Component Replacement Guidelines For AIRSYS Wall Packaged Units Models 6.E1C2 8.E1C2 10.E1C2 13.E1C3 15.E1C3 18.E1C4
1. Preparation 1) Components list Work flow instruction of WPU components replacement NO Name Pictures Tools Labor Mechanical Parts 1 Compressor Welding torch Compressor Welding material 1 preson Wrench 2 Compressor crankcase heat belt Compressor heat belt Terminals Needle nose pliers 1 Oblique pliers Crimping pliers 3 High pressure switch Wrench 1 High pressure switch 4 Low pressure switch Wrench 1 Low pressure switch
5 Condenser fan Speeder Wrench 1 6 Dry filter Welding torch 1 Welding material Wet cloth 7 Thermal expansion valve Welding torch Welding material Wet cloth 1 8 Air Damper Actuator Terminals 1 Needle nose pliers Oblique pliers Crimping pliers wrench 9 Fin Electric Heater Terminals 1 Needle nose pliers Oblique pliers Crimping pliers wrench
10 Condenser fan Terminals 1 Needle nose pliers Oblique pliers Crimping pliers Wrench 11 Evaporator fan Terminals 1 Needle nose pliers Oblique pliers Crimping pliers Wrench Screw driver 12 Run capacitor Multi-driver 1 13 Air pressure differential switch Multi-driver Oblique pliers 1 2. Procedures Note: For security, who charged for the WPU system service, must comply with the follow rules. 1) Before maintain the WPU system, all the components must be powered off. 2) If the electric heaters are broken, after powered off the WPU, should make sure the electric heaters are cold. 3) All the maintenance of the refrigerant circuit need to discharge all the refrigerant of R407c. Compressor replacement Procedures of compressor replacement
1) Turn off the WPU, using screw driver to open the middle-front panel, down-front panel. 2) Using the driver to remove the high pressure gas temperature switch. (In the latest product, the switch has been removed) Remove the switch 3) Take off the cover, disconnected the cable. 4) Release the spring, and then, take off the compressor crankcase heating belt. Disconnected the cable Release the spring, then, take off the compressor crankcase heating belt. 5) Using wrench to remove the screw at the bottom of compressor. 6) Remove the heat insulating material around the low pressure tube Remove 4 screws Remove the heat insulating material 7) Take out the valve core of the valve. (6 valves) 8) Put the wet cloth around the copper tube where has joint. Using the welding torch to melt the connection material, then, remove the compressor.
9) Replace a new one in the unit, fastened the 4 screws first, take on the compressor heating belt, then, using the welding torch to connect the copper tubes with compressor inlet and outlet. Remove or connect the copper tube Compressor crankcase heating belt replacement Procedures of compressor crankcase heat belt replacement 1) Cut off the electrical cable, then, take off the compressor crankcase heating belt. Cut off the electrical cable 2) Replace a now one, take on the compressor crankcase heating belt, as the cable find the connection joint, reconnect the cables. High pressure switch replacement Procedures of High pressure switch replacement 1) Take off the terminals from high pressure switch. 2) Using wrench to loosen the connector, and remove it quickly.
Take off the terminals Loosen the connector 3) Replace a new one, fasten the connector quickly, and then, put the two terminals back. Low pressure switch replacement Procedures of low pressure switch replacement 1) Take off the terminals from low pressure switch. 2) Using wrench to loosen the connector, and remove it quickly. Take off the terminals Loosen the connector 3) Replace a new one, fasten the connector quickly, and then, put the two terminals back. Condenser fan speeder replacement Replace the low pressure switch need not to discharge refrigerant of R407c. Procedures of low pressure switch replacement 1) Using multi-drivers to remove the electrical connector. 2) Using the wrench to loosen the connector, and then, remove the condenser fan speed quickly.(in the latest product the fan speeder was replaced by the pressure switch )
Remove the electrical connector. Loosen the connector 3) After remove the tube, don t lose the core. 4) Replace a new one, fastened the connector quickly, and then, put the electrical connector back.
