A - C Unit (Air Innovations) PDF

CH APTER 4: PO W
ER
DI STRI BU TI ON
A/C U N IT ( AIR IN N OVATION S)

OVER VIEW
O utput M odul e
Condensor
Evaparator
Fi gure 4-16
A/C U ni t( Ai rI nnovati ons)
The Ai rI nnovati ons H VAC uni t( P/N 2603-0006)i s a heati ng and ai r-condi ti oni ng system that i s desi gned to m ai nt ai n the ai r tem perature and hum i di ty w i thi n the x-ray generati ng envi ronm ent. The Ai rI nnovati ons H VAC uni ti s a cl osed l oop system ,m eani ng that al lthe ai r suppl i ed to the uni ti s then returned f or recondi ti oni ng.Thi sm i ni mi zes the heat l oad on the H VAC system and al so mi ni mi zes cont am i nati on ofthe el ectroni cs by dustand parti cul ates f rom the am bi entai r .Thi s cl osed ai rl oop passes through a fi l ter l ocated i n the H VAC uni tw i th each pass.The H VAC system i si ntended to operate conti nuousl y,even w hen the CTX 9000 D Sii si ni dl e or of fm ode. NO T E : Although all supporting documentation on the Air Innovations A/C unit indicates a measured voltage of350 VD C,the actual measured voltage is 330 VD C.
CTX 9000 D SiTrai ni ng M anual 66 of378
GE I nV i si on,I nc.Com pany Confi denti al M arch 10,2005
CHAPTER 4: POWER DISTRIBUTION
DESCRIPTION
The HVAC system has two separate refrigeration circuits (situated in series with respect to each other), which allows for greater load shedding when 50% or less of the total cooling power is required (i.e. days when ambient temperatures are approximately 70 F and below). In addition, the two separate refrigeration circuits provide a level of redundancy if one of the circuits should fail. NOTE: At temperatures above 70 F, both circuits are required to maintain setpoint.
Environm entalSpecifications:The system is designed to operate in environments ranging from 15 F to 120 F and with either 60 Hz or 50 Hz power supplies. NOTE: Even w hen the A/C unit is optimally functional, there is no guaranteed temperature setpoint. Indeed, system limits are determined by the follow ing factors:ambient temperature, humidity and pow er specifications ( i.e. w hether the system is operating at 50 H z or 60 H z) .
Tem perature Control :Temperature control is achieved by modulating an electronic EPR (Evaporator Pressure, Regulating) valve installed on circuit #1 (the primary circuit). Circuit #2 operates in an ON/OFF mode controlled by the controller. The controller uses its alarm contacts to turn each compressor on or off. NOTE: If the ambient temperature is very low , the unit may sw itch over to a heating mode. Should this occur, both compressors are automatically locked out of operation and the heater is pulsed to maintain setpoint.
System Indicators:The LEDs and Digital Temperature Controller, mounted on the front of the electric panel, will indicate system status and any faults while the system is powered (even if the ON/OFF switch is turned to OFF). NOTE: The LEDs and Digital Temperature Controller can only be shut dow n via the main pow er breaker located on the front of the electric panel.
GE InVision, Inc. Company Confidential March 10, 2005
CTX 9000 DSi Training Manual 67 of 378
COM PONENTS
Figure 4-17
A/C Unit (Air Innovations)
The system is physically comprised of three separate main assemblies and one sub-assembly (see Figure 4-17):

Evaporator (for more information, see Evaporator on page 68.) Condenser (for more information, see Condenser on page 69.) Electric Panel (for more information, see Electrical Panel on page 71.) Drain Tube Assembly (for more information, see Drain Tube Assembly on page 75.)
Each of these components is installed individually in the CTX 9000 DSi and then connected together with quick connects for refrigerant piping and electrical connections.
EVAPORATOR
Main Components:

Evaporator fan (draw-thru impeller). Evaporator coil (divided into two circuits in series).
Pre-filter. NOTE: The evaporator filter is a 14" x 16" x 1", medium efficiency pleated type U.L. Class 2 filter. The average efficiency is 25 - 30% with an arrestance of 90 - 92% on ASHRAE Standard 52-76. The filter media is high density glass micro fibers laminated to an all glass woven mesh backing.

Two TXV valves. Two filter driers. Two sight glasses. EPR valve (circuit #1). Two air proving switches for filter monitoring and fan safety. Three electric heater elements. Temperature sensor in supply air stream. Four flexible refrigerant hoses for connection to condenser section. Electrical harness for connecting sensors, safeties and power to electrical panel.
Two openings in the evaporator provide for return air and supply air connections to the baffle plate. Return air first passes through the pre-filter and then enters the evaporator coil. It then flows through the rows dedicated to circuit #2 and then those rows dedicated to circuit #1. After leaving the evaporator coil, the air passes over the electric heater elements and then through the fan. Once the return air has left the fan, the air passes over the temperature sensor and then out the supply air opening.
CONDENSER
Main Components:

Two condenser fans. Two compressors. Two condenser coils. Two combination High/Low pressure switches.
Figure 4-18

