INSTALLATION MANUAL LCA

AIR COOLED LIQUID CHILLER

QUALITY • FLEXIBILITY • VISION

PPUPACKAGED UNIT

0 1

Installation, Start-Up andService Instructions

CONTENTS

SAFETY CONSIDERATIONS.............................................................1• INSTALLATION..........................................................................1-8Step 1--Receive and Inspect..............................................................1Step 2--Protect Unit from Damage.....................................................1Step 3--Provide Unit Support.............................................................1Step 4--Rig and Place Unit.................................................................1Step 5--Field Fabricate Ductwork......................................................1Step 6--Install Condensate Drain Line and External Trap...........................................................................................................2Step 7--Make Electrical Connections................................................2Step 8--Adjust Evaporator-Fan Speed...............................................4PRE-START-UP..................................................................................9START-UP..........................................................................................9SERVICE..........................................................................................10TROUBLESHOOTING.....................................................................11APPENDIX ASTART-UP CHECKLIST

INDUSTRIES

SAFETY CONSIDERATIONS

Installation and servicing of air conditioning equipment can behazardous due to system pressure and electricalcomponents.Only trained and qualified service personnel shouldinstall, repair or service air conditioning equipment.Untrained personnel can perform basic maintenance functionsof cleaning coils and filters and replacing filters. All otheroperations should be performed by trained personnel.Whenworking on air conditioning equipment, observe the precautionsstated in the literature, tags and labels attached to the unit andany other safety precautions that may apply. Follow all safetycodes. Wear safety glasses and work gloves. Use quencher clothfor brazing and unbrazing operations. Have a fire extinguisheravailable during brazing operations.

WARNING!BEFORE PERFORMING SERVICE OR MAINTENANCE OPERATIONSON UNIT, TURN OFF MAIN POWER SWITCH TO UNIT. ELECTRICALSHOCK COULD CAUSE PERSONAL INJURY OR DEATH!

Step 1-- Receive and Inspect Unit -Check unit against shipping order. Inspect carefully for concealedshipping damage. If shipping is damaged or incomplete, fileclaim with transportation company and advise Peake imme-diately.

Step 2- Protect Unit From Damage -To maintain warranty, protect unit against adverse weather condi-tions, theft or vandalism on the jobsite.

Step 3 - Provide Unit Support -Refer to Table 1 for unit weight.If desired, construct a stand or frame of I-beams or angle iron thatadequately supports the unit. The floor and floor joists of exist-ing buildings may require reinforcement; follow applicable codes.

Step 4 - Rig and Place Unit -Provide space around unit for service, filter access and overheadclearance.

Move and install unit. Refer to Fig. 4 for rigging details.

Unit should be level. Refer to Fig. 2 for unit leveling tolerance.

Step 5 - Field Fabricate Ductwork -Connect supply and return ducts to flanges on unit using a flex-ible connection. Attach ductwork to building structure and insu-late with fiberglass and vapor barrier to reduce sound transmis-sion and prevent vapor condensation.

Insulate and weatherproof all external ductwork, joints, and open-ings with counter flashing and mastic in accordance with appli-cable codes.

Ducts passing through an unconditioned space must be insulatedand covered with a vapor barrier.

A - B B - C A - C0.5 1.0 1.0

Fig. 2 -- Unit Leveling Tolerance

Maximum Allowable Difference

PPU096 - 480Single Packaged Unit

Side Discharge

2

Step 6--Install Condensate Drain Line and External Trap -

Condensate drain connections are located at both sides of theunit. All units must have an external trap for condensate drain-age. Install a trap at least 4-in. deep and protect against freeze-up. See Fig.3 . If drain line is installed downstream from theexternal trap, pitch the line away from the unit at 1 in. per 10 ft.of run. Do not use a pipe size smaller than the unit connection.

NOTE: Trap should be deep enough to offset maximum unitstatic difference. A 4-in. trap is recommended.

