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CH APTER 4: PO W

ER

DI STRI BU TI ON

A/C U N IT ( AIR IN N OVATION S)
OVER VIEW

O utput M odul e

Condensor

Evaparator

Fi gure 4-16

A/C U ni t( Ai rI nnovati ons)

The Ai rI nnovati ons H VAC uni t( P/N 2603-0006)i s a heati ng and ai r-condi ti oni ng system that i s desi gned to m ai nt ai n the ai r tem perature and hum i di ty w i thi n the x-ray generati ng envi ronm ent. The Ai rI nnovati ons H VAC uni ti s a cl osed l oop system ,m eani ng that al lthe ai r suppl i ed to the uni ti s then returned f or recondi ti oni ng.Thi sm i ni mi zes the heat l oad on the H VAC system and al so mi ni mi zes cont am i nati on ofthe el ectroni cs by dustand parti cul ates f rom the am bi entai r .Thi s cl osed ai rl oop passes through a fi l ter l ocated i n the H VAC uni tw i th each pass.The H VAC system i si ntended to operate conti nuousl y,even w hen the CTX 9000 D Sii si ni dl e or of fm ode. NO T E : Although all supporting documentation on the Air Innovations A/C unit indicates a measured voltage of350 VD C,the actual measured voltage is 330 VD C.

CTX 9000 D SiTrai ni ng M anual 66 of378

GE I nV i si on,I nc.Com pany Confi denti al M arch 10,2005

CHAPTER 4: POWER DISTRIBUTION

DESCRIPTION
The HVAC system has two separate refrigeration circuits (situated in series with respect to each other), which allows for greater load shedding when 50% or less of the total cooling power is required (i.e. days when ambient temperatures are approximately 70 °F and below). In addition, the two separate refrigeration circuits provide a level of redundancy if one of the circuits should fail. NOTE: At temperatures above 70 °F, both circuits are required to maintain setpoint.

Environm entalSpecifications:The system is designed to operate in environments ranging from 15 °F to 120 °F and with either 60 Hz or 50 Hz power supplies. NOTE: Even w hen the A/C unit is optimally functional, there is no guaranteed temperature setpoint. Indeed, system limits are determined by the follow ing factors:ambient temperature, humidity and pow er specifications ( i.e. w hether the system is operating at 50 H z or 60 H z) .

Tem perature Control :Temperature control is achieved by modulating an electronic EPR (Evaporator Pressure, Regulating) valve installed on circuit #1 (the primary circuit). Circuit #2 operates in an ON/OFF mode controlled by the controller. The controller uses its alarm contacts to turn each compressor on or off. NOTE: If the ambient temperature is very low , the unit may sw itch over to a heating mode. Should this occur, both compressors are automatically “locked” out of operation and the heater is pulsed to maintain setpoint.

System Indicators:The LEDs and Digital Temperature Controller, mounted on the front of the electric panel, will indicate system status and any faults while the system is powered (even if the ON/OFF switch is turned to OFF). NOTE: The LEDs and Digital Temperature Controller can only be shut dow n via the main pow er breaker located on the front of the electric panel.

GE InVision, Inc. Company Confidential March 10, 2005

CTX 9000 DSi Training Manual 67 of 378

CHAPTER 4: POWER DISTRIBUTION

COM PONENTS

Figure 4-17

A/C Unit (Air Innovations)

The system is physically comprised of three separate main assemblies and one sub-assembly (see Figure 4-17):

Evaporator (for more information, see “Evaporator” on page 68.) Condenser (for more information, see “Condenser” on page 69.) Electric Panel (for more information, see “Electrical Panel” on page 71.) Drain Tube Assembly (for more information, see “Drain Tube Assembly” on page 75.)

Each of these components is installed individually in the CTX 9000 DSi and then connected together with quick connects for refrigerant piping and electrical connections.

EVAPORATOR
Main Components:

Evaporator fan (draw-thru impeller). Evaporator coil (divided into two circuits in series).

CTX 9000 DSi Training Manual 68 of 378

GE InVision, Inc. Company Confidential March 10, 2005

92% on ASHRAE Standard 52-76. Two filter driers. It then flows through the rows dedicated to circuit #2 and then those rows dedicated to circuit #1. Return air first passes through the pre-filter and then enters the evaporator coil. CONDENSER Main Components: Two condenser fans. Four flexible refrigerant hoses for connection to condenser section. Two openings in the evaporator provide for return air and supply air connections to the baffle plate. Two TXV valves. After leaving the evaporator coil. Once the return air has left the fan. The filter media is high density glass micro fibers laminated to an all glass woven mesh backing. medium efficiency pleated type U. safeties and power to electrical panel. Two sight glasses. Two condenser coils. Electrical harness for connecting sensors. the air passes over the temperature sensor and then out the supply air opening.CHAPTER 4: POWER DISTRIBUTION Pre-filter. The average efficiency is 25 . Two compressors. NOTE: The evaporator filter is a 14" x 16" x 1". Two combination High/Low pressure switches. Three electric heater elements. Class 2 filter. Inc. Temperature sensor in supply air stream. 2005 CTX 9000 DSi Training Manual 69 of 378 .L.30% with an arrestance of 90 . Two air proving switches for filter monitoring and fan safety. GE InVision. Company Confidential March 10. EPR valve (circuit #1). the air passes over the electric heater elements and then through the fan.