Pressure Switches
Two push button high pressure switches for alarm indication. Two head pressure control valves. Two refrigerant receivers (welded on top of each other). Q uench valve (circuit #1). Electrical harness for connecting sensors, safeties and power to electrical panel.
Ambient air is drawn into the A/C unit through the evaporator s louvered covers found on both sides of the Input module. A replaceable mesh filter in installed in each louvered cover. The ambient air is drawn through the condenser coils and is then exhausted from the A/C unit through louvered deflector covers on both sides of the Input module. NOTE: The evaporator section is pie shaped to provide air paths to these coils.
Hot condenser air exits the unit via the louvers installed in the base section on the condenser side. Circuit #1 exhausts on the left side and circuit #2 on the right side. Each compressor is dedicated to one circuit. Compressors are turned on and off based on the inputs from the controller. Circuit #1 comes on first (and only as required) to maintain setpoint and, if necessary, circuit #2 comes on for additional cooling capacity. NOTE: The nominal capacity of each circuit is 2 tons.
ELECTRICAL PANEL
Figure 4-19 Main Components:

Electric Panel
Temperature controller. All LED indicators.
Figure 4-20
Temperature Controller and Control LEDs
All breakers.
Figure 4-21

Breakers
All relays. All switches. Siemens LOGO for discreet controls.
Figure 4-22
Siemens LOGO
Quad I/O.
Figure 4-23
Quad I/O (Air Innovations Air Conditioner)
Mitsubishi FR-S540-0.4K-NA Variable Frequency Drive (VFD) to control the evaporator fan.
Figure 4-24
Mitsubishi FR-S540-0.4K-NA Variable Frequency Drive (VFD)
Cables for connecting to evaporator and condenser sections (quad I/O cable for connecting the A/C unit to the CTX 9000 DSi main computer).
Figure 4-25
Controller Cables
The electrical panel controls all functions of the HVAC system as well as provides power and electrical circuit protection to all components.
DRAIN TUB E ASSEMB LY

Main Components:

Pre-formed PVC piping. Kazoo assembly.
Figure 4-26
Drain Tube Assembly
The drain assembly removes the condensate from the evaporator coil and is connected to an external drain or condensate pump. The kazoo allows the system to be self-priming, meaning that condensate will flow properly even if the unit runs with no water in the trap.
OPERATING RANG ES
The HVAC system is designed to operate continuously across a wide variety of ambient environments. The supply air setpoint to achieve these ranges is 60 F (with an allowable control range of +/- 10 F). When the supply air temperature is above 70 F, an alarm signal is sent to the quad I/O. Nonetheless, the A/C unit will continue to operate until manually shut down (if so desired).
Ambient Dry Bulb Maximum 120 F 105 F
Ambient Relative H umidity @ Maximum F 50% RH 50% RH
Ambient Temp Minimum 14 F 14 F
Supply Air Temp Minimum/ Maximum 50 / 70 F 50 / 70 F
Pow er Supply 480 VAC 3 PHASE / 60 Hz 380 VAC 3 PHASE / 50 Hz
S YSTEM SPECIF ICATIONS
System Specifications Construction Weight Construction External Construction Internal Hardware Condensate Drain Condenser Coils 500 lbs. Painted Galvanized and Aluminum Components Galvanized and Stainless Steel Stainless Steel Metric Fasteners Gravity Drain 5 Row Copper Tubes Aluminum fins Coated with Mt. Holly Gold (or equivalent) 6 Row (Circuited 3 and 3 in a Series) Copper Tubes Aluminum fins Coated with Mt. Holly Gold (or equivalent) Direct Drive Motorized Impellers 30/30 Filter on Evaporator Inlet Digital PID Controller Performance Supply Air Volume Nominal Capacity Electrical Heating Coils 800 CFM @ 1.0" wg External Maximum Pressure Circuit #1 = 2 tons Circuit #2 = 2 tons 3 - 2000 W Solid Rod Type
Evaporator Coil
Fans Filter Controller
System Specifications Refrigerant Noise (maximum) Supply Voltage Amperage R-134a 85 dB A-weighted 480 / 3 / 60 Hz VAC or 380 / 3 / 50 Hz VAC 11.4 FLA @ 480V / 60Hz Status LED Indicators Control Circuit Circuit #1 Cooling Circuit #2 Cooling Heater Evaporator Filter Replacement Circuit #1 Low Pressure Circuit #2 Low Pressure Circuit #1 High Pressure Circuit #2 High Pressure Green Green Green Yellow Red Red Red Red Red Agency Approvals North America European Union (CE / LVD EMC) UL recognized to UL1995 / C22.2 no. 236 EN60335-1, 60335-2-24, 55014-1, 61000-3-2, 61000-3-3, 55014-2
THEORY OF OPERATION
The following topics are reviewed in this section:

Startup Sequence on page 78. Normal Running Sequence on page 78. Cooling Control Logic on page 79. Heating Control Logic on page 80. PID Control Functions on page 80.
STARTUP SEQ UENCE
TEMP > AL1 1 Mi nut e
Ci r c ui t#1 " ON"
TEMP > AL2 2 Mi nut es
Ci r c ui t#2 " ON"
ON/ OFF Swi t c h " ON"
Ev ap Fan " ON"
TEMP > AH1 & TEMP < AL1
Ot her " No ac t i on"
TEMP < AH1
Heat er " ON"
Figure 4-27
Startup Sequence
Legend

TEMPTemperature reading of the RKC controller. AL1Alarm Setting for circuit #1 (62.5 F). AL2Alarm Setting for circuit #2 (65.0 F). AH1Alarm #1 Hysteresis (differential gap) compressor #1 (Shut off point is 55.0 F). AH2Alarm #2 Hysteresis (differential gap) compressor #2 (Shut off point is 57.5 F).
NORMAL RUNNING SEQ UENCE
TEMP > AL1 I fc ompr es s orhasbeen of f f or1 mi nut e
Ci r c ui t#1 " ON"
TEMP > AL2 I f c ompr es s orhas been of ff or2 mi nut es
Ci r c ui t#2 " ON"
Ev ap Fan " Runni ng"
TEMP > AH1 & TEMP < AL1
Ot her " No ac t i on"
TEMP < AH1
Heat er " ON"
Figure 4-28
Normal Running Sequence
Legend
TEMPTemperature reading of the RKC controller.

