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FINAL DRAWING

TITLE PACKAGED TYPE UNIT COOLER


FOR ENGINE CONTROL ROOM

SHIPYARD HYUNDAI MIPO DOCKYARD Co., Ltd.


SHIP NO. 6028~035
SHIP KIND 58K BULK CARRIER

HI AIR KOREA Co., Ltd.

1432-11, DAMAN-RI, JILLYE-MYEON


GIMHAE CITY, KYUNGNAM, KOREA
TEL. : +82 55 340 5200
FAX. : +82 55 346 3501∼2, 3884
PACKAGE TYPE UNIT COOLER HI AIR KOREA
HMD 6028~035

GENERAL SPECIFICATION

* YARD : HYUNDAI MIPO DOCKYARD Co., Ltd.

* YARD NO : 6028~035

* APPLICATION : ENGINE CONTROL ROOM

* EQUIPMENTS : PACKAGE TYPE UNIT COOLER (1UNIT / SHIP)

* REFRIGERANT : R-404A

* COOLING WATER : FRESH WATER 36℃

* POWER SOURCE : 440Vac, 60Hz, 3-Phase

* CONTROL SOURCE: 220Vac, 60Hz, 1-Phase

E.C.R (HIP-5WG) PAGE. 1


PACKAGE TYPE UNIT COOLER HI AIR KOREA
HMD 6028~035

GENERAL DESCRIPTION

1. Cooling system

(1) Cooling method : R-404A direct expansion cooling system

(2) Temperature control : Automatically controlled by thermostatic


expansion valve and thermostat
which is actuated by room temperature.

2. Heating system

(1) Heating method : N/A

(2) Temperature control : N/A

3. Ventilation system

(1) Ducting method : Plenum chamber type

(2) Air velocity : Low velocity

(3) Air pressure : Low pressure

4. Power source

(1) Power source : 440Vac, 60Hz, 3-Phase

(2) Control source : 220Vac, 60Hz, 1-Phase

5. Painting color : RAL 7032

E.C.R (HIP-5WG) PAGE. 2


PACKAGE TYPE UNIT COOLER HI AIR KOREA
HMD 6028~035

TECHNICAL SPECIFICATION & SUPPLY SCOPE

1. Package type unit cooler ---------------------------------------- 1 Unit/Ship


. Model : HIP – 5WG
. Refrigerant : R-404A
. Cooling capacity : 15,000 kcal/h (5 RT)
. Power source : 440Vac, 60Hz, 3-Phase
. Control source : 220Vac, 60Hz, 1-Phase

2. Components of Water cooled package type unit cooler


(1) Compressor ---------------------------------------- 1 Set/Unit
. Type : One-stage hermetic type
. Model : MTZ 64HM
. Manufacturer : DANFOSS MANEUROP
. Cooling capacity : 15,000 kcal/h at Te=+ 5.0℃ and Tc=+ 45.0℃
. Capacity regulation : 100%, 0%
. Power consumption : 7.3 kW
. Max. Running current : 15A

(2) Marine water-cooled condenser ---------------------------------------- 1 Set/Unit


. Type : Horizontal shell and tube type
. Size : φ165 x 800L
. Material : Tube = Copper (3/4”)
: Tube plate = SS400
. Water flow rate : 6.3 m³/h
. Pressure drop : 2.63 mH2O
. Heat dissipation : 20,000 kcal/h

(3) Evaporator ---------------------------------------- 1 Set/Unit


. Type : Multi-pass crossed fin tube type
. Material : Fin = Aluminum / Tube = Copper
. Cooling method : R-404A direct expansion cooling system
. Cooling capacity : 15,000 kcal/h
. Evaporating temper' : Approx + 5.0℃
. Accessories
1 piece - Distributor

E.C.R (HIP-5WG) PAGE. 3


PACKAGE TYPE UNIT COOLER HI AIR KOREA
HMD 6028~035

(4) Electric heater ---------------------------------------- N/A


. Type : N/A
. Heating capacity : N/A

(5) Fan with motor ---------------------------------------- 1 Set/Unit


. Type : Double suction multi blade Centrifugal fan
. Model : DDM 9-9
. Manufacturer : NICOTRA
. Discharge Type : Plenum chamber type
. Air flow rate : 45 m3/min (2,700 m3/h)
. Motor Output : 0.25kW x 6Poles
. Running Current(Max.) : 1.2 A
. Starting Current : 2.6 A
. Insulation class : “F”
. IP Grade : IP 44

(6) Control & Safety Devices ---------------------------------------- 1 Lot/Unit


. 1 piece - Dual pressure switch
.High pressure setting : Cut-out 24 bar
: Cut-in Manual reset
.Low pressure setting : Cut-out 2.5 bar
: Cut-in 3.5 bar
. 1 piece - Water pressure switch
.low pressure setting : Cut-out 0.7 bar
: Cut-in 1.1 bar

. 1 piece - High pressure gauge : 0 ∼ 3.5 Mpa (0 ~ 35 kg/cm²)


. 1 piece - Low pressure gauge : -0.1∼ 2.0 Mpa (-76cmHg ~ 20 kg/cm²)
. 1 piece - Water pressure gauge : 0∼ 0.6 Mpa (0 ~ 6 kg/cm²)

(7) Charging chemicals ---------------------------------------- 1 Lot/Unit


. 5 kg - Refrigerant R-404A (initially filled)
. 1.8 Liter - Polyolester oil 160PZ(initially filled, Maker: DANFOSS MANEUROP)

(8) Air- filter ---------------------------------------- 2 Set/Unit


. Type : Washable Vinyl Chloride Fiber
. Size : W390 x H380(5t)
E.C.R (HIP-5WG) PAGE. 4
PACKAGE TYPE UNIT COOLER HI AIR KOREA
HMD 6028~035