Ambient air is drawn into the A/C unit through the evaporator’ s louvered covers found on both sides of the Input module. Compressors are turned on and off based on the inputs from the controller.CHAPTER 4: POWER DISTRIBUTION Figure 4-18 Pressure Switches Two push button high pressure switches for alarm indication. Two refrigerant receivers (welded on top of each other). Two head pressure control valves. NOTE: The evaporator section is “pie” shaped to provide air paths to these coils. Each compressor is dedicated to one circuit. CTX 9000 DSi Training Manual 70 of 378 GE InVision. Company Confidential March 10. Inc. circuit #2 comes on for additional cooling capacity. Q uench valve (circuit #1). Hot condenser air exits the unit via the louvers installed in the base section on the condenser side. Circuit #1 comes on first (and only as required) to maintain setpoint and. A replaceable mesh filter in installed in each louvered cover. NOTE: The nominal capacity of each circuit is 2 tons. Circuit #1 exhausts on the left side and circuit #2 on the right side. The ambient air is drawn through the condenser coils and is then exhausted from the A/C unit through louvered deflector covers on both sides of the Input module. 2005 . if necessary. Electrical harness for connecting sensors. safeties and power to electrical panel.

CHAPTER 4: POWER DISTRIBUTION ELECTRICAL PANEL Figure 4-19 Main Components: Electric Panel Temperature controller. GE InVision. Inc. All LED indicators. Company Confidential March 10. 2005 CTX 9000 DSi Training Manual 71 of 378 .

All switches. Figure 4-21 Breakers All relays. Siemens “LOGO” for discreet controls.CHAPTER 4: POWER DISTRIBUTION Figure 4-20 Temperature Controller and Control LEDs All breakers. CTX 9000 DSi Training Manual 72 of 378 GE InVision. Company Confidential March 10. 2005 . Inc.

Inc. Company Confidential March 10.CHAPTER 4: POWER DISTRIBUTION Figure 4-22 Siemens LOGO Quad I/O.4K-NA Variable Frequency Drive (VFD) to control the evaporator fan. Figure 4-23 Quad I/O (Air Innovations Air Conditioner) Mitsubishi FR-S540-0. 2005 CTX 9000 DSi Training Manual 73 of 378 . GE InVision.

Figure 4-25 Controller Cables CTX 9000 DSi Training Manual 74 of 378 GE InVision.4K-NA Variable Frequency Drive (VFD) Cables for connecting to evaporator and condenser sections (quad I/O cable for connecting the A/C unit to the CTX 9000 DSi main computer). 2005 .CHAPTER 4: POWER DISTRIBUTION Figure 4-24 Mitsubishi FR-S540-0. Company Confidential March 10. Inc.

The supply air setpoint to achieve these ranges is 60 °F (with an allowable control range of +/. GE InVision. Kazoo assembly. the A/C unit will continue to operate until manually shut down (if so desired). Company Confidential March 10. an alarm signal is sent to the quad I/O. DRAIN TUB E ASSEMB LY Main Components: Pre-formed PVC piping. The kazoo allows the system to be self-priming.10 °F). Inc. meaning that condensate will flow properly even if the unit runs with no water in the trap. When the supply air temperature is above 70 °F. OPERATING RANG ES The HVAC system is designed to operate continuously across a wide variety of ambient environments. Figure 4-26 Drain Tube Assembly The drain assembly removes the condensate from the evaporator coil and is connected to an external drain or condensate pump. 2005 CTX 9000 DSi Training Manual 75 of 378 . Nonetheless.CHAPTER 4: POWER DISTRIBUTION The electrical panel controls all functions of the HVAC system as well as provides power and electrical circuit protection to all components.

Inc.2000 W Solid Rod Type Evaporator Coil Fans Filter Controller CTX 9000 DSi Training Manual 76 of 378 GE InVision. Company Confidential March 10. 2005 . Holly Gold (or equivalent) 6 Row (Circuited 3 and 3 in a Series) Copper Tubes Aluminum fins Coated with Mt.0" wg External Maximum Pressure Circuit #1 = 2 tons Circuit #2 = 2 tons 3 . Holly Gold (or equivalent) Direct Drive— Motorized Impellers 30/30 Filter on Evaporator Inlet Digital PID Controller Performance Supply Air Volume Nominal Capacity Electrical Heating Coils 800 CFM @ 1. Painted Galvanized and Aluminum Components Galvanized and Stainless Steel Stainless Steel Metric Fasteners Gravity Drain 5 Row Copper Tubes Aluminum fins Coated with Mt.CHAPTER 4: POWER DISTRIBUTION Ambient Dry Bulb Maximum 120 °F 105 °F Ambient Relative H umidity @ Maximum °F 50% RH 50% RH Ambient Temp Minimum 14 °F 14 °F Supply Air Temp Minimum/ Maximum 50 / 70 °F 50 / 70 °F Pow er Supply 480 VAC— 3 PHASE / 60 Hz 380 VAC— 3 PHASE / 50 Hz S YSTEM SPECIF ICATIONS System Specifications Construction Weight Construction— External Construction— Internal Hardware Condensate Drain Condenser Coils 500 lbs.

2 no. 55014-1.CHAPTER 4: POWER DISTRIBUTION System Specifications Refrigerant Noise (maximum) Supply Voltage Amperage R-134a 85 dB A-weighted 480 / 3Ø / 60 Hz VAC or 380 / 3Ø / 50 Hz VAC 11. “Normal Running Sequence” on page 78. 61000-3-3.4 FLA @ 480V / 60Hz Status LED Indicators Control Circuit Circuit #1 Cooling Circuit #2 Cooling Heater Evaporator Filter Replacement Circuit #1 Low Pressure Circuit #2 Low Pressure Circuit #1 High Pressure Circuit #2 High Pressure Green Green Green Yellow Red Red Red Red Red Agency Approvals North America European Union (CE / LVD EMC) UL recognized to UL1995 / C22. Inc. 2005 CTX 9000 DSi Training Manual 77 of 378 . “PID Control Functions” on page 80. GE InVision. Company Confidential March 10. 61000-3-2. 60335-2-24. “Cooling Control Logic” on page 79. 236 EN60335-1. “Heating Control Logic” on page 80. 55014-2 THEORY OF OPERATION The following topics are reviewed in this section: “Startup Sequence” on page 78.