AL1Alarm Setting for circuit #1 (62.5 F). AL2Alarm Setting for circuit #2 (65.0 F). AH1Alarm #1 Hysteresis (differential gap) compressor #1 (Shut off point is 55.0 F). AH2Alarm #2 Hysteresis (differential gap) compressor #2 (Shut off point is 57.5 F).
COOLING CONTROL LOGIC

Consisting of two 2 ton circuits, the cooling control system is a redundant system so that in the event that one of the circuits fails, the other circuit can act as a backup. NOTE: Should the one evaporator fan fail, the system cannot operate.
Circuit Specifications:
Circuit #1 has a capacity control valve that will allow the circuit to throttle back should the entire 2 or 4 tons not be necessary. Circuit #2 does not have capacity control;it provides a full 2 tons of capacity. The cooling system will control at or about the setpoint of 60 F. When the temperature rises to 62.5 F, alarm # 1 of the temperature controller will close and start compressor circuit #1. When the temperature drops to 55 F, circuit #1 will shut off. Should the temperature continue to rise to 65 F, alarm #2 of the controller will close and start circuit #2. When the temperature drops to 57.5 F, circuit #2 will shut off. There is a one minute time delay for circuit #1 and a two minute time delay for circuit #2.
Cooling Control System Operation:

NOTE:
The timers start timing when the compressor has been shut down. As long as circuit #1 has been off for one minute and circuit #2 has been off for two minutes, the compressors will start once the alarm has been activated. Electronic Evaporator Pressure RegulatorThe electronic evaporator pressure regulator (capacity control valveSporlan CDS-9) is a stepper motor controlled valve. The electronic evaporator pressure regulator allows the A/C unit to match the heat load requirements of the CTX 9000 DSi, the ambient temperature as well as any leakage air that may be present. Receiving control signals (5.5 - 20mA) from the temperature controller, the electronic evaporator pressure regulator reduces or increases the amount of suction return gas to compressor circuit #1. When the supply air temperature is at or below 60 F, the valve will begin to close which will reduce the capacity of circuit #1. NOTE: This valve also modulates while circuit #2 is running.
Finally, the temperature controller provides a current (5.5 - 20mA) PID control output to allow the valve to precisely position itself. The output is proportional to the amount of deviation between the temperature and the setpoint and also the rate at which the temperature is either rising or falling and the PID settings programmed into the controller. For more information, see PID Control Functions on page 80.
HEATING CONTROL LOGIC

The heating control system is designed to bring the system up to temperature before the CTX 9000 DSi system is started.
Heating Control System Operation:

The heating control system will control at or about the setpoint of 60 F. If the temperature is below 60 F, and neither compressor is running, the heater will be energized. If the temperature rises to 62.5 F, compressor circuit #1 will come on and automatically disable the heater output circuit.
The three 2 kW heaters (Output #1) are controlled by the RKC temperature controller. The controller outputs a time-proportioned PID (proportional, integral, derivative) on/off DCV control signal which is applied to the 2 Solid State Relays (SSRs). When the control signal is applied to the SSRs, the high voltage (AC) is allowed to pass through to the heater elements. NOTE: The control signal and high voltage circuit are optically isolated from each other.
When the control signal is removed, the SSRs drop out. The amount of on and off time is regulated by:

The amount of deviation between the temperature and the setpoint. The rate at which the temperature is either rising or falling. The cycle time and PID settings programmed into the controller. For more information, see PID Control Functions on page 80.
NOTE:
PID CONTROL FUNCTIONS

Proportional Band (P)
The proportional band parameter regulates the effect of the proportional action. This setting causes the output to change continuously in proportion to the input deviation magnitude. A small proportional band value will (with a small deviation in input) cause a large change in output, and visa versa.
A small proportional band setting will cause control fluctuations or oscillations.
A large proportional band setting will cause a control offset. The smaller the value, the small the offset. If the proportional band value is set to zero, an ON/OFF control will result. As a rule, adj ust for larger numeric values rather than smaller ones. If cycling or oscillating occurs, the value is too small. The longer the derivative time, the stronger the corrective action, and the more likely it is that oscillations will occur. The derivative is OFF when set to zero. For control of fast-response input such as flow and pressure, or of input that fluctuates rapidly, set the derivative to zero. As a rule, adj ust from smaller numeric values to larger ones. If the derivative is too large, very short-period oscillations will result. These oscillations will be much smaller than those caused by the proportional band or integral time and are unlikely to cross the setpoint, but will instead fluctuate above or below it.
When manually setting the proportional band, keep the following in mind.

Oscillations will likely go above and below setpoint.

When manually setting the derivative time, keep the following in mind:

NOTE:
Normal offset cannot be corrected by a proportional band change.
Integral Time (I)
Integral time (I) can be defined as the time required to develop an output change due to integral action that is equal to the change due to proportional action. The integral time (I) will automatically diminish the offset or normal deviation (offset) that cannot be prevented by adj usting the proportional band. The integral time will continuously increase or decrease the output in proportion to the time integral of the deviation from setpoint.