(9) Other components and accessories, fitted in/on PAC unit --------- 1 Lot/Unit
a) On internal piping lines
. 1 piece - Expansion valve
. 1 piece - Filter drier 1/2" on liquid line
. 1 piece - Service angle valve 1/2” on liquid line

b) For external pipe connections


. 2 piece - Cooling water in/outlet pipe connection, size 32A 5K flange
. 1 piece - Lower drain pipe connection, size 15A socket with hose

c) For electric cable entries


. 1 piece - Cable glands, OSNJ 25b (Power source); 3x10.0(O.D:18.3mm)
. 1 piece - Cable glands, OSNJ 16b (Alarm); 2x1.0(O.D:10.0mm)

(10) Control Box with Starter Panel ---------------------------------------- 1 Set/Unit


. Type : Dead-front built-in type, Mounted on inside of the front
panel of PAC unit
. Components :
.Manual start/stop push buttons for fan motor
.Manual start/stop push buttons for cooling
.Indicating lamps
.Magnetic contactor with over-current relays
.Transformer (440/220Vac) for control voltage
.Automatic indicator temp' controller
.Other components

3. Spare Parts and Tools (Maker's standard) ---------------------------------------- 1 Set/Unit


. 1 Set of spare parts & tools, according to spare parts drawing

E.C.R (HIP-5WG) PAGE. 5


PACKAGE TYPE UNIT COOLER

COMPRESSOR
HI AIR KOREA INSTRUCTION MANUAL
B
Co., Ltd.
#1432-11,daman-ri, Jillye-myeon,
Gimhae-city, Korea
Tel. +82 (0)55 340 5200
Fax:+82 (0)55 346 3502
INSTRUCTIONS / INSTRUKTION

RECIPROCATING COMPRESSORS

8510196 P02-A © Danfoss Commercial Compressors 06/04


Danfoss Commercial
Compressors
Instructions

Modifications or alterations (such as brazing • Perform a check on the discharge lines : piping
Contens to the condenser must be designed so as to
on the shell) not expressly approved by the party
responsible for ensuring compliance could prevent liquid return to the compressor. The
1 - Introduction
invalidate the user’s authorization to operate the use of non-return valves may prove necessary,
2 - Transportation, storage depending on the position of the compressor with
3 - Safety measures prior to assembly equipment.
respect to the condenser. A suitably-sized U-trap
4 - Assembly may also be necessary if the condenser has been
5 - Leak detection 2 - Transportation, storage placed above the compressor (refer to Fig. 2).
6 - Vacuum dehydration procedure • The piping connected to the compressor must
• The compressor must be handled in the vertical
7 - Electrical connections position (maximum offset from the vertical: 15°). be configured on the basis of a flexible 3-axis
8 - Filling the system Should the compressor be handled in an upside- design to dampen vibrations and designed in
9 - Verification before commissioning down position, its performance may no longer be such a way as to prevent free liquid refrigerant
10 - Start up insured. migration and drainage back to the compressor
11 - Troubleshooting sump and discharge cylinder heads (refer to fig. 2).
• Beware that all compressor handling must be
12 - Maintenance carried out with extreme caution to avoid any Note that all local and regional regulations and
13 - Replacement shocks. Dedicated packing handles are to be used safety standards, such as EN378, must be taken
14 - User advisory for all required manipulation of the compressor; into account when designing, connecting and
otherwise appropriate and safe lifting equipment running the system.
is to be used during handling and unpacking.
1 - Introduction
• Any damage noticed on either the packaging 4 - Assembly
These instructions pertain to the Maneurop® or the product itself upon reception should
hermetic reciprocating compressors used for A/C be indicated on a Customer Claim addressed to The compressor’s time of exposure to the
and refrigeration purposes. They are intended to the shipping company.The same recommendation atmosphere during installation shall be held to
provide necessary information regarding safety applies to all instances when transport instructions aminimum (less than 1/2 hour). The compressor
features and proper handling of this product. have not been fully respected. connection must be fast in order to avoid moisture
Note that this is a general document for the entire • Please review the safety instructions printed on contamination of the lubricant.
range of reciprocating compressors; certain details the cardboard packaging before storage. • The grommets must be installed under the
therefore may not be applicable to the particular • Verify that the compressor is never stored in an compressor feet, as shown in Fig. 5. Rubber
model you purchased. Please keep your manual and ambient temperature of below -35°C (-31°F) or grommets are to undergo compression until
all relevant information handy for future reference. above 50°C (122°F). contact is made between the flat washer and the
• Equipment description: This compressor is • Ensure that the compressor and its packaging steel mounting sleeve.
delivered with all assembly equipment (rubber are not exposed to rain and/or a corrosive, Before opening the compressor connection
grommets + screws + washers), an electrical box flammable atmosphere. fittings, it is mandatory to connect a 1” service hose
