Aumrg1 Cadxag1

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IO

nstallation,
peration
INSTALLATION, OPERATION & MAINTENANCE

&M aintenance
anual

Split Air Conditioners


AUMRG1 + CADX-AG1

| 1
INSTALLATION, OPERATION & MAINTENANCE

Table of Contents
1 Introduction 4
Nomenclature . . . . . . . . . . . . . . . . . . . . . 5
Safety Instruction. . . . . . . . . . . . . . . . . . . 5
Specific Hazard . . . . . . . . . . . . . . . . . . . . 5
Points To Remember. . . . . . . . . . . . . . . . . . 6
Component Features . . . . . . . . . . . . . . . . . . 7
Electrical Controls. . . . . . . . . . . . . . . . . . . 8
Liquid Line Controls. . . . . . . . . . . . . . . . . . 11

2 Installation
Receiving of Equipment. . . . . . . . . . . . . . . . 12
Rigging . . . . . . . . . . . . . . . . . . . . . . . 12
Location & Space Requirement. . . . . . . . . . . . . 13
Electrical Connections. . . . . . . . . . . . . . . . . 15
Pre-Installation Checkup. . . . . . . . . . . . . . . 15
Preparation For Installation . . . . . . . . . . . . . . 16

3 Operation
Pre-Startup Procedure. . . . . . . . . . . . . . . . . 17
Service Record. . . . . . . . . . . . . . . . . . . . 18
Pre-Startup Checklist . . . . . . . . . . . . . . . . . 19
Commissioning Test Report . . . . . . . . . . . . . . 21

4 Maintenance
Periodic Maintenance. . . . . . . . . . . . . . . . . 22
Leak Testing, Evacuation &
Charging Procedures . . . . . . . . . . . . . . . . . 24
Fan Belt Adjustment. . . . . . . . . . . . . . . . . 29
Fan Pulley Adjustment. . . . . . . . . . . . . . . . . 31
Alignment of Shaft & Sheaves . . . . . . . . . . . . . 31
Mold In And Around Drain Pans. . . . . . . . . . . . . 32
Coil Cleaning . . . . . . . . . . . . . . . . . . . . . 33
Compressor Oil. . . . . . . . . . . . . . . . . . . . 33
Adding & Removing Oil. . . . . . . . . . . . . . . . 33
Dismantling & Disposal. . . . . . . . . . . . . . . . 33
Expansion Valve Service & Maintenance. . . . . . . . . 34
Refrigerant recovery, Recycling &
Reclamation . . . . . . . . . . . . . . . . . . . . . 35
Trouble Shooting. . . . . . . . . . . . . . . . . . . 38

2 |
INSTALLATION, OPERATION & MAINTENANCE

5 Appendix
Appendix I. . . . . . . . . . . . . . . . . . . . . . 43
Loading Points . . . . . . . . . . . . . . . . . . 43

Appendix II . . . . . . . . . . . . . . . . . . . . . 44
Dimensional Data . . . . . . . . . . . . . . . . . 44

Appendix III . . . . . . . . . . . . . . . . . . . . . 49
Electrical Data . . . . . . . . . . . . . . . . . . 49

Appendix IV . . . . . . . . . . . . . . . . . . . . . 50
Typical Wiring Diagram . . . . . . . . . . . . . . 50

Appendix V . . . . . . . . . . . . . . . . . . . . . 52
Spare Parts . . . . . . . . . . . . . . . . . . . 52

Appendix VI . . . . . . . . . . . . . . . . . . . . . 53
P-T Chart . . . . . . . . . . . . . . . . . . . . . 53

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INSTALLATION, OPERATION & MAINTENANCE

Introduction
This manual must be carefully read and followed in
Note:- It is not the intention of this manual
order to avoid unnecessary/dangerous conditions in the
to cover all possible variations in systems
machine and to guarantee the safety of the equipment.
that may occur or to provide comprehensive
The contents in this manual are mainly the installation information concerning every possible contingence that
and operating instructions of your Split Air Conditioning may be encountered during an installation, operation and
system. The precautions mentioned through out this manual maintenance. If additional information is required or if
should be taken seriously to derive maximum safety for specific problems arise that are not fully discussed in this
all. Installation, service and start up of any air-conditioning manual, contact your local office.
equipment should be done only by a qualified personnel or
service technician. Always observe precautions in the manual
and be familiar of all the symbols/ labels attached in the unit Always heed all WARNING and SAFETY
when dealing or working with the equipment. INSTRUCTION boxes. Always read and heed all
instructions in this manual carefully. Failure to
follow WARNING, SAFETY INSTRUCTIONS and all
Unit Description other instructions could result in severe personal
injuries and death!
SKM AUMRG1 + CADX-AG1 series is a modern diversified and
environment friendly Split Air conditioning equipment which use For the representation and understanding of the points of
R-410A as the refrigerant. The complete AUMRG1 + CADX- caution, attention, danger, information etc. Following symbols
AG1 provides extremely rugged, heavy duty, long life, energy are used throughout the manual.
efficient which is durable, dependable, strong, versatile and
quiet. AUMRG1 + CADX-AG1 units are designed, rated and
manufactured in accordance with AHRI 210/240 and 340/360
standards. General Warning
• High efficiency totally sealed scroll hermetic CAUTION
compressors.

• Totally enclosed, Class F insulated,


condenser and evaporator fan motors. Take special attention
and points to be noted.
• Heavy duty condenser and evaporator coils
optimised in design for long-life maintenance ATTENTION
free operation.

• Cabinet construction specifically designed Indicates dangers


for Gulf climates. through electrical
shock, system
• IP54 Electrical panel pressure, and
DANGER
location.
• Typically, much heavier gauge tubing and
thicker fins for ruggedness and long life.

• Electronic control board for unit operation


with diagnostic LEDS on the control board General Information.
for easy troubleshooting.
INFORMATION

AUMRG1 + CADX-AG1 series Split Air Indicates dangers by


conditioners are factory assembled, leak tested, high voltage
evacuated, internally wired and shipped with HIGH VOLTAGE
nitrogen holding charge only.

Indicates dangers by
moving/rotating parts

MOVING/ROTATING PARTS

Indicates dangers by
hot pipes
HOT PIPES

4 |
INSTALLATION, OPERATION & MAINTENANCE

Nomenclature
This manual explains how to install, operate and
maintain SKM AUMRG1+CADX-AG1 series, Air cooled
A U M R - 055 G1 Y condensing unit. The manufacturer shall not be
responsible for damages arising from wrong practices
used. So SKM recommends to do the installation including
Power Suppy Code
Air Cooled the connection of electricity, operation and maintenance by a
Y: 380-415V/3Ph/50Hz
person qualified for the air- conditioning and refrigeration work only.
Condensing Units
The manufacturer shall not be responsible for damages
Hermetic Scroll originating from unauthorized changes or the improper
Compressor connection of electricity and not adhering to the operation limits
included in the manual. Also this shall invalidate the warranty.
R-410A G1: High Efficiency
The air conditioning equipment should be used only for the
applications for which it has been designed.
Nominal Capacity (MBh)
Refer product name plate, wiring diagrams and catalogues
for the electrical characteristic, of the equipment to select
CA DX - 055 A G1 Y correct wire sizes and isolators prior to the insulation.
It is the responsibility of the user or the person installing
Power Suppy the equipment to provide proper grounding and branch
Comfort Air Y: 380-415V/3Ph/50Hz circuit protection according to NEC, Local & National
Conditioner safety regulations.
This Air Conditioning equipment must be disconnected
Direct Expansion
from the mains if any repair work is to be carried out.
Cooling Coil
G1: High Efficiency Do not use the units if damaged. If problems occur, switch
Nominal the unit off and disconnect it from the power supply.
Capacity
The control ON/OFF switch in the control panel does not
Applicable for R-410A disconnect the equipment from the mains and thus it is
not to be used as a safety switch.
Do not attempt to repair, move, alter or reinstall the unit. If
SKM reserves the right to performed by an unauthorized personal, these operations
change, in part or in whole the may cause electrical shock or fires.
specifications of its Air Conditioning Always remember to inspect the units, refrigerant tubes
Equipment at any time in order to add and protection regularly. These operations should be
the latest technology. Therefore, the performed by a qualified personnel only.
enclosed information may change Contact SKM After sales in case any technical support
without any prior notice. is required.
This appliance is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or lack of experience and
Safety Instructions knowledge,unless they have been given supervision or
instruction concerning use of the appliance by a person
responsible for their safety.
Carefully read the content of this
Children should be supervised to ensure that they do not
manual before installing the air
play with the appliance.
conditioning equipment. For maximum
safety installers should always follow
the list of warnings. During the
installation process care should be Specific Hazards
taken to avoid any accidents related to:
Noise Emission
1. High voltage The sound emission expected in normal use of the fan
should be duly taken into account.
2. High pressure in the system
3. Hot pipes due to discharge
temperature Wear ear defenders when
working near to or on the
4. Moving/Rotating parts running fan!

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INSTALLATION, OPERATION & MAINTENANCE

Heavy Loads
The heavy weight of fans and their
components entail the Points To Remember
following risks during
maintenance: Being an electromechanical machine, the unit may fail or
• Risk of being cause difficulties. Remembering the following few points will
trapped, crushed ensure correct and prompt rectification and continued optimal
performance.
or cut by moving
or toppling machinery.
• Danger of falling components.
• Do not stand or work under suspended
loads.
• Wear a hard hat, safety shoes and
gloves.

Rotating Shafts and Impellers A correct installation ensuring proper clearances for
correct condenser air flow and maintenance as per the
• Objects fixed to rotating shafts and impellers drawings shown for “recommended clearances”
can fly off at an angle and cause serious injury.
• Articles of clothing and hair can get caught in Proper level base on foundation with appropriate
rotating shafts and impellers. vibration mount. All connections and hook up to be
followed as per instructions, which ensures long term trouble
• Do not remove guards free operation and performance.
during operation.
• Do not wear loose-fitting If power fuse is blown off, be sure to replace the same
clothing when working with a new fuse having pre designed Amperage. Do
near rotating shafts and not use a steel wire or copper wire instead of proper
impellers. fuse. Genuine fuse ensures safety and proper protection.
Incorrect fusing may cause fire or trouble with your equipment.
• Wear goggles.

Before replacing any fuse or opening any electrical


panel door, make sure the main switch is OFF.

Hot Surfaces Do not spray or sprinkle water directly over or into the
equipment for cleaning because electric insulations and
• There is a risk of sustaining burns or scalds
terminal of the components are opened.
on hot surfaces during operation.
• Do not touch the
The unit controller is programmed to stop functioning
Motor, Compressor
the Air conditioning equipment including the
body, Discharge
compressor in the event of a safety device trips. The problem
line during
should be investigated and repaired or rectified as per trouble
operation.
shooting instruction in this manual before attempting to reset
• When the and restarting the machine.
condenser fan has
stopped wait until the motor
Following a power supply interruption during operation,
has cooled down.
the unit controller is programmed to restart the unit
• Wear protective gloves. automatically when power supply has returned to normal.

This equipment is meant to be installed out doors and


Electrical Shock Hazards suitable to normal environment elements. Do not try to
cover or block any inlets or discharge openings to condenser.
• All power must
be disconnected
prior to Periodical maintenance of the unit will give better
installation and performance in the long run than only break down
servicing this maintenance.
equipment.
More than one source of power
Insist on maintenance from a reputable maintenance
may be present. Disconnect
contractor to ensure a trouble free operation.
all power sources to avoid
electrocution or shock injuries.

6 |
INSTALLATION, OPERATION & MAINTENANCE

Component Features
Reverse rotation for 5 to 15 minutes
Compressors will result in the overheating of motor
Compressors used in AUMRG1 + CADX-AG1 Split units windings. In this case, the thermostat in the
series are hermetically sealed, compact scroll with the motor windings open and result in stopping of
following features: the compressor. Continued reverse operation of
• High efficiency scroll compressor will result in failure of scroll
• Quiet operation, low sound levels. compressors. Such failures are NOT covered
• Better debris handling under the manufacturer’s limited warranty.
• Self compensating of wear (“Wear-in Vs. Wear-out”)
• 70% fewer moving parts than comparably sized reciprocating
• Internal motor protection/Advanced scroll temperature
• Suction gas motor cooling Casing and Structure
• Suction screen The unit casing used in AUMRG1 series is made of hot dip
• Disc type check valve. galvanized (zinc coated) steel sheets, conforming to JIS-G
• Centrifugal force for oil lubrication 3302 and ASTMA653, which is phosphatized and baked after an
• Brazed fittings as standard, rotalock as an option. electrostatic powder coat of approx. 60 microns. This finish and
coating can pass a 1000 hour in 5% salt spray testing at 95°F

Condenser Coils (35°C) and 95% relative humidity as per ASTM B117.

Condenser coils are manufactured from corrugated fin and Hi-X


seamless copper tubes mechanically bonded to aluminium fins
to ensure optimum heat transfer. All coils are tested against
Condenser Fans
leakage by high air pressure 715psig(4930kPa)under water. Condenser fans are propeller type with aluminum alloy blades and
An integral sub cooling circuit is incorporated in the lower are directly driven by electric motors. Motors are Totally Enclosed
section of the condenser to increase system capacity. The Air Over (TEAO), six pole or four pole with Class F insulation and
additional condenser surface provides more cooling using IP54/55 protection depending on models. The TEAO and Class
less energy at no additional cost. F insulation features ensure long life and are unique to SKM.
The condenser fans are individually statically and dynamically
balanced at the factory. Complete fan assembly is provided with
Vacuum operation! acrylic coated fan guard.
Compressor damage!

Scroll compressors should


never be used to evacuate a
refrigeration or air-conditioning
system.

Do not pump down the scroll


compressor into a vacuum!

Three phase compressors


only:

On initial start up, if the


compressor sound is abnormally
high and the readings of suction and
discharge pressures are outside
normal range, there is a possibility
that the compressor rotation is in
the reverse direction. In this case,
interchange any two legs of the
power supply and attempt to restart.
Running a scroll compressor in
reverse direction for an extended
period of time will cause damage
to the compressor. such damage is
not covered under manufacturer’s
warranty.

| 7
INSTALLATION, OPERATION & MAINTENANCE

CADX-AG1 Air Handling Unit


Benefits
Casing \ Structure
• No ozone depletion potential or phase-out date.
The unit casing for CADX-AG1 is made of zinc coated
Using chlorine-free R-410A with zero Ozone Depletion
galvanized steel sheets conforming to JIS-G3302 and ASTM
Potential (ODP) helps protect both the environment and your
A653 which is phosphatized and baked after an electrostatic
investment. That’s because new equipment using R-410A
powder coat of approximately 60 microns. This finish and
faces no mandated phase-out date over a 20 to 30 year
coating can pass a 1000 hour in 5% salt spray testing at 95°F
equipment life expectancy.
(35°C) and 95% relative humidity as per ASTM B117. Panels
and casing are insulated with 1” (25mm) thick fiberglass (with • Reduced service costs.
BGT coating) thermal and acoustic insulation having density R-410A refrigerant has no significant “glide.” If a leak occurs,
of 2 lb/ft3. (32 kg/m3) and thermal conductivity of 0.23 BTU. only the lost refrigerant must be replaced.
in/ft2°Fh (0.033 W/m°K). Insulation meets the requirements of
NFPA 90A and 90B for fire resistance.

Evaporator Coils
All evaporator coils are made of inner grooved copper tubes
mechanically bonded into corrugated aluminum fins to ensure • Pressure level: 1.6 times of R22
optimum heat transfer. Coils conform to AHRI-410. All evaporator • Lubricating oil: Ester Oil Absorb moisture easily
coils are tested against leakage by air pressure of 450 psig • Never mix with mineral oil
(3102kPa) under water. Each evaporator coil is supplied with a
• Tools exclusive for R-410A
factory sized and matched thermostatic expansion valves and
4 mounting holes for ceiling suspension. • Never mix R-410A with other refrigerant
• Driers, valves and even copper tube must be approved
Evaporator Fans for use with R-410A
Evaporator fans are forward curved centrifugal double inlet,
double width statically and dynamically balanced. Bearings
used in the fans are self aligning and lubricated for life.
Evaporator fans are belt driven and use “V” belts with Electrical Controls
an adjustable variable pitch motor pulley resulting in an
accurate fan air flow adjustment. Fans are driven by Totally The Outdoor Condensing Units are provided with IP-54 control
Enclosed, IP55 Protected, 4 poles Class F insulated panel enclosure comprising all starting, operating and safety
electric motors. The motors can be field wired to the controls. Following are the
control panel of the condensing unit where the motor standard components used in
starters are located. the AUMRG1 control panel:

Warning • Starting contactors for com-


pressors and motors
Please make sure to open supply • Internal overload protection for  

air dampers fully (if any) before compressors


starting the fan motor. • Internal OR External overload protection for the motors (de-
pending on the model)
• Electronic control board for unit operation
Otherwise blower fan • Diagnostic LEDs on the control board for easy troubleshooting
can be damaged due • Compressor short cycling protection
to back pressure and • Control switch for unit on/off
warranty will be void • Control circuit breaker
• Power and control circuit terminal blocks
• High pressure protection
• Low pressure protection
Refrigerant R- 410A • Starter (contactor & overload relay) for CADX-AG1 evaporator
fan motor. (Power wiring from AUMRG1 control panel to CADX-
Why 410A?
AG1 motor to be done at site by others)
R-410A has a higher volumetric cooling capacity
Note: Photo shown above is for representation only for typical
compared to R22 and has better thermal
control panel layout.
exchange properties. This results in overall
performance gains in terms of system efficiency.
The greater density of the vapour in R-410A permits
higher system velocities, reduces pressure drop
losses and allows smaller diameter tubing to be
used. In other words a smaller unit can be developed
using a smaller displacement compressor, less coil and
less refrigerant while maintaining system efficiencies
comparable to current day R22 equipment.