The smaller or shorter the integral time, the faster the output changes, and visa versa. Shortening the integral time, like lowering the proportional band setting, will cause output to oscillate. However, such oscillations will have a longer period than those caused by a small proportional band. As a rule, adj ust from larger numeric values to smaller ones. If the integral time is too small, long-period oscillations will result. These oscillations are likely to go above and below setpoint with a long period.
When manually setting the integral time, keep the following in mind:

Derivative Time (D)
The derivative action is the action that changes the output in proportion to the deviation derivative or rate of change. Just as the proportional and integral action cause the controlled obj ect to approach the setpoint, the derivative time (D) slows this approach to prevent over-shoot.
EVAPORATOR COIL CAPACITY CONTROL

The electronic evaporator pressure regulator (capacity control valveSporlan CDS-9) is a stepper motor controlled valve. This valve controls the evaporator coil capacity from the RKC controller. When cooling output LED (Output 5) on the front of the controller is illuminated, the valve is active. The controller applies a minimum of 5.5 mA output so that the valve will not close completely. (4 mA would close the valve completely.) Its maximum output (fully open, full capacity) is 20 mA and is automatic. The output to the valve is based on the difference between the process value (supply air temperature) and the setpoint. It is a PID controlled output (PID2) and no adjustment or calibration of this valve is required. For more information, see PID Control Functions on page 80.
PRESSURE TEST POINTS

Pressure test points (shrader valves) for a manifold gauge set are located at the end of the compressor/condenser section (on the side of the CTX 9000 DSi opposite the control box).
OPERATING PROCEDURES
Uncrating the A/C Unit

The evaporator, condenser and control box are all shipped on separate skids. Each section is banded to its skidno screws or bolts are used to mount the sections. A heavy tri-wall cardboard covering is installed over each section which is then banded to a skid. To remove the units from their containers, cut the banding and remove the cardboard. Discard the banding and cardboard. Confirm with the site personnel on where to store or dispose of the A/C unit skids.
1. 2. 3.
Inspecting the A/C Unit 1. 2. 3. 4. 5. 6. 7. After uncrating the three sections of the A/C unit, inspect for any visible damage that may have occurred during shipping. Report any damage to the carrier and file a written damage claim. Check for any concealed irregularities by removing all access panels. Check for loose hardware. Ensure that no components inside the A/C unit shifted due to extreme force during shipping. Rotate the three A/C fans to be sure that they spin freely. Check the compressor(s) mounts to be sure they are securely attached.
NOTE:
While shaking the compressor back and forth, ensure that there is no noise. Should you hear any noise, ensure that the compressor(s) mounting are secure.
8.
Inspect the refrigerant flex hoses for signs of damage, kinks or cracks. NOTE: If the insulation on either suction flex line is torn, inspect the line carefully for damage.
9.
Check all other tubing and valves for signs of stress or damage.
10. Inspect the wiring and wiring connectors on the evaporator and condenser section for signs of any damage that may have occurred. NOTE: The male-female spade connectors are very difficult to pull apart. As such, it is highly unlikely that any of these will come apart.
11. Check the interior or exterior of the control box for any signs of damage to the cables, connectors, EMI filter, controller, LED' s etc. 12. Remove the return air filter access panel to ensure the filter is installed properly. 13. Check the entire system for any refrigerant leaks that may have occurred during shipping. Installing the A/C Unit
The CTX 9000 DSi HVAC system consists of 4 individually shipped components: the evaporator section, condenser section, control (electronic) box and condensate drain assembly. To install the condensate drain assembly, mount the drain assembly to the top of the forklift pocket below the control box. Attach the tubing to the right side of the kazoo-mounting bracket. This tubing section runs over to the left end of the CTX 9000 DSi where it is attached to the drain nipple.
1. 2.
3. 4. 5.
Slide the evaporator and condenser section into their respective locations within the CTX 9000 DSi. To secure the evaporator section to the mounting rails, install one bolt on the side toward the control box and two bolts on the opposite side. To secure the condenser section to its mounting rails, only one bolt can be installed on each side. NOTE: The mounting holes on the condenser section will be somewhat difficult to reach due to obstructions.
6.
Before proceeding, ensure that all bolts have been tightened.
7. 8.
Attach the pre-formed p-trap tubing to the copper drain pipe on the evaporator section and attach the other end to the kazoo mounting bracket with hose clamps. While installing the four refrigerant lines, consider the following: NOTE: The refrigerant lines are marked so that they cannot be connected improperly.
It is crucial that the two suction and two liquid refrigerant lines are mated to their corresponding circuits or the system will not function properly. (The suction lines are insulated.) Be careful not to bend any of the fins on the condenser coil when positioning the suction lines or the liquid lines. a. b. c. d. Apply some refrigerant oil (POE oil) to the quick connects. While installing the refrigerant lines, ensure that there is some oil visible on the threads. After identifying the proper connection points, use the appropriate wrench to tighten each connection. Tighten each connection until it stops. Do not overtighten the connections. There should be no threads visible on the male end after properly tightening the fittings.
CA U TI ON:
e. 9.
Once you have tightened the fittings, install the two small pieces of pipe insulation on the suction lines.
Install the control box to the mounting brackets on the CTX 9000 DSi.
10. To install the four electrical cables (one 24-pin, one 16-pin, one 9-pin and the quad I/O cable), feed the 24-pin, 16-pin and 9-pin cables through the two holes in the Input module located to the right of the control box. NOTE: There are also two 4-pin connectors located on the bottom of the control box. The one located on the right side of the control box is the remote start connection. The one located on the left side of the control box is for RS-485 communication from the temperature controller.
11. Attach the 24-pin cable connector to the condenser section. NOTE: The connector is keyed so that it cannot be installed incorrectly.
12. Attach the 16-pin and 9-pin cable connectors to the evaporator section. NOTE: The connectors are keyed so that they cannot be installed incorrectly.
13. Once you have each individual connector lined up, push it together and tighten the threaded collar. 14. Hook the quad I/O cable to its appropriate connector. 15. Install the two brackets (shipped loose) to attach the supply/return air plenum to the evaporator. NOTE: The brackets will help to eliminate any leakage that may occur around the felt gasket area of the plenum.
Starting Up the A/C Unit
CAUTION:
1. 2. 3. 4. 5. 6. 7.
High voltage may be present at the line side of the circuit breaker.
Ensure that the main cable (3-phase power) is disconnected from the control box. Ensure that the main breaker (visible from the outside of the control box) is in the OFF position (switched down). Ensure that the start/stop (black and red) rocker switch is in the OFF position. Open the right hand side control box door. Ensure that all the circuit breakers are in the ON position (switched to the left). Close the control box door. Attach the 3-phase power cable to the flanged inlet at the bottom of the control box.
CAUTION:
This is a twist lock-style connector. O nce it is seated, twist the connector to the right to lock it in place. O nce it is connected, pull the connector downward to ensure that it is securely attached.
8.
Switch the main breaker to the ON position to energize the control circuit of the HVAC unit. The controller will display the temperature and the green control circuit LED will illuminate. Should no LEDs illuminate after switching the breaker on, one of the following conditions may need to be rectified:

