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INSTALLATION

OPERATION AND SERVICE MANUAL

PCG – PS SERIES

4 PIPE HYDRONIC CASSETTE

AIR CONDITIONERS

2010 V.1.0

Содержание PCG-06

Страница 1: ...INSTALLATION OPERATION AND SERVICE MANUAL PCG PS SERIES 4 PIPE HYDRONIC CASSETTE AIR CONDITIONERS 2010 V 1 0 ...

Страница 2: ...The Highest Standards of Manufacturing In order to guarantee the very highest standards and performance we manage every stage in the manufacturing of our products Throughout the production process we maintain strict control originating with our extensive resources in research and development through to the design and manufacture of almost every individual component from molded plastics to the asse...

Страница 3: ...MOUNTING FRONT PANEL ASSEMBLY FILTER REMOVAL MAINTENANCE HOW TO ACCESS AIR VENT AND WATER PURGE HOW TO CONNECT NON DEFAULT FAN SPEED HOW TO FIX THE MOTOR AND FAN BLOWER HOW TO FIX CONDENSATE PUMP AND INTERNAL VALVE HOW TO FIX CONTROL BOX HOW TO INSTALL ELECTRIC HEATER 14 36 14 14 15 15 16 17 18 20 21 21 21 22 23 23 24 24 25 26 27 28 28 29 30 30 31 32 33 34 35 36 D EXPLODED DRAWINGS WITH PARTS DESC...

Страница 4: ...TTE 4 CASSETTE MODEL ASSIGNMENTS P C G 0 6 P S S 230V 1PH 50HZ P CHILLED HOT WATER 4 PIPE 06 NOMINAL 3 24 KW 08 NOMINAL 3 60 KW 09 NOMINAL 4 15 KW 12 NOMINAL 5 10 KW 16 NOMINAL 5 90 KW PCG HYDRONIC CASSETTE G SERIES ...

Страница 5: ...ing Current A 0 76 0 89 0 88 1 52 1 77 Operation Control Thermostat Remote Control Handset Wired Wall Pad Cooling Water Flow Rate L h 580 636 733 901 1043 Heating Water Flow Rate L h 354 380 571 617 677 Cooling Water Pressure Drop kPa 12 0 14 7 27 8 22 4 29 0 Heating Water Pressure Drop kPa 3 0 3 5 8 7 10 1 12 0 Cooling Water Content L 1 07 1 07 1 36 1 91 1 90 Heating Water Content L 0 49 0 49 0 8...

Страница 6: ...Ph Hz 230 1 50 Fan Motor Power W 58 66 100 116 132 Fan Motor Running Current A 0 26 0 29 0 44 0 52 0 58 Fan Motor Starting Current A 0 77 0 88 1 33 1 54 1 77 Operation Control Thermostat Remote Control Handset Wired Wall Pad Cooling Water Flow Rate L h 533 636 749 883 1057 Heating Water Flow Rate L h 342 380 571 598 678 Cooling Water Pressure Drop kPa 10 7 14 7 28 8 20 9 29 0 Heating Water Pressur...

Страница 7: ... 21 85 807 5 6 588 2 24 1 96 13 8 13 1 6 15 395 3 08 2 48 14 05 13 35 15 95 545 3 395 2 435 14 3 13 35 12 85 599 5 4 215 2 53 14 75 13 65 18 8 744 5 750 2 2 2 14 15 3 14 2 5 76 389 3 24 2 75 15 8 14 4 12 580 3 6 2 66 16 1 14 5 14 636 4 66 2 79 16 6 14 8 22 4 823 648 1 94 1 9 15 14 1 4 52 343 2 86 2 48 15 2 14 3 9 37 505 3 2 2 43 15 4 14 3 11 4 565 4 04 2 53 15 9 14 7 17 3 714 7 588 1 82 1 79 14 7 ...

Страница 8: ...Design and specification are subject to change without prior notice for product improvement PCG 09 PS TAI DB24 WB17 4 TAI DB27 WB19 TAI DB27 WB19 5 TAI DB28 WB21 Twi qa Pf Pfs Tad Taw dPw Qw Pf Pfs Tad Taw dPw Qw Pf Pfs Tad Taw dPw Qw Pf Pfs Tad Taw dPw Qw C m3 h kW kW C C kPa l h kW kW C C kPa l h kW kW C C kPa l h kW kW C C kPa l h 1098 4 5 3 21 15 4 13 5 32 795 5 9 4 08 16 1 13 5 52 3 1043 6 3 ...