5 °F).CHAPTER 4: POWER DISTRIBUTION STARTUP SEQ UENCE TEMP > AL1 1 Mi nut e Ci r c ui t#1 " ON" TEMP > AL2 2 Mi nut es Ci r c ui t#2 " ON" ON/ OFF Swi t c h " ON" Ev ap Fan " ON" TEMP > AH1 & TEMP < AL1 Ot her " No ac t i on" TEMP < AH1 Heat er " ON" Figure 4-27 Startup Sequence Legend TEMP—Temperature reading of the RKC controller. Inc. AH2—Alarm #2 Hysteresis (differential gap) compressor #2 (Shut off point is 57.0 °F). 2005 . AL1—Alarm Setting for circuit #1 (62. Company Confidential March 10. CTX 9000 DSi Training Manual 78 of 378 GE InVision. AH1—Alarm #1 Hysteresis (differential gap) compressor #1 (Shut off point is 55.5 °F). AL2—Alarm Setting for circuit #2 (65. NORMAL RUNNING SEQ UENCE TEMP > AL1 I fc ompr es s orhasbeen of f f or1 mi nut e Ci r c ui t#1 " ON" TEMP > AL2 I f c ompr es s orhas been of ff or2 mi nut es Ci r c ui t#2 " ON" Ev ap Fan " Runni ng" TEMP > AH1 & TEMP < AL1 Ot her " No ac t i on" TEMP < AH1 Heat er " ON" Figure 4-28 Normal Running Sequence Legend TEMP—Temperature reading of the RKC controller.0 °F).

Inc.0 °F). circuit #1 will shut off. The cooling system will control at or about the setpoint of 60 °F. When the temperature rises to 62. NOTE: Should the one evaporator fan fail.5 °F). AL2—Alarm Setting for circuit #2 (65.20mA) from the temperature controller. When the supply air temperature is at or below 60 °F. Receiving control signals (5. The electronic evaporator pressure regulator allows the A/C unit to match the heat load requirements of the CTX 9000 DSi. When the temperature drops to 55 °F.5 . COOLING CONTROL LOGIC Consisting of two 2 ton circuits. There is a one minute time delay for circuit #1 and a two minute time delay for circuit #2.5 °F). NOTE: This valve also modulates while circuit #2 is running. Circuit #2 does not have capacity control. the ambient temperature as well as any leakage air that may be present. Electronic Evaporator Pressure Regulator—The electronic evaporator pressure regulator (capacity control valve—Sporlan CDS-9) is a stepper motor controlled valve. the compressors will start once the alarm has been activated. the system cannot operate. GE InVision. 2005 CTX 9000 DSi Training Manual 79 of 378 .5 °F. the electronic evaporator pressure regulator reduces or increases the amount of suction return gas to compressor circuit #1. As long as circuit #1 has been off for one minute and circuit #2 has been off for two minutes. Cooling Control System Operation: NOTE: The timers start timing when the compressor has been shut down.5 °F. Circuit Specifications: Circuit #1 has a capacity control valve that will allow the circuit to throttle back should the entire 2 or 4 tons not be necessary. the cooling control system is a redundant system so that in the event that one of the circuits fails. AH2—Alarm #2 Hysteresis (differential gap) compressor #2 (Shut off point is 57.0 °F). the valve will begin to close which will reduce the capacity of circuit #1.CHAPTER 4: POWER DISTRIBUTION AL1—Alarm Setting for circuit #1 (62. circuit #2 will shut off. alarm #2 of the controller will close and start circuit #2.it provides a full 2 tons of capacity. alarm # 1 of the temperature controller will close and start compressor circuit #1. When the temperature drops to 57. AH1—Alarm #1 Hysteresis (differential gap) compressor #1 (Shut off point is 55. Company Confidential March 10. the other circuit can act as a backup. Should the temperature continue to rise to 65 °F.

and visa versa. derivative) on/off DCV control signal which is applied to the 2 Solid State Relays (SSRs). NOTE: The control signal and high voltage circuit are optically isolated from each other.5 °F. the heater will be energized. NOTE: PID CONTROL FUNCTIONS Proportional Band (P) The proportional band parameter regulates the effect of the proportional action. see “PID Control Functions” on page 80. Inc. For more information. When the control signal is removed. see “PID Control Functions” on page 80. A small proportional band value will (with a small deviation in input) cause a large change in output. compressor circuit #1 will come on and automatically disable the heater output circuit.CHAPTER 4: POWER DISTRIBUTION Finally. Company Confidential March 10. The output is proportional to the amount of deviation between the temperature and the setpoint and also the rate at which the temperature is either rising or falling and the PID settings programmed into the controller. If the temperature is below 60 °F. The amount of on and off time is regulated by: The amount of deviation between the temperature and the setpoint. and neither compressor is running. the temperature controller provides a current (5. If the temperature rises to 62. the high voltage (AC) is allowed to pass through to the heater elements. This setting causes the output to change continuously in proportion to the input deviation magnitude.5 . The rate at which the temperature is either rising or falling. CTX 9000 DSi Training Manual 80 of 378 GE InVision. When the control signal is applied to the SSRs. A small proportional band setting will cause control fluctuations or oscillations.20mA) PID control output to allow the valve to precisely position itself. The controller outputs a time-proportioned PID (proportional. 2005 . For more information. integral. The cycle time and PID settings programmed into the controller. the SSRs drop out. HEATING CONTROL LOGIC The heating control system is designed to bring the system up to temperature before the CTX 9000 DSi system is started. Heating Control System Operation: The heating control system will control at or about the setpoint of 60 °F. The three 2 kW heaters (Output #1) are controlled by the RKC temperature controller.

