Ak Ecu 5T - STD

Installation, Operation and Maintenance Instructions with Parts List
COMMERCIAL MANUAL
ALASKA 5-Ton ECU

Model No. AK-ECU-5T
04 January, 2010
Copyright 2010 Alaska Structures, Inc. U.S. GOVERNMENT LIMITED RIGHTS NOTICE (NOTICE): (a) This documentation and any technical data, including drawings, are submitted by the Contractor to the Government with limited rights. This documentation and these data may be used, modified, reproduced, released, performed, or disclosed by the Government only as provided under paragraph (a) of DOD FAR 227.7102-2 Rights in Technical Data, with the express limitation that the data may not be used to manufacture additional quantities of the commercial items and, except as provided in subparagraphs (b)(1)(ii), (iii), and (iv) and subparagraph (b) (2)(ii) of DOD FAR clause 252.227-7015 released performed, displayed, or disclosed outside the Government. Any such modification, release, performance, or disclosure the Government makes is subject to prohibition against further use and disclosure. (b) This Notice shall be marked on any reproduction of this documentation and these data, in whole or in part.
LIMITED TWO-YEAR WARRANTY

Except as otherwise provided below, Alaska Structures, Inc. (Seller) warrants to the original buyer (Buyer) that all Goods sold under this Contract shall be free from defects in material and workmanship under normal use and service for a period of two years. SELLERS SOLE OBLIGATION, AND BUYERS SOLE AND EXCLUSIVE REMEDY, UNDER THIS WARRANTY SHALL BE THE REPAIR OR REPLACEMENT, AT SELLERS OPTION, F.O.B. ORIGIN AND SUBJECT TO THE TERMS AND CONDITIONS OF THIS WARRANTY, OF ANY PART OR PARTS WHICH ARE DETERMINED BY SELLER TO BE DEFECTIVE. This warranty does not cover failures caused by improper installation, abuse, misuse, misapplication, improper or lack of maintenance, negligence, accident, normal deterioration including normal wear and tear, use of improper parts or improper repair. This warranty does not cover any Goods or part thereof that is worn out or altered, used for a purpose other than that which it was intended, or used in a manner inconsistent with any instructions regarding its use. This warranty does not cover any Goods or part thereof which has been repaired, modified or altered in such a way as to, in the Sellers sole judgment, have affected its usefulness or viability. This warranty does not include costs for removal, transportation, or re-installation of the Goods. This warranty does not cover damage caused by any acts of nature such as hail, fire, earthquakes, floods, ultraviolet light degradation, or other factors over which Seller has no control. No agent, employee, or representative of Seller has any authority to bind Seller to any affirmation, representation, or warranty concerning the Goods except as stated in this warranty. Sellers obligation under this warranty is limited to repairing or replacing at the place of origin any part or parts which shall within the warranty period be returned to the Seller, with transportation charges prepaid and which the Sellers examination shall disclose to its sole satisfaction to have been defective. Anything in Buyers purchase order or confirmation to the contrary notwithstanding, SELLER SHALL NOT BE LIABLE FOR ANY INDIRECT, INCIDENTAL, SPECIAL, OR CONSEQUENTIAL DAMAGES, INCLUDING WITHOUT LIMITATION LOST PROFITS, FOR ANY BREACH OF WARRANTY, AND THE BUYER ASSUMES ALL RISK AND LIABILITY WHATSOEVER RESULTING FROM THE USE OF THE GOODS, WHETHER USED SINGULARLY OR IN COMBINATION WITH OTHER EQUIPMENT. Seller neither assumes, nor authorized nor authorizes any person to assume for it, any other liability in connection with the sale or use of the Goods, and there are no oral agreements or warranties collateral or pertaining to the Goods. EXCEPT AS HEREIN ABOVE SET FORTH, SELLER MAKES NO WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, WITH RESPECT TO THE GOODS, AND THE WARRANTY HEREIN ABOVE SET FORTH IS EXPRESSLY IN LIEU OF ANY WARRANTIES AND REPRESENTATIONS, EXPRESS OR IMPLIED, AND ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF SELLER. WITHOUT LIMITING THE FOREGOING, SELLER DISCLAIMS ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE. Any claim under the above specified warranty shall be forwarded to the Seller in writing, specifying the defect claimed, the length of service of the Goods involved, and, if known, the purchase order or contract number under which the Goods was procured. The Buyer agrees to permit the Seller to conduct an investigation of the claimed defect at the Buyers facility if considered necessary by Seller. NO GOODS MAY BE RETURNED WITHOUT THE ALASKA STRUCTURES, INC.S PRIOR WRITTEN PERMISSION.
Copyright 2010 Alaska Structures, Inc. ALL RIGHTS RESERVED January, 2010
INTRODUCTION
PURPOSE OF THIS MANUAL
The AK-ECU-5T is a custom environmental control unit (ECU) specifically designed for special applications described in this manual. It will provide years of trouble free service if installed, operated and maintained in accordance with this operational manual. Damage to the unit from improper installation, operation or maintenance is not covered by the warranty. It is Very Important To Study the instructions contained in this manual. They must be followed to avoid difficulties. Spare parts are available from Alaska Structures, and it is the responsibility of the user to have an ample supply of parts available to ensure continuous unit operation. Using substitute parts or bypassing electrical or refrigeration components in order to continue operation is not recommended and will Void The Warranty. A spare parts kit with basic replacement parts has been provided with each ECU.
CONTENTS OF THIS MANUAL

Chapter titles are as follows: Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Introduction Installation Instructions Unit Operation Maintenance Repair and Removal Procedures Troubleshooting
Appendix A Appendix B Appendix C
Alaska 5-Ton ECU Schematics Parts List Recommended Refrigeration Tools List
USE OF THIS MANUAL
Use the table of contents to identify chapters, paragraph numbers, titles and page numbers to help locate information. A list of illustrations and list of tables indicates illustration and table numbers, titles and locations. The text is supported by illustrations, tables and diagrams. Abbreviations, phrases and words which are on a decal, placard or engraving are written exactly as they appear on the equipment.
TABLE OF CONTENTS
INTRODUCTION
PURPOSE OF THIS MANUAL ...........................................................................................................................................................................i CONTENTS OF THIS MANUAL.........................................................................................................................................................................i USE OF THIS MANUAL .....................................................................................................................................................................................i
TABLE OF CONTENTS.................................................................................................................................................................... iii SAFETy SUmmARy.......................................................................................................................................................................... vii ChApTER 1

