y VOLTAS LIMITED EM&R Business Group INSTALLATION, OPERATION AND MAINTENANCE MANUAL PACKAGED UNITS A TATA Enterpriseot Installation, Operation & Maintenance Manual for Packaged Unitsv SAFETY NOTE 1. SAFETY Safety Notice 1, Please read this manual carefully before using the unit and operate it correctly according to the manual. 2. Please note the meaning of following labels: A fj H Pe PP PPE Waring | it means that incorrect operation may cause casualty or badly harm people. Caution | It means incorrect operation may cause damage to property, ‘Symbol indicates warming of coming in contact with electrical parts ‘Warning ! This machinery is not intended for use by unskilled persons including people with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, Waring ! Please have the unitinstalled, operated and maintained by trained personnel familiar with Air handling unit operation and maintenance. Contaet our authorized Installation / Servioe personnel in case of any doubt Warning | Improper installation will cause water leakage, electric shock and fire atc. Warming | Please install the unit where the flooring / ceiling (as the case may be, in case of ceiling suspended units) have been property designed and constructed to carry such loading, Ifit is not strong enough, unit may drop and casualty may result Caution | Drainage piping should be installed correctly according to this manual far correct water drainage.¥v LVOLTAS LIMITED i> ‘Warnine Woening AA > Warning improper pipeline installation may cause water orrelrigerant gas leakage (in case of direct expansion coils). Proper ventilation should be maintained in the AHU room to ventilate: any leaked refrigerant due te pipe damage. Note that refrigerant gasinhalation in excess amount can cause severe body damage and sometimes death. In case of chilled water installation, leaking pipes.can cause waler accumulation near and around the unit and can result in hazard ‘when in contact with electrical conduits Warning ! When matiunction occur (such as buming odour), please turn off general supply at ‘once. Maintain well ventilation to prevent oxygen lack. Don't insert finger or things into air inlet / outlet of blower, pulley, belts ormator Caution | Please check if power supply is the same with power requirement listed on nameplate and check power safely before installation ( Waring ! Please check and confirm, it wire, drainage hose and pipeline are connected conectly to-prevent water leakage, relrigerant / water leakage, electric shock and fie. ‘Caution ! General power supply must be earthed reliably to quarantee effective earth of the ‘whole unit and prevent electric shock. Note that AHU body should be earthed only from the positions marked with the earthing symbol ‘Caution ! Do not connect earth fo gas pipe, water pipe, lightning rad orconnect wire of telephone. Caution | Don't operate the unit with wet hand, Please tum off the general power supply fist when cleaning the unit or changing air filters or carry out any other mairslenance or inspection of the unitcONTENTS Section | Section it ‘Section it Section IV Section V Section Vi Section VilINTRODUCTION ‘This manual contains. installation, aperation start-up and maintenance recormmendation for VOLTAS Packaged Units. A careful study of this manual and following the racommended maintenance procedure will ensure smoath and trouble tree ‘operation of the unit: Trouble shooting chart in this manual aids in resolving minor problems during operation.SECTION - I TECHNICAL DATAWouTAS LiwreD: NOMENCLATURE PACKAGED UNIT (PAC) ‘Pac a sc 110 HS s07G PAC - Packaged | | Unit Retrigerent HiSensi k 14.0TR A = Ait Cooked W = Water Cooled Type of Compressor SH - Semi Hermetic Reciprocating SC - Scroll Rotary Optional Features MN - Standard Microprocesscr. MA - Units With Real time Ciock.¥ TECHNICAL DATA (RECIPROCATING : SEMI-HERMETIC COMPRESSOR UNITS) Packaged Units Nominal TA 75 15.0 15.0 Refrigerant No. of Compressor Model :Air-Cooled DPUASH150C 2No, DPUASH50C 2.Nos. S.OHP Number of Fans. i No. Bare Weight (ka) HO. 450 500 Length im) 900, 1800 1490 Depth (mm) 660 740 745 Height (mm) 1850 1850 1790 Nominal Air Cty, 3000 6000 6000 Condenser (Air-Cooled Unit) Number of Fans Motor Number of Units No. 2.Nos. Bare Weight tka) 90 Ee Length (en) 1320 1320 Depth mm) 460) 460 Height (mm) 720 750 ‘Type of Tubes: internally grooved high effieciency copper tubes. (Product development is @ continuous process in Voltas, hence specifications and technical data are subject to alterations without notice.) awouras unrrE@ TECHNICAL DATA (SCROLL COMPRESSOR UNITS) Packaged Unit No. af Compressor Model Air-Cooled Na. of Compressor Motor Number of Fans 1No. Bare Weight (ko) bud Length (mm) 2040 Depth (mm) 740 745 745 745 Height (mm) 1650 1850 1750 1790 1780 1790 Nominal Air Cty. 2200 3400 4400 6800 ‘6800 8800 ‘Condenser (Air-Cooled Unit) Model Number of Fans Motor Number of Units Bare Weight (kg) Length (mm) 920 460 750 11No. 2.No, Bepth (mm) Height (mm) Type of Tubes Internally grooved high effieciency copper tubes (Product development is a continuous process in Voltas, hence specifications and technical data are ‘subject to alterations: without notice.) + Water-cooled - Condenser is part of the packaged unitvouras useere® TECHNICAL DATA (SCROLL COMPRESSOR UNITS) Height (mm) HISENSIPACKAGEACUNIT Nominal TR 55 B75 11.00 17.00 Reetrigerant R22 Ree R22 R22 Compressar Scroll Scroll Scroll Scroll Model : Air-cooled DPUASCSSHS | DPUASCS7SHS | DPUASCI10HS [OPUASCI70CHS: No. af Compressor 1 2 2 4 Motor hp/ph i Hp/'3 Ph 2Hp/3 Ph 3Hp/SPh | SHp/3Ph Number of Fans: 1 1 1 Bare Weight (ka) 00 525 300 900 660 250 1750 Nominal Air Qty Condenser (Air-Cooled Unit) 3000 Mode! Dears Number of Fans 1 Motor OS HP Number of Units 1 Bare Weight (kg) 15 2x18 2x15 axt5 Length (rm) 1320 1320 1320 1320 Depth (mm) 460 460 460 460 Height (mm)VoLTAS LIMITED SECTION - I INSTALLATIONVv ies ai INSTALLATION The packaged/spit units are self-contained, assembled and pre-wired at Voltas Factory. Water Cooled units need field piping connection to the cooling water system, Main electric supply is tobe connected to the unit condenser water pumps, cooling tower fans etc, ‘The air-cooled packaged units