Dry filter replacement Procedures of dry filter replacement 1) Put the wet cloth around the sight glass near the dry filter, and take off the valve core. 2) Using the welding torch to melt the connection material, then, remove the dry filter. Remove the dry filter 3) Replace a new one, using welding torch to connect the copper tube with dry filter inlet and outlet.
Thermal expansion valve replacement Procedures of thermal expansion valve replacement 1) Before take off the thermal expansion valve, take the valve core out of the valve Take the valve core out 2) Put the wet cloth around the copper tube near the thermal expansion valve inlet joint and outlet joint. Using the welding torch to melt the connection material, then, remove the thermal expansion valve. Put the wet cloth around the tube. 3) Replace a new one, using welding torch to connect the copper tube with thermal expansion valve inlet and outlet, and connect by-pass tube with thermal expansion valve. Run capacitor replacement Procedures of run capacitor replacement 1) Take off the terminals from the run capacitor. 2) Replace a new run capacitor. Take off the terminals
Air pressure differential switch replacement Procedures of air pressure differential switch replacement 1) Take off the cover, disconnect the cable. 2) Cut out the zip tape. Disconnect the cables Disconnect the cables ` 3) Replace a new one. Air damper actuator replacement Procedures of air damper actuator replacement 1) Open the damper cover of the unit by using screws. 2) Loosen the nuts, and the remove the damper. Loosen the nuts. 3) Remove the air damper actuator. 4) Take off the plug and replace it.
Take out the block. Remove it by hand Take out the plug.
Electric heater replacement Procedures of air damper actuator replacement 1) Remove the left panel and right panel 2) Take off the electric connectors, and disconnect the cable from heater. Take off the connectors 3) Loosen the nuts at the both terminals of the electric heater, and the remove the broken one. Loosen the nuts 4) Replace a new one, reconnect the cable to the electric heater, and put the electric connector back.
Condenser fan replacement Procedures of condenser fan replacement 1) Disconnect the cables and make a record of the cable. Loosen the 4 screws 2) Loosen the 4 screws and remove the condenser fan. 3) Replace a new one, fasten the 4 screws first, and then, reconnect the cables.
Evaporator Fan (EC Fan) Replacement The procedures of evaporator fan (EC fan) replacement 1) Turn off the WPU, and open the front panel, electrical box panel. 2) Take off the left and right cover, you will find there is a fan, that s evaporator fan, also called EC fan. Evaporator fan, also called EC fan. 3) Cut out the junction terminals, record which cable connect which cable. Junction terminals of the EC fan 4) In order to protect the fin of evaporator coil, using a wooden board or metal sheet up to the evaporator. Wooden board or sheet metal
5) Remove the 6 screws from the plate, and take out of the fan, replace a new one. the 6 screws and remove the wooden board. 7) Reconnected the cables as the record, the connection should protect water. 6) After replaced the fan, assembled the fan, fastened
Replacement of Condenser Coil The procedures of condenser coil replacement 1) Turn off the WPU. 2) Remove the middle-front panel, up-front panel, right panel and left panel using the screw driver. Condenser Coil 3) Disconnect the cables of the condenser fan first, and then remove the condenser fan using the screw driver.