keep the following in mind: NOTE: Normal offset cannot be corrected by a proportional band change. The smaller the value. Company Confidential March 10. However. adj ust for larger numeric values rather than smaller ones. such oscillations will have a longer period than those caused by a small proportional band. the small the offset. If cycling or oscillating occurs. When manually setting the derivative time. an ON/OFF control will result. As a rule. the faster the output changes. The smaller or shorter the integral time. will cause output to oscillate. As a rule. adj ust from larger numeric values to smaller ones. the stronger the corrective action. These oscillations are likely to go above and below setpoint with a long period. The longer the derivative time. GE InVision. Oscillations will likely go above and below setpoint. or of input that fluctuates rapidly. 2005 CTX 9000 DSi Training Manual 81 of 378 . If the proportional band value is set to zero. Integral Time (I) Integral time (I) can be defined as the time required to develop an output change due to integral action that is equal to the change due to proportional action. set the derivative to zero. As a rule. like lowering the proportional band setting. These oscillations will be much smaller than those caused by the proportional band or integral time and are unlikely to cross the setpoint. Shortening the integral time. Inc. When manually setting the proportional band. keep the following in mind: Derivative Time (D) The derivative action is the action that changes the output in proportion to the deviation derivative or rate of change. keep the following in mind. For control of fast-response input such as flow and pressure. The integral time (I) will automatically diminish the offset or normal deviation (offset) that cannot be prevented by adj usting the proportional band. If the derivative is too large. and visa versa. long-period oscillations will result. If the integral time is too small. The integral time will continuously increase or decrease the output in proportion to the time integral of the deviation from setpoint. adj ust from smaller numeric values to larger ones. and the more likely it is that oscillations will occur.CHAPTER 4: POWER DISTRIBUTION A large proportional band setting will cause a control offset. the value is too small. The derivative is OFF when set to zero. When manually setting the integral time. very short-period oscillations will result. Just as the proportional and integral action cause the controlled obj ect to approach the setpoint. the derivative time (D) slows this approach to prevent over-shoot. but will instead fluctuate above or below it.

OPERATING PROCEDURES Uncrating the A/C Unit The evaporator. Inspecting the A/C Unit 1. When cooling output LED (Output 5) on the front of the controller is illuminated. full capacity) is 20 mA and is automatic. Inc. see “PID Control Functions” on page 80. Check for any concealed irregularities by removing all access panels.5 mA output so that the valve will not close completely. 1. Ensure that no components inside the A/C unit shifted due to extreme force during shipping. 3. Rotate the three A/C fans to be sure that they spin freely. Company Confidential March 10. For more information. 7. Each section is banded to its skid—no screws or bolts are used to mount the sections.) Its maximum output (fully open.CHAPTER 4: POWER DISTRIBUTION EVAPORATOR COIL CAPACITY CONTROL The electronic evaporator pressure regulator (capacity control valve—Sporlan CDS-9) is a stepper motor controlled valve. This valve controls the evaporator coil capacity from the RKC controller. Check for loose hardware. 6. 4. inspect for any visible damage that may have occurred during shipping. Report any damage to the carrier and file a written damage claim. Check the compressor(s) mounts to be sure they are securely attached. CTX 9000 DSi Training Manual 82 of 378 GE InVision. To remove the units from their containers. The output to the valve is based on the difference between the process value (supply air temperature) and the setpoint. 3. A heavy tri-wall cardboard covering is installed over each section which is then banded to a skid. condenser and control box are all shipped on separate skids. PRESSURE TEST POINTS Pressure test points (shrader valves) for a manifold gauge set are located at the end of the compressor/condenser section (on the side of the CTX 9000 DSi opposite the control box). Discard the banding and cardboard. It is a PID controlled output (PID2) and no adjustment or calibration of this valve is required. Confirm with the site personnel on where to store or dispose of the A/C unit skids. the valve is active. 2. 2. (4 mA would close the valve completely. The controller applies a minimum of 5. 2005 . cut the banding and remove the cardboard. After uncrating the three sections of the A/C unit. 5.

To secure the condenser section to its mounting rails. Installing the A/C Unit The CTX 9000 DSi HVAC system consists of 4 individually shipped components: the evaporator section. ensure that the compressor(s) mounting are secure. control (electronic) box and condensate drain assembly. Before proceeding. condenser section. 8.CHAPTER 4: POWER DISTRIBUTION NOTE: While shaking the compressor back and forth. 13. 6. 2005 CTX 9000 DSi Training Manual 83 of 378 . To install the condensate drain assembly. NOTE: The mounting holes on the condenser section will be somewhat difficult to reach due to obstructions. 11. 3. To secure the evaporator section to the mounting rails. ensure that all bolts have been tightened. 5. 9. LED' s etc. Inc. 4. install one bolt on the side toward the control box and two bolts on the opposite side. Attach the tubing to the right side of the kazoo-mounting bracket. it is highly unlikely that any of these will come apart. This tubing section runs over to the left end of the CTX 9000 DSi where it is attached to the drain nipple. controller. EMI filter. only one bolt can be installed on each side. Check the interior or exterior of the control box for any signs of damage to the cables. kinks or cracks. Check all other tubing and valves for signs of stress or damage. Inspect the refrigerant flex hoses for signs of damage. 2. Company Confidential March 10. 1. GE InVision. As such. mount the drain assembly to the top of the forklift pocket below the control box. inspect the line carefully for damage. Inspect the wiring and wiring connectors on the evaporator and condenser section for signs of any damage that may have occurred. 12. NOTE: If the insulation on either suction flex line is torn. ensure that there is no noise. connectors. Should you hear any noise. Remove the return air filter access panel to ensure the filter is installed properly. Slide the evaporator and condenser section into their respective locations within the CTX 9000 DSi. Check the entire system for any refrigerant leaks that may have occurred during shipping. 10. NOTE: The male-female spade connectors are very difficult to pull apart.

