Table of Contents
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Package Gas/Electric Cooling Units
And Micro−channel Condenser Coils
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Service and Maintenance Instructions
RGS Series
7.5 to 12.5 Ton
With R−410A Refrigerant
TABLE OF CONTENTS
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06/14/10
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Table of Contents
Related Manuals for International comfort products RGS Series
Summary of Contents for International comfort products RGS Series
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Page 1: Table Of Contents
RGS Series 7.5 to 12.5 Ton Package Gas/Electric Cooling Units With R−410A Refrigerant And Micro−channel Condenser Coils TABLE OF CONTENTS SAFETY CONSIDERATIONS .... -
Page 2: Safety Considerations
SAFETY CONSIDERATIONS WARNING Installation servicing air-conditioning FIRE, EXPLOSION HAZARD equipment can be hazardous due to system pressure Failure to follow this warning could result in and electrical components. Only trained and qualified personal injury, death and/or property damage. service personnel should install, repair, or service air-conditioning equipment. -
Page 3: Unit Arrangement And Access
WARNING Fig.2−Typical Access Panel Location (Front) FIRE, EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death. Disconnect gas piping from unit when pressure testing at pressure greater than 0.5 psig. Pressures greater than 0.5 psig will cause gas valve damage resulting in hazardous condition. - Page 4 Heating Fig. 3 − Filter Installation S Heat exchanger flue passageways cleanliness S Gas burner condition 22 3/8 (569 mm) S Gas manifold pressure S Heating temperature rise Economizer or Outside Air Damper S Inlet filters condition S Check damper travel (economizer) DIVIDER S Check gear and dampers for debris and dirt OUTSIDE...
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Page 5: Supply Fan (Blower) Section
SUPPLY FAN (BLOWER) SECTION 1. Use a belt with same section type or similar size. Do not substitute a “FHP” type belt. When in- stalling the new belt, do not use a tool (screw- WARNING driver or pry−bar) to force the belt over the pulley flanges, this will stress the belt and cause a re- ELECTRICAL SHOCK HAZARD duction in belt life. -
Page 6: Cooling
To align fan and motor pulleys: motor mounting base; this is part of the motor grounding system. Ensure the teeth on the lock 1. Loosen fan pulley setscrews. washer are in contact with the motor’s painted base. 2. Slide fan pulley along fan shaft. Make angular Tighten motor mounting bolts to 120 +/−... - Page 7 Carefully remove any foreign objects or debris Fig. 8 − Micro−channel Coils attached to the coil face or trapped within the mounting frame and brackets. Using a high pressure TUBES water sprayer, purge any soap or industial cleaners from hose and/or dilution tank prior to wetting the coil. FINS Clean condenser face by spraying the coil core steadily and uniformly from top to bottom, directing...
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Page 8: R−410A Refrigerant
S water rinse with low velocity spray nozzle 7. Thoroghly rinse all surfaces with low velocity clean water using downward rinsing motion of wa- CAUTION ter spray nozzle. Protect fins from damage from the spray nozzle. PERSONAL INJURY HAZARD Evaporator Coil Metering Devices Failure to follow this caution may result in The metering devices are multiple fixed−bore devices corrosion and damage to the unit. - Page 9 Because R−410A refrigerant is a blend, it is strongly are different from the type normally used. Charts are recommended that refrigerant always be removed based on charging the units to the correct superheat from the cylinder as a liquid. Admit liquid refrigerant various operating conditions.
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Page 10: Cooling Charging Charts
COOLING CHARGING CHARTS Fig. 10 − Cooling Charging Charts 509 08 3601 00... - Page 11 COOLING CHARGING CHARTS Fig. 11 − Cooling Charging Chart 509 08 3601 00...
- Page 12 COOLING CHARGING CHARTS Fig. 12 − Cooling Charging Chart (Circuit A) 12.5 Ton 509 08 3601 00...
- Page 13 COOLING CHARGING CHARTS Fig. 13 − Cooling Charging Chart (Circuit B) 12.5 Ton 509 08 3601 00...