(cover + spring), connecting sleeves and gaskets, to the Schrader fitting on the compressor shell in
and instructions. order to gradually release the nitrogen holding
3 - Safety measures prior to assembly
• Approved list of refrigerants: charge.
- The MT series can be used with R22, R12 and • All installation and servicing is to be performed by • Ensure that no material enters into the system
R502. qualified personnel in compliance with all pertinent while cutting the tubing. Moreover, never drill
- The MTZ series can be used with R404A, practices and safety procedures. holes in the pipe work after installation.
R507A, R134a and R407C.
• The compressor must be located in a ventilated
- The LT series can be used with R502 and R22 area to ensure that the ambient temperature
• Should additional components need to be
(booster). connected onto the compressor sight glass or oil
never exceeds 50°C (122°F) during the off-cycle. equalization ports, it is recommended that such
- The LTZ series can be used with R404A and
R507A. • Make certain that the compressor can be mounted an operation be carried out prior to final assembly,
• Compressors are filled with lubricant before onto a horizontal plane with a maximum slope to allow for compressor inclination and movement.
leaving the factory: of 3°.
• Avoid flare-type connections and exercise great
- The MT and LT series with mineral oil (ref. 160P), • Check that the compressor model corresponds care while brazing (use only state-of-the-art
- The MTZ series with polyolester oil (ref. 160PZ), to system specifications (capacity, use of refrigerant, practices); apply a nitrogen gas flow to prevent
- The LTZ series with polyolester oil (ref. 160Z). etc.). oxidation inside the tubing, especially when HFC
These lubricants must not be mixed with one • Verify that the power supply corresponds to refrigerants are being used. All brazing material is
another. compressor motor characteristics (refer to the to contain a minimum of 5% silver. If flux additive
Be aware that alkylbenzen oil (ref. 160ABM) is compressor nameplate for precision). is used, don't put the copper tube into the receiver of
available for refrigerant substitutes (not listed on flux, but put flux around the tube (i.e. with a pencil).
• Ensure that refrigerant charging equipment,
the compressor nameplate), yet is never filled in This will prevent pure flux getting inside the tube.
vacuum pumps, etc. for HFC refrigerant systems
the compressors at the factory.
have been specifically reserved for these • When brazing, protect the terminal box and
• Maneurop® compressors must only be used for refrigerants and never used with other CFC, painted surfaces of the compressor from torch
their designed purpose(s) and within their scope HCFC refrigerants. heat damage.
of application (refer to Fig. 1).
• Use only clean and dehydrated refrigeration-grade • Remove the Teflon gaskets when brazing
Compressors are delivered under nitrogen copper tubes as well as silver alloy brazing material. Rotolock connectors with the solder sleeve and
gas pressure (between 1 and 2 bar) and hence • Verify that all system components are appropriate be aware that original suction and discharge
cannot be connected as is; please refer to the (use of refrigerant, etc.), clean and dehydrated gaskets must be replaced.
«Assembly» section for further details. before being connected to the completed assembly. • When installing Rotolock fittings, always use two
Compressors are not certified for mobile and • Perform a check on the suction lines: horizontal wrenches when tightening any fittings to insure that
explosion-proof applications. Any use of flammable sections are to be sloped downwards towards the the torque is effectively cancelled on the adjacent
refrigerant (e.g. hydrocarbons) or air is also strictly compressor. Suction gas velocity must be high tubing and fittings. Do not exceed the maximum
forbidden. enough to provide for an adequate oil return. This tightening torque for Rotolock connections to the
• Under all circumstances, the EN378 (or other velocity must be with in 8 to 12 m/s in vertical compressor :
applicable local regulation) requirement must be risers. In horizontal pipes, this velocity can 1 ” rotolock 80 Nm
fulfilled. decrease to 4 m/s. 1 ” 1/4 rotolock 90 Nm
1 ” 3/4 rotolock 110 Nm.
When pressure tests are required on the • The use of U-trap and double-suction risers may
system, they are to be performed by qualified be required on vertical sections, but not in excess • Be sure to connect the required safety and
personnel, in paying close attention to potential of 4 m unless a second U-trap system has been control devices onto compressor shut-off valves
pressure related hazards and heeding the pressure fitted (refer to Figs. 3 and 4). Suction line piping or fittings. In case of oil return through the
limits displayed on the compressor nameplate or must be insulated in order to minimize the effects Schrader fitting on the compressor shell, make
in the application guidelines. of superheating. sure the internal valve is removed.