are ta be used in conjunction with matching remote air-cooled condensers. Fieldwork includas interconnecting refrigerant piping. electrical pawer connection to the packaged unit and the outdoor condenser units. Air-cooled split units are supplied as a separate indoor unit and outdoor unit together with electric control box. Fieldwork invalves interconnecting refrigerant piping, electrical connection to the outdoor condensing Unit and the indoar evaporator unit. All packaged and ductable split units need to be connected to the field ductwork with a. canvass connection at the fan outlet, 2.1. RECEIVING AND PLACEMENT OF THE UNIT Inspect the unit on arrival at site for ransit dariages. In case of damages, file claim immediately with Transporteriinsurance Company. Ensure that the intimation of such damages are reported to Voltas office/Dadra factory. Install the Unitas per drawing, ensuring thal adequate space is provided around for servicing filter and access 10 piping connections. Recommended clearance for the various units shown in Figure 2.1, 2.3 and 2.4. “To ensure proper functioning af air cooled condenserfoutdoor unit, place the condenser unit such that a, Adequate access is available for intake of fresh air and warm air to be thrown away without recirculation. b, Bottom of condenser cailis slightly above the expansion valvein the evaporator unit ¢. If condenser is to be installed below the level of expansion valve, receiver may be needed. Manufacturer will guide you on proper selection and installation of this, Packaged unit should be installed on a clean level flocr. To ensure dampening of vibration, use neoprene rubber pads under the unit as shown in Figure 2.2. In case the packaged units are installed before completion of the ductwork, cover the supply air ‘opening and protect fiter from any din. Ifthe units are to be stored for some reasons, move the units toa store and keep them in an-upright position and cover the units with polythene sheets for protection. 2.2 ELECTRICAL CONNECTION Electric power supply should be 415V 4 wire, 50 HzAC supply complete with earthing as per local electricity rule. Fatlaw the contro! wiring schematic for the entire installation for haoking up different packaged units, condenser units, pumps, cooling towers, etc. Follow manufacturer's recommendations for wiring of pumps, cooling towers fan duet, heatars, atc. —S—24 24 ¥ vourns LnwreD ‘Safety interlocks must be provided to the installation as per drawing to ensure following logic : @. Packaged unit compressor should start only when condenser water pump is working and the ‘condenser water flow switch is healthy. Internal wiring of the unit ensures that the evaporator fan motor is working before the compressor can start, In case of air cooled units, micraprocessor ‘ensures that condenser fan motor is working before the compressor can start, b. _Ifpackaged unit installation calls for a heater battery either in the units or in the supply air duct ‘work, then ensure that heater are energised only when evaporator fan motor is working and the heather safety thermostat is healthy. ¢. _HP/LP cutout is provided in the standard units to protect the compressors from operating in adverse refrigerant pressure condition, The unit alsa has overload relays and compressor is, further protected by a motor protection retay to provide a comprehensive protection against single phasing and overload. Winding protection thermostats protect the compressor motor ‘fram overheating. The standard wiring of the unit takes care of these safety devices. In field wiring, the condenser water flow switch (where installed), should be hooked up inthe compressor intertock circuit DUCTING CONNECTION ‘Carry out ductwork as per drawing, Ensure all duct jaints are properly made and adequate supports are provided to the ductwork. For installation where return air is taken back through RA ducts, ensure that entire ductwork (supply 45 well as return air ducts) is thermally insulated, Where return air is taken back around SA ducts, ensure adequate area around SA ducts for passage of return air is provided as required in the drawing, Check various RA opening in walls, partitions, etc. Check provision ‘of the thermal and acoustic insulation on SA ducts as per drawing. Where false calling are to be Provided, care should be taken to avoid supporting ducts on the false celling and vice versa. Ensure that all grills, diffusers, dampers, etc. are provided as intendad In the drawings. Ensure adequate provision of access door for duct dampers, PIPING CONNECTIONS 1, Water Cooled Units ‘The water-cooled condenser in model DPUW packaged units should be-connected to the cooling water circuit, as per drewings. Care should be taken to ensure that the cooling water pumps get free gravity feed to the suction connection from the cooling tawer. Where a number of units are located on different floors having a common cooling water circuit, itis advisable to locate the coaling tower above the topmost unit on the rect. Otherwise water from the units above the cooling tower is likely to drain into the cooling tower sump, during shutdown of A/C plants. In such cases during the restart, there are chances of air getting trapped in the cooling water Circuit and the pump may even suck air through the cooling tower basin due to inadequate rate of makeup. 2. Air Cooled Units In case of air-cooled packaged units, the room units must be connected to the outdaor condenser unit by adequately sized copper refrigerant piping. The piping route must be kept shart and free from bends, as much as possible. Adequate protections must be provided to the pipes to avoid‘any mechanical damage, especially whi qunning on the roof. Areceiver should be installed in the liquid line immediately after the condenser installations where evaporator is located above the condenser. See Table no. 2.1 for recommended copper refrigerant pipe sizes. A reliel valve (400 psig) must be installed on the hot gas line near the air-cooled condenset or on receiver {finstalled). However manufacturers recommendation should be so ight for proper sizing and 3. Drain Piping ‘Condensate fram evaporator coil is collected in the drain tray provided undemeath ‘Connect suitable size drain piping to the drain tray on convenient side of the unit and ensure that the other drain connection provided in the opposite side of drain tray is. plugged. Provide adequate slope in the horizontal run af the drainpips. PVC pipe ean be used for disposal ‘of the condensate drain but utmost care is to be taken to ensure that the pipes are supported at close intarvals at 4 FOr 80, 86 a to avoid Sagging of pipes between supports. Though the sagged drain header may continue te allow condensate to flow aver @ period of time, fungus is likely to collect in the trapped water which will ultimately clog the drain. A 1 to 1.5° slope is recommended for efficient drainage. 