8 |
Outputs from controller (for 2 stage models)

Output Description
INSTALLATION, OPERATION & MAINTENANCE
CM1 Compressor-1
CM2 Compressor-2
P1 Pump Down Solenoid 1 (option)
P2 Pump Down Solenoid 2 (option)
IDF Evaporator Fan
HTR1 Heater 1 (option)
HTR2 Heater 2 (option)
X1 Compressor-1 Trip (option)
X2 Compressor-2 Trip (option)
Electronic Control Board (ECB) ODF1 Condenser Fan-1
ECB
ODF2
DIP Switch selection guide
Condenser Fan-2
All AUMRG1 series condensing unit(s) is equipped with
Selection of mode can be configured on the DIP switch provided
an electronic control board suitable for air-cooled system
comprises of 1 to 2 compressors. as follows:
The control board is pre- DIP Stage
DIP Switch
programmed and designed Switch
Number
Position Single Dual
for cool mode, heat mode
and fan mode which oper- ON 3-Speed Blower Test mode ON
S1
OFF Single Speed Blower Test Mode OFF
ates on fuzzy logic control. In ON Compressor 1 lead
order to maximize the usage of S2
OFF Compressor balance Loading
air conditioning system being S3
ON Pump down solenoid enable
controlled. It allows optional us-
 
OFF Pump down solenoid disable
ON Single Stage
age of dedicated wired panel controller or in conjunction with a S4
OFF Dual Stage
standard 24V thermostat. Table 3
The main features of the controller are as follows and can
be selected and configured on the DIP switch provided in ECB Diagnostic LED’s Information
the control board:
There are five (5) LED indicators mounted in the control board
• Compressor 1 lead option which corresponds to different level of indication for Normal and
• Balance loading up to 2 compressors system Test Mode operation. In case of system fault, LED’s on the board
• Single speed indoor fan emits a flashing signal indicating where the fault occurs. This is to
• Pump down solenoid (output 230-240V) for cooling
only (optional) guide the service personnel in identifying the source of fault/failure.
• Compressor trip output
• Compressor re-cycle protection During NORMAL Mode/Operation
• Compressor High/Low pressure protection LED # During LED
Indication NORMAL
status Mode/Operation
Diagnostic details
• Control via dedicated wired panel or optional using a LED
D5 # Indication
Green LEDON status Diagnostic
System details
ON
standard 24V thermostat D5
D4
Green
Orange
Blinking
ON slow Comp-2 Low pressure
System ON trip
Blinking
Blinking slow
fast Comp-2 High
Low pressure
pressure trip
trip
• Diagnostic LED’s on the control board for easy trou- D4 Orange
Blinking slow
fast Comp-2 Low
High pressure
pressure trip
trip
Blinking Comp-1
bleshooting D3 Yellow Blinking slow
Blinking fast Comp-1 Low pressure trip
Comp-1 High pressure trip
D3 Yellow
• Provision of digital Input terminals for On/Off Blinking
ON fast Comp-1 tripped
Comp-2 High pressure
(lockout)trip
ON Comp-2 tripped (lockout)
control, High and low pressure switches. D2
D2
Red-2
Red-2
Blinking slow
Blinking slow
Comp-2 recovery after LP trip
Comp-2 recovery after LP trip
• Test run mode Blinking fast Comp-2 recovery after HP trip
Blinking fast Comp-2 recovery after HP trip
ON
ON
Comp-1 tripped (lockout)
Comp-1 tripped (lockout)
D1
D1 Red-1
Red-1 Blinking
Blinking slow
slow Comp-1
Comp-1 recovery
recovery after
after LP
LP trip
trip
Blinking
Blinking fast
fast Comp-1
Comp-1 recovery
recovery after
after HP
HP triptrip
Control Board Digital Input /Output Table 4
During TEST Mode/Operation
The unit’s control board is compatible to operate
LED # Indication LED status Diagnostic details
with a DDC controller or any standard 24Vac ther-
D3
D3 Yellow
Yellow Blinking fast
Blinking fast Single stage
Single stage
mostat commercially available. D3 &
& Orange &&
D3 Orange Blinking fast
fast Dual Stage
Stage
D4 Yellow Blinking Dual
D4 Yellow
Inputs from
Inputs from thermostat
thermostat to
to the
the controller
controller (for
(for 22 stage
stage models)
models) Table 5
Input
Input Description
Description Inputs from DDC or thermostat to the controller (for 1 stage models)
G
G Indoor Fan
Indoor Fan Energized
Energized
Y1
Y1 11st stage
st stage cooling
cooling Input Description
Y2
Y2 22nd stage
nd stage cooling
cooling G Indoor Fan
W1
W1 1 st stage Heating
1 stage Heating
st
Y1 cooling stage
W2
W2 2 nd stage Heating
2nd stage Heating W1 1 st stage Heating
Table 1 W2 2nd stage Heating
Outputs from
from controller
controller (for
(for 22 stage
stage models)
models)
Table 6
Outputs
Output Description Outputs from controller (for 1 stage models)
Output Description
CM1
CM1 Compressor-1
Compressor-1
CM2 Compressor-2 Output Description
CM2 Compressor-2
P1
P1 Pump Down
Pump Down Solenoid
Solenoid 11 (option)
(option) CM1 Compressor-1
P2
P2 Pump Down
Pump Down Solenoid
Solenoid 22 (option)
(option) P1 Pump Down Solenoid 1 (option)
IDF
IDF Evaporator Fan
Evaporator Fan IDF Evaporator Fan
HTR1
HTR1 Heater 11 (option)
Heater (option) HTR1 Heater 1 (option)
HTR2
HTR2 Heater 22 (option)
Heater (option) HTR2 Heater 2 (option)
X1
X1 Compressor-1 Trip
Compressor-1 Trip (option)
(option) X1 Compressor 1 Trip (option)
X2 Compressor-2 Trip
Trip (option)
(option)
X2 Compressor-2 ODF1 Condenser Fan-1
ODF1
ODF1 Condenser Fan-1
Fan-1
Condenser ODF2 Condenser Fan 2
ODF2 Condenser Fan-2
ODF2 Condenser Fan-2
Table 7
Table 2

DIP Stage
DIP Switch DIP Stage
DIP Switch Switch
Number
Number
Switch
Position Single Dual | 9
Position Single Dual
INSTALLATION, OPERATION & MAINTENANCE

System Protection
The electronic controller monitors all the safeties related
to the unit and makes necessary protection by shutting-
down the entire unit or the affected circuit. System cannot be restarted
The protection includes: automatically after lock-out happen. It
can be reset by turning or switching ON/OFF the
• Compressor short cycling unit power. High and Low pressure checking is
• Low pressure protection always bypassed when compressor is off.

• High pressure protection


• Compressor motor high temperature
(for compressors with Internal motor protector)
Points to consider with ECB
• Evaporator fan motor overload
• Compressor lock-out function • The electronic control board is with in-built fuse for primary
supply protection. If fuse is blown, replace only with same
rating specified. Before restarting the operation, ensure
that root cause has been verified and action is taken ac-
3 Minutes minimum Off time for compressor cordingly.
• The 24V transformer is solely for electronic control board
For thermostat cycles, a compressor can only cut-I after 3-min- only, do not tap to use for other purposes.
utes from the time it cuts-off (not applicable for the first time • When using a third party thermostat, make sure that “R”
start-up, compressor will cut-in immediately upon unit start). and “C” terminals are not shorted or shunted.

Low Pressure protection Crankcase Heaters


If low pressure contact is open, compressor is not allowed Each compressor is equipped with a crank case heater and
to cut-in for 3 minutes (The LED will be blinking SLOW wired ahead of the control circuit in such a way as to prevent the
for 3 minutes). Low pressure monitoring is bypassed absorption of liquid refrigerant by oil in the compressor crank-
for 10 seconds after compressor cut-in. Should the case during the OFF period.
Low Pressure in open before the compressor has
cut-in, compressor shall run as usual and checking
on the LP will be done after 10 minutes operation.
The system will lock-out if: Thermostat Control (Optional)
a) Low pressure trip for 3 times within 30 minutes
time frame. As standard optional feature, 24V thermostat can be provided
to control one or two stage heating and cooling applications.
b) Low pressure contact open time frame more The thermostat normally displays room temperature and mode
than the compressor minimum off time of 3 of operation. The temperature can be set by up/down buttons
minutes. for both cooling and heating cycles. The thermostat also allows
you to select continuous fan operation, or have the fan on inter-
mittent operation with the equipment.

High Pressure protection The thermostat is best located at least 4 ½ feet above the floor
level, on a partition wall (not an outside wall), and should not be
If high pressure contact is open, compressor exposed to direct light from lamps, sun etc. Admissible ambient
is not allowed to cut-in for 3 minutes (The LED conditions are to be observed. It should be in a location with
will be blinking FAST for 3 minutes). High pres- good air circulation; away from ventilation inlets, doors, win-
sure fault delay is 1 sec. During HP opened, dows or other fresh air entry points.
outdoor fan will be started when there is com-
pressor loading demand. System will display There are different varieties of thermostat available in the mar-
error only if HP remains opened for 2 seconds ket. It is the responsibility of the end-user to select the best
after outdoor fan started. component based on required preference. Be sure to follow
The system will lock-out if: supplier’s instruction manual when installing the thermostat.
Installation must be carried out with unit power-off in order to
a) High pressure trip for 3 times within 30 minutes prevent possible short-circuit.
time frame.
b) High pressure contact open time frame more than
the compressor minimum off time of 3 minutes.

10 |
INSTALLATION, OPERATION & MAINTENANCE

Pressure Controls

Low Pressure Cut Out Liquid Line Controls


To monitor the suction pressure of each refrigerant circuit
and shutdown the compressor should the suction pressure Thermostatic Expansion Valve
fall below the set point.
For controlling the flow of liquid refrigerant into the evaporator,
based on refrigerant superheat. An orifice in the valve meters
the flow into the evaporator, based on temperature sensed by
the Bulb & the adjusted superheat.

High Pressure Cut Out


To monitor the discharge pressure of each compressor and
shutdown the compressor should the discharge pressure exceed
the set point. Ball Valve
Used in order to isolate High side and Low side of the system
and for maintenance purposes.

Filter Driers
Head pressure Switch (Fan cycling)
Driers are mounted in the refrigerant liquid line to ensure that all
This external switch(s) are fitted to monitor the the refrigerant in circulation passes through the drier each time
condenser pressure difference in relation with the it circulates through the system so as to remove any moisture or
ambient temperature and switch ON or OFF the foreign matter from the refrigerant stream.
required condenser fan to maintain sufficient head
pressure inorder to operate the unit within the
design parameters of ambient temperatures.

Disposal of filter drier cores should be


handled according to local laws.

Pressure Cut-Out, psig Cut-in, psig Always seal used filter driers. They contain
Low Pressure 54 85 small amounts of refrigerant & oil residue which
High Pressure 650 500 may contaminate the environment.

Table 8

| 11
INSTALLATION, OPERATION & MAINTENANCE

Receiving of Equipment
Rigging
Responsibility should be assigned to a dependable
individual at the job site to receive material. Each • Regardless of the packaging used in
shipment should be carefully checked against the transporting of the units, it should preferably
bill of lading. The shipping be lifted with a fork lift truck or a crane and
receipt should not be signed belts. The units should be unpacked as close
until all items listed on the bill of as possible to its final installation position. The unit
lading have been accounted for. should always be left standing upright.
• Before positioning the unit, it is advisable to re-check
When uncrating, care the weights.
should be taken to
prevent damage. • Remove the wooden pallet from underneath the machine
Heavy equipment should be left before installation
on its shipping base until it has • Use protectors to prevent sling or cable as per
been moved to the final location. Figure 1.
• The Unit should be installed in an upright position within
Check carefully for concealed damage. Any shortage or damages a gradient shown in Figure 1.
should be reported to the delivering carrier. Damaged • All protection/spreader Bars shown in the rigging
material becomes the delivering carrier’s responsibility, illustration should be provided by the customer on site.
and should not be returned to the manufacturer unless
prior approval is given to do so.

The packing list included with each shipment should be


carefully checked to determine if all parts and
equipment have been received. Any accessories
such as starters, contactors or controls should
be fastened to the basic unit to avoid loss and prevent
possible interchanging with other units.

Storage
AUMR-G1

When the Split units need to be


stored in a prolonged period prior to
installation, the following protective
measures are required:

1. Split units must be stored in a protected area


and safe from construction debris. Do not
remove the wooden coil guard.

2. Take special care to protect electrical


components.

3. For long stocking periods, remove electrical


equipment and store in dry atmosphere.

4. Periodically, manually turn the wheel to


permit the redistribution of the grease inside
the bearing and to prevent corrosion. CADX-G1

5. The unit has to be protected against any


external loads or vibration. Figure 1
6. Protect it against any direct exposure to
sunlight and UV-rays.

7. Protect the fans from corrosive agents.

12 |
INSTALLATION, OPERATION & MAINTENANCE

Each unit has been carefully Units should not be completely shrouded with
tested and inspected at the higher uninterrupted wind shield in order to
factory, where every precaution was taken prevent reversing of airflow. In case, such a
to ensure that it reaches its destination configuration cannot be avoided , a properly
in perfect condition, It is therefore, very designed exhaust duct or hood that does not
important that installers, movers, riggers influence any additional pressure on the fans
use the same care in handling the unit. and which is of the same height as surrounding
Chains,Cables or other moving equipment shield to be installed.
should be placed to avoid damage to any part
of the unit. All protection/spreader bars shown
in the rigging illustration should be provided by
the customer on site.
When selecting a location for the unit, the following
points should be considered:

• There should be enough space for air movement beside


Use all lifting points. Improper lifting can cause the condenser coils which should be approximately equal
severe personal injury and property damage. to the height of the coils.
• The discharged air from the condenser fan should not
be obstructed by any roofing, ducting etc which could
cause air short circuiting.
Foundation • There should be sufficient area provided to allow for the
servicing of the unit.
Provide a level and rigid concrete foundation or a steel
platform that is strong enough to carry the operating The schematic shown on Pages 12-13 in gives the recommended
weight of the unit. SKM Air Conditioning is not liable for clearance areas around the unit for both maintenance and air flow.
any damages and problems in the equipment caused by
erroneous design in the foundation.

Location & Space Requirements


• Foundation or flooring leveled for correct drain
& condensate flow.
• There should be sufficient space & adequate
lighting to be provided near the unit for correct
operation & effective maintenance.

Recommendations
It is a necessity that the units are installed with
adequate free space around them to ensure
proper circulation of air that is rejected by the
condensers and to provide adequate space
for unit access for servicing and maintenance.
There is a possibility of recycling of air if the
rejected air from condenser encounters any
obstacles leading to an increase in the ambient
air temperature surrounding the units.

Air distribution across the entire heat exchange


area will be impaired if the air outlet is obstructed.
These conditions lead to a reduction in the heat
exchange capacity of the coils causing an increase
in discharge pressure of the compressors. This
leads to a loss of capacity & increase in compressor
power input.

| 13
INSTALLATION, OPERATION & MAINTENANCE

UNIT CLEARANCE

SPACING FOR SERVICE

SPACING FOR AIR FLOW

ALL DIMENSIONS ARE IN INCHES [mm]

A A
A 30
[762]

A A
A

[762]
30
[762]
30

AUMR - 055G1 to 120G1 AUMR - 130G1 to 260G1

Single Unit MODEL


A B
AUMR
A 45
40
[1143] 055G1 / 070G1
[1016]
44
080G1 / 090G1 -
[1118]
[762]
30

A
52
100G1 & 120G1
[1321]
40 64
130G1
[1016] [1626]
44 72

Table 9
150G1 & 180G1
[1118] [1829]
52 88
200G1 - 260G1
[1321] [2235]
[762]

A ALL DIMENSIONS ARE IN INCHES [MM]


30

AUMR - 055G1 to 120G1

A B A

A A
[762]
30

AUMR - 130G1 to 260G1


Multiple Unit
Figure 2

14 |
INSTALLATION, OPERATION & MAINTENANCE

Electrical Connections
FieldField
Wiring Requirement Schematic
Wiring
After the unit has been positioned, the necessary electrical
connections must be made between the unit and the power L1 L2 L3 N

source as well as the thermostat.


CIRCUIT BREAKER
OR FUSED
DISCONNECT SWITCH
• Check all wires are securely screwed into their terminals. (NOT BY SKM)

• Check that the voltage and frequency of the power supply


corresponds to that stipulated on the unit nameplate. 3 PHASE,
4WIRE SYSTEM
380-415V/3PH/50HZ

• Check that only copper conductors are used for both power
L1
L2
L3

and control wiring.


N

GROUND

• Cable gland to be used for external connections.