Страница 9: ...bulb temperature Note Design and specification are subject to change without prior notice for product improvement PCG 16 PS TAI DB24 WB17 4 TAI DB27 WB19 TAI DB27 WB19 5 TAI DB28 WB21 Twi qa Pf Pfs Tad Taw dPw Qw Pf Pfs Tad Taw dPw Qw Pf Pfs Tad Taw dPw Qw Pf Pfs Tad Taw dPw Qw C m3 h kW kW C C kPa l h kW kW C C kPa l h kW kW C C kPa l h kW kW C C kPa l h 1650 6 4 4 15 5 13 2 28 9 1060 8 4 5 5 16 ...

Страница 10: ... by the values given in the following table Freezing point 0 5 10 15 20 25 Percentage of ethylene glycol in weight 0 12 20 28 35 40 cPf 1 0 985 0 98 0 974 0 97 0 965 cQ 1 1 02 1 04 1 075 1 11 1 14 cdp 1 1 07 1 11 1 18 1 22 1 24 cPf correction factor cooling capacity cQ correction factor flow rate cdp correction factor pressure drop ...

Страница 11: ...1 56 3 46 40 1 296 6 1 44 3 29 41 2 282 2 1 32 TAI Air in temperature Twi Fluid in temperature Pf Total heating capacity Qw Fluid flow rate in heat exchanger Tad Discharge air temperature Dpw Pressure drop standard coil Qa Air flow PCG 08 PS TAI 18 TAI 20 TAI 22 TAI 24 Twi Two qa Pf Tad Qw dPw Pf Tad Qw dPw Pf Tad Qw dPw Pf Tad Qw dPw C C m3 h kW C l h kPa kW C l h kPa kW C l h kPa kW C l h kPa 84...

Страница 12: ...9 5 5 27 44 9 528 8 5 5 61 45 5 467 7 5 TAI Air in temperature Twi Fluid in temperature Pf Total heating capacity Qw Fluid flow rate in heat exchanger Tad Discharge air temperature Dpw Pressure drop standard coil Qa Air flow PCG 12 PS TAI 18 TAI 20 TAI 22 TAI 24 Twi Two qa Pf Tad Qw dPw Pf Tad Qw dPw Pf Tad Qw dPw Pf Tad Qw dPw C C m3 h kW C l h kPa kW C l h kPa kW C l h kPa kW C l h kPa 1296 4 54...

Страница 13: ... 531 8 8 2 77 32 7 474 7 1650 5 12 27 3 439 6 2 4 7 28 5 402 5 3 4 24 29 7 363 4 4 3 78 30 9 324 3 5 1300 4 54 28 3 389 5 4 14 29 5 354 4 2 3 75 30 6 321 3 54 3 36 31 7 288 2 88 50 40 1100 3 86 29 7 330 3 7 3 53 30 8 302 6 3 2 3 21 31 8 275 2 7 2 89 32 8 247 4 2 2 1650 8 51 35 3 755 18 9 7 90 36 5 677 17 5 7 33 37 7 620 15 9 7 07 38 9 601 14 3 1300 7 42 37 2 681 15 2 6 95 38 4 627 13 9 6 81 39 4 5...

Страница 14: ...ure that the electrical supply and frequency are adequate for the operating current required for this specific installation WARNING Before any service or maintenance operations turn off the main power switch 1 The manufacturer denies any responsibility and warranty shall be void if these installation instructions are not observed 2 Never switch off the power main supply when unit is operating in t...

Страница 15: ...heck immediately for installation accessories inside the packaging 5 Do not lift unit by the condensate drain discharge pipe or by the water connections lift it by the four corners Fig 1 6 Check and note the unit serial number SELECT LOCATION 1 Do not install the unit in rooms where flammable gas or alkaline acid substances are present Aluminum copper coils and or internal plastic components can b...