2.5 SAFETY PROVISIONS a. The packaged units are provided with following satety devices : 1. Refrigerant HP/LP pressure switch, LP is self-resetting type. (LP switch is provided for scroll compressors 8.75 & 17 TR only} 2, Compressor motor winding thermastat, internal for compressors. \Where packaged units are installed with equipment such as heaters, humidifiers, etc. addi heater safety switches, level switches, elc. must be used.Table 2.1 Guidelines For Refrigerant Piping for PAC. Connections Sizes OD Equivalent Length of Line (m)* (Inches) 7rex2 | sexe [r1ex2] sexe [11002] sexe Liquid Line Hot Gas Line ‘Straight Pipe Length (m) + (1.0.x:no. of loows) Table 2.2 Guidelines For Refrigerant Piping for Ductable Split Unit Connections Equivalent Length of Line (m)* “Model” Sizes OD (Inches) L 5.57R We 78 a75TR | 58 | 148 11.00TR | 2x2 | 718x2 se [tie | se | 18 | se | tas | se | 138 vax2 | 7x2 | 5x2 |tmx2| 12x2 |1-1/8x2| 1x2 |14/ex2 ATOOTA | SGx2 | 1-/8x2] SOx? |1-1/8x2 | 5x2 |t-yex2| S82 [1arex2| Saxe | 1-96x2 22.007R | 5x2 | 1-1/8x2| SBx2 [1-1/8x2] SBx2 |1-18x2| SBx2 |1-98x2| Siax2|1-3ex2 Lo = Liquid Line S = SustionLineSERVICE CLEARANCE FOR PACKAGED UNITS af . PLENUM" ALLEL. ® |e, € S57R | 600 | 450380 | ae [erie so e00 | eso | 160 | 480 Tin ‘| eo | 0 | 180 | too WTR 30 _[ 700_| 450180 | ean ZR ‘s0[ 700 | «50 | 180] a8 * FOR PIPING CONNECTIONS * SITE FABRICATED IF NECESSARY * FOR MULTIPLE UNITS, PLEASE CONTACT VOLTAS OFFICEVIBRATION ISOLATION PADS LAYOUT PAIR OF 100 X 100 X12 SERRATED RUBBER PADS: a | MODEL 5TR CONDENSING! maven 7TR CONDENSING! MODEL 7TRICONDENSING! CONDENSER UNET CONDENSER UNIT SCROLL ‘CONDENSER Uf SEMI HERMETIC a 5 o = LL w» ta ta Lm a _| Figure No. 2:2 SERVICE CLEARANCE FOR A) CONDENSER COIL PACKAGED UNITS B) CONDENSING UNIT nnn OD ABOVE (FERC. | W eT 351 20 460 70 x oo eect ETS Ve ’ a Se att Figure No. 2-3SECTION - Ill START-UP COMMISSIONINGv ‘COMMISSIONING 3.1 START-UP “The follewing procedures should be observed step by stap for startup of packaged units after installation or after a prolonged shut down. (It is assumed that all installation work has been completed). 1, Remove shipping bolts and adjust compressor mounts so that it floats freely on the resilient ‘mounts, 2. _ Fix fan motor if supplied loose. Connect fan motor power wiring to the electrical control Box. Put V belt on the fan drive and check belt tension and alignment, 3a, Incase of water-cooled unit, fil soft water in cooling tower sump. Ensure adequate soft make ‘up water is available to the cooling tower float valve. Ensure that the entire cooling water pipeline is filled with water. 9b. For air cooled units, check that refrigerant piping connecting the condenser unitiand evaporator unit is laid properly. Carry aut pressure test, vacuumising, and then charge the refrigerant gas, 4. Road the standing pressure in the condenser in case-of water-cooled units. Standing pressure should be equal to the saturation pressure of the refrigerant gas at ambient temperature. 5. For air cooled packaged unit gas charging will be required at the time of startup. Follow gas- charging procedure as described in Section IV. 6. Check main electric supply voltage. It shauld be 415 plus minus 6 % V, AC 3 phase. Start the blower check direction of rotation. To reverse the direction of rotation of blawer, interchange any two-line terminals on the fan starter. The ductwork must be completed before startup and all grils dampers etc. must be in position. This will help in balancing the system to the design airfiow through the ducts, Note fan motor current and see that @) Fan mator dogs not draw more than its rated current. b) The overload setting on tan motor starter is lass than, or equal to the full oad rated current of the motor. ©) Check and adjust the dampers in the ductwork as required to get required air quality in various outlets. Measure total air quantities across retum air fiters on the packaged unit. Recheck fan motor current. Step up / step down the fan speed ta ensure the design air quantity. 7a. For water cooled units, start the condenser water pump, check direction of its rotation and reverse if necessary. Check cooling tower spray and observe water pressures on inlet and outlet of condensers, Check pumps current and see that iis within rated limit, Set the averioad relay on the pump startup to thé rated current. Adjust condenser water globe valve on the outiet cof pump oF on outlet of packaged unit to adjust the flow. 7. Incase of air cooled units start the air-cooled condenser fan after checking that the condenser unit panel is properly closed and fan motor is wired properly. Check and adjust fan motor overloads as above. 