8510196 P02-A © Danfoss Commercial Compressors 06/04 3


Instructions
Vacuum pump: - In the event additional oil is required, use only
5 – Leak detection A two-stage vacuum pump with gas ballast an approved lubricant (refer to the «Introduction»
(0,04-mbar standing vacuum) shall be used; its section of this manual).
Never use oxygen or dry air in order to avoid
capacity is to be consistent with system volume. - An oil sight glass compressor model is
the risk of fire or explosion.
Never use the compressor as a vacuum pump. recommended for split systems and remote
Perform a leak detection test on the complete condenser installations.
system by means of: a dry nitrogen pressure test, It is recommended to use large-diameter connection
For all information necessary on adding oil to
a mixture of nitrogen and the refrigerant to be lines and to connect these lines to the shut-off
the compressor, refer to TI 2-025.
used in the system, a helium leak test and/or a valves, rather than to the Schrader connection.
deep vacuum test. This recommendation allows avoiding excessive • Make sure the refrigerant used to fill the system
pressure losses. is compatible with compressor design. Refer to
• The test should be long enough in duration to the “Introduction” section of this manual for an
ensure the absence of any slow leaks in the system. Moisture level:
approved list of refrigerants.
At the time of commissioning, system moisture
• Use tools specifically designed for detecting leaks.
content may be as high as 100 ppm. During • Compressor switched off: the liquid refrigerant is
• The low side test pressure must not exceed operation, the liquid line filter dryer must reduce charged into the condenser and/or liquid receiver
1.1 x Ps pressure indicated on the compressor this level to < 20 ppm. in the liquid phase (compulsory for refrigerant
nameplate. blends). The charge must be as close to the nominal
Additional notes:
• For high side test pressure recommendations, • To improve moisture removal, the temperature system charge as possible in order to avoid both low
please refer to the Application Guidelines. of the system should not be lower than 10°C. pressure operations and excessive superheating
at start-up. Throughout this operation, both
• Whenever the compressor is equipped with
• A proper vacuum procedure is even more compressor service valves must remain closed.
suction and discharge shut-off valves, these
important with HFC and polyolester lubricant than
valves are to remain in the closed position while • Remember that vapor-charging is only
it has “traditionally” been with HCFC (R22) or
performing the leak test (compressor leak test appropriate for pure refrigerants, such as R22.
CFC and mineral oil.
already performed in the factory).
• For further details, please refer to TI 2-026. • To the extent possible, maintain the refrigerant
Should a leak be discovered, proceed with repair charge below 2.5 kg per cylinder. Above this limit,
steps and repeat the leak detection. Do not use a megohmeter or apply power to the install a system, such as a pump-down cycle or
• When a deep vacuum leak detection test is compressor while it is under vacuum, as this may suction line accumulator, to prevent against liquid
selected, observe the following: cause motor winding damage (motor burn-out). flood-back into the compressor.
1) The level to reach is 500 µm Hg.
2) Wait 30 min. • Be sure that the refrigerant charge is suitable for
7 - Electrical connections both winter and summer operations.
3) If pressure increases rapidly, the system is not
airtight. Locate and repair leaks. Restart the • Make sure the main power supply to the system
vacuum procedure, followed by steps 1, 2, etc. has been switched off and isolated, in accordance 9 - Verification before commissioning
4) If pressure increases slowly, the system contains with applicable regulations, before performing
moisture inside. Break the vacuum with nitrogen any electrical connection. Ensure that all service valves are in the open
gas and restart the vacuum procedure, followed position before start-up. A closed discharge or
• Refer to Fig. 6 for wiring connection details with suction service valve may cause serious damage
by steps 1, 2, etc.
respect to the various motor codes. to the compressor and/or compromise safety
5) Connect the compressor to the system by
opening the valves. • Note that Maneurop® compressors are protected device operation, thereby resulting in potential
6) Repeat the vacuum procedure, followed by against overheating and overloading by an internal injury to personnel.
steps 1, 2, etc. safety motor protector. However, an external manual • Check that all safety devices are operational and
7) Break the vacuum with nitrogen gas. reset overload is recommended for protecting the properly set (safety pressure switch set point,
8) Repeat the vacuum procedure, steps 1, 2; a circuit against over-current. The “must trip” value mechanical relief valve if necessary, etc.).Make sure
vacuum of 500 µm Hg (0.67 mbar) should be of this overload relay must be set in that these devices comply with both generally -
reached and maintained for 4 hours. This pressure accordance with power line sizing and design and and locally - applicable regulations and standards
is to be measured in the refrigeration system, not shall never exceed the “A max.” value stamped on (e.g. EN378).
at the vacuum pump gauge. the nameplate.
• When using high-pressure switches or relief
Do not use a megohmeter or apply power to the • The single-phase compressor models are valves, the setting must not exceed maximum
compressor while it is under vacuum, as this may internally protected by a bimetallic temp./current service pressure of any system component.
cause motor winding damage (motor burn-out). sensor cut-out, which senses both the main Refer to the Application Guidelines for relevant
Do not use colored leak detection fluids. Do winding current and the start winding current. compressor pressure safety limits.
not use chlorofluorocarbon in leak testing systems • Maneurop® compressors are able to operate in
designed for HFC fluids. • A low-pressure switch is recommended to
both directions (rotation).
prevent operation under vacuum. Use a minimum
• Depending on motor size, the power supply setting of 1.1 bar (absolute).
6 - Vacuum dehydration procedure connection utilizes either a spade connector
(1/4”-AMP-AWE) or a T-block connector • Verify that all electrical connections are properly
Whenever possible (if shut-off valves are present), fastened and in compliance with local safety
(screw type 10-32 UNF x 9.5 mm). For screw
the compressor must be isolated from the system. regulations.
type connections, be aware that the maximum
It is essential to connect the vacuum pump to both
tightening torque is 3 Nm. • When a crankcase heater is required (refer to the
the LP & HP sides, in order to avoid dead-ending
system parts. • A 5-mm earth terminal screw is provided in the Application Guidelines), ensure that it has been
compressor junction box for the grounding energized for a minimum of 12 hours before initial
Recommended procedure: start-up and/or after prolonged shutdown periods.
1) Once leak detection has been completed, connection.
2) Pull down the system under a vacuum of 500 µm All electrical components must be selected as per
Hg (0.67 mbar). local standards and compressor requirements. 10 - Start up
3) When the vacuum level of 500 µm Hg has been Never start the compressor in the absence of
reached, the system must be isolated from the 8 - Filling the system a refrigerant charge.
pump.
4) A vacuum of 500 µm Hg (0.67 mbar) has to be • Before charging the refrigerant, verify that the oil • Do not bypass the LP or any other safety
reached and maintained for 4 hours. This pressure level is between 1/4” and 3/4” on the compressor switches during start-up.
is to be measured in the refrigeration system, not oil sight glass (when mounted) and/or ensure that
• Check current draw and voltage levels.
at the vacuum pump gauge. If pressure increases, the oil charge of the original compressor is sufficient
restart the leak-detection procedure (refer to as regards system dimension and piping design: • Suction superheat setting: optimal compressor
the «Leak detection» section of this manual if - An additional quantity of oil might be necessary suction superheat would be around 10K, with the
necessary). for line lengths (back and forth) inexcess of 20 m. maximum allowable superheat being 30K.