GENERAL INFORmATION .................................................................................................................................................................. 1-1 1-1. INTROdUCTION .................................................................................................................................................................................... 1-1 1-2. dESCRIPTION ....................................................................................................................................................................................... 1-1 1-3. PURPOSE ANd FUNCTION .................................................................................................................................................................. 1-1 1-4. EqUIPMENT dESCRIPTION ................................................................................................................................................................ 1-1 1-4.1. Capabilities and Features................................................................................................................................................................ 1-1 1-5. dESIgN PARAMETERS ........................................................................................................................................................................ 1-2 1-6. MISCELLANEOUS FEATURES ............................................................................................................................................................. 1-4 1-7. ELECTRICAL PANEL ............................................................................................................................................................................. 1-4 1-8. VIEwS .................................................................................................................................................................................................... 1-6 1-8.1. Rear View (Figure 1-4) .................................................................................................................................................................... 1-6 1-8.2. Left Side View (Figure 1-5) .............................................................................................................................................................. 1-7 1-8.3. Front Side View (Figure 1-6) ........................................................................................................................................................... 1-8 1-8.4. Right Side View (Figure 1-7) ........................................................................................................................................................... 1-9 1-8.5. Top Side View (Figure 1-8) ............................................................................................................................................................ 1-10 1-8.6. Access Panels Removed (Figure 1-10) ..........................................................................................................................................1-11 1-8.7. Optional wheel Kit (Figures 1-11,1-12) ......................................................................................................................................... 1-12 1-9. INTERNAL COMPONENTS (Figure 1-13) ........................................................................................................................................... 1-13 1-9.1. Control Panel................................................................................................................................................................................. 1-16 1-9.2. Electrical disconnect Switch ......................................................................................................................................................... 1-16 1-9.3. wiring Harness .............................................................................................................................................................................. 1-17
ChApTER 2
INSTALLATION INSTRUCTIONS ...................................................................................................................................................... 2-1 2-1. UNLOAdINg & INSPECTION / UNCRATINg & INSPECTION ............................................................................................................. 2-1 2-2. INSTALLATION & SITE PREPARATION................................................................................................................................................ 2-1 2-3. ECU gENERAL PREPARATION ........................................................................................................................................................... 2-1 2-4. PLACEMENT OF THE UNIT .................................................................................................................................................................. 2-1 2-5. CONNECTION OF THE MAIN POwER ................................................................................................................................................ 2-2 2-6. CONdENSATE PANS & dRAINS .......................................................................................................................................................... 2-2 2-7. STACKAbLE FEATURE ......................................................................................................................................................................... 2-3 2-7.1. Stacking Hardware .......................................................................................................................................................................... 2-5 2-8. STACKINg INSTRUCTIONS / dIMENSIONS ....................................................................................................................................... 2-6 2-9. dUCT ASSEMbLY.................................................................................................................................................................................. 2-7 2-10. FAbRIC dUCT SCREEN INSTALLATION (OPTIONAL) ..................................................................................................................... 2-8 2-11. ECU dRAIN KIT INSTALLATION ......................................................................................................................................................... 2-9
iii
ChApTER 3
UNIT OpERATION .................................................................................................................................................................................. 3-1
3-1. gENERAL .............................................................................................................................................................................................. 3-1 3-2. CONTROL PANEL.................................................................................................................................................................................. 3-1 3-3. CONTROL SEqUENCE ......................................................................................................................................................................... 3-1 3-4. COOLINg PROCESS ............................................................................................................................................................................ 3-2 3-5. CONdENSER AIR FLOw ..................................................................................................................................................................... 3-2 3-6. HOT gAS bYPASS ................................................................................................................................................................................ 3-2 3-7. COMPONENT SETTINgS ..................................................................................................................................................................... 3-2 3-8. PRESSURE SwITCHES (S1-S4) .......................................................................................................................................................... 3-3 3-9. MAIN ExPANSION VALVE (VE1) .......................................................................................................................................................... 3-3 3-10. HOT gAS REgULATOR (VH1) ............................................................................................................................................................ 3-3
ChApTER 4
mAINTENANCE....................................................................................................................................................................................... 4-1 4-1. PREVENTIVE MAINTENANCE- CHECKS ANd SERVICES ................................................................................................................. 4-1
ChApTER 5
5-1. gENERAL .............................................................................................................................................................................................. 5-1 5-1.1. Field Repairs ................................................................................................................................................................................... 5-1 5-1.1.1. Leak detection ............................................................................................................................................................................. 5-1 5-1.1.2. Leak Repair .................................................................................................................................................................................. 5-1 5-1.1.3. Component Repairs ..................................................................................................................................................................... 5-2 5-1.1.4. Component Replacement............................................................................................................................................................. 5-2 5-1.1.5. Compressor Replacement............................................................................................................................................................ 5-2 5-1.1.6. burn-Out Clean Up Procedure ..................................................................................................................................................... 5-2 5-1.1.7. Charging Procedures .................................................................................................................................................................. 5-3 5-1.1.7.1. before Charging the System ..................................................................................................................................................... 5-3 5-1.1.7.2 Charging the System .................................................................................................................................................................. 5-3 5-2. REMOVAL / INSTALLATION PROCEdURES ........................................................................................................................................ 5-3 5-2.1. blower (MT1) Removal / Installation .............................................................................................................................................. 5-4 5-2.2. Return Air Filter Removal / Installation ............................................................................................................................................ 5-5 5-2.3. Primary Overheat Safety Switch (SOS1) Removal / Installation .................................................................................................... 5-6 5-2.4. Secondary Overheat Safety Switch (SOS2) Removal / Installation ............................................................................................... 5-7 5-2.5. Unit Heater Removal / Installation ................................................................................................................................................... 5-8 5-2.6. Removal of Contactors, Circuit breakers and Relays ..................................................................................................................... 5-9 5-2.7. Main Expansion (VE1) Valve Removal / Installation...................................................................................................................... 5-12 5-2.8. Removal of Temperature Responsive Expansion Valve (VE3)...................................................................................................... 5-13
REpAIR AND REmOvAL pROCEDURES ...................................................................................................................................... 5-1
ChApTER 6
TROUBLEShOOTING........................................................................................................................................................................... 6-1 6-1. gENERAL .............................................................................................................................................................................................. 6-1
AppENDIx B
pARTS LIST.............................................................................................................................................................................................. b-1 b-1. INTROdUCTION ................................................................................................................................................................................... b-1 b-2. PARTS LIST ........................................................................................................................................................................................... b-1
iv
AppENDIx C
RECOmmENDED REFRIGERATION TOOLS ...............................................................................................................................C-1
C-1. INTROdUCTION ...................................................................................................................................................................................C-1
TAbLE 1-1. COOLINg................................................................................................................................................................................... 1-2 TAbLE 1-2. HEATINg ................................................................................................................................................................................... 1-2 TAbLE 1-3. POwER...................................................................................................................................................................................... 1-2 TAbLE 1-4. PHYSICAL dIMENSIONS .......................................................................................................................................................... 1-2 TAbLE 1-5. PERFORMANCE SPECIFICATIONS......................................................................................................................................... 1-2 TAbLE 1-6. COOLINg CAPACITIES AT VARIOUS OUTdOOR AMbIENT TEMPERATURES .................................................................... 1-3 TAbLE 1-7. POwER CONSUMPTION CHART ............................................................................................................................................ 1-3 TAbLE 1-8. SYSTEM CHARgINg REqUIREMENTS .................................................................................................................................. 1-3 TAbLE 1-9. ELECTRICAL PANEL COMPONENTS (FIgURE 1-3) ............................................................................................................... 1-5 TAbLE 1-10. INTERNAL COMPONENTS .................................................................................................................................................. 1-13 TAbLE 2-1. STACKINg HARdwARE ........................................................................................................................................................... 2-5 TAbLE 3-1. COMPONENT SETTINgS ......................................................................................................................................................... 3-3 TAbLE 4-1. PREVENTIVE MAINTENANCE- CHECKS ANd SERVICES (PMCS) ....................................................................................... 4-1 TAbLE 5-1. ELECTRIC bOx COMPONENT IdENTIFICATION ANd REMOVAL....................................................................................... 5-10 TAbLE 6-1. TROUbLESHOOTINg ............................................................................................................................................................... 6-1 TAbLE b-1. AK-ECU-5T PARTS LIST ........................................................................................................................................................... b-1 TAbLE C-1. RECOMMENdEd REFRIgERATION TOOLS ..........................................................................................................................C-1 TAbLE C-1. RECOMMENdEd REFRIgERATION TOOLS, CONTINUEd ...................................................................................................C-2
LIST OF TABLES
Figure 1-1. ECU Nomenclature Plate ........................................................................................................................................................... .1-1 Figure 1-2. Electrical Panel Components ..................................................................................................................................................... .1-4 Figure 1-3. Electrical Panel Components ..................................................................................................................................................... .1-5 Figure 1-4. Rear View................................................................................................................................................................................... .1-6 Figure 1-5. Left Side View ............................................................................................................................................................................ .1-7 Figure 1-6. Front Side View ......................................................................................................................................................................... .1-8 Figure 1-7. Right Side View ......................................................................................................................................................................... .1-9 Figure 1-8. Top View .................................................................................................................................................................................. .1-10 Figure 1-9. Tool Actuated Latch .................................................................................................................................................................. .1-10 Figure 1-10. Access Panels Removed ........................................................................................................................................................1-11 Figure 1-11. ECU wheel Kit Installed ........................................................................................................................................................ .1-12 Figure 1-12. ECU wheel ........................................................................................................................................................................... .1-12 Figure 1-13. Major Internal Components ................................................................................................................................................... .1-13 Figure 1-14. Circuit breakers..................................................................................................................................................................... .1-15 Figure 1-15. Secondary Overheat Safety Switch ....................................................................................................................................... .1-15 Figure 1-16. Control Panel ........................................................................................................................................................................ .1-16 Figure 1-17. Electrical disconnect Switch ................................................................................................................................................. .1-16 Figure 1-18. Main wiring Harness .............................................................................................................................................................. .1-17 Figure 1-19. Heater wiring Harness ........................................................................................................................................................... .1-17 Figure 2-1. Condensation drain ................................................................................................................................................................... .2-2
LIST OF ILLUSTRATIONS
Figure 2-2. Stackable Feature (Side View).................................................................................................................................................. .2-3 Figure 2-3. Stacking Feature ....................................................................................................................................................................... .2-4 Figure 2-4. Stackable Feature ..................................................................................................................................................................... .2-4 Figure 2-5. Stacking Hardware .................................................................................................................................................................... .2-5 Figure 2-6. Stacking ECUs Together .......................................................................................................................................................... .2-6 Figure 2-7. Fabric duct Assembly ................................................................................................................................................................ .2-7 Figure 2-8. Fabric duct Screen Installation (optional) .................................................................................................................................. .2-8 Figure 2-9. ECU drain Kit Installation........................................................................................................................................................... .2-9 Figure 5-1. Evaporator blower Assembly .................................................................................................................................................... .5-4 Figure 5-2. Return Air Filter Removal / Installation ...................................................................................................................................... .5-5 Figure 5-3. Primary Overheat Safety Switch Removal / Installation ............................................................................................................ .5-6 Figure 5-4 Secondary Overheat Safety Switch Removal / Installation ........................................................................................................ .5-7 Figure 5-5. Heater Removal ........................................................................................................................................................................ .5-8 Figure 5-6. Component Removal ................................................................................................................................................................ .5-9 Figure 5-7. Typical Release Clip for Circuit breaker....................................................................................................................................5-11 Figure 5-8. Main Expansion Valve ............................................................................................................................................................. .5-12 Figure 5-9. Temperature Responsive Expansion Valve ............................................................................................................................. .5-13
vi
SAFETY SUMMARY
Read and understand all instructions in this manual relating to the specific function you are to perform prior to starting the task. Carefully read and understand all notes, cautions and warnings contained in this manual that pertain to the task you are to perform. WARNINGS indicate potential threats to personal safety. CAUTIONS indicate potential threat of damage to equipment. Never operate the ECU with any cover, screen, or panel removed unless the instructions specifically instruct you to do so. When required to operate ECU with any cover, screen, or panel removed, do so with extreme caution and follow all procedures as outlined in the safety summary. The following is a condensed list of WARNINGS and CAUTIONS that are noted throughout this manual. All personnel who operate, service and maintain this ECU should read and understand these WARNINGS and CAUTIONS. All WARNINGS indicate a potential threat to personnel and all CAUTIONS indicate a potential threat to equipment damage. Prior to using any chemicals, cleansers, or solvents, refer to the Manufacturers Safety Data Sheets (MSDS) for proper handling and usage of such materials.
WArNINg
Avoid skin contact or inhaling fumes from any acid formed by burn out of oil. Wear protective goggles or glasses to protect eyes. Wear rubber gloves to protect hands, use care to avoid spilling compressor burn out sludge. If sludge is spilled, clean area thoroughly to prevent injury.
WArNINg
Avoid injury by using adequate equipment and personnel to remove compressor from cabinet.
WArNINg
Clean parts in a well-ventilated area to avoid inhalation of solvent fumes and prolonged exposure of skin to cleaning solvent. Wash exposed skin thoroughly.
WArNINg
Do not use solvent near open flames or excessive heat. Flash point of solvent is 100F to 150F (38C to 59C).
WArNINg
Wear eye protection when blowing solvent from parts. Air pressure should not exceed 30 PSIG (206 kPa).
WArNINg
All solutions should be disposed of in accordance with local state pollution control laws. Consult local bio-environmental unit for guidance.
vii
WArNINg
High voltage is used in the operation of this equipment. Death on contact or severe injury may result if personnel fail to observe safety precautions.
WArNINg
Do not work on electrical equipment unless there is someone nearby familiar with the operation and hazards of the equipment. All personnel should be competent in administering first aid. When operators aid the technician, the technician must warn them about the dangerous areas.
WArNINg
Be careful not to contact high voltage connections of 208 volts AC input when installing or operating this equipment.
WArNINg
Whenever the nature of the operations permits, keep one hand away from the equipment to reduce the hazard of current flowing through vital organs of the body.
WArNINg
Do not be misled by the term low voltage. Voltage as low as 50 volts may cause severe injury or even death, under adverse conditions.
WArNINg
When possible, disconnect input power to the ECU before performing any maintenance to the electrical system. Voltage that is used to power the ECU can be deadly. Shutting the unit off at the control panel does not disconnect power to the various components of the ECU.
WArNINg
Do not allow anyone under equipment while it is suspended from a lifting device.
WArNINg
Do not allow the unit to swing while it is suspended from a lifting device. Failure to observe this warning may result in injury to personnel and damage to the equipment.
viii
WArNINg
The covers, grilles and screens installed on this unit are there for a purpose. Unless otherwise specifically instructed, do not operate the equipment without all grilles, guards and covers in place and tightly secured. When instructed to operate without all grilles, guards, and covers in place, do so with care.
WArNINg
Failure to observe WaRninG may result in death or serious injury to personnel.
Caution
Be sure the refrigeration system has been completely evacuated with nitrogen flowing through the system at a rate of not less than 1-2 CFM (0.028-0.057 M/Minute) before all brazing or debrazing operations.
Caution
Use a vacuum pump with a reverse flow check valve. The vacuum pump oil may flow back into the refrigerant system and cause the POE oil to deteriorate. It is recommended that a dedicated vacuum pump be used for this R407C system.
Caution
Charge the system with liquid R407C only. If gas refrigerant is used to charge the system the composition of the refrigerant charge will change and performance may drop.
Caution
Do not use the following tools that have been used with conventional refrigerants: gauge manifold sets, charging hoses, vacuum gauge and refrigerant recovery equipment. If small amounts of conventional refrigerant and mineral oil are mixed with R407C, the refrigerant may deteriorate.
Caution
Improper phasing will cause damage to the scroll compressor. Do not operate the compressor in reverse rotation.
ix
Caution
Do not use steam to clean coil, the high temperatures could result in extremely high pressures and possible rupture.
Caution
Do not use steam to clean coil, the high temperatures could result in extremely high pressures and possible rupture.
Caution
Do not use steam, open flame, heat gun or any other high-temperature heat source to thaw an iced coil. Thaw an iced coil by using a lamp bulb (75 watt maximum), operating unit in high heat mode, with a hair drier, electric fan or by leaving the unit shut down until the ice melts.
Caution
When the ECU is in cooling mode, the condenser air intake and discharge openings must be completely free of obstructions. Ensure panels are on and latched into position.
Caution
Compressed air used for cleaning purpose should not exceed 30 PSI. Do not direct compressed air against the skin. Use goggles or a full face shield.
Caution
Do not use mineral oil on flared parts. Prevent mineral oil from getting in the system as this will reduce the lifetime of the equipment. Use POE oil to coat flare connections.
Caution
Damage to equipment may result if Caution is not observed.
CHApTER 1
1-1. INTROdUCTION
GENERAL INFORMATION
This manual contains information for the installation, operation, troubleshooting, maintenance and repair, and recommended spare parts list for selection of replacement parts for the AK-ECU-5T.
1-2. dESCRIPTION
The AK-ECU-5T is a horizontal, air cooled, self contained, Environmental Control Unit (ECU) with a rated capacity of 60,000 BTU/HR cooling, and 12 kW of heat in one stage. It uses a 120 volt control circuit with a 208 volt supply, three phase, 60 hertz, four wire plus ground. For field reference see ECU nomenclature plate located on the control panel side of the ECU (Figure 1-1).
ALASKA ECU MODEL NO: AK5-ECU-5T SERIAL NO:AK5040#### JOB NO: AK04-001 MANUFACTURED BY ALASKA STRUCTURES CAGE CODE: OGC93 TELEPHONE NO: 425-889-1205 COOLING CAPACITY: 60,000 BTU/HR HEATING CAPACITY: 12.0 kW VOLTAGE: 208 PHASE: 3 Hz:60 FLA: 37.8 WIRES:5 COMPRESSOR LOCKED ROTOR AMPS: 156 REFRIGERANT: 407C CHARGE: 7 LBS. MAX. WORKING PRESSURE: 500 PSIG DESIGN HIGH-SIDE WORKING PRESSURE: 475 PSIG DESIGN LOW-SIDE WORKING PRESSURE: 80 PSIG MFG. DATE: 12/09 Q.C. ACCEPTANCE: QC WEIGHT: 495 LBS. NSN:8340-01-541-0646
Figure 1-1. ECU Nomenclature Plate
1-3. PURPOSE ANd FUNCTION
The AK-ECU-5T is designed to control and condition air to user defined temperatures. The ECU will provide a conditioned and controlled supply of air to support personnel and equipment.
1-4. EqUIPMENT dESCRIPTION 1-4.1. Capabilities and Features