8 Check and record all electrical characteristics, pressure and temperatures. Iffound in order, the startup operation can be treated as complete. — —_— fis} —¥ votras umreo 3.2 OPERATING PARAMETER CONTROL SETTINGS: Paramet Evaporator Fan motor overtoad (A) as 2. Compressor overioad (A) | 21.0 2. HP cutout (psig) 2e0\W.C3 400 (A.C) LP cutout (psigh Note : Figures are likely to vary for different makes of motors. Check motor data plate to set over load. 3.3. ELECTRICAL SERVICE The packaged units are shipped from the factory completely pre-wired. When fan motors.are supplied loose, the fanmotor leads need to be connected at site. Power supply required is balanced 3-phase, 4 wire, 50 cycles, AC supply voltage must be 415 V plus minus 6 %. All control wiring is Suitable-for 230 V. single-phase 50 cycle AC. Electrical Test ‘Any test that has to be conducted to check electrical performance of the unit orits components must be done by authorised maintenance personne! only. Improper test procedures may lead to damage to the unit and cause fatal accidents. Disconnect main supply before attempting to touch any electrical ‘component. Following testiprocedure are required to be done on the unit, A. Continuity Test Use a multi meter for checking continuity in electric circuit. While checking motor: disconnect powor leads to the motor and see resistance of each pair of compressor terminals, A healthy winding will indicate zero resistanee. An open winding will indicate infinite resistance. {Caution — even a bumt or internally short winding will show continuity). tis essential 10 carry out meggar test to check the insulation resistanca of any motor. Check the motors for earthen winding by checking each motor terminal with the body of campressor. B. Meggar Test Use a S00V D.C. meggar Higher voltage might damage insulation ofthe winding. Doroteary 1. The resistance of a healthy winding is normally more than 1 megaohins (when windings are coo) f the resistance is betwoon 0.5 megachms to 1 megaohms the windings should be baked once again at 120 Deg C-tor 3-4 hours and resistance should be rechecked after the winding are cooled. tf resistance does not improve with rebaking, the compressor must be rewound, The resistance of fan motors can be improved on field by either running motor from the unit or heating the motor body with the help OF 2 or 3 100 watts bulbs placed around the mator.Vv C, Measurement Of Motor Current And its Adjustments Measurements of current is done by using a Tong Test or clip-on-ammeter. Ta measure current of any motor, set the ammeter range to the maximum first and measure line current at the starter outlet feeders. The line current of any motor should never exceed rated full load current for a long time. Motor current Is directly proportional te the load on the motor fan ar a pump motor is designed to give a design flow rate at an estimated head (the resistance offered by the system). An overestimation of head results in excess flow (through fan or pump) which is generated to create additional head. This results in increase of BHP and overloading moter, Adjust flow by regulating globe valve (on the outlet of condenser) in case of pumps and by reducing fan RPM or by regulating volume Control dampers in case of fans. For compressor motor check system for overcharge, mechanical fault or non-condensable in system. COMMISSIONING TIPS FOR SCROLL COMPRESSORS. “The scroll sets are lubricated by oll mist induced along with the refrigerant vapours. Atiew suction pressure below 25 psig the velocity of refrigerant being low the scroll set won't get adequate lubrication-oll mist Due to this dry running of scrail sets it gets overheated within a minute of operation which may damage the serail sets. Hence after vacuumising the system, charge the system with 70-75% of estimated refrigerant charge in liquid form from the liquid ine access fiting, Before starting the compressor ensuite thatthe suction pressure ‘does not fall below 25 psig. Top-up the balance quantity of refrigerant in to suction line in liquid form in a controlled manner. Note: ‘The initial filling should be based on the quantity of refrigerant charged by weight rather than by locking at the pressure gauge looking for some particular standing pressure. Filling oniy.a ite retrigerant- say hatf akg. or 1 kg, -and trying to charge refrigerant vapor only through the ‘compressor suction access valve, as is done in a reciprocating system, will overheat the compressor and ‘result in a failure due to high current and tripping. Contralled liquid charging into the suction is probably better than vapor charging that allows vacuum operation. ‘To enable the technician to putin the initial charge, suitable access valves on the suction and liquid lines are provided in the unit. To sum-up the above points, following care need ta be taken at site while commissioning a new scroll compressor 4. Charging a new scroll compressor is different from a reciprocating compressor. 2 After-vacuurnising the unit fil-in app. 80-75% of charge by weight -thréugh the access valves on the liquid line and suction line of the system. 3. Use a gauge manifold ta keep a watch on the suction pressure, Do not allow it to fall to vacuum or very lowsuction pressure, 4. After starting the new compresser, charge controlled liquid refrigerant into the suction and not vapour. Neen nnn nn Een aevouras usiree SECTION — IV MAINTENANCE AND TROUBLE SHOOTING ] E44 ¥ MAINTENANCE ROUTINE MAINTENANCE ‘Although packaged air conditioners will require minimum attention itis recommended and important to do maintenance REGULARLY. Routine maintenance is part of general checkup; it helps in trouble free operation of the AC units. Follow the given schedule as routine maintenance. Carry out maintenance with units stopped. It is recommended that skilled personne! carry cut all maintenance including daily and weekly. Daily 4 Inspect unit, cooling tower, pump for plumbing leak, clogged drains ete. fix and clean them. b. Check main electric supply on the unit. Weekly a. Remove filters from units. Take out of the plant room. Dedust and wash with water. Dry filters and refit. b. Inspect cooling tower sump and strainer(s) for water-cooled units. Clean if necessary. This may have to be done daily for applications where the fitters get choked faster. in such cases, the filters. should be cleaned in the evening after units are stopped for the day, so that the filters are dry before starting next moming. In piace where filter chokes fast, it is recommended to keep an additional set of fitter. ‘Quarterly 8, Inspect finned surface of air-cooled condenser, clean with a blower anda non-metallic brush, Donot clean with a spray of water, as outdoor dust would quickly clog the fins af the condensers upon restarting the fan, Clean air-cooled condenser with approved chemical once in six months or so depending upen surrounding atmosphere. b. Check compressor mounts for any undue vibrations or cracks. Replace mounts if necessary. c. Check operating pressure of the compreador. Investigate deviations from operating pressure. d. Open fan sections cover, check belts for wear and tear, Replace if necessary, check bearings and alignment of belt driver, Refit fan section cover. fe. Inspect starter contacts for chatter marks; check operation of overicad, HP/LP eutouts, and single-phase praventors. f Check if there are any rust spots on steel panels, bottom and intermediate (drain) trays. Dry, emery such spots, pateh up with red oxide and paints,Ig ay a2 Half Yearly @, _Glean air-coaled condenser/evaparatars.coil with approved chemicals b. Descale water cooled condenser with approved chemicals. Yearly a. Cary out leak test for refrigerant circuit. b. Camry out electrical meggar test; check current of all motors. ©. Clean and repaint unit, condenser water pipes with valves. 