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Summary of Contents for Air Change PCU
- Page 1 INSTALLATION AND MAINTENANCE MANUAL Air Change Precise Control Unit (PCU) Air Change Australia Pty Ltd 2 Ashford Avenue, Milperra (02) 8774 1400 sales@airchange.com.au April 2019 Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
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Page 2: Table Of Contents
Table of Contents INTRODUCTION ..........................4 Inspection and Unpacking ..........................5 Unit Handling ..............................5 Lifting with a Forklift ............................6 Lifting with a Crane ............................6 INSTALLATION ..........................7 Location ................................7 General ..............................7 Level and Suitable Base .......................... 7 Suspending the Unit .......................... - Page 3 Status Page ..............................24 Alarm History ..............................25 Trends ................................26 SERVICE & MAINTENANCE ......................27 Heat exchangers............................27 Air Change Sensible Heat Exchangers ....................27 Maintenance Schedule ..........................27 General ................................27 Monthly Maintenance Schedules ........................28 Three‐Monthly Checks ........................... 28 Annual Maintenance ............................
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Page 4: Introduction
Improper installation, service, maintenance or use can cause explosions, fire, electrical shocks or other conditions which may cause personal injury or property damage and will void the warranty. Check with Air Change or your nearest Air Change dealer for any information required on this equipment. -
Page 5: Inspection And Unpacking
A claim should be lodged with shipping company within three (3) days if shipment is damaged or incomplete. If major damage is apparent, do not lift unit on to site without prior approval from Air Change. All units are tested and inspected prior to packing and leave Air Change premises in perfect condition. -
Page 6: Lifting With A Forklift
Lifting with a Forklift Exercise extreme caution when lifting with a forklift. Do not exceed the height limit of the forklift and never allow fork to lift against the bottom panel of the unit. Make careful consideration of the unit’s centre of gravity and distribute the weight equally on both forks. -
Page 7: Installation
Location General The PCU unit is marked with stickers “SA” (Supply Air), and “OA” (Outdoor Air), showing the air path through the unit. The Fresh Air supply inlet should be clear of any polluted air from other units, exhaust fans, etc. -
Page 8: Noise Levels
Drainage IMPORTANT Installation of a “P” Trap is mandatory for all drainage points. Air Change will not accept any liability for any water damage resulting from incorrect installation. A minimum of 50 mm elevation difference between three levels are required. Schematics are as follows. -
Page 9: Phase Rotation
A separate safety tray must be fitted under the unit and drained separately. Air Change will not accept any liability for any water damage resulting from incorrect installation. The unit should be installed with a positive fall to ensure water drains away freely through drain holes provided. -
Page 10: Filters
Filters IMPORTANT Never operate the unit without filters fitted to the Return and Fresh Air intakes with blower access panels removed. Make-up air quantity (if any) is to be incorporated into outdoor air filtered airflow. G4 panel and bag filters are included in standard units. NOTE: If these units are being used during construction when adhesive or sealants are in use, and if ducts and carpets are being installed or removed, make sure all equipment is fitted and adequately protected. -
Page 11: Ducting
Ducting Flexiduct ducting is recommended for use with all Air Change systems. See image below. Ducts should be insulated in accordance with ASHRAE Standard 90.1. Fan inlet conditions can affect the fan performance, particularly ducting elbows which can cause non‐uniform inlet flow and swirl at the inlet. To reduce losses due to fan system effect, adequate length of straight duct between elbow and fan inlet should be provided or turning vanes used in the elbow. -
Page 12: Refrigeration Piping
The unit is designed for use with specific refrigerants (R-410A or R-407C). Check serial number plate for type of refrigerant. The use of other refrigerants is not authorised or approved by Air Change, and may cause operational problems such as poor performance and efficiency, loss of capacity, degradation of materials, and refrigerant leaks. -
Page 13: System Components
SYSTEM COMPONENTS Requirement The PCU has been developed by Air Change to dehumidify outdoor air and maintain the supply air temperature. The PCU incorporates a series of sensible heat exchangers that transfer temperature only. These units are manufactured to meet the design criteria. The system is professionally assembled, and internally wired throughout, with large access panels where required for service and maintenance. -
Page 14: Fans
Air Change will not be held responsible for compromised performance or a pressure drop. If the heat exchanger is the incorrect length, please return to Air Change for a replacement unit. Heat Exchangers are constructed of plastic moulded plates with media between each plate. The heat exchanger has been secured by end plates under pressure. -
Page 15: Scroll Compressors
Scroll Compressors (Not applicable in PCU-D Systems only) Air Change units employ Scroll compressors. Scroll compressors and all electrical components are housed in their own separate compartment, together with reversing valves, other refrigerant parts and pipe work. Compressors are suitable for condensing temperatures of not greater than 55°C at design ambient. -
Page 16: Electrical
If specified by the client, coils can be treated against corrosion using coil saver epoxy. Hot water coils in the PCU can be designed into units according to the client’s requirements. Velocity through coils is designed at around 2.0 m/s for a low pressure drop and high efficiency. -
Page 17: Optional Fire Control Circuitry