Operates in environmental conditions from Tropic to Arctic. Filters the return air and fresh air. Two independently controlled condenser fan motors. Heavy duty welded aluminum cabinet. Equipped with removable access/service covers. Vibration isolation of compressor. Powder coating provides light coastal exterior salt and fog protection. Stackable unit design.
Technical data disclosed herein is subject to the limited rights of the government and third parties as provided in FAR 227.7102 and 252.227-7015. Copyright 2010 Alaska Structures, Inc. ALL RIGHTS RESERVED January, 2010
1-1
1-5. dESIgN PARAMETERS

table 1-1. Cooling Cooling capacity Number of stages per unit Design Ambient Temperature Maximum Ambient Temperature Design Return Air Dry Bulb Temperature Design Return Air Wet Bulb Temperature Conditioned Supply Air Flow Rate External Supply Air Static Pressure table 1-2. Heating Heating Capacity Number of stages per unit Minimum Ambient Temperature Conditioned Supply Air Flow Rate External Supply Air Static Pressure table 1-3. Power Voltage Frequency Number of Phases Number of Wires 120/208 Volts 60 Hertz Three (3) Four (4) Plus Ground 12.0 kW One (1) -25F DB 2200 CFM 1.0" Refer to Table 1-6 One (1) Refer to Table 1-6 132F 75F 62F 2200 CFM 1.0"
table 1-4. Physical Dimensions Height Width Depth Weight 24.38" 51.75" 41.75" 495 lbs.
table 1-5. Performance Specifications STATIC PrESSUrE 1.0" 1.2" 1.5" AIrFLOW 2200 CFM 2150 CFM 2000 CFM
Technical data disclosed herein is subject to the limited rights of the government and third parties as provided in FAR 227.7102 and 252.227-7015.
1-2
table 1-6. Cooling Capacities at Various outdoor ambient temperatures rETUrN AIr TEMPErATUrE 105F Outdoor Ambient Temperature 80F DB 75F DB 80F DB 75F DB 80F DB 75F DB 67F WB 62F WB 67F WB 62F WB 67F WB 62F WB 50% RH 50% RH 50% RH 50% RH 50% RH 50% RH 66,500 BTU/HR 65,500 BTU/HR 62,500 BTU/HR 61,500 BTU/HR 62,000 BTU/HR 61,500 BTU/HR CAPACITY
115F Outdoor Ambient Temperature
125F Outdoor Ambient Temperature
table 1-7. Power Consumption Chart 120/208 VOLT, 60 Hz., 3 PH., 4 WIrES PLUS grOUNd Component Compressor Evaporator Motor (1 HP) Condenser Motor, #1 ( HP) Condenser Motor, #2 ( HP) Heater (12.0 kW) Control Heating Mode Cooling Mode Auto Mode Component Compressor FLA 23.0 amps 3.8 amps 2.0 amps 2.0 amps 33.3 amps 0.3 amps 37.8 amps 31.5 amps 37.8 amps LrA 156 amps
table 1-8. System Charging Requirements refrigerant Type refrigerant Charge R-407C 7 lbs.
1-3
1-6. MISCELLANEOUS FEATURES

Fungus Protection Components containing nutrients have not been used. The compressor is hermetically sealed and the condenser and evaporator motors are totally enclosed. Salt Spray Protection The cabinet is constructed of unitized welded aluminum and powder coated. All external hardware is zinc plated for protection against corrosion. The evaporator coil is constructed from copper tubes and aluminum fins. The condenser coil is constructed of all aluminum. Maintenance Features A sight glass with a moisture indicator is provided to detect any moisture in the refrigeration circuit and low refrigerant levels. Suction and discharge schraeder service valves have been provided to enable servicing of the ECU. All major components are easily accessible for maintenance. Safety Features Low and high pressure switches are provided. They are factory set for the application. They will disengage control power to the compressor contactor if suction pressure drops below a specific pressure. The Compressor will stop if the discharge pressure rises above a specific pressure and a manual reset of the safety switch is required. These pressure switches are installed as safety devices and will help prevent compressor failure or other serious damage. The ECU Heater section is equipped with primary and secondary overheat safety switches. If the temperature should exceed the set point of the primary switch (120F) SOS1, it will remove control power to the heater. The switch will automatically reset once the heater cools down to normal operating temperature. If the temperature should exceed the set point of the secondary switch (150F) SOS2, it will remove main power to the heater. This switch requires a manual reset once the heater cools to a normal operating temperature.
1-7. ELECTRICAL PANEL
The electrical panel supplies 208 volt 3-phase power to environmental control unit (Figure 1-2).
Figure 1-2. Electrical Panel Components

1-4
table 1-9. Electrical Panel Components (Figure 1-3) rEF dES CB1 CB2 gNd K1 K2-1 K2-2 K-3 K-4 FUNCTION Circuit Breaker - Control Circuit Circuit Breaker - Heater Ground Lug Contactor - Evaporator Blower Motor Contactor - Condenser Fan Motor #1 Contactor - Condenser Fan Motor #2 Contactor - Compressor Contactor - Heater rEF dES OL1 OL2-1 OL2-2 SM1 TB1 TB2 TH1 FUNCTION Overload - Evaporator Blower Motor Overload - Condenser Fan Motor #1 Overload - Condenser Fan Motor #2 Mode Selection Switch Terminal Board- Heater Wires Terminal Board- Main Power Thermostat
GND
TH1 CB2 CB1 SM1
TB1
TB2
K1
K2-1
K2-2
K3
OL1 K4
OL2-1
OL2-2
Figure 1-3. Electrical Panel Components
1-5
1-8. VIEwS 1-8.1. Rear View (Figure 1-4)

The following items are located on the Rear side of the unit. A. Forklift Slots Two forklift slots are provided at both the front and rear sides of the unit. These slots are 9.5" wide and 2.5" high to allow for standard forklift maneuvering. B. Condenser Section A screened panel to allow the discharge of hot air and to protect the condenser.
Figure 1-4. Rear View
1-6
1-8.2. Left Side View (Figure 1-5)
The following items are located on the Left side of the unit. A. Control Panel This Cover is a hinged access cover for the main control switch and the control thermostat. B. Electrical Access Panel This is a removable access panel to the electrical components of the ECU for servicing and / or maintenance. C. Main Power Supply Receptacle Stored within the ECU is a 25' main power cable with receptacle. This cable is supplied with a class "L" type plug.
Figure 1-5. Left Side View
1-7
1-8.3. Front Side View (Figure 1-6)
The following items are located on the Front side of the unit. A. Conditioned Air discharge A 15.75" OD duct connection with bead for ducting the conditioned air to the user-defined space. A stainless steel screen is located in the supply air duct connection to prevent accidental contact with the electric heater. B. Return Air Intake A 15.75" duct connection with bead for ducting return air from the conditioned air space to the unit. A stainless steel screen is located in the return air duct connection to prevent accidental contact with the rotating blower wheel. C. Fresh Air Intake Intake for the ECU fresh air includes a cleanable aluminum filter.
Figure 1-6. Front Side View
1-8
1-8.4. Right Side View (Figure 1-7)
The following items are located on the right side of the unit. A. Condenser Access Screen A condenser access screen has been provided to gain access to the condenser section components. B. Access Panel Spring Latches Latches have been provided to secure the evaporator and condenser section top panels.
Figure 1-7. Right Side View
1-9
1-8.5. Top Side View (Figure 1-8)
The top side of the unit is comprised of two latched panels for access to the condenser section and the evaporator section. A. Access Panel Top Latch (Figure 1-9) Tool actuated latches have been provided to secure the evaporator and condenser section top panels.
Figure 1-8. Top View
Figure 1-9. Tool Actuated Latch
1-10
1-8.6. Access Panels Removed (Figure 1-10)

A. Evaporator Access Cover Removed Access cover, secured by five compression spring latches. In addition, two tool action top latches have been provided. Opening this cover will allow access to the evaporator section of the unit for service and / or maintenance. Disconnect main power prior to removing access cover. Rotating equipment is present and may be hazardous. B. Condenser Access Cover Removed Access cover, secured by four compression spring latches. In addition, two tool action top latches have been provided. Opening this cover will allow access to the compressor section of the unit for service and / or maintenance. Disconnect main power prior to removing access cover. Rotating equipment is present and may be hazardous.
Figure 1-10. Access Panels Removed
1-11
1-8.7. Optional wheel Kit (Figures 1-11,1-12)
Wheel kits are optional on the AK-ECU-5T. The wheel kit slides into the frame of the ECU and is secured by the attached pin.
Figure 1-11. ECU Wheel Kit Installed
Figure 1-12. ECU Wheel

1-12
1-9. INTERNAL COMPONENTS (Figure 1-13)
The interior of the unit is comprised of the following components. table 1-10. internal Components rEF dES MT1 MT3 CC1 MT2-1 MT2-2 P2 RC1 COMPONENT Evaporator Motor Compressor Condenser Coil Condenser Motor #1 Condenser Motor #2 Main Power Supply Receptacle Receiver rEF dES CE1 HR1 SOS1 SOS2 L1 DS1 COMPONENT Evaporator Coil Heater Coil Overheat Safety Switch, Primary Overheat Safety Switch, Secondary Liquid Line Solenoid Valve Filter Drier
Figure 1-13. Major Internal Components
1-13
A. Compressor (MT3) The Copeland Complaint Scroll compressor is designed around two identical spirals or scrolls that, when inserted together, form crescent shaped pockets. During a compression cycle, one scroll remains stationary while the other scroll orbits around the first. As this motion occurs, gas is drawn into the scrolls and moved in increasingly smaller pockets towards the center. At this point, the gas, now compressed to a high pressure, is discharged from a port in the center of the fixed scroll. During each orbit, several pockets of gas are compressed simultaneously, creating smooth, nearly continuous compression. Due to the design of the scroll compressor, the internal compression components always start unloaded even if the system pressures are not balanced. In addition, since internal compressor pressures are always balanced at start-up, low voltage starting characteristics are excellent for scroll compressors. With fewer moving parts, the scroll compressor sets the industry standard for reliability among one to nine kilowatt compressors. The compressors simple design and proven day-to-day performance means less maintenance calls for field personnel. The scroll compressor has demonstrated superior durability. Its axial and radial compliance make the scroll compressor more tolerant to liquid refrigerant and debristwo of the most common causes of system failure. The scroll compressor is quiet, but not silent. On average, the compressor is up to five decibels quieter than standard piston compressors. A scroll compressor, however, has different sound characteristics from reciprocating compressors. These do not affect system reliability or performance. Upon shut-down of a normal run cycle, the compressor will run backwards for one or two seconds as the scroll internal pressures are equalized. A short reverse rotation burp will result. This sound is normal. A check valve in the discharge tube of the compressor prevents the compressor from running backwards for more than a second or two. This normal direction reversal of the scrolls at shut down has no effect on compressor reliability. The compressor is protected from high pressure conditions by a high pressure switch and low pressure conditions by a low pressure switch. The compressor is mounted to the unit with rubber mounts to reduce vibration, shock, and noise. B. Condenser Coils (CC1) The condenser coil is rated at 5-Tons. It is an all aluminum coil with 2 rows and 14 fins per inch. C. Condenser Motor (MT2-1) (MT2-2) The two condenser fan motors are direct drive, each -hp motor is rated for continuous operation. They are equipped with 17" diameter, four blade fans. The condenser motors are protected from over current conditions by overload relays. d. Evaporator Motor (MT1) The evaporator motor is a 1-hp direct drive motor that operates in a counter-clockwise rotation as viewed from the drive side of the blower. E. Evaporator Coil (CE1) A copper tube, aluminum finned coil. F. Filter drier (dS1) A catch-all filter drier has been provided in the refrigeration system. It removes moisture, foreign matter and acid. g. Heater (HR1) The unit is equipped with a single stage, 12.0 kW, electric resistance heater. This heater is protected from high temperature conditions by a heater safety switch, and from over current conditions by a 40-amp circuit breaker (Figure 1-14).
1-14
H. Primary Overheat Safety Switch (SOS1) Located directly above the heater, the primary overheat safety switch is a preset, non-adjustable switch that will de-energize the heater if the temperature conditions reach 48.8 C or above. The switch will automatically reset when normal temperatures are regained. I. Secondary Overheat Safety Switch (SOS2)
WArNINg
Disconnect main power before resetting the overheat safety switch. Voltage that is used to power the ecu can be deadly. Shutting the unit off at the control panel does not disconnect power to the various components of the ECU. Located directly on the side of the heater, the secondary overheat safety switch is a preset, non-adjustable switch that will remove main power to the heater if the temperature conditions reach 65.5 C or above. The secondary overheat safety switch requires a manual reset when normal temperatures are regained.
Figure 1-14. Circuit Breakers
Figure 1-15. Secondary Overheat Safety Switch
J. Liquid Line Solenoid Valve (L1) A compact liquid line solenoid valve with a pilot operated disk. Construction has been provided to aide in isolating the refrigerant. K. Main Power Supply Receptacle (P2) Supplies 3 phase power to the ECU. L. Receiver (RC1) The unit is provided with a vertical receiver with a sight glass, float ball and service valve.
1-15
1-9.1. Control Panel
The unit operates from an integral control panel (Figure 1-16). This panel consists of the thermostat for setting the desired temperature and a five-(5) position (OFF-VENT-HEAT-COOL-AUTO) rotary mode selector switch for setting the desired mode of operation. Refer to Chapter 3 for operation information.
Figure 1-16. Control Panel
1-9.3. wiring Harness
The unit features two braided wiring harnesses, one main harness (Figure 1-18) and one heater harness (Figure 1-19). Each quickdisconnect harness is securely fastened to the ECU cabinet and is neatly routed within the ECU compartment. The motors, pressure switches and the refrigerant solenoid can be replaced without making any wiring connections. Each of these components has a quick connect connector that makes replacement extremely simple and easy and if necessary the The wires within the harness are continuous with no splices.
Figure 1-18. Main Wiring Harness