Company Confidential March 10. To install the four electrical cables (one 24-pin. There should be no threads visible on the male end after properly tightening the fittings. feed the 24-pin. a. Tighten each connection until it stops. CTX 9000 DSi Training Manual 84 of 378 GE InVision. 2005 . one 16-pin. The one located on the right side of the control box is the remote start connection. 12. NOTE: There are also two 4-pin connectors located on the bottom of the control box. b. While installing the four refrigerant lines. NOTE: The connectors are keyed so that they cannot be installed incorrectly. (The suction lines are insulated. 8. Install the control box to the mounting brackets on the CTX 9000 DSi. The one located on the left side of the control box is for RS-485 communication from the temperature controller. 10.) Be careful not to bend any of the fins on the condenser coil when positioning the suction lines or the liquid lines. Once you have tightened the fittings. While installing the refrigerant lines. use the appropriate wrench to tighten each connection. It is crucial that the two suction and two liquid refrigerant lines are mated to their corresponding circuits or the system will not function properly. 16-pin and 9-pin cables through the two holes in the Input module located to the right of the control box. Inc. ensure that there is some oil visible on the threads. After identifying the proper connection points. install the two small pieces of pipe insulation on the suction lines. NOTE: The connector is keyed so that it cannot be installed incorrectly. d. one 9-pin and the quad I/O cable). c.CHAPTER 4: POWER DISTRIBUTION 7. CA U TI ON: e. Attach the 24-pin cable connector to the condenser section. 9. Apply some refrigerant oil (POE oil) to the quick connects. Attach the 16-pin and 9-pin cable connectors to the evaporator section. 11. Attach the pre-formed p-trap tubing to the copper drain pipe on the evaporator section and attach the other end to the kazoo mounting bracket with hose clamps. consider the following: NOTE: The refrigerant lines are marked so that they cannot be connected improperly. Do not overtighten the connections.

Hook the quad I/O cable to its appropriate connector. 2. O nce it is seated. ~OR~ GE InVision. Install the two brackets (shipped loose) to attach the supply/return air plenum to the evaporator. The controller will display the temperature and the green control circuit LED will illuminate. The twist lock connector has not been connected properly. 2005 CTX 9000 DSi Training Manual 85 of 378 . Starting Up the A/C Unit CAUTION: 1. Once you have each individual connector lined up. O nce it is connected. Switch the main breaker to the ON position to energize the control circuit of the HVAC unit. Attach the 3-phase power cable to the flanged inlet at the bottom of the control box. NOTE: The brackets will help to eliminate any leakage that may occur around the felt gasket area of the plenum. Either: Push the system start/stop rocker switch to the ON position for manual operation. Ensure that the main breaker (visible from the outside of the control box) is in the OFF position (switched down). CAUTION: This is a twist lock-style connector. one of the following conditions may need to be rectified: The main power feeding the CTX system has not been switched on. 3. 9. 4. Open the right hand side control box door. 5. 8. 7. The breaker feeding the HVAC unit has not been switched on. 15. Inc. Ensure that the main cable (3-phase power) is disconnected from the control box. 6. Ensure that all the circuit breakers are in the ON position (switched to the left). 14. pull the connector downward to ensure that it is securely attached. push it together and tighten the threaded collar. Close the control box door. Ensure that the start/stop (black and red) rocker switch is in the OFF position. Company Confidential March 10. High voltage may be present at the line side of the circuit breaker. twist the connector to the right to lock it in place. Should no LEDs illuminate after switching the breaker on.CHAPTER 4: POWER DISTRIBUTION 13.

disconnect the power cable attached to the bottom of the control box to de-energize all remaining circuits. ~OR~ For remote operation. 6. Once the switch is activated. CTX 9000 DSi Training Manual 86 of 378 GE InVision. NOTE: The temperature controller will remain energized as will the green control circuit indicating LED. Company Confidential March 10. Once SV illuminates on the upper display (the set value—it actually looks like an S and an upside down A). Turn the main breaker to the OFF position to de-energize the HVAC system. Either: For manual operation. There is a two minute time delay for compressor/condenser circuit #2 (the timer starts timing when the compressor shuts off). the evaporator (supply air) fan will ramp up to speed (40 Hz for 460480/3/60. 5. Should any A/C maintenance or troubleshooting be necessary. press the Set key to save the new setpoint. activate the shutdown command from the motion control computer system. 7. Press the Set key on the RKC controller. Inc. The setpoint of the controller is 60 °F. Use the up or down arrow key to make the new change. 2005 . The system will automatically start to control around this setpoint. NOTE: There is a one minute time delay for compressor/condenser circuit #1 (the timer starts timing when the compressor shuts off). Shutting Down the A/C Unit 1. 45 Hz for 380-400/3/50).CHAPTER 4: POWER DISTRIBUTION Leave the switch in the OFF position for remote start operation. 4. 11. turn the system start/stop switch to the OFF position. 2. This will shut down the fan and de-energize any compressor/condenser circuits and the heater control. 3. push the R/S key to move the brightly lit digit to the position that needs to be changed. Once the correct setpoint is displayed. CAUTION: High voltage is still present on the line side of the breaker until the power cable is disconnected or the CTX 9000 DSi breaker is turned off. 10.

