Verde GSE PCA Bridge and Ground Mount Units 30/45/60/90/120 Tons. Installation and Maintenance Manual

Transcription

1 Verde GSE PCA Bridge and Ground Mount Units 30/45/60/90/120 Tons Installation and Maintenance Manual Rev. 09/17/2016

2 Table of Contents SAFETY... 3 GENERAL DESCRIPTION... 4 MOVING AND STORAGE... 4 INITIAL INSPECTION... 5 LOCATION... 5 INSTALLATION... 5 Ground Mount Installations... 6 Condensate Connections... 6 Duct Connections... 6 Electrical High Voltage... 7 Electrical Low Voltage... 8 Unit Controls and Start Up... 9 Standard Units 30T/45T/60T/90T/120T OPTIONS Heat Condensate Collection Premium Efficiency Unit Air Filter and Evaporator Pressure Difference Sensors Maintenance Blower Characteristics Compressor Characteristics Wiring Diagrams 60Ton PCA Unit... 19

3 SAFETY WARNING: Installation and servicing of this equipment can be hazardous due to system pressure and electrical components. Only trained and qualified personnel should install, repair, or service the equipment. DANGER: Before performing service or maintenance operations on the system, turn off main power to the unit. Electrical shock could cause personal injury or death. WARNING: When working on equipment, always observe precautions described in the literature, tags, and labels attached to the unit. Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing, and place a fire extinguisher close to the work area. NOTE: To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must be serviced only by technicians who meet local, state, and federal proficiency requirements. NOTE: All refrigerant discharged from this unit must be recovered WITHOUT EXCEPTION. Technicians must follow industry accepted guidelines and all local, state, and federal statutes for the recovery and disposal of refrigerants. If a compressor is removed from this unit, refrigerant circuit oil will remain in the compressor. To avoid leakage of compressor oil, refrigerant lines of the compressor must be sealed after it is removed. NOTE: To avoid equipment damage, DO NOT use these units as a source of heating or cooling during the construction process. Doing so may affect the unit s warranty. The mechanical components and filters will quickly become clogged with construction dirt and debris, which may cause system damage.

4 GENERAL DESCRIPTION Verde GSE Pre-conditioned air (PCA) units are high performance, high efficiency air conditioning units spanning 30 ton to 120-ton nominal cooling capacities. The units are built on a common refrigeration system design, sharing common components for reduced maintenance inventory and simplified maintenance training. All Verde GSE Pre-conditioned air units conform to UL 1995 standard and are certified to CAN/CSA C22.2 No 236 by Intertek-ETL. Verde GSE units are designed to operate from -20F to 120F outdoor ambient conditions. All PCA units are designed for outdoor use. The units are designed for 100% fresh air operation with delivery air temperatures down to 25F. Verde PCA units can provide heated air with Verde s heat pump option. The frame is constructed of heavy gauge steel with a durable powder coat paint. All side and top panels are fabricated from aluminum for light weight and ease of handling. Verde GSE s Verde-ICE (ICE = Intelligently Controlled Environment) online monitoring and control system is standard on each unit, providing supervisory personnel and facilities/operations personnel with current and archived data on every PCA unit operation. Options available for Verde GSE PCA units include: Bridge mount bracket option Ground mount stand option Heat pump option (higher capacity, higher efficiency and improved safety over electric heaters) Premium efficiency option package Filter and evaporator differential pressure diagnostics package Condensate collection and management package On board safety features will protect the major components from damage under most foreseeable installation and operation problems. MOVING AND STORAGE If the equipment is not needed for immediate installation upon arrival at the job site, it should be left in its packaging and stored in an area protected from construction debris. Units must be moved and stored in the normal upright position at all times. Use caution to avoid damage to enclosure panels and duct fittings when storing or handling units. NOTE: Never lift or move units by external duct fittings or attached options/ accessories. NOTE: Never stack units.