E

Field Control Wiring

DOL
EFM CONTACTOR CONNECTION
U
V M

All field wiring must comply with national and local electrical
W 3~

E
requirements. EFM

CONTROL TERMINAL
• Operating voltage to the unit must be within voltage range CADXA-G1 UNIT SERIES

BLOCK
indicated in Table 13 on Page 38. Voltages between phases
must be balanced within 2%.
• Unit must be grounded. AUMR-G1 SERIES

COOLING STAGE-1 ON / OFF


COOLING STAGE-2 ON / OFF
EVAPORATOR FAN ON / OFF
CONTROL PANEL

• Wiring connections to be carried out in accordance with the

24V AC
REFER ACTUAL WIRING DIAGRAM
wiring diagram provided with each unit. FURNISHED WITH THE UNIT FOR
EXACT IDENTIFICATION OF WIRE NUMBERS.
LINE VOLTAGE
FIELDWIRING (BY OTHERS)

LOW VOLTAGE
TYPICAL ROOM THERMOSTAT ( BY OTHERS ) FIELDWIRING (BY OTHERS)
( 1 STAGE OR 2 STAGE - COOLING OR COOLING & HEATING )

Thermostat Location & Wiring


Figure 3
The thermostat should be located away from the rooms
cooling vents or device in such a way that it senses the
average temperature to be regulated. An open hallway
may be most appropriate for a single zone system. If Pre-Installation Check-Up
the hallway may be closed by doors from the regulated
spaces then these should be left open when the
system is in use. If the thermostat is too close to the Electrical
source controlled then the system will tend to “short
cycle”, and numerous starts and stops will shorten
equipment life. IMPORTANT: When installing the unit, always
Carry out wiring in accordance to the wiring diagram disconnect the electric supply.
provided with the unit.
• Make sure that the power supply is compliant with current
safety standards. Always install the air conditioner in
Electrical Wiring Diagrams compliance with current local safety standards.
All SKM AUMRG1 + CADX-AG1 series Split units • Verify that suitable grounding connection is available.
require at most field supplied and field installed
fused disconnect switches or circuit breakers for • Verify that the voltage and frequency of the power supply
power & control and a low/voltage temperature comply with the specifications and that the installed power
controller (room thermostat). Shown in Figure is sufficient to ensure the operation of any other domestic
9 is typical field wiring diagram. appliance connected to the same electric lines.

Each Split unit is supplied with electrical wiring • Verify that the cut-off and protection switches are suitably
diagrams placed inside the control panel of sized.
the unit. • Verify that the air conditioner is connected to the power
supply in accordance with the instructions provided in the
WARNING! wiring diagram included in the manual.
• Verify that electric connections (cable entry, section
Hazardous Hazardous Voltage
of leads, protections....) are compliant with the electric
Disconnect Disconnect all electric specification and with the instructions provided in the
power including remote disconnect wiring scheme. Verify that all connections comply with the
switch before servicing or maintenance. standards applicable to the installation of air conditioners.
Proper lockout procedures to be
• After completing the installation, always carry out the
followed so that power cannot be
factional test and provide the instructions on how to operate
energized. Failure to disconnect power
the air conditioner to the user.
before servicing could result in serious
injury or death.

| 15
INSTALLATION, OPERATION & MAINTENANCE

Preparation For Installation


When deciding on the location of the unit with the owner, Condensate Drain
the following restrictions must be taken into consideration:

General
Do NOT install the unit in a location where it will
come in contact with the following elements :

• Combustible gases
• Saline air
• Machine oil
• Sulphide gas
• Special environment conditions, if you must install the unit
in such conditions, first consult SKM.

Avoid installing the unit in the following areas:


Figure 4
• In areas where it is exposed to direct sunlight. Close to any
heat source.
• In damp areas or locations where it could come into contact It is mandatory to install a properly sized drain trap in order to
with water. ensure proper draining of condensate collected in the drain pan.
Below mentioned are recommendations for sizing a drain trap.
• In areas where curtains and furniture could affect the
supply and discharge of air. Use a 1 inch standard pipe. Measure the maximum negative static
pressure upstream from the fan. The height “H1 ” shown in figure
• In areas in which there is no enough space around the 7 must be greater than or equal to the negative static pressure
unit. (Must install as per the required/ recommended at design conditions. Ensure that there is sufficient water in the
spacing, shown in the lay out drawings). trap before starting in order to maintain the seal.
• On surfaces that are unable to support the
weight of the unit without deforming, breaking or H1= 1” for each 1” of negative static pressure + 1”
causing vibrations when the unit is running. H2= H1/2
H= H1 + H2+ Pipe Diameter + Insulation

Condensate traps serving the cooling coils should be of sufficient


Carrying Out Installation height to be effective.
The unit should be located on a suitable base to provide adequate
1. Unpack the unit carefully. height from the ground in order to accommodate the drain trap.
2. Unfasten or dismantle transport locks.
Failure to provide adequate condensate
3. Packing material to be fully removed and piping to the drain trap may result in
disposed. water damage to the equipment or
4. The units base frame must be building.
fixed without stresses to the supporting
structure.
Condensate traps serving the cooling coils on CADX-AG1 Units
5. AVM to be regularly placed around
should be of sufficient height to be effective.
centre of gravity and firmly fixed. Check
whether AVM is balanced under load.
The CADX-AG1 Unit should be located on a suitable base
6. No forces or vibrations may be to provide adequate height from the ground in order to
transferred from other plant parts accommodate the drain trap.
7. The flexible connections at intake and/or
discharge should be installed, well aligned
and freely moving.
8. The AVM should be freely moving and under
even load.
9. The impeller should be turning idly and should
not touch the intake cone.
10. The stability against collapse of the unit
should be checked.

16 |
INSTALLATION, OPERATION & MAINTENANCE

Pre-Startup Procedure
After the installation has been completed, the following causes low refrigeration capacity and promotes liquid slugging
points should be covered before the system is placed in and compressor bearing washout. Liquid refrigerant must
operation. be prevented from reaching the crankcase. If proper control
cannot be achieved with the system in normal operation, a
a. Check electrical connections. Be sure they are all tight. suction accumulator must be installed in the suction line just
b. Observe compressor oil level before start-up. The oil a head of the compressor to prevent liquid refrigerant from
level should be at or slightly above the center of the sight reaching the compressor.
glass. Use only oil approved by compressor manufacture. e. Using suitable instruments, carefully check line voltage and
c. Remove or loosen shipping retainers under motor- amperage at the compressor terminals. Voltage must be
compressors. Make sure hold down nuts on spring mounted within 10% of that indicated on the compressor nameplate. If
compressors are not touching the compressor feet. high or low voltage indicated, notify the power company. The
current normally should not exceed 120% of the nameplate
d. Check high and low pressure controls, pressure regulating
rating. If amperage draw is excessive, immediately determine
valves and all other safety controls, and adjust if necessary.
the cause and take corrective action. On three phase motor-
e. Check refrigerant used in the system. compressors, check to see that a balanced load is drown
f. Wiring diagrams, instruction bulletins, etc attached to by each phase.
AUMRG1 + CADX-AG1 units should be read and filed for f. All fan motors on air cooled condensers, evaporators, etc
future reference. should be checked for proper rotation. Fan motor mounts
g. Make the proper refrigerant connections and charge the unit should be carefully checked for tightness and proper
with the refrigerant to be used. Weigh the refrigerant drum alignment. If belt drives are used, check the belt tension.
before charging so an accurate record can be kept of the All motors requiring lubrication should be oiled or greased
weight of refrigerant put in the system. R-410A refrigerant as necessary.
is to be charged in liquid phase only. Charging may be
done on the suction side by throttling the gas using the Precaution: Carry out a fan test run
manifold gauge.
h. Observe system pressures during charging and initial Risk of injury from rotating impeller!
operation. Do not add oil while the system is short of
refrigerant, unless oil level is dangerously low.
i. Continue charging until system has sufficient refrigerant Never reach into the impeller when the fan is open.
for proper operation. Do not over-charge. Remember
that bubbles in a sight glass may be caused by a • Take measures to prevent centrifugal fan from being
restriction as well as a shortage of refrigerant. switched on accidentally.
j. Do not leave unit unattended until the system • Clear the ducting system and fan of all foreign bodies
has reached normal operating conditions and the (tools, small parts, construction waste, etc.).
oil charge has been properly adjusted to maintain • Close all the inspection openings.
the oil level at the center of the sight glass. • Switch on fan and check direction of rotation of impeller
by comparing it with the arrow on the fan indicating the
Operational Check-Out direction of rotation.
After the system has been charged and has • If the direction of rotation is wrong, reverse the polarity of
operated for least two hours at normal operating the motor having due regard to the safety instructions.
conditions without any indication of malfunction, • Once operating speed has been reached measure the
it should be allowed to operate over-night on current consumption and compare it with the nominal
automatic controls. Then a through recheck of motor current on the fan type plate or motor rating plate.
the entire system operation should be made • If there is continuous overload switch the centrifugal fan
as follows: off immediately.
k. Check compressor head and suction • Check that the fan runs smoothly and quietly. Ensure that
pressures. If not within system design limits, there are no unusual oscillations or vibrations.
determine why and take corrective action.
• Check the motor for any abnormal noises.
l. Check liquid line sight glass and expansion
valve operation. If there are indications that
If the state of the fan does not allow
more refrigerant is required, leak test all
connections and system components and adapted action for repair it has to be put
repair any leaks before adding refrigerant. out of order immediately and to be replaced if
required.
m. When applicable, observe oil level in
compressor crankcase sight glass, and add
oil as necessary to bring level to center of the Prior to starting up the units, we recommend checking
sight glass. if the following steps have been carried out:
d. Thermostatic expansion valves must be
checked for proper superheat settings. Feeler 1. The units has been inspected for shipping and handling
bulbs must be in positive contact with the suction damages.
line. Valves with high superheat settings produce little 2. The power supply cables have been wired correctly and
refrigeration and poor oil return. Too little superheat the unit has been earthed.

| 17
INSTALLATION, OPERATION & MAINTENANCE

3. All service valves have been opened.


4. The unit has been checked against pipe leakages
using a leak detector. Cooling Sequence
Once the unit is started and temperature is set in the thermostat,
5. The control, wiring and thermostat arrangement is as
the thermostat checks for cooling demand. If the cooling
per the wiring diagram furnished with the unit. demand is available from thermostat, the digital input terminal
6. All terminals and wire connections are tightly secured. “G” gets energized; provided that EFM overload contact is
healthy, evaporator fan motor operates, provided that the field
7. All fuses have been checked and all push button wiring has been done between the AUMRG1 and CADX-AG1
switches reset. units.
Note that On/Off switch mounted in the control panel should
be switched-on to have permissive signal from the controller.
Below sequential control is for cooling start sequence in cool
Service Record mode through thermostat.
A permanent data sheet should be prepared on each
installation, with a copy for the owner and the original for the Cooling start sequence through thermostat for Single Stage
installing contractor’s files. If another firms are to handle service Units with 1 Compressor and 1 to 2 Outdoor Fans (CFM):
and maintenance, additional copies should be prepared as During cool mode operation, the cool command from thermostat
necessary. will energize Y1. The control board will activate the output relay
The form of the data sheet may vary, but a complete record (Comp) and energize the compressor along with the condenser
of sizes and identification of all components used in the fan motor-1. When the discharge pressure reaches the ON
installation, together with any pertinent information should be pressure value of the fan cycling switch, condenser fan motor-2
included, Following is suggested check-off list: will be energized (applicable for units with 2 condenser fan
motors)
a. Compressor manufacturer, model, and serial
number. Cooling start sequence through thermostat for Dual Stage
Units with 2 Compressors and 2 Outdoor Fans (CFM):
b. Equipment manufacturer, model, and serial
number. During cool mode operation, the cool command from thermostat
will energize Y1. The control board will activate the output
c. Design operating temperatures.
relay (OutFan1) to energize condenser fan motor-1. At pre-
d. Refrigerant and weight of charge. determined timings, the compressor-1 will start accordingly.
e. Electrical service, volts, cycles, phase, wire size. In two stage units, if the first stage cooling is insufficient to
maintain the required space temperature, the second stage of
f. Control circuit, voltage, fuse size. cooling circuit closes and Y2 from the thermostat will energize.
g. Contactor or starter, manufacturer, model, size, At this time, output relay in the board for OutFan-2 will activate.
part number. Since the circuit is provided with head pressure control through
fan cycling switch, condenser fan motor-2 will still be inactive
h. Compressor motor protection, type, size, part as FCS still open or off.
number. After pre-determined timings, the compressor-2 will start to
i. Data on relays, or other electrical components. operate and consequently developed pressure in the circuit.
Condenser Fan motor-2 will activate once the discharge
j. Pressure control, type, size, model number, pressure reaches the fan cycling close/ON pressure setting.
setting. The system continues to run until the space temperature
k. Data on miscellaneous components such drop causes de-energizing of the second stage cooling of the
as pressure controls, crankcase heaters, thermostat.
solenoids, valves, etc.
A typical two compressor control is shown below:
l. Liquid line drier, manufacturer, size, model
number, connections.
m. Schematic diagram of refrigerant piping.
n. Final settings on all pressure, regulating, and
safety controls.

Sequence of Operation Figure 5


Generally, with input signals from the thermostat
or DDC, the motor(s) in the equipment is started in Note:
sequential order:
If compressor anti-short cycle timer is not satisfied, outdoor fan
cut-in delay will more than 5 secs. This typically happen when
Supply fan >>> condenser fan motor >>> compressor unit is power-ON whereby the system will impose a 3-minute
(at a pre-determined timings) anti-short cycle delay.

18 |
INSTALLATION, OPERATION & MAINTENANCE

Pre-Startup Checklist

Table 10

| 19
INSTALLATION, OPERATION & MAINTENANCE

Unit start-up
Precaution: Carry out a fan test run
Make sure all the system hand or manual
valves are in full open position and the system
contains an operating charge of refrigerant. Risk of injury from rotating impeller!

Make sure the main fuse disconnect switch is in OFF


position and equipped with properly sized fuses. Never reach into the impeller when the fan is open.

In the event of a fuse blow out, do not use steel or copper


wire in lieu of a proper recommended fuse. • Take measures to prevent centrifugal fan from being
switched on accidentally.

• Clear the ducting system and fan of all foreign bodies


Unit start-up (tools, small parts, construction waste, etc.).

• Close all the inspection openings.


• Switch on power supply to the unit keeping the control
circuit MCB ON and control switch (CS) OFF for a period of • Switch on fan and check direction of rotation of impeller by
minimum 2 hours to allow the crankcase heaters to warm comparing it with the arrow on the fan indicating the
up the compressor crank case.
• direction of rotation.

• Visually check the evaporator fan motor rotation and belt • If the direction of rotation is wrong, reverse the polarity of
tension with the unit control switch still at OFF position. the motor having due regard to the safety instructions.

• Once operating speed has been reached measure the


• Switch-ON the thermostat power button. Set the current consumption and compare it with the nominal
thermostat to “COOL” mode and if required adjust the motor.
temperature setting through temperature set button.
(Up to increase, Down to decrease temperature) • Current on the fan type plate or motor rating plate.

• If there is continuous overload, switch-off the centrifugal fan


• Switch on the unit control ON/OFF toggle
immediately.
switch (CS) in the condensing unit control panel.
• Check that the fan runs smoothly and quietly. Ensure that
• Start the indoor fan operation through there are no unusual oscillations or vibrations.
thermostat. Note for thermostat fan mode
selection. • Check the motor for any abnormal noises.

• If the air conditioning unit is started after


long idle period of time, be aware of the
If the state of the fan does not allow
accumulated dust that might blow into the
room.
adapted action for repair it has to be put
out of order immediately and to be re-
placed if required.
• Compressor will start based on the
temperature set point set in the room
thermostat. Make sure that the unit is
cooling mode which can be selected from
room thermostat.

• Condenser fans will start with compressor


and will cycle based on discharge pressure.

Note:
Do not operate the units below or
beyond the mentioned ambient
temperatures.

20 |
INSTALLATION, OPERATION & MAINTENANCE

Commissioning Test Report

SPLIT UNITS PRE-STARTUP CHECKLIST

Table 11

| 21
INSTALLATION, OPERATION & MAINTENANCE

Periodic Maintenance
Following Checklist describes the suggested maintenance schedule to maintain proper operation of the
unit. Detailed procedures are mentioned in the corresponding pages.

