User Manual 10-1008-92 10-1008-92 101111111021

User Manual
Air Conditioning Unit
Model T51-1426-G010 220 VAC 51T3-1426-G010 220 VAC

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Revisions
Revision 0 1 2 3 4 5 6 Description of Change Preliminary New W/D, updated p2p Updated P2P, Replacement Parts List Updated per customer feedback. E-mail from Mike S on 10-20-03. Added +/-3Hz, website information Add 51T3-1426-G010 Information Added Cooling Thermostat (p/n: 10-1061-13) to replacement parts list per ECO#95580. Updated page 13 & 14 Author DJR DJR KJK RCW DJR DJR FHH Effective Date Aug 05, 2002 Aug 15, 2002 Sep 30, 2003 Oct 20, 2003 Dec05, 2003 May 10, 2004 9/9/04

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Contents
Section Page Application...................................................................................................................... 4 Unpacking and Inspection ............................................................................................. 5 Installation ...................................................................................................................... 5 Wiring ............................................................................................................................. 5 Operation........................................................................................................................ 6 Air Conditioner Alarms................................................................................................... 6 Air Conditioner Functions Table .................................................................................... 7 Maintenance................................................................................................................... 7 Parts Replacement Instructions..................................................................................... 8 Replacement Parts Lists ................................................................................................ 9 Appendix I Technical Data........................................................................................ 10 Appendix II Drawings ................................................................................................. 11-14 Appendix III Warranty ................................................................................................. 15

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Application
Cooling electronic cabinets protects temperature sensitive components and reduces the heat stress and therefore increases the life expectancy of these components. An Air Conditioning Unit is particularly suitable for a temperature range of +40 C to +55 C whereas comparable units such as an air/air heat exchanger or fan and filter units cannot be used to dissipate the heat effectively or economically. Additionally, any requirement to have the enclosure temperature below the maximum ambient temperature forces the design to be an air conditioning unit. The Model T51-1426-G010 & 51T3-1426-G010 Air Conditioning Units were designed to operate in most markets. Therefore, the unit must operate in a very wide voltage range. In order to accomplish this task, a transformer was incorporated into the design (reference wiring section). The transformer allows a wide range of input voltages to the unit while maintaining its cooling capabilities. This unit also includes a heating element for low temperature applications. The Model T51-1426-G010 & 51T3-1426-G010 Air Conditioning Units incorporate a simple design with a dry contact closure, each for malfunction switch (ACU fail) and low temp alarm (Heater fail). ACU fail and Heater fail are combined into one outlet. When properly installed onto the cabinet, the air conditioning unit achieves IP56 protection on the internal air circuit and IP34 on the external air circuit.

Figure 1 - External View (T51-1426-G010)

Unpacking and Inspection

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User Manual 10-1008-92 Directly upon receipt, inspect the Air Conditioning Unit. Check for concealed damage that may have occurred during shipment. Any damage evident should be noted on the freight bill. Damages should be brought to the attention of the delivering carrier within 15 days of delivery. Save the carton and packing material and request an inspection. Then file a claim with the delivering carrier. APW Thermal Management cannot accept any responsibility for freight damage; however, we are ready to assist you in any way possible.

Installation
NOTE: Prior to operating the Air Conditioning Unit, ensure the transformer is configured properly (See wiring section). Failure to follow the proper configuration will void APW s warranty. Mounting hole locations are shown in the Model Drawing in Appendix II. The Air Conditioning Unit is designed for a door mount application. Ensure the mounting rail gasket has been applied onto the units mounting rail prior to installation. Step 1: Mount air conditioner on enclosure taking care not to damage the mounting gasket (Use M5 hardware). Step 2: Allow unit to remain upright for a minimum of five (5) minutes before starting. Caution: Air conditioner must be in upright position during operation. Step 3: Refer to the nameplate for electrical requirements. Wire the unit to a properly grounded power supply. Electrical circuit should be fused with slow blow or HACR circuit breaker.