Fig. 3--External Trap Condensate Drain

Fig. 4- Rigging Detail

NotesHook rigging shackles through holes in skids. Use wooden topskid when riging to prevent rigging straps from damaging unit.

CAUTION

All panels must be in place when rigging.

Step 7--Make Electrical Connections -

WARNING!

Unit cabinet list have an uninterrupted unbroken electrical groundto minimize the possibility of personal injury if an electrical faultshould occur. This ground may consist of electrical wire con-nected to unit ground lug in control compartment, or conduit ap-proved for electrical ground when installed in accordance with NEC(National Electrical Code) ANSI (American National StandardsInstitute) /NFPA (National Fire Protection Association) 70-1987and local electrical codes. Failure to follow this warning couldresult in the installer being liable for personal injury of others.

FIELD POWER SUPPLY -- All units are factory-wired for thevoltage shown on the unit nameplate.

Refer to unit label diagram for additional information.

When installing units, provide a disconnect per the NEC.

All field wiring must comply with the NEC and local requirements.In Canada, electrical connections must be made in accordance withCSA (Canadian Standards Association) C22. I Canadian ElectricalCode Part One.

Install field wiring as follows:1. Install conduit through side panel openings.Install power lines to terminal connections as shown in electricalschematic, located on inside of control box cover.

During operation, voltage to compressor terminals must be withinrange indicted on unit nameplate (see Table 2). On 3-phase units,voltages between phases must be balanced within 2 %, and the cur-rent within 10%. Use the formula shown in Table 2. Note 2 onpage 6 to determine the percentage of voltage imbalance. Opera-tion on improper line voltage or excessive phrase imbalance con-stitutes abuse and may cause damage to electrical components.Such operation would invalidate any applicable PEAKE warranty.

2 3

Table 1 PH Y SICAL DATA

BASE UNIT PPU096 PPU120 PPU144 PPU180NOM INAL CAPACITY(tons) 7.5 10 12 15COMPRESSOR QTY 1 1 1 2REFRIGERANT TYPE R-22Operating Charge(lbs) 16 18 26 28CONDENSER COILSFace Area (sq. ft) 15.9 18.9 25.7 25.7Rows...Fins/in . 3...14 3...14 3...14 4...14EVAPORATOR COIL Alum inum Fins with Copper TubingFace Area (sq. ft) 7 10 17.7 17.7Rows...Fins/in . 3...14 4...14 3...14 4...14OUTDOOR AIR FANS PropellerQty...Diam eter (in .) 1...24 1...24 2...24 2...24Nominal Cfm 5000 6000 8800 8800M otor Hp 1/2 1/2 1/2 1/2Rpm 1075 1075 1075 1075INDOOR AIR FANS CentrifugalSize (in) 12.12x12 15.5x15 15.5x15 15.5x15Qty 1 1 2 2Drive Type BeltNominal Cfm 3000 4000 4600 5800M otor Pulley Pitch Diameter A/B (in) 3.4/4.4 2.8/3.8 4.3/5.3 4.3/5.3Fan Pulley Pitch Diameter (in) 11.0 11.0 11.4 11.4Belts- Qty..Type..Length (in) 1..A...50 1..A..54 2..B..60 2..B..62Full Load Efficiency % 81.2 83.4 84.1 84.1M otor Hp 2 2 3 3