Component Checklist Weekly Monthly Half Yearly Annually


Visual Inspection Yes
Check for Corrosion
and Repaint as Yes
Necessary
Check amperage
Yes
draw on blower motor
Check condensate
Evaporator line and clean if Yes
Fan/Motor necessary
Section Check for correct
Yes
voltage at unit
Motors Visual
Yes
INDOOR Inspection
UNIT Check for unusual
Yes
noise from the motor
Check all wiring for
Yes
loose connections
Air filter to be washed
Filter Section Yes
& cleaned
Check for Debris /
Blockage over fins &
Yes
clean coil if
Coil Section necessary
Check connecting
lines , joints & coil for Yes
evidence of oil leaks
Oil Level at Sight
Yes
Glass
Superheat at
Yes
Operation Compressor
Level
Crank Case Heater
Maintenance Yes
Operation
Refrigerant Sub
Yes
cooling in Liquid Line
Operating Pressures Yes
Dust & Debris on
Power Terminals/
Yes
Contactors /Loose
Cable Lugs
Control Panel
Check for correct
voltage at unit (Unit
OUTDOOR Yes
operating)
UNIT
Check for Vibrations
Yes
& Noise
Check unbalance of
Yes
the Fan
Condenser
Motor Bearings to be
Fan & Motor Yes
checked
Corrosion Yes
Fan Blades to be
Yes
checked /Balancing
Check connecting
lines , joints & coil for Yes
evidence of oil leaks
Coil Clean & inspect
outdoor coil , wash
Yes
with water if
necessary
Table 12

22 |
INSTALLATION, OPERATION & MAINTENANCE

Maintenance
The maintenance of this equipment shall be in accordance brazing rod and flame from the joint as soon as a complete fillet
with the regulation of authorities having jurisdiction and is formed to avoid possible restriction in the line.
all applicable codes. It is the responsibility of the installer
to determine and follow the applicable codes. Low head
pressure may lead to poor, erratic refrigerant feed control at 7 . Visually inspect the connection after brazing to locate any
pin holes or crevices in the joint .
the thermostatic expansion valve. The units have automatic
control of the condenser fans which should provide adequate
head pressure control down to 50 ºF (10 ºC) provided the
unit is not exposed to windy conditions. The system design is
responsible for assuring the condensing section is not exposed
to excessive wind or air recirculation. Never use oxygen for pressurizing a
system; an explosion may occur if oil
is present in the system. Always use a
Procedures gauge equipped pressure regulator on the high
It is quite probable that a majority of operating failures can be pressure back-up gas, and never interconnect
traced to careless or inadequate maintenance procedures. The the refrigerant cylinder and the inert gas
following instructions have been prepared to help the service cylinder through a gauge manifold. Nitrogen
engineer systematically cover the many points which must and carbon dioxide cylinder pressures can
be considered to provide each installation with trouble free rupture a refrigerant cylinder.
performance.
Take extreme care to keep refrigeration tubing clean and
dry prior to installation. The following procedures should be
followed:

Brazing Procedures Never solder, braze or weld on

1 . When copper is heated in the presence of air, refrigerant lines or any unit
Copper oxide forms. To prevent copper oxide from components with pressures that are
forming inside the tubing during brazing, an inert gas above atmospheric pressure or where
should be passed through the line at low pressure to refrigerant may be present. Always remove
prevent scaling and oxidation inside the tubing. Dry refrigerant by following the local guidelines.
nitrogen is preferred. Nitrogen displaces air in the After refrigerant removal, use dry nitrogen to
tubing and prevents oxidation of the interior surfaces. bring system back to atmospheric pressure
A pressure regulating valve is to be used to control before opening system for repairs. Mixtures of
the flow.
refrigerants and air under pressure may become

2 . Ensure that the tubing surfaces to be brazed


are clean, reaming at the ends of tubes is to be
done to remove any burrs and keep the surface
combustible in the presence of an ignition source
leading to an explosion. Excessive heat from
soldering, brazing or welding with refrigerant
even. vapours present can form highly toxic gases
Failure to follow all proper safe refrigerant

3 . Make sure the inner and outer tubes


of the joint are symmetrical and have a
close clearance, providing an easy slip fit. If
handling practices could result in death or
serious injury!

the joint is too loose, the tensile strength of


the connection will be significantly reduced.
The overlap distance should be equal to the
diameter of the inner tube.

4 . Wrap the body of each refrigerant line


component like “expansion valve, solenoid
valve, Hot gas bypass” with a wet cloth to keep
it cool during brazing. Move any tube entrance
grommets away for the brazing area.

5 . Flux , when used is to be applied in small


quantities only. Excessive flux, when used, can
enter the system and contaminate the refrigerant
system.

6 . Apply heat evenly over the length and


circumference of the joint to draw the brazing
material into the joint by capillary action. Remove the

| 23
INSTALLATION, OPERATION & MAINTENANCE

Using OFN (oxygen free nitrogen) during “Use only dry nitrogen with a pressure
regulator for pressurizing unit. Do not
brazing: use acetylene, oxygen or compressed
All pipe work shall be cut square with a proprietary pipe air or mixtures of a hydrogen containing
cutter to give a clean cut, without copper fragmentation. refrigerant and air above atmospheric pressure
Hacksaws must not be used. When brazing, all pipe work containing them for pressure testing as they
shall be purged with low-pressure oxygen-free nitrogen, may become flammable and could result in an
above atmospheric pressure (to provide a positive pressure
explosion. Refrigerant, when used as a trace
in the pipe) to prevent the formation of copper oxides and
gas should only be mixed with dry nitrogen
scale, and to prevent moisture from the surrounding air
entering the system. Any annulus between the oxygen-free for pressurizing units.”“Failure to follow these
nitrogen feed pipe and the refrigerant pipe shall be sealed to recommendations could result in death or
prevent the ingress of air due to the ejector effect of the higher serious injury or equipment !”
pressure oxygen free nitrogen.

The pipe work should be flushed with oxygen free, high- Leak Testing, Evacuation & Charging
pressure nitrogen to ensure that any moisture and debris are Procedures:
removed. All fittings should be kept to a minimum to reduce
the number of joints (i.e. potential leaks) and frictional losses. The below mentioned procedures are to be followed whenever
Swept bends should be formed using a bending tool with the any major repair or replacement is done on the system. These
correct dies/mandrill /spring to prevent reeking or barreling. procedures of Leak Testing, Evacuation & Charging are required to
be made in order to bring the system back to its original operating
condition after any major repair or replacement.
MANIFOLD GAUGE
“Do NOT release refrigerant to MANIFOLD GAUGE
the atmosphere! Use appropriate
procedures as per local directives.”

These procedures are to be followed once the brazing


of the refrigerant lines is completed.
SKM units are Leak Tested at Factory and are
shipped with nitrogen gas which is to be removed at
the time of installation of lines.

1 . Close the field supplied liquid line service


valve(s) installed near the evaporator.
Pressure test the liquid line & suction line at
pressures specified by local codes. Figure 6

2 . The complete system should be pressurized


to not more than 175 psig with dry nitrogen.
Warning - use of Manifolds with sight
glass: This guide assumes the use of
Refrigerant Manifold and Gauges. It is essential

3 . Use soap bubbles to check for leaks. that the manifold does not have a sight glass.
Check all piping joints, valves etc... These sight glasses have been known to fail
and risk causing serious injury to the engineer
carrying out the test. The manifold gauges
4 . In case a halide torch/leak detector is used
for leak testing appropriate procedures are
to be followed as per local directives while
and service lines must be in good condition.
Manifolds with sight glasses are only suitable
releasing the refrigerant. for refrigerant recovery.

5 . Repeat the test procedure for the low side Handling of nitrogen cylinders: When
of the system, charging through the suction the cylinder is not being used ensure
pressure gauge port or through an access the valve is closed. Never transport or store the
provided on the suction line by the installer. cylinder with the regulator fitted.
Increase the system pressure to 100 psig.
Manifold gauge used with R-410A require

6 . If leaks are found again, repeat by brazing the


joint again. Retest for leaks after making repairs.
a high side range of 800 psig and a low
side of 250 psig. Hoses are required to
have a service pressure rating of 800 psig.

24 |
INSTALLATION, OPERATION & MAINTENANCE

16. Repair any leaks found and then repeat the test procedure
Dangers of Use of Nitrogen: You using OFN.
will be pressure testing at high 17. When it is established that the system is safe and leak tight
pressures with nitrogen. The the OFN can be evacuated and the system can be recharged
pressures are high enough to cause serious with refrigerant.
injury or death. Nitrogen is an asphyxiant –
it will suffocate you in high concentrations. Pressurise the system using Nitrogen to the below mentioned
pressures based on the refrigerant being used in the system.
The following guidelines show how to
minimise risk during pressure testing.
Maximum Maximum
Refrigerant Suitable Regulator
Pressure, bar g Pressure, psig
Leak testing procedure R 22 23.6 342 Maximum output of 33 Bar
If there is any residual refrigerant left in the system this must be
recovered prior to following this procedure. R 134 a 13.7 200 Maximum output of 26 Bar
R 407 C 23.6 342 Maximum output of 33 Bar
1. Ensure the nitrogen cylinder is either secured or located in a R 410 A 33 478 Maximum output of 40 Bar
position so that it cannot fall over.
Table 13
2. Ensure the regulator valve is wound fully out (counter
clockwise / anti clockwise). LEAK TESTING
3. Fit the regulator to the cylinder.
4. Fit gauges to the system and ensure there are no
isolated sections within the part of the system to be
pressure tested.
5. Fit the common manifold hose to the nitrogen cylinder.
6. Open the system valves and open the high side manifold
valve (to avoid damaging the low side manifold gauge
do not pressurise the low side of the manifold with
the test pressure).
7. Open the nitrogen cylinder valve.
8. Slowly wind the nitrogen regulator in (clockwise)
to pressurise the system:

• Pressurise the system in stages of no


more than 3 bar (45 psi) at a time;
• Ensure you only pressurise the relevant
sections of the system to their maximum
allowable pressure.
Figure 7
• Listen for audible pressure loss at every
pressure increment increase;
Evacuation
9. When the maximum system allowable
pressure (Refer to Table No: 2) has been
reached, close the nitrogen cylinder valve
and the high pressure manifold valve.
10. Note the pressure shown on the high
pressure gauge.
11. Wind the nitrogen regulator valve fully
out (counter clockwise / anti clockwise).
12. Carefully remove the common hose
from the regulator, slowly venting the nitrogen
pressure. Vacuum Pump
13. Maintain the system at the maximum allowable
pressure for the duration of the test. Whenever there is a replacement of system components like
14. Test each joint with leak detection spray or compressor, filter drier, expansion valve etc, the refrigerant
soapy water to identify the leak point. If leaks are system should be evacuated in order to remove moisture from
found, they must not be repaired with the system the system.
pressurised.
Moisture affects the proper functioning of the system. Air
15. Slowly vent the remaining nitrogen. being a non-condensable will exist in the top of the condenser

| 25
INSTALLATION, OPERATION & MAINTENANCE

Triple Evacuation Method


A vacuum pump capable of pumping down to 500 microns
should be connected to both the low and high side evacuation
valves with Copper tube or high vacuum hoses (¼” ID minimum).
If the compressor has service valves, they should be opened.

1. Operate pump to bring down the system pressure to 1500


microns and continue operating for another 10 minutes.

2. Close all the service valves and shut off the vacuum pump.

3. Connect a nitrogen cylinder and regulator to system and


open until system pressure is 5 Psig.

Figure 8
4. Close all service and ball valves and allow the system to
stand for 30 minute in order to allow Nitrogen to absorb
moisture in the system.

5.
and the receiver. When the system is operated ,the discharge Repeat steps 1- 4 again, i.e. evacuate for a second time
pressure will be a combination of the refrigerant condensing down to 1500 microns.
pressure and the pressure exerted by the nitrogen and
oxygen. Increase in pressure depends on the amount of air
in the system. Any time a system is running with abnormally
high head pressure, air in the system is a prime suspect.
6. The triple evacuation method is completed by final
operation of the pump to bring down the system pressure
to 500 microns.

7.
The presence of air reduces the lubricating properties of Close all service valves on the gauge and shut off the
the oils especially POEs which are Hygroscopic in nature. vacuum pump.
Air in the system increases the risk of Acid formation

8.
thus damaging the Copper Plating and Motor insulation, Maintain Vacuum at 500 microns for minimum of 30
thus leading to electrical and mechanical failure of minutes.
the compressor. In order to avoid these, system
vacuum should be done according to the procedures
mentioned 9. Connect the cylinder of the refrigerant that is to be used in
the system using gauges and open until system pressure
is 10 psig or proceed to refrigerant charging procedures.

10. The triple evacuation method to a pressure of 500


microns is practical under field conditions, and
System Evacuation Procedures represents a specification that can be met.

Equipment Required:
To evacuate a system properly
• Vacuum Pump- Two stage type with Gas requires time and care. Any slight
Ballast and a capacity matching the system carelessness in protecting the sealed
volume (Using a vacuum pump larger than the system can undo all the precautions
system volume increases the risk of freezing taken previously. But the slight extra effort
the moisture in the system. required to make an evacuation properly and
• Connection lines (¼ in for Small Systems completely will pay big dividends in reduced
& ½ in for larger systems are recommended) maintenance and trouble free operation.

A Manifold Gauge or a Micron gauge capable


of measuring vacuum down to 200 microns is to
be installed between the System and the vacuum Under no conditions is the motor/
pump to allow the system pressure to be checked compressor to be started or operated
after evacuation while the system is under a high
vacuum. To do so may cause serious damage
• Nitrogen Cylinder with regulator and hose kit. to the motor windings because of the reduced
dielectric strength of the atmosphere within the
motor chamber.
Do not turn off vacuum
pump when connected to
an evacuated system before closing Never use a Meghommeter to apply
ball valve/Manifold Gauge. power to compressor while it is under
vacuum, doing so will cause motor
winding damage.

26 |
INSTALLATION, OPERATION & MAINTENANCE

Refrigerant charging
The proper performance of air conditioning system is the saturated
dependent on the proper refrigerant charge. An under- condensing
charged system will starve the evaporator, resulting temperature,
in excessively low compressor suction pressures, corresponding to the
loss of capacity, and possible compressor overheating. discharge pressure
Overcharging can flood the condenser resulting in high (Available on page
discharge pressures, liquid refrigerant flooding, and potential 52). The difference
compressor damage. between these two
Each system must be considered separately, since systems temperatures gives
with the same capacity or horsepower rating may not the measure of Sub
necessarily require the same refrigerant or the same amount cooling leaving the
of charge. Therefore it is important to first determine the type condenser. The
of refrigerant required for the system, the unit nameplate optimum sub cooling
normally identifying both the type of refrigerant and the weight for a system is 8-14
of refrigerant required.
o
F.
Figure 9

R-410A System Charging 541.4 psig (R-410A)


541.4

Even though R-410A has a very small fractionation potential,


it cannot be ignored completely when charging. To avoid
fractionation, charging of system incorporating R-410A
541.4
should be done with “liquid” to maintain optimum system 541.4 psig (R-410A)
performance. To ensure that the proper blend composition is Figure 10
charged into the system, it is important that the liquid only be WARNING: Never charge Liquid
removed from the charging cylinder. Some cylinders have refrigerant to Low side of the system
dip tubes which allow refrigerant to be removed from the when the system is in the Off state
cylinder when it is in upright position. Cylinders without
P-T EQUIVALENT AT 107.3 psig (R-410A)
dip tubes have to be tipped upside down in order for the
liquid to be removed. • Measuring the Refrigerant Superheat: Measure the suction
Once the liquid is removed from the charging cylinder, pressure and obtain the saturated suction temperature from
R-410A can then be charged into the system as the P-T Chart. Measure
107.3 psig the Actual Suction temperature.

vapor as long as all the refrigerant in the charging The difference


cylinder is charged into the system by throttling of between
P-T EQUIVALENT AT 107.3 psig (R-410A)
the manifold gauge. the two
temperatures
gives the
Checking the Sight Glass measure of 107.3 psig
Superheat
Charging based on visual entering the
inspection/sight glass compressor.
is not recommended for The optimum
R-410A. value for
superheat is
8-12 oF. Figure 11
Many service technicians will often attempt to
charge an air conditioning system by making
sure the liquid line sight-glass is full of liquid Fan
refrigerant. Often, as a refrigerant blend travels
through a liquid line sight-glass, some of For smooth operation fan must be serviced regularly. The most
the liquid may flash as it passes through the important maintenance measures to be made at least twice a
increased volume of the sight-glass and re- year are:
enters the smaller liquid line, it will form 100% 1. Vibration and sound level to be checked. Anomalous
liquid again. values indicate a problem on the unit.
If the system has a sight-glass, it is of utmost 2. Check the presence of corrosion on the fan especially on
importance for service technicians not to try the rotating path to prevent breaking.
to clear the sight-glass when charging with 3. Check if there are any objects within the range of the
refrigerant blends like R-410A or R-407C. fan which might be sucked into the rotor once the fan is
Attempts to clear a sight-glass may overcharge running.
the system and lead to poor system performance 4. Check whether the fans rotor rotates freely, without any
and/or compressor damage. friction against the casing body.
• Measuring the Refrigerant Sub cooling: 5. Check the fan design speed as it must not exceed the
This is the best method provided the proper rotary speed.
instrumentation is available, Check the discharge 6. Check whether the supply cables in the fan section are
pressure and the liquid line temperature and check firmly fixed.

| 27
INSTALLATION, OPERATION & MAINTENANCE

Bearing
• Slide down the bearings, straightening the screwed ring
1. Check bearing for sound, a normal bearing generates tongue located on the sleeve, ease at each side screwed
a smooth uniform sound, while a damage bearing rings with a centre pouch and hammer. Install the bearings,
generates a loud and irregular sound. tighten up the sleeves with the screwed ring bend the rings
tongue. Install a new sealing sleeve into grooves located
2. Excess vibrations or temperature are often a sign of in the lower part of the block. Install the lubricated shaft
possible damages Check the bearing locking and seals assembly with a bearing on the block basis. Assemble
periodically. fixing ring (or more fixing rings) at a side of one bearing
3. Check for excessive grease leakage from the bearing. only (the other bearing is not adjustable). Insert the other
Leakage of small quantity from the bearing is normal. sealing ring onto the upper block side. Put the upper block
part onto the lower one and tighten up the screws. Fill the
bearing with suitable grease. Turn the wheel several times
Replacement instruction of fan bearings in order to check if it rotates correctly.
assembled on Cross bars

• Remove protection screws and protection rings out of the


bearings. Remove protection rings out of the shaft. Using
appropriate tools, hold the shaft in an appropriate position Cover
in order not to damage the rotors wheel.
Cross bars

Protection rings
Protection screw

Cast iron separate casing

Fan Motor
Cross bars
Checking the insulation
• Remove nuts and bolts from cross bars and If the unit has been stored for long time or if it has been kept
separate assembly from shaft and bearing. in a damp atmosphere, insulation resistance test for the motor
Replace the old rubber rings and bearings should be carried out. This measurement must be carried out
and assemble the new ones onto the cross using a megohmmeter at 500V D.C. (do not use a magneto
bars. electric system).
• Install protection rings onto the bearings
clamping them according to the fan’s Draining off condensation water
rotations direction and secure them with
Temperature variations cause condensation to form inside the
fixing screws. Turn the wheel several times
motor, which must be removed before it adversely affects motor
in order to check if it rotates correctly.
operation. Condensation drain holes, located at the bottom of
Assemble cross bars on side panels and
the motors (bearing in mind their operating position) are sealed
make sure to preserve coaxiality of the
with plugs which must be removed and then replaced every
rotor. Tighten the nuts and bolts on cross
six months (if they were not replaced, the motor degree of
belts to the side panels.
protection would no longer be maintained). Clean the orifices
and plugs before reassembling them.
Replacement instructions of fan
bearings assembled on Cast iron Cleaning
pillow blocks
To ensure the motor operates correctly, remove any dust or
• Unlock the casing cover easing screws at foreign bodies which might clog the cover grille and the housing
both sides. Using appropriate tools, hold the fins. Before carrying out any cleaning operation check that the
shaft in an appropriate position in order not to motor is completely sealed (terminal box, drain holes, etc).
damage the inlet funnel or rotors wheel. Dry cleaning (vacuuming or compressed air) is always motor
• Remove protection rings from the bearing preferable to wet cleaning.
side (only one bearing is equipped with it). After Always clean at reduced pressure from the centre of the motor
removing grease, remove sealing half-rings from towards the extremities to avoid introducing dust and particles
the upper and lower port of the block casing. under the seals.