Wiring
Wiring details are shown in the Wiring Diagrams in Appendix II. There is a 220 VAC transformer in the T51-1426-G010 & 51T3-1426-G010 units. It is VERY important to properly configure EACH air conditioner for the specific application or nominal voltage at each site. Prior to powering the ACU, measure line voltage and frequency with a hand held voltmeter. The 220VAC unit ships with a nominal 220VAC 50 HZ and 60 HZ (Drawing supercedes these values). If you do not measure 220VAC, you MUST re-configure the transformer located behind the internal upper access panel. Failure to do this will void any warranty and may have an adverse affect on thermal performance. To determine the proper tap locations, reference Appendix II wiring diagrams.

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Operation
The air conditioning unit incorporates a simple, but effective control scheme to provide reliable cooling performance. After installation, the air conditioning unit is connected to the cabinet power supply by power cords using commonly available electrical connectors. As there is no ON/OFF switch facility included, the cabinet supply circuitry must include any necessary circuit breakers or electrical cutoffs. See the Technical Data table in Appendix I for power requirements. The air conditioner will operate as soon as 220 VAC power is applied. Once power is applied to the air conditioner, the internal fan is ON at all times. The compressor is ON when the internal air temperature is >35 C and OFF at <25 C as determined by the cooling thermostat located on the electrical panel. The condenser blower is ON when the internal temperature is >35 C and condenser pressure is >165psig; it is OFF at <25 C and/or condenser pressure <95psig as determined by the cooling thermostat and head pressure control switch. The heater is turned ON when the internal air temperature <7 C and turned off when the internal air temperature is >10 C. The heating thermostat located on the electrical panel controls when the heater turns on/off. There is one AC fan on the internal air circuit. The external air circuit has one AC fan. The AC circuit powers the heater, which allows the heater to function during cold temperature startup conditions.

Air Conditioning Alarms

The malfunction switch determines the Air Conditioner alarm and the heater alarm is determined by the temperature of the air in the A/C inlet on the internal air circuit. Both alarms are combined into one outlet. Alarm Item Pins

Alarm.

Possible cause

Contacts Contacts CLOSED OPEN >350psig <275psig Internal fan malfunction External fan malfunction Clogged coil or inlet Heater malfunction Heater Control Thermostat malfunction Auto High temp limit switch malfunction Manual High temp limit switch malfunction Internal fan malfunction

A/C Alarm

1&2

Heater Alarm

1&2

<-4 C

>7 C

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Air Conditioner Functions Table

Item Internal fans External fan Heater ON Temp ALL >35 C <7 C OFF Temp N/A <25 C >10 C ON Press. N/A >165psig N/A OFF Press N/A <95psig N/A

MAINTENANCE
Compressor The compressor requires no maintenance. It is hermetically sealed, properly lubricated at the factory and should provide years of satisfactory operating service. Should the refrigerant charge be lost, recharging ports (access fittings) on the suction and discharge sides of the compressor are provided for recharging and/or checking suction and discharge pressures. Under no circumstances should the access fitting covers be loosened, removed or tampered with. Breaking of seals on compressor access fittings during warranty period will void warranty on hermetic system. Recharging ports are provided for the ease and convenience of reputable refrigeration repair service personnel for recharging the air conditioner. Condenser and Evaporator Blower Motors Blower motors require no maintenance. All bearings, shafts, etc. are lubricated during manufacturing for the life of the motor. If the condenser blower motor (ambient blower) should fail, it is not necessary to remove the air conditioner from the cabinet or enclosure to replace the blower. The condenser blower is mounted on it s own bulkhead and is easily accessible by removing the front cover. Caution: Operation of the air conditioner in areas containing airborne caustics or chemicals can rapidly deteriorate condenser coils, blowers and motors, etc. Contact APW Thermal Management for special recommendations. Refrigerant Loss Each air conditioner is thoroughly tested prior to leaving the factory to insure against refrigeration leaks. Shipping damage or microscopic leaks not found with sensitive electronic refrigerant leak detection equipment during manufacture might require repair or recharging of the system. This work should only be performed by a qualified professional, generally available through a local, reputable air conditioning repair or service company. Refer to the data on the nameplate that specifies the type of refrigerant and the charge size in ounces. Before recharging, make sure there are no leaks and that the system has been properly evacuated into a deep vacuum. Screen & Coil Inspect and clean bug screen and dirty coil as required.