BASE UNIT PPU240 PPU300 PPU360 PPU480NOM INAL CAPACITY(tons) 20 25 30 40COMPRESSOR QTY 2 2 2 2REFRIGERANT TYPE R-22Operating Charge(lbs) Sys1/Sys2 32/32 25/25 25/25 36/36CONDENSER COILSFace Area (sq. ft) 37.2 40.6 49.2 63.7Rows...Fins/in . 3...14 3...14 3...14 3...14EVAPORATOR COIL Alum inum Fins with Copper TubingFace Area (sq. ft) 19.7 23.6 23.1 30.2Rows...Fins/in . 4...12 4...14 4...12 4...14OUTDOOR AIR FANS PropellerQty...Diam eter (in .) 2...24 4...24 4...24 5...24Nominal Cfm 8800 17500 20000 24000M otor Hp 1/2 1/2 1/2 1/2Rpm 1075 1075 1075 1075INDOOR AIR FANS CentrifugalSize (in) 15.5x15 15.5x15 18.62x18 18.62x18Qty 2 2 2 2Drive Type BeltNominal Cfm 8000 10000 12000 16000M otor Pulley Pitch Diameter A/B (in) 4.3/5.3 4.9/5.9 4.9/5.9 4.9/5.9Fan Pulley Pitch Diameter (in) 11.4 11.4 11.0 11.0Belts- Qty..Type..Length (in) 2..B..75 2..B..71 2..B..84 2..B..84Full Load Efficiency % 84.3 84.8 87.4 87.5M otor Hp 5 7.5 10 15

4

FIELD CONTROL WIRING -- Install a PEAKE approved ac-cessory thermostat assembly according to installation instructionsincluded with accessory. Locate thermostat assembly on a solidwall in the conditioned space to sense average temperature in ac-cordance with thermostat instructions.

Route thermostat cable or equivalent single leads of colored wirefrom subbase terminals to low voltage connections on unit (Referto Appendix A) as described in steps 1-3 below.NOTE: For wire runs up to 50 ft, use no. 18 AWG(American WireGage) insulated wire(35C minimum). For 51 to 75 ft, use no. 14AWG insulated wire(35C minimum). All wire larger than no. 18AWG cannot be directly connected to the thermostat and will re-quire a junction box and splice at the thermostat.

1. Pass control wires through the hole provided on unit, located on condenser side corner post.2. Feed wire into the control box to terminal block no. 2(TB2), located in control box.3. Connect thermostat wires to terminals of the terminal block no.2.

Step 8-- Adjust Evaporator Fan Speed -Adjust evaporator fan speed to meet job site conditions.

Table 1 shows evaporator fan motor data. Refer to Fan Perfor-mance Data (pages 7&8) to determine fan speed settings. Fanmotor pulleys are factory set for speed shown in Table 1.

To change fan speeds:1. Shut off unit power supply.2. Loosen belt by loosening fan motor mounting nuts.3. Loosen movable pulley flange setscrew (see diagram)4. Screw movable flange toward fixed flange to increase speed

or away from fixed flange to decrease speed. Increasing fanspeed increases load on motor. Do not exceed maximum speedspecified in Table 1.

5. Set movable flange at nearest keyway of pulley hub and tightensetscrew. (See table 1 for speed change for each full turn ofpulley flange.)

To align fan and motor pulleys:1. Loosen fan pulley setscrews.2. Slide fan pulley along fan shaft.3. Make angular alignment by loosening motor from mounting

plate.

To adjust belt tension:1. Loosen fan motor mounting nuts.2. Slide motor mounting plate away from fan scroll for proper

belt tension (1/2-in. deflection with one finger) and tightenmounting nuts

3. Adjust bolt and nut on mounting plate to secure motor evapo-rator in fixed position.

STRAIGHT EDGE MUST BEPARALLEL WITH BELT

MOTORS AND FAN SHAFTSMUST BE PARALLEL

MOVABLE FLANGE

SET SCREWS

PULLEYS

SINGLE GROOVE

FIXED FLANGE

Fig.5 Evaporator Fan Pulley Adjustment

4 5

Table 2 ELEC TR IC A L D A TA(60Hz)U N IT N O M IN A L V O LTA GE O FM IFM

V O LTA GE RA N GE RLA LRA FLA FLA M CA M O CP *

P P U 096 208/230 187-254 25.0 185.0 3.9 6.4 44.0 70

(3-phase)