28 |
INSTALLATION, OPERATION & MAINTENANCE

Bearing • Do not operate equipment without guards


in place. Exposed equipment can result in
As soon as any abnormal noise or vibration is noted on
severe injury or death.
the motor or abnormal temperature rise is noted in the
bearing, the condition of the bearings must be checked.
Damaged bearings must be replaced as soon as possible • Periodic inspections should be performed.
to prevent worse damage to the motor and the fan. It is also Failure to perform proper maintenance
recommended to change the bearing after 100,000 hours of can result in premature product failure and
operation under normal operating conditions. If one bearing
personal injury.
needs to be replaced, the other bearing must also be replaced.
The seals should be changed routinely when the bearings are
changed. • To avoid damage, supporting structure
including shafts and bearings must be
designed to handle transmitted loads and
Fan Belt Adjustment belt tension(s).

The supply fan belts must be inspected periodically to ensure


proper unit operation. Replacement is necessary if the belts V-Belt Installation Check List
appear frayed or worn. Units with dual belts require a matched
set of belts to ensure equal belt lengths. 1 Turn off and lock out power ( ) Yes ( ) No
source
Periodic inspections should be performed. 2 Observe all other safety ( ) Yes ( ) No
Failure to perform proper maintenance procedures
can result in premature product failure and 3 Select proper replacement ( ) Yes ( ) No
personal injury. belts
4 Remove belt guard ( ) Yes ( ) No
Maintenance of the fan equipment 5 Inspect drive elements– ( ) Yes ( ) No
should only be carried out by skilled bearings, shaft, etc.
and adequately trained staff. To 6 Inspect sheave grooves ( ) Yes ( ) No
ensure complete safety do not start any for wear
maintenance procedure or inspection 7 Check sheave alignment ( ) Yes ( ) No
without disconnecting the unit from 8 Install new belts ( ) Yes ( ) No
the power supply and before the fan
9 Tension belts ( ) Yes ( ) No
and motor have completely stopped
rotating. 10 Check sheave alignment ( ) Yes ( ) No
(final)
11 Replace guard ( ) Yes ( ) No
Close any inlet or outlet
12 Start drive (look & listen) ( ) Yes ( ) No
damper to avoid a rotation of
the impeller due to induced 13 Re adjust the tension after ( ) Yes ( ) No
airflow. first 24 hours of operation
Table 14

When installing new belts or during replacement, • Never mix new and used belts on a drive.
do not stretch them over the sheaves; Instead
• Never mix belts from more than one
loosen the adjustable motor mounting base.
manufacturer.
Once the new belts are installed, adjust the belt
tension using tension gauge. • Always replace with the right type of
V-belt.
• Always observe V-belt matching limits.
• Disconnect and lock-
out power before installation
and maintenance. Belt Tensioning Instructions

• Working on or near energized


equipment can result in severe
injury or death.

| 29
INSTALLATION, OPERATION & MAINTENANCE

• Ideal tension is the lowest tension at which the


belt will not slip under peak load conditions.
• Check tension frequently during the first 24 hours Belt Deflection Force, lb
of operation. Check after jog start or 1-3 minutes Smallest
of operation, at 8 hours, 24 hours, 100 hours and Belt Sheave Super
RPM Gripnotch Belts
periodically thereafter are recommended. Cross Diameter Gripbelts
Range
• Over tensioning shortens belt and bearing life. Section Range
(inches) Used New Used New
• Keep belts free of foreign material which may cause slip.
Belt Belt Belt Belt
• Make v-drive inspection on a periodic basis. Under-tensioned
belt drives often produce audible squeal noise. Tension 860-2500 - - 4.9 7.2
3.4 - 4.2
when slipping. 2501-4000 - - 4.2 6.2
860-2500 5.3 7.9 7.1 10.5
B, BX 4.4 - 5.6
2501-4000 4.5 6.7 6.1 9.1
Before doing maintenance or tensioning
860-2500 6.3 9.4 8.5 12.6
on belt drives, turn equipment off and 5.8 - 8.6
2501-4000 6.0 8.9 7.3 10.9
lock out the power source.
Table 15
In order to ensure the correct belt tension, use a belt tension
checker (Figure 13-16) and use the deflection formula below and
compare with the data given in table

Sample:
If belt span = 20 inches
Belt Cross Section B, Super grip belt
Small sheave PD = 5 in
Deflection = (Belt span)/64 Figure 12

Solution
1. From table 6, check for the deflection force for
type B , super grip belt with 5 inch smaller sheave
, the deflection shown is 7.9 lb
2. The deflection = 20 in/64 = 0.3125 in
3. Tension of the belt to be increased or decreased
using the adjustable motor mount until the force
for 0.312 inches deflection is 7.9 lb as indicated
by the tension checker tool.
4. Check belt tension at least twice during first
operating day. Re adjust the tension until the Figure 13
tension is maintained within the recommended
range.

Excessive belt tension


shortens belt life and may
cause bearing & shaft
damage

Note: When new belts are installed


on a drive, the tension will drop
rapidly during the first few hours.
Thus, for new belts, tighten to the
initial installation defection force
shown in the tables below. Check
tension frequently during the first
Figure 14
24 hours of operation. Subsequent
re tensioning should fall between
the minimum and maximum forces
shown in the tables.

Note: The proper tension for V-belt


drive is the lowest tension at which Figure 15
the belts won’t slip under peak load
conditions.

30 |
INSTALLATION, OPERATION & MAINTENANCE

Fan Pulley adjustment (For variable pitch


pulleys only) the straightedge will touch both sheaves at the points indicated
Blower speeds are factory adjusted by default as per the by arrows in below image. A string, drawn tight, may be used in
fan selection data. The required airflow rate and the total the same manner. For uneven width sheaves, place a string in
static pressure adjustment of pulley should be done only when the centre groove of both sheaves and pull tight. Adjust sheaves
the actual external static pressure exceeds the design data. and tighten the sheave setscrews to the proper torques.
Adjustment of blower speeds should be done as per the Parallel operation of the fan and motor shafts is necessary to
following procedure: prolong belt life. Place a level on the shafts to check horizontal
1. Measure the initial RPM and motor current
drawn. alignment. The pillow block bearing with double setscrew locking
arrangement requires specific tightening instructions.
2. The motor is moved towards the blower shaft
via the adjustable mounting to loosen the belt
tension. NOTE: At or before start-up check the wiring of
the three phase fan motor to assure proper shaft
3. Loosen the two set screws in order to adjust
rotation. Incorrect fan rotation may loosen the
the motor pulley flange.
locking collar resulting in pre-mature bearing
4. Blower speed shall be increased by rotating failure.
the adjustable pulley in a clockwise direction in
such a way, it moves towards the fixed flange.
5. Blower speed shall be decreased by rotating the
adjustable pulley in an anti-clockwise direction in
such a way, it moves away from the fixed flange.
6. The adjustments are to be done only in half
turn adjustments.
7. Once the adjustments have been made, replace
the external key and tighten the adjustment
set screw.
8. The belt may now be installed and the belt
tension adjusted by using the adjustable motor
mounts.
9. Measure the RPM and the motor current drawn
and record the change in current and RPM.

Note:
In case the unit has variable pitch
pulley, do not alter the CFM beyond
the catalogue limits.

Alignment of shafts & sheaves


Figure 16
Make sure that fan shafts and motor shafts
are parallel and level. Common causes of
misalignment are improper location of sheaves Coil
and nonparallel shafts. When shafts are not
If the coil is to deliver its full cooling or heating capacity both its
parallel, belts on one side are drawn tighter and
internal and external surfaces must be clean.
pull more than their share of the load. Due to this
, the belts wear out faster leading to replacement 1. Periodic verification of the coil cleanliness is required.
of the entire set before utilising it for the maximum Dirty coil increases air pressure drop and reduces heat
given service. transfer potential, thus unbalancing the system.
If misalignment occurs in the sheave, the belts will 2. Examine finned surface for accumulation of dirt or lent.
enter and leave the grooves at an angle , causing If necessary wash down the affected areas with a mild
excessive belt /sheave wear. detergent solution and a soft brush. (Take care of the fin
Alignment of Shafts: surface while cleaning).
By measuring the distance between shafts at 3 or 3. Compressed air line may be used to blow out any solids
more locations to check if the distances are equal. between the fans. Do not probe the coils with a metal
Equal distances denote parallel shafts. scraper as any damage may cause tube leaks. Clean
refrigerant coils with cold water and detergent or one of
Alignment of Sheaves:
the commercially available chemical coil cleaners.
In order to check the location of adjustable sheave on
4. Inspect the drain pan and condensate drain at the same
shafts , a straight edge or a string are to be used. If the
time the evaporator coil is checked. Clean the drain
sheaves are properly aligned .When the sheaves are aligned,
pan by flushing with water and removing any matters of
obstructions which may be present.

| 31
INSTALLATION, OPERATION & MAINTENANCE

Mold In And Around Drain Pans


Drain pans under cooling coils are a common source of than the pressure of the fan. (The stem height is the vertical
mold and mildew problems. If the drain pan does not actually distance between the outlet of the trap and the bottom of
drain water— for whatever reason—mold and mildew will the drain pan
certainly grow in the pan and spread through the duct work 3. The contractor must be certain that the drain line actually
to the occupied spaces. Also, if water leaks or spills out of the connects to a drain.
drain pan, mold and mildew will grow in the soaked food source.
The problems fall into three categories: maintenance, pan design
and drain line installation.
Duct Connections
Maintenance: Connections of supply and return ducting to the AUMRG1 series
Problem – Split units should be by means of flexible duct connections to
prevent any vibrations being transmitted to the ducting. It must
be ensured that the connection is weather proofed to prevent
1. Dirt collects in the line . water from entering onto the unit/ducting.
2. Drain line is clogged.
3. Pan can over flow.
4. Possibility of mold growing.
Solution –

1. Using compressed air to unclog the line


2. Frequently changing the filters to keep dirt
and fibers from collecting in the drain pan.

Pan design:
Problem –

1. Drain pan is not long enough to catch the


droplets
2. Pan is not slopped to its drain in two directions
3. Standing water in parts of the pan which
Solution –never drain

1. All SKM cooling coils have drain pans sloped


all the way to their drains.
2. SKM drain pans length is adequate to capture
water droplets coming off the coil when the
system is operating at the peak dew point
design condition.

Drain line installation:


Problem –

1. No drain line or no connection to the line.


Either the designer fails to specify a drain
line, or the Contractor fails to install it
2. No trap, or an improperly-designed trap in
the drain line Without a trap, condensation
cannot drain from the unit. The fan suction
holds water in the pan until it overflows.
3. Drain line not connected to a drain. Drain
lines that feed water into building cavities
are surprisingly common.
Solution –

1. There must be a drain line, and it must be


connected—through a trap—to the drain pan.
2. The trap stem height should be greater

32 |
INSTALLATION, OPERATION & MAINTENANCE

Coil Cleaning
appears to be dirty, repeat Steps 7 and 8.
10. Reinstall all of the components and panels removed in
Step 2; then restore power to the unit.
11. With a fin comb, straighten any coil fins which were
inadvertently bent during the cleaning process.

Hazardous chemicals! Coil cleaning


can be either acidic or highly alkaline.
Handle chemical carefully. Ensure
proper handling by wearing goggles or face
shield, chemical resistant gloves, boots, and
apron or suit as required.

Regular coil maintenance, including annual cleaning enhances Compressor Oil


the unit’s operating efficiency by minimizing:
If a motor burn out is suspected, use an acid test kit to check
1. Compressor head pressure and amperage draw,
the condition of the oil. Test results will indicate an acid level
2. Fan brake horsepower and has exceeded the limit if a burn out occurred.
3. Static pressure losses If a motor burn out has occurred, change the oil in both
At least once each year—or more often if the unit is located compressors in a tandem set. This will require that the oil
in a “dirty” environment—clean the condenser coils using equalizer tube be removed to suck the oil out of the oil sump. A
the instructions outlined below. Be sure to follow these catch pan must be used to catch the oil when the compressor
instructions as closely as possible to avoid damaging the oil equalizer line is loosened.
coils. 1. To clean coils, use a soft brush and a Note: Refrigerant oil is detrimental to some roofing
sprayer. materials. Care must be taken to protect the roof from oil
2. Remove enough panels from the unit to leaks or spills.
gain safe access to coils. Charge the new oil into the Schrader valve on the shell of the
3. Straighten any bent coil fins with a fin comb. compressor.
4. Remove loose dirt and debris from both
sides of the coil with a soft brush.
5. Mix the detergent with water according to Adding & Removing Oil
the manufacturer’s instructions. If desired,
Schrader- The oil fill connection and gauge port is a 1/4” male
heat the solution to 150° F maximum to
flare connector incorporating a schrader valve.
improve its cleaning capability.
6. Pour the cleaning solution into the sprayer. For compressor with
If a high-pressure sprayer is used: access valve port oil
a. The minimum nozzle spray angle is 15 should be added by
degrees. schrader connection,
for other compressor oil
b. Do not allow sprayer pressure to
should be added through
exceed 600 psi.
the suction lines.
c. Spray the solution perpendicular (at 90
degrees) to the coil face. To remove this excess oil an access valve port has been added
to the lower shell of the service compressor. After running the
d. Maintain a minimum clearance of 6”
replacement compressor for a minimum of 10 minutes, shut down
between the sprayer nozzle and the
the compressor and drain excess oil from the Schrader valve until
coil.
the oil level is at one-half of the sight-glass level. This should be
7. Spray the leaving-airflow side of the coil repeated twice to make sure the proper oil has been achieved.
first; then spray the opposite side of the coil.
POE must be handled carefully and the proper protective
Allow the cleaning solution to stand on the
equipment (gloves, eye protection, etc.) must be used when
coil for five minutes.
8. Rinse both sides of the coil with cool, clean
Liquid line filter drier should be replaced
Note:- Do not use excessive whenever there is a motor burn out.
water pressure. Excessive
water pressure can bend
the fans and tubing of Dismantling & Disposal
the coil and lead to inadequate unit
performance. Be careful not to splash • Removing oil and refrigerant
water excessively into unit. • Do not disperse in the environment
• Use the correct equipment and method of removal
water. • Dispose of oil and refrigerant properly
9. Inspect both sides of the coil; if it still
• Dispose of compressor properly

| 33
INSTALLATION, OPERATION & MAINTENANCE

Warning:
Disposal of filter drier
cores, compressor oil and system
components should be handled according
to local laws.

For disassembly and disposal the unit


must be consigned to an authorised
disposal centre.
Warning: Don’t place open
• During disassembly the fan, motor and coils, if in working flame near or on bulb
order may be recycled or reused. Figure 18
• All materials should be recycled or disposed of according
to local bylaws.
• Electrical and electronic components must not be disposed
off as domestic waste. Current local laws for disposal of
electronic waste are to be observed.

Expansion Valve Service & Maintenance


Expansion valve is responsible for allowing the proper amount
of refrigerant to enter the evaporator regardless of cooling load.
It does this by maintaining a constant superheat. Typically,
superheat should run in the range of 8°F to 12°F (4.4°C to
6.6°C). Maintaining correct superheat to the compressor is an
Valve Orientation
important element in extending compressor life.
Figure 19
Expansion Valve Overfeeding
Overfeeding of the evaporator results in high suction pressure,
low superheat and possible liquid carryover. This set of
conditions is usually remedied by readjusting the valve
superheat. If this falls to correct the condition, the valve
should be replaced.
Expansion Valve Underfeeding
Underfeeding of the evaporator results in low suction
pressure and high superheat. It may be caused by
Bulb and external equalizer
improper super heat adjustment, restricted solenoid
locations
valve or drier or an inoperative expansion valve
power element. Test the power element in the Figure 20
following manner:
1. Stop the unit and allow it to warm to ambient
temperature.
2. Remove remote bulb from suction line and
place it in container of ice water.
3. Start system.
4. Remove the bulb from the ice water and warm
in hand. At the same time feel the suction line
for a drop in temperature. If liquid refrigerant
floods through the valve, the power element
is operating properly. If there is no change Bulb locations
in the suction line temperature, the power Figure 21
element is defective. Replace it.