1-16
Figure 1-19. Heater Wiring Harness
1-17
CHApTER 2
INSTALLATION INSTRUCTIONS
2-1. UNLOAdINg & INSPECTION / UNCRATINg & INSPECTION
Upon receipt of the ECU, remove the access panels, and thoroughly inspect the unit interior and exterior for any signs of transit incurred damage*. Position the unit in the desired location. Make sure the mounting surface is able to support the equipment. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies to appropriate authority. The installation instructions will only apply to the model AK-ECU-5T Alaska ECU.
NOTE
*If any damage is found, notify Alaska Structures, Inc. before making any necessary repairs. Alaska Structures is not liable for any equipment damage due to negligent handling or transit damage.
2-2. INSTALLATION & SITE PREPARATION

The following general requirements should be considered: An unobstructed flow of air near the area of the three inlets of the condenser section and the outlet of the condenser air discharge. An unobstructed flow of air from inside the conditioned area to the conditioned air intake and discharge. Access to the unit for routine operation, servicing, and for necessary maintenance actions. A power source of 230/400 volt, 3 phase, 50 hertz, 5 wire input power is required. The power source outlet should be located as near as possible to the installed location of the air conditioner. The power source wiring should include a main power circuit breaker. However, provisions should be made to ensure that power is not disconnected during normal operation and that the disconnect is not used to turn off the air conditioner for normal shut down.
If possible, utilize terrain features such as trees and buildings to provide a shaded location. This will minimize the solar load on the air conditioner. If possible, avoid locations where the air intakes will be laden with dust, dirt, soot, smoke or other debris. Refer to wiring diagram (page A-1) and refrigeration diagram (page A-2) for electrical connections.
2-3. ECU gENERAL PREPARATION 2-4. PLACEMENT OF THE UNIT
Locate and clear the location of where the ECU will be placed.
This unit is designed for outdoor use. Forklift slots have been provided for lifting and placing the unit in the desired location.
2-1
2-5. CONNECTION OF THE MAIN POwER
CAUTION
Improper phasing or rotation could cause damage to the scroll compressor. Damage to equipment may result if CAUTION is not observed. The main power connector is provided on the control side of the unit as indicated in Figure 1-5. Connect this connector to a mating receptacle and a 120/208 volt, 3phase, 5 wire power source. After connecting main power to the unit, check for proper rotation and phasing. (The evaporator motor rotation will be counter-clockwise when viewing from the air inlet duct).
2-6. CONdENSATE PANS & dRAINS
A stainless steel drain pan is provided to collect the condensate. Two condensate drains are provided on the bottom of the unit. If desired, an optional drain hose kit may be attached to the two copper drain stubs to drain condensate away from the unit up to 15 feet.
Figure 2-1. Condensation Drain
2-2
2-7. STACKABLE FEATURE
The Alaska ECU units are stackable for storage or transport. They may be stacked up to four high for air transport on a standard 463L pallet Figures 2-2, 2-3, 2-4).
83.5in 41.75in
Figure 2-2. Stackable Feature (Side View)
2-3
463L Pallet 108in (104in Usable)
463L Pallet 88in (84 Usable )
Figure 2-3. Stacking Feature

103.50in
96.75in
Figure 2-4. Stackable Feature

2-4
2-7.1. Stacking Hardware
Table 2-1 lists all stacking hardware, and Figure 2-5 illustrates stacking hardware. The hardware that is used to secure the units together is tethered to the outside of the corner support channel on all four corners of the unit. table 2-1. Stacking hardware ITEM # 1 2 3 4 5 6 7 QTY. rEQUIrEd 4 4 4 4 8 8 8 dESCrIPTION Assembly Lanyard 6 - 32x1" Pan Head Screw w/Flat Washer and Nylon Insert Locknut Screw, Cap, Hex Head Bolt Retainer Nut Jam Washer, Flat Nut, Self Locking with Flange
6 5 1
Figure 2-5. Stacking Hardware
2-5
2-8. STACKINg INSTRUCTIONS / dIMENSIONS
The following procedure provides instructions for stacking the unit. 1. Using a forklift, insert the forks of the lift in the slots provided on the unit. 2. Raise the unit and relocate it to the unit that it will be stacked upon. (Figure 2-6) 3. Carefully lower the unit onto the top of another unit so that the foot pads at the bottom of the frame line up with the channels on the base unit taking care to line up the holes in the channel with the holes in the foot pads. 4. Secure the units together using stacking hardware from the base unit on all four corners.
Figure 2-6. Stacking ECUs Together
2-6
2-9. dUCT ASSEMBLY
Each Alaska 5-Ton ECU is supplied with two folding ducts and six aluminum support rings. The ducts attach to the supply and return ports on the shelter and ECU. The following procedures should be used to assemble the ducts. 1. Unfold the first duct and install the three aluminum rings on the inside of the duct. Unlatch the hook and loop strips on the inside of the duct and place the rings in between the hook and loop straps. Reattach the hook and loop around the duct rings. 2. Place the buckle end of the fabric duct around the return air intake ring attached to the ECU cabinet at the 12 oclock position. Secure by pulling the excess strap snug and snapping the buckle down.
ALUMINUM RING HOOK & LOOP STRAP
BUCKLE
Figure 2-7. Fabric Duct Assembly
2-7
2-10. FABRIC dUCT SCREEN INSTALLATION (oPtionaL)
An optional fabric screen is available for the return duct of the AK-ECU-5T. The screen is designed to fit over the end of the open end (inside the shelter) of the return duct of the ECU to prevent foreign objects from entering the ECU. To install the fabric screen, install the fabric return duct per section 2-9 (page 2-7). Place the duct screen over the open end of the fabric duct evenly and secure the H&L edges on the end of the duct and duct screen to each other (Figure 2-8).
FABRIC RETURN DUCT
HOOK FASTENEROn outer edge of duct
THIS SIDE TO ECU.
FABRIC DUCT SCREEN
FABRIC DUCT SCREEN INSTALLED
Figure 2-8. Fabric Duct Screen Installation (optional)
2-8
2-11. ECU dRAIN KIT INSTALLATION
An ECU drain kit is supplied with each AK-ECU-5T. The ECU drain kit is designed to allow the user to direct the condensate created by the ECU to anywhere within a 2.7 m. radius. To install the drain kit, unfold the drain kit and slide the two short drain tubes over the copper condensate drain pipes until they are flush with the surface of the ECU (Figure 2-9). Run the end of the drain hose to the desired area.
CONDENSATE DRAIN
CONDENSATE DRAIN
DRAIN TUBE
DRAIN TUBE Place plastic drain tubes over copper condensate drains.
DRAINAGE KIT
Figure 2-9. ECU Drain Kit Installation
2-9
CHApTER 3
3-1. gENERAL
UNIT OpERATION
The following information provides overview and specific detail regarding operational procedures, theories and sequences.
3-2. CONTROL PANEL
The control panel consists of a five position (OFF-VENT-HEAT-COOL-AUTO) rotary mode selector switch and a single stage thermostat with a temperature range of 40F to 90F.
3-3. CONTROL SEqUENCE
The electrical control sequence occurs as follows: VENT Position the mode selector switch in the VENT mode. The evaporator blower motor will be energized and the condenser fan motors, compressor motor, and the heater, will be de-energized. HEAT Position the mode selector switch in the HEAT mode. The evaporator blower motor runs continuously and the heater will cycle on and off to maintain the selected return air temperature. COOL Position the mode selector switch in the COOL mode. Set the thermostat to the lowest setting. The evaporator blower motor, the condenser fan motor and the compressor motor will be energized and the heater will be de-energized. The liquid line solenoid valve will be energized to allow refrigerant flow to the expansion valve. When the thermostat is satisfied, the liquid line solenoid valve de-energizes and the compressor will be de-energized. The liquid line solenoid and compressor cycle on and off to maintain air temperature. AUTO Position the mode selector switch in the AUTO mode. Set the thermostat to the lowest setting. The evaporator blower motor, the condenser fan motor and the compressor motor will be energized and the heater will be de-energized. The liquid line solenoid valve will be energized to allow refrigerant flow to the expansion valve. If the thermostat temperature setting is increased so that cooling is not being called for, the liquid line solenoid valve and compressor will be de-energized. If the return air temperature is below the thermostat set point, the heater will be energized and will cycle on and off to maintain return air temperature.
NOTE
In the AUTO mode, the ECU will cycle between heating and cooling, as necessary, to maintain the thermostat set point.
3-1
3-4. COOLINg PROCESS
The refrigeration system is a closed-loop circuit in which refrigerant is continuously circulated by the existing pressure differential created by the compressor. The compressor maintains high side condensing pressure, and the thermostatic expansion valve separates the high pressure side from the low pressure side (evaporator). The compressor is designed to increase refrigerant pressure to a level high enough for it to be cooled and condensed into liquid by the effect of ambient air being drawn over the condenser coil. The thermostatic (liquid) expansion valve is a pressure-reducing device metering high pressure refrigerant into the low pressure evaporator coil(s) in the required amount. The high pressure liquid refrigerant is forced out of the receiver as a result of the pressure differential created by both the compressor and the liquid expansion valve; it flows through the sight glass, a device for visual inspection of the refrigerant and continues through the drier/strainer, where moisture and other impurities are removed. The liquid then flows through the liquid solenoid valve to the thermostatic (liquid) expansion valve, which meters the high pressure liquid into the low pressure refrigerant circuit. As the liquid enters the low pressure side of the circuit, it flows through the evaporator coil(s), boils by absorbing the latent heat of vaporization at the low pressure, and evaporates into a low pressure (and low temperature) gas. Heat from the surrounding air is extracted through the finned tubing of the coil by the refrigerant. The gas then returns to the compressor, where it is compressed and forced into the condenser coil. Here, the high pressure (and high temperature) gas is condensed into high pressure liquid. Ambient air drawn over the condenser coil extracts the latent heat of vaporization at the higher pressure from the refrigerant, causing condensation. The high pressure liquid flows from the condenser coil to the receiver, completing the cycle.
3-5. CONdENSER AIR FLOw
To control the condensing temperature, two condenser fan motors are cycled by the condenser cycling switches. When the pressure in the condenser line reaches 250 PSIG, the condenser cycling switch causes the condenser fan motor (MT2-1) to be energized. Once the pressure is reduced to 170 PSIG, the condenser fan motor is de-energized until the pressure builds back up to 250 PSIG and the process is repeated. The second condenser fan motor (MT2-2) will cycle on when the pressure in the condenser line reaches 320 PSIG and de-energized once the pressure is reduced to 210 PSIG.
3-6. HOT gAS BYPASS
A snap acting hot gas bypass system is provided to prevent coil freezing. The hot gas by-pass system provides freeze protection for the evaporator coil by limiting the minimum refrigerant pressure. The minimum pressure is adjustable and factory set to prevent surface temperature of the evaporator coil from dropping below 32F. A hot gas regulator senses the pressure in the suction line and meters hot gas to keep the evaporator coil from freezing during low load conditions or during reduced evaporator air flow conditions (i.e. dirty return air filter). The hot gas regulator valve allows refrigerant to flow from the discharge line, through the auxiliary connection on the expansion valve, to the evaporator coil.
3-7. COMPONENT SETTINgS
All controls, with the exception of the temperature control, are factory set. (No further adjustments are required in the field.) If a failure occurs, and component replacement is necessary, the following table will aid the service technician in making the replacement.
3-2
table 3-1. Component Settings COMPONENT High Pressure Switch (Manual Reset) Low Pressure Switch (Automatic Reset) #1 Condenser Fan Cycling Switch (Automatic Reset) #2 Condenser Fan Cycling Switch (Automatic Reset) Primary Overheat Safety Switch (Automatic Reset) Secondary Overheat Safety Switch (Manual Reset) Main Expansion Valve Hot Gas Regulator NOrMAL FACTOrY SETTINg 500 PSIG (Cut Out) 10 PSIG open, 32 PSIG closed 170 PSIG open, 250 PSIG closed 210 PSIG open, 320 PSIG closed 120F (Open) 150F (Open) 15F - 20F (Superheat) 45-48 PSIG dESIgNATOr S1 S2 S3 S4 SOS1 SOS2 VE1 VH1
3-8. PRESSURE SwITCHES (S1-S4)
Switches are non-adjustable encapsulated control switches. If the high-pressure switch is tripped for any reason, it must be manually reset. The cause for tripping of the high-pressure switch must be determined. The other switches are reset automatically.
3-9. MAIN ExPANSION VALVE (VE1)
Remove the cap from the valve. Turn the adjustment stem CLOCKWISE to increase the superheat and COUNTER-CLOCKWISE to decrease the superheat.
To adjust the hot gas regulator remove the cap and turn the adjustment nut with a 516 SAE hex wrench. A clockwise rotation increases the setting and a counter-clockwise rotation decreases the setting. The valve should only be adjusted with a reduced load condition.
3-10. HOT gAS REgULATOR (VH1)
3-3
CHApTER 4
MAINTENANCE
4-1. PREVENTIVE MAINTENANCE- CHECKS ANd SERVICES
Regularly scheduled Preventive Maintenance Checks and Services (PMCS) are essential to ensure that the unit is ready for operation at all times. They correct defects and deficiencies before they can cause serious damage or complete failure of the equipment. Any effective preventive maintenance program must begin with the indoctrination of operators to report all unusual conditions noted during daily checks or unusual operation to the appropriate maintenance personnel. A system should be established to record all problems, defects, and deficiencies noted by operators and discovered during maintenance inspections together with corrective actions taken. A schedule for preventive maintenance inspection and services should be established immediately after installation of the unit. A quarterly interval is recommended for normal operating conditions. Any component requiring preventive maintenance, more often than quarterly, is specifically identified in PMCS Table 4-1. When operating under unusual conditions, such as an extremely dusty, dirty, or sandy environment, it may be necessary to reduce the interval to monthly or less, dependant upon the severity of the environmental conditions. The refrigerant compressor and its drive motor are hermetically sealed. The compressor crankcase has a lifetime supply of oil and is pressure lubricated by an internal oil pump. If compressor failure or motor burnout occurs, the compressor must be replaced. Refer to the Recommended Spare Parts list for the correct replacement part. The evaporator blower motor and the condenser fan motors have sealed bearings and do not require additional lubrication. The PCMS Table (Table 4-1) lists the preventive maintenance checks and services that should be performed at quarterly (or otherwise established) intervals. The PCMS items in the table have been arranged and numbered in logical sequence to provide for greater personnel efficiency and least amount of required maintenance downtime. table 4-1. Preventive Maintenance- Checks and Services (PMCS) ITEM NO. 1 ITEM TO BE INSPECTEd / SErVICEd Return Air Filter and Fresh Air Filter PrOCEdUrES Remove, clean, inspect, service, discard / replace damaged or unserviceable filter. rECOMMENdEd INTErVAL Quarterly Depending on Operating Conditions
Evaporator Coil
Quarterly Examine for accumulated dirt / dust. Use a soft brush or vacuum sweeper (if available) to remove the dirt from areas and surrounding areas of the coils. Depending on Weather Examine the following areas for accumulated dirt, dust and sand. 1. Condenser Fans 2. Condenser Coil 3. Condenser Air Inlet Grilles and Outlet Grill 4. Surrounding areas 5. Condenser Motor 6. Compressor NOTE: Use a soft brush, cloth or vacuum sweeper as appropriate to clean dirt from components in the condenser section. Quarterly Depending on Weather
Condenser and Compressor Section
4-1
table 4-1. Preventive Maintenance- Checks and Services (PMCS), continued ITEM NO. 4 ITEM TO BE INSPECTEd / SErVICEd Evaporator Blower Section PrOCEdUrES Examine the following areas for accumulated dirt and dust. 1. Evaporator Coil 2. Heater 3. Impeller 4. Evaporator Blower 5. Surrounding area NOTE: Use a soft brush, cloth or vacuum sweeper as appropriate to clean dirt from components in the section. 5 Condensate Drain Pour approximately one quart of clean water into the condensate Quarterly drain pan and watch for it to flow through the drain stubs in the bottom of the unit. If water does not drain, check pan for blockages. Depending on Weather Using the sight glass / moisture indicator to inspect refrigerant while Quarterly unit is running in cool mode, view the sight glass located on the side of the receiver. The white float ball should float while discharge pressures are 2 413.2 kPa and the refrigerant system is stabilized. Examine for evidence of chafing, loose connections or other obvious damage. Repair as necessary. Examine for loose or missing attaching hardware or other obvious damage. Install all components and panels removed during PMCS. Ensure all items are back in place and secure. Quarterly Quarterly Quarterly rECOMMENdEd INTErVAL Quarterly Depending on Weather
Refrigerant Charge
7 8 9
Wiring Brackets, Mounts, Hardware, Etc. Reassemble
4-2
CHApTER 5
5-1. gENERAL
REpAIR AND REMOVAL pROCEDURES

