Outdoor Cooling System AH3000 (Q Type) User Manual 01

Outdoor Cooling System AH3000(Q Type)

User Manual

Issue

01

Date

2013-04-10

HUAWEI TECHNOLOGIES CO., LTD.

Copyright © Huawei Technologies Co., Ltd. 2013. All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means without prior written consent of Huawei Technologies Co., Ltd.

Trademarks and Permissions and other Huawei trademarks are trademarks of Huawei Technologies Co., Ltd. All other trademarks and trade names mentioned in this document are the property of their respective holders.

Notice The purchased products, services and features are stipulated by the contract made between Huawei and the customer. All or part of the products, services and features described in this document may not be within the purchase scope or the usage scope. Unless otherwise specified in the contract, all statements, information, and recommendations in this document are provided "AS IS" without warranties, guarantees or representations of any kind, either express or implied. The information in this document is subject to change without notice. Every effort has been made in the preparation of this document to ensure accuracy of the contents, but all statements, information, and recommendations in this document do not constitute a warranty of any kind, express or implied.

Huawei Technologies Co., Ltd. Address:

Huawei Industrial Base Bantian, Longgang Shenzhen 518129 People's Republic of China

Website:

http://www.huawei.com

Email:

[email protected]

Issue 01 (2013-04-10)

Huawei Proprietary and Confidential Copyright © Huawei Technologies Co., Ltd.

i

Copyright © Huawei Technologies Co., Ltd. 2013. All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means without prior written consent of Huawei Technologies Co., Ltd.

Trademarks and Permissions and other Huawei trademarks are trademarks of Huawei Technologies Co., Ltd. All other trademarks and trade names mentioned in this document are the property of their respective holders.

Notice The purchased products, services and features are stipulated by the contract made between Huawei and the customer. All or part of the products, services and features described in this document may not be within the purchase scope or the usage scope. Unless otherwise specified in the contract, all statements, information, and recommendations in this document are provided "AS IS" without warranties, guarantees or representations of any kind, either express or implied. The information in this document is subject to change without notice. Every effort has been made in the preparation of this document to ensure accuracy of the contents, but all statements, information, and recommendations in this document do not constitute a warranty of any kind, express or implied.

Huawei Technologies Co., Ltd. Address:

Huawei Industrial Base Bantian, Longgang Shenzhen 518129 People's Republic of China

Website:

http://www.huawei.com

Email:

[email protected]

Issue 01 (2013-04-10)


i

Outdoor Cooling Sys tem AH3000(Q Type) Type) User Manual

About This Document

About This Document Overview This Manual describes notice of use, product composition, working principle, product wiring, operating instructions, routine maintenance, troubleshooting and technical data of AH3000 DC Air conditioner with heat exchanger.

Target Reader This Manual mainly applies to the following engineers: 

Technical support engineer



Maintenance engineer



Market engineer



Service engineer

Modified Records Changes between document issues are cumulative. The latest document issue contains all the changes made in earlier issues.

Issue 01 (2013-04-10) This is the first official release.

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ii

Outdoor Cooling System AH3000(Q Type) User Manual

Content

Content About This Document ....................................................................................................................... ii

1 Notice of Use .................................................................................................................................... 1 2 Product Overview ........................................................................................................................... 2 2.1 Product Appearance.......................................................................................................................................... 2 2.2 Features ............................................................................................................................................................ 2 2.3 Applied Scenario .............................................................................................................. ................................ 3 2.4 Product Nameplate ........................................................ .............................................................. ..................... 3 2.5 Performance Parameters .......................................................... ............................................................... .......... 4 2.6 Cooling Performance Curves ........................................................................................... ................................ 5 2.7 Components...................................................................................................................................................... 5 2.8 Airflow Cycle ................................................................ .............................................................. ..................... 6 2.9 System work princple .............................................................. ............................................................... .......... 6 2.10 User Parameters ............................................................................................................................................. 6 2.11 Cooling set parameters ................................................................................................... ................................ 7 2.12 System Work Logic ................................................................................................................... ..................... 8 2.13 Alarm and Failure Management ..................................................................................... ................................ 9 2.14 Failure Alarm Code List ......................................................................................... ...................................... 10

3 Packaging and Transportation ..................................................................................................... 11 4 Unpacking and Acceptance .......................................................................................................... 12 5 Installation ..................................................................................................................................... 14 5.1 Mechanical Installation .................................................................................................................................. 14 5.2 Electrical installation ............................................................... ............................................................... ........ 14 5.3 Installation of Electrical Wiring ................................................................. .................................................... 15

