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- Zamil
- Air Conditioner
- MAC-240
- Installation, Operation & Maintenance Manual
Zamil MAC-240 Installation, Operation & Maintenance Manual
Summary of MAC-240
Page 1
Mobile air conditioning system model: mac-240 installation, operation & maintenance manual.
Page 2: Index
1 contents page general ................................................................................................................................................................... 3 1. Foreword .....................................................................................................
Page 3
2 contents page 5. Start-up & shutting down sequence .................................................................................................... 26 5.1 visual inspection of equipment (check list) ................................................................................ 26-27 5.2 star...
Page 4: General
3 general general statement the zamil mobile air conditioning units are designed & built for the optimum performance. However, it is required that you become well acquainted with good practices for the proper installation/operation/and maintenance procedures in order to ensure a safe trouble free op...
Page 5: 1. Foreword
4 1. Foreword the purpose of this document is to give a brief description of the mac240 mobile air conditioning equipment, its speci- fication and other relevant information related to maintenance and safe operation of the equipment. 2. Standard specification the zamil mac240 mobile air-conditioning...
Page 6
5 unit top view & access door location • complete back side access is provided with two easy open lockable latched hinged doors to access the power genera- tor and its components. The first one is to access the genset’s control panel and provided with outer sight glass allowing quick visual monitori...
Page 7
6 the trolley system is designed with front turnable axle by means of swivel bearing and both front and rear axles are mounted on heavy duty leaf springs allowing the required vibration damping to the upper components. This design allows towing the mac240 from the front side of the trolley toward th...
Page 8
7 b. Alternator this type alternators are brushless, self-regulating and incorporate a rotating inductor with damper cage winding and a fixed stator with skewed slots. The stator windings have a shortened pitch to reduce the harmonic content of the output waveform. The alternators are made in compli...
Page 9
8 d. Alarms & shutdowns:.
Page 10
9 2.3 unit physical data model number mac240 nominal capacity (tons) @ 95 0 f ambient 24 capacity (tons) @ 115 0 f ambient 21 application industrial, 100% fresh air power supply (v-ph-hz) 460-3-60 compressor type scroll part # (qty.) 800-674-19 (2) refrigerant r-22 operating charge per system, oz 45...
Page 11
10 2.3.1 unit specification summary 1. General • length (overall): 141.7 inches (3600mm) • width (overall): 86.9 inches (2210 mm) • height (overall): 104.5 inches (2654mm) • weight (approximate): 8800 lbs (4000 kg) • storage temperature: 40 ° f to 120 ° f(clean and dry place) • fuel tank capacity(ap...
Page 12
11 2.4 air conditioning section (acu) the factory assembled air conditioning unit has cooling or combination of heating (optional) and cooling as a single package, suitable for mobile applications. The cooling system consists of two stage refrigeration compressors, with each stage having a closed lo...
Page 13
12 2.5 electrical enclosure assembly the unit has two electrical enclosures, one for the generator engine’s control and the other serves as the unit’s main control panel. The main unit control panel enclosure is designed with hinged access door and according to nema 4 requirements. The internal powe...
Page 14: 3. Refrigeration System
13 2.6 operating from external power source the equipment may also be operated from an external power source. The power source rating shall be having a nominal voltage rating of 460v-3ph-60hz and can adequately handle the equipment’s power consumption of 55kva. When the equipment is operated from an...
Page 15
14 schematic refrigeration diagram.
Page 16
15 3.3 major refrigeration components the model mac240 is equipped with two copeland hermetic scroll compressor. The compressors have a rated cooling capacity of 12 tons each and one compressor is used in each refrigerant circuits. Located in the condensing section and are accessible through front a...
Page 17
16 the scroll compressor consists of two involutes or archimedean spirals. One spiral is positioned inside the other to form a series of crescent-shaped pockets. During compression the upper spiral remains stationary and the lower one, being eccentrically mounted on the drive shaft, describes an orb...