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Parts Replacement Instructions

Should it be necessary to service the air conditioner, disconnect the cabinet circuit breaker and remove all power from the power cords and disconnect the power cords before disassembling or servicing the unit. Items that can be accessed from the internal side of the unit are: Internal AC fan Heater Auto High temperature limit switch Manual High temperature limit switch Head Pressure Control Thermal Expansion Valve Low temperature Alarm Thermo-Stats (Heating & Cooling) Run Capacitors (Internal & External Fans, Compressor) Transformer Items that can be accessed from the external side of the unit are: External fan Compressor Filter Dryer Malfunction Switch To replace the internal fan, first remove the upper internal access panel. Next, remove the fan-mounting panel. The fans are attached to the mounting panel with (4) M4 screws. Replace all components in reverse order. To replace the external fan, perform the following: Disconnect the power & neutral wires for the condenser motor by unplugging the 4-position Mate-N-Lok (reference the Wiring section). Remove (4) screws that hold the Condenser Blower and mounting bracket onto the unit. Remove the entire assembly. To replace the motor loosen motor mounting bracket screws and remove motor. Replace all components in reverse order. To replace the heater or one of the limit switches, remove the lower internal access panel (disconnect wires as needed). The heater is mounted on the backside of the access panel using (2) screws. The limit switches are mounted to the switch bracket directly above the heater element. Replace all components in reverse order. All other items except the malfunction switch, filter dryer and compressor are replaced through the upper internal access panel.

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Replacement Parts List

T51 Series Components List

Part Description
Blower Assembly, T51 MI, Evaporator Capacitor, Condenser Blower Capacitor, Evaporator Blower Capacitor, Compressor, Run Compressor Heater, Comp, 240V Filter/Dryer Limit Switch, Malfunction (A/C Fail) Terminal Block Thermal Expansion Valve Transformer Heating Thermo-Stat, 60-101F Cooling Thermo-Stat, SPST, 55-100F or Cooling Thermo-Stat, SPST, 82-105F

Part Number 50-5012-02 10-1091-88 52-6083-00 52-6084-02 52-6032-01 10-1026-91 10-1030-06 52-6028-06 52-6104-42 10-1003-31 10-1040-31 10-1006-138 10-1061-03 10-1061-02 or 10-1061-13

Notes

Look at the Cooling Thermo-Stat label to determine the temperature range. Match the temperature range to the corresponding replacement cooling Thermo-Stat.

Limit Switch, 165/95 psig Heater, Rod, 240V Heater Limit Switch, Auto-Reset Heater Limit Switch, Manual Reset (Low Temperature/Heater Fail) Limit Switch, OP45F, CL25F

52-6104-26 10-1030-24 10-1033-01 10-1033-07 10-1033-18

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Appendix I Technical Data

Model No.:
Rated voltage AC Frequency AC Rated current AC Start-up current AC Rated voltage DC Rated current DC Start-up current DC Dimensions Width Height Depth Position Material Useful cooling output (in cabinet) Nominal power consumption Heater External Airflow circuit (in cabinet @ nominal VAC) Internal Airflow circuit (in cabinet @ nominal VAC) Temperature range ACU Alarm (Normal=Open/Error=Close) Heater Alarm (Normal=Open/Error=Close) Alarm connector AC connector DC connector Protection category (Ext. circuit / Int. circuit) Weight

T51-1426-G010
220 V AC +/- 10%. 50/60 +/- 3Hz 15 A (AC) w/2500 W heater 0.5 A (AC) without heater 10.5 A (AC) during cooling TBD N/A N/A N/A 848 mm 1298 mm 248 mm Vertical Mounted G90U Galvanized Steel, 1.6 mm thick, and Polyester Urethane Powder Paint 4100 watts 15 A (AC) w/2500 Watt heater 0.5 A (AC) without heater 10.5 A (AC) during cooling 2500 W 1084 m 3/h 786 m 3/h Internal -5C to +65C External -55C to + 55C Internal fans ON only External fan ON >35C & >165psig; OFF <25C and/or <95psig Heater ON <7C; OFF >10C Compressor ON >35 C; OFF <25 C >350psig = Close >7C = Open, <-4C = Close 15-Pin AMP D-Sub P/N 745494-6 Plug Qualtek IEC320-C20 P/N 744W-00/04 N/A IP34 / IP56 89 kg