- Page 14 Table 1 – Cooling Service Analysis PROBLEM CAUSE REMEDY Power failure. Call power company. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Defective thermostat, contactor, Replace component. transformer, or control relay. Compressor and Condenser Fan Will Not Start. Insufficient line voltage.
- Page 15 Compressors 6. Reverse any two of the unit power leads. 7. Reapply power to the compressor. Lubrication The suction and discharge pressure levels should Compressors are charged with the correct amount of now move to their normal start−up levels. oil at the factory. NOTE: When the compressor is rotating in the wrong CAUTION direction, the unit makes an elevated level of noise...
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Page 16: Convenience Outlets
CONVENIENCE OUTLET electric heaters for overnight use). Observe a 50% limit on circuit loading above 8−amps (i.e., limit loads exceeding 8−amps to 30 minutes of operation every WARNING hour). Maintenance ELECTRICAL OPERATION HAZARD Periodically test the GFCI receptacle by pressing the Failure to follow this warning could result in personal injury or death. - Page 17 The sensor uses a process called differential sensing Fig. 17 − Controller Assembly to prevent gradual environmental changes from triggering false alarms. rapid change environmental conditions, such as smoke from a fire, causes the sensor to signal an alarm state but dust and debris accumulated over time does not.
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Page 18: Sensor And Controller
FIOP Smoke Detector Wiring and Response Fig. 19 − Typical Supply Air Smoke Detector Sensor Location All units: FIOP smoke detector is configured to automatically shut down all unit operations when smoke condition is detected. See Fig.20, Smoke Detector Wiring. Highlight A: JMP 3 is factory−cut, transferring unit control to smoke detector. - Page 19 Sensor Alarm Test Procedure CAUTION 1. Hold the test magnet where indicated on the side of the sensor housing for seven seconds. OPERATIONAL TEST HAZARD 2. Verify that the sensor’s Alarm LED turns on. Failure to follow this caution may result in 3.
- Page 20 CAUTION CAUTION OPERATIONAL TEST HAZARD OPERATIONAL TEST HAZARD Failure to follow this caution may result in Failure to follow this caution may result in personnel and authority concern. personnel and authority concern. If the test/reset station’s key switch is left in the This test places the duct detector into the alarm RESET/TEST position for longer than seven state.
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Page 21: Indicators
2. Using a vacuum cleaner, clean compressed air, Fig. 23 − Controller Assembly or a soft bristle brush, remove loose dirt and debris from inside the sensor housing and cover. Trouble Use isopropyl alcohol and a lint−free cloth to re- move dirt and other contaminants from the gasket Alarm Power... -
Page 22: Protective Devices
2. Check the wiring between the sensor and the controller. If wiring is loose or missing, repair or replace as required. Table 3 – Detector Indicators CONTROL OR INDICATOR DESCRIPTION Resets the sensor when it is in the alarm or trouble state. Activates or tests the sensor when it is in Magnetic test/reset switch the normal state. -
Page 23: Gas Heating System
Table 4 − Overcurrent Device Type Fig. 25 − Limit Switch Location Motor Size (bhp) Overload Device Reset Internal Linebreak Automatic Limit Switch Internal Linebreak Automatic and Shield Thermik Automatic Thermik Automatic External Manual (Circuit Breaker) Condenser Fan Motor Protection The condenser fan motor is internally protected against overtemperature. - Page 24 Table 7 – Liquid Propane Supply Line Pressure Fig. 26 − LP Low Pressure Switch (Installed) Ranges UNIT UNIT SIZE MODEL 11.0 in. wg 13.0 in. wg (2740 Pa) (3240 Pa) Manifold pressure for LP fuel use must be adjusted to specified range.
- Page 25 1. Remove the combustion blower wheel and motor 1. Slide burner access panel out. assembly according to directions in Combustion− 2. Remove the 7 screws that attach induced−draft Air Blower section. (See Fig.28.) motor housing to vestibule plate. (See Fig.28.) 2.