Page 18
17 refrigerant enters the compressor at the suction connection and flows around the motor’s housing and enters at the bottom side through the openings. Oil droplets separate from the refrigerant and fall into the oil sump. All suction refrigerant passes through the electrical motor, ensuring full mo...
Page 19
18 3.3.7 hot gas by-pass control hot gas bypass control is provided in the both circuit to permit operation of the system down to 80 % of its unloaded capacity. Under low ambient condition, it controls temperature by eliminating the need to cycle the compressor on and off, ensuring narrow temperatur...
Page 20
19 01 03 02 08 15 06 05 02 evaporator coil 03 condenser coil 04 expansion valve 05 vibration eliminator 06 hgbp line 07 vibration eliminator 08 muffler 09 ball valve 01 compressor 04 07 08 09 3.4 refrigeration system assembly.
Page 21: 4. Control System
20 4. Control system 4.1 general description: the acu section control is managed by a 16-bit microprocessor board fixed in the main control panel with a separate lcd display as user’s interface. The control board completely controls the operation of the refrigeration system; i.E., compressors and co...
Page 22
21 compressor run/off timing in different cooling modes a) low cool mode – in this mode, cooling is in intermittent operation. Cooling is active for 10 minutes and stops for 3 minutes in every 13 minutes timing interval. Compressors are alternated in a way that at least one compressor in the unit is...
Page 23
22 4.3 supply fan speed control 4.3.1 general description the supply fan motor is connected to a variable frequency drive device (vfd) to regulate its speed and thereby control- ling the air flow. At start-up, the motor will gradually increase its speed until the desired or set cfm is met. The devic...
Page 24
23 main control panel switches & indicators the description and function of each of the switches and lamps are as follows: 1) temperature lcd display – this lcd window will display the temperature of the supplied air. In the process of parameter changing, the lcd will display the data that is being ...
Page 25
24 16) acu alarm lamp – this lamp will light if there’s a fault in the acu system. The nature of the fault will be described in the lcd window #2 of the acu’s control panel. 17) alarm reset button – if there’s a fault, pushing this button will re-set the system. The lighted fault indicating lamps wi...
Page 26
25 the description and functions of the control buttons on the module panel are as follows: 1) stop/reset button – this button places the module into its stop/reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. The fuel supply will be removed and if ...
Page 27
26 the description and function of the sensors are as follows: a) air velocity sensor – the function of this sensor is to measure the air velocity (mass flow). The working range air velocity is adjustable up to 20 m/s. Output signal is 0~10v range and transmitted to the microprocessor board which wi...
Page 28
27 instructions down discharge application (optional) plenum extension fixing bolts (middle two bolts only) plenum extension make sure, this part to be fixed inside discharge opening as shown , for down discharge application prior to fix spiral flexible duct connection. Plenum extension fixing bolts...
Page 29
28 5.2 starting the generator engine a) switch “on” the isolating switch of the dc battery in the generator set section. The “lever” should be pointing towards the operator to be in “on” position. B) turn the key provided in the generator module to switch “on” power to the module. The module’s lcd d...
Page 30
29 5.4 machine shutdown a) the system is stopped by pressing again the on/off” button on the user interface board. The “on” led is switched “off” and on the lcd display will show the status “stopping”. All the compressors will stop and the supply fan shuts off after a pre-set timing of 30 seconds. B...
Page 31
30 6. Alarms and troubleshooting guide 6.1 description of alarms (fault) this section describes the various alarms that can be shown in the lcd display of the user interface board in the main control panel. The alarms are handled only if the controller is in “on” status. Once the alarm condition has...
Page 32
31 6.2 trouble shooting guide fault description probable cause a) loosed wiring connections on relay ar4-3b (nc) terminal to terminal a11 of mb board. B) clogged or crimped hose fixed at high/ low pressure outlet of air flow switch. C) defective ar4 relay. D) defective time delay switch (tds) vfd fa...
Page 33: 7. Protection Devices
32 fault description probable cause low refrigerant pressure high pressure at discharge line fault on generator fuel level is low (10%) 1. No control power (24v circuit) 2. No control power (230v) 3. Serial cable (uib to mb) loose or defective corrective measure - check hot gas by-pass solenoid if n...