B.rkcinst. Inc.j p/english/pdf_manual/imr01h01e4.pdf Ins t r u c t i o na l Ma nu a l : http://www. The Mitsubishi frequency drive speed is adjusted with the dial on the front of the unit. C TERMINAL FUNCTION SELECTION NUMBER OF RETRIES RETRY WAITING TIME PWM FREQUENCY SELECTION OPERATION MODE SELECTION Adjusting the Frequency Drive Speed NOTE: For more information on the Mitsubishi FR-S frequency drive.j p/english/pdf_manual/ imr01h02e3. Turn the dial to the desired speed (40 Hz for 480 VAC systems.co.co. 1. 2. The flickering frequency is the set frequency.rkcinst. review the OEM documentation. The only parameters shown are the ones that change from the default settings. Company Confidential March 10.pdf GE InVision.CHAPTER 4: POWER DISTRIBUTION Adjusting the Frequency Drive Parameters NOTE: For more information on the Mitsubishi FR-S frequency drive. review the following OEM documentation: S p e c i f i c a t i o ns : http://www. Adjusting the RKC Temperature Controller Setpoint NOTE: For more information on the RKC temperature controller.rkcinst.j p/english/pdf/ma900_02e.pdf Co mmu ni c a t i o ns Ins t r u c t i o na l Ma nu a l : http://www. Press Enter to store the new speed. 2005 CTX 9000 DSi Training Manual 87 of 378 . 45 Hz for 380 VAC systems).co. review the OEM documentation.1 1 0 10 5 3 3 ELECTRONIC THERMAL OVERLOAD RELAY LOAD PATTERN SELECTION A. Parameter Number P7 P8 P9 P14 P65 P67 P68 P72 P79 ACCELERATION TIME DECELERATION TIME Parameters Settings 10 15 1.

1. 3. Replace defective SSR(s). Use the up or down arrow key to make the new change. Check DC control voltage to SSRs. If necessary. Symptom Supply air temperature remains below setpoint. Compressor(s) running when it/ they should not. Supply Air Temperature Too High (above 70 °F—Quad I/O Indicator). NOTE: There is no LED or Quad I/O indicator for this condition.CHAPTER 4: POWER DISTRIBUTION The RKC temperature controller setpoint is changed by using the set key. TROUBLESHOOTING THE AIR INNOVATIONS A/C UNIT S UPPLY AIR CONDITIONS TROUBLESHOOTING 1. Check heater Amp draw (it should be ~ 7. raise setpoint—(Output 1 LED on controller will be on). CTX 9000 DSi Training Manual 88 of 378 GE InVision. Check sensor against an accurate hand held device.2 A at 480 VAC and ~ 5. Press the Set key. press the Set key to save the new setpoint. If there is no DC signal at the SSRs. Company Confidential March 10. Heater control system not functioning properly. 2005 . they normally fail closed.) Check controller alarm and hysteresis (differential gap) settings. Same Temperature sensor is defective. 2. 2. When SSRs fail. and there is amperage to the heaters. If in error. Recommended Action Check controller setpoint setting (the normal setting is 60 °F. Same Check amperage to heaters. the SSRs are defective. temporarily offset the input to the controller until a new sensor can be obtained. Once SV illuminates on the upper display (the set value—it actually looks like an S and an upside down A). Once the correct setpoint is displayed. push the R/S key to move the brightly lit digit to the position that needs to be changed. 4.5 at 380-400 VAC). Supply Air Temperature Too Low. Same Possible Cause The temperature controller setpoint has been lowered. Inc.

Possible Cause Power failure. Symptom Electric circuit test Same Electric circuit test shows power on line side but not on the load side of compressor. Be sure both compressors are running.CHAPTER 4: POWER DISTRIBUTION Symptom Supply air temperature remains above setpoint. If there is no DC signal at the SSRs. Dirty evaporator coil filter. If the high temperature alarm (activates at 70 °F) is triggered (quad I/O pin 4-1). Disconnect switch is open. Defective fan motor. Insufficient cooling. Unit being operated in an excessively hot and humid condition. Compressor(s) not running. #3. Check main circuit breaker. and wiring using OEM schematic. switches. temporarily offset the input to the controller until a new sensor can be obtained.# 2. Contact Air Innovations. Reset or replace breaker if defective. Check sensor against an accurate hand held device. Temperature sensor is defective. Same Supply air temperature remains above setpoint. Same Possible Cause Temperature controller is defective. Defective heater control system. AIR CONDITIONING TROUBLESHOOTING 1. Check DC control voltage to SSRs. Check controls. the SSRs are defective. Determine why the switch was opened. Compressor Fails To Start (LED Indicator #1. If the system is in working order. 2005 CTX 9000 DSi Training Manual 89 of 378 . Replace defective SSR(s). Circuit breaker is tripped or defective. they normally fail closed. Recommended Action Check for blown line fuse or breaker. No air conditioning. Low airflow in evaporator section. and there is amperage to the heaters. breaker or wiring. frequency drive. Inc. shut the CTX 9000 DSi system down. If in error. Quad I/O High Pressure Indicator). Recommended Action Check programming parameters. Company Confidential March 10. #8 or #9. GE InVision. When SSRs fail. Replace filter. close the switch.