5 INITIAL INSPECTION Be certain to inspect each unit as received at the job site before signing the freight bill. Verify that all items have been received and that there is no visible damage. Note any damage or shortage on all copies of the freight bill. In the event of damage or a shortage it is the responsibility of the purchaser to file the necessary claims with the carrier. Concealed damage not discovered until after removing the units from packaging must be reported to the carrier within 24 hours of receipt. LOCATION Locate the unit outside in an area with unrestricted access to outdoor air. Ground mounted units must be placed on stands (available from Verde GSE) that provide proper clearance for air flow into the unit. Verde GSE bridge mount option package provides proper clearance from bridge (requires bridge manufacturer information). The back of the unit must have sufficient clearance to allow facilities personnel to remove the back panel for air filter replacement. INSTALLATION The following are installation instructions for all Verde GSE PCA units. Bridge Mount Installations Verde PCA units can be suspended from a passenger boarding bridge by using the Verde GSE bridge mount option package (see Figure 1). Verde GSE s bridge mount package includes options for major bridge manufacturer designs. Custom bridge mount bracket packages may also be designed. Standard bridge mount kits for 30, 45 and 60-ton units consist of two structural frame members that span the width of the unit and four brackets that are bolted to the bridge flange structure. Four threaded rods and associated hardware fasten the PCA unit to the mount frame members. Larger 90 and 120-ton PCA units require two bridge mounting kits. Figure 1: Photo of Verde GSE bridge mounted PCA unit.

6 Ground Mount Installations Verde PCA units can be ground mounted with Verde GSE s PCA ground stands (See Figure 2). Four ground stands are required for Verde GSE s 30, 45, and 60-ton PCA units. Eight ground stands are required for Verde GSE s 90 and 120-ton units. Figure 2: Verde GSE ground mounted PCA. Condensate Connections Verde GSE PCA units can either allow water condensate during cooling mode to flow freely on the tarmac below or to be pumped to a drain by using Verde GSE s condensate collection and pump system. For both configuration, a plastic condensate collection tube exits the bottom of Verde GSE PCA units. The tube can be connected to other tubing, piping or hoses using standard fittings. Duct Connections Standard aircraft industry flexducts connect to a Verde GSE PCA unit s outlet ducts. Verde GSE s 30, 45, and 60-ton PCA units can be ordered with either a single 14-inch diameter outlet duct or with dual outlets for aircraft and passenger boarding bridge air supply. For dual duct units, one duct is a standard 14-inch diameter aircraft delivery air duct. The other duct for passenger boarding bridge air supply can be either 8 inches or 12-inch diameter, depending on bridge supply duct size. Verde GSE s 90 ton and 120-ton units with large wide body and jumbo air supply capability are equipped with two 14-inch diameter aircraft delivery ducts. An optional bridge supply duct (8 inch or 10-inch diameter) can also be ordered. Contact Verde GSE for custom outlet duct configurations.

7 Electrical High Voltage Ground Lug High Voltage Connections All field installed wiring must comply with the National Electric Code as well as all applicable local codes. Refer to the unit electrical data on the unit name plate for wire and branch circuit protection sizing. Supply power voltage and phasing should match the required voltage and phasing shown on the unit name plate. Operating the unit below the minimum voltage, above the maximum voltage or with incorrect phasing can result in poor system performance or damage to the PCA unit. All field wiring should be installed by qualified and trained personnel. Field power should be connected to the marked terminals on the PCA disconnect switch (see Figure 3). A phase monitor shown in Figure 3 checks phase order. An LED on the phase monitor illuminates when phases are in proper order. If the LED does not light when power is applied to the unit, switching two phases should correct the phase order. Phase Monitor Figure 3: Verde GSE high voltage connections.