6 Power-on and Inspection .............................................................................................................. 18 6.1 Inspection before Power-on ................................................................ ............................................................ 18 6.2 Starting up and Running .......................................................... ............................................................... ........ 18 Self-test Running ........................................................................................................................................... 18 Normal Running ................................................................................ ............................................................ 19 6.3 Display Operations ........................................................ .............................................................. ................... 19 Parameter Settings and View ................................................................................ ......................................... 19

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Content

Operation Menu ............................................................................................................................................. 20 Open Level ......................................................... .............................................................. .............................. 20 User Level .......................................................... .............................................................. .............................. 21 Manufacturer Level ................................................................. ............................................................... ........ 22 6.4 Cooling Function Inspection .......................................................................................................................... 22 Inspection Steps ............................................................................................................................................. 22 Normal Judgment of Cooling............................................................. ............................................................ 22

7 Product Maintenance .................................................................................................................... 23 7.1 Routine Maintenance...................................................................................................................................... 23 7.1.1 Tools .......................................................... .............................................................. .............................. 23 7.1.2 Spare Parts ............................................................................................................................................ 24 7.1.3 Maintenance Period............................................................................................................................... 24 7.1.4 Cleaning of Condenser .............................................................. ............................................................ 25 7.2 Common Fault and Alarm Solution............................................................... ................................................. 26 7.3 Part Replacement ........................................................................................................................................... 29 7.3.1 Controller Replacement ........................................................................................................................ 29 7.3.2 Replacement of Internal Circulating Fan ............................................. ................................................. 30 7.3.3 Replacement of External Circulating Fan ................................................................ ............................. 32 7.4 Schematic Diagram for Internal Wiring ................................................................ ......................................... 33

8 Communication Protocol .............................................................................................................. 34

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1 Notice of Use

1

Notice of Use

Please carefully read the product manual before installation, operation and maintenance, and pay attention to warning signs and warning statements about the air conditioner with heat exchanger. Please keep properly after reading all information for future reference.

CAUTION 

All wiring connections must comply with national and local electrical code; voltage, frequency and power capacity must be consistent with the provisions of the use of this product.



The product must be installed by trained professionals.



Don’t upside down, excessive tilt and collision.



Need circuit breaker for both DC and AC power supply.



Grounding connection must be reliable. Grounding wires can’t be connected to gas pipe, water pipe, lightning rod, telephone wire. Otherwise, it causes the electric shock hazard.



Prohibited lead or extend the power line, the prohibition of weight, heating, pull the power line.



Compressor use power input of 220 V AC (or 110 V AC dual live wire). Controller and fans use power input of -48 V DC.



Power inputs of 220 V AC (or 110 V AC dual live wire) and -48 V DC are both on, the equipment works well. Only 220 V AC power input is on and -48 V DC is not on, the whole equipment doesn’t work. Only -48 V DC is on and 220VAC is not on, only fans and heat exchanger work, compressor doesn’t work.

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2 Product Overview

2

Product Overview

2.1 Product Appearance Figure 2-1 Product appearance

2.2 Features 

High reliability with lightning protection and voltage protection and EMC compliance.



Intelligent control



Energy-saving



Package compact design



Integrated air conditioner and heat exchanger into a package



Skilled technology and effective combination



Air conditioner and heat-exchanger are backup each other.

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Outdoor Cooling System AH3000(Q Type) User Manual 

2 Product Overview

Controller DC power input and adopting DC fans, heat-exchanger can still work after AC power failure and compressor failure. DC fans speed can adjust to reduce noise according to ambient and heat load.



Wide voltage range: 220 V AC±15% 50 Hz and supporting 110 V AC 60 Hz dual live cable input.



Offer dry contact and RS485 intelligent communication interface.



With memory functions in case of power-down and calls from start function.

2.3 Applied Scenario Air-Conditioner with Heat-Exchanger is a cooling product developed for cabinets. It is applicable for the scenarios where internal equipment of the cabinet emits a large quantity of heat and needs to be isolated from the outdoor environment completely. The unit integrates the heat pipe exchanger with air conditioner. When the external ambient temperature is lower than the cabinet inner temperature, the heat pipe exchanger takes precedence to work, and realize reduce heat-dissipating consumption.