P P U 120 208/230 187-254 34.5 239.0 3.9 6.4 56.0 90

(3-phase)

P P U 144 208/230 187-254 41.0 269.0 7.8 9.0 72.2 110

(3-phase)

P P U 180 208/230 187-254 50.0 370.0 7.8 9.0 83.5 120

(3-phase)

P P U 240 208/230 187-254 69.0 478.0 7.8 14.4 91.2 130(3-phase)

P P U 300 208/230 187-254 82.0 538.0 15.6 21.0 148.2 160

(3-phase)

P P U 360 208/230 187-254 135.0 565.0 15.6 25.0 219.5 350

(3-phase)

P P U 480 208/230 187-254 177.0 856.0 19.5 38.0 293.1 430

(3-phase)

P P U 096 460 414-506 12.4 89.0 2.0 3.2 22.0 40

(3-phase)

P P U 120 460 414-506 17.0 119.0 2.0 3.2 27.7 50

(3-phase)P P U 144 460 414-506 17.0 119.0 4.0 4.5 31.9 50

(3-phase)P P U 180 460 414-506 24.8 178.0 4.0 4.5 41.6 60

(3-phase)P P U 240 460 414-506 34.0 238.0 4.0 7.2 56.5 70

(3-phase)P P U 300 460 414-506 34.0 238.0 8.0 10.5 65.6 80

(3-phase)P P U 360 460 414-506 67.5 283.0 8.0 12.5 110.0 150

(3-phase)P P U 480 460 414-506 88.5 856.0 10.0 19.0 146.9 175

(3-phase)

LEGEN DFLA Full Load A mps LR A Locked Rotor A mpsIFM Indoor Fan motor M C A M inimum Circuit A mpsLR A Locked Rotor A mps R LA Rated Load A mpsM C A M inimum Circuit A mps H A C R H eating, A ir-Conditioning and Refrigeration

N EC N ational Electrical Code

*Fuse or H A CR circuit breaker

P O W ER SU P P LYCO M P RESSO R

6

N O TES:1. In compliance w ith N EC requirements for miltimotor and combination load and equipment(referto N EC A rtic les 430 and 440), the overcurrent protective device for the unit shall be fuse or H A CR breaker.

2. U nbalanced 3-P hase Supply VoltageNever opera te a mo tor where a pha se imba lan ce in sup ply vo ltag e is g rea ter tha n 2 % . U se the following formula to determine the percentage of voltage imbalance.

% Voltage Imbalance = 100 x max voltage deviation from average voltageaverage voltage

Example: Supply voltage is 230 -3-60 A verage Voltage = (252 + 261 + 255)/3

A B=252 V = 768/3BC=261 V = 256A C=255 V

D etermine maximum deviation from average voltage:(A B) 256 - 252 = 4 V(BC) 261 - 256 = 5 V(A C) 256 - 255 = 1 VMaximum deviation is 5 VD etermine percentage of voltage imbalance :

% V oltage imbalance = 100 x 5/256 = 1.95 %

This amount of phase is sa tisfactory as it is below the maximum allow able 2%

IM PO RTA N T : If the s upply vo ltage phas e imbalance is more than 2% contact your locale le ctric utility co mpany imme diate ly

6 7

Fan Pe rformance Data

PPU-096 EXTERNAL STATIC PRESSURE (in.wg)AIRFLOW 0.2 0.6 1 .0 1 .4 1 .8

(Cfm) Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp2000 500 0.50 650 0.92 770 1.38 884 1.95 910 2 .642250 511 0.52 659 0.95 778 1.43 885 1.97 947 2 .662500 555 0.67 690 1.14 806 1.64 904 2.18 1004 2 .842700 581 0.81 717 1.31 828 1.83 925 2.42 1012 3 .013000 629 1.06 760 1.59 864 2.15 960 2.78 1040 3 .413200 663 1.25 786 1.80 887 2.41 980 3.04 - -3500 713 1.57 825 2.14 928 2.84 1014 3.48 - -3750 755 1.89 864 2.49 964 3.23 - - - -4000 796 2.23 864 2.49 - - - - - -

