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Air PreciseAIR PPW Series Installation, Operation And Maintenance Manual

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PreciseAIR
7.5 to 60 tons
Series PPW
Packaged Water Cooled DX Unit
Series PCA
Split System Air Cooled DX Unit
Series PPA
Packaged Air Cooled DX Unit
Series PHW
Chilled Water Air Handling Unit
Installation, Operation,
and Maintenance
IOM-PreciseAIR
Release Date: 11-12-20

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Summary of Contents for Air PreciseAIR PPW Series

  • Page 1 Maintenance PreciseAIR 7.5 to 60 tons Series PPW Packaged Water Cooled DX Unit Series PCA Split System Air Cooled DX Unit Series PPA Packaged Air Cooled DX Unit Series PHW Chilled Water Air Handling Unit IOM-PreciseAIR Release Date: 11-12-20...

  • Page 2: Table Of Contents

    IOM-PreciseAIR Page 2 of 50 Table of Contents 1. General ..............................4 1.1. Resources ..................................4 2. Installation .............................. 5 2.1. Safety considerations ..............................5 2.2. Receiving ..................................5 2.3. Handling ..................................5 2.4. Lifting ....................................6 2.5. Storage .................................... 8 2.6.
  • Page 3 IOM-PreciseAIR Page 3 of 50 4.2. Compressors .................................. 40 4.3. Air Cooled Condensers ..............................40 4.4. Water Cooled Condensers ............................. 41 4.5. Filters ..................................... 42 4.6. Drives (sheaves and belts) ............................. 42 4.7. Blower Bearings ................................43 4.8. Blower Wheel and Shaft Maintenance .......................... 44 4.9.

  • Page 4: General

    Advance Industrial Refrigeration, Inc. reserves the right to make changes and/or improvements in designs, features, options, and procedures without notice or obligation. 1.1. Resources The following information is available for download: https://www.air-eng.com/resources Product Catalog and IOM Manual • Catalog-PreciseAIR, “Product Catalog - PreciseAIR”.

  • Page 5: Installation

    Move the unit in its upright position to the installation site. The unit contains one or two lifting access points for forklift and four brackets in the frame for hoist rings. If the air handler section frame is used for lifting, caution must be taken to ensure that the bolts connected to both frames are tightened when moving the compressor section and air handler section together.

  • Page 6: Lifting

    IOM-PreciseAIR Page 6 of 50 2.4. Lifting 1. Before lifting the unit, be sure that all the shipping material has been removed from the unit. 2. To assist in determining rigging requirements, weights are provided in the unit mechanical submittal. 3.
  • Page 7 IOM-PreciseAIR Page 7 of 50 The load in each hoist ring is not simply the total weight divided by the number of hoist rings. The resultant force can be significantly greater at shallow lifting angles and with unevenly distributed loads. L = Load experienced by each hoist ring N = Number of hoist rings = 4 W = Total weight...

  • Page 8: Storage

    (1 – 5 psig) inert gas, such as nitrogen. This will prevent contaminants from entering the coil. If the coils are not charged and sealed, condensation mixes with air pollutants forming a weak acid and over time it can cause pinhole leaks to develop in the coil tubes.

  • Page 9: Ductwork Connections

    IOM-PreciseAIR Page 9 of 50 2.7. Ductwork Connections The discharge and return opening dimensions are provided in the chart below. For proper fan performance, match the duct size to the dimensions indicated. Discharge Sizes Unit Discharge Recommended Duct Unit size Opening Size (H X W) Size (H X W) 11-¼”...
  • Page 10 IOM-PreciseAIR Page 10 of 50 Figure 3: Discharge and Return Connections Unit sizes 090, 120, and 180 have only 1 discharge connection. Duct connections to unit should be flanged connect flush to the supply fan outlet (on top) or to the filter rack inlet (rear of unit) using self-tapping screws.

  • Page 11: Condenser Water Or Chilled Water Piping

    Air vents must be installed in various locations in the piping system to purge the air and avoid problems due to the presence of air in the water loop.
  • Page 12 Use Piping Strainers! To prevent condenser damage, pipe strainers must be installed in the water supplies to protect components from water borne debris. AIR is not responsible for equipment damage caused by water borne debris. 0.5 to 1.5 mm mesh recommended.

  • Page 13: Series Pca - Split System Field Refrigerant Piping

    2.11. Condensate Drain Piping All cooling coil drain pans have a connection for condensate removal. A P-trap should be built into the drain line to prevent air from backing up into the unit. Refer to technical bulletin TB-15. 2.12. Electrical Drawings and Connections All electrical connections must be performed by a qualified electrical technician and must follow all local electrical and safety regulations.
  • Page 14 IOM-PreciseAIR Page 14 of 50 EW (Electrical Power) Shows the wiring schematic for the high voltage components. EP (Electrical Panel) Shows the wiring schematic for the low voltage components. ED (Electrical Detailed) Shows the connections between the electrical boxes and devices. EI (Electrical Instruction) Shows information about network communication, addressing, cables colors conventions, and any other information that is particular to the design.