The main power feeding the CTX system has not been switched on. The breaker feeding the HVAC unit has not been switched on. The twist lock connector has not been connected properly.
9.
Either:
Push the system start/stop rocker switch to the ON position for manual operation.
~OR~
Leave the switch in the OFF position for remote start operation.
10. Once the switch is activated, the evaporator (supply air) fan will ramp up to speed (40 Hz for 460480/3/60; 45 Hz for 380-400/3/50). 11. The setpoint of the controller is 60 F. The system will automatically start to control around this setpoint. NOTE: There is a one minute time delay for compressor/condenser circuit #1 (the timer starts timing when the compressor shuts off).

There is a two minute time delay for compressor/condenser circuit #2 (the timer starts timing when the compressor shuts off).
Shutting Down the A/C Unit 1. Either:

For manual operation, turn the system start/stop switch to the OFF position.
~OR~
For remote operation, activate the shutdown command from the motion control computer system.
This will shut down the fan and de-energize any compressor/condenser circuits and the heater control. NOTE: The temperature controller will remain energized as will the green control circuit indicating LED.
2.
Turn the main breaker to the OFF position to de-energize the HVAC system.
CAUTION:
High voltage is still present on the line side of the breaker until the power cable is disconnected or the CTX 9000 DSi breaker is turned off.
3. 4. 5. 6. 7.
Should any A/C maintenance or troubleshooting be necessary, disconnect the power cable attached to the bottom of the control box to de-energize all remaining circuits. Press the Set key on the RKC controller. Once SV illuminates on the upper display (the set valueit actually looks like an S and an upside down A), push the R/S key to move the brightly lit digit to the position that needs to be changed. Use the up or down arrow key to make the new change. Once the correct setpoint is displayed, press the Set key to save the new setpoint.
Adjusting the Frequency Drive Parameters NOTE: For more information on the Mitsubishi FR-S frequency drive, review the OEM documentation.

The only parameters shown are the ones that change from the default settings.
Parameter Number P7 P8 P9 P14 P65 P67 P68 P72 P79 ACCELERATION TIME DECELERATION TIME
Parameters
Settings 10 15 1.1 1 0 10 5 3 3
ELECTRONIC THERMAL OVERLOAD RELAY LOAD PATTERN SELECTION A, B, C TERMINAL FUNCTION SELECTION NUMBER OF RETRIES RETRY WAITING TIME PWM FREQUENCY SELECTION OPERATION MODE SELECTION Adjusting the Frequency Drive Speed NOTE: For more information on the Mitsubishi FR-S frequency drive, review the OEM documentation.
The Mitsubishi frequency drive speed is adjusted with the dial on the front of the unit. 1. 2. Turn the dial to the desired speed (40 Hz for 480 VAC systems, 45 Hz for 380 VAC systems). The flickering frequency is the set frequency. Press Enter to store the new speed.
Adjusting the RKC Temperature Controller Setpoint NOTE: For more information on the RKC temperature controller, review the following OEM documentation: S p e c i f i c a t i o ns : http://www.rkcinst.co.j p/english/pdf/ma900_02e.pdf Ins t r u c t i o na l Ma nu a l : http://www.rkcinst.co.j p/english/pdf_manual/imr01h01e4.pdf Co mmu ni c a t i o ns Ins t r u c t i o na l Ma nu a l : http://www.rkcinst.co.j p/english/pdf_manual/ imr01h02e3.pdf
The RKC temperature controller setpoint is changed by using the set key. 1. 2. 3. 4. Press the Set key. Once SV illuminates on the upper display (the set valueit actually looks like an S and an upside down A), push the R/S key to move the brightly lit digit to the position that needs to be changed. Use the up or down arrow key to make the new change. Once the correct setpoint is displayed, press the Set key to save the new setpoint.
TROUBLESHOOTING THE AIR INNOVATIONS A/C UNIT