Page 34: 8. Accessories
33 8. Accessories 8.1 fuel fill station assembly the diesel fuel fill station assembly is mounted on the side of the unit. This assembly contains a protecto-seal cap, an electrically operated fuel level gauge with “push-to-check” switch and a level gauge to indicate fuel quantity available in the ta...
Page 35: 9) Maintenance & Servicing
34 9) maintenance & servicing 9.1 general maintenance this section contains instructions for servicing, inspecting, and preventive maintenance on the model mac240 air conditioner unit. To ensure that the unit is kept in correct operating condition, inspect and maintain it on a regular basis. Proper ...
Page 36
35 engine related systems # operation 50 daily 125 250 500 1000 12000 1 2 hour hour hour hour hour hour year year e10 e20 e30 e40 e50 e60 e70 8 inspect for leaks x 9 replace fuel filter cartridge x 10 clean fuel pre-cleaner x 11 drain sediment from tank x x x x 12 inspect air intakes for restriction...
Page 37
36 # operation every time used 1 3 6 12 36 clean pre- & final air filters & replace if required. X 37 clean evaporator coil, drain pan & drain line. X 38 clean condenser coil. X 39 lubricate blower motor/condenser motor. X 40 check/clean electrical connections, controls & control box. X 41 check all...
Page 38
37 9.3 air conditioning system the model mac240 air conditioner unit provides reliable operation while requiring a minimum of service and mainte- nance. This chapter contains information on servicing and maintaining the unit for optimum performance. Detailed ser- vice and maintenance procedures on t...
Page 39
38 9.4 moisture in a refrigerant system: the filter drier in the system removes particles and small amounts of moisture which may enter the system during minor servicing or fault conditions. Major moisture intrusion through fault or contamination may require complete system evacu- ation for moisture...
Page 40
39 table-2: boiling temperatures of water at converted pressure temperature in degrees inches of vacuum microns ,, pounds per square inch fahrenheit ( ° f) (pressure) 212 ° 0.00 759,968 14.696 205 ° 5.00 535,000 12.279 194 ° 9.81 525,526 10.162 176° 16.02 355,092 6.866 158 ° 20.80 233,680 4.519 140 ...
Page 41
40 9.5 evacuating the refrigerant system anytime the compressor or refrigerant system is exposed for long periods of time to atmospheric air, becomes contami- nated, or requires removal of the refrigerant charge, evacuate the system using the procedures that follow. Caution: potential for serious da...
Page 42
41 ( 1) testing methods (a) electronic leak detector: this is the easiest method for leak detection. Electronic leak detectors can be used in areas where an open flame is not permitted. Pass the detecting probe over the area of the suspected leak. If a leak is present, the detector sounds a high fre...
Page 43
42 9.8 refrigerant charging & pressure limits if the air conditioning unit is to provide the proper amount of cooling, the refrigerant system needs to be adequately charged with r-22 refrigerant. A shortage of refrigerant is evident by a loss of cooling effect, a low suction pressure, and many bubbl...
Page 44: 10. Equipment Dimensional
43 10. Equipment dimensional det ails model no.: mac240fz600
Page 45
44 11. Main control panel component layout.
Page 46
45 12. Main control panel component parts list.
Page 47: 13. Parts List –Mac240
46 13. Parts list –mac240 zamil part no. Description uom qty 04940003 refrigerant – freon 22 (per system) lb 28 60020008 wrg dgm mobile ac/mac240 fz601 460v-3-60 hz ea 1 80000502 air flow switch ea 1 80000934 fusdel dual element 2 amp 250v ea 2 80000937 fusdel dual element 3.5amp 250v ea 2 80000961 ...
Page 48: Parts List –Mac240
47 zamil part no. Description uom qty 80006200 canopy lock [s/s] ea 4 80006201 end collar [s/s] s.A. Outlet ea 1 80006202 pull handle ea 2 80006204 stkadh towing instruction ea 1 80006205 screw machine pan head (ss) ea 44 80008300 luggnd ea 3 80008615 coupling s.Steel 3/4 size ea 1 80008630 coupling...
