Industrial Climate Engineering ECUA90 Manuale utente

Chapter 1 Description........................... 5

Chapter 2 Installation......................... 11

Chapter 3 Start-Up ............................. 20

Chapter 4 Troubleshooting ................. 21

Chapter 5 Maintenance....................... 24

Chapter 6 Warranty ............................ 25

ECU Installation & Operation Manual

Vertical Air Conditioners

Part Number 02118 12/2014 NEW

Models ECUA90/120

Manufactured By:

Industrial Climate Engineering™ Division of AIRXCEL®, Inc.

P.O. Box 5104 • Cordele, Georgia 31010

2002 Hoover St. • Cordele, Georgia 31015

(229) 273-9558 • Fax (229) 273-5154

E-mail: [email protected] • Internet: www.acice.com

The most current version of this manual can be found at www.acice.com.

2 ECU 12/2014 NEW

How To Use This Manual

This manual is intended to be a guide to Industrial Climate Engineering's line of vertical air conditioners. It contains

installation, troubleshooting, maintenance, warranty, and application information. The information contained in this

manual is to be used by the installer as a guide only. This manual does not supersede or circumvent any applicable

national or local codes.

If you are installing the air conditioner rst read Chapter 1 and scan the entire manual before beginning the installation as

described in Chapter 2. Chapter 1 contains general, descriptive information and provides an overview which can speed

up the installation process and simplify troubleshooting.

If a malfunction occurs, follow this troubleshooting sequence:

1. Make sure you understand how the air conditioner works (Chapters 1 & 3).

2. Identify and correct installation errors (Chapter 2).

3. Refer to the troubleshooting information in Chapter 4.

If you are still unable to correct the problem, contact the Factory at 1-229-273-9558 for additional assistance.

Please read the following “Important Safety Precautions” before beginning any work.

Important Safety Precautions

1. USE CARE when LIFTING or TRANSPORTING equipment.

2. TRANSPORT the UNIT UPRIGHT. Laying it down on its side may cause oil to leave the compressor and breakage

or damage to other components.

3. TURN ELECTRICAL POWER OFF AT THE breaker or fuse box BEFORE installing or working on the equipment.

LINE VOLTAGES ARE HAZARDOUS or LETHAL.

4. OBSERVE and COMPLY with ALL applicable PLUMBING, ELECTRICAL, and BUILDING CODES and ordi-

nances.

5. SERVICE may be performed ONLY by QUALIFIED and EXPERIENCED PERSONS.

* Wear safety goggles when servicing the refrigeration circuit

* Beware of hot surfaces on refrigerant circuit components

* Beware of sharp edges on sheet metal components

* Use care when recovering or adding refrigerant

6. Use COMMON SENSE - BE SAFETY-CONSCIOUS

This is the safety alert symbol . When you see this symbol on the air conditioning unit and in the instruction manu-

als be alert to the potential for personal injury. Understand the signal word DANGER, WARNING and CAUTION.

These words are used to identify levels of the seriousness of the hazard.

Failure to comply will result in death or severe personal injury and/or property damage.

Failure to comply could result in death or severe personal injury and/or property damage.

Failure to comply could result in minor personal injury and/or property damage.

IMPORTANT is used to point out helpful suggestions that will result in improved installation, reliability or operation.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

!DANGER

!WARNING

!CAUTION

3 ECU 12/2014 NEW

WARNING

• If the information in these instructions are not followed exactly, a re may result

causing property damage, personal injury or loss of life.

• Read all instructions carefully prior to beginning the installation. Do not begin

installation if you do not understand any of the instructions.

• Improper installation, adjustment, alteration, service or maintenance can cause

property damage, personal injury or loss of life.

• Installation and service must be performed by a qualied installer or service agency in

accordance with these instructions and in compliance with all codes and requirements

of authorities having jurisdiction.

INSTALLER: Afx the instructions on the inside of the building adjacent to the

thermostat.

END USER: Retain these instructions for future reference.