S UPPLY AIR CONDITIONS TROUBLESHOOTING
1. Supply Air Temperature Too Low. NOTE: There is no LED or Quad I/O indicator for this condition.
Symptom Supply air temperature remains below setpoint. Same
Possible Cause The temperature controller setpoint has been lowered. Compressor(s) running when it/ they should not. Heater control system not functioning properly.
Recommended Action Check controller setpoint setting (the normal setting is 60 F.)
Check controller alarm and hysteresis (differential gap) settings.
Same
Check amperage to heaters. If necessary, raise setpoint(Output 1 LED on controller will be on). Check heater Amp draw (it should be ~ 7.2 A at 480 VAC and ~ 5.5 at 380-400 VAC). Check DC control voltage to SSRs. If there is no DC signal at the SSRs, and there is amperage to the heaters, the SSRs are defective. When SSRs fail, they normally fail closed. Replace defective SSR(s). Check sensor against an accurate hand held device. If in error, temporarily offset the input to the controller until a new sensor can be obtained.
Same
Temperature sensor is defective.
2.
Supply Air Temperature Too High (above 70 FQuad I/O Indicator).
Symptom Supply air temperature remains above setpoint. Same
Possible Cause Temperature controller is defective. Defective heater control system. Defective fan motor, frequency drive, breaker or wiring. Dirty evaporator coil filter. Temperature sensor is defective.
Recommended Action Check programming parameters.
Check DC control voltage to SSRs. If there is no DC signal at the SSRs, and there is amperage to the heaters, the SSRs are defective. When SSRs fail, they normally fail closed. Replace defective SSR(s). Contact Air Innovations.
Low airflow in evaporator section. Same Supply air temperature remains above setpoint. No air conditioning. Insufficient cooling.
Replace filter. Check sensor against an accurate hand held device. If in error, temporarily offset the input to the controller until a new sensor can be obtained. Check controls, switches, and wiring using OEM schematic. Be sure both compressors are running. If the high temperature alarm (activates at 70 F) is triggered (quad I/O pin 4-1), shut the CTX 9000 DSi system down.
Compressor(s) not running. Unit being operated in an excessively hot and humid condition.
AIR CONDITIONING TROUBLESHOOTING

1. Compressor Fails To Start (LED Indicator #1,# 2, #3, #8 or #9; Quad I/O High Pressure Indicator).
Symptom Electric circuit test Same Electric circuit test shows power on line side but not on the load side of compressor.
Possible Cause Power failure. Disconnect switch is open. Circuit breaker is tripped or defective.
Recommended Action Check for blown line fuse or breaker. Check main circuit breaker. Determine why the switch was opened. If the system is in working order, close the switch. Reset or replace breaker if defective.
Symptom Full voltage at motor terminals but compressor will not run. Test for burned-out contactor coil or broken contacts. Contactor coil is not energized.
Possible Cause Compressor burned out. Inoperative compressor contactor. Open control circuit for:
Recommended Action Contact Air Innovations. Replace contactor.
Locate open control circuit and determine its cause.
Start/Stop switch.
Pressure switches.
Frequency drive switch.
Airflow switches.
Condenser fan is not starting which causes the compressor to shut off on high pressure.
Motor winding protector is open. Motor is defective.
The motor winding protector will reset itself when the A/C unit temperature drops. If the motor does not restart, replace the A/C motor.
2.
Compressor Rapid Cycles (#1 or #2 Low Pressure LED Indicator; Quad I/O Indicator).
Symptom Compressor cuts out intermittently from its low pressure cut-out switch. (Caution: Rapid cycling can damage the compressor if allowed to continue for an extended period.) Same
Possible Cause Lack of refrigerant.
Recommended Action Certified technician should perform the following: 1. 2. 3. Shut off breaker to the affected compressor circuit. Isolate refrigerant leak. Repair and recharge system.
System being operated in a low ambient condition. Return air filter clogged.
System should not be operated in an ambient condition below 25 F. If condition is above 25 F, the refrigerant charge may be low. Clean or replace filter.
Same
4.
Compressor is Noisy. NOTE: There is no LED or Quad I/O indicator for this condition.
Symptom Compressor knocks. Abnormally cold suction line. Compressor knocks. Same Same
Possible Cause Compressor running in opposite direction. Liquid flood back.
Recommended Action Reverse direction of compressor Certified technician should check and adjust the superheat setting. (Note: Setting may be too low or the remote bulb is loose on suctionthe normal superheat setting is 10 - 12 F.)
Expansion valve stuck in open position. Check evaporator coil for ice. 5.
Certified technician should repair or replace valve. De-ice coil.
System Short of Capacity (LED Indicator #6 or #7; Quad I/O Low Pressure Indicator).
Symptom Bubbles in sight glass.
Possible Cause Lack of refrigerant (Note: Some flashing in low ambient conditions is acceptable, at least to of the sight glass should appear to have refrigerant flowing through it). Plugged filter drier.
Recommended Action Certified technician should add refrigerant (if so recommended by Air innovations).
Temperature change in refrigerant line through dryer. Short cycling. Superheat too high. 6.
Certified technician should replace the filter drier.
Expansion valve stuck or obstructed. Improper superheat adjustment.
Certified technician should repair or replace valve. Certified technician should adjust TXV to maintain a minimum 10 F superheat.
Discharge Pressure Too High (LED Indicator #8 or #9; Quad I/O High Pressure Indicator).
Symptom Exceptionally hot condenser and excessive discharge pressure. Same Same
Possible Cause System operating in an excessively hot and humid environment.
Recommended Action If system operates at 350 PSI, the high pressure switch will open and shut down the compressor. Once the temperature rises above 70 F, the quad I/O is triggered and an indicator will display with a warning to shut down the CTX 9000 DSi or internal damage could occur. Certified technician should purge non-condensable gas. Certified technician should remove excess refrigerant. (Note: Sight glass will start flashing at around 8 lbs.). Repair or replace defective parts.
Air or non-condensable gas in system. Overcharge of refrigerant.
Same
Defective condenser fan motor or controls. 7.
Discharge Pressure Too Low (LED Indicator #6 or #7; Quad I/O Low Pressure Indicator).
Symptom Bubbles in sight glass. Excessively cold liquid returning from condenser. 8.
Possible Cause Lack of refrigerant. Faulty low ambient control valve. (Note: This valve should maintain a head pressure of 125 PSI.)
Recommended Action Repair leak and charge. Contact Air Innovations.
Suction Pressure Too High. NOTE: There is no LED or Quad I/O indicator for this condition.
Symptom Abnormally cold suction line. Liquid flooding back to compressor. Same
Possible Cause Overfeeding of expansion valve.
Recommended Action Certified technician should modify the superheat setting of the expansion valve and check to see that remote bulb is properly attached to the suction line. Certified technician should repair or replace valve.
Expansion valve stuck in open position.
9.
Suction Pressure Too Low (If Pressure is Below 2 - 4 PSI, LED Indicator #6 or #7; Quad I/O Low Pressure Indicator).
Symptom Bubbles in sight glass.
Possible Cause Lack of refrigerant (Note: Some flashing in low ambient conditions is acceptable, at least to of the sight glass should appear to have refrigerant flowing through it). Frequency drive setting not at 40 Hz or 45 Hz. Clogged filter drier.
Recommended Action Certified technician should repair leak and charge.
Evaporator discharge air is too low. Temperature change in refrigerant line through dryer. No flow of refrigerant through valve. Unit short cycles. Loss of capacity.
Adjust drive. Certified technician should replace the filter drier. Certified technician should replace expansion valve power element. Certified technician should clean valve or replace as necessary.
Expansion valve power element has lost charge. Obstructed expansion valve.
SPARE PARTS LIST FOR THE AIR INNOVATIONS A/C UNIT