System pressures: Solder techniques


Installation or Removal
Figure 22
Figure 17

34 |
INSTALLATION, OPERATION & MAINTENANCE

Voltage

Check the voltage across incoming power terminals when


• Manually rotate the condenser fans to ensure free
the system is operating. Voltage requirements are:
movement and check motor bearings for wear. Verify that
1. Voltage should not to exceed voltage utilization all of the fan mounting hardware is tight.
range. See table below.
2. Voltage imbalance between phases not to exceed
2%. Refrigerant Recovery, Recycling, & Reclamation
Rated Power Supply Operating Limits (Volts) There are many environmental and economic benefits to
V/Ph/Hz Minimum Maximum be gained from recovery, recycling and reclamation efforts
380-415/3/50 342 440 worldwide. The major benefits include:
440/3/50 400 462
Table 16 • Minimized atmospheric emissions and reduced
380/3/60 342 418 environmental impact;
460/3/60 208 253 • Expanded market opportunity for used refrigerant;
220/3/60 414 506 • Reduced environmental compliance costs;
• Reduced need for new refrigerant;
• Increased lifetime of refrigeration equipment due to
% Voltage imbalance = 100 * (Max. Voltage deviation contaminant removal
from average voltage of three
phases / Average voltage of The following describes the specific differences between
three phases) refrigerant recovery, recycling and reclamation:

As an example, nominal 440V, 3Ph power source


produces following voltages between the terminals.

L1 – L2 = 371V, L1 – L3 = 377V, L2 – L3 = 384V

Average Voltage = (371 + 377 + 384)= 377V


3

Max. Deviation = 384 – 377 = 7V

% Voltage Imbalance = (100 * 7) = 1.86%


Lifting Point
377

Contactor
1. Inspect the contacts. If they appear pitted
or burned, replace the contacts or contactor.
2. Using an ohmmeter, test continuity of the
contactor holding coil. If the coil does not
test continuous, replace it. Fork Lifting

Refrigerant RECOVERY involves the removal of a refrigerant


from a system and the placement of that refrigerant into a
container. The recovery process:
Cooling Season
• Is conducted whenever technicians need to open
• Check the unit’s drain pans and condensate or dispose of air conditioning or refrigeration
piping to ensure that there are no blockages. equipment.
• Inspect the evaporator and condenser • Includes removal of refrigerant vapor (heels) to
coils for dirt, bent fins, etc. If the coils established vacuum levels to maximize the amount
appear dirty, clean them according to the of refrigerant captured and minimize releases.
instructions described in “Coil Cleaning” Performance specifications are included in Air
later in this section. Conditioning and Refrigeration Institute (AHRI)
740.
• Inspect the F/A-R/A damper hinges and
• Involves service technicians, equipment operators,
pins to ensure that all moving parts are
appliance disposal facilities, equipment and
securely mounted. Keep the blades clean.
refrigerant manufacturers.

| 35
INSTALLATION, OPERATION & MAINTENANCE

• Is conducted whenever technicians need


to open or dispose of air conditioning or
is clean before starting every job. This screen prevents
refrigeration equipment.
damage to the unit from debris that may get past the inline
• Includes removal of refrigerant vapor filter. When pumping dirty refrigerant, this screen may
(heels) to established vacuum levels quickly clog and slow the process when used without an
to maximize the amount of refrigerant inline filter.
captured and minimize releases.
Performance specifications are included 1. Setup the machine as shown in the diagram below.
in Air Conditioning and Refrigeration Make sure that all the connections are tight.
Institute (AHRI) 740.
A. Connect the AC system High side to the Manifold
• Involves service technicians, equipment High side.
operators, appliance disposal facilities,
equipment and refrigerant manufacturers. B. Connect the AC system Low side to the Manifold
Low side.
Refrigerant RECYCLING involves processing used refrigerants
to reduce contaminants, then reusing the refrigerant. C. Connect the Manifold center port to the Recovery
Unit input port.
• Recycling is recommended only when
recharging to the same owner’s equipment. D. Connect the Recovery Unit output to the Recovery
• Recycling involves removal of some Cylinder liquid port.
contaminants prior to reuse. Contaminants 2. Connect the recovery unit to a 230V outlet using a 12PSivG
can result in early system failure. cord (minimum) and not more than 15 feet long.
Contaminants include oil, moisture,
3. Make sure the input valve on the recovery unit is closed,
acid, chlorides, particulates, and non-
this will make it easier for the compressor to start when the
condensable gases.
power is turned on.
• The Industry Recycling Guide (IRG-2)
4. Open the liquid port of the Recovery Cylinder and the
published by AHRI describes maximum
output valve of the recovery unit.
recommended levels of impurities.
5. Open the liquid port on the Manifold Gauge Set. Removing
• International Organization for Standards
the liquid first will keep the recovery time to a minimum.
(ISO) 11650 or AHRI 740 standards may
be used to measure recovery/recycling 6. Turn on the recovery unit with the On/Off switch on the
equipment performance. front panel. The compressor and fan should start.
7. Slowly open the input valve of the recovery unit.
Refrigerant RECLAMATION involves purifying used
refrigerant to meet industry product specifications. 8. When all the liquid has been removed, slowly open the
vapor port on the Manifold Gauge Set. Both valves to
• Reclamation identifies bad or mixed system should now be fully open to maximize vapor flow.
refrigerants which could result in
9. Run the unit until the vacuum required by the EPA is
equipment damage or leakage. Chemical
achieved.
analysis also is required to verify
specification values to meet or exceed 10. Close both
product standards. (e.g. ISO 12810, AHRI valves on the
700). Manifold Gauge
Set and on the
• Reclamation may include filtering,
recovery unit.
separation, distillation, dilution, or
reformulation of the recovered refrigerant. 11. Shut off
machine.
• Reclamation is recommended when used
refrigerants will be charged into equipment 12. Close the valves
other than the equipment it was removed on the Recovery
Cylinder and Figure 23
from, or into equipment owned by a
different company. disconnect the
hoses.
• Reclamation facilities and processes
should be designed to minimize emissions. Self Purging The Recovery Unit
• Non-reclaimable refrigerants should
be disposed of in an environmentally 1. Close all the ports on the system you are servicing that are
acceptable manner, and in accordance connected to the recovery unit.
with applicable regulations. 2. Close the input valve on the recovery unit.
Refrigerant Recovery Techniques 3. Turn off the recovery unit to prevent high pressure shutoff.
Standard Recovery Procedure 4. Turn the Purge/Recover knob to the Purge Setting.
5. Turn on the recovery unit and run the machine until you
Note: A scale must be used to avoid overfilling
achieve the desired vacuum.
the storage tank.
Note: Use an inline filter when you are pumping 6. Close all valves on the recovery unit and the recovery tank.
dirty refrigerant. 7. Turn off the recovery unit and return IN the Purge/Recover
Note: Check that the debris screen (on inlet port) knob to the Recover setting.

36 |
INSTALLATION, OPERATION & MAINTENANCE

Figure 24
Figure 25
Push/Pull Recovery Procedure (for Bulk Liquid Tank Cooling Procedure (Optional)
Refrigerant)
In order for this procedure to work, you must have at least 2.3
kgs. of liquid refrigerant in the storage tank.
Note: A scale must be used to avoid
overfilling the storage tank. 1. Connect the hoses as shown.
A. Connect the Recovery Unit input to the
The Push/Pull method is useful for recovering large
Recovery Cylinder vapor port.
amounts of liquid from a system. This will only work
on large systems where the liquid can be accessed B. Connect the Recovery Unit output to the
easily. Do not attempt this on systems that contain Recovery Cylinder liquid port.
less than 15 Ibs of refrigerant unless it has a 2. Open all valves.
receiver tank or it may not work correctly. 3. Start Machine.
4. Throttle the output valve
Once the siphoning starts, it so that the output pressure
can continue to fill the tank is at least 100psi greater
even when the machine has (but never greater than psi)
been shut off. To avoid overfilling, than the input pressure.
you must be sure to close all valves 5. Run until the tank is cold.
on the tank and system when you are
finished. Figure 26

Alternative Cooling Setup (Optional)


1. Setup the machine as shown in the diagram
below. Make sure that all the connections are By setting up your equipment as shown here, it is possible to
tight. cool the tank during the recovery procedure if necessary.
A. Connect the System Vapour side to Normal Recovery:
the Recovery Unit output port. A. Tank vapor valve
B. Connect the System Liquid side to - Closed.
the Recovery Tank liquid port.
Tank Cooling:
C. Connect the Recovery Unit input
A. Tank vapor
port to the Recovery Tank vapor
valve- Open.
port.
B. Manifold
Note: Keep valves on tank and Gauge Set-
system closed at this time. 80th Closed.
C. Follow steps
3-5 above to Figure 27
4. Slowly open valves on the Recovery Unit. cool tank.
5. Switch on the power to the Recovery Unit. Purging Non-Condensables from Storage Tanks
6. Slowly open the valves on the tank and The tank must be left undisturbed for at least 24 hours so that
system. The liquid should now begin all of the air will rise to the top.
to be pulled out of the system. You can Connect a Manifold Gauge Set to the tank and check the
monitor the progress with an Inline sight pressure at the vapour port.
glass. Look up the refrigerant you are using on a Refrigerant
Temperature/Pressure chart and use the ambient air
7. When all the liquid has been siphoned off,
temperature to determine what the tank pressure should be.
turn off the Recovery Unit and close all
If the tank pressure is higher than the pressure on the chart.
the valves.
Slowly open the vapour port and let the excess pressure bleed
8. You can now proceed to remove the off until it is about 5psi above the pressure on the chart.
remaining vapor using the standard Close the valves and let the tank stand still for 10 minutes.
recovery procedure. Repeat if necessary.

| 37
INSTALLATION, OPERATION & MAINTENANCE

Trouble Shooting

Problem: Units runs normally , but short cycles or periodic on-off occurs

Possible Cause • Overload protector.


Recommended Action • Check the cause.

Possible Cause • Thermostat.


Recommended Action • Differential set too close increase the differential setting

Possible Cause • High pressure cut-out due to:


(a) Insufficient air.
(b) Overcharge.
(c) Air in system.

Recommended Action (a) Check airflow to the condenser correct.


(b) Reduce refrigerant charge.
(c) Purge.

Possible Cause • Low pressure cut-out due to


(a) Undercharge.
(b) Restriction in expansion device.

Recommended Action (a) Fix leak, add refrigerant.


(b) Replace device.

Problem: Unit operates continuously for a long time


Possible Cause • Shortage of refrigerant.
Recommended Action • Fix leak, add charge.

Possible Cause • Control contacts stuck or frozen closed.


Recommended Action • Clean contacts or replace control.

Possible Cause • Refrigerated or air conditioned space has excessive load or poor
Recommended Action insulation.
• Determine the fault and correct.
Possible Cause • System inadequate to handle load.
Recommended Action • Replace with larger system.

Possible Cause • Evaporator coil iced.


Recommended Action • Defrost.

Possible Cause • Restriction in refrigeration system.


Recommended Action • Determine location and remove.

Possible Cause • Dirty condenser.


Recommended Action • Clean condenser.

Possible Cause • Filter dirty.


Recommended Action • Clean or replace.

38 |
INSTALLATION, OPERATION & MAINTENANCE

Trouble Shooting

Problem: Evaporator ices up

Possible Cause • Restricted airflow.


Recommended Action • Check for dirt or lint on coil.

Possible Cause • Dirty air filter.


Recommended Action • Clean or replace. Advice customer on periodic cleaning of filter.

Possible Cause • Short of refrigerant.


Recommended Action • Check system pressure. Take super- heat reading. Add refrigerant.

Possible Cause • Low air volume.


Recommended Action • Check for dirty air filter or loose belt.

Possible Cause • Restricted distributor tube.


Recommended Action • Check for warm distributor tube.

Possible Cause • Restricted liquid line/low liquid line pressure.


Recommended Action • Check for restriction in lines/improve liquid line pressure by proper
charging or installing fan cycle switch, etc.

Problem: Head pressure too high


Possible Cause • Refrigerant overcharge.
Recommended Action • Correct the refrigerant charge.

Possible Cause • Air in system.


Recommended Action • Recharge the system after a thorough triple evacuation.

Possible Cause • Dirty condenser.


Recommended Action • Clean.

Possible Cause • Malfunction of condenser fan (air- cooled).


Recommended Action • Check and correct or replace.

Possible Cause • Excessive air temperature entering condenser.


Recommended Action • Check for short circuiting of con-denser discharge air, correct it.

Possible Cause • Restriction in discharge line.


Recommended Action • Correct it.

Problem: Compressor will not start


Possible Cause • Line disconnects switch open.
Recommended Action • Close start or disconnect switch.

Possible Cause • Fuse removed or blown.


Recommended Action • Replace fuse.

Possible Cause • Overload protector tripped.


Recommended Action • Refer to electrical section.

| 39
INSTALLATION, OPERATION & MAINTENANCE

Trouble Shooting
Possible Cause • Control stuck in open position.
Recommended Action • Repair or replace control.

Possible Cause • Control off due to cold location.


Recommended Action • Relocate control.

Possible Cause • Wiring improper or loose.


Recommended Action • Check wiring against diagram.

Possible Cause • Thermostat defective or improperly installed.


Recommended Action • Replace or relocate.

Possible Cause • Control circuit open.


Recommended Action • Trace control circuit with wiring diagram and repair.

Possible Cause • Burned/open circuit motor winding.


Recommended Action • Replace the compressor with all pre- cautions.

Problem: Compressor will not start, humming noise but trips on overload protector
Possible Cause • Improperly wired.
Recommended Action • Check wiring against diagram.

Possible Cause • Low voltage to unit.


Recommended Action • Determine reason and correct.

Possible Cause • Compressor motor has a winding open or shorted.


Recommended Action • Replace compressor.

Possible Cause • Internal mechanical trouble in compressor.


Recommended Action • Replace compressor.

Possible Cause • Liquid refrigerant in compressor.


Recommended Action • Check crankcase heater.

Possible Cause • High discharge pressure.


Recommended Action • Un-equalized pressure in the system.

Problem: Compressor starts and runs, but short cycles on overload protector
Possible Cause • Additional current passing through overload protector.
Recommended Action • Check wiring diagram. Check for added fan motors, pumps, etc
connected to wrong side of protector.
Possible Cause • Low voltage to unit (or unbalanced if three phase).
Recommended Action • Determine the reason and correct.

Possible Cause • Overload protector defective.


Recommended Action • Check current, replace protector.

Possible Cause • Excessive discharge pressure.


Recommended Action • Check airflow across the condenser coil, restrictions in refrigeration
system.

Possible Cause • Suction pressure too high.


Recommended Action • Check for possibility of misapplication. Use stronger unit.

Possible Cause • Compressor too hot - return gas hot.


Recommended Action • Check refrigerant charge (fix leak), add if necessary.

40 |
INSTALLATION, OPERATION & MAINTENANCE

Trouble Shooting

Problem: Space temperature too high.

Possible Cause • Control setting too high.


Recommended Action • Reset control.

Possible Cause • Expansion valve too small.


Recommended Action • Use larger valve.

Possible Cause • Cooling coils too small.


Recommended Action • Add surface or replace.

Possible Cause • Inadequate air circulation.


Recommended Action • Improve air movement.

Problem: Suction line frosted or sweating.


Possible Cause • Expansion valve passing excess refrigerant or is oversized.
Recommended Action • Re-adjust valve or replace with smaller valve.

Possible Cause • Expansion valve stuck open.


Recommended Action • Clean valve of foreign particles, re- place if necessary.

Possible Cause • Evaporator fan not running.


Recommended Action • Determine reason and correct.

Possible Cause • Overcharge of refrigerant.


Recommended Action • Correct charge.

Problem: Liquid line frosted or sweating.


Possible Cause • Restriction in dehydrator or strainer.
Recommended Action • Replace part.

Possible Cause • Liquid ball valve partially closed.


Recommended Action • Open valve fully.

Problem: High suction pressure.


Possible Cause • High load on evaporator. Load in ex- cess of design conditions.
Recommended Action • Check the design.

Possible Cause • Unbalanced system. Oversized air handling unit matched with under
sized condensing unit.
Recommended Action • Follow manufacturer’s guide line and correct it.

Possible Cause • Compressor discharge valve leaking.


Recommended Action • Repair/replace compressor.

Possible Cause • Expansion valve widely open.


Recommended Action • Check and adjust the superheat accordingly.

Possible Cause • Improper bulb location or installation.


Recommended Action • Check the expansion valve bulb is properly tighten at correct location.

| 41
INSTALLATION, OPERATION & MAINTENANCE

Trouble Shooting

Problem: Loss of oil pressure.


Possible Cause • Loss of oil from compressor due to:
(a) Oil trapping in system.
(b) Compressor short cycling.
(c) Insufficient oil in system.
(d) Operation at excessively low suction pressure.

Recommended Action • (a) Correct the system piping.


(b) Trace out the wiring/defective con- trols/components, etc. and
correct it
(c) Add oil.
(d) Check the superheat of expansion valve and other possible causes
like clogged filter, low CFM, iced evaporator etc. & correct it.

Possible Cause • Excessive liquid refrigerant returning to compressor.


Recommended Action • Check the system for correct super- heat & other possible causes like
clogged filter, low CFM, iced evaporator, etc. and correct it.

Possible Cause • Malfunctioning oil pump.


Recommended Action • Repair or replace it.

Possible Cause • Restriction in oil pump inlet screen.


Recommended Action • Clean/replace it (oil change recommended).

Problem: Relay defective or burned out.


Possible Cause • Incorrect relay.
Recommended Action • Check and replace.

Possible Cause • Incorrect mounting angle.


Recommended Action • Remount relay in correct position.

Possible Cause • Line voltage too high or too low.


Recommended Action • Determine reason and correct.

Possible Cause • Excessive short cycling.