2.4 Product Nameplate Figure 2-2 Product nameplate

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2 Product Overview

2.5 Performance Parameters Table 2-1 Unit performance Parameter Performance Index

Parameter Value

Rated Voltage

1), 220 V AC 50 Hz; or 110 V AC 60 Hz Dual Live Line 2), -48 V DC

AC Circuit Breaker Capacity (A)

≥16

DC Circuit Breaker Capacity (A)

6

Rated Cooling Capacity (W) (L35/L35)

3000

Rated Power Consumption(W) (L35/L35)

660 (220 V AC); 200 (-48 V DC)

Rated heat exchanger coefficient (W/K) (L45/L35)

120

Rated heat exchanger power input (W) (L45/L35)

200 (-48 V DC)

Refrigerant /VOL

R134a/550g

Working Ambient Range(degC)

-40~+55

Relative Humidity Range (%)

5~95

Storage Ambient Range (degC)

-40~+70

Solar radiation

1120 W/m

Transportation Performance

Adapt to train, car, airplane, shipping and other

2

transportation modes. Max. Noise Level dB(A) (GR487)

65

IP Protection

IPX5

Working altitude(m)

≤4000. While altitude > 2000 m, ambient used will be decreased 1 degC/200m raised.

Environment protection

Comply with RoHS

Certification

CE

Dimension (H x W x D) (mm)

1350 x 655 x 220

Weight (kg)

59

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2 Product Overview

2.6 Cooling Performance Curves Figure 2-3 Cooling performance curves

2.7 Components Figure 2-4 Product Composition Diagram

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2 Product Overview

2.8 Airflow Cycle The Air-Conditioner with Heat-exchanger internal cycle air path drives the hot air from the upside, and discharges the cold air from the downside. The external cycle air path drives the external ambient air from the downside, and discharges the hot air from the upside after heat exchange, shown as Figure 2-5. Figure 2-5 Air flow cycle

2.9 System work princple AH3000 has integrated compressor cooling and heat exchanger cooling. During it works, the internal fan will suck the hot air from the upper inside the cabinet, and then the cooled air will be blown from the lower wind-screen air outlet after flowing through inside heat exchanger and evaporator. The rotating speed of internal fan is controlled by the main controlling according to the temperature in the cabinet and working status. The external fan will suck the air from the lower air inlet, and the air will be blown outlet from outside top air outlet after flowing through the outside heat exchanger and condenser. The working status of AH3000 is that the main controlling panel based on the scheduled program and with reference to the difference between ambient temperature and the temperature in the cabinet, automatically select either heat exchanger or compression type cooling system to independently run or the above two systems running together. When either of the systems fails, the other device will be automatically put into operation to meet the requirements of cooling in the cabinet.

2.10 User Parameters Table 2-2 User parameters

Parameter (Code)

Value Description (Item)

Scope

Default Value

CH

Self-Test

NO, YES

NO

Sta

Start and Stop

ON, OFF

ON

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2 Product Overview

Parameter (Code)

Value Description (Item)

Scope

Default Value

CS1

Cooling Set Point

28~60 degC

40 degC

CS2

Refrigeration Hysteresis

3~7 degC

5 degC

DF1

High and Low Temperature Alarming Hysteresis

3~10 degC

5 degC

HS3

Alarm Set Value of High Temperature Deviation

5~30 degC

25 degC

LS1

Alarm Set Value of Low 10~-15 degC Temperature Absolute Value

-1 degC

LS2

Alarm Set Value of Evaporation Freezing

0 degC

DF2

Alarming Hysteresis of 3~25 degC Evaporator-Freezing

20 degC

DEF

Restore Factory Default NO, YES Value

NO

10~-5 degC

NOTE

The activating method of self-check for AH series is achieved by changing the user’s parameter “CH” to be “YES”.

2.11 Cooling set parameters Table 2-3 Cooling parameter setting parameters

Definition

Parameter Default Code Value

Range

Unit

Setting Point Description

Cooling Set Point

CS1

[28~60]

degC

Cooling Set Point

Refrigeration Hysteresis

CS2

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Unit system cooling start set point at which the compressor and heat exchanger cooling start. 5

[3~7]

degC

Refrigeration Hysteresis Unit system cooling stop point = CS1-CS2= 35degC (default)


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2 Product Overview

2.12 System Work Logic After installation and inspection of the air conditioner, connect with required AC & DC power supplies and the Air conditioner with heat exchanger enters working state. The working logic is as follows.

Air supply running: Air supply running will be start up after power is on 30s late. Internal fan only will run.

Compressor cooling running Cooling start point = CS1 = 40 degC (default) Cooling stop point = CS1-CS2 = 40-5 = 35 degC (default) When the temperature in the cabinet is higher than the temperature of starting set value (CS1, default 40 degC), then the compressor will work. When the compressor runs for cooling, the compressor, the external and internal fans start. The external fan starts 30 seconds later than the compressor, and the internal fan starts 8 seconds later than the compressor. When the temperature in cabinet is lower than 35 degC, the compressor and heat exchanger stop work. External fan stops.