4 8510196 P02-A © Danfoss Commercial Compressors 06/04


Instructions
• In all cases, the application limits of the compressor • Compressor maximum short cycling: there must test always proves helpful in diagnosis when
must be respected; moreover, high superheat be a minimum delay of five minutes between two undertaking compressor replacement.
values lead to high discharge temperatures and compressor starts. DCC recommends the com-
• Check that the new Maneurop® compressor and
decrease compressor capacity. The maximum pressor should run at least two minutes after
the on-site compressor to be replaced display the
discharge temperature is 130°C: operating at a each start, and between each stop and start must
same electrical and refrigeration performance
higher temperature may result in refrigerant be three minutes standstill. Only during pump
characteristics.
decomposition. down cycle, the compressor may run much shorter
• Under steady-state operating conditions, check until the pumpdown pressure has been reached • Use the rubber grommets and gaskets supplied
refrigerant piping or capillary tubes for abnormal or when safety devices will prohibit compressor with the new compressor.
vibrations (refrigeration line movement in excess further operation. • Whenever piping needs to be modified, please
of 1.5 mm necessitates corrective actions, pipe refer to the «Safety measures prior to assembly»
brackets, etc.). 12 - Maintenance section.
• Monitor the oil sight glass (when mounted) Maneurop® compressors do not necessitate any • For further details on replacement steps, refer to
to ensure proper oil return to the compressor. special maintenance procedure. However, it the previous sections of this manual.
After 2 to 4 hours of operations under established must be recalled that proper operations and
conditions, check the oil level and add oil if Note: In the event of motor failure, flush and clean
maintenance of the system serve to prevent
necessary (refer to TI 2-025). If oil return continues the entire circuit before replacing the compressor
against system-related compressor problems.
to perform poorly, further investigation of the in order to remove acids and contaminants.
The following preventive maintenance checks, to
piping design is required. Systematically install a new filter dryer on the liquid
be performed at regular intervals, are highly
line. Prior to this step (if necessary), run the system
• Ensure that refrigerant flow through the liquid recommended:
for at least 2 hours with anti-acid cartridges (in such
line sight glass (when mounted) is adequate - Control operating conditions (evaporating
instances, the installation of a suction filter might
and that operating temperatures correspond with temperature, condensing temperature, com-
also be required). After an operating period of
system specifications. pressor discharge temperature, temperature
approximately 2 weeks, check the level of oil acidity.
difference on heat exchangers, superheat,
• When needed, refrigerant may be added in the If the oil acid test proves positive, drain and replace
sub-cooling). These conditions must always
liquid phase, carefully throttling the refrigerant the oil, replace the anti-acid liquid line filter dryer
remain within compressor operation limits.
on the low-pressure side and as far as possible cartridges and the suction filter previously installed.
from the compressor. The compressor must be - Verify that safety devices are operational and Repeat oil and filter dryer replacements until the
operating during this process. properly set. system is clean and acid-free. When there is no
- Check the compressor oil level and quality; this longer any sign of acidity, replace the anti-acid
Do not overcharge the system.
step may include an acid test, humidity check, cartridges by the standard model and remove the
spectrometer analysis, etc. whenever the oil suction strainer cartridge as required.
11 – Troubleshooting becomes discolored.
- Ensure that the circuit is leak tight. 14 - User advisory
• Compressor failure to start: verify that the
compressor is hooked up to the power supply; - Verify the proper operation of heat exchangers Insist that all service operations only be performed
check the power lead connections and all suitable and, if necessary, clean them. by qualified personnel.
capacitors on single-phase models. If these - Check the current draw on the compressor
verifications reveal no abnormality, control the motor as well as proper voltage balance The compressor and tubing surface tempe-
motor windings with an ohmmeter. between phases. ratures may exceed 100°C (212°F) and cause
severe bodily burns. Special precaution must be
Note: when the internal motor protector has - Check that all electrical connections are still taken when working around the compressor and
tripped out, it may take up to several hours toreset adequately fastened. refrigerant tubing. Moreover, a compressor
and restart the compressor. - Make sure the compressor is clean and in inoperation can generate very cold surface
• Compressor failure to build up pressure: check good working order; verify the absence of rust temperatures (as low as -45°C / -49°F), thereby
to make sure that all bypass valves in the system on the compressor shell, piping and electrical exposing personnel to the risk of freezing burns.
have not been opened. connections.
Pressure inside the compressor can reach
Also check that all solenoid valves are in their - Make sure the refrigerant charge is suitable for dangerously high levels (e.g. abnormal operation,
proper position. If the internal pressure relief valve both winter and summer operations. Insure fire,…) leading to personnel injury if suddenly
is open, the compressor sump will be warm and the that periodic in-service inspections required by released; therefore, never drill, weld or cut the
compressor will trip out on the motor protector. If local regulations are performed. compressor shell and adjacent tubing (release of
this happens, it may take up to 2 or 3 hours to liquid refrigerant can cause flash freezing on
reset and automatically restart thecompressor. 13 – Replacement exposed skin).
• Abnormal running noise: ensure the absence
Precaution must be taken when disconnecting, Be aware that the product warranty may be
of any liquid flood-back to the compressor by
cutting or drilling holes in the tubing to ensure that deemed null and void in the following cases :
means of measuring the return gas superheat
no refrigerant under pressure is present in the • external modifications to the compressor
and compressor sump temperature. The sump
system. (absence of nameplate, drilling, welding, broken
should be at least 10K above the saturated suction
feet, shock marks),
temperature under steady-state operating conditions. The refrigerant shall not be discharged
• The high-pressure switch trips out: check directly into the atmosphere; rather, it must be • compressor opened by the customer or returned
condenser operations (condenser cleanliness, fan removed using approved reclamation techniques unsealed (i.e. open discharge or suction ports),
operations, water flow and water pressure valve, and equipment and then safely stored, in • presence of rust or water inside the compressor,
water filter, etc.). If above check out OK, the problem accordance with applicable legislation.
• addition of leak-detection fluid in the lubricant,
may be due to either refrigerant overcharging or the The presence of refrigerant vapor can
presence of a non-condensable (e.g.air) in the circuit. displace air and lead to suffocation. Proper • use of a refrigerant or lubricant not approved by
• The low-pressure switch trips out: check ventilation is mandatory at all times when servicing Danfoss Commercial Compressors,
evaporator operations (coil cleanliness, fan the equipment. • any deviation from recommended instructions
operations, water flow, water filter, etc.), liquid A refrigeration system component change pertaining to installation, application or maintenance,
refrigerant flow and pressure drops (solenoid valve, must be carried out in compliance with local
filter dryer, expansion valve, etc.), refrigerant charge. • use in mobile applications (boats, trains, trucks,
regulations. etc.) or under explosive atmospheric conditions
• Low refrigerant charge: the correct refrigerant • Make sure that the main power supply has been (the compressor connecting box is not explosion-
charge is given by the liquid sight glass switched off. proof).
indication, the condenser delta T in relation to the
refrigerant pressure tables (pressure-temperature), • Before replacement, it is necessary to determine The date of production of the compressor is indi-
the superheat and the sub-cooling, etc.(if additional the cause of failure and implement remedial action. cated on the nameplate. Ensure that the model
charge is deemed necessary, refer to the “Filling If such analysis and repair are not performed, and serial number information is always trans-
the system” section). repetitive failure may occur. Note that an oil acidity mitted with any claim filed regarding this product.

8510196 P02-A © Danfoss Commercial Compressors 06/04 5


PACKAGE TYPE UNIT COOLER

CONTROLLER
OPERATING MANUAL
C
HI AIR KOREA
Co., Ltd.
#1432-11,daman-ri, Jillye-myeon,
Gimhae-city, Korea
Tel. +82 (0)55 340 5200
Fax:+82 (0)55 346 3502
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

INSTRUCTION & OPERATION MANUAL

TEMP.