8 Electrical Low Voltage One or two low voltage, weatherproof connectors are located on the upper frame member at the duct exit end of Verde GSE PCA units. One connector is for an Operator Station ( Op Station) and the other is for a Passenger Boarding Bridge (PBB) Station (for units equipped with the PBB conditioning option). When two connectors are present, either connector can be used for connecting the Op Station and PBB Station control boxes. Figure 4 shows the location of the low voltage connectors. Both the Op Station and the PBB Station are digital controllers that communicate over CANbus communication to the Verde-ICE controller. The low voltage cable also includes 24VAC voltage for powering Op Station and PBB Station status lights and control board. Figure 4: Op Station and PBB Station weatherproof connectors.

9 Unit Controls and Start Up Verde GSE PCA units require no field tuning nor charge adjustments due to local climate or usage. After mounting a PCA unit (bridge or ground), connecting power wiring (and determining proper phase orientation), and connecting the Op Station (and optional PBB Station), the unit is ready to operate. Verde GSE PCA units are controlled with a weatherproof Op Station, shown in Figure 5. Single frame units (30, 45, and 60 ton) can be operated in RJ (Regional Jet), NB (Narrow Body or Single Aisle) and WB (Wide body or Two Aisle) aircraft modes. PCA units can have Cool, Vent and Heat mode capability. The white status light indicates that the PCA unit has power and is ready to operate. A flashing white light indicates a fault and that PCA maintenance personnel should be contacted. After setting aircraft and conditioning mode switches, the green Run button is pressed to operate the PCA unit. The green button will illuminate, indicating operation of the PCA. The red Stop button is pressed in order to stop the unit. For units with the PBB conditioning option, blue light illuminates when the unit is operating in PBB conditioning mode. Ground personnel can discontinue PBB operation by pressing the Stop button on the ground mounted Op Station. The PCA can then be placed in one of the aircraft conditioning modes and restarted by pressing the green button on the Op Station. A PBB Station is included when the PBB conditioning option is used with a Verde PCA unit. Figure 6 shows the PBB Station. The white status light informs bridge personnel that the unit is operational. If the green light is illuminated, the unit is operating in one of the aircraft conditioning modes. Bridge personnel can deactivate aircraft air conditioning by pressing the stop button on the PBB Station. Bridge personnel can then initiate bridge conditioning by pressing the green start button on the PBB Station. The green light will illuminate to show that the PCA unit is operating and the blue light will illuminate to show that the PCA unit is in bridge conditioning mode. Bridge personnel can stop PBB conditioning by pressing the red Stop button. Ground personnel can also press the Stop button on the ground mounted Op Station to discontinue PBB mode operation. The PBB Station Stop button will also discontinue the PCA operation in one of the aircraft conditioning modes. Figures 7 and 8 are operation diagrams describing starting and stopping a PCA unit with the Op Station and PBB Station.

10 Figure 5: Op Station mounted in convenient location for ground personnel. Figure 6: PBB Station mounted in convenient location on the PBB for PBB conditioning.

11 Figure 7: Diagram of Verde GSE PCA unit startup operations.

12 Figure 8: Diagram of Verde GSE PCA stopping operation.

13 Standard Units 30T/45T/60T/90T/120T Nominal Verde GSE PCA unit capacities of 30, 45, 60, 90 and 120-ton cooling and heating capacities. Schematic layouts of these units are shown in Figure 9. Verde 30Ton units are based on a single 32 ton scroll compressor with associate microchannel condenser, aluminum fin/copper tube evaporator, electronic refrigerant valves (expansion and hot gas for AC only systems), delivery air blower (20/30/40hp) and condenser fan. Electronic controls are housed in a NEMA 4 electrical enclosure that is actively cooled with air from the PCA. Verde 45Ton and 60Ton units are identical with dual (independent, non-tandem) refrigeration circuits. Verde 45Ton PCA unit uses a 15 ton scroll compressor for the second cooling circuit while the 60Ton PCA unit uses a second 32 ton scroll compressor. The standard 45Ton PCA uses a 20hp blower while the 60Ton PCA uses a 40hp blower. Note that 20, 30 and 40 hp delivery air blowers are available and mount on a common frame with a common connection to the delivery air plenum. Delivery air blower and condenser fan motors are speed controlled with high quality variable frequency drives (vfd). Verde GSE 90Ton and 120Ton PCA units consist of twin 45Ton and twin 60Ton PCA units. Dual duct outlets exit the 90Ton and 120Ton units. When used for jumbo jet operation, the second (slave) unit is controlled by the first (master) unit. The units can also be operated individually, providing flexibility for MARS (Multiple Apron Ramp System) airport operation. All major components (compressors, condensers, blower, and evaporator) can be removed from adjacent side panels. Compressors can be removed from front or side panels as well as lowered out of the unit by removing four bolts from the bottom mount panel. Major components (Verde-ICE controller, condensers, evaporators, refrigerant valves, condenser fans) are identical across all units. In addition, large and small compressors (32 ton and 15 ton) and large and small blowers (40hp and 20hp) are interchangeable with the common Verde GSE PCA base frame. That is, a 45-ton cooling system can convert to a 60 ton unit by interchanging a compressor and blower. All refrigeration circuits have identical refrigerant charge (11 pounds of R410A).