PPU-120 EXTERNAL STATIC PRESSURE (in.wg)AIRFLOW 0.2 0.6 1 .0 1 .4 1 .8

(Cfm) Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp3000 532 0.64 670 0.97 778 1.28 874 1.60 974 2 .113200 558 0.75 692 1.10 798 1.44 888 1.77 988 2 .183500 597 0.94 722 1.33 826 1.71 915 2.07 998 2 .433700 622 1.09 745 1.50 846 1.91 935 2.28 1013 2 .674000 662 1.33 778 1.78 879 2.22 960 2.63 1043 3 .064300 702 1.61 815 2.11 908 2.58 994 3.05 1069 3 .484500 728 1.83 836 2.35 930 2.85 1017 3.33 - -4700 756 2.06 862 2.61 952 3.12 - - - -5000 797 2.44 899 3.04 - - - - - -

PPU-144,180 EXTERNAL STATIC PRESSURE (in.wg)AIRFLOW 0.2 0.6 1 .0 1 .4 1 .8

(Cfm) Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp3700 654 1.12 768 1.50 860 1.85 952 2.27 1031 2 .654000 697 1.37 805 1.80 895 2.16 978 2.62 1060 3 .044300 740 1.66 847 2.12 931 2.54 1012 2.97 1088 3 .464500 770 1.89 872 2.37 956 2.82 1034 3.23 1108 3 .764700 800 2.13 899 2.63 982 3.11 1056 3.52 1129 4 .075000 843 2.52 938 3.08 1020 3.60 1092 4.05 1162 4 .535200 873 2.82 962 3.40 1046 3.93 1116 4.42 1183 4 .885500 918 3.30 1005 3.92 1084 4.47 1152 5.03 1217 5 .515800 963 3.83 1045 4.50 1124 5.07 1191 5.69 - -

PPU-240 EXTERNAL STATIC PRESSURE (in.wg)AIRFLOW 0.2 0.6 1 .0 1 .4 1 .8

(Cfm) Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp6000 690 1.80 759 2.40 835 2.90 902 3.60 974 4 .007000 760 2.70 836 3.30 920 3.80 993 4.50 1073 5 .208000 820 3.80 902 4.50 992 5.00 1072 5.70 1157.3 6 .69000 880 5.20 968 5.80 1064 .8 6 .5 1150 7.6 1242 8.6

10000 930 6.7 1023 7 .6 1125 .3 8 .6 1215.3 9 .6 1312.5 10.5

8

PPU-300 EXTERNAL STATIC PRESSURE (in.wg)AIRFLOW 0.2 0.6 1.0 1.4 1.8

(Cfm) Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp7000 588 2.30 664 2.80 738 3.30 819 3.90 884 4.608000 645 3.10 729 3.80 809 4.50 898 5.00 970 5.709000 700 4.40 791 4.90 878 5.60 975 6.20 1053 7.20

10000 750 5.70 848 6.30 941 7.20 1044.2 8.4 1127.7 9.611000 800 7.00 904 8.00 1003.4 9 1113.8 10 1202.9 11.1

PPU-360 EXTERNAL STATIC PRESSURE (in.wg)AIRFLOW 0.2 0.6 1.0 1.4 1.8

(Cfm) Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp8000 667 2.80 740 3.20 822 3.80 879 4.20 941 5.009000 720 3.50 799 4.20 887 4.80 949 5.40 1016 6.10

10000 772 4.90 857 5.40 951 6.10 1018 6.60 1089 7.611000 823 6.10 914 6.70 1014 7.7 1085 8.9 1160.9 10.112000 870 7.3 965.7 8.5 1071.9 9.4 1147 10.4 1227.2 11.5