Страница 16: ...cted and the conditioned air is able to blow all over the room 3 From where condensate can be easily run to drain 4 Check the distance between the upper slab and false ceiling to ensure the unit will suit the distance See Fig 4 A B Fig 5 5 Ensure there is sufficient space around the unit to service it See Fig 5 Model A mm B mm PCG 09 250 10 or more PCG 06 08 12 16 290 10 or more Fig 4 ...

Страница 17: ... the installation template open ceiling panels and install the suspension bolts as in Fig 6 below 600 x 600 Dimensions for opening 632 x 280 Suspension Bolts 600 x 1160 Dimensions for opening 750 x 632 Suspension Bolts FIG 6 MODELS PCG 06 08 MODELS PCG 09 12 16 ...

Страница 18: ...uts and washers to lock the unit in position The Cassette brackets will then hook over the washers 7 When lifting the Cassette into position care should be taken not to lift the unit by the drip tray which could be damaged 8 Lift unit without the air panel with care by its four corners only Do not lift unit by the condensate drain discharge pipe or by the piping connections 9 Incline unit Fig 10 F...

Страница 19: ...HYDRONIC CASSETTE 19 12 After connection of the condensate drain piping and piping connections check again that the unit is level MODEL PCG 06 08 A mm 3 Fig 10 Fig 11 Fig 12 ...

Страница 20: ...between the unit and ceiling can now be adjusted Use the drop rods to make the adjustment 14 Check to ensure the unit is level The drain will then automatically be lower than the rest of the drip tray 15 Tighten the nuts on the suspended rods Fig 13 Fig 14 Fig 15 ...

Страница 21: ...lated WATER CONNECTIONS The hydraulic connections of the PCG unit is 3 4 water connection with gaskets it is advisable to tighten the gaskets with a spanner For piping dimensional drawing please refer to DIMENSIONAL DRAWINGS VALVE CONFIGURATION There are two types of valve configuration for PCG cassette a Internal integrated valve and b external valve a Pre installed 2 way and 3 way integrated val...

Страница 22: ...egrated valve using spanner 2 Replace with plug and play connector Fig 18 3 Connect the external valve directly onto the cassette ii Disable integrated valve functionality using valve cap Procedures 1 Remove integrated valve actuator by pressing on both sides Fig 19 2 Place the valve cap onto the valve body Fig 20 3 Connect the external valve directly onto the cassette Fig 18 Fig 19 Fig 20 ...

Страница 23: ... connecting pipe with insulation to prevent leakage to ceiling tile FRESH AIR RENEWAL CONNECTION The fresh air system for PCG cassette allows up to 15 of unit airflow as fresh air intake per connection Maximum 2 fresh air connections per unit 1 The corners of the cassette allow separate ductwork to be installed for outside air intake Fig 23 2 Cut and remove anti condensate insulating material 3 Op...

Страница 24: ... condensate insulating material Install your flanges and conduits to casing Conduit can be flexible polyester with spring core or corrugated aluminium externally coated dia 4 in with anti condensate material fiberglass 12 25 mm thickness Order flanges spigots and blanking plates as accessories separately BRANCH DUCT DIMENSION Fig 24 Fig 25 Fig 26 ...

Страница 25: ...e casing for location of branch duct or fresh air intake connections 2 The sticker is at the center of a knock out hole underneath the casing insulation Use a cutter and follow along the pre cut circular marking as shown and trim off the insulation 3 Knock out the pre cut hole 4 Connect the flange on to the opening with Φ3 mm x 12 mm tapping screws ...

Страница 26: ...aves exist use shielded sensor cable 5 Install a noise filter if any harmful noise exists in the power supply Important note Please ensure the cable of the main powers supply will be 500mm long from the control box terminal block This is to ensure the control box can be slide out easily during maintenance activities Wiring procedures 1 Open the terminal block cover by removing 4 screws 2 Connect L...

Страница 27: ...e refer to Appendix I DIP Switch A SW1 SW6 is used for master slave address setting DIP switch address setting 1 for ON 0 for OFF SW7 SW8 Model setting 0 0 Cool Heat 0 1 Cool Heat booster heater 1 0 Cooling only 1 1 Cool primary heater DIP Switch B is used for model configuration as follow DIP switch setting 1 for ON 0 for OFF SW1 PR O contact setting 0 Economy contact 1 Window contact SW2 System ...