Heat exchanger cooling running When cooling running, 1) The temperature in the cabinet is higher 2 degC than that of outside the cabinet, the heat exchanger and compressor cooling starts working together. 2) When ambient is lower 15 degC than the CS1, the heat exchanger works first. Only both compressor and heat exchanger will work when the heat exchanger is not stopped after 15 minutes later. 3) When the difference of ambient-temperature inside >-2 degC, only compressor cooling works. In case of sensor failure during working process, the Air conditioner with heat exchanger enters the timing working program of ON for 10 minutes and OFF for 3 minutes. Figure 2-6 AH3000 cooling logic

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2 Product Overview

Figure 2-7 Smart work logic

2.13 Alarm and Failure Management The unit provides the following alarm information. Please refer to Table 2-4 Failure List and Failure Report Method. Public alarm dry contact, no alarm output dry contact for closed state, have alarm output dry contact for off state. Contact capacity: impedance load 5 A @ 30 V DC / 5 A @ 277 V AC. Table 2-4 Failure List and Failure Report Method

S.N.

Code

Failure Content

Remarks

1

LE

Evaporator Freezing

Display in LED, Dry contact output and open

2

Y1

High Pressure of Refrigerant

Display in LED, Dry contact no output and close

3

H1

Too High Temperature in the Cabinet


4

LO

Too Low Temperature in the Cabinet


5

FJ

DC Power Alarm


6

Y2

High-pressure Frequent Alarm


7

UL

AC Voltage Abnormal


8

E1

Failure of Temperature Sensor in Cabinet


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Reverse-Connection


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2 Product Overview

S.N.

Code

Failure Content

Remarks

9

E2

Failure of Ambient Temperature Sensor


10

E3

Failure of Evaporator Temperature Sensor

Surface


11

E4

Failure of Condenser Temperature Sensor

Outlet


2.14 Failure Alarm Code List

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3

3 Packaging and Transportation

Packaging and Transportation

Figure 3-1 Packaging Schematic Diagram

This product uses corrugated case for packaging with stable and reliable structure. The internal buffer uses forming modular design, and the material is environmental protection and meets export standards. Modes of packing are divided into four-unit packing and single unit packing. The four-unit packing uses the mode of packing of corrugated cases plus wooden pallets for delivery, and the single unit packing method can also be used for delivery, as the case may be. The bottom of the four-unit packing case sets aside handling base in advance, suitable for mechanical handling, with forklifts, pallet trucks, manual pallet trucks and other tools.

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4

4 Unpacking and Acceptance

Unpacking and Acceptance

Unpacking and Acceptance Please pay attention to safety when removing the packaging, and protective gloves should be worn (preventing from scratching the arms, etc.). Smashing and striking is not allowed to prevent from damaging the goods in the packaging. After removal of the packaging, make sure the equipment is placed vertically without flat wise. Be careful when handling or moving the equipment. Do not make upside down; avoid excessively tilting or collision, and damage the panels of the equipment and cables. If the product is not installed immediately or needs to be transferred to other areas, re-pack the product after inspection (original packaging is recommended). Check whether the equipment packaging is intact, whether the parts are complete in accordance with the packing list and whether all parts have obvious damage. In case of any part missing or damage during inspection, please report to the responsible department immediately. Packing list: one set of air-conditioner, a packing list and an accessory box (including AC and DC power cable, alarm cable).

CAUTION In case of significant deformation for equipment appearance or oil stain, it indicates the possible damage of equipment or the leakage of refrigerant, so professionals should be reported and invited for maintenance. Otherwise, the forced installation and use may lead to serious failure. 



When the package is removed, make sure that the unit is placed vertically. It can’t be placed horizontally or upside down. When the external package is removed, please check carefully whether the unit appearance is damaged or whether there is any oil stain. If any damage is found, please report this with the barcode number on the package to the retailer or Huawei within a week.



If there is no need to install the unit immediately or it needs to be transported to other place, please repack the unit after checking.



In order to protect the environment, it is recommended to recycle the packing cartons.

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4 Unpacking and Acceptance

Packed configurations list Table 4-1 Packed configurations list

No.

Name

Model

Quantity

Unit

1

Air-Conditioner with Heat-Exchanger

AH3000

1

PCS

2

AC power input cable

5.5m

1

PCS

3

DC power input & alarm cable

5.5m

1

PCS

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5 Installation

5

Installation

Introduce the installation and wiring of structural parts of air conditioner.

5.1 Mechanical Installation Figure 5-1 Installation Schematic Diagram

NOTE

Installation Schematic Diagram is only for reference and the users can install in accordance with the actual environment!

5.2 Electrical installation The air conditioner electrical installation includes: 1.

Make sure the unit power is disconnected;

2.

Connect the power cable according to the electrical schematic diagram for wiring;

3.

Check whether any short circuit or open circuit exists on the power supply cable and signal cable with tong-type ammeter.