Recommended Action • Determine reason and correct.

Possible Cause • Relay being influenced by loose mounting.


Recommended Action • Remount rigidly.

Problem: Unit is noisy


Possible Cause • Loose parts or mountings.
Recommended Action • Find and tighten.

Possible Cause • Vibration in Tubes


Recommended Action • Tighten the pipe support.

Possible Cause • Bent fan blade causing vibration.


Recommended Action • Replace blade.

Possible Cause • Fan motor bearings worn.


Recommended Action • Replace motor.

42 |
APPENDIX- I

Loading Points
MODEL LOAD AT EACH POINT Lbs (Kgs) TOTAL MODEL LOAD AT EACH POINT Lbs (Kgs) TOTAL
AUMR A1 A2 A3 A4 WEIGHT CADX A1 A2 A3 A4 WEIGHT
83 103 86 106 378 66 62 57 51 236
055G1 055AG1
[38] [47] [39] [48] [172] [30] [28] [26] [23] [107]
85 105 88 108 386 75 85 74 79 313
070G1 070AG1
[38] [48] [40] [49] [175] [34] [38] [34] [36] [142]
111 130 114 134 489 83 86 78 77 324
080G1 080AG1
[50] [59] [52] [61] [222] [38] [39] [35] [35] [147]
121 141 125 144 531 83 86 78 77 324
090G1 090AG1
[55] [64] [57] [65] [241] [38] [39] [35] [35] [147]
133 156 132 155 576 83 86 78 77 324
100G1 100AG1
[60] [71] [60] [70] [261] [38] [39] [35] [35] [147]
147 183 133 170 633 107 116 109 114 446
120G1 120AG1
[67] [83] [60] [77] [287] [48] [53] [49] [52] [202]
173 173 185 185 716 122 139 108 107 476
130G1 130AG1
[78] [78] [84] [84] [324] [55] [63] [49] [49] [216]
219 219 233 233 904 128 135 124 115 502
150G1 150AG1
[99] [99] [106] [106] [410] [58] [61] [56] [52] [227]
236 236 258 258 988 140 146 148 138 572
180G1 180AG1
[107] [107] [117] [117] [448] [63] [66] [67] [63] [259]
258 258 274 274 1064 140 146 148 138 572
200G1 200AG1
[117] [117] [124] [124] [482] [63] [66] [67] [63] [259]
297 297 290 290 1174 163 198 143 155 659
230G1 230AG1
[135] [135] [131] [131] [532] [74] [90] [65] [70] [299]
310 310 303 303 1226 163 198 143 155 659
Recommended
260G1
Suction and Liquid Line Sizes:
[140] [140] [137] [137] [554]
260AG1
[74] [90] [65] [70] [299]
Table 17 Table 18
PIPE LENGTH - FEET (m)
Models
25 (7.6) 50 (15.2) 75 (22.9) 100 (30.5)
Recommended
Circuit A Suction
Circuit Band Liquid
Circuit A LineCircuitSizes:
B Circuit A Circuit B Circuit A Circuit B
ACUM CADX
Liquid Suction Liquid Suction Liquid Suction Liquid
PIPE Suction
LENGTH - FEET (m)Liquid Suction Liquid Suction Liquid Suction Liquid Suction
Models
055LCE 055LCE 1/2 25 7/8 - 7.6)- 1/2 7/8 50 (15.2)- - 1/2 75 (22.9)
7/8 - - 100 1/2 30.5)
1 1/8 - -
Circuit 1 Circuit 2 Circuit 1 Circuit 2 Circuit 1 Circuit 2 Circuit 1 Circuit 2
070LCE
AUMR 070LCE
CADX 1/2 7/8 - - 1/2 1 1/8 - - 1/2 1 1/8 - - 5/8 1 1/8 - -
Liquid Suction Liquid Suction Liquid Suction Liquid Suction Liquid Suction Liquid Suction Liquid Suction Liquid Suction
080LCE
055G1
080LCE
055AG1
1/2
1/2
7/8
7/8
- - - - 1/2 1/2 1 1/8
7/8
-- -
- 1/2
1/2
7/8
1 1/8
-
-- - 1 1/85/8
1/2 -
1 1/8
-
- -
100LCE
070G1 100LCE
070AG1 1/2
1/2 1 1/8
7/8 - - - - 1/2 1/2 1 1/8
1 1/8 -- -- 1/2 5/8 1 1/8 1 1/8 - -- 1/2- 1 1/85/8 - 1 3/8 - - -
110LCE
080G1 110LCE
080AG1 1/21/2 1 1/87/8 - - - - 5/8 1/2 1 1/81 1/8 -- -- 1/2 5/8 1 1/8 1 1/8 - -- 5/8- 1 1/85/8 - 1 3/8 - - -
090G1
120LCE 090AG1
120LCE 5/81/2 1 1/81 1/8 - - - - 5/8 1/2 1 1/81 1/8 -- -- 5/8 5/8 1 1/8 1 3/8 - -- 5/8- 1 3/85/8 - 1 3/8 - - -
100G1
130LCE 100AG1
130LCE 1/21/2 7/81 1/8 1/2 - 7/8 - 1/2 5/8 1 1/81 1/8 1/2- 1- 1/8 5/8 1/2 1 1/8 1 1/8 - 1/2- 5/8
1 1/8 1 3/85/8 - 1 1/8 - 5/8 1 1/8
120G1 120AG1 5/8 1 1/8 - - 5/8 1 1/8 - - 5/8 1 3/8 - - 5/8 1 3/8 - -
160LCE 160LCE 1/2 7/8 1/2 7/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 5/8 1 1/8 5/8 1 1/8
130G1 130AG1 1/2 7/8 1/2 7/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 5/8 1 1/8 5/8 1 1/8
180LCE 180LCE 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 5/8 1 1/8 5/8 1 1/8 5/8 1 3/8 5/8 1 3/8
150G1 150AG1 1/2 7/8 1/2 7/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8
200LCE
180G1 200LCE
180AG1 1/21/2 1 1/81 1/8 1/2 1/2 1 1/8 1 1/8 5/8 1/2 1 1/81 1/8 5/8
1/2 1 1/8
1 1/8 5/8 5/8 1 1/8 1 1/8 5/8 5/8
1 1/8 1 1/8
5/8 1 3/85/8 5/8 1 3/8 1 3/8 5/8 1 3/8

240LCE
200G1 240LCE
200AG1 5/81/2 1 1/81 1/8 5/8 1/2 1 1/8 1 1/8 5/8 5/8 1 1/81 1/8 5/8
5/8 1 1/8
1 1/8 5/8 5/8 1 1/8 1 3/8 5/8 5/8
1 1/8 1 3/8
5/8 1 3/85/8 5/8 1 3/8 1 3/8 5/8 1 3/8

230G1
280LCE 230AG1
280LCE 5/85/8 1 1/81 1/8 5/8 5/8 1 1/8 1 1/8 5/8 5/8 1 1/81 1/8 5/8
5/8 1 1/8
1 1/8 5/8 5/8 1 3/8 1 3/8 5/8 1 3/8
5/8 5/8
1 3/8 1 3/83/4 5/8 1 3/8 1 3/8 3/4 1 3/8
260G1 260AG1 5/8 1 1/8 5/8 1 1/8 5/8 1 1/8 5/8 1 1/8 5/8 1 3/8 5/8 1 3/8 3/4 1 3/8 3/4 1 3/8

Notes : Table 19
1. Pipe diameters are based on equivalent length of copper tubing sizes.
2. Pipe sizes are based on 2°F (1.1°C) or less temperature losses for liquid and suction line in equivalent pipe length.
3. If the condensing unit is below the evaporating unit, the maximum lift should not exceed to 66 feet.
4. Do not exceed 100 feet piping length without checking with SKM.
5. These sizes are for guidance only. For detailed proper piping, refer to recognized piping references like ASHRAE
Guide and Data Book.
The recommended or required suction and liquid line sizes do not necessarily correspond with the refrigerant
connections available on the outdoor or indoor unit. Necessary transformation may be required and it’s field performed.

| 43
APPENDIX- II

Condensing Unit Dimensional Data

Models: AUMR- 055G1 & 070G1


04 03 ACCESS

LEGEND

[152]
6
A1 A3
01 - CONTROL PANEL
02 - COMPRESSOR
03 - CONDENSER FAN
4-Ø0.79 [20] HOLES 04 - CONDENSER COIL
FOR ANCHOR BOLTS
A2
A4

[152]
ALL DIMENSIONS ARE IN INCHES [mm]

6
A1-A4 ARE LOADING POINTS

34 34
[864] [864]

01
[1027]
40.44

[922]
36.3

SUCTION Ø POWER SOURCE


HOLE Ø1.2 [31]
LIQUID Ø CONTROL CIRCUIT
HOLE Ø0.8 [20]

VALVE PLATE

1.6 02 1.6
[50]

ACCESS FOR
2

[40] [40] COMPRESSOR


34
[864]
Figure 28

Models: AUMR- 080G1 & 090G1


ACCESS
[152]

03
6

4-Ø0.79[20] HOLES
FOR ANCHOR BOLTS
A3
A1
LEGEND
01 - CONTROL PANEL
04
02 - COMPRESSOR
03 - CONDENSER FAN
04 - CONDENSER COIL
A2
A4 ALL DIMENSIONS ARE IN INCHES [mm]
A1-A4 ARE LOADING POINTS
[152]
6

45 42.7
[1143] [1085]

01
[1306]
51.42

[1024]
40.3

POWER SOURCE
HOLE Ø1.2[31]

SUCTION Ø CONTROL CIRCUIT


LIQUID Ø HOLE Ø0.8[20]

VALVE PLATE
1.97
[50]

02 ACCESS FOR
COMPRESSOR

Figure 29

44 |
Condensing Unit Dimensional Data

Models: AUMR- 100G1 & 120G1


ACCESS

[152]
03

[152]6
03

6
4-Ø0.79[20] HOLES
4-Ø0.79
FOR[20] HOLESBOLTS
ANCHOR
FOR ANCHOR BOLTS L E G E N D
A3
A1 A3
A1 LEGEND
01 - CONTROL PANEL
04 02 01 - CONTROL PANEL
- COMPRESSOR
04
03 02 - COMPRESSOR
- CONDENSER FAN
04 03 - CONDENSER
- CONDENSER COILFAN
04 - CONDENSER COIL
A2A2 ALL DIMENSIONS ARE IN INCHES [mm]
A4 A4 A1-A4
ALLARE LOADING POINTS
DIMENSIONS ARE IN INCHES [mm]
A1-A4 ARE LOADING POINTS
[152]
[152]
6
6

45 42.7
45 42.7
[1143] [1085]
[1143] [1085]

01
01
[1306]
51.42
[1509]
59.41

[1024]
40.3
[1227]
48.3

POWER SOURCE
HOLE Ø1.2[31]
POWER SOURCE
HOLE Ø1.2[31]
SUCTION Ø CONTROL CIRCUIT
LIQUID HOLE
CONTROL Ø0.8[20]
CIRCUIT
SUCTION Ø Ø
LIQUIDPLATE
Ø HOLE Ø0.8[20]
VALVE
VALVE PLATE
[50]1.97
[50]

02 ACCESS FOR
1.97

02 COMPRESSOR
ACCESS FOR
COMPRESSOR Figure 30

Models: AUMR- 130G1


03
[254]
10

A3
A1
04 4-Ø0.79[20] HOLES
FOR ANCHOR BOLTS
LEGEND
01 - CONTROL PANEL
02 - COMPRESSOR
03 - CONDENSER FAN
04 - CONDENSER COIL

ALL DIMENSIONS ARE IN INCHES [mm]


A2 A4 A1-A4 ARE LOADING POINTS
[254]
10

8
[203]

40 68
[1016] [1727]

01
[922]
[1077]

36.3
42.41

SUCTION Ø POWER SOURCE


HOLE Ø1.6[40]
LIQUID Ø
CONTROL CIRCUIT
SUCTION Ø HOLE Ø1.2[31]
LIQUID Ø
VALVE PLATE

02 ACCESS
[100]
3.94

Figure 31

| 45
Condensing Unit Dimensional Data

Models:AUMR- 150G1 & 180G1

03
[254]
10

A3
A1
4-Ø0.79[20] HOLES
04 FOR ANCHOR BOLTS

LEGEND
01 - CONTROL PANEL
02 - COMPRESSOR
03 - CONDENSER FAN
04 - CONDENSER COIL

ALL DIMENSIONS ARE IN INCHES [mm]


A1-A4 ARE LOADING POINTS

A2 A4
[254]
10

6
[152]
45 86
[1143] [2184]

01
[1356]
53.4

[1024]
40.3

POWER SOURCE
SUCTION Ø HOLE Ø1.6[40]
LIQUID Ø CONTROL CIRCUIT
SUCTION Ø HOLE Ø1.2[31]
LIQUID Ø
VALVE PLATE

02 ACCESS
[100]

RIGGING HOLES
3.94

Ø0.79 [20] x 4Nos.

Figure 32

Models: AUMR- 200G1 & 230G1


03
[254]
10

A3
A1
4-Ø0.79[20] HOLES
04 FOR ANCHOR BOLTS

LEGEND
01 - CONTROL PANEL
02 - COMPRESSOR
03 - CONDENSER FAN
04 - CONDENSER COIL

ALL DIMENSIONS ARE IN INCHES [mm]


A1-A4 ARE LOADING POINTS

A2 A4
[254]
10

6
45 86
[152]
[1143] [2184]

01
[1559]
61.4

[1227]
48.3

POWER SOURCE
SUCTION Ø HOLE Ø1.6[40]
LIQUID Ø CONTROL CIRCUIT
SUCTION Ø HOLE Ø1.2[31]
LIQUID Ø
VALVE PLATE

02 ACCESS
[100]

RIGGING HOLES
3.94

Ø0.79 [20] x 4Nos.


Figure 33

46 |
Condensing Unit Dimensional Data
Models: AUMR- 260G1

03

[254]
10
A3
A1
4-Ø0.79[20] HOLES
04 FOR ANCHOR BOLTS
LEGEND
01 - CONTROL PANEL
02 - COMPRESSOR
03 - CONDENSER FAN
04 - CONDENSER COIL

ALL DIMENSIONS ARE IN INCHES [mm]


A1-A4 ARE LOADING POINTS

A2 A4
[254]
10

6
45 [152] 86
[1143] [2184]

01
[1610]
63.4

[1227]
48.3

POWER SOURCE
SUCTION Ø HOLE Ø1.6[40]
LIQUID Ø CONTROL CIRCUIT
SUCTION Ø HOLE Ø1.2[31]
LIQUID Ø
VALVE PLATE

02 ACCESS
[100]

RIGGING HOLES
3.94

Ø0.79 [20] x 4Nos.

Figure 34

| 47
Air Handling Unit Dimensional Data

Models: CADX-055AG1 to 120AG1

LEGEND 1.5 0.7

[50]
2
ACCESS
01 - EVAPORATOR FAN [38] [19]
02 - EVAPORATOR FAN MOTOR A3
03 - EVAPORATOR COIL A1
4-Ø0.5 (13)
04 - 1"THK. FLAT FILTER MOUNTING HOLES

DIMENSIONS
Model
CADX
L W H A B C D E F J G

B
45 48 26.2 25 39.2 21.4 17.48 17.48 2.7 11.38 13.03
055AG1
[1143] [1219] [665] [635] [996] [544] [444] [444] [68] [289] [331]
45 55 25.2 24 47 21.4 19.72 19.72 2.2 13.43 15.55
070AG1
[1143] [1397] [640] [610] [1194] [544] [501] [501] [57] [341] [395]

080AG1 FILTER
REMOVAL
50 56 28.2 27 47 23.3 20.2 20.2 3.5 13.43 15.55
090AG1
[1270] [1422] [716] [686] [1194] [592] [514] [514] [89] [341] [395]

Table 20
A2 A4
100AG1
ACCESS
60 60 31.2 30 50.5 26.8 20.7 20.7 2.5 15.91 18.54
* 120AG1 [1524] [1524] [792] [762] [1283] [681] [526] [526] [63] [404] [471]

*USE DRAIN SIZE Ø1[25] FOR MODEL 120AG1


W ALL DIMENSIONS ARE IN INCHES[MM] 1 L
[25]
D G E
F
01 02 03 04
J

S/A
[83]
3.3
A
H

C
CABLE ENTRY
2.5 LIQ. Ø SUC. Ø
DRAINØ3/4 [19]
[30]
1.2

[63]

Figure 35

Models: CADX-130AG1 to 260AG1


DIMENSIONS
Model
CADX
4-Ø0.5 (13)
1.5 .7
L W H A B C D E F J G H1 MOUNTING HOLES
[38] [19]
ACCESS
[50]
2

60 70 31.2 30 62.6 26.8 25.7 25.7 2.5 15.91 18.54 1.2


* 130AG1 A3
[1524] [1778] [792] [762] [1589] [681] [653] [653] [63] [404] [471] [30]
A1
60 70 33.2 32 62.6 28.8 13.2 13.2 9 13.43 43.7 1.2
150AG1
[1524] [1778] [843] [813] [1589] [732] [334] [334] [229] [341] [1109] [30]

180AG1
60 80 33.2 32 69.9 28.8 18.2 18.2 9 13.43 43.7 1.2
[1524] [2032] [843] [813] [1775] [732] [461] [461] [229] [341] [1109] [30]
200AG1
Table 21

230AG1
61.4 92 35.2 33.5 81.7 28.8 19.86 19.86 6 15.91 52.3 1.8
[1560] [2337] [895] [850] [2074] [732] [504] [504] [152] [404] [1328] [45]
260AG1
B