Страница 28: ... panel 2 Move the front panel to casing 3 Tighten 4 screws as shown in Fig 28 29 FILTER REMOVAL 1 Unlock the two fasteners on the front panel 2 Open the grille downward with care 3 Pull the filter out along the slot 4 Clean the filter and reassemble PCG 06 08 PCG 09 12 16 Fig 28 Fig 29 ...

Страница 29: ...e and current values correspond with the unit nameplate values check electrical connections 9 Verify that air outlets are not closed MAINTENANCE 1 Before performing any service or maintenance operations turn off the main power switch 2 The air filter is made of acrylic fiber and is washable in water To remove filter simply open the intake grille by releasing the two catches See Fig 19 and the sect...

Страница 30: ...s HOW TO CONNECT NON DEFAULT FAN SPEED 1st STEP remove the grill 2nd STEP remove the finger guard by removing 4 screws 3rd STEP remove the finger guard and venturi 4th STEP Fan speed terminal is located in the area inside the red rectangle 1st STEP remove the grill air vent and water purge are located at the pointed area ...

Страница 31: ...HYDRONIC CASSETTE 31 5th STEP change the fan speed wiring according to below wiring diagram ...

Страница 32: ...ER 1st STEP remove the grill 2nd STEP remove the finger guard by removing 4 screws 3rd STEP remove the finger guard and Venturi 4th STEP remove fan blower using a spanner 5th STEP remove the motor by removing 4 bolts and disconnect fan motor wire connector ...

Страница 33: ...2nd STEP remove the front panel by removing 4 screws 3rd STEP remove the front panel by disconnecting stepping motor and IR receiver 4th STEP removing the drain pan fixture by removing 8 screws 5th STEP remove the drain pan fixture and internal drain pan 6th STEP remove the drain pump or valve ...

Страница 34: ...removing 4 screws 3rd STEP remove the front panel by disconnecting stepping motor and IR receiver 4th STEP remove 2 screws on the control box 5th STEP sliding out the control box 6th STEP Remove the terminal cover by removing 4 screws and unplug the wiring on the terminal And replace with a new control box ...

Страница 35: ...ng 4 screws 3rd STEP remove the front panel by disconnecting stepping motor and IR receiver 4th STEP remove the drain pan fixture by removing 8 screws 5th STEP remove internal drain pan fixture and internal drain pan 6th STEP slide in the insulated ring of the electric heater to the electric heater mounting shown above ...

Страница 36: ...YDRONIC CASSETTE 36 7th STEP slide in the rest insulated rings of the electric heater to the electric heater mounting shown above 8th STEP Plug in the electric heater wiring to the connector shown above ...

Страница 37: ...ptional 05 02 float switch 11 fan blower 05 03 flexible hose 1 12 drain pan with 3mm insulation 05 04 non return valve 13 drain pan fixture 05 05 flexible hose 2 14 finger guard 05 06 drainage head 15 Venturi 05 07 pump fixture 16 returned air grill 06 coil 17 filter 07 coil and EH s fixture 18 front panel 08 control system 18 01 stepping motor 2 corotation 08 01 back of control box 18 02 stepping...

Страница 38: ...5 02 float switch 11 fan blower 05 03 flexible hose 1 12 drain pan with 3mm insulation 05 04 non return valve 13 drain pan fixture 05 05 flexible hose 2 14 finger guard 05 06 drainage head 15 Venturi 05 07 pump fixture 16 returned air grill 06 coil 17 filter 07 coil and EH s fixture 18 front panel 08 control system 18 01 stepping motor 2 corotation 08 01 back of control box 18 02 stepping motor 2 ...

Страница 39: ...HYDRONIC CASSETTE 39 DIMENSIONAL DRAWINGS PCG 06 08 PS ...

Страница 40: ...HYDRONIC CASSETTE 40 PCG 09 PS ...

Страница 41: ...HYDRONIC CASSETTE 41 PCG 12 16 PS ...

Страница 42: ...HYDRONIC CASSETTE 42 VALVE INFORMATION ...

Страница 43: ...HYDRONIC CASSETTE 43 ...

Страница 44: ...HYDRONIC CASSETTE 44 REMOTE CONTROL HANDSET WIRELESS LCD HANDSET DISPLAY ...