- Page 26 to prevent excessive gas flow from the side of the Fig. 29 − Orifice Projection burner assembly. If the pinched crossovers are ORIFICE installed between two burners, the flame will not ignite properly.) Fig. 31 − Unit Control Box/IGC Location 1.00-in (25.4 mm) INTEGRATED GAS UNIT...
- Page 27 they are blue in appearance, and that the flames Limit Switch are approximately the same for each burner. Remove blower access panel. Limit switch is located 10. Turn off unit, remove pressure manometer and on the fan deck. (See Fig.25.) replace the 1/8 in.
- Page 28 Fig. 33 − Gas Valve All RGS except RGS090 RGS090 only Orifice Replacement Check that each replacement orifice is tight at its threads into the manifold pipe and that orifice This unit uses orifice type LH32RFnnn (where nnn projection does not exceed maximum value. (See indicates orifice reference size).
- Page 29 Fig. 34 − Integrated Gas Control (IGC) Board Red LED-Status Table 10 – IGC Connections CONNECTION TERMINAL LABEL POINT DESCRIPTION SENSOR LOCATION TYPE OF I/O PIN NUMBER INPUTS RT, C Input power from TRAN 1 control box 24 VAC — Speed sensor gas section analog input...
- Page 30 Table 11 – Orifice Sizes ORIFICE DRILL DRILL SIZE PART NUMBER DIA. (in.) LH32RF129 0.1285 LH32RF125 0.1250 LH32RF120 0.1200 LH32RF116 0.1160 LH32RF113 0.1130 LH32RF111 0.1110 LH32RF110 0.1100 LH32RF105 0.1065 LH32RF104 0.1040 LH32RF102 0.1015 LH32RF103 0.0995 LH32RF098 0.0980 LH32RF096 0.0960 LH32RF094 0.0935 LH32RF089 0.0890...
- Page 31 Minimum Heating Entering Air Temperature comfort may be compromised when heating is initiated using low entering air temperatures with When operating on first stage heating, the minimum insufficient heating temperature rise. temperature of air entering the dimpled heat exchanger is 50_F continuous and 45_F intermittent Fig.
- Page 32 Table 14 – IGC Board LED Alarm Codes ACTION TAKEN BY FLASH DESCRIPTION RESET METHOD PROBABLE CAUSE CONTROL CODE Normal Operation — — — Loss of power to the IGC. Check 5 amp fuse on IGC, power to unit, 24V circuit Hardware Failure No gas heating.
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Page 33: Economizer Systems
The repair procedure requires the use of MAPP gas transition joint. Avoid applying torch flame directly and torch (must be supplied by servicer) instead of onto the aluminum tubing. conventional oxyacetylene fuel and torch. While the flame temperature for MAPP is lower than that of ECONOMIZER SYSTEMS oxyacetylene (and thus provides more flexibility when units... - Page 34 Table 15 – Economizer Input/Output Logic Enthalpy* Compressor N Terminal† Demand Control Occupied Unoccupied Stage Stage Ventilation (DCV) Outdoor Return Damper INPUTS OUTPUTS High (Free Cooling LED Minimum position Closed Off) Below set Modulating** (between Modulating** (DCV LED Off) min. position and (between closed and (Free Cooling LED High...
- Page 35 Economizer Standard Sensors Outdoor Air Temperature (OAT) Sensor Fig. 40 − Economizer Controller Potentiometer The outdoor air temperature sensor (HH57AC074) is And LED Locations a 10 to 20 mA device used to measure the outdoor-air temperature. The outdoor-air temperature is used to determine when the Economizer can be used for free cooling.
- Page 36 For enthalpy control, accessory enthalpy sensor (part Fig. 43 − Return Air Temperature or Enthalpy number AXB078ENT) is required. Replace the Sensor Mounting Location standard outdoor dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location. (See Fig.40.) When the outdoor air enthalpy ECONOMIZER CONTROLLER rises...