  • Page 15: Main Control Panel Layout And Components

    IOM-PreciseAIR Page 15 of 50 2.13. Main Control Panel Layout and Components Figure 4: Main Control Panel Layout...

  • Page 16: Smoke Detector

    • Mount sensors 5’-0” above finished floor. • Do not locate wall mounted sensor in the direct path of supply air from the supply grilles. • Do not locate wall mounted sensor adjacent to high heat producing electrical equipment. •...
  • Page 17 Condensers Series PPW units will be equipped with water cooled shell and tube condenser(s). Series PCA and PPA units will be equipped with an air cooled condenser with vertical air flow. Expansion Valves DX units are equipped with one externally adjustable thermostatic expansion valve per refrigerant circuit.
  • Page 18 IOM-PreciseAIR Page 18 of 50 Figure 5: Components Location Item Description AHU Section Compressor Section Filter rack Electrical enclosure Air Filter...
  • Page 19 IOM-PreciseAIR Page 19 of 50 Figure 6: AHU Section Internal Components Item Description Flex duct connection Centrifugal blower Blower motor with adjustable base (one per blower) Thermal or electronic expansion valve DX Evaporator coil Drain pan...
  • Page 20 IOM-PreciseAIR Page 20 of 50 Figure 7: Compressor Section Internal Components Item Description Compressor Sight glass (moisture indicator) Solenoid valve Filter drier Figure 8: Air Cooled Condenser (may have 1 or 2 fans)
  • Page 21 IOM-PreciseAIR Page 21 of 50 Figure 9: Series BH Compressor Section Internal Components Item Description Water cooled condenser Scroll compressor Filter drier High pressure cutout switch Ball valve with electronic actuator Sight glass (moisture indicator) Water regulation valve Hose connecting high pressure to water valve...
  • Page 22 IOM-PreciseAIR Page 22 of 50 Figure 10: Compressor Details Item Description Low Pressure Sensor High Pressure Sensor Crankcase Heater Compressor Oil Sight Glass...

  • Page 23: Sequence Of Operation

    5. Temperature Control: A PLC will control system capacity by cycling the compressor(s) and lead compressor VFD. As space/room air temperature rises above set point, the system demand increases and the first compressor starts. As temperature continues to rise and the calculated system demand increases, the first compressor loads and eventually the second compressors is started.
  • Page 24 The system demand will increase to maintain the temperature of the air leaving the coil at a setpoint which corresponds to the wet bulb temperature of the space/room temperature and relative humidity set points.

  • Page 25: Allen-Bradley Compactlogix Plc With Panelview Touch

    Page 25 of 50 3.3. Allen-Bradley CompactLogix PLC with PanelView Touch This chapter applies to systems fitted with Allen-Bradley CompactLogix PLC and PanelView Touch HMI. Sample graphic displays are shown below. Contact AIR for details for your specific unit control system. 3.4. Main All main variables and equipment status are listed under this screen.

  • Page 26: Compressors

    IOM-PreciseAIR Page 26 of 50 3.5. Compressors Both compressors status are listed. Some of the variables on this screen can also be seen on the main screen.

  • Page 27: Setpoint Screens

    IOM-PreciseAIR Page 27 of 50 3.6. Setpoint Screens:...
  • Page 28 IOM-PreciseAIR Page 28 of 50...

  • Page 29: Active Alarm / Alarm History

    IOM-PreciseAIR Page 29 of 50 3.7. Active Alarm / Alarm History The Alarm History screen contains the time of the alarm, the acknowledgment time and the message corresponding to the alarm. The alarm message is a self-explanatory text that allows quick troubleshooting of the equipment.

  • Page 30: Carel Pco5+ With Pgd1

    Page 30 of 50 3.8. Carel PCO5+ with pGD1 This chapter applies to systems fitted with Carel PCO5+ PLC and pGD1 HMI. Sample graphic displays are shown below. Contact AIR for details for your specific unit control system. 3.8.1. HMI How to Navigate the Screens All the screens are configured in loops.

  • Page 31: Main Loop

    Values for room temperature and room relative (high pressure) pressure values for each humidity from sensor mounted in the controlled room environment, evaporator entering air compressor. These values vary with running temperate from sensor mounted on the inlet of condition. Common values are:...
  • Page 32 Demand. compressor delivers 0% of its maximum cooling capacity, therefore running fully unloaded. Heater Air Out is the temperature of the air leaving the heaters. When the Heater Demand is The compressors and unloaders states (ON or higher than 0% this temperature should be OFF) are based on the System Demand %.

  • Page 33: On/Off Unit

    3.8.3. On/Off Unit When Humidity control is desired, change the status to ENABLE. There are 2 components for humidity control. The first one is the humidity setpoint (shown here as 40.0%) and the...

  • Page 34: Alarms

    IOM-PreciseAIR Page 34 of 50 Set Point is the speed at which the blower(s) shall run when not in humidity control. This value Press the ALARM button to enter the alarm corresponds to the maximum frequency setup in loop. the VFD (typically 60Hz). Minimum Output is the minimum speed proportional to the VFD minimum frequency that the blower is allowed to run when in...
  • Page 35 IOM-PreciseAIR Page 35 of 50 All alarms are OPEN to alarm. The alarm is active During the countdown, the PLC will de-energize if the respective input is open. The exceptions the respective sensor/device, which allows the are the compressor and blower overload alarms: alarm state of the device to be reset.