If condition is above 25 °F.CHAPTER 4: POWER DISTRIBUTION Symptom Full voltage at motor terminals but compressor will not run. Recommended Action Certified technician should perform the following: 1. replace the A/C motor. Condenser fan is not starting which causes the compressor to shut off on high pressure. Test for burned-out contactor coil or broken contacts. Inoperative compressor contactor. Return air filter clogged. Compressor Rapid Cycles (#1 or #2 Low Pressure LED Indicator. Replace contactor. 3. If the motor does not restart. Contactor coil is not energized. 2. Locate open control circuit and determine its cause. Same CTX 9000 DSi Training Manual 90 of 378 GE InVision. Start/Stop switch. Repair and recharge system. Isolate refrigerant leak. Motor winding protector is open. Shut off breaker to the affected compressor circuit. The motor winding protector will reset itself when the A/C unit temperature drops. Company Confidential March 10. System being operated in a low ambient condition. the refrigerant charge may be low. Pressure switches. Symptom Compressor cuts out intermittently from its low pressure cut-out switch. Frequency drive switch. 2. 2005 . System should not be operated in an ambient condition below 25 °F. Airflow switches. Clean or replace filter.) Same Possible Cause Lack of refrigerant. Possible Cause Compressor burned out. Motor is defective. Open control circuit for: Recommended Action Contact Air Innovations. Inc. (Caution: Rapid cycling can damage the compressor if allowed to continue for an extended period. Quad I/O Indicator).

Certified technician should replace the filter drier. NOTE: There is no LED or Quad I/O indicator for this condition. Liquid “flood back”. Recommended Action Reverse direction of compressor Certified technician should check and adjust the superheat setting. Inc. 2005 CTX 9000 DSi Training Manual 91 of 378 . De-ice coil. 5. Certified technician should repair or replace valve. Expansion valve stuck or obstructed. Abnormally cold suction line. Check evaporator coil for ice. Symptom Bubbles in sight glass.CHAPTER 4: POWER DISTRIBUTION 4. Same Same Possible Cause Compressor running in opposite direction. Short cycling. GE InVision.12 °F. 6.) Expansion valve stuck in open position. Symptom Compressor knocks. Recommended Action Certified technician should add refrigerant (if so recommended by Air innovations). Discharge Pressure Too High (LED Indicator #8 or #9. Quad I/O Low Pressure Indicator). Improper superheat adjustment. Superheat too high. Plugged filter drier. Company Confidential March 10. Possible Cause Lack of refrigerant (Note: Some flashing in low ambient conditions is acceptable. Certified technician should repair or replace valve. System Short of Capacity (LED Indicator #6 or #7. Compressor knocks. Quad I/O High Pressure Indicator). at least ½ to ¾ of the sight glass should appear to have refrigerant flowing through it). Certified technician should adjust TXV to maintain a minimum 10 °F superheat. Temperature change in refrigerant line through dryer. (Note: Setting may be too low or the remote bulb is loose on suction—the normal superheat setting is 10 . Compressor is Noisy.

7. Possible Cause Lack of refrigerant. 8. the quad I/O is triggered and an indicator will display with a warning to shut down the CTX 9000 DSi or internal damage could occur. Certified technician should repair or replace valve. NOTE: There is no LED or Quad I/O indicator for this condition. (Note: This valve should maintain a head pressure of 125 PSI. (Note: Sight glass will start flashing at around 8 lbs. Air or non-condensable gas in system.CHAPTER 4: POWER DISTRIBUTION Symptom Exceptionally hot condenser and excessive discharge pressure. Once the temperature rises above 70 °F. Discharge Pressure Too Low (LED Indicator #6 or #7. CTX 9000 DSi Training Manual 92 of 378 GE InVision. Company Confidential March 10. Same Same Possible Cause System operating in an excessively hot and humid environment. Symptom Abnormally cold suction line. Same Defective condenser fan motor or controls. Quad I/O Low Pressure Indicator). Excessively cold liquid returning from condenser.) Recommended Action Repair leak and charge. 2005 . Recommended Action If system operates at 350 PSI. Certified technician should purge non-condensable gas. Certified technician should remove excess refrigerant. Symptom Bubbles in sight glass. Overcharge of refrigerant. Suction Pressure Too High. Faulty low ambient control valve. Repair or replace defective parts. Inc. Contact Air Innovations. Recommended Action Certified technician should modify the superheat setting of the expansion valve and check to see that remote bulb is properly attached to the suction line.). Same Possible Cause Overfeeding of expansion valve. the high pressure switch will open and shut down the compressor. Liquid flooding back to compressor. Expansion valve stuck in open position.

Frequency drive setting not at 40 Hz or 45 Hz. Clogged filter drier. Unit short cycles. 2 POLE BREAKER. 3 POLE BREAKER.CHAPTER 4: POWER DISTRIBUTION 9. Adjust drive. Expansion valve power element has lost charge.4 PSI. Obstructed expansion valve. Company Confidential March 10. Quad I/O Low Pressure Indicator). 3 POLE BREAKER. 1 POLE BREAKER. at least ½ to ¾ of the sight glass should appear to have refrigerant flowing through it). SPARE PARTS LIST FOR THE AIR INNOVATIONS A/C UNIT Table 4-3 Air Innovations Part Number 34C0072-00 34C0072-01 34C0072-02 34C0072-03 34C0072-04 34C0072-05 51C0028-00 33C0056-00 BREAKER. Certified technician should clean valve or replace as necessary. LED Indicator #6 or #7. 2005 CTX 9000 DSi Training Manual 93 of 378 . 3 POLE COMPRESSOR CONTACTOR. Symptom Bubbles in sight glass. Suction Pressure Too Low (If Pressure is Below 2 . Evaporator discharge air is too low. Temperature change in refrigerant line through dryer. Inc. 24 VDC COIL. 3 POLE BREAKER. No flow of refrigerant through valve. Loss of capacity. 20 AMP Spare Parts List for the Air Innovations A/C Unit Description Quantity 1 1 1 2 1 1 2 2 Manufacturing Part Number 5SX2104-7 5SX2203-7 5SX2303-7 5SX2308-8 5SX2310-7 5SX2316-8 ZB21KCE-TFD-230 3RT1016-1B B42 GE InVision. Possible Cause Lack of refrigerant (Note: Some flashing in low ambient conditions is acceptable. Recommended Action Certified technician should repair leak and charge. Certified technician should replace the filter drier. Certified technician should replace expansion valve power element.