- Page 37 be wired to the AQ and AQ1 terminals of the Fig. 45 − Economizer Control controller. Adjust potentiometers correspond to the DCV voltage output of the indoor air quality sensor at the user-determined setpoint. (See Fig.46.) 24 Vac Fig. 46 − CO Sensor Maximum Range Settings CO SENSOR MAX RANGE SETTING Open...
- Page 38 the minimum position potentiometer should be used Thermostats to set the occupied ventilation position. The maximum The Economizer control works with conventional demand ventilation position should be turned fully thermostats that have a Y1 (cool stage 1), Y2 (cool clockwise. stage 2), W1 (heat stage 1), W2 (heat stage 2), and Adjust the minimum position potentiometer to allow G (fan).
- Page 39 of 6.7 volts provides the maximum ventilation rate of Sensor Configuration 20% (or base plus 15 cfm per person). Use Fig. 46 to The CO sensor has preset standard voltage settings determine the maximum setting of the CO sensor. that can be selected anytime after the sensor is For example, an 1100 ppm setpoint relates to a 15 powered up.
- Page 40 3. Use the Up/Down button to toggle to the Single Enthalpy NONSTD menu and press Enter. To check single enthalpy: 4. Use the Up/Down button to toggle through each 1. Make sure Economizer preparation procedure of the nine variables, starting with Altitude, until has been performed.
- Page 41 8. Return Economizer settings and wiring to 2. Set enthalpy potentiometer to previous setting. normal after completing troubleshooting. 3. Set DCV maximum position potentiometer to previous setting. Supply−Air Sensor Input 4. Set minimum position, DCV setpoint, and To check supply−air sensor input: exhaust potentiometers to previous settings.
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Page 42: Wiring Diagrams
WIRING DIAGRAMS See Fig.47 and 48 for typical wiring diagrams. Fig. 47 − Typical Unit Wiring Diagram − Power ( 208/230−3−60) - Page 43 Fig. 48 − Typical Unit Wiring Diagram − Control ( 208/230−3−60)
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Page 44: Pre Start−Up
PRE−START−UP 1. Remove all access panels. WARNING 2. Read and follow instructions on all WARNING, CAUTION, and INFORMATION labels attached PERSONAL INJURY HAZARD to, or shipped with, unit. Failure to follow this warning could result in personal injury or death. WARNING 1. - Page 45 The suction and discharge pressure levels should WARNING now move to their normal start−up levels. NOTE: When the compressor is rotating in the wrong UNIT OPERATION AND SAFETY HAZARD direction, the unit will make an elevated level of noise Failure to follow this warning could result in and will not provide cooling.
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Page 46: Operating Sequences
8. Adjust airflow to obtain a temperature rise within 10−minute period during which the modification can occur. If the limit switch trips during this period, the range specified on the unit nameplate. evaporator−fan off delay will increase by 15 seconds. A maximum of 9 trips can occur, extending the NOTE: The default value for the evaporator−fan... -
Page 47: Fastener Torque Values
setpoint and 100% open. With SAT from 50_F to control modification will be required on the RGS unit 45_F, the dampers will maintain at the Minimum to implement the Unoccupied period function. Position setting. With SAT below 45_F, the outside air Supplemental Controls dampers will be closed. -
Page 48: Appendix I. Model Number Significance
Table 18 – Torque Values Supply fan motor mounting 120 12 in−lbs 13.5 1.4 Nm Supply fan motor adjustment plate 120 12 in−lbs 13.5 1.4 Nm Motor pulley setscrew 72 5 in−lbs 8.1 0.6 Nm Fan pulley setscrew 72 5 in−lbs 8.1 0.6 Nm... -
Page 49: Appendix Ii. Physical Data
APPENDIX II. PHYSICAL DATA Physical Data (Cooling) 7.5 − 12.5TONS RGS090 RGS120 RGS150 Refrigeration System # Circuits / # Comp. / Type 2 / 2 / Scroll 2 / 2 / Scroll 2 / 2 / Scroll refrig. R−410A charge per 4−6 / 4−6 6−0 / 6−0 7−6/8−0... - Page 50 APPENDIX II. PHYSICAL DATA (cont.) Physical Data (Heating) 7.5 − 12.5TONS RGS090 RGS120 RGS150 Gas Connection # of Gas Valves Nat. gas supply line press (in. w.g.)/(PSIG) 4−13 / 0.18−0.47 4−13 / 0.18−0.47 4−13 / 0.18−0.47 LP supply line press (in. w.g.)/(PSIG) 11−13 / 0.40−0.47 11−13 / 0.40−0.47 11−13 / 0.40−0.47...