4. Carry out chemical cleaning of evaporator coil and descale water-cooled condensers where necessary. ‘TROUBLE SHOOTING Itis essential that a correct diagnosis be made before any remedial action is started for trouble in unit operation. A Trouble-shooting chart is given here to help maintenance persennel in maintaining the packaged units. Itis often noticed that the malfunctioning of packaged units can be avoided if following points are: ‘checked and verified, 1. 1s the supply voltage stable and within operating limits? 2. Is. sufficient water available to the condensers? Are water temperatures to and from the condensers Satistactory? ‘Are the pumps and fans in good working condition? ‘Are the safety controls set properly? Are they defective? ‘What is the condition of evaporator (condenser) coil? Is it choked? Is expansion valve operating properly? Is the unit operating with the design load? Nene oevouras LamreD TROUBLE SHOOTING CHART Symptoms Possible Cause Remedy A. Compressertan a. Power off a. Check and Restore Supply. or pump motor b Blown fuses (s), b. Replace fuses (s). notworking, c. Thermostat switch open. €. Check Thermostat Setting. d. Interlock not complete. . Check contro! wiring ant see thal auxiliary equipment like pump, fans are running. -e. Loose power connection. @. Tighten connections. 4. Improper wiring. 1. Check and correct, g. Lower voltage. g. Provide adequate vottage. h. Motor winding open. hh. Disconnect power supply Disconnect terminals at motor. Check resistance of winding. Ifresistance is infinite motor windings are open Rewind stator, raft on ‘compressor. i. Starter detective. i. Check starter contacts, plunger movement. Replace coil burnt, with ‘correct voltage coil i. Tripped pressure switch j, Reset switch, restan and orovertoad. ‘observe operating pressure and current. B. Compressor a. Low Refrigerant Charge a. Check and add charge Short cycle on Restricted air flow over Clean orreplace fiers, lowpressure. evaporator /fiter clogged. heck for closed dampers and fan mator drive, b. Expansion vaive bulb b. Replace power Eloment! capillary broken. Expansion valves. ©. Compressor service valves c. Open Valves. not fully open. 4. Clogged refrigerant strainer 0. Clean strainerfine. or suction lines. ©. Compressor a. Low condenser water ‘a. Provide adequate water/a OFF on high {or air) flow and high flow to condenser. Chack pressure, water temp. cooling tawer performance, b. Fouled condenser tubes. b. Descaleiciean condensers. 2H. Air conditioned space too warm, a. Inadequate cooling. b. Excessive toad on unit. ‘c. Ar in system, ©. Purge system d. Overcharges gas. 1. Remove excess charge. ‘©, Faulty condenser pump fe. Check and repair, (orfan). 4. Condenser air short cycling. | 1. Prevent by using suitable baffles, 9. Service at proper intervals. D. Excessive noise in a. Inadequate lubrication a. Service at proper intervals. unit. b. Loose fan batt bb. Tighten of replace entire set of belts. ¢. Damaged orloose ©. Tighten all bolts, components. compressor and fan mounts, Check compressor for broken parts. Check fan bearings. d. Loose fan section panel d. Fix properly. E. Unit operates a. Shortage arrefrigerant. a. Check leakirepair and Ccontinuousiy or far charge. too long b. Unitundersized, b. Recheck design and actual loads . Leaking suction ¢. Check compressor and repair, 4. Detective thermostat. d. Replace thermostat. F. High suction pressure. | a. Excess load ‘a. Reduce joad on system b, Damaged compressor valve b, Check/Repair. plates. ©, Frost on evaporator, @. Lack of refrigerant a. Check leaks/Repairand distributor oF suction sharge refrigerant. tine. b, Clogged expansion valve. b Clean or replace, c. Low evaporator air flow. ¢. Clean titers, coll check. batt drive and open dampers. Check symptoms a, b, ¢, d, 18g. jecheck actual and design foad, reduce load or install unit for additional capacity. ‘Check air balancing. 2¥ wourns wire ‘Symptoms Possible Cause Remedy | |. Air-conditioned a. Defective thermostat. (Check thermostat & control ‘Space toa cold. circuit b. Compressor starter stuck in ‘Check starter and replace "ON" position. if necessary. J. Discomfon in air a. Lack of air movement. Check fan belts, dampers conditioned space. and air fiters. b. High humidity b. Check fresh air inittration, draw fresh air through unit. €. Inadequate cooling. c. Asper (h), FIELD SERVICE OPERATIONS. A. Pressure Testing Pressure testing (followed by vacuum tes!) a refrigerant circuit is essential: before refrigerant is charged in the system either initially or far topping up gas after a suspected leak. itis advisable to locate the leak, rectity and then charge gas after Pressure Testing (before pressure testing the remaining FREON gas should be removed into an empty cylinder. In case af a compressor winding burnout, the system should be thoroughly flushed with dry N, to drive out contaminants generated in the system, before the compressor is replaced. Its imperative that a new catchall Grier is fited in circuit (after a bumou). 4. Charge dry nitrogen in the system by connecting cylinder at the compressor service valve and check pressure in the system. Charge nitrogén up to a pressure of 3 to 4 Kalem?. 2. hack all joints with soap salution. Locate all leaks. 