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5 Installation

CAUTION All the electrical connections should comply with the standards of the national and local electrical codes. Please disconnect all the power supplies for the unit before the installation. Select proper wire diameter and circuit protection device according to the unit nameplate and technical parameters. Figure 5-2 AC power cable

Figure 5-3 DC Power and Alarm Cables

5.3 Installation of Electrical Wiring Figure 5-4 Wiring Schematic Diagram of Air Conditioner

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5 Installation

Figure 5-5 Photo of Air Conditioner Wiring Port

Power input cable includes: AC power input cable and DC power input cable.

CAUTION 

Disconnect all power supply to unit.



Select suitable circuit breaker capacity according to Table 2-1 Unit performance Parameter.



AH3000 used both AC 220 V AC and DC -48 V power supply input.



AC can be connected to dual live wire with 2P circuit breaker.



-48 V DC is for PCB control and fan assembly.



220 V AC is for compressor.



AH3000 has no work and LCD has no power on while -48 V DC is broken or circuit breaker is off.



Compressor has no work while AC power supply is broken or circuit breaker is off.



AC power cable is forbidden to DC power supply.



DC power cable is polarized and forbidden to AC power supply.



Alarm cable is forbidden to AC and DC power supply.

Communication port Communication port adopts RJ45 communication coupler. COM IN port is connected to monitor. COM OUT is connected to cascade unit. Figure 5-6 RS485 communication coupler pin definition RJ45 Pin/color

RJ45 pin function

1 Orange/white

TX+

2 Orange

TX-

4 Blue

RX+

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5 Blue/White

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6 Power-on and Inspection

6

Power-on and Inspection

Introduce the power-on and inspection of air conditioner.

6.1 Inspection before Power-on After completing the installation and electrical connection, please check the following table: Table 6-1 Check List of Air Conditioner before Power-on

S.N.

Inspection Items

1

Assembled screws have been tightened.

2

No obvious obstacles near the internal and external circulating of air inlet and outlet.

3

The power cord is connected correctly and securely, and alarm signal cable is connected correctly.

4

Check the circuit breaker is in line with the requirements of 5.4.

5

First close the AC circuit breaker, and then close the DC circuit breaker.

6

Use a multimeter to check whether the DC supply voltage is normal and complies with the requirements on the nameplate.

6.2 Starting up and Running Self-test Running The artificial self-test procedure can be activated by buttons. Automatically switch back to normal logic control after the self-test is completed, and the self-test process is as follows: 

The compressor runs for 60s and stops for 3s;



The external fan runs for 30s and stops for 3s;



The internal fan runs for 30s and stops for 3s;



The shield pump runs for 10s, then stop for 3s, and then re-connect for 10s;

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Outdoor Cooling System AH3000(Q Type) User Manual 


The audio alarm rings for 10s to complete.

Normal Running The normal running state of air conditioner is described as follows:  

The controller normally displays the temperature inside the cabinet; The controller has no alarm code, and the alarm indicator light is not lit (such as having a buzzer, but the buzzer does not ring);



Dry contact output meets the requirements;



All components operate or stop in accordance with the specified logic;



Components operate stably and the current is steady;



All components operate without abnormal noise.

6.3 Display Operations Parameter Settings and View Figure 6-1 Manual Operator Appearance Schematic Diagram

u （Sel Key ）（down ） Temperature Failure Display Area

Table 6-2 Key function list S.N.

Items

Functions

1

Value Increase Up Key

2

Value Decrease Down Key

3

Confirm and Return Sel

Key

4

Failure Confirmation Sel +Up key

+

5

Enter password setting menu Sel + Down Key

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S.N.


Items

Functions

6

Back to main menu Up key + Down Key

+

NOTE

During use of composite keys “Sel Key

+ Up Key

+ Down Key

”, please first press and hold “Sel Key

“Up Key

or Down Key

” and “Sel Key

”, then press

”.

Operation Menu Operation menus have three levels, namely, open level, user level and manufacturer level;

Open Level Open-level parameters can be viewed without a password, and the information that can be viewed is the value of the temperature sensors and the fault code when the fault occurs. After the power-on, the controller displays “E0”, and waits for about 20 seconds for system starting, and then displays the value of temperature inside the cabinet. This interface is the main interface.

Press “Up Key or Down Key ” on main menu to dis play the codes of Pb2, Pb3, Pb4 and other parameters in order. When the above codes are displayed, pressing “Sel Key

” can view the temperature of various temperature sensors. Repeatedly

pressing “Sel Key

” can return to the previous menu interface. Press “Up Key

” and “Down Key

” at the same time, return to main menu.