Under normal operating conditions and with the proper preventive maintenance, the unit should provide excellent service for many years. After this time, the ECU should be returned to the manufacturer or a suitably qualified depot for major overhaul and refurbishment. All work must be performed by qualified refrigeration and electrical technicians and should include replacement of compressors, motors, contractors, bearings and other accessories as necessary.
NOTE
Refer to safety precautions section on this manual. Failure to adhere to these recommendations could result in serious injury.
5-1.1. Field Repairs
It may be necessary from time to time to perform field repairs on the refrigeration system. If field repairs are necessary, the following procedures apply:
5-1.1.1. Leak detection
Several methods can be used to detect a leak in the refrigeration system. The most modern and easiest method is to use on electronic leak detector. The leak detector must be designed and approved for R407C refrigerant. Follow the manufacturers directions and any leak can be quickly located.
5-1.1.2. Leak Repair
Handling refrigerant and repairing any leaks shall be performed only by certified service technicians. When a leak is located, properly recover the remaining refrigerant charge before attempting repairs. The refrigerant recovery device must meet EPA evacuation standards. Adjacent piping must be thoroughly cleaned by removing all paint, dirt and oily film. Use wire brush, sandcloth or sandpaper and wipe the area with clean, dry cloths. Protect nearby parts from heat damage by wrapping with water-soaked cloths.
WArNINg
Death or serious injury may result if personnel fail to observe proper safety precautions. Great care must be exercised to prevent contact of liquid refrigerant or refrigerant gas discharged under pressure, to any part of the body. The extremely low temperature resulting from the rapid expansion of liquid refrigerant, or refrigerant gas released under pressure, can cause sudden and irreversible tissue damage through freezing. At a minimum, all personnel must wear thermal protective gloves and face shield or goggles when working in any situation where refrigerant contact with the skin or eyes is possible. Application of excessive heat to any component in a charged system will cause extreme pressure that may result in a rupture, possibly explosive in nature. Exposure of Refrigerant R407C to an open flame or a very hot surface will cause a chemical reaction in the gas to form hydrogen fluoride. In its natural state, Refrigerant R407C is a colorless odorless vapor with no toxic characteristics. It is heavier than air and in a wellventilated area will disperse rapidly. However, in an unventilated area it presents danger as a suffocant.
5-1
5-1.1.3. Component Repairs
For copper-to-copper (piping) discharge or suction line repairs, use Silfos Alloy. No flux is required with Silfos Alloy. Silver solder (Stay-Silv #45) and flux are to be used on copper-to-brass or copper-to-steel repairs. For liquid line repairs at the drier/strainer, and the expansion valve, use Stay-Brite solders with flux for repairs. When repairs are complete, remove all traces of flux. After any repairs, pressure check system with Dry Nitrogen and a holding charge of Refrigerant R407C checking for leaks prior to recharging the system.
5-1.1.4. Component Replacement
Expansion valves, solenoid valve, drier strainers, hot gas regulator, etc. can be readily replaced by any qualified refrigeration service technician following standard refrigeration procedures. Refer to the wiring diagram and refrigeration schematic for the location of the system components and their relationship to each other. Refer to any adjustments and settings that may be required before or after installation.
5-1.1.5. Compressor Replacement
The compressor is the most important component of the air conditioner. Numerous safety devices are provided to protect the compressor from contamination damage and burn-out. When replacing a burned-out compressor, it is mandatory that the refrigeration system be thoroughly cleaned before operating the replacement compressor. When a compressor burn-out occurs, acid is created as a result of refrigerant-oil mixture being exposed to the extreme high temperatures the motor burn-out generates. The acid diffuses throughout the refrigeration system and must be removed by use of a burn-out filter kit (see below) before a new compressor is placed in service, or the acid will attack the windings of the new compressor motor. Any dirt, scale, air or water vapor also drastically shortens the operating life of a new compressor.
NOTE
Cleaning operation must be performed by a qualified HVAC service technician.
5-1.1.6. Burn-Out Clean Up Procedure
NOTE
Use appropriate service practices to properly recover the refrigerant removed from the refrigeration system. 1. Unsolder the suction and discharge lines from the compressor. Remove and retain the hardware that mounts the compressor to the ECU. Remove the compressor from the ECU. 2. Test the refrigerant oil of the defective compressor for acid using an acid test kit. If the refrigerant oil is found to be acidic, replace the liquid line filter/drier and add a suction line filter/drier. If the analysis of the oil shows no acidity, then the system can be cleaned by simply replacing the liquid line filter/drier. 3. The refrigerant oil contained within this system is an ester-based synthetic (POE) oil. It is highly hydroscopic and will readily absorb moisture. Do not allow the refrigeration system to be open to the environment for a total time period of 10 minutes or damage to the system will occur. 4. Install the new compressor using the hardware removed from the defective compressor. Re-solder the suction and discharge lines. Make all electrical connections to the compressor. 5. Purge the system with dry nitrogen then add a holding charge of Refrigerant 407C. Refer to the leak detection section of this manual and perform a leak check. 6. Once the unit has passed the leak detection test, evacuate the refrigeration system to below 80 microns of vacuum, then break vacuum with liquid Refrigerant, R-407C. 7. Charge and operate unit (see Paragraph 5-1.1.7.2). 5-2
8. After installation and start-up are complete the following tests should be performed on the replacement compressor and the information recorded. a. Suction Pressure b. Discharge Pressure c. Amp Draw d. Superheat Temperature
5-1.1.7. Charging Procedures
Care must be taken when charging the system to ensure the proper total amount of refrigerant is in the system. Use only Refrigerant R-407C to charge this ECU. Always charge the system with a liquid form.
5-1.1.7.1. Before Charging the System
When charging a unit without a refrigerant charge, a vacuum must be drawn on the refrigerant system prior to charging the system. Failure to evacuate the system adequately will cause the refrigerant to form hydrochloric/hydrofluoric acid with the water moisture remaining in the piping and eventually cause compressor failure. After ensuring that there are no piping leaks, evacuate the system to 80 microns or -29 mm and hold the vacuum for at least 2 hours. Keep in mind that worn refrigerant gauges or refrigerant hoses will leak and a proper vacuum may not be possible. Break the vacuum to a positive pressure by servicing the unit with R-407C liquid to its recommended capacity.
5-1.1.7.2 Charging the System
The total system charge is 7 lbs. of refrigerant. Topping off with refrigerant gauges connected to the suction and discharge ports near the compressor, slowly add R-407C liquid through the SUCTION side until the sight glass has cleared of all bubbles. Raise the discharge pressure by blocking the condenser flow to 350-375 PSIG. Add liquid refrigerant and observe the sight glass located on the side of the receiver. When the white float ball moves to the top of the sight glass stop adding refrigerant because the system is fully charged. Do not over charge the refrigeration system because reduced performance at high ambient temperature will occur.
Caution
Bubbles in the sight glass can be caused by flashing due to pressure from pipe leaks or incidental losses, etc. Damage to equipment may result if CAUTION is not observed.
5-2. REMOVAL / INSTALLATION PROCEdURES
WArNINg
Prior to attempting this procedure, ensure that all electric power has been removed from the unit. Standard tag-out / lock out procedures in accordance with local policy are required. Failure to observe WARNING may result in death or serious injury to personnel. The following procedures provide instruction for the removal / installation of items in a tactical environment.
5-3
5-2.1. Blower (MT1) Removal / Installation