3. it no leaks are found, increase pressure upto 10.5 kglcm? adding more nitrogen. ‘Check for leaks 4. After all leaks are located, remove nitrogen completely by opening charging line. Repair leaks and retest. Do not start work unless entire nitrogen is removed from syste, CAUTION Never use oxygen gas for pressure testing as fatal explosion may ocour. Avoid use of CO2 for pressure test as CO2 gas may contain excessive moisture, which might remain in system. Do not se eompressor to build pressure for leak tast as overheating might damage the compressor NOTE Minor leak suspected during operation can be located by using Halide leak detector. g4 Vacuumising and Charging of refrigerant Evacuating the system by pulling deep vacuum enable dehydrating the system and removing of air (non-condensable), In the event of a compressor burnout, it helps to remove carbon deposits and smoke that is generated. A good 2 stage vacuum pump should be employed to get vacuum down to 5 microns (1 microns = 0.001 mm) of Hg absolute, A vacuum gauge for reading vacuum should be used. 1. Put a jumper line (1/4" OD) to equalise high and low side on the compressor. Connect vacuum pump and vacuum gauge to the system. Open compressor services valves and start he pump. 2. Run pump till vacuum the boiling point of moisture (water) which will be about 0 Deg C. hence for normal ambient temperature (10 Deg C and above pulling a deeper vacuum is neither recommended nor necessary. 3. vacuum, is stabilised, close charging valve and stop the pump. 4, Allow vacuum in the system for an hour or $0, recheck vacuum, break vacuum by charging Refrigerant R-22 from the ‘% inch FPT service port at compressor suction shut-off valve. Fevacuumise and check. Charge gas as needed by the system, 5. Open the cylinder vaive a litle and purge air in the charging line by cracking the flare nut ‘al compressor valve port and allowing some refrigerant to drive out air. Tighten the flare nut. Open compressor services valve partially by turing stem clockwise and start ‘compressor. Follow start-up pracedure. Purging Non-condensable Gases Non condensable gases are likely to be accumulated at the higher portions of the system, This causes reduction in cooling capacity and waste of power resulting fram higher condensing temperature, 1. Short the LP switch. Close liquid lines shut off valve and connect gauges on suction and discharge service valves. 2. Start the compressor. Suction pressure will drop as the liquid valve is clased. Stop the compressor after suction pressure drops down to zero psig. The suction pressure will start raising again. When it becomes steady start compressor again. When sucton pressure again drops to zero, stop the compressor. Repeat this procedure til suction pressure slays more or less close to zero after stopping compressor. 3. Run the condenser water pump for abort half an hour and read the condenser shell pressure compare this with the saturation pressure of the refrigerant at cooling tower water temperature. If the shell pressure is more than 2 to 5 psi than the saturation pressure crack open the purge valve on the condenser. Repeat the pracess til the shell pressure ‘comes dawn te the saturation pressure of the refrigerant at water temperature. Bi¥v 4. Close fully the purge valve and restart the unit. Compare operating pressure. Ifthe pressures are not within limits follow steps (1) and (2) once again. investigate unit performance it results are not satisfactory. Condenser Water Requirements \Water-cooled condenser should have a soft, filtered water supply. Hard water with hardness over BOppm of CaGOS circulated in the water circuit results in rapid scale formation inside the ‘tube surface. This results in reduction of heat transfer from condensing refrigerant to condenser water, thereby resulting into reduction of system cooling capacity, increased pressure, clogging of tube and nozzles and eventual break down of AC system. Atmospheric oxygen, carbon dioxide, sulphur diexide absorbed from air in cooling tower and dissolved in water causes carresion. "As the candenser water is recycled the concentration of corrosive minerals increases, Ifrepeated operational problems are altributed to condenser water, then it is advisable, in critical cases, that.chemical analysis is asked for rather than frequent descaling operabons that would eventually shorten the condenser life. Sof make-up water al rate of 1.5% 10 2% of flow-rate is recommended to be provided at the cooling tower, Descaling of condenser Carry out condenser descaling work when unit is not in operation. Following precautions should be taken. 1. Domnot run evaporator blower while descaling is being dane. Fumes/gases liberated during descaling with cause discomfort to the occupants and might cause harm to instruments! apparatus kept in air-conditioned space, 2 Descaling chemical should be circulated fram bottom port of condenser water connections and outlet pipe must be vented as shown. ‘Add water to the tank and start descaling pump. Check that there is na leak in the connections, Add descaling chemicals slowly to the tank, do not exceed ph of 4 Maintain pph valve by checking at regular intervals and adding chemical slowly. It Should take about 2-9 hours. Use descaling chemical that is manufactured by Vasu Chemicals, Mumbai or other chemical if approved by Voltas. ‘After descaling is aver, flush the system with water tll ph valve comes upto a little more than 7. Inspect the condenser tubes by opening end covers; use a nylon brush for brushing tubes if necessary.| ¥ GUIDELINES FOR HANDLING R407C REFRIGERANTS A HFC REFRIGERANT The following refrigerant is being used in place of the HCFC22 (R22) retrigerant. Main differences in specification are pressure difference (higher) and compatible refrigerant oil type Refrigerant Name New Alternative Refrgerant (HFC) Rare Previous Refrigerant (HCFC) Ree Principal use Package and ductable spilt air-conditioners Composing substances Non-azeatropicmixture of Single-componentrefrigerant FR32,F1125 and A13da (1) 4 | Standard design pressure 3.2MpaG 2.75 MpaG | |_5 | Retrigerant oi ‘Synthetic olf (POE oi) Mineral oil (suriso) ' 6 | Ozone destruction tactor \\ 7 | Combustibitity (o0P) o ons: 8 | Toxicity (1) Non-azeottapic miture refrigerant: mixture of tw or more refrigerants having cfferent boiling points. (Since the design pressure differs with model, the design pressure should be confirmed with the machine nameplate.or installation manual attached to the outdoor unit, B. CAUTIONS IN HANDLING R407 ‘The new R407G refrigerant differ from the previous refrigerant (R22) in the following characteristics. ‘Utmost caution must be exercised after precautions are thoroughly understood when handling the | new refrigerants, Different Points Precautions to be noted 1. | The new refrigerants are extremely susceptible to mixing of impurities (oi, water,oxidized film) in the refrigerant system ascompared to the previaus refrigerant. *Be sure to charge a nitrogen gas into thepipe during brazing *Careful storage and management of pipes*Prohibition of mixing of impurities about 10% highay than that of the previous refrigerant. 