WPU Component Replacement 4) Remove the top-cover using the screw driver 5) Remove the bar around the condenser coil by electronic driver. 6) Using the welding torch to melt the connection material and using the wet cloth to prevent the sheet metal from burning. Page 18 of 20 Write: Wu Bo Date: 16/1/12 www.air-sys.com
WPU Component Replacement 7) After disconnect the copper tube, remove the condenser coil (2 persons). 8) Replace a new condenser and reconnect condenser inlet and outlet using the welding torch, put back the top-cover, condenser fan, finally reconnect the condenser cable. Page 19 of 20 Write: Wu Bo Date: 16/1/12 www.air-sys.com
WPU Component Replacement Product Name & Part No. Mobilecool-outdoor.DL.8E1C2/4070141100; 13E1C3/4070132100; 18E1C4/4070141400 Item No. Manufacturer Supplier Description Used for WPU 8251004640 Condensor fan 8E1C2(2.5TR) 8252026800 Condensor fan 13E1C3(3.5TR) & 18E1C4(5.0TR) 8252027340 Evaporator fan 8E1C2(2.5TR) & 18E1C4(5.0TR) 9RD2007002-0026 Evaporator fan 13E1C3(3.5TR) 8151008720 Compressor 8E1C2(2.5TR) 8151008400 Compressor 13E1C3(3.5TR) 8151008750 Compressor 18E1C4(5.0TR) 5000000460 Condensor coil 8E1C2(2.5TR) 2070220330 Condensor coil 13E1C3(3.5TR) TBD Condensor coil 18E1C4(5.0TR) 8155411330 Thermal Expansion Valve 8E1C2(2.5TR) 8155411810 Thermal Expansion Valve 13E1C3(3.5TR) & 18E1C4(5.0TR) 8355005210 Dry Filter 8E1C2(2.5TR) 8355005220 Dry Filter 13E1C3(3.5TR) & 18E1C4(5.0TR) 2855043550 Main Air Filter 8E1C2(2.5TR) 8252505930 Main Air Filter 13E1C3(3.5TR) 8252506940 Main Air Filter 18E1C4(5.0TR) 8252505470 Premilinary Air Filter 8E1C2(2.5TR) 8252505940 Premilinary Air Filter 13E1C3(3.5TR) 8252506950 Premilinary Air Filter 18E1C4(5.0TR) 8455521300 8455520690 8454516270 8454516050 8454507290 8454505250 8454507290 Micro Breaker S202-C25 Micro Breaker S202-C32 AC Contactor A16-30-01 AC Contactor A26-30-01 AC Contactor A30-30-01 AC Contactor A16-30-10 AC Contactor A30-30-10 8455520990 8455520710 8454516400 8454516070 8454516430 8454516060 8454516420 Micro Breaker GSB2-C25/2 Micro Breaker GSB2-C32 AC Contactor GSC1-1801 AC Contactor GSC1-2501 AC Contactor GSC1-3201 AC Contactor GSC1-1810 AC Contactor GSC1-3210 8E1C2(2.5TR) 13E1C3(3.5TR) & 18E1C4(5.0TR) 8E1C2(2.5TR) 13E1C3(3.5TR) 18E1C4(5.0TR) 8E1C2(2.5TR) & 13E1C3(3.5TR) 18E1C4(5.0TR) TBD Run Capacitor 8E1C2(2.5TR) 8457003090 Run Capacitor 13E1C3(3.5TR) TBD Run Capacitor 18E1C4(5.0TR) 8454020690 Low Pressure Switch All WPU 8454020600 High Pressure Switch All WPU 8254002380 Fin Electric Heater 0.8kW All WPU 8254002180 Fin Electric Heater 1.0kW All WPU 8254002200 Fin Electric Heater 1.5kW All WPU 8254002390 Fin Electric Heater 2.0kW All WPU 8254002210 Electric heater protection All WPU 8452000770 Condensor fan pressure switch All WPU 8459600760 Crankcase heater All WPU 8456034350 Intermediate Relay with Seat All WPU 9000001327 Air Damper Actuator All WPU 8454020540 Air Pressure Switch All WPU ASLLC.2 / 2040303110 WPU: Replacement Part List 8453001460 Controller Board All WPU 8453500380 User Interface All WPU 9000000357 NTC Temperature Sensor All WPU 8454020720 Humidty Sensor All WPU 8453001280 Communication Card All WPU 8453512130 Clock Card All WPU 8455520230 AC to DC Convertor All WPU 8455520680 Micro Breaker S202-C6 8455520700 Micro Breaker GSB2-C6 All WPU For Spare Parts or other Support in the United States Contact Telecom Solutions, LLC HVACSupport@tempesttelecom.com 855-874-5380 Page 20 of 20 Write: Wu Bo Date: 16/1/12 www.air-sys.com