Page 49: Parts List –Mac240
48 zamil part no. Description uom qty 80030082 term marker tag # 2 symbol (10nos./strip) ea 1.2 80030083 term marker tag # 3 symbol (10nos./strip) ea 0.2 80030084 term marker tag # 4 symbol (10nos./strip) ea 0.2 80030085 term marker tag # 5 symbol (10nos./strip) ea 0.2 80030086 term marker tag # 6 s...
Page 50: Parts List –Mac240
49 zamil part no. Description uom qty 80044421 labadh cb3 ea 1 80044422 labadh cb4 ea 1 80045026 labadh 7/16" x 1/2" f1 ea 1 80045027 labadh 7/16" x 1/2" f2 ea 1 80045028 labadh 7/16" x 1/2" f3 ea 1 80045029 labadh 7/16" x 1/2" f4 ea 1 80045057 labadh 7/16" x 13/16" cb5 ea 1 80045140 labadh adhesive...
Page 51: Parts List –Mac240
50 zamil part no. Description uom qty 80064650 user interface card-ch [pje] ea 1 80064655 ptc temp sensor (l=7m) for lwt&rwt ch(pje) ea 2 80064656 relative pr transducer (0to40bar)(for dp)[pje] ea 2 80064658 relative pr transducer (-05to10bar)(for sp) [pje] ea 2 80064659 connector serial interface r...
Page 52: Parts List –Mac240
51 zamil part no. Description uom qty 80107915 washer m10 din 9021 a2 ea 20 80107918 washer m5 x 5.3mm - gal din 125 ea 8 80107919 washer 6.4 vz din 125 ea 64 80107920 washer 8.4 vz ea 19 80107921 washer 10.5 din 125 vz ea 2 80107930 washer m12 vz din9021 ea 183 80107947 spring washer m5 x 5.1mm - g...
Page 53: 14. Wiring Diagram
52 ar9-3a vfd ready/fault ar2 47 model 60020008 sw4 ar7-1a (re-set) 18c 18o to mb ar6-1a to mb ar8 55 pn:- ar7 54 comp2 trip relay 53 ar6 relay comp1 trip 2 67 ar10-4a ar5-4a to atb 1 230v ac 8no 49 ar5-1a 17c 17o ar4-1a low fuel sensor relay contact no afs ar3-1a bmr1-2a 50 nc tds 8c to mb relay +1...
Page 54: Wiring Diagram
53 fuse f suction pressure transducer discharge pressure transducer suction pressure transducer discharge pressure transducer 31b + + (a9-dp2) 24b ambient air temp. Sensor (ptc : -10 ~ +50 c) tout=10°c tin=15°c set * menu cooling 75% * esc user interface board on/off * (a10-op2) 1 2 4 3 com1 gnd sh ...
Page 55: 15. Symbols And Legend
54 15. Symbols and legend olr# - 1 (normally closed) external overload relay contact # cc#a -1a cc#a -1b cc# external overload contactor (auxiliary contact) relay (normally open) compressor # (normally closed) contactor (auxiliary contact) compressor # contactor coil compressor # fm # motor contacto...
Page 56: 16. Unit Overall View
55 16. Unit overall view.
Page 57: Unit Rear Side (Genera
56 unit rear side (genera t or section).
Page 58: Optional
57 optional down discharge plenum extension (flexible duct st orage box).
Page 59
58 diesel filling point & fuel gauge.
Page 60: Coil Section
59 coil section.
Page 61: Fan & Motor Assembly
60 fan & motor assembly.
Page 62: Condenser Section
61 condenser section.
Page 63: Opera
62 opera tional p anel.
Page 64: Main Control Box
63 main control box.
Page 65: Vfd & Genera
64 vfd & genera t o r.
Page 66: Generator Display Panel
65 generator display panel.
Page 67: Genera
66 genera t or section.