Optional Fire Control Circuitry Units can be supplied with a 24 V DC circuit supplied by the Fire Department’s Fire Control Board. In case of fire, the 24 V DC circuit will be de‐activated, causing the unit to switch off, shutting down the system completely except for the exhaust fans which act independently for smoke exhaust. -
Page 18: Operations
The Supply airflow quantity set point has been pre-set in the factory, allowing the fan to automatically adjust the speed to meet the required airflow. The airflow setpoint can still be adjusted using the air volume controller (UNIcon CPG). Please contact the Air Change technical support team for instructions. -
Page 19: Ec Plug Fan Air Volume Controller Setpoint Change Procedure
EC PLUG FAN AIR VOLUME CONTROLLER SETPOINT CHANGE PROCEDURE EC Plug Fans employ a UNIcon CPG Controller from Ziehl‐Abegg to deliver the correct amount of air volume. IMPORTANT Do NOT change any parameters under the BASE SETUP menu. Alteration of any parameter under this menu will reset the entire program and result in fans not delivering accurate air volume. -
Page 20: Climasync™ Controller
CLIMASYNC™ CONTROLLER The following is a general guide for the use of Air Change units which have the Climasync™ Control option with touch screen interface (ABB CP620 HMI). Please be advised that Air Change units and the accompanying Climasync™ controls package ips custom made, and may differ from this guide. -
Page 21: Service Page
Service Page 1. Component Status. This section will display the status speeds, and other relevant information of components such as compressors, fans etc. There is a general colour code to display the state of the component: Grey: OFF • Blue: RUNNING •... -
Page 22: Settings
Settings Page 1 1. Set points for unit. Depending on the unit this can be temperature, humidity or pressure set points. They can be adjusted by using the up and down arrows; 2. Compressor pressure set points. It is recommended to keep these within the recommended range to avoid premature wear or failure of the compressor;... -
Page 23: Settings
Settings Page 2 1. Sensor Offsets. Sensors can be calibrated if necessary. Use up and down arrows to adjust; 2. Previous page button will take you to the previous page; 3. Home button will take you back to the service page. Installation and Maintenance Manual Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz... -
Page 24: Status Page
Status Page 1. Displays all faults on units; 2. Displays component run status; 3. Compressor lockout. If a compressor has 3 faults within 1 hour the compressor will be locked out. The fault must be fixed then the reset button can be pressed to unlock the compressor. -
Page 25: Alarm History
Alarm History 1. Displays Faults with a timestamp; 2. Shows the time range of the faults being displayed; 3. Time settings. Time and time range can be adjusted. Installation and Maintenance Manual Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz... -
Page 26: Trends
Trends 1. Displays a trend graph of different parameters of the unit. Depending on the unit there will be a trend graph for Refrigerant Pressure, Temperature, Humidity, Component Speeds etc. 2. Colour coded legend as well as any set points for certain parameters; 3. -
Page 27: Service & Maintenance
Preventative maintenance programs will vary according to actual working conditions and location and hours of usage by the client. Air Change will be pleased to provide expert advice on special service requirements for particular installations. Installation and Maintenance Manual Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz... -
Page 28: Monthly Maintenance Schedules
Monthly Maintenance Schedules A washable bag filter is provided by Air Change as factory-fitted standard. New filters can be supplied by Air Change if required. Filters should be inspected frequently immediately after installation to confirm the frequency of cleaning needed for the particular location. Regular change/clean of filters is necessary to ensure normal operating conditions. -
Page 29: Troubleshooting Guide
TROUBLESHOOTING GUIDE Problem Probable Cause Correction Method Blocked supply-air filter Clean/replace filter Lock out due to low P Gas leak Find leak, repair appropriately Faulty expansion device Repair or replace Blocked condenser coil Clean coil Lock out due to high P Overcharging of refrigerant Check superheat and adjust Faulty condenser fan motor... -
Page 30: Technical Data
TECHNICAL DATA ‐ TABLES Heat Exchanger Data Specification Small Heat Exchanger Large Heat Exchanger Height 710 mm 1290 mm Depth 330 mm 640 mm Width 645 mm 650 mm Weight 25 kg/m 75 kg/m 150 Pa @ 750 L/s per metre up to 120 Pa @ 1000L/s per metre up to Pressure Drop 250 Pa @ 1000 L/s per metre... -
Page 31: Warranty Information, Terms & Conditions
Your equipment is a major investment and will last for many years if properly maintained and serviced. Air Change Australia Pty Ltd will only accept a completed warranty card (issued in each manual; see page 32) or a copy of the original invoice complete with matching serial numbers as proof of purchase. -
Page 32: Warranty Claim Form
Phone Site Contact Phone MODEL # SERIAL # Details of problem Print Name Signature Position AIR CHANGE OFFICE USE ONLY Service Agent: M1 PO# Technician Name: Phone: Warranty Claim Number (WAN): Approved / Declined DATE: Details of Approval/Decline: Parts List:... -
Page 33: Details Of Servicing
Details of Servicing DATE CONTRACTOR /SERVICING FIRM DETAILS Installation and Maintenance Manual Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz... -
Page 34: Warranty Policy
2.3. “Price” shall mean the price to be paid by the Purchaser for the Product(s) excluding Goods and Services Tax (GST). 2.4. “Product” shall mean the product(s) as set out in the Contract. 2.5. “Purchaser” shall mean any and all party / parties entering into a Contract with Air Change for the sale and/or supply of Product(s) by Air Change. - Page 35 Air Change may in its sole discretion waive the requirement for inspection. 5.12. The source of all part(s) supplied by Air Change pursuant to the Parts Warranty shall be sourced from or through Air Change and at the sole discretion of Air Change. Air Change shall not be liable for replacement parts sourced from other suppliers, manufacturers or wholesalers.
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