RUN/HOUR

START/STOP COOL/HEATER

PCB CONTROLLER

1
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

TABLE OF CONTENTS

1. INSTRUCTION

2. LAY-OUT FOR PAC-01 CONTROLLER

3. SWITCHES AND INDICATION

4. OPERATION INSTRUCTION

5. INPUT AND OUTPUT DESCRIPTION

6. MAIN BOARD SETTING AND PROGRAMING

7. TROUBLE SHOUTING

2
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

1. INSTRUCTION
The cool/heater electronic controller printed circuit board
(PAC-01) has been designed as a controller for use in automatic control for temperature
On the room.

PAC-01 is a feature packed microprocessor(atmega 128) based on control unit suitable


to perform fan motor run and compressor solenoid valve open/close, DPS, WPS, LPS
sensor detection.

PAC-01 PCB is designed for maximum reliability with 100% solid state circuity and
Isolated operations for the local/remote use.

PAC-01 PCB incorporated a temperature controller, running hour meter, current


meter(option).

An alpha-numeric display(main controller 8-digit operation panel 5-digit, 7-segment) is


Visible through window on the front of enclosure. During normal condition, room
Temperature shall be indicated.

System alarm condition are signaled at the panel visually(by alarm LED) and alpha
-numeric display.
In an alarm condition present, the display will emit an alpha-numeric code. This code
Can be interpreted using a affixed to the outside door to pinpoint the circuit affected
By the alarm condition.

Pad switches are provided with the alpha-numeric display to the facility programming,
Monitoring of room temperature, cool/heater, fan running hours, start/stop fan motor.

**IMPORTANT
Followings are to be completely read and understood for using this controller.

-PAC-01 controller shall be supplied separately in local and remote.

-delay time

3
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

The compressor is protected to the delay time(2 minute) from running it. But
after significant delay time it is running immediately. In case of heater , there is
no delay time.

2. LAY-OUT FOR PAC-01 MAIN CONTROLLER

Fig. 1 OPERATION PANEL DETAIL

TEMP.

RUN/HOUR

START/STOP COOL/HEATER

4
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

Fig. 2 OPERATION PANEL DETAIL(ONLY COOLLER)

TEMP.

RUN/HOUR

START/STOP

5
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

Fig. 3 BACK VIEW AND MAIN CONTROLLER DETAIL

6
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

3. DESCRIPTION FOR SWITCHES AND INDICATION


3.1 SWITCHES
1. A/C start/stop switch:
This switch can be “ON” / “OFF” by pressing, alternately.
2. Lower/high switch:
Lower switch decrease for setting of required value and search the mode
High switch decrease for setting of required value and search the mode
3. Cool/heater switch:
Cool: press this switch, and then cooling to be started/and or stopped,
Alternately green LED lamp turn on.
Heater : press this switch, and then heating to be started/and or stopped,
Alternately the red LED lamp turn on.
4. Display/reset switch:
Alpha-numeric display indicates room temperature usually.
If you want to see/confirm surface temperature on cooling or fan motor
Running hour, you can do by pressing this switch. Indicated value shall be
Corresponded with relevant LED at left column.

This figure show alpha-numeric display indicate fan running hour cooperated
“HOUR” LED.

TEMP.
ON
RUN/HOUR PAC-01 Running : 3755 Hour

Reset switch:
Permit / indicate setting for all parameters and save a changed value.

7
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

3.2 INDICATION
1. Fan run LED:
Fan run LED will be illuminated when fan motor running.
2. Compressor run LED:
This LED mean cooling valve is opened.
3. Alarm LED:
Alarm LED will be illuminated when any alarm condition with error code on the
Alpha-numeric display.
4. Temp. run/ Hour LED:
Some value shall be indicated on the alpha-numeric display
You can identify what mean this value.
Temp.: room temperature
Hour: fan motor running time(Hour).

ON
TEMP.

RUN/HOUR ROOM TEMP. : 20° C

Using/pressing by display change switch, you can see other value, one by one.

3.3 alpha-numeric display(operation panel:5-digit, main board:8-


digit, 7-segments):
alpha-numeric display indicates temperature or running hour under display view
conditions pressing by display switch “display”.
You can choose/search using by “up” “down” switch, and display shall be changed.
When alarm occurred, the display shows error code.

8
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

4.0 OPERATION INSTRUCTION

4.1 INITIAL START UP


1. Cut power supply to the controller.
Check the external connection ( especially, motor power line and temperature sensor).
If all are ok, go to the next step.
2. Supply the power again. Then all of the LED and 7-segment will be lit for 5 seconds.
you can check all lamp and 7-segmenat are ok or not.
*** As soon as the power supplied, the running hour timer will begin to work, therefore if you
want to start at cooling time again, you must be cut controller’s supply power at least 10 seconds
and supply the power again.
3. The room temperature is indicated to 7-segment of the controller.
4. Confirm that each of parameter is set exactly, based on quick reference guide affixed
outside of the door.
5. Check the cooling compressor and heating operation, if not, you should running it
6. Press the “ START SWITCH” a front of controller.
*** During startup, the room temperature is higher than the high alarm setting temperature. So
an alarm will occur. This high alarm signal should be neglected due to the fact that that
everything is working normally. And then, confirm whether the room temperature has decreased
normally, Or not.
7. Confirm if the cooling LED lamp is running.
8. Confirm if the fan is running at setting temperature.
*** Fan for cooling or heating room should be operated immediately.
*** For this state, confirm if the room temperature is below to set temperature.
9. Confirm the cooling or heating lamp whether “ON”, “OFF” state are repeated in the
setting temperature and DIFF temperature.
*** Repeat the above procedure for 2~3 times, then, confirm the operation.
10. Stop the fan to press the stop switch.
11. Press the start switch.
*** If the above procedure is working normally, re-set all setting point in front of the panel. And
then run to the normal operation.

9
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

4.2 FLOW CHART FOR PAC-01

10
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

5. INPUT/OUTPUT DESCRIPTION
5.1 INPUT DESCRIPTION
5.1.1 Analogue input
a. Room temperature: semiconductor temperature.
Room semiconductor temperature sensor in the room.