In case of failure, pressing “Up Key ” or “Down Key ” on main menu can view alarm code. If no operation is conducted, the manual operator alternatively displays the temperature in cabinet and failure alarm code. Table 6-3 Description of Open Level Parameters

Parameter (Code)

Parameter (Item)

XX.X

Temperature Sensor “1”

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Definition Temperature Sensor in Cabinet

20



Parameter (Code)

Parameter (Item)

Description

Pb2


Ambient Temperature Sensor

Pb3


Evaporator Surface Temperature Sensor

Pb4


Condenser Outlet Temperature Sensor

Definition

User Level User-level parameters need to enter the correct password before the view, and the information that can be viewed is parameters commonly used for the air conditoner.

Press and hold “ Sel Key display Pa1.

Press “Sel Key

” on main menu, then press “Down Key

” to

” to display the figure “0”when displaying code Pa1, press and

hold “Up Key or from “999” to “0”.

” or “Down Key

”. The figure dispalys from “0” to “999”

Input the correct user-level password, then press “Sel Key parameters to view and set the menu.

” to enter user -level

The user password is “123” default. User-level parameters refer to Table User Parameters.

Dispaly “Sta” after entering user -level menu; press “Up Key

” or “Down Key

” to view various user -level parameter codes. If the corresponding parameter values of various codes need to be viewed, press “Sel Key ” once, then the corresponding value is dis played. If it is required to change parameters, on the basis of displaying value, press “Up Key ” or “Down Key

” to adjust to the target value, then press “Sel Key

” to confirm and return to the parameter code.

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Manufacturer Level Manufacturer-level authority is only for the debugging and use before the air conditioner leaves the factory by the manufacturer. In order to prevent misoperation, generally it is not provided to customers.

6.4 Cooling Function Inspection Inspection Steps Use the heating equipment to rise the temperature of the temperature sensor outside the cabinet and remain above the refrigeration point; Use the heating equipment to rise the temperature of the temperature sensor inside the cabinet to the refrigeration point;; Check whether the compressor starts immediately, whether the external fan delays the operation, and whether the internal fan runs at a high speed; Reduce the temperature of temperature sensor inside the cabinet to the refrigeration off point after the refrigeration runs for 3 minutes; View whether the compressor stops running, whether the internal fan runs at a low speed, and whether the external fan stops to delay.

Normal Judgment of Cooling Start cooling; To use the multimeter to check the compressor current is normal; To check whether the air inlet and outlet have temperature difference; To use the controller to check the temperature of the evaporator surface and temperature inside the cabinet; the refrigeration is normal when the temperature of the evaporator surface is less than the temperature inside the cabinet more than 5degC; Determine whether the refrigeration is normal after meeting all the above 4 points

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7 Product Maintenance

7

Product Maintenance

This Chapter describes the maintenance of AH3000 DC Air conditioner with heat exchanger.

7.1 Routine Maintenance It is required to check some maintenance items periodically during the maintenance of the air conditioner.

7.1.1 Tools Table 7-1 Tools Tool Name

Picture

Function

No. 2 Phillips Screwdriver

Remove / Install screws;

T20 Cross Screwdriver

Remove and install screws;

Trumpet “Straight Screwdriver”

Remove and install screws;

Specification: 3X75mm, trumpet Clip-on Ammeter

Detect voltage and current;

Vehicle Air Pump

Equipment of dedusting maintenance (Working hours: 20-30 minutes, gross weight: 2.6kg)

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Tool Name

7 Product Maintenance Picture

Function

High-pressure Cylinder

Dedusting maintenance equipment: (Type: environmental friendly gas tank (fluoride-free type) Capacity: 350mml Weight: 0.43 kg)

Water

Weight ≥25 KG Cleaning method: Use a soft brush with water to scrub up and down, or use the connected pipe to wash up and down, but do not flush the machine to avoid contacting with the electrical device.

7.1.2 Spare Parts Table 7-2 V1.0 Version Spare Parts List

Item

Description

Model

Supplier part number

1

PCO Controller

MPC1QT0X0K(98C523C074)

50311008

2

Expansion board

AH-PCO-AP2.0

50322004

3

Operator

PLDOOSF400

MPC1Q0X0K

50260101

Communication 4

board

FX-CBV1.0

50322009

5

DC power supply

SU60-48S24-EB

50540001

6

Fan

R1G225-AF11-21/A03

50112323

7.1.3 Maintenance Period It is recommended that periodic maintenance is given to equipment once every six months. Maintenance cycle is depended on the air pollution level of different regions; do not use hot water or gasoline-type solvent to clean. The dust may cover the fins of the heat exchanger during the running process of the Air conditioner with heat exchanger, affecting the performance of the heat exchanger and even leading to the shutdown of the Air conditioner with heat exchanger in severe case; therefore, the cleaning and maintenance should be conducted in accordance with the using environment and frequency of refrigeration equipment. Use a brush, compressed air and vacuum cleaner to clean fan blades; use a small brush, compressed air or vacuum cleaners to clean the condenser fins with the compressed air pressure less than 0.5bar;

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7.1.4 Cleaning of Condenser 1.