1. Disconnect main power.
The following procedure details the removal / installation of the evaporator blower assembly. (Figure 5-1)
2. Remove evaporator access panel along with condenser access panel. 3. Remove electrical motor cover and disconnect wires. 4. Install puller removal bolts (use "-20 bolts in shroud as remover bolts) 5. Remove the two bolts through the air inlet side of the turbine. 6. Remove the eight bolts that secure the shroud in place. 7. Remove the four bolts that secure the motor in place. 8. Remove the motor. (be sure not to damage any pipes or switches) 9. After motor has been removed, slide turbine & shroud together and pull straight up. 10. Reverse this procedure for installation of evaporator blower assembly.
Figure 5-1. Evaporator Blower Assembly
5-4
5-2.2. Return Air Filter Removal / Installation

1. Disconnect main power. 2. Remove evaporator access panel. 3. Locate the filter directly behind the evaporator. 4. Lift filter straight up and remove from the unit.
The following procedure details the removal / installation of the return air filters. (Figure 5-2)
5. Reverse the procedure to install a new or cleaned filter. Ensure arrow on the filter points in the direction of air flow.
Figure 5-2. Return Air Filter Removal / Installation
5-5
5-2.3. Primary Overheat Safety Switch (SOS1) Removal / Installation

1. Remove all power from the unit and follow the lockout / tag-out procedure. 2. Remove evaporator access panel. 3. Locate the primary overheat safety switch.
The following procedure details the removal / installation of the heater safety switch. (Figure 5-3)
4. Remove wire leads from safety switch. These are standard fasten electrical connectors, they slide onto the terminal of the switch. 5. Place a shop rag or small drop cloth under the heater to capture any fillings or debris that may fall onto the drain pan during this procedure. 6. Carefully drill out the pop rivets from the bracket using a drill. Once both pop rivets have been removed, the switch will lift off of the bracket. 7. Install the new primary overheat safety switch. 8. Using a rivet tool and pop rivets, rivet the new safety switch onto the bracket. 9. Replace wire leads. 10. Replace evaporator access panel. 11. Reconnect main power.
Figure 5-3. Primary Overheat Safety Switch Removal / Installation
5-6
5-2.4. Secondary Overheat Safety Switch (SOS2) Removal / Installation

The following procedure details the removal / installation of the heater safety switch. (Figure 5-4) 1. Remove all power from the unit and follow the lockout / tag-out procedure. 2. Remove evaporator access panel. 3. Remove the heater from the unit (refer to page 5-8). 4. Locate the secondary overheat safety switch. 5. Label BLACK wires based on numbers on the overheat safety switch 6. Remove wire leads from safety switch using a standard screwdriver. These are standard fasten electrical connectors, they slide onto the terminal of the switch. 7. Using a standard screwdriver remove the two (2) mounting screws and then remove the overheat safety switch. 8. Install the new overheat safety switch. 9. Replace wire leads using a Standard screwdriver. 10. Reinstall the heater in the unit. 11. Replace evaporator access panel. 12. Reconnect main power.
Figure 5-4 Secondary Overheat Safety Switch Removal / Installation
5-7
5-2.5. Unit Heater Removal / Installation

1. Disconnect all power to the unit. 2. Remove evaporator access panel.
The following procedure details the removal / installation of the heater (Figure 5-5).
3. Remove two wires attached to primary overheat safety switch. 4. Locate three wires on the side of the heater that are attached and provide power to the heater. 5. Using a box, open-end or socket wrench, remove the retaining hardware and set aside. 6. Tag each wire so they can be reattached in the correct location. 7. Locate and remove four screws that support the heater. (Figure 5-5) 8. Lift heater element straight out, taking care not to damage the evaporator coil fins or the overheat safety switch located directly above the heater. 9. Re-install the new heater by sliding the heater component back in the same way it was removed. 10. Using the four Phillips head screws and washers, secure the heater to the frame. 11. Re-connect all wires in accordance with the tags to the correct terminal. Remove tag-out tags. 12. Place access panel cover on the unit and lock spring latches into place. 13. Re-apply power to the unit and run in heat mode to ensure correct operation.
Figure 5-5. Heater Removal
5-8
5-2.6. Removal of Contactors, Circuit Breakers and Relays
WArNINg
Always remove electrical power to the unit before attempting to perform any of the following procedures. Failure to observe WARNING may result in death or serious injury to personnel. Components are located in the electric box on the front side of the unit, remove the access panel with a flat tip screw driver.
GND
TH1 CB2 CB1 SM1
TB1
TB2
K1
K2-1
K2-2
K3
OL1 K4
OL2-1
OL2-2
Figure 5-6. Component Removal
5-9
table 5-1. Electric Box Component identification and Removal rEF. dESIgNATOr CB1 rEMOVAL PrOCEdUrE 1. As you are facing the circuit breaker, on the bottom of the breaker is a small retaining clip (Figure 5-7). 2. Using a small flat blade screwdriver, pull down the clip to release the tension. 3. Once the tension is released, the breaker will be free of the bracket. 4. Reverse the procedure to install a new breaker. 1. As you are facing the circuit breaker, on the bottom of the breaker is a small retaining clip (Figure 5-7). 2. Using a small flat blade screwdriver, pull down the clip to release the tension. 3. Once the tension is released, the breaker will be free from the bracket. 1. Locate the Phillips-head screws that secure the contactor to the bulkhead. 2. Remove the screws and set aside. 3. Remove overload relay. 4. Reverse procedure for replacement. NOTE: This overload relay MUST be removed in order to replace K2-1. OL2-1 1. Locate the Phillips-head screws that secure the relay to the bulkhead. 2. Remove screws and set aside. 3. Remove overload relay. 4. Reverse procedure for replacement. NOTE: This overload relay MUST be removed in order to replace K2-2. OL2-2 1. Locate the Phillips-head screws that secure the relay to the bulkhead. 2. Remove screws and set aside. 3. Remove overload relay. 4. Reverse procedure for replacement. NOTE: This overload relay MUST be removed on order to replace K3. K1 1. Locate the Phillips-head screws that secure the contactor to the bulkhead. 2. Remove screws and set aside. 3. Remove contactor. 4. Reverse procedure for replacement. NOTE: OL1 must be removed before this procedure can be accomplished. K2-1 1. Locate the Phillips-head screws that secure the contactor to the bulkhead. 2. Remove screws and set aside. 3. Remove contactor. 4. Reverse procedure for replacement. NOTE: OL2-1 must be removed before this procedure can be accomplished. K2-2 1. Locate the Phillips-head screws that secure the contactor to the bulkhead. 2. Remove screws and set aside. 3. Remove contactor. 4. Reverse procedure for replacement. NOTE: OL2-2 must be removed before this procedure can be accomplished. K3 1. Locate the Phillips-head screws that secure the contactor to the bulkhead. 2. Remove screws and set aside. 3. Remove contactor. 4. Reverse procedure for replacement.
CB2
OL1
5-10
table 5-1. Electric Box Component identification and Removal (continued) rEF. dESIgNATOr K4 rEMOVAL PrOCEdUrE 1. Locate the Phillips-head screws that secure contactor to the bulkhead. 2. Remove screws and set aside. 3. Remove contactor. 4. Reverse procedure for replacement.
Figure 5-7. Typical Release Clip for Circuit Breaker
5-11
5-2.7. Main Expansion (VE1) Valve Removal / Installation

1. Disconnect the power. 2. Remove access panel. 3. Locate the main expansion valve (Figure 5-8).
The following procedure explains how to remove and replace the main expansion valve.
Figure 5-8. Main Expansion Valve 4. Recover all refrigerant in accordance with local policies and EPA regulations. 5. Remove the Prestite insulation covering from the valve, sensor bulb. 6. Remove the sensing bulb from the line by removing the two Phillips-head screws and 716 nuts securing it to the line with two copper straps. 7. Purge system with nitrogen while unsoldering and soldering. 8. Unsolder the " line leading into the valve. 9. Once the solder has melted, pull up on the line and remove it from the valve. 10. Repeat steps 8 and 9 on the " line on the bottom side of the valve. This is also a soft solder joint and requires only low to medium heat to melt solder. 11. Locate the " distributor tube on the valve. This is soldered with SILFOS and will require a hotter torch to melt the connection. 12. Once melted, pull the " tube out of the valve. 13. Remove valve. 14. To replace the valve, reverse this procedure and re-charge system in accordance with the instructions provided in Paragraph 5-1.1.1.8.2 15. Once charged, perform leak testing in accordance with the instructions provided in Paragraph 5-1.1.1.
5-12
5-2.8. Removal of Temperature Responsive Expansion Valve (VE3)