2. | The pressureishigh-The pressure of RAOTC is | Tools and devices (charge hose, gaugemanitold) used with the previous refrigerant cannot be u for the new-refrigarants sincetheir pressure with standing capability is lower.¥ Different Points Precautions to be noted 3 | HFC R407C consists of three kinds ‘Charge the refrigerant inthe liquid state. of non-azeotropie substances. Donot charge the refrigerant in the gaseous stale, (Charging the refrigerant in thegaseous state causes the refrigerantcomposition ta change.) 4 | Therequiredrefrigerantoltis ether oil Gauge manifolds and charge hoses used with Mixing of the previous mineral oil causes the previous refrigerant cannot be used far the ‘sludge generation new refrigerants. C. ON-SITE WORK RaOTC. Refrigerant Piping Prevention for mixing of foreign items such as moisture, dust in therefrigerant pipe. (Thorough management for pipe at site) Ensuring of nitrogen charge during brazing. Vacuum drying with vacuum purnp (Air purge with gas is strictly prohibited) Refrigerant charging, refrigerant oll application (Charge the refrigerant in the liquid state, Prevention for mixing of R22in refrigerant ollbecause of difference in liquid type. (R22: mineral il, R407C: synthetic oll, HEC is not soluble in mineral oil) = D, CAUTIONS IN WORKING WITH HFC REFRIGERANTS Ran7c 1 | Charginganitrogengas | When brazing tor R407C models thatrequire brazing, itis mandatory intopipe during brazing | to charge a nitrogen gas into the pipe. A thorough service work control more severe than previous models is required. 2. | Flaring Itis necessary to apply an appropriate amount of ail an the inside and outside of the flared section, Be sure to use ether-hase or alkylbenzene-base oil. 3. | Retrigerant charge Previous HCFCs could be charged in either liquid or gaseous state, For the new refrigerants, however, it is very important to.charge in the liquid state. Blv — PROCEDURE FOR ADDITIONAL REFRIGERANT CHARGING ‘Additional refrigerant charging after the piping work is complete Since Rh407C non-azeotropic , be sure to charge those refrigerants in liquid state. ‘Therefore, the refrigerant cylinder should be turned upside down to charge refrigerant. | le raster l Se ee ee ‘Caution ‘Structure of certain refrigerant cylinder is as shown in the figure below other than above mentioned. (A siphon tube is provided inside the cylinder not to tum upside down.) Therefore, be sura to check the sirueture of cylinder before use. Identification of refrigerant cylinders (Color coding) atoBi] 9 emma oe 8 or oz 0 ox 1 1 r 1 vo tae Bd INBEO'O= 29/1541 espe i ot: a woure 2 zL- Z 5 & - ¥ 8 & ie S-L¢ a w & & uogty Aobne6h ery 1 1 4 a ob awonby 1 edWy jo uosedWwoD i ‘BRUNO LOREJMIES I ‘SANVH3DIMIIH MAN HOS 318VL NOISH3ANOO SUNSS3Ud-SHNLEVadNAL aSECTION - V SCHEMATIC & WIRING DIAGRAM 30WIRING DIAGRAM OF 5.5TR /8.5TR IDU 16- S PENDENT CONTROLL FROM ODU CONTROL PANEL (CONDUNIT) 2 8) (10) INGSUPPLY 230 AC FROM TBI ODU UNIT II es CORE, 18 sn 1 at q z 3 = 3 wh] i yal’ (ucron! tes IMP. NOTE PL, DO NOT MIX 14 CORE CABLE ty rowrr CABLE KEEP $00 mm MIN, DISTANCE BETWEEN 14 CORE & POWER CABLEvouras usrreo INCOMING SUPPLY v WIRING DIAGRAM FOR IITR, 16 IDU UNIT (TWIN COMP) WITH 2 NOS BLOWER MOTOR IMP. NOTE PL. DO NOT P S00 eas MIN, DISTANC FROM ODU CONTROL PANEL (COND UNIT) For FoR COND UNIT? CoD UNIT (CSicancroyicsxe9y Cio) San 3 CORE CABLE AM.CORE Cable 2 Mus IX 14 CORE CABLE IN rower canve WEEN CORE CABLE & POWER CABLE a¥ WIRING DIAGRAM FOR I7TR, 16 IDU UNIT (TWIN COMP) WITH 3 NOS BLOWER MOTOR. FROM ODU CONTROL PANEL, «COND UNIT} FoR, FOR COND UNITE COND UNITE —— (CHICORCIOKERCINC OD CORE CABLE Pee Re N Pi Bl J CORE CABL py 14 CORE Cable Pecfoa[n aon 2M "OV A.C. FROM INCOMING SUPPLY IMP. NOTE :- PL. DQ NOT MIX 14 CORE CABLE IN POWER CABLE. [KEEP 500 nin MIN, DISTANCE BETWEEN 14CORE CABLE & POWER-CABLE e| Fs = iE = aoe ae tambien € af S | o 8 e Ae wo1on ed pdagan § NO'dNOD = SRA 3 —) AV8 Z etn ry nu a = 5% = OL el 3] s aL g ag Ep) at & +, woo q : SAS 3 £ pe age q EEE aie Anaans wood o€ ‘ans a" : eer Yi a ast eet {woposyoad asey & pcre BEE ORE OL FV ASIP & & cate SNTIWOONT8.75TR CONDENSING UNIT TWIN (ODU-T) 72 [-y cua pyr tispep? RR Go gepO tan w-M2PD TUA-DI (7-208mp) (=I WS Fy roto OED ass LU we PEE tuoi gy THER nas oleate a pn at oP} gio ao - rood Ww PACH TWO VAM OL, we ‘tas = WOLAHCY AT zw ‘ora 0 RNANE i) “aL (sania any ‘OC ASIP wtaans aNTWOONTHeeb ie cn ae FEg GS 2 (@E-OE)TANVd TOULNGD LTS “LIND DNISNIGNOD 3 OM OL DNLLJINNOD #4 TIONLNOD LIND ONLEVHOAWAA INVANSE NWS RLU) LEIDanauag Sa WoMIaNa AKO WaMOTO ME [Sua na mana wal oat oar ALOWSY LNOHLIM O/¥ LITdS (OT - Ot) Gd WN NINS ULL WV ETHIS (OF O8) Ga NIRS ASE {37}Of4NOF-OlGNOD-OF18 TAN LMS NIML BLTTveh a4 Sy DRL worn AF ONULTS VO 15 LON z 8 Ol- OE AdIW NINd UL SL'8/5'L (S'S dO WVAOVIC ONTHIA,Of WOD-GLONOD- OF TH WA OVd HL SLOfdNOD-O10NOD OFTH YW LIAS MLS s/sL {ai}LITR/ISTRIITTR PMN MPD TWIN (30 - 10) eI[pauaiaa yee won Geo aoa : 5 Ol- OF GdW Nd OVd ISNAS UL $$ AO AVYOVIC ONTvouras Limrree. 