It is recommended to use the compressed air with 6-7bar to blow the condenser.

Figure 7-1 Blow off dust of heat exchanger

2.

The accumulated dust may fall into the below water accumulation disc during the process of blowing the condenser. Use Phillips screwdriver / pneumatic Phillips screwdriver to remove four cross M5 screws in external circulating wind screen.

Figure 7-2 Remove the external circulating by Phillips screwdriver / pneumatic Phillips screwdriver

Wind Screen

3.

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Remove the external circulating wind screen, blow the dust in water accumulation disc and blow the dust in water accumulation disc with dedusting equipment.


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4.


Finally, cover the wind screen, then tighten the wind screen with T20 cross screwdriver.

7.1.5 Common Fault and Alarm Solution Unit common fault and solution are showed as follows:

In case of alarm, the buzzer sings, and

indicator light is on at the same time; press

for once, the buzzing can be eliminated, but the indicator light will not go out until the alarm is cleared; The cooling system will be locked when the system has frequent high-pressure alarm, at this time, unlock by power off or by pressing

+

.

Table 7-3 Common fault and alarm solution S.N.

Failure Content

Cause Analysis

Troubleshooting Methods

1

C1F

1. Blockage or scaling of condenser;

1. Clean the condenser at regular time;

2. The air conditioner with heat exchanger is suffered from impact for carried wildly;

2. Try to move vertically and gently;

Failure of compressor

3. Increase the device to make the voltage stable;

3. The voltage of AC power is too low or too high; 2

LNF Failure of external fan

1. The working voltage overrun;

1. Adjust the DC voltage to fit for the request;

2. Serious dust environment;

2. Increase the protection mask; 3. Remove the barrier;

3. The fan is stuck; 3

ZFF Failure of internal fan

4

SBF Failure of water pump

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The working voltage overrun;

Adjust the DC voltage to fit for the request;

1. The working voltage overrun;

1. Adjust the DC voltage to fit for the request;

2. The secondary refrigerant is revealed or filled in wrong type.

2. Remove the revealing point, and fill in secondary refrigerant from the original factory;


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S.N.

Failure Content

Cause Analysis

5

LE

1. Short circuit of the internal air circulation;

Freezing of evaporator

2. Failure of internal fan; 3. The cooling system can’t be closed; 4. False alarm of frozen sense circuit;


3. Ensure the appropriate distance between air conditioner and the equipments in cabinets, and increase the intermediate partition in air way of air conditioner inlet and outlet inside the cabinet to avoid short circuit of the air; 4. Replace internal fan; Check whether the main controlling panel and the contact of the relay switch are adhesive; 5. Regularly clean the condenser.

6

Y1 Too high pressure for the refrigerant



2. Failure of condensing fan;

2. Replace the condensing fan;

3. Short circuit of the external circulating air or being blocked; 4. Filling too much refrigerant during maintenance;

7

H1 Too high temperature in cabinet

3. The air inlet and outlet of external enclosure must be separated well, and it must be ensured that there is no close barrier during installation of the field equipment cabinet; 4. Professionals are invited for maintenance, and the appropriate amount of refrigerant is added according to nameplate requirements;



2. Too high ambient temperature;

2. Add the solar protection devices;

3. Failure of cooling system or heat exchanger system;

3. Professionals are invited for inspection and maintenance;

4. Added the equipment with higher heat value in cabinet; 5. Improper setting of temperature of cooling start point;

4. Re-evaluate heat value and adjust; 5. Re-evaluate the set value of temperature at cooling start point and deviation; 6. Check main controlling panel, and replace temperature sensor;

6. False alarm of temperature sensor in cabinet;

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S.N.

Failure Content

Cause Analysis


8

LO

1. Improper setting of working temperature;

1. Re-evaluate the set value of working temperature and deviation;

Too low temperature in cabinet

2. The cooling system can’t be closed; 3. False alarm of temperature sensor in cabinet;

9

Y2 Frequent high-pressure alarm


2. Failure of condensing fan;

2. Replace the condensing fan;

4. Filling too much refrigerant during maintenance;

UL AC voltage deviation

3. Check main controlling panel, and replace temperature sensor;


3. Short circuit of the external circulating air or being blocked;

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2. Check whether the main controlling panel and the contact of the relay switch are adhesive.