5.1.2 digital input

INPUT nos NORMAL Error code REMARK


T31 close Err-08 FAN MC or OCR ERROR
T32 close Err-09 COMP.1 MC or OCR ERROR
T38 close Err-10 COMP.2 MC or OCR ERROR
T33 close Err-11 HEATER1 MC ERROR
T34 close Err-12 HEATER2 MC ERROR
T35 close Err-13 HEATER3 MC ERROR
T37 close Err-03 DPS1 FEED BACK SIGNAL
T36 close Err-02 WPS FEED BACK SIGNAL
T39 close Err-04 DPS2 FEED BACK SIGNAL
T40 open Err-05 LPS FEED BACK SIGNAL

5.2 OUTPUT DESCRIPTION


5.2.1 FAN RUN SIGNAL
Transistor output 1: out 1 shall be energized during fan motor running. These ports shall
Be normally connected with fan magnetic contactor.
5.2.2 COMP.1 SIGNAL
Transistor output 2: out 2 shall be energized during compressor1 motor running. These
ports shall be normally connected with fan magnetic contactor.
5.2.3 COMP.2 SIGNAL
Transistor output 3: out 3 shall be energized during compressor2 motor running. These
ports shall be normally connected with fan magnetic contactor
5.2.4 HEATER1 SIGNAL
Transistor output 4: out 4 shall be energized during heater1 running. These ports shall be

11
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

normally connected with fan magnetic contactor


5.2.5 HEATER2 SIGNAL
Transistor output 5: out 5 shall be energized during heater2 running. These ports shall be
normally connected with fan magnetic contactor
5.2.6 HEATER3 SIGNAL
Transistor output 6: out 6 shall be energized during heater3 running. These ports shall be
normally connected with fan magnetic contactor
5.2.3 ALARM SIGNAL
Transistor output AL: out AL shall be energized when alarm occurred. To be transferred
alarm condition to external alarm device(normal close dry contact).

6. PROGRAMMING(This section provide for supervisor or authorized person)

MODE DESCRIPTON FOR SETTING


NO PARAMETER VALUE DESCRIPTION DEFAULT SETTING VALUE

MIN MAX

1 Cn 1 2 Comp. number 2
2 Hn 1 3 Heater number 2
3 Tr 1 1 Temperature setting of step 3
4 Ft 1 50 Fan off delay time 3
5 Ce 1 50 Comp. off delay time 5
6 He 1 50 Heater off delay time 5
7 Fb 0 50 Feedback signal check time 1
8 Pd 0 50 spare .
9 Sd 0 120 Start delay time.(only comp.) 60
10 To -50 50 Temp. offset 0
11 Lo 10 30 High temp. setting value 55
12 Cu 1 200 Low temp. setting value 0
13 St 10 40 Setting current temp.(option) 20
14 Dt 1 3 Diff. temp. value 2
15 Ct 1 250 Current setting value(option) 0

The controller utilizes a memory device called an EEPROM.


This memory, once programmed, will store the desired program information permanently, even if

12
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

power is removed; yet it will allow adapt the controller to the system requirement.

6.1 MAIN BOARD CONTROLLER PARAMETER SETTING.


6.1.1 Set up method
1. Press switch “set up”.
2. Press down switch marked “down” switch, select parameter table.
3. “Cn”, “Hn”, ………. Is shown 7-segment.
-- If “Cn” is shown 7-segment, Press switch “display” and exit menu.
-- If “Hn” is shown 7-segment, Press “set up” switch and then, “5” is flicking.
3-1. Press switch “set up”.
3-2. Press up switch marked “up” switch, “Ct” appear, then press switch marked “set up”
One more time to save your setting, follow above step to repeat the other designated to
Main controller.

6.1.2 Confirmation for ERROR message.


PAC-01 controller has a function to store alarm messages.
You can find out what alarms are occurred in menu “E-XX”.
Total 20 alarm messages were stored in controller.

For confirmation alarm message, as follows;;


1. Press switch “set up”.
2. Press down switch marked ”down” switch.
3. “”E-1xx” is shown

13
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

6.2 MAIN BOARD AND OPRATION PANEL.


These contents are set before from factory. So it is not necessary to change the setting in
main board panel. But is must be measured according to the content when there is a need to
change each/common parameter change of the controller in the further.

6.2.1 MAIN BOARD & OPRATION PANEL CONNECTION.

*** OP1 of the operation panel is connected OP1 of the main board, from 4 wire connector.

6.3 confirmation for ERROR message.


PAC-01 controller has a function to store alarm messages.
You can find out what alarms are occurred in menu “Err-xx”.
Total 10(ten) alarm messages, to see error table next page .

7. TROUBLE SHOOTING.

ERROR CODE DESCRIPTION


NUMBER ERROR CODE DESCRIPTION
1 Err-04 DPS,WPS,LPS ERROR

14
INSTRUCTION & OPERATION MANUAL
FOR P.A.C & F.C.U
Project Name - Date MAY 04, 2010
Doc. No. - Sign H.C.PARK

2 Err-05 COMP. CRANKASE HEATER ERROR


3 Err-06 TEMPERATURE SENSOR ERROR
4 Err-07 FAN ERROR AND OCR(OVER CURRENT RELAY)
5 Err-08 COMP.1 ERROR
6 Err-09 COMP.2 ERROR
7 Err-10 HEATER1 ERROR
8 Err-11 HEATER1 ERROR
9 Err-12 HEATER1 ERROR
10 Err-13 COMUNICATION CONNECTION ERROR
11 Err-14 SPARE

The PAC-01 controller have been tested two(2) years at our company with actual
condition and we could not found any malfunction. We believe the controller will never happen
trouble controller, please check follows:

-Alarm with error code displaying:


Most errors are caused by mis-external wiring or connection between local instruments
and controller input port therefore, if alarm with error or happened, please check external wiring
and connection according to table 7.0 of the error code if not clear trouble, consult with HI-AIR
KOREA or authorized engineer.
-Controller not working:
Check power supply and correct according to drawing.
-Strange display on seven segments:
Carried out lamp test being power off and power on, and check faulty LED of the seven
segments. If fault LED were found, replace new switches & display PCB.