1. Locate the temperature responsive expansion valve. (Figure 5-9) 2. Recover all refrigerant in accordance with local policies and EPA regulations. 3. Purge system with nitrogen while unsoldering and soldering. 4. Unsolder both ends of the valve. This is silfos and high heat is required. 5. Pull both ends free from the valve. 6. Disconnect valve from bulkhead.
The following procedure lists the steps for the removal of the temperature responsive expansion valve.
7. To replace the valve, reverse this procedure and re-charge system in accordance with the instructions provided in paragraph 5-1.1.1.8.2. 8. Once charged, perform leak testing in accordance with the instructions provided in paragraph 5-1.1.1.
Figure 5-9. Temperature Responsive Expansion Valve
5-13
CHApTER 6
6-1. gENERAL
TROUBLESHOOTING
The following table provides a list of typical problematic symptoms, possible causes and remedies. This list is not intended to be all-inclusive and requires that all troubleshooting, extended maintenance and servicing be performed by a trained and qualified technician. table 6-1. troubleshooting SYMPTOM ECU fails to start. POSSIBLE CAUSE Insufficient Voltage Power Failure Compressor fails to start. Tripped circuit breaker Defective contactor Head pressure too high (high pressure switch open) Complete loss of refrigerant charge Defective compressor motor Noisy compressor. Expansion valve stuck in the open posi tion (indicated by abnormally cold suction line). Worn or failed compressor bearings (indicated by excessive knocking). Improper scroll rotation. High pressure too high. Low condenser air flow (indicated by excessive warm air leaving the condenser fan). Air or other non-condensable gas in system. Over charge of refrigerant. Condenser fan(s) not on. Loss of refrigerant (indicated by bubbles in the sight glass) Head pressure is too low. Expansion valve stuck in the open position (indicated by abnormally cold suction line). rEMEdY Correct voltage input. (208v, 3ph, 60Hz.) Ensure neutral is present. Check power source, power input and fuses. Check control cables and connections. Reset circuit breaker. If breaker trips again, determine cause. Repair or replace. Check for overload. Check condenser air inlet and discharge for obstruction. Reset high pressure switch. Check condenser motor contactors. Repair leak and recharge system. Replace compressor. Ensure the feeler bulb is tight. Check superheat. Adjust or replace valve. Replace compressor. Check phasing of input power. Make sure indoor impeller rotates counter-clockwise when facing the inlet cone. Open air passages. Clean coil. Check condenser fan.
Reclaim system and recharge. High side new drier/strainer. Reclaim excess refrigerant from unit. Check that overload is closed. Repair leak and recharge system. Repair or replace valve.
6-1
table 6-1. troubleshooting, continued SYMPTOM Suction pressure too low. POSSIBLE CAUSE Low charge, flash gas in liquid line. (Indicated by bubbles in sight glass). Clogged drier/strainer (feels cool to the touch). Obstructed expansion valve (Indicated by bubbles in the sight glass). Loss of control fluid from expansion valve, control head (Indicated by bubbles in sight glass). Overload trip. No condenser air flow. Defective high or low pressure switch (S3 or S4). Overload trip. No heat from ECU. Defective Heater Safety Switch (SOS1, SOS2). SOS2 requires manual resetting. Evaporator blower motor continually trips the overload relay. Improper adjustment of overload relay OL-2. Defective overload relay. Improper main power phasing. No cooling. Improper main power phasing. Loss of charge. rEMEdY Repair leak, recharge unit. Replace drier/strainer. Replace valve. Replace valve or control head.
Determine cause and repair. Reset overload. If in manual position, change overload to automatic. Replace valve or control head. Determine cause and repair. Reset OL2-1 or OL2-2. Replace SOS1 or SOS2 as needed. Reset SOS2. Check and adjust relay to proper setting of 4 amps. Replace overload relay Check input power phasing to determine correct phasing. Check input power phasing to determine correct phasing. Leak check refrigeration system.
6-2
AppENDICES
APPENdIx A - ALASKA 5-TON ECU SCHEMATICS APPENdIx B - PARTS LIST APPENdIx C - RECOMMENdEd REFRIgERATION TOOLS LIST
Copyright 2008 Alaska Structures, Inc. ALL RIGHTS RESERVED August, 2008
ALASKA 5-TON ECU ELECTRICAL SCHEMATIC
AK-ECU-5T 01/04/2010
DESIGNATOR CB1 CB2
PART NAME Circuit Breaker, Control Circuit Breaker, Heater Heater, Resistance Contactor, Evaporator Contactor, Condenser Motor No.1 Contactor, Condenser Motor No.2 Contactor Coil, Compressor Contactor Coil, Heater Solenoid, Liquid Line with Plug Motor, Evaporator Motor, Condenser No.1 Motor, Condenser No.2 Motor, Compressor Overload Relay, Evaporator Overload Relay, Condenser Motor No.1 Overload Relay, Condenser Motor No.2 Overload Relay, Motors Electrical Power Cable High Pressure Switch with Plug Low Pressure Switch with Plug Switch, Refrigerant Condenser Pressure 1, with: Plug Switch, Refrigerant Condenser Pressure 2, with: Plug Switch, Mode Selector with wires and heat shrink Primary Overheat Safety Switch Secondary Overheat Safety Switch Terminal Block Terminal Block Thermostat Control
PART NUMBER AK-ECU-5T-MG24500 AK-ECU-5T-MG24544 AK-ECU-5T-76B-1112-02 AK-ECU-5T-LC1D09G7 AK-ECU-5T-LC1D09G7 AK-ECU-5T-LC1D09G7 AK-ECU-5T-LC1D32G7 AK-ECU-5T-LC1D32G7 AK-ECU-5T-MKC-1 120V-P AK-ECU-5T-34K526X419G1 AK-ECU-5T-33E620W159G1 AK-ECU-5T-33E620W159G1 AK-ECU-5T-ZR72KCE-TFD-130 AK-ECU-5T-LRD08 AK-ECU-5T-LRD08 AK-ECU-5T-LRD08 AK-ECU-5T-LRD07 AK-ECU-5T-UEC77290-27 AK-ECU-5T-P100DA-44D-P AK-ECU-5T-P100AP-201D-P AK-ECU-5T-P100AP-4D-P AK-ECU-5T-P100-AP-51D-P AK-ECU-5T-CA4-US6372-6-Kit AK-ECU-SOS1 AK-ECU-SOS2 AK-ECU-5T-GV1G09 AK-ECU-5T-GV1G09 AK-ECU-5T-A28AA-36D
QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
SM1
HEAT VENT OFF COOL AUTO
RED BLACK BLACK BLACK BLACK
Main Power Input 120/208V, 3 Phase, 50/60 HZ

GND A B ORANGE BLACK
HR1 K1
C N
P2
K2-1 K2-2 K3 K4
RED
LIGHT ORANGE
TB2
L1 MT1 MT2-1 MT2-2 MT3 OL1 OL2-1
BLACK
BLACK
BLACK
RED
5-Position Switch
CB1
CB2
BLACK
BLACK
TB1
BUS BAR
ORANGE ORANGE ORANGE ORANGE
ORANGE
OL2-2 OL2-3
A1
1/L1 ORANGE
3/L2
5/L3
13/NO 21/NC A1
1/L1
3/L2
5/L3
13/NO 21/NC A1
1/L1
3/L2
5/L3
13/NO 21/NC A1
1/L1
3/L2
5/L3
13/NO 21/NC A1
1/L1
3/L2
5/L3
13/NO 21/NC
P2 S1
L1
PURPLE
K4
2/T1 4/T2 BROWN
14/NO 22/NC A2
K1
14/NO 22/NC A2
K2-1
BROWN 2/T1 4/T2 6/T3 2/T1 4/T2
14/NO 22/NC A2
K2-2
BROWN 6/T3 2/T1 4/T2
14/NO 22/NC A2
S2
K3
BLACK/RED 6/T3 2/T1 4/T2
14/NO 22/NC A2
S3
6/T3
WHITE
BLACK
BLACK
WHITE
6/T3
S4 SM1 SOS1 SOS2 TB1 TB2 TH1
95
RED
GREY
TH1
RED
R Y B Y R
SOS2
BLACK 1 3 5 7 2 4 6 8 GREY BLACK PURPLE BLUE BLACK
96
96
96
OL2-2
YELLOW BLACK RED
BLACK
OL1
YELLOW BLACK BROWN/YELLOW
95
OL2-1
YELLOW BLACK RED/WHITE RED
95
YELLOW
WHITE
High Stage WHITE
Low Stage
BROWN
HR1 SOS1
SM1
WHITE
M
WHITE
RED
RED
RED
GREEN
M
MT2-1
GREEN
M
MT2-2
M
GREEN
MT3
S2
WHITE/BLUE WHITE/BLUE BROWN/YELLOW
S3 S4
RED/WHITE
MT1
BROWN/YELLOW
RED
RED/WHITE
S1
BLACK/RED BLACK/RED
U.S. GOVERNMENT LIMITED RIGHTS NOTICE (NOTICE): (a) This documentation and any technical data, including drawings, are submitted by the Contractor to the Government with limited rights. This documentation and these data may be used, modified, reproduced, released, performed, or disclosed by the Government only as provided under paragraph (a) of DOD FAR 227.7102-2 Rights in Technical Data, with the express limitation that the data may not be used to manufacture additional quantities of the commercial items and, except as provided in subparagraphs (b)(1)(ii), (iii), and (iv) and subparagraph (b)(2)(ii) of DOD FAR clause 252.227-7015 released performed, displayed, or disclosed outside the Government. Any such modification, release, performance, or disclosure the Government makes is subject to prohibition against further use and disclosure. (b) This Notice shall be marked on any reproduction of this documentation and these data, in whole or in part. Technical Data disclosed herein is subject to the limited rights of the Government and third parties as provided in FAR 227.7102 and 252.227-7015. Copyright 2010 Alaska Structures, Inc. ALL RIGHTS RESERVED January, 2010
A-1
ALASKA 5-TON ECU REFRIGERATION SCHEMATIC