Table of Contents

Chapter 1 Air Conditioner Description & Specications

1.1 General Description .................................................................................................................................5

1.2 Model Identication .................................................................................................................................5

1.3 Serial Number Date Code ........................................................................................................................5

1.4 Air Flow, Weights and Filter Sizes...........................................................................................................6

1.5 General Operation ....................................................................................................................................6

1.6 Electronic Control Board Mode of Operation..........................................................................................7

1.7 Optional Controls and Packages ..............................................................................................................8

1.8 Electrical Operation .................................................................................................................................9

Chapter 2 Installation

2.1 Equipment Inspection.............................................................................................................................11

2.2 Installation Requirements.......................................................................................................................11

2.3 Installation Materials ............................................................................................................................12

2.4 Porting and Duct Work ..........................................................................................................................14

2.5 Top Flange Installation ..........................................................................................................................14

2.6 Installing the Lifting Brackets................................................................................................................15

2.7 Mounting the Unit .................................................................................................................................15

2.8 Electrical Connections ...........................................................................................................................16

Chapter 3 Start-Up

3.1 Check-Out of Cooling Cycle .................................................................................................................20

3.2 Check-Out of Heating Cycle..................................................................................................................20

Chapter 4 Troubleshooting

4.1 Overview ................................................................................................................................................21

4.2 Failure Symptoms Guide........................................................................................................................21

4.3 Compressor Troubleshooting .................................................................................................................22

4.4 Control Board Diagnosis........................................................................................................................23

4 ECU 12/2014 NEW

Table of Contents

Chapter 5 Maintenance

5.1 Scheduled Maintenance .........................................................................................................................24

Chapter 6 Warranty

6.1 Limited Product Warranty ......................................................................................................................25

Illustrations

Figure 1. Typical Electrical Schematic.................................................................................................. 10

Figure 2. Top Flange and Lifting Bracket Installation .......................................................................... 15

Figure 3. Wall Mounting Detail............................................................................................................. 16

Figure 4a. Thermostat Connection Diagram ........................................................................................... 19

Figure 4b. CommStat™ 3 Wiring Detail................................................................................................. 19

Tables

Table 1 Cooling Performance and Air Flow ......................................................................................... 6

Table 2 Return Air Filter Sizes.............................................................................................................. 6

Table 3 Shipping Weights & Dimensions ............................................................................................. 6

Table 4 Minimum Clearances ............................................................................................................. 12

Table 5 Voltage Limitations ................................................................................................................ 12

5 ECU 12/2014 NEW

Chapter 1 Description & Specications

1.1 General Description

Industrial Climate Engineering's (ICE) Environmental Control Units (ECU) are a series of vertical

wall-mounted air conditioning systems that provide heating, cooling, and ventilation for electronic

equipment shelters, process control centers, E-Houses, and other applications with high internal heat

gains. The series includes multiple sizes and nominal cooling capacities from 90,000 to 120,000 BTUH.

Resistance heating elements are available in various wattages.

Industrial Climate Engineering ECU's feature an exclusive electronic control board.

The control board consolidates several of the electrical components, improves the air conditioner’s

reliability and has LED’s to indicate operating status and fault conditions to assist the service technician.

A complete description of functions of the control board is in Section 1.6

Other standard components include:

• Hot gas by-pass valve to allow operation in cold temperatures

• Thermal expansion valve to improve both efciency and capacity over a wide range of ambient

temperatures

• Phase monitor to prevent operation if the unit is not properly phased

The ECU's are designed for easy installation and service. Major components are accessible for service

beneath external panels.

All units have internal disconnects. Depending upon state and local code requirements, this feature

may eliminate the need for an external breaker or disconnect.

1.2 Model Identication

The model identication number is found on the data sticker. Rating plate located on side panel.

Cabinet Color

100 = Beige

200 = Gray

(standard)

Environmental

Control Unit

Nominal Cooling

90 = 90,000 BTUH

120 =120,000 BTUH

System Type

Air Conditioner

Electric Heat – kW

000 = No Heat

090 = 9 kW

150 = 15 kW

180 = 18 kW

Power Supply

D = 460V,3ø,60Hz

E = 380V,3ø,50Hz

C = 208/230V,3ø,60Hz

Z = 575V, 3ø,60Hz

Compressor

U = Scroll Compressor

Ventilation

A = No Outside Air

(standard)

C = Economizer

Special Option Code

F = Reverse Air Flow2

I = Factory Installed

Filter Rack Allows

Changing of Filters

from the Return Air

Grille3

Internal Disconnect

A2 = Factory Installed

Internal Disconnect

Refrigerant

A = R410A

D = Dual

Compressors1

ECU D A ••• AC • ••• • • U A2 •••

1The standard conguration is with one compressor. Add "D" to the model number to indicate dual compresssors.