Table 4-3 Air Innovations Part Number 34C0072-00 34C0072-01 34C0072-02 34C0072-03 34C0072-04 34C0072-05 51C0028-00 33C0056-00 BREAKER, 1 POLE BREAKER, 2 POLE BREAKER, 3 POLE BREAKER, 3 POLE BREAKER, 3 POLE BREAKER, 3 POLE COMPRESSOR CONTACTOR, 24 VDC COIL, 20 AMP
Spare Parts List for the Air Innovations A/C Unit
Description
Quantity 1 1 1 2 1 1 2 2
Manufacturing Part Number 5SX2104-7 5SX2203-7 5SX2303-7 5SX2308-8 5SX2310-7 5SX2316-8 ZB21KCE-TFD-230 3RT1016-1B B42
Air Innovations Part Number 39C0054-00 35C0056-00 54C0029-00 54C0029-01 54C0030-00 54C0030-01 73C0077-00 30C0017-00 50A0009-00 36C0119-00 35C0057-00 37C0048-00 54C0035-00 54C0033-00 71C0046-00 32C0019-00 32C0019-01 32C0019-02 50C0029-00 73C0075-00 39C0104-00 74C0053-00 33C0058-00 50C0030-00 33C0053-00
Description CONTROL BOARD FOR SPORLAN ELECTRONIC EPR (TCB BOARD) CONTROLLER, TEMPERATURE COUPLING, FEMALE, 3/8 ODS COUPLING, FEMALE, 5/8 ODS COUPLING, MALE, 3/8 ODS COUPLING, MALE, 5/8 ODS FAN, CONTROL BOX COOLING FILTER, EMI (CORCOM) FILTER DRIER, 3/8 C x C FLANGED INLET, TWIST LOCK, GROUNDING, 4 CONDUCTOR FREQUENCY DRIVE HEATER ELEMENT DRAIN TUBE (KAZOO), 6" LONG DRAIN TUBE, EVAPORATOR PRE-FORMED DRAIN TUBE (KAZOO) MOUNTING BRACKET LED, GREEN, 24 VDC LED, RED, 24 VDC LED, YELLOW, 24 VDC MOISTURE INDICATOR, 3/8 F x S MOTORIZED IMPELLER POWER SUPPLY, 24VDC, 5A PREFILTER, 30%, 14" x 16" x 1", CLASS 2 QUAD I/O, PCB RECEIVER, SPECIAL 2 CIRCUIT RELAY, SOLID STATE
Quantity 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 5 1 1 3 1 1 1 1 2
Manufacturing Part Number 952660 MA900-4ADA1-V83*AAH-N6/1/Y 5505-06B-06 5505-10S-08 55006B-06 55010S-08 CR0924HB-A70GL (P/N 032768) 16FCD10 C-053-S L1620-FL FR-S540-0.4K-NA L17A-7239
1904X351 1904X353 1904X352 SA-K202 TMK280-2-34 6EP1333-3BA00 54862001 SDS-C2SUB-4 X9499 W6425DSX-1
Air Innovations Part Number 39C0101-00 32A0010-00 32A0010-01 32A0032-01 32A0041-00 36F0004-00 32H0006-00 32H0007-00 33C0057-01 33C0057-00 52C0063-00 52C0061-00 52C0064-00 52C0062-00 54C0032-00 54C0032-01 36C0116-00 36C0117-00 36C0118-00
Description SENSOR, RTD, 100 OHM, STAINLESS STEEL SHEATH SWITCH, AIR PRESSURE (.1 to .5" WC) SWITCH, AIR PRESSURE (.4 - .6" WC) SWITCH, HIGH PRESSURE SWITCH, HIGH / LOW PRESSURE SWITCH, ROCKER, SPST SWITCH, SNAP ACTION, 135-175 DEG F SWITCH, SNAP ACTION, MAN., 160 DEG F TIMER/RELAY EXPANSION MODULE TIMER/RELAY MODULE VALVE, ELECTRONIC EPR VALVE, EXPANSION VALVE, HEAD PRESS.CONTROL VALVE, QUENCH TEV, 3/8 IN x 1/2 OUT VIBRA-SORBER, 3/8 x 24 VIBRA-SORBER, 5/8 x 24 WIRE HARNESS, CONDENSER, 24-PIN WIRE HARNESS, EVAPORATOR, 16-PIN WIRE HARNESS, EVAPORATOR, 9-PIN
Quantity 1 1 1 2 2 1 1 1 1 1 1 2 1 1 2 2 1 1 1
Manufacturing Part Number RBJB0TA080AB020 PSF100A-0.5 PSF100A-20929 29PSL012-389 343R02 P70SA-1 RSCA701-VB-B-1-V 3L05-1 3L02-161 6ED1055-1HB00-0BA0 6ED1052-1MD000BA3 CDS-9-10'-S Y-1017-FJE-C LAC-4 125 Y-1253-EFJ-1/2 VAF3 X 30 VAF5 X 30
UPS
The CTX 9000 DSi uses UNIX, DOS and Windows operating systems for different system operation functions.