EQUALIZER LINE L1 EQUALIZER LINE CE1 1/2" SG1 DS1 1/2" V1 AS1 RC1 VE1
DESIGNATOR CC1 CE1 AS1 DS1 L1 MT1 MT2-1 MT2-2 MT3 RC1 SG1 S1 PART NAME Coil, Condenser Coil, Evaporator Auxiliary Side Connector Drier/Strainer Solenoid, Liquid Line Motor, Evaporator Blower Motor, Condenser Fan No.1 Motor, Condenser Fan No.2 Motor, Compressor Receiver Sight Glass Switch, High Pressure, 500 PSIG Switch, Low Pressure, 10 PSIG Switch, Condenser Close 250 PSIG Switch, Condenser Close 320 PSIG Solenoid Valve, Liquid Line Valve, Expansion Valve, Desuperheating Valve, Hot Gas Regulator Guage Port, Lowside Guage Port, Highside
AK-ECU-5T 01/04/2010
PART NUMBER AK-ECU-5T-01-0826 AK-ECU-5T-105945800 AK-ECU-5T-ASC-7-4 AK-ECU-5T-C-084-S AK-ECU-5T-MKC-1 120V AK-ECU-5T-34K5263254G1 AK-ECU-5T-33E6200673G1 AK-ECU-5T-33E6200673G1 AK-ECU-5T-ZR72KCE-TF5-130 AK-ECU-5T-X8779 AK-ECU-5T-SA-14S AK-ECU-5T-P100DA-44D AK-ECU-5T-P100AP-201D AK-ECU-5T-P100AP-4D AK-ECU-5T-P100AP-51D AK-ECU-5T-B6S1 AK-ECU-5T-SNE-5-CP85 AK-ECU-5T-Y1037-FV-1-1/2-230 AK-ECU-5T-ADRPE-3-0/80
QTY. 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1
5/8"
VE3
EXPANSION VALVE FEEDER BULB
S2 S3 S4 V1 VE1
VH1 EQUALIZER LINE
1/2" 7/8"
VE3 VH1 GP1 GP2
DESUPERHEATING VALVE FEEDER BULB
MT1 7/8" 3/8" 7/8" 7/8" 7/8"
MT2
MT2 5/8" 5/8"
7/8" LP MT3 GP1 S2
S1 HP S3 CS 7/8" CC1 GP2 S4 CS
NOTES: 1) ALL TUBING IS AIR CONDITIONING AND REFIGERATION L COPPER TYPE. 2) EQUALIZER LINES TO BE 1/4".
U.S. GOVERNMENT LIMITED RIGHTS NOTICE (NOTICE): (a) This documentation and any technical data, including drawings, are submitted by the Contractor to the Government with limited rights. This documentation and these data may be used, modified, reproduced, released, performed, or disclosed by the Government only as provided under paragraph (a) of DOD FAR 227.7102-2 Rights in Technical Data, with the express limitation that the data may not be used to manufacture additional quantities of the commercial items and, except as provided in subparagraphs (b)(1)(ii), (iii), and (iv) and subparagraph (b)(2)(ii) of DOD FAR clause 252.227-7015 released performed, displayed, or disclosed outside the Government. Any such modification, release, performance, or disclosure the Government makes is subject to prohibition against further use and disclosure. (b) This Notice shall be marked on any reproduction of this documentation and these data, in whole or in part.
Technical Data disclosed herein is subject to the limited rights of the Government and third parties as provided in FAR 227.7102 and 252.227-7015.
A-2
AppENDIx B
pARTS LIST
B-1. INTROdUCTION B-2. PARTS LIST
This appendix contains the parts available to help maintain the Alaska 5-Ton ECU (AK-ECU-5T) in good working order.
The following items make up the entire parts list for the Alaska 5-Ton ECU. When spare parts are required, please contact Alaska Structures, Inc. at 1-888-370-1800, or fax (425) 899-1206. table B-1. aK-ECu-5t Parts List dESIgNATOr ALASKA PArT NAME Alaska 5-Ton ECU, European Option (GREEN) Alaska 5-Ton ECU, European Option (TAN) CABINET COMPONENTS 15.75 OD Duct Ring Kit, with: Screws and Caulk (GREEN) 15.75 OD Duct Ring Kit, with: Screws and Caulk (TAN) Electric Box Cover Panel, with: Fasteners (GREEN) Electric Box Cover Panel, with: Fasteners (TAN) Control Panel Aluminum Top Cover, Electric Box Cover, Evaporator Compartment, with: Top latches and strikes (GREEN) Cover, Evaporator Compartment, with: Top latches and strikes (TAN) Cover, Condenser Compartment, with: Top latches and strikes (GREEN) Cover, Condenser Compartment, with: Top latches and strikes (TAN) Side Access Grille (GREEN) Side Access Grille (TAN) Cover Kit, Control Panel, with: Fasteners, Hinge and Rivets (GREEN) Cover Kit, Control Panel, with: Fasteners, Hinge and Rivets (TAN) MECHANICAL ASSEMBLY COMPONENTS CC1 CE1 MT1 MT2-1, MT2-2 Coil, Condenser, with: Fasteners and Copper Tube Stub Coil, Evaporator, with: Fasteners Motor, Evaporator- 0.75kw, 1425 RPM Motor, Condenser Fan- 0.37KW,1425RPM AK-ECU-5T-01-0826 AK-ECU-5T-105945800 AK-ECU-5T-34K526X419G1 AK-ECU-5T-33E620W159G1 0GC93 0GC93 0GC93 0GC93 B-1 AK-ECU-P1-25-1-Kit AK-ECU-P1-25-2-Kit AK-ECU-5T-EPC01-1 AK-ECU-5T-EPC01-2 AK-ECU-P33 AK-ECU-P59 AK-ECU-P27-1 AK-ECU-P27-2 AK-ECU-P26-1 AK-ECU-P26-2 AK-ECU-P28-1 AK-ECU-P28-2 AK-ECU-P34-KIT-1 AK-ECU-P34-KIT-2 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 ALASKA PArT NUMBEr AK-ECU-5T-1 AK-ECU-5T-2 CAgE COdE 0GC93 0GC93
table B-1. aK-ECu-5t Parts List, continued dESIgNATOr MT3 RC1 ALASKA PArT NAME Motor, Compressor Receiver Fan Blade Blower Wheel Inlet Cone Compressor Vibration Mount Rubber Mounts PIPINg AS1 DS1 SG1 V1 VE1 VE3 VH1 ELECTrICAL CB1 CB2 HR1 K1, K2-2,K2-2 K3 K4 L1 OL1, OL2-1, OL2-2 S1 S2 S3 S4 SM1 SOS1 SOS2 TB1 TH1 Circuit Breaker, Control Circuit Breaker, Heater Heater, Resistance Contactor Coil, Motors Contactor Coil, Compressor Contactor Coil, Heater Solenoid, Liquid Line with Plug Overload Relay, Motors High Pressure Switch with Plug Low Pressure Switch with Plug Switch, Refrigerant Condenser Pressure 1 with Plug Switch, Refrigerant Condenser Pressure 2 with Plug Switch, Mode Selector with wires and heat shrink Primary Overheat Safety Switch Secondary Overheat Safety Switch Terminal Block Thermostat Control BUSSBAR, 63AMP Ground Lug- 1 Conductor, 14 Gauge 2/0 Strain Relief- 1.045" Cable Sealing Lock Nut- 1" Disconnect Box FASTENErS B-2
ALASKA PArT NUMBEr AK-ECU-5T-ZR72KCE-TFD-130 AK-ECU-5T-X8779 AK-ECU-5T-S-17-12HD AK-ECU-5T-T1-TEK400-1R AK-ECU-5T-TO-ICP400-IM AK-ECU-5T-527-0116-00 AK-ECU-5T-51153 AK-ECU-5T-ASC-7-4 AK-ECU-5T-C-084-S AK-ECU-5T-SA-14S AK-ECU-5T-B6S1 AK-ECU-5T-SNE-5-CP85 AK-ECU-5T-Y1037-FV-1-1/2-2303/8X3/8 AK-ECU-5T-ADRPE-30/80
CAgE COdE 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93
Auxiliary Side Connector Filter Drier Strainer Sight Glass, Refrigerant Solenoid Valve, Liquid Refrigerant Expansion Valve, Main Expansion Valve, Liquid Hot Gas Valve
AK-ECU-5T-MG24500 AK-ECU-5T-MG17472 AK-ECU-5T-76B-1112-04 AK-ECU-5T-LC1D09U7 AK-ECU-5T-LC1D32U7 AK-ECU-5T-LC1D32U7 AK-ECU-5T-MKC-1 240V-P AK-ECU-5T-LRD07 AK-ECU-5T-P100DA-44D-P AK-ECU-5T-P100AP-201D-P AK-ECU-5T-P100AP-4D-P AK-ECU-5T-P100-AP-51D-P AK-ECU-5T-CA4-US6372-6-Kit AK-ECU-SOS1 AK-ECU-SOS2 AK-ECU-5T-GV1G09 AK-ECU-5T-A28AA-36D AK-ECU-5T-GV2-G445 AK-ECU-5T-KA2U AK-ECU-5T-2546 AK-ECU-5T-SLG-100S AKECU-5T-3LD25650TB51-0US2
0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93
table B-1. aK-ECu-5t Parts List, continued dESIgNATOr ALASKA PArT NAME Top Access Cover Cam Latch Top Access Cover Lever Top Access Cover Strike Top Access Cover Spring Latch Series 85 1/4 turn fastener kit Series 82 1/4 turn fastener kit ACCESSOrIES Alaska 5-Ton ECU Technical Manual, European Option Alaska 5-Ton ECU Drain Kit Insulated Folding Duct, 16 Dia. (GREEN) Insulated Folding Duct, 16 Dia. (TAN) Fabric Duct Ring Cover, 16 Dia. (GREEN) Fabric Duct Ring Cover, 16 Dia. (TAN) ECU Duct Support Ring (Inside) Return Air Filter Fresh Air Filter OPTIONAL PArTS Insulated folding Duct, 16 Dia., with: Hook & Loop Fastener for Fabric Duct Screen (GREEN) Insulated folding Duct, 16 Dia., with: Hook & Loop Fastener for Fabric Duct Screen (TAN) Fabric Duct Screen ECU Wheel Set (GREEN) ECU Wheel Set (TAN) ECU Wheel Set Carry Bag (GREEN) ECU Wheel Set Carry Bag (TAN) AK-ECU-5T-686ATT-FDS01-1 AK-ECU-5T-686ATT-FDS01-2 AK-ECU-FDS16 AK-ECU-WHEEL-1 AK-ECU-WHEEL-2 AK-ECU-WHEELB-1 AK-ECU-WHEELB-2 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 AK-ECU-5T-ECU-TM AK-ECU-5T-DKIT01 AK-ECU-5T-686ATT-02-1 AK-ECU-5T-686ATT-02-2 AK-ECU-686ATC-1 AK-ECU-686ATC-2 AK-ECU-3/8ISRING-5T AK-ECU-5T-3400-19.5X28.87 AK-ECU-5T-3400-4.5X9 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93 ALASKA PArT NUMBEr AK-ECU-5T-E5-6-215-UU1 AK-ECU-5T-E5-6007 AK-ECU-5T-SCD2065025-SS AK-ECU-5T-SCD20649ZE AK-ECU-5T-SERIES85-KIT AK-ECU-5T-SERIES82-KIT CAgE COdE 0GC93 0GC93 0GC93 0GC93 0GC93 0GC93
B-3
AppENDIx C
C-1. INTROdUCTION
RECOMMENDED REFRIGERATION TOOLS

Table C-1 of this appendix contains the refrigeration tools recommended to help maintain the Alaska 5-Ton ECU (AK-ECU-5T) in good working order. It is the responsibility of the user to have these tools available to ensure continuous operation of the Alaska 5-Ton ECU (AK-ECU5T). table C-1. Recommended Refrigeration tools QTY. 1 Ea. 1 Ea. 1 Ea. 1 Ea. 1 Ea. 1 Kit 1 Ea. 1 Set 1 Set 1 Set 1 Set 1 Ea. 1 Ea. 1 Ea. 1 Ea. 1 Ea. 1 Ea. dESCrIPTION Multi-Function Meter (Volts, Ohms, Amps) Refrigeration Pressure Gauges (w/ hoses) Sling Type Psychrometer Digital Temperature Indicator (w/ thermocouple wire) Refrigeration Vacuum Pump Oxygen / Acetylene Torch Kit B Prestolite Tank or Refrigerant Leak Detector Wrench Set, Box End, 5 Piece (SAE) Wrench Set, Open End, 6 Piece (SAE) Wrench Set, Flare nut, 5 Piece (SAE) Wrench Set, Ratchet (1/2 drive, w/ sockets) Screwdriver, Phillips (#1) Screwdriver, Phillips (#2) Screwdriver, Phillips (#3) Screwdriver, Common (1-) Screwdriver, Common (4) Screwdriver, Common (6) MFgr Grainger Grainger Grainger Grainger Grainger Grainger Grainger Snap-On Snap-On Snap-On Snap-On Klein Klein Klein Klein Klein Klein PArT NO. 1TC66 621-C 2T703 4GU15 1RK24 5KZ91 1TC17 XB605A VO806B RXS605B 317MSPC 603-3 603-4 603-6 600-1 600-4 600-6 PUrPOSE Measuring volts, amps and ohms. Measuring refrigeration pressure and levels every 6 months. Measuring dry and welt bulb temperatures every month. Measuring air and refrigerant temperatures every 6 months. Evacuating moisture from refrigeration system before charging system. Soldering refrigeration lines (soft solder, silver solder, silfos) as needed. Detection of refrigerant leaks, every 6 months. Tightening and loosening hex head nuts, bolts and screws, as needed. Tightening and loosening hex head nuts, bolts and screws, as needed. Tightening and loosening hex head nuts, bolts and screws, as needed. Tightening and loosening hex head nuts, bolts and screws, as needed. Tightening and loosening Phillips head screws, as needed. Tightening and loosening Phillips head screws, as needed. Tightening and loosening Phillips head screws, as needed. Tightening and loosening common head screws, as needed. Tightening and loosening common head screws, as needed. Tightening and loosening common head screws, as needed.
C-1
table C-1. Recommended Refrigeration tools, continued QTY. 1 Ea. 1 Ea. 1 Ea. dESCrIPTION Screwdriver, Common (12) Channel-Lock Pliers (9-1/4) Refrigeration Wrench, Square End (SAE) MFgr Klein Snap-On Klein PArT NO. 602-12 CHN480 68310 PUrPOSE Tightening and loosening common head screws, as needed. General gripping of fittings, as needed. Front and backseating refrigeration valves, as needed.
C-2

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Installation, Operation and Maintenance Instructions with Parts List

ALASKA 5-Ton ECU

LIMITED TWO-YEAR WARRANTY

CONTENTS OF THIS MANUAL

Appendix A Appendix B Appendix C

USE OF THIS MANUAL

REpAIR AND REmOvAL pROCEDURES ...................................................................................................................................... 5-1

Figure 1-1. ECU Nomenclature Plate

1-3. PURPOSE ANd FUNCTION

1-4. EqUIPMENT dESCRIPTION 1-4.1. Capabilities and Features

1-5. dESIgN PARAMETERS

115F Outdoor Ambient Temperature

125F Outdoor Ambient Temperature

1-6. MISCELLANEOUS FEATURES

1-7. ELECTRICAL PANEL

Figure 1-2. Electrical Panel Components

TH1 CB2 CB1 SM1

Figure 1-3. Electrical Panel Components

1-8. VIEwS 1-8.1. Rear View (Figure 1-4)

Figure 1-4. Rear View

1-8.2. Left Side View (Figure 1-5)

Figure 1-5. Left Side View

1-8.3. Front Side View (Figure 1-6)

Figure 1-6. Front Side View

1-8.4. Right Side View (Figure 1-7)

Figure 1-7. Right Side View

1-8.5. Top Side View (Figure 1-8)

Figure 1-8. Top View

Figure 1-9. Tool Actuated Latch

1-8.6. Access Panels Removed (Figure 1-10)

Figure 1-10. Access Panels Removed

1-8.7. Optional wheel Kit (Figures 1-11,1-12)

Figure 1-11. ECU Wheel Kit Installed

Figure 1-12. ECU Wheel

1-9. INTERNAL COMPONENTS (Figure 1-13)

Figure 1-13. Major Internal Components

Figure 1-14. Circuit Breakers

Figure 1-15. Secondary Overheat Safety Switch

1-9.1. Control Panel

Figure 1-16. Control Panel

1-9.3. wiring Harness

Figure 1-18. Main Wiring Harness

Figure 1-19. Heater Wiring Harness

2-2. INSTALLATION & SITE PREPARATION

2-3. ECU gENERAL PREPARATION 2-4. PLACEMENT OF THE UNIT

2-5. CONNECTION OF THE MAIN POwER

2-6. CONdENSATE PANS & dRAINS

Figure 2-1. Condensation Drain

2-7. STACKABLE FEATURE

Figure 2-2. Stackable Feature (Side View)

463L Pallet 108in (104in Usable)

463L Pallet 88in (84 Usable )

Figure 2-3. Stacking Feature

Figure 2-4. Stackable Feature

2-7.1. Stacking Hardware

Figure 2-5. Stacking Hardware

2-8. STACKINg INSTRUCTIONS / dIMENSIONS

Figure 2-6. Stacking ECUs Together

2-9. dUCT ASSEMBLY

ALUMINUM RING HOOK & LOOP STRAP

Figure 2-7. Fabric Duct Assembly

2-10. FABRIC dUCT SCREEN INSTALLATION (oPtionaL)