2The standard conguration is with the supply (conditioned) air at the top of the unit and the return air below it. In the reverse air ow conguration, the return

is at the top and the supply air below it.

3Filter acces in the standard conguration is through the hinged, sheet metal panel on the exterior of the air conditioner. The "I" conguration allows access to

the lter from inside the building through the return air grille.

1.3 Serial Number Date Code

A = January E = May J = September D = 2014

B = February F = June K = October E = 2015

C = March G = July L = November F = 2016

D = April H = August M = December

6 ECU 12/2014 NEW

1.4 Weights and Filter Sizes

Complete electrical and performance specications and dimensional drawings are in the Product Data

Sheet.

Model Number ECUA90 ECUA120

Cooling BTUH190,000 120,000

Rated Air Flow (CFM2)3,500 4,000

ESP3@ Rated Conditions 0.30 0.30

1Cooling rated at 95°F (35°C) outdoor and 80°F DB/67° WB (26.5°C DB/19.5°C WB) return air

2CFM=Cubic Feet per Minute

3ESP=External Static Pressure

Ratings are with no outside air. Performance will be affected by altitude.

Ratings are at 230 volts for 208/230 volt units (“C” models), 460 volts for “D” models, 380 volts for “E” models, 575 volts for “Z”

models. Derate performance by 17% for ACE (380v. 3ø, 50 Hz) models

Operation of units at a different voltage from that of the rating point will affect performance and air ow.

Table 1. Cooling Performance and Air Flow Ratings

MODEL Description INCHES MILLIMETERS PART NO. FILTERS PER UNIT MERV RATING

ECUA90/120 Exterior Access Return Air Filter 25" x 16" x 2" 635 x 406

x 51 80137 3 8

ECUA90/120 Interior Access Return Air Filter 15" x 20" x 2" 381 x 508

x 51 92365 3 8

Table 2. Return Air Filter Sizes

MODEL

Unit Weight Shipping

Weight

Shipping Dimensions

Height Width Depth

LBS KG LBS KG Inches MM Inches MM Inches MM

ECUA90 1,053 478.6 1,178 535.5 98 2,489 56 1,422 42 1,067

ECUA120 1,160 527.3 1,285 584.1 98 2,489 56 1,422 48 1,219

Table 3. Shipping Weights & Dimensions

1.5 General Operation

Refrigerant Cycle (Cooling Mode)

The air conditioners use R-410A refrigerant in a conventional vapor-compression refrigeration cycle to

transfer heat from air in an enclosed space to the outside. A motorized impeller assembly blows indoor

air across the evaporator. Cold liquid refrigerant passing through the evaporator is boiled into gas by

heat removed from the air. The warmed refrigerant gas enters the compressor where its temperature

and pressure are increased. The hot refrigerant gas condenses to liquid as heat is transferred to outdoor

air drawn across the condenser by the condenser fan. Liquid refrigerant is metered with a thermal

expansion valve (TXV) into the evaporator to repeat the cycle.

Heating Mode

A wall-mounted thermostat controls the heating cycle of models which incorporate resistance heating

elements. On a call for heat, the thermostat closes the heat relay to energize the indoor fan and the

resistance elements.

7 ECU 12/2014 NEW

1.6 Electronic Control Board Mode of Operation

Normal

24 VAC power must be continuously applied to “R” and “C”. Upon a call for cooling “Y” and with

the high pressure switch (HPS) closed, the compressor will be energized. (Note: See the delay on

make feature.) The compressor will remain energized during the 3 minute timed low pressure by-pass

cycle. If the low pressure switch (LPS) is open after the 3 minute by-pass cycle, the compressor will

de-energize.

Lock-out

If either of the fault conditions (LPS or HPS) occurs twice during the same call for cooling, the control

board will enter into and indicate the lockout mode. In the lockout mode, the compressor is turned off.

If there is a call for indoor air ow “G”, the blower remains energized, the alarm output is energized and

the status LED will blink to indicate which fault has occurred. When the lockout condition is cleared, the

unit will reset if the demand for the thermostat is removed or when the power is reset. With the control

board, the user can now have either normally closed or normally open remote alarm dry contacts. The

air conditioners are factory wired to be normally open.

Delay on Break

If the compressor is de-energized due to a loss of a cooling “Y” call or the rst fault, the unit re-start

will be delayed 3 minutes from the time the contactor is de-energized. (Note: There is no delay on

break if the lockout condition is reset.)