PPU-480 EXTERNAL STATIC PRESSURE (in.wg)AIRFLOW 0.2 0.6 1.0 1.4 1.8

(Cfm) Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp12000 687 2.02 748 2.27 830 2.77 888 2.98 950 3.6513000 742 2.52 807 2.98 896 3.50 958 3.83 1025 4.4514000 795 3.53 865 3.83 961 4.45 1027 4.69 1099 5.5515000 848 4.39 923 4.76 1024 5.62 1095 6.32 1171.8 7.37316000 896 5.26 975 6.04 1083 6.86 1157.7 7.384 1238.7 8.395

LEG ENDBhp - Brake HorsepowerRpm - Revolutions per minuteNOTES:1. Boldface indicates field-supplied drive required.2. Shading indicates alternate motor required.3. Shading indicates field-supplied motor and drive required.4. Use of a field-supplied motor may affect wire sizing. Contact your Peake dealer to verify.5. Values include losses for filters, unit casing and wet coils.6. Conversion - Bhp to Watts

Bhp x .746Watts = Motor Efficiency

See Physical Data Tables for motor efficiency.

8 9

PRE-START-UP

WARNING!Failure to observe the following warnings could result

in serious personal injury:1. Follow recognized safety practices and wear protective

goggles when checking or servicing refrigerant system.2. Do not operate compressor or provide any electric power to

unit unless compressor terminal cover is in place and se-cured.

3. Do not remove compressor terminal cover until all electri-cal sources are disconnected.

4. Relieve all pressure from system before touching or dis-turbing anything inside terminal box if refrigerant leak issuspected around compressor terminals. Use accepted meth-ods to recover refrigerant.

5. Never attempt to repair soldered connection while refriger-ant system is under pressure.

6. Do not use torch to remove any component. System con-tains oil and refrigerant under pressure. To remove a com-ponent, wear protective goggles and proceed asfollows:

a. Shut off electrical power to unit.b. Relieve all pressure from system using both high and low-

pressure ports. Use accepted methods to recover refriger-ant.

c. Cut component connection tubing with tubing cutter, and re-move component from unit.

d. Carefully unsweat remaining tubing stubs when necessary.Oil can ignite when exposed to torch flame .

Proceed as follows to inspect and prepare the unit for initial start-up:

1. Remove all access panels.2. Read and follow instructions on all WARNING, CAUTION,

and INFORMATION labels attached to or shipped with unit.3. Make the following inspections:

a. Inspect for shipping and handling damages such asbroken lines, loose parts, or disconnected wires.b. Inspect for oil at all refrigerant tubing connections andon unit base. Detecting oil generally indicates a refrigerantleak. Leak-test all refrigerant tubing connections risingelectronic leak detector, halide torch, or liquid-soapsolution.c. Inspect all field- and factory-wiring connections. Besure that connections are completed and tight.d. Inspect coil fins. If damaged during shipping and handling,carefully straighten fins with a fin comb.

4. Verify the following conditions:a Make sure that outdoor-fan blades are correctly posi-

tioned in fin orifice.b Make sure that air filter(s) is in place.

c Make sure that condensate drain trip is filled with water to ensure proper drainage.

d Make sure that all tools and miscellaneous loose parts have been removed.

START-UP

Unit Preparation -- Make sure that unit has been installed in ac-cordance with these installation instructions and applicable codes.Return-Air Filters-- Make sure correct filters are field installedin unit. Do not operate unit without return-air filters.

Compressor Mounting-- Compressors are internally springmounted. Do not loosen or remove compressor holddown bolts.

Internal Wiring -- Check all electrical connections in unit con-trol boxes; tighten as required.

Refrigerant Service Ports -- Each refrigerant system has 2Schrader-type service gage ports: one on the suction line, one onthe liquid line. Be sure that caps on the ports are tight.