14 (a) 30 Ton configuration (c) 90 Ton and 120 Ton configurations (b) 45 Ton and 60 Ton configurations Figure 9: Schematics of 30Ton (a), 45Ton/60Ton (b), and 90Ton/120Ton (c) PCA units.

15 OPTIONS Heat Verde GSE has developed a cold temperature heat pump with increased airflow, increased heating capacity and increased heating efficiency in comparison to traditional electric resistance heat. The heat pump option includes additional refrigerant control valves and operation algorithms. During cold weather conditions, the heat pump operates in reverse of the air conditioning mode with aircraft delivery air heated while heat is removed from air flowing through the microchannel heat exchangers. Heat pumps reduce the frequent breakdown of electric heating elements and minimize the fire hazard of electric resistance heating. Additionally, heat pump operation provides greater heating capacity that allows higher air flows into the aircraft, avoiding the low flow winter operation common to electric heating systems. Condensate Collection Verde GSE condensate collection option consists of a 10-gallon condensate collection tank and diaphragm pump that can pump condensate to a remote drain rather than direct drainage on the tarmac. Premium Efficiency Unit Verde GSE premium efficiency units include a 50hp variable frequency drive (vfd) for operating one of the system compressors. The vfd increases the PCA unit s part load efficiency, and can result in fast payback at airports with significant PCA unit operation hours. The vfd is enclosed in an actively cooled NEMA 4 electrical enclosure mounted on the base frame within the PCA unit. Air Filter and Evaporator Pressure Difference Sensors Differential pressure sensor options provide maintenance information for monitoring dirty air filters at the blower inlet and dirty evaporators. The pressure sensors are housed in a NEMA 4 enclosure with tube fittings that connect to barb coupling located on the filter and evaporator housings. Signal wire connections to the Verde-ICE control board provide online information for just-in-time maintenance. Maintenance Filter changes or cleaning are required at regular intervals. The time period between filter changes will depend upon type of environment the equipment is used in. Blower and fan motors require lubrication based on hours of operation and motor manufacturer recommendations. Periodic inspection of high and low voltage wiring and connections should be performed and any frayed or corroded wires attended to.

16 Blower Characteristics 20hp Aerovent blower characteristics (30 and 45-ton PCA units)

17 40hp Aerovent blower characteristics (60, 90 and 120-ton PCA units) Note: 90 and 120-ton units use two 40hp blowers

18 Compressor Characteristics Verde GSE PCA units use Bitzer R410A, hermetically sealed scroll compressors. 32-ton Bitzer scroll compressors are common to all PCA units. However, 16-ton Bitzer scroll compressors are used in 45 ton and 90-ton units in addition to 32-ton Bitzer scroll compressors. Bitzer 32-ton compressor model: GSD80385VA Orbit 8 Bitzer 15-ton compressor model: GSD80182VA Orbit 8

19 Wiring Diagrams 60Ton PCA Unit

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