Delay on Make

On initial power up only, the unit will wait 0.03 to 10 minutes from the cooling “Y” call before al-

lowing the contactor to energize. The delay can be adjusted by the DOM wheel on the board. Factory

recommended wait is 3 minutes.

Low Pressure By-Pass Time

When starting, the low pressure switch (LPS) fault condition will be by-passed for 3 minutes before

the contactor is de-energized.

Post Purge

Upon a call for indoor airow “G” the blower will energize immediately. When in the cooling mode,

the blower will remain energized for 10 to 90 seconds (adjustable) after the compressor has been de-

energized. The time period can be changed by fan purge wheel on the board. Factory setting is 90 seconds.

LED Indicator Lights

COLOR TYPE STATUS DESCRIPTION

Green Power Contstant On 24 VAC power has been applied

Red Status Contstant On Normal operation

Red Status 1 Blink High pressure switch has opened twice

Red Status 2 Blinks Low pressure switch has opened twice

High Pressure Switch

The high pressure switch is mounted on the liquid line. It is electrically connected to a lockout circuit

on the board which shuts down the system if the refrigerant pressure rises to 650 PSIG. This protects

the unit if airow through the condenser is blocked or if the outdoor fan motor fails.

Although the contacts of the high pressure switch close when the refrigerant pressure falls to approxi-

mately 450 PSIG, the system must be manually reset once the lockout circuit is activated. A manual

8 ECU 12/2014 NEW

reset is necessary to prevent harmful short-cycling. To reset switch, turn primary power off, then back

on or turn thermostat system switch off, then back on.

Low Pressure Switch

The low pressure switch is mounted on the compressor suction line. It is designed to open if the refrigerant

pressure drops to 40 PSIG; it resets when the pressure rises to 60 PSIG. The switch protects the unit if

airow through the indoor blower is impeded, if the blower motor fails, or if there is a loss of refrigerant.

LEDs

POST PURGE

WHEEL

DELAY ON MAKE

(COMPRESSOR TIME DELAY)

WHEEL

1.7Optional Controls & Packages

Protective Coating Packages

Two corrosion protection packages are offered- one for the condenser section (the Coastal Environmental

package) and the other for the entire unit (the Coat-All Package).

The condenser protection package includes:

• Corrosion resistant fasteners

• Sealed or partially sealed condenser fan motor

• Two layer epoxy/urethane applied to all exposed internal copper and metal in the in the condenser

section

• An impregnated polyurethane on the condenser coil

The Coat-all package includes all of the above but also includes an impregnated polyurethane on the

evaporator coil and the two layer epoxy/urethane on all exterior and interior components and sheet metal.

(Note: the internal sheet metal which is insulated and the internal control box are not coated).

Three Phase Voltage Monitor

Continuously measures the voltage of each of the three phases. The monitor separately senses low and

high voltage, voltage unbalance including phase loss and phase reversal. A red LED glows to indicate

a fault. When all voltages are acceptable a green LED glows. Automatically resets when voltages and

phases are within operating tolerances. Not required on 1ø units.

Dirty Filter Indicator

A diaphragm type of indicator measures the air pressure on either side of the lter and when the pressure

drops below the set point, a red LED is illuminated. The set point is adjustable.

Protective Coil Coatings

Either the condenser or evaporator coil can be coated. For harsh conditions, e.g., power plants, paper mills

or sites were the unit will be exposed to salt water, the condenser coil should be coated. Note: Cooling

capacity may be reduced by up to 5% on units with coated coils.

9 ECU 12/2014 NEW

Cabinet Color and Material

The air conditioners are available in two standard cabinet colors -the standard grey with beige as an

option. The standard cabinet’s sides, top and front panels are constructed of 16 gauge painted steel.

Contact your ICE representative for color chips, custom colors and 316 stainless steel cabinets.

1.8Electrical Operation

The compressor and condenser fan are energized with a contactor controlled by a 24 VAC pilot

signal.

Some compressors incorporate an internal PTC crankcase heater that functions as long as primary power

is available. The heater drives liquid refrigerant from the crankcase and prevents loss of lubrication

caused by oil dilution. Power must be applied to the unit for 24 hours before starting the compressor.

The condenser (outside fan) motor is energized by the same contactor.

The indoor evaporator fan motor is controlled by the fan purge on the electronic control board.

10 ECU 12/2014 NEW

Figure 1. Typical Electrical Schematic

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