Cooling-- To start unit, turn on main power supply. Set systemselector switch at COOL position and fan switch at AUTO posi-tion. Adjust thermostaht to a setting below room temperature.Compressor starts on closure of contactor.

Reset thermostat at a position above room temperature.Compressor will shut off.

TO SHUT OFF UNIT-- Set system selector switch at OFF posi-tion. Resetting thermostat to a position above room temperatureshuts unit off temporarily until space temperature exceeds ther-mostat setting.

Compressor restart is accomplished by manual reset at the ther-mostat by turning the selector switch to OFF position and thenON position.

Ventilation (Continuous Fan)-- Set fan and system selectorswitches at ON and OFF positions, respectively. Evaporator fanoperates continuously to provide constant air circulation.

Operating Sequence

COOLING UNITS -- When the thermostat call for cooling, ter-minals R and Y1 are energized. The indoor (evaporator) fancontactor (IFC), and compressor contactor no.1 (CCI) are ener-gized and the evaporator-fan motor, compressor and condenserfan start. The condenser-fan motor runs continuously while unit iscooling. If the thermostat calls for a second stage of cooling byenergizing Y2, compressor contactor no.2 (CC2) is energized andcompressor becomes fully loaded.

10

SERVICE

CAUTION !When servicing unit, shut off all electrical power tounit avoid shock hazard or injury from rotating parts.Cleaning-- Inspect unit interior at the beginning ofcooling season or as operating conditions require.

EVAPORATOR COIL

1. Turn unit power off. Remove evaporator coil access panel.2. Remove filters, if present.3. Clean coil using a commercial coil cleaner or dishwasher de-tergent in a pressurized spray canister. Wash both sides of coiland flush with clean water. For best results, backflush toward re-turn-air section to remove foreign material.4. Flush condensate pan after completion.5. Reinstall filters.6. Reconnect wiring.7. Replace access panels.

CONDENSER COILS-- Inspect coils monthly. Clean condensercoils annually, and as required by location and outdoor air condi-tions.

Clean coils as follows:1. Turn off unit power.2. Remove top panel screws on condenser end of unit.3. Remove condenser coil corner post and plastic mesh. To holdtop panel open, place coil corner post between top panel and cen-ter post. (See Fig. 6)4. Use a water hose or other suitable equipment to flush downbetween the coil sections to remove dirt and debris. Clean the outersurfaces with a stiff brush in the normal manner.5. Reposition the outer coil section, and remove the coil cornerpost from between the top panel and centre post. Secure the sec-tions together. Install the coil corner post, coil side panels andreplace all screws.

CONDENSATE DRAIN-- Check and clean each year at start ofcooling season. In winter, keep drain dry or protect against freeze-up.

FILTERS-- Clean or replace at start of each cooling season, ormore often if operating conditions require it. Replacement filtersmust be same dimensions as original filters.

Lubrication

COMPRESSORS-- Each compressor is charged with correctamount of oil at the factory.

FAN MOTOR BEARINGS-- Lubricate condenser fan motors ev-ery six months with SAE 20 oil.

Condenser Fan Adjustment1. Shut off unit power supply.2. Remove grille, and loosen fan hub setscrew.

3. Adjust fan height4. Tighten setscrew and replace condenser-fan grille.

Refrigerant Charge-- Amount of refrigerant charge is listed onunit nameplate (also refer to Table 1). Unit panels must be in placewhen unit is operating during charging procedure.NO CHARGE -- Use standard evacuating techniques. After evacu-ating eystem, weigh in the specified amount of refrigerant (referto Table 1).