DOS is used for system control functions. The GUI (Graphical User Interface) runs on Windows. UNIX is utilized for image reconstruction and inspection functions.

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CH APTER 4: PO W

A/C U N IT ( AIR IN N OVATION S)

A/C U ni t( Ai rI nnovati ons)

CTX 9000 D SiTrai ni ng M anual 66 of378

GE I nV i si on,I nc.Com pany Confi denti al M arch 10,2005

CHAPTER 4: POWER DISTRIBUTION

GE InVision, Inc. Company Confidential March 10, 2005

CTX 9000 DSi Training Manual 67 of 378

CHAPTER 4: POWER DISTRIBUTION

A/C Unit (Air Innovations)

CTX 9000 DSi Training Manual 68 of 378

GE InVision, Inc. Company Confidential March 10, 2005

CHAPTER 4: POWER DISTRIBUTION

GE InVision, Inc. Company Confidential March 10, 2005

CTX 9000 DSi Training Manual 69 of 378

CHAPTER 4: POWER DISTRIBUTION

CTX 9000 DSi Training Manual 70 of 378

GE InVision, Inc. Company Confidential March 10, 2005

CHAPTER 4: POWER DISTRIBUTION

Figure 4-19 Main Components:

Temperature controller. All LED indicators.

GE InVision, Inc. Company Confidential March 10, 2005

CTX 9000 DSi Training Manual 71 of 378

CHAPTER 4: POWER DISTRIBUTION

Temperature Controller and Control LEDs

All relays. All switches. Siemens LOGO for discreet controls.

CTX 9000 DSi Training Manual 72 of 378

GE InVision, Inc. Company Confidential March 10, 2005

CHAPTER 4: POWER DISTRIBUTION

Quad I/O (Air Innovations Air Conditioner)

GE InVision, Inc. Company Confidential March 10, 2005

CTX 9000 DSi Training Manual 73 of 378

CHAPTER 4: POWER DISTRIBUTION

Mitsubishi FR-S540-0.4K-NA Variable Frequency Drive (VFD)

CTX 9000 DSi Training Manual 74 of 378

GE InVision, Inc. Company Confidential March 10, 2005

CHAPTER 4: POWER DISTRIBUTION

DRAIN TUB E ASSEMB LY

Pre-formed PVC piping. Kazoo assembly.

Drain Tube Assembly

GE InVision, Inc. Company Confidential March 10, 2005

CTX 9000 DSi Training Manual 75 of 378

CHAPTER 4: POWER DISTRIBUTION

Ambient Dry Bulb Maximum 120 F 105 F

Ambient Relative H umidity @ Maximum F 50% RH 50% RH

Ambient Temp Minimum 14 F 14 F

Supply Air Temp Minimum/ Maximum 50 / 70 F 50 / 70 F

Pow er Supply 480 VAC 3 PHASE / 60 Hz 380 VAC 3 PHASE / 50 Hz

S YSTEM SPECIF ICATIONS

Fans Filter Controller

CTX 9000 DSi Training Manual 76 of 378

GE InVision, Inc. Company Confidential March 10, 2005

CHAPTER 4: POWER DISTRIBUTION

GE InVision, Inc. Company Confidential March 10, 2005

CTX 9000 DSi Training Manual 77 of 378

CHAPTER 4: POWER DISTRIBUTION

STARTUP SEQ UENCE

TEMP > AL1 1 Mi nut e

Ci r c ui t#1 " ON"

TEMP > AL2 2 Mi nut es

Ci r c ui t#2 " ON"

ON/ OFF Swi t c h " ON"

Ev ap Fan " ON"