Страница 45: ...HYDRONIC CASSETTE 45 When unit with handset is master settings are automatically sent to slaves Auto Cool Heat operation will be applicable in 4 pipe system only Swing is not applicable to PCG models ...

Страница 46: ... whether it is 2 pipes or 4 pipes Auto Cool Heat operation will be applicable in 4 pipe system only When the wall pad is connected to the main board air sensor inside the wall pad will be automatically set as primary source and the return air sensor from the unit will be disabled ...

Страница 47: ...CANCEL key to cancel the current on timer selected and the timer display area will show Press DAY button to change the day the on timer is to be programmed b Press TIMER button again and OFF symbol blinking indicates off timer programming mode The setting method is the same as on timer setting above c Press TIMER button again to exit timer on off setting function d Should there be any on or off ti...

Страница 48: ... to all slave units Clock synchronization by master unit is as follows 1 Press TIME and TIME buttons for 3 seconds to activate clock synchronization to all slave units Master wall pad will respond with a beeping sound 4 Key lock In order to prevent unauthorized access to the system setting a key lock function is provided to prevent mischief Hold down and for 3 seconds to activate key lock symbol l...

Страница 49: ...owsing mode Unit display area shows the slave unit under browsing Slave unit selection method is the same as in networking control above Press HUMIDIFY or HUMIDIFY to browse various parameters as follow Wall pad display temperature area Wall pad display time area C0 Return air temperature displayed C1 Indoor coil temperature displayed C2 DIP switch setting displayed C3 Indoor coil 2 temperature Pr...

Страница 50: ...lly open If the contact has been closed for 10 minutes the unit will go to stand by mode all output signals will be disabled When the contact is open again the unit will resume running normally DIP SWITCH IS OFF Economy contact Cooling operation will only be activated when Tr Ts 4 ºC If Tr Ts cool operation will be terminated Heating operation will only be activated when Tr Ts 4 ºC If Tr Ts heatin...

Страница 51: ...e COOL MODE 1 MTV2 AUX1 and heater always off 2 If Tr Ts 1ºC or 4 ºC if economy contact is activated cool operation is activated MTV1 and AUX2 are turned on Indoor fan runs at set speed 3 If Tr Ts cool operation is terminated MTV1 and AUX2 are turned off Indoor fan runs at set speed 4 The range of Ts is 16 30 ºC 5 Indoor fan speed can be adjusted for low medium high and auto 6 When turned on MTV1 ...

Страница 52: ... 30 seconds before it is turned on 8 MTV2 will delay for 120 seconds before it is turned off iii PRE HEAT WITHOUT ELECTRICAL HEATER 1 If Ti1 36 ºC or 28C depends on DIP setting when MTV2 and AUX1 are on indoor fan remains off 2 If Ti1 38 ºC or30C depends on DIP setting when MTV2 and AUX1 are on indoor fan runs at set speed 3 If indoor coil temperature sensor is damaged pre heat time is set for 2 m...

Страница 53: ... has stop 10 min 2 If current running mode is auto heat mode it will change over to auto cool mode upon satisfy all the conditions below Tr Ts 1 0 C or 4 ºC if economy contact is activated MTV2 has stop 10 min Note Auto cool or auto heat operation are the same as cool or heat mode respectively SLEEP MODE a Sleep mode can only be set in cool or heat modes only b In cool mode after sleep mode is set...

Страница 54: ...stop at the desired position Louver angle 0 100 º opens clockwise with largest angle at 100 º Swing angle 35 100 º opens clockwise to 68º Below are the 4 fixed positions which can be set from wireless LCD handset Position Angle 1 35 º 2 57 º 3 83 º 4 100 º For wired wall pad Louver angle 0 100 º opens clockwise and with biggest angle at 100 º Swing angle 35 100 º opens clockwise to 68º User may st...

Страница 55: ...rmostat cut out During mode change from cooling to non cooling mode water pump will on for minimum 5 minutes Warning If turn off the system by circuit breaker or main power supply the drain pump does not work after turn off FLOAT SWITCH Float switch open before turning on If float switch N C is opened before the unit is turned on MTV1 is off Drain pump and indoor fan will operate After float switc...