  • Page 36: Alarm History

    R_RH: room relative humidity • E_In: evaporator air entering temperature • E_out: evaporator air leaving temperature • H_out: heater air leaving temperature • C1_LP: compressor 1 low pressure (suction) • C1_HP: compressor 1 high pressure (discharge) • C2_LP: compressor 2 low pressure (suction) •...

  • Page 37: List Of Alarms

    21. Cmp2 High Pressure Switch 22. Smoke Detected 23. Blower 1 Overload/SC 24. Blower 2 Overload/SC 25. Heater Fault 26. Air Filter Dirty 27. Condenser Flow 28. Drain Pan Full 29. Emergency Stop 30. Voltage Phase Monitor 31. EVD/EVO A Alarms...

  • Page 38: Maintenance

    IOM-PreciseAIR Page 38 of 50 AINTENANCE 4.1. Troubleshooting Charts NOTE: All repairs to the unit should be done by qualified service personnel (i.e. for refrigeration, a licensed refrigeration mechanic; for electrical, a licensed electrician). For mechanical repairs, plant personnel can be used. Call Advance Industrial Refrigeration service technician for any additional support or service assistance needed.
  • Page 39 IOM-PreciseAIR Page 39 of 50 Symptom 3 High Refrigerant Discharge Pressure Dirty tube and fin surface (air cooled Clean with compressed air or water spray, Use fin comb condenser) if fins bent. Condenser problems Check if the condenser is clogged.

  • Page 40: Compressors

    Do not use an alkaline or acidic solution as it will attack the coil material. The inner face of the coil may be cleaned by the access panel on the side of the units or by removing the fan guards. Always pressure clean in reverse of the air flow.

  • Page 41: Water Cooled Condensers

    Heads Removal When a head is removed for cleaning, it is recommended to replace the sealing gasket. Consult AIR for required gasket. Observe the gasket orientation during assembly. Wrong gasket orientation will cause the condenser not to perform properly due to improper cooling fluid flow.

  • Page 42: Filters

    Doors must remain closed when determining if an adjustment is necessary. Clogged filter can restrict air flow and create problems such as coil icing or poor air distribution. Liquid Line Filter Drier The filter drier core normally does not need to be changed.

  • Page 43: Blower Bearings

    4.7. Blower Bearings For instructions covering, bearing assembly or disassembly, or installation details, contact AIR Engineering. Any bearing which is disassembled should be kept separate from other bearing parts, as components may not be interchangeable. Maintain cleanliness of components and bearings to prevent bearing contamination.

  • Page 44: Blower Wheel And Shaft Maintenance

    IOM-PreciseAIR Page 44 of 50 Figure 11: Ball Bearing Decal 4.8. Blower Wheel and Shaft Maintenance Periodically inspect the shaft and wheel for dirt buildup, corrosion, and signs of excess stress or fatigue. Clean the components and, when appropriate, apply new coatings. Any addition of coatings or weld can create an imbalance.

  • Page 45: Evaporator Coil

    AIR cannot be held responsible for the malfunctioning of any equipment it provides if it is caused by a lack of maintenance or by operating conditions beyond those recommended in this manual or the original design conditions.
  • Page 46 IOM-PreciseAIR Page 46 of 50 Model Number: Serial N0.: Every Every Every Every Prepared by: Date: Month Year 2 Years Months Temperature Set at (°F) Discharge Pressure (psig): Suction Pressure (psig): Evaporator / Water Coil Location / Comment Check for leaks Check the percentage of antifreeze (if applicable) Check coating (if applicable) Compressor...
  • Page 47 Month Mont Year 2 Years Temperature Set at (°F) Discharge Pressure (psig): Suction Pressure (psig): Air Filters Location / Comment Check for restricted airflow Check filter differential switch (if applicable) Wipe filter rack section clean Blower Section Location / Comment...
  • Page 48 IOM-PreciseAIR Page 48 of 50 Model Number: Serial N0.: Every Every Every Every Prepared by: Date: Month Month Year 2 Years Temperature Set at (°F) Discharge Pressure (psig): Suction Pressure (psig): Corrosion Location / Comment Check for corrosion at support points, bolts or between flanges Check for coating or painting deterioration Structural Parts...

  • Page 49: Maintenance Logs

    IOM-PreciseAIR Page 49 of 50 4.11. Maintenance Logs...
  • Page 50 Installation, Operation, and Maintenance Advance Industrial Refrigeration, 1765 Tobacco Rd., Augusta, GA, 30906 706-364-0010 | info@air-eng.com ©2020 Advance Industrial Refrigeration, Inc. All rights reserved. IOM-PreciseAIR Release Date: 11-12-20...

This manual is also suitable for:

Preciseair pca seriesPreciseair ppa seriesPreciseair phw series

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