51T3-1426-G010
220 V AC +/- 10%. 50/60 +/- 3Hz 15 A (AC) w/2500 W heater 0.5 A (AC) without heater 10.5 A (AC) during cooling TBD N/A N/A N/A 848 mm 1298 mm 248 mm Vertical Mounted G90U Galvanized Steel, 1.6 mm thick, and Polyester Urethane Powder Paint 4100 watts 15 A (AC) w/2500 Watt heater 0.5 A (AC) without heater 10.5 A (AC) during cooling 2500 W 1084 m 3/h 786 m 3/h Internal -5C to +65C External -55C to + 55C Internal fans ON only External fan ON >35C & >165psig; OFF <25C and/or <95psig Heater ON <7C; OFF >10C Compressor ON >35 C; OFF <25 C >350psig = Close >7C = Open, <-4C = Close 15-Pin AMP D-Sub P/N 745494-6 Plug Qualtek IEC320-C20 P/N 744W-00/04 N/A IP34 / IP56 89 kg

Temperature control

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Appendix II Drawings

Figure 2 T51 Model Drawing, 51-G001

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Figure 3 51T3 Model Drawing, 51-G002

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Figure 4 W/D, T51-1426-G010 & 51T3-1426-G010

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Figure 5 P2P, T51-1426-G010 & 51T3-1426-G010

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Appendix III - Warranty

Supplier warrants that the Material manufactured by Supplier will be free from defects in material and workmanship for a period of one (1) year from the date of shipment by Supplier, subject to the following conditions and exclusions: A) Conditions. All Material must be installed and operated according to the following specifications: 1. Maximum voltage as follows: i) Model T51-1426-G010 & 51T3-1426-G010: 244 VAC. ii) Prior to operating the Air Conditioning Unit, ensure the transformer is configured properly (See wiring section). Failure to follow the proper configuration will void APW s warranty. 2. Maximum frequency variation no greater than plus or minus 3 Hz. of nameplate nominal rating; 3. Must not exceed minimum and maximum stated temperatures on the nameplate; 4. Not to exceed (BTU/Hr) rating, including any heat sink as indicated on the nameplate; 5. Refrigerant bearing Material must not be restarted for a period of one (1) minute after intentional or accidental shut -off; 6. The filters (if applicable) must be cleaned regularly; 7. The Material and any parts thereof must not be modified, unless prior written authorization is received form Supplier; 8. All Material must be installed and grounded in accordance with all relevant electrical and safety codes, as well as the National Electric Code and OSHA rules and regulations; 9. A violation of any one of these conditions shall render the warranty hereunder void and of no effect. B) Exclusions. No warranty shall apply to: 1. Any APW McLean Material that does not have proper protective coatings and/or options for operating in abnormal or corrosive environments if operated in such an environment; 2. Damage to refrigerant-bearing Material caused by the use of other than nameplatedesignated refrigerant. Supplier s sole obligation to Company under this warranty will be at Supplier s option. 1) to repair or replace any Material or parts thereof manufactured by the Supplier which are defective in material or workmanship, or 2) to refund the portion of the purchase price paid by the Company relating to such defective Material or part. In the event of a warranty claim, the Company may, with prior notice to Supplier, return the defective Material or part(s) to Supplier for repair at no charge, or the Company may repair the Material at the Company s own expense and Supplier will supply repair parts at no charge, providing that the defective part(s) is (are) returned to the Supplier and such part(s) has (have) failed and is (are) covered by the warranty as determined by the Supplier. Parts supplied as warranty replacement parts will assume the balance of such warranty. THIS WARRANTY CONSTITUTES THE ENTIRE WARRANTY WITH RESPECT TO THE PRODUCT AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY AND WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL SUPPLIER BE RESPONSIBLE FOR ANY CONSEQUENTIAL OR INCIDENTIAL DAMAGES OF ANY KIND WHATSOEVER

APW Thermal Management

11611 Business Park Blvd. No. Champlin, MN 55316 (Tel) 763-323-8200 www.apw.com OR http://www.mcleanthermal.com/

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APW Thermal Management

11611 Business Park Blvd. No. Champlin, MN 55316 (Tel) 763-323-8200 www.apw.com OR http://www.mcleanthermal.com/

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