Страница 56: ...sec Unit 17 failure Blink 17 times stop 3 sec Unit 18 failure Blink 18 times stop 3 sec Unit 19 failure Blink 19 times stop 3 sec Unit 20 failure Blink 20 times stop 3 sec Unit 21 failure Blink 21 times stop 3 sec Unit 22 failure Blink 22 times stop 3 sec Unit 23 failure Blink 23 times stop 3 sec Unit 24 failure Blink 24 times stop 3 sec Unit 25 failure Blink 25 times stop 3 sec Unit 26 failure Bl...

Страница 57: ... all units Red LED light on the unit High speed Red LED On Medial speed Yellow LED On Low speed Green LED On For all units Green LED light on the unit Electrical heater failure Blink 1times stop 3 sec Return air sensor failure Blink 3 times stop 3 sec Indoor coil sensor 1 failure Blink 4 times stop 3 sec Indoor coil low temperature protection Blink 5 times stop 3 sec Indoor coil over heat protecti...

Страница 58: ...6 14 69 15 05 15 41 17 79 8 83 17 86 64 17 14 03 14 37 14 7 16 75 39 78 53 81 76 18 13 41 13 72 14 03 15 71 26 74 18 77 19 19 12 81 13 1 13 4 14 67 37 70 1 72 9 20 12 24 12 52 12 79 13 63 73 66 26 68 88 21 11 7 11 96 12 22 12 60 3 62 67 65 1 22 11 19 11 43 11 67 11 57 08 59 28 61 55 23 10 71 10 93 11 15 10 54 05 56 1 58 22 24 10 24 10 45 10 66 9 51 19 53 12 55 08 25 9 8 10 10 2 8 48 51 50 3 52 14 ...

Страница 59: ...2 3 225 3 326 3 43 89 0 8998 0 9401 0 9818 53 3 105 3 204 3 305 90 0 8721 0 9115 0 9522 54 2 99 3 086 3 185 91 0 8455 0 8839 0 9237 55 2 88 2 974 3 07 92 0 8198 0 8573 0 8961 56 2 774 2 866 2 959 93 0 795 0 8316 0 8696 57 2 673 2 762 2 854 94 0 7711 0 8069 0 8439 58 2 576 2 663 2 752 95 0 748 0 783 0 8192 59 2 483 2 568 2 655 96 0 7258 0 7599 0 7953 60 2 394 2 477 2 562 97 0 7043 0 7376 0 7722 61 ...

Страница 60: ...HYDRONIC CASSETTE 60 CONTROL AND POWER SUPPLY WIRING DIAGRAMS ...

Страница 61: ...HYDRONIC CASSETTE 61 MASTER SLAVE CONTROL WIRING DIAGRAM ...

Страница 62: ...heck for presence of voltage Place in the ON position Check the room control Check fan motor Filter clogged Air flow obstructed Room control regulation Incorrect water temperature Air present Insufficient output Clean the filter Remove obstacles Check Check Vent Contact between metal parts Loose screws Noise and vibrations Check Tighten screws ...

Страница 63: ... HANDSET AS MASTER CONTROL UNIT a Connect all the units PCBs according to the wire color and type of connector b Select the master unit by closing the SW6 DIP switch on the main PCB c Ensure the SW6 DIP switch in the PCB of the slave unit is opened d Switch on the units by connecting the main power supply e Using handset set the operation parameters for the Master unit which will automatically sen...

Страница 64: ... communication Master will broadcast the settings to all slave units During normal operation slave units can receive commands from its wireless handset and wall pad control panel Upon reception of master global commands all slave unit settings will be replaced by the master settings Addressable communication Master controller must be LCD wall pad Slave unit parameters are set as usual Upon receivi...

Страница 65: ... Slave 1 0 0 1 1 20 Slave 1 0 1 0 0 21 Slave 1 0 1 0 1 22 Slave 1 0 1 1 0 23 Slave 1 0 1 1 1 24 Slave 1 1 0 0 0 25 Slave 1 1 0 0 1 26 Slave 1 1 0 1 0 27 Slave 1 1 0 1 1 28 Slave 1 1 1 0 0 29 Slave 1 1 1 0 1 30 Slave 1 1 1 1 0 31 Slave 1 1 1 1 1 32 Slave ...

Страница 66: ...HYDRONIC CASSETTE 66 ...

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Содержание PCG-06

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