Company Confidential March 10. TWIST LOCK. YELLOW. GROUNDING. 5/8” ODS COUPLING. SOLID STATE Quantity 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 5 1 1 3 1 1 1 1 2 Manufacturing Part Number 952660 MA900-4ADA1-V83*AAH-N6/1/Y 5505-06B-06 5505-10S-08 55006B-06 55010S-08 CR0924HB-A70GL (P/N 032768) 16FCD10 C-053-S L1620-FL FR-S540-0. 14" x 16" x 1". 30%. 24 VDC LED. Inc. GREEN. CLASS 2 QUAD I/O. 24VDC. 3/8” C x C FLANGED INLET.4K-NA L17A-7239 1904X351 1904X353 1904X352 SA-K202 TMK280-2-34 6EP1333-3BA00 54862001 SDS-C2SUB-4 X9499 W6425DSX-1 CTX 9000 DSi Training Manual 94 of 378 GE InVision. 3/8” ODS COUPLING. 24 VDC LED. PCB RECEIVER. FEMALE. 3/8” ODS COUPLING. SPECIAL 2 CIRCUIT RELAY. 5/8” ODS FAN. RED. MALE. TEMPERATURE COUPLING. EMI (CORCOM) FILTER DRIER. MALE. 4 CONDUCTOR FREQUENCY DRIVE HEATER ELEMENT DRAIN TUBE (KAZOO). 2005 .CHAPTER 4: POWER DISTRIBUTION Air Innovations Part Number 39C0054-00 35C0056-00 54C0029-00 54C0029-01 54C0030-00 54C0030-01 73C0077-00 30C0017-00 50A0009-00 36C0119-00 35C0057-00 37C0048-00 54C0035-00 54C0033-00 71C0046-00 32C0019-00 32C0019-01 32C0019-02 50C0029-00 73C0075-00 39C0104-00 74C0053-00 33C0058-00 50C0030-00 33C0053-00 Description CONTROL BOARD FOR SPORLAN ELECTRONIC EPR (TCB BOARD) CONTROLLER. EVAPORATOR PRE-FORMED DRAIN TUBE (KAZOO) MOUNTING BRACKET LED. 3/8” F x S MOTORIZED IMPELLER POWER SUPPLY. CONTROL BOX COOLING FILTER. 24 VDC MOISTURE INDICATOR. 5A PREFILTER. 6" LONG DRAIN TUBE. FEMALE.

2005 CTX 9000 DSi Training Manual 95 of 378 .. DOS is used for system control functions. EVAPORATOR. 5/8” x 24 WIRE HARNESS. ELECTRONIC EPR VALVE.6" WC) SWITCH. GE InVision.1 to .5 PSF100A-20929 29PSL012-389 343R02 P70SA-1 RSCA701-VB-B-1-V 3L05-1 3L02-161 6ED1055-1HB00-0BA0 6ED1052-1MD000BA3 CDS-9-10'-S Y-1017-FJE-C LAC-4 125 Y-1253-EFJ-1/2 VAF3 X 30 VAF5 X 30 UPS The CTX 9000 DSi uses UNIX. HIGH PRESSURE SWITCH. STAINLESS STEEL SHEATH SWITCH. 3/8 IN x 1/2 OUT VIBRA-SORBER. CONDENSER.4 . 24-PIN WIRE HARNESS. AIR PRESSURE (. UNIX is utilized for image reconstruction and inspection functions. 135-175 DEG F SWITCH. RTD. 9-PIN Quantity 1 1 1 2 2 1 1 1 1 1 1 2 1 1 2 2 1 1 1 Manufacturing Part Number RBJB0TA080AB020 PSF100A-0. MAN. EVAPORATOR. SNAP ACTION. The GUI (Graphical User Interface) runs on Windows. SNAP ACTION. QUENCH TEV. 16-PIN WIRE HARNESS. ROCKER. HEAD PRESS. Inc. DOS and Windows operating systems for different system operation functions.CHAPTER 4: POWER DISTRIBUTION Air Innovations Part Number 39C0101-00 32A0010-00 32A0010-01 32A0032-01 32A0041-00 36F0004-00 32H0006-00 32H0007-00 33C0057-01 33C0057-00 52C0063-00 52C0061-00 52C0064-00 52C0062-00 54C0032-00 54C0032-01 36C0116-00 36C0117-00 36C0118-00 Description SENSOR. 100 OHM. EXPANSION VALVE. HIGH / LOW PRESSURE SWITCH. Company Confidential March 10.CONTROL VALVE.. AIR PRESSURE (.5" WC) SWITCH. 160 DEG F TIMER/RELAY EXPANSION MODULE TIMER/RELAY MODULE VALVE. SPST SWITCH. 3/8” x 24 VIBRA-SORBER.