8.78 / 11 TR SENSE PAC PMN MPD TWIN (30 - 10) iss tt fel | 1B, [aa}MERONSECTION - VI MICROPROCESSOR CONTROLLERmaitine THE VOLTAS MICROPROCESSOR CONTROLLER SEVEN UNIQUE BENEFITS ‘The microprocessor controller installed on all the units, offers you the follawing benefits: Power Saving The microprocessor controller switches off the condenser fan when the compressor cuts olf, thereby soving volvoble power. Fault Diagnostics The microprocessor controller disploys tip conditions enabling quicker identification of the fault and faster remedial oction. This results in lower dowrime of the unit Operation Friendly (Our units con be started end stopped with © single bution and the microprocessor does the rest, thus making them very user friendly. Precise Control The electronic temperaiure sensor ensures precise control on temperature, 05 & compored to @ conventional thermostat. Auto Re-stort [Unlike conventional units, our units hove @ unique power-down memory, which ensures ‘quiomatic restort of the unit os soon as power is restored, This saves the eort of “ES re-storiing the Unit Anti-Recycle timer ov The microprocessor controller stars the compressor after a set delay, thereby enhancing as fe, Frequont sors/stops in the conventional units decrease the le of the compressor and the electrical swtchgeor. Programmable Operation PF] 1 oxtiona feature isthe rea clack wich enables programmable operation for ‘one yeor including holidays. This ovoids the need of on eperatet INTELLIGENT SYSTEMS FROM VOLTAS:vous umirE. "SIaWD YIMGd Ni AWIdSIG 40 FIeYD XIN LON OG Td —? ZLON “dil 300N8 Nd = 440 O87 30004 1000 = NO a1 | [a yon Ojon iq | Ed osjes 09 POH APO NAM? hi Gum]. 6 Guia] 9 BUY seed ‘Nar wepued jo mo eh 140 Keno =! emo}q Jo 1uawINa 385 BUINBS 304 BION 70965 O81 0 LL ue 9,4 + doy 199 UPL NOISY WORLNOS aREL TNO -ORPaMWog Yaa Cue Ya = OL i SONSIOSS NO WNT 430.50 = 40 O37 NO SIN NOG | (TeESSaEE] denon Bison hq | ena 13834 / AOUSILAWLS PRONE DIN. ao 9g Ba A onuowiaisop aq ues anjen sasusEseS ANSONSd oun 8 clea 4 GT Uo dpm BURDEN, a {L440 duos} NO Ie a) Ww4NO ® Poe on BURDEN UBL #0H (0) Le raat (ia) nda wrBia 1 mas, ‘Ae enn Cursed Aq | | ama. osunnu 9 ve eren mui, SNOLLONAS AB Aay vor oor ¥ 02 O1 of ~30NvH Gh) [NiReenD 135 23, 0b 04 ~ ona ta Las. a @ gone Nalamena | HSLaNWAVA sirvenaue. woce sweug |G 2 NOLLWIONTINNY AvidSIC NN VO HLIM ( dWOS FIONIS ) BE - YATIONLNOD LNIN3d 40 TWANY ONLLWHSdO“318V9 HSMOd NI AVTdSIO JO 318¥D OYS XIW LON OF “Id = SION “dil Ts tome samemsasronsmmmines | HUE] (PF a == fl (nc ld cece w |tuay Ga) sememavnmn PB eucmescamenee bad ramen ang mon wang maa GION Sear maT ir ma opto oY NO Oh srry eng nate 9 eee ast veun) opfoey guy <— rae meg on TN = ore 37} rotorsgumatenttiar [id me ove 5] sven megs (Garp te ow eas (23) Me RHO ‘csomuasomesin Pg] oops oa amd om moe wi (opening ™ pare awe rewrote | (AK) [ESA] rao | (4) [2514] mary) wi Can NRHN ge Rm -300n TY NI NOILVIONNNNY inva | arse 25 oNNSH (-dINGO STONIS ) GdW-NINd JO TYNNVIN ONILVESdO‘TIGVI HSMOd Ni AVTdSIC JO STV OUa XI LON Od Td = LON ‘dil m8 a SGML) SDs Tv 40 SROUWIONTAINE SURLGNVEVE iV! 30 ONS ‘SBNTWA “ANI JO SNITIONSS: (a0 NUM) CaMe-Nvte 30 TAN ONLLYEIO¥. PURCHASE DETAILS ‘The following purchase information will be required by Volias/SSP in case of any warranty claims or service requests. Hence kindly ensure our Engineer/SSP fills in the follawing details before handing aver this manual to you 1, Customer's Name & Address. 2 Voltas Office / SSP address from whom purchased Phane : 3. Madet No.: i 4 SI. No. 4, Invoice No.: 5. Date of Despatch Date of Commissioning 6 Warranty Gommencement Date Warranty Expiry Date : 7. Compressor & Fan Motor SI. Nos. (Compressor Si. No. Fan Motor Si. No. Circuit 1 Cireuit2; Signature & Seal of Signature & Seal of ‘Customer Voltas Engineer or SSP Date of Filling CUSTOMER COPY {55]SECTION - VI WARRANTY & SERVICE 56Vv rts arr COMMITMENT TO SERVICE SERVICE AFTER WARRANTY Votas offers a range of Maintenance Service Contracts at reasonable prices, fo its customers 4. Comprehensive annual maintenance service scheme '8) Under this scheme all the spares & consumables required for repairs, overhauling the AC Plant are included, 2. Annual Maintenance Service Scheme Under this scheme repairs and overhauling is covered The following items of warks are net covered under this schema a) The consumables like refrigerant, ol. 1b) Transportation of equipment for repairs and octrol payment, '€) Replacement of detective equipment by new equipment ADVANTAGES OF ENTERING INTO AN MS CONTRACT WITH VOLTAS: ‘Voltas technicians and authorised representatives ar ‘= Extensively trained in troubleshooting of airconditioning & refrigeration equipment & systems. + Amare of the standards, tests & procedurs for upkeep of the unit, thus saving downtime of equipment. © Responsive to: your customised service needs beyond the above mentionad services. + Possesing adequate knowledge to assists you in refurbishment of existing unitsystem for providing totally fresh solution for your new equipment. «Voltas carries an inventary of genuine spares for various models ‘+ It works: out economical in the long run. YOU ARE ENTITLED TO GOOD SERVICE... ‘SOHOW DO YOUREAGH VOLTAS FOR SERVICE? 1. your system is under warranty or Maintenance Service Contract : Please contact the nearest Voltas service centre (See telephone nas. on next page). While lodging a complaint, please inform the following «Whether the system is under warranty, and if so the: date of installation, the unit mode! number and the ‘unit serial number and GO. No. ‘© Whather the system ig under a Maintenance Service Contract, and if s0, GO. No. ©The nature of complaint. 2. ifthe system is out of warranty but NOT covered under any Maintenance Service Contract : Pionse contact the nearest Vollas Service Centre, lodge your complaint, and ask for senvice on a chargeable basis. Vollas will undertake to repair on a chargeable basis, but you will be required to sign a work-ortier form, 3. ifthe warranty is getting aver, and you wish te sign a Maintenance Service contract OF If the eurrent Maintenance Service Contract is expiring and you wish to renew the same Normally Voltas executives will get in touch with you, with the Maintenance Service Contract proposal. For further assistance, you are requested to contact the Vols Service Centre betore the expiry of warranty current Maintenance Service Contract<4 ALL INDIA CONTACT NUMBERS: ~ ones tmenione cornet TaBONE ux CE RMSHROR mem AAP amtege aaa andr ‘vrs sshon oes SSE AREY te om sot ne “ct STWR nae VOLTAS inTecnaTina sysTens. INCOMPARABLE VALUE, wwen.voltas.comL-cono/ovanvanasreeNa