1. The capacity of AC power is too limited or the diameter of the power line is not fit for the standard; 2. False alarm of protection board for voltage deviation;

3. The air inlet and outlet of external enclosure must be separated well, and it must be ensured that there is no close barrier during installation of the field equipment cabinet; 4. Professionals are invited for maintenance, and the appropriate amount of refrigerant is added according to nameplate requirements; 1. Change the power line to fit for the capacity; 2. Change the protection board for voltage deviation; 3. Increase stable device for voltage;

3. The power voltage is fluctuant to much which exceeds the given scope; 11

E1 Failure of temperature sensor in cabinet

12

E2 Failure of ambient temperature sensor

13

E3 Failure of evaporator surface temperature sensor

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1. Sensor breakdown or short circuit;

1. Inspect the connections of sensor lines;

2. Damage of sensor;

2. Replace sensor;




2. Replace sensor;




2. Replace sensor;


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S.N.

Failure Content

Cause Analysis


14

E4




2. Replace sensor;

DC power reverse-connection alarm;

Adjust DC power line to be connected correctly;

Failure of outlet temperature sensor of condenser 15

FJ DC power module reverse-connection alarm

7.2 Part Replacement When the temperature controlling device fails, you can replace the temperature controlling device module to troubleshoot, and restore the temperature controlling function.

7.2.1 Controller Replacement “

”

1.

Use Straight Screwdriver to align with the controller gap (in left bottom), i.e. the gap in the left bottom of the controller, to gently pry up, then the enclosure can be removed. The controller set aside a gap for removal in advance

2.

Take out controller enclosure with left hand;

3.

Two fixed screws can be seen after the enclosure is removed;

4.

Use “straight screwdriver ” to align with two fixed screws of the controller, rotate clockwise, then the manual operator can be take out of the air conditioner metal plate.

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Note: It can be OK if the screws are loose, that is, it is not required to remove the screws completely.

NOTE

In the event of return to install, use “straight screwdriver” to align with two fixed screws of the controller, rotate counterclockwise.

5.

The connecting wires and terminals can be seen after the controller is taken out;

6.

Unplug the connectors, then the damaged controller can be replaced;

7.

Install the controller in accordance with the reverse order of steps 1, 2, 3, 4 and 5. Note: Make sure to turn off all power sources before operation.

7.2.2 Replacement of Internal Circulating Fan To listen to the sound of the fan running when the equipment runs. If the sound is continuous and has few fluctuations, it means the fan runs well; otherwise, it will indicate that the fan loses balance, so it should be replaced immediately, but please make sure that all external circuits connected to the cabinet air conditioner are disconnected before replacement. Please make sure you have the following tool and equipment before changing the fan: one Phillips screwdriver or pneumatic screwdriver, one new fan (to ensure that the model is the same with the fan replaced).

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1.

Before commencement of operation, make sure to turn off all power sources, Remove the screws on cover plate (removal of the internal circulating panel).

2.

Disconnect fan terminal.

3.

Use a Phillips screwdriver or pneumatic screwdriver to remove fan mounting plate.

4.

Fix the wiring harness to the fly-over bridge of s ide metal sheet of the main control panel during replacement of internal circulating fan, and finally fix with cable ties.

5.

The excess part of the cable ties is cut with pliers.

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Steps of replacing internal circulating fan are as follows: Before the commencement of operation, make sure to turn off all power sources; Remove the screws on internal circulating panel, and remove the internal circulating panel; Unplug the connectors of internal circulating fan; Then, use Phillips screwdriver to remove the fan from the components, and replace with the fan of the same model; Install the new fan following the reverse order of steps 2.3.4.

7.2.3 Replacement of External Circulating Fan 1.

Use a Phillips screwdriver / pneumatic Phillips screwdriver to remove four screws of external circulating wind screen.

2.

Disconnect fan terminal.

3.

Use a Phillips screwdriver or pneumatic screwdriver in order to remove the mounting plate of fan, the external circulating fan can be replaced.

4.

Install the new fan following the reverse order of steps 1, 2 and 3. Note! Before the commencement of operation, make sure turn off all power sources.

The steps of replacement of external circulating fan are as follows:

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Before the commencement of operation, make sure to turn off all power sources; Remove the screws on cover plate of the external circulating wind screen, and remove the external circulating wind screen; Unplug the connectors of the external circulating fan; Then, use the Phillips screwdriver to remove the fan from the components, and replace with the fan of the same model; Install the new fan following the reverse order of steps 1, 2 and 3.

7.3 Schematic Diagram for Internal Wiring The unit’s schematic diagram for internal wiring is showed in Figure 7-3. Figure 7-3 Schematic diagram for internal wiring

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Outdoor Cooling System AH3000 (Q Type) User Manual 01

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