Fig. 6 -- Cleaning Condenser Coil

10 11

PROBLEM CAUSE REMEDYPower failure Call power companyFuse blown or circuit breaker tripped Replace fuse or circuit breaker

Compressor and Defective thermostat, contactor, transformer or control relay Replace componentcondenser fan Insufficient line voltage Determine cause and correctwill not start Incorrect or faulty wiring Check wiring diagram and rewire correctly

Thermostats setting to high Lower thermostat setting below room temperatureHigh pressure switch tripped See problem 'Excessive head pressure'Low pressure switch tripped Check wiring diagram and rewire correctly

Faulty wiring or loose connections in compressor circuit Check wiring and repair or replaceCompressor will not start Compressor motor burned out, seized, or internal overload open Determine cause, replace compressorbut condenser fan run Defective run/start capacitor, overload, or start relay Determine cause and replace

One leg of three phase power dead Replace fuse or reset circuit breaker. Determine cause

Refrigerant overcharge or undercharge Reclaim refrigerant, evacuate system, and recharge to nameplateDefective compressor Replace and determine causeInsufficient line voltage Determine cause and correct

Compressor cycles Blocked condenser Determine cause and correct(other than normally Defective run/start capacitor, overload, or start relay Determine cause and replacesatisfying thermostat) Defective thermostat Replace thermostat

Faulty condenser fan motor or capacitor ReplaceRestriction in refrigerant system Locate restriction and remove

Dirty air filter Replace filterUnit undersized for load Decrease load or increase unit size

Compressor operates Thermostat set to high Reset thermostatcontinuously Low refrigerant charge Locate leak, repair and recharge

Leaking valves in compressor Replace compressorAir in system Reclaim refrigerant, evacuate system, and recharge to nameplateCondenser coil dirty or restricted Clean coil or remove restriction

Dirty air filter Replace filterDirty condenser coil Clean coil

Excessive head pressure Refrigerant overcharged Remove excess refrigerantAir in system Reclaim refrigerant, evacuate system, and recharge to nameplateCondenser air restricted or air short-cycling Determine cause and correct

Low refrigerant charge Check for leaks, repair and rechargeHead pressure too low Compressor valves leaking Replace compressor

Refrigerant overcharged Reclaim excess refrigerant

Excessive suction High heat load Check for leaks, repair and rechargepressure Compressor valves leaking Replace compressor

Refrigerant overcharged Reclaim excess refrigerant

Dirty air filter Replace filterLow refrigerant charge Check for leaks, repair and recharge

Static pressure too low Metering device or low side restricted Remove source of restrictionInsufficient evaporator airflow Increase air quantity. Check filter and replace if necessaryTemperature too low in conditioned area Reset thermostatField installed filter drier restricted Replace

TROUBLESHOOTING

12

START-UP CHECKLIST(Remove and Store in Job File)

TECHNICIAN: DATE:

JOB NAME: JOB NO.:

JOB LOCATION: MAKE:

MODEL NO: SERIAL NO:

PRE-START-UP (Check box as each item is completed)

Verify that condensate connection is installed per installation instructions

Check all electrical connections and teminals for tightness

Check that indoor filters are clean and in place

Verify that unit installation is level

Check fan wheel and propeller for location in housing/orifice and set screw tightness

Check pulley alignment and belt tension per installation instruction

START-UP

COMPRESSOR

SUCTION PRESSURE DISCHARGE PRESSURE

MOTOR AMPS VOLTS

COIL PRESSURE UNLOADER SET POINT

DISCHARGE LINE TEMP

CONDENSER/AIR COOLED

TEMPERATURE IN TEMPERATURE OUT

FAN MOTOR AMPS VOLTS

SIGHT GLASS LIQUID LINE TEMP

EVAPORATOR/AIR COOLED

TEMPERATURE IN TEMPERATURE OUT

FAN MOTOR AMPS VOLTS

TIME OF DAY ________________________________

WEATHER SUNNY CLOUDY RAINY

PEAKE INDUSTRIES LIMITED177 WESTERN MAIN ROAD,COCORITE, P.O. BOX 1221,

PORT OF SPAIN, TRINIDAD, WESTINDIES

TEL: (868) 622-PEAK (7325)FAX: (868) 622-4580

e-mail: peake@peakeind.com http://www.peakeind.com