ALL DIMENSIONS ARE IN INCHES[MM]

LEGEND
01 - EVAPORATOR FAN
02 - EVAPORATOR FAN MOTOR
03 - EVAPORATOR COIL FILTER
REMOVAL
04 - 1"THK. FLAT FILTER

ALL DIMENSIONS ARE IN INCHES [mm] A2 A4


A1-A4 ARE LOADING POINTS
ACCESS
* MODEL 130AG1 WITH SINGLE BLOWER FAN

W
1 L
[25]
D G E

01 02 03
F

04

S/A
J
A

C
H

2.5
[83]
3.3
H1

[63] DRAINØ1[25]
CABLE ENTRY SUC.Ø1 SUC.Ø 2
LIQ.Ø 1 LIQ.Ø 2

Figure 36

48 |
APPENDIX- III
ELECTRICAL DATA

Power Supply: 380~415V/3Ph/50Hz


Model Unit Characteristic Compressor Condenser Fan Motor Model Evaporator Fan Motor
AUMR CADX
MFA MCA ICF QTY RLA LRA QTY FLA LRA FLA LRA
055G1 32 17 80 1 11 74 1 1.2 3.6 055AG1 1.5 11.6
070G1 40 21 106 1 14 100 1 1.2 3.6 070AG1 1.5 11.6
080G1 40 22 112 1 14 101 1 2.2 9.0 080AG1 1.5 11.6
090G1 40 25 106 1 16 95 1 2.2 9.0 090AG1 1.9 14.3
100G1 50 29 123 1 19 111 1 2.2 9.0 100AG1 2.7 16.5
120G1 50 30 130 1 20 118 1 2.2 9.0 120AG1 2.7 16.5
130G1 50 33 94 2 12 74 2 1.2 3.6 130AG1 2.7 16.5
150G1 63 39 128 2 14 100 2 2.2 9.0 150AG1 2.7 16.5
180G1 63 44 126 2 16 95 2 2.2 9.0 180AG1 3.6 22.5
200G1 80 52 146 2 19 111 2 2.2 9.0 200AG1 4.3 32.3
230G1 80 54 154 2 20 118 2 2.2 9.0 230AG1 4.3 32.3
260G1 100 62 167 2 21 118 2 4.0 16.5 260AG1 6.7 42.8

Table 22

Legend
MFA Maximum Fuse Amps (for fuse sizing), complies with RLA Rated Load Amps. (at worst operating condition)
NEC Article 440-22 & 430-52. LRA Locked Rotor Amps
FLA Full Load Amps
MCA Minimum Circuit Amps.(for wire sizing), complies with
NEC article 440-33.
ICF Maximum Instantaneous Current Flow

Note :
Voltage imbalance not to exceed ± 2 % of the rated voltage

| 49
50 |
FDS ( BY OTHERS ) POWER SUPPLY (V/Ph/hZ)
-XM
LEGEND
_____ FIELD CONNECTIONS & FIELD
SUPPLIED DEVICES
SS FDS FUSED DISCONNECT SWITCH
LPS LOW PRESSURE SWITCH
HPS HIGH PRESSURE SWITCH
-K1 -K2
CS CONTROL SWITCH
CCH CRANK CASE HEATER
-OLR F MINIATURE CIRCUIT BREAKER
FIELD WIRING EFM EVAPORATOR FAN MOTOR
(BY OTHERS)
OLR OVER LOAD PROTECTOR
CFM CONDENSER FAN MOTOR
CM COMPRESSOR MOTOR
K CONTACTOR
XM POWER TERMINAL BLOCK
L1 L2 L3
X2 CONTROL TERMINALS BLOCK
SV SOLENOID VALVE
-F TFR TRANSFORMER
TK THERMAL OVERLOAD PROTECTION

M M M
3~ 3~ 3~

-CM -CFM -EFM


INDOOR UNIT

-K1 -K2
AC EFM
APPENDIX- IV

Figure 37
SEC1

-ECB
CM1
P1
IN-FAN
HTR1
HTR2
X1
O-FAN1

-DOs
ID

P-COM1
OD

-TFR
Typical Wiring Diagram(WITH SINGLE COMPRESSOR)

-X2
BLK
BLK
WHITE
WHITE

RLY1
RLY2
RLY3
RLY4
RLY5
RLY6
RLY7

ECB
SEC1

10V 24V

S1 DIP SWITCH
TFR

SEQ. CONTROL
4
3
2
1

220~
PRI1

ON OFF 240VAC
RED
RED

* 1 TEST MODE NORMAL MODE


ON
T5A L250V

CCH
2 COMP.1 LEAD BALANCE MODE
OFF 1 2 3 4 3 PDS ENBL PDS DISBL

S1 4 SINGLE STAGE * DUAL STAGE


F1

-K1
POWER DIs THERMOS
N
ON/OFF ON/OFF HP1 HP1 LP1 LP1
R C G Y1 Y2 W1 W2
L

X2
-S P P
NO
ON/OFF
-HPS -LPS
-OLR R C G Y
THERMOSTAT
(BY OTHERS)
FDS ( BY OTHERS )
-XM POWER SUPPLY (V/Ph/hZ)

LEGEND
_____ FIELD CONNECTIONS & FIELD
SS
SUPPLIED DEVICES
FDS FUSED DISCONNECT SWITCH
LPS LOW PRESSURE SWITCH
-K5 HPS HIGH PRESSURE SWITCH
-K1 -K2 CS CONTROL SWITCH
-K3 -K4 CCH CRANK CASE HEATER
-OLR F MINIATURE CIRCUIT BREAKER
EFM EVAPORATOR FAN MOTOR
OLR OVER LOAD PROTECTOR
FIELD WIRING
(BY OTHERS) CFM CONDENSER FAN MOTOR
CM COMPRESSOR MOTOR
K CONTACTOR
L1 L2 L3 XM POWER TERMINAL BLOCK
X2 CONTROL TERMINALS BLOCK
-F SV SOLENOID VALVE
TFR TRANSFORMER
M M M M M TK THERMAL OVERLOAD PROTECTION
3~ 3~ 3~ 3~ 3~
Θ Θ

TK1.1
TK1.2
TK2.1
TK2.2
-CM1 -CM2 -EFM
-CFM1 -CFM2 INDOOR UNIT

-K1 -K2 -K5 -K3 -K4


AC BC EFM ABF.1 ABF.2

TK1.1 TK2.1

TK1.2 TK2.2

P P

-FCS1 -FCS2
SEC1

-ECB
CM1
CM2
P1
P2
IN-FAN
HTR1
HTR2
X1
X2
O-FAN1
O-FAN2

-DOs
ID

P-COM1
OD

-TFR
-X2
BLK
BLK
WHITE
WHITE

RLY1
RLY2
RLY3
RLY4
RLY5
RLY6
RLY7
RLY8
RLY9
RLY10
RLY11
Typical Wiring Diagram(WITH DOUBLE COMPRESSOR)

ECB
SEC1

10V 24V

S1 DIP SWITCH
TFR

SEQ. CONTROL
4
3
2
1

220~
PRI1

ON OFF 240VAC
RED
RED

1 TEST MODE NORMAL MODE


ON
T5A L250V
2 COMP.1 LEAD BALANCE MODE
OFF 1 2 3 4

CCH1
3 PDS ENBL PDS DISBL

-CCH2
S1 4 SINGLE STAGE DUAL STAGE
F1

-K1 -K2
POWER DIs THERMOS
N1
ON/OFF ON/OFF HP1 HP1 HP2 HP2 LP1 LP1 LP2 LP2
R C G Y1 Y2 W1 W2
L1

P P P P
-S
ON/OFF -HPS1 -HPS2 -LPS1 -LPS2 X2

-OLR
R C G Y1 Y2
THERMOSTAT
(BY OTHERS)

| 51
APPENDIX- V

Spare Parts

AUMRG1

CADX-AG1

Figure 38

52 |
APPENDIX- VI

P-T Chart
All temperatures and pressures are shown at sea level.
Pressures are listed as psig, except (*) indicates inches in mercury vacuum.

ºF ºC R-22 R-410A R-407C R134a ºF ºC R-22 R-410A R-407C R134a ºF ºC R-22 R-410A R-407C R134a

-60 -51.1 *11.9 *0.9 *16.0 *21.6 12 -11.1 34.8 65.4 29.0 13.2 42.0 5.6 71.5 123.6 64.6 37.0
-55 -48.3 *9.2 1.8 *13.7 *20.2 13 -10.6 35.8 67.0 29.9 13.8 43.0 6.1 73.0 125.9 66.1 38.0
-50 -45.6 *6.1 4.3 *11.1 *18.6 14 -10.0 36.8 68.6 30.9 14.4 44.0 6.7 74.5 128.3 67.6 39.0
-45 -42.8 *2.7 7.0 *8.1 *16.7 15 -9.4 37.8 70.2 31.8 15.1 45.0 7.2 76.1 130.7 69.1 40.0
-40 -40.0 0.6 10.1 *4.8 *14.7 16 -8.9 38.8 71.9 32.8 15.7 46.0 7.8 77.6 133.2 70.6 41.1
-35 -37.2 2.6 13.5 *1.1 *12.3 17 -8.3 39.9 73.5 33.8 16.4 47.0 8.3 79.2 135.6 72.2 42.2
-30 -34.4 4.9 17.2 1.5 *9.7 18 -7.8 40.9 75.2 34.8 17.1 48.0 8.9 80.8 138.2 73.8 43.2
-25 -31.7 7.5 21.4 3.7 *6.8 19 -7.2 42.0 77.0 35.9 17.7 49.0 9.4 82.4 140.7 75.4 44.3
-20 -28.9 10.2 25.9 6.2 *3.6 20 -6.7 43.1 78.7 36.9 18.4 50.0 10.0 84.1 143.3 77.1 45.4
-18 -27.8 11.4 27.8 7.2 *2.2 21 -6.1 44.2 80.5 38.0 19.2 55.0 12.8 92.6 156.6 106.0 51.2
-16 -26.7 12.6 29.7 8.4 *0.7 22 -5.6 45.3 82.3 39.1 19.9 60.0 15.6 101.6 170.7 116.2 57.4
-14 -25.6 13.9 31.8 9.5 0.4 23 -5.0 46.5 84.1 40.2 20.6 65.0 18.3 111.3 185.7 127.0 64.0
-12 -24.4 15.2 33.9 10.7 1.2 24 -4.4 47.6 85.9 41.3 21.4 70.0 21.1 121.5 201.5 138.5 71.1
-10 -23.3 16.5 36.1 11.9 2.0 25 -3.9 48.8 87.8 42.4 22.1 75.0 23.9 132.2 218.2 150.6 78.6
-8 -22.2 17.9 38.4 13.2 2.8 26 -3.3 50.0 89.7 43.6 22.9 80.0 26.7 143.7 235.9 163.5 86.7
-6 -21.1 19.4 40.7 14.6 3.7 27 -2.8 51.2 91.6 44.7 23.7 85.0 29.4 155.7 254.6 177.0 95.2
-4 -20.0 20.9 43.1 15.9 4.6 28 -2.2 52.4 93.5 45.9 24.5 90.0 32.2 168.4 274.3 191.3 104.3
-2 -18.9 22.4 45.6 17.4 5.5 29 -1.7 53.7 95.5 47.1 25.3 95.0 35.0 181.9 295.0 206.4 113.9
0 -17.8 24.0 48.2 18.9 6.5 30 -1.1 54.9 97.5 48.4 26.1 100.0 37.8 196.0 316.9 222.3 124.1
1 -17.2 24.8 49.5 19.6 7.0 31 -0.6 56.2 99.5 49.6 26.9 105.0 40.6 210.8 339.9 239.0 134.9
2 -16.7 25.7 50.9 20.4 7.5 32 0.0 57.5 101.6 50.9 27.8 110.0 43.3 226.4 364.1 256.5 146.3
3 -16.1 26.5 52.2 21.2 8.0 33 0.6 58.8 103.6 52.1 28.6 115.0 46.1 242.8 389.6 274.9 158.4
4 -15.6 27.4 53.6 22.0 8.6 34 1.1 60.2 105.7 53.4 29.5 120.0 48.9 260.0 416.4 294.2 171.1
5 -15.0 28.3 55.0 22.8 9.1 35 1.7 61.5 107.9 54.8 30.4 125.0 51.7 278.1 444.5 314.5 184.5
6 -14.4 29.1 56.4 23.7 9.7 36 2.2 62.9 110.0 56.1 31.3 130.0 54.4 297.0 474.0 335.7 198.7
7 -13.9 30.0 57.9 24.5 10.2 37 2.8 64.3 112.2 57.5 32.2 135.0 57.2 316.7 505.0 357.8 213.5
8 -13.3 31.0 59.3 25.4 10.8 38 3.3 65.7 114.4 58.9 33.1 140.0 60.0 337.4 537.6 380.9 229.2
9 -12.8 31.9 60.8 26.2 11.4 39 3.9 67.1 116.7 60.3 34.1 145.0 62.8 359.1 571.7 405.1 245.6
10 -12.2 32.8 62.3 27.1 12.0 40 4.4 68.6 118.9 61.7 35.0 150.0 65.6 381.7 607.6 430.3 262.8
11 -11.7 33.8 63.9 28.0 12.6 41 5.0 70.0 121.2 63.1 36.0 155.0 68.3 405.4 645.2 456.6 281.0
Table 23
Note: To determine subcooling for R-407C, use bubble point values (temperatures above 50 o
F, shown with
shaded gray background).
To determine superheat for R-407C, use dew point values (temperature 50 oF and below)

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54 |
UAE Factory & Head Office
P.O Box: 6004, Sharjah, United Arab Emirates
Tel: +9716 514 3333
Fax: +9716 514 3300
Toll Free Number: 800 MYSKM (69756)

KSA Factory & Head Office


Warranty – Terms & Conditions C.R. 2050038465, Dammam, KSA
Phone + 966-3-8123332/4/5
Fax + 966-3-8123337
P.O.Box (20539) Al-Khobar 31952

Should the equipment fail to meet warranty within coverage period– due to any manufacturing defect and provided the original
owner notifies the Company or its authorized representative within 7 days of the discovery of such failure. The Company shall at
It option, replace or repair any defective part thereof.

GENERAL CONDITIONS
18
This warranty is subject to the following terms and conditions:

1. Warranty constitutes the owner’s sole remedy. It is given in lieu of all other warranties. There is no implied warranty of merchantability or
Fitness for a particular purpose. In no event and under no circumstance shall the company be liable for incidental, indirect, special,
Contingent, or consequential damages of whatsoever nature and caused for whatsoever reason, whether the theory be in breach of this
or any warranty negligenceor strict liability in tort.

2. This warranty applies only to the original owner, and with respect to the original installation.
3. No changes in this warranty, or in the terms and conditions herein, shall be valid unless confirmed in writing and signed by an authorized
Officer of the Company, and carrying the company stamp.

4. This warranty includes replacement of parts/repair (wherever applicable) – based on Coverage & Product-line.

5. The Warranty does not cover any consumables nor any wear & tear parts - Refrigerant gas, fluids, oil, lifting of
Compressor/cooler/condenser and expendable items such as filters, belts etc.

6. The Company shall have no obligation under this warranty, unless the equipment was installed and operated at its specified conditions
And maintained either by SKM or Skilled Professionals in strict accordance with the Company's written recommendations as stipulated in
The “Installation, Operation and Maintenance Manuals”. Warranty is subject to periodic maintenance of equipment and maintaining log
Sheet of operation/maintenance. It requires to be furnished on request of SKM.

7. The Company shall have no obligation under this warranty, if in the opinion of the Company, the equipment was subject to damage in
Transit, deterioration or damage while stored by someone other than the Company, or on the Site, or was improperly maintained, serviced
Or repaired by any third party in such a way as to adversely affect its reliability or if the equipment was subjected to misuse, neglect,
Alterations, accidents, floods, acts of god or if the equipment was operated by a site generator with associated, external to the equipment,
Electrical wiring not in accordance with local codes.

8. The Company shall have no obligation under this warranty, if the equipment serial number has been altered, defaced or removed.

9. This warranty applies only to equipment installed within the boundaries of the company's operating territory.

10. The parts thereof, shall be returned in accordance within structions received from the Company or its authorized representatives. This
warranty shall not include the cost of associated freight or delivery charges. Prior to the return of any such part, due notification must be
Given in writing, to the installation contractor, the Company's authorized representative or direct to the Company.

11. The company shall have no obligation under this warranty, if the Chiller startup was not executed by SKM or its authorized representative
or if water quality reports or chiller schematics are not available with the owners (This clause is applicable for Chillers only).

12. The company does not warrant, in any way, the suitability or fitness, of the supplied equipment for any specific application or the
performance of the equipment to match specific conditions for a specific end-usage. Capacities as catalogued by the Company for its
Equipment are correct subject to normal stated industry standards.

13. Warranty of compressor is applicable only for one-time repair (Semi-Hermetic) or replacement (Hermetic), unless proven it is due to
Manufacturing defect.

14. Any replacement and/or repairs carried by the company under this warranty shall not extend the original equipment warranty beyond the
Stated period of this warranty, unless previously agreed as per Clause-3 above.

15. For additional consideration, if in any case the company is providing an extended warranty on certain products or components thereof,
Then the terms of the extended warranty will be shown on a separate extended warranty statement.

Note: Original Warranty Certificate for products will be issued subject to clearance of payment

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INSTALLATION, OPERATION & MAINTENANCE

Manual # 225-IOM-2023
Supersedes Manual#: 225- IOM- 2022

56 |

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