3 The mode the unit is running in The number refers to the number of compressors running For example COOLING 1 means the unit is in cooling mode with 1 compressor running 4 Displays temperature and humidity readings and set points 5 Displays damper position and speeds or positions of other components if necessary 6 Buttons to other pages 1 2 3 4 5 6 ...

Page 22: ...sor 3 Dead band for the thermostat This is the temperature range for the set point For example if the set point is 27 degrees and the dead band is 0 5 degrees the unit will run so that the temperature in the room is between 26 5 and 27 5 degrees It is recommended to set dead bands to a minimum value of 0 5 to ensure stable operation 4 Home button will take you back to the service page 5 Next butto...

Page 23: ...can be calibrated if necessary Use up and down arrows to adjust 2 Previous page button will take you to the previous page 3 Home button will take you back to the service page 1 2 3 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 24: ...t run status 3 Compressor lockout If a compressor has 3 faults within 1 hour the compressor will be locked out The fault must be fixed then the reset button can be pressed to unlock the compressor 1 2 3 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 25: ...ory 1 Displays Faults with a timestamp 2 Shows the time range of the faults being displayed 3 Time settings Time and time range can be adjusted 1 2 3 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 26: ...a trend graph for Refrigerant Pressure Temperature Humidity Component Speeds etc 2 Colour coded legend as well as any set points for certain parameters 3 Press next to see other trend graphs like temperature humidity component speeds etc 1 2 3 Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 27: ...dule WARNING Always disconnect line voltage before servicing electrical equipment Ensure there are no loose electrical connections at services intervals IMPORTANT Failure to carry out regular maintenance with a licensed and reputable refrigeration company may render warranty claims invalid if faults have been caused by lack of proper maintenance Air Change may request to see the maintenance schedu...

Page 28: ...s should be checked for tension on each maintenance visit with main switch off Clear coils of obstructions or dirt Clean condensate drain trays Annual Maintenance Repeat monthly and three monthly checks Apply grease into fan bearings through greasing points only applicable for pillow block bearings Connect service gauges and record operating pressures and mode Test the superheat setting by placing...

Page 29: ...sulation breakdown Replace faulty component Dirty loose contacts Clean tighten or replace Tripped circuit breaker Short Circuit Trace and correct Earth leakage or overheating cables due to high load Meggar and place as necessary Power fluctuations Contact electricity supplier Evaporator fan running but no cooling or heating Faulty condenser fan motor Check operation Controller SA temperature setpo...

Page 30: ...intenance Supply and exhaust air must be filtered to avoid particles entering the heat exchanger Sandwich Panel Data Skins CRP Colorbond 0 6 mm Australian Standard AS 2728 Category 2 and or 3 Substrate ZINCFORM G300 BFC Z275 1 Pretreatment Corrosion resistant proprietary conversion coating Primer Coat Universal corrosion inhibitive epoxy primer Nominal thickness 5 µm each side Finish Coat Custom f...

Page 31: ...d is a summary of your service documentation for easy reference for management in case of a warranty claim Your equipment is a major investment and will last for many years if properly maintained and serviced Air Change Australia Pty Ltd will only accept a completed warranty card issued in each manual see page 32 or a copy of the original invoice complete with matching serial numbers as proof of p...

Page 32: ...s of problem Print Name Signature Position AIR CHANGE OFFICE USE ONLY Service Agent M1 PO Technician Name Phone Warranty Claim Number WAN Approved Declined BY DATE Details of Approval Decline Parts List Send Date Invoice Receive Date Invoice Completion Date Date Client Informed Please remember to send Details of Servicing Report with this page if warranty is required Cooke Industries Phone 64 9 57...

Page 33: ...Installation and Maintenance Manual 33 Details of Servicing DATE CONTRACTOR SERVICING FIRM DETAILS Cooke Industries Phone 64 9 579 2185 Email sales cookeindustries co nz Web www cookeindustries co nz ...

Page 34: ... Purchaser provided that the Purchaser has complied with the conditions of warranty Warranty Conditions including those in clauses 5 and 6 3 3 The Warranty Period may be extended so that the 12 month period commences upon commissioning of the Product s provided that a the date of commissioning occurs within 3 months of delivery of the Product s and b a commissioning report which specifies the date...

Page 35: ...design stipulated by the Purchaser 6 Making a Warranty Claim 6 1 In order for a Purchaser to make a claim under the Parts Warranty or the Labour Warranty the Purchaser must provide to Air Change a a completed warranty card supplied with the installation or instruction manual provided with the Product s or a copy of the original invoice with matching serial numbers as proof of purchase and b full w...

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