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Page 51: Appendix Iii. Fan Performance
APPENDIX III. FAN PERFORMANCE RGS090 3 PHASE 7.5 TON HORIZONTAL SUPPLY AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) Standard Static Option Medium Static Option 2250 0.52 0.73 0.97 1.22 1.50 2438 0.62 0.85 1.09 1.36 1.65 2625 0.74 0.98 1.23 1.51 1.81 2813 0.88... - Page 52 RGS120 3 PHASE 10 TON HORIZONTAL SUPPLY AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) Field−Supplied Drive Standard Static Option Medium Static Option 3000 0.70 0.89 1.09 1.29 1.50 3250 0.85 1.06 1.27 1.49 1.71 3500 1.03 1.25 1.48 1.71 1.95 3750 1.23 1.47 1.71...
- Page 53 RGS150 3 PHASE 12.5 TON HORIZONTAL SUPPLY Available External Static Pressure (in. wg) Standard Static Option Medium Static Option 3438 0.98 1.20 1.43 1.65 1.88 3750 1.23 1.47 1.71 1.96 2.21 4063 1.52 1.78 2.04 2.31 2.57 4375 1.85 2.13 2.41 2.70 1001...
- Page 54 APPENDIX III. FAN PERFORMANCE (cont.) Pulley Adjustment MOTOR PULLEY TURNS OPEN UNIT MOTOR/DRIVE COMBO Standard Static Medium Static High Static 1102 1083 1063 1044 1025 1006 Standard Static Medium Static 1084 1059 1035 1010 High Static 1240 1218 1196 1175 1153 1131 1109...
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Page 55: Appendix Iv. Electrical Data
APPENDIX IV. ELECTRICAL INFORMATION RGS090 2-Stage Cooling 7.5 Tons VOLTAGE COMP (Cir 1) COMP (Cir 2) OFM (ea) RANGE V−Ph−Hz WATTS TYPE EFF at Full Load MIN MAX WATTS AMP Draw 1448 2278 208−3−60 13.6 13.6 HIGH 4400 15.0 15.0 1448 2278 230−3−60... - Page 56 MCA/MOCP DETERMINATION NO C.O. OR UNPWRD C.O. NO C.O. or UNPWRD C.O. COMBUSTION POWER NOM. NO P .E. w/ P .E. (pwrd fr/ unit) FAN MOTOR EXHAUST V-Ph-Hz TYPE DISC. SIZE DISC. SIZE MOCP MOCP 43.6 47.4 208/230-3-60 0.48 45.9 49.7 HIGH 53.8...
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Page 57: Appendix V. Motormaster Sensor Locations
APPENDIX V. MOTORMASTER SENSOR LOCATIONS Fig. 49 − RGS090 − 120 Outdoor Circuiting RGS090 RGS120 NOTE: The low ambient kit for the 12.5 ton unit utilizes a pressure transducer, and therefore there is no Motormaster temperature sensor location for this unit. -
Page 58: Unit Start-Up Checklist
UNIT START-UP CHECKLIST I. PRELIMINARY INFORMATION: MODEL NO.: TECHNICIAN: ___________________________________ DATE: ______________ BUILDING LOCATION:____________________________ SERIAL NO: _____________________________________ II. PRE-START-UP (insert check mark in box as each item is completed): VERIFY THAT ALL PACKAGING MATERIALS HAVE BEEN REMOVED FROM UNIT VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS VERIFY THAT FLUE HOOD IS INSTALLED CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS CHECK TO ENSURE NO WIRES ARE TOUCHING REFRIGERANT TUBING OR SHARP EDGES...