15
PACKAGE TYPE UNIT COOLER

MISCELLANEOUS
HI AIR KOREA INSTRUCTION MANUAL
Co., Ltd. - THERMOSTATIC EXPANSION VALVE
#1432-11,daman-ri, Jillye-myeon, - DUAL PRESSURE CONTROLER D
Gimhae-city, Korea - DRYER
Tel. +82 (0)55 340 5200
Fax:+82 (0)55 346 3502
INSTRUCTIONS

TE 5, TE 12, TE 20, TE 55
067R9504

067R9504
Range N = –40°C ® +10°C (–40°F ® +50°F)
Range B = –60°C ® –25°C (–75°F ® –15°F )
TE 5
Orifice Orifice Y = ±1 mm
no. code R 22 R 134a R 404A R 12 R 502
no. Range Range Range Range Range
N B N N B N N B
01 067B2089 26 26 27 27.5 27.5 28 26 26
02 067B2090 26 26 27 27.5 27.5 28 26 26
03 067B2091 26 26 27 27.5 27.5 28 26 26
04 067B2092 26 26 27 27.5 27.5 28 26 26
SH= 4°C (7°F)
TE 12
Orifice Orifice Y = ±1 mm
no. code R 22 R 134a R 404A R 12 R 502
no. Range Range Range Range Range
N B N N B N N B
01 067B2005 35 35 35 36 36 36 32 32
02 067B2006 35 35 35 36 36 36 32 32
03 067B2007 35 35 35 36 36 36 32 32
04 067B2008 35 35 35 36 36 36 32 32

TE 20
Orifice Orifice Y = ±1 mm
no. code R 22 R 134a R 404A R 12 R 502
no. Range Range Range Range Range
N B N N B N N B
01 067B2170 - - 32 - - 34 - -
02 067B2172 33.5 36 - - - - - -
03 067B2175 - - - 35 35 - 33 33

TE 55
Orifice Orifice Y = ±1 mm
no. code R 22 R 134a R 404A R 12 R 502
no. Range Range Range Range Range
N B N N B N N B
01 067G2001 - - 31 33 33 33 - -
02 067G2002 - - 31 33 33 33 - -
01 067G2005 32 34 - - - - - -
02 067G2006 32 34 - - - - - -
01 067G2011 - - - - - - 33 34
02 067G2012 - - - - - - 33 34

© Danfoss A/S RI.1A.1F.02 11 - 1998


TE

TE 5 TE 5, TE 12, TE 20 TE 55

RI.1A.1F.02 © Danfoss A/S (AC-SP.kaa) 98.11


INSTRUCTIONS
KP 15, 15A, 17W, 17B

060R9753
060R9753

KP 15, 17W, 17B: R 12, R 22, R 500, R 502


KP 15A: R 717 (NH3)

KP 15, 17 KP 15, 17 KP 15A

ptest max.35 bar(505 psig)


PB/ MWP

ptest max. 20 bar (285 psig)


PB/ MWP

Type Range PB MWP


KP 15 LP: -0.2 ® 7.5 bar 17 bar 250 psi
HP: 8 ® 32 bar 35 bar 505 psi
t1 min. KP 15: –40°F (–40°C) KP 15 LP: -0.9 ® 7 bar 17 bar 250 psi
KP 17: –25°C (–13°F) HP: 8 ® 32 bar 35 bar 505 psi
t1 max. 65°C (150°F) Reset
KP 17 LP: -0.2 ® 7.5 bar 17 bar 250 psi
HP:8 ® 32 bar 35 bar 505 psi

© Danfoss A/S RI.5A.B4.00 04 - 2001


When used acc. to UL regulations

AC1 16 A DC 11
LR 112A AC3 16 A 400 V@ 12 W
AC11 10 A 220 V@

-1 bar (Pe)(30in.Hg)

LP, aut. reset LP, man. reset HP

Manual test

Konvertibel reset / Convertible reset / Austauschbares Reset / Réarmement convertible


KP 15 060-1154, 060-1220, 060-1261, 060-1263, 060-1283

LP-man. LP-auto. LP-auto. LP-man.


HP-man. HP-man. HP-auto. HP-auto.

RI.5A.B4.00 © Danfoss A/S (AC-TMP, mr) 04 - 2001


INSTRUCTIONS
KP 1, 1W, 1A, 2, 5, 5A, 6, 7W, 7B, 7S

060R9750
060R9750

KP 1, 2, 5, 6, 7: HFC, HCFC, CFC


KP 6: HFC, CO2
KP 1A, 5A: R 717 (NH3)

KP 1, 2, 5, 6, 7 KP 1, 2, 5, 6, 7 KP 1A, 5A

KP 1, 2,
KP 5, 6, 7

Ptestmax.:
KP 1,2: 20 bar pe (285 psig)
KP 5, 7: 35 bar pe (505 psig)
KP 6: 46,5 bar pe (675 psig)

MWP/PB

Type Range MWP/PB


KP 1 –0.2 → 7.5 bar 250 psi / 17 bar
KP 1, reset –0.9 → 7 bar 250 psi / 17 bar
KP 1W 0.5 → 3 bar 250 psi / 17 bar
KP 2 –0.2 → 5 bar 250 psi / 17 bar
KP 5, 7W 8 → 32 bar 505 psi / 35 bar
KP 5, reset 8 → 32 bar 505 psi / 35 bar
KP 6 8 → 42 bar 675 psi / 46.5 bar
KP 7B, 7S 8 → 32 bar 505 psi / 35 bar

© Danfoss A/S RI.5A.A6.00 02 - 2003


Electrical rating - General
AC 1: 16A DC 11
LR 112A AC 3: 16A 400 V~
_ 12 W
AC 11: 10 A 220 V~
_

When used acc. to UL regulations

Automatic reset Manual reset

Diff.
KP 1, 1A: 0.7 bar (10 psi)
KP 5, 5A: 3 bar (43 psi)
KP 6, 7B, 7S: 4 bar (58 psi)

RI.5A.A6.00 © Danfoss A/S (IC-MC, mr) 02 - 2003

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