# Operation manual of Marine packaged air conditioner – SCU CLD

Marine packaged air conditioner is the cooling device which can deal the air inside the chamber directly, has features of the new design, convenient operation, stable run, safety & reliable and easy maintenance, widely used for passenger ships, cargo ships, navies, and offshore platform, etc.

## Attentions for installation

• The packaged air conditioner should be laid the wires as per the shipyard drawing and install as per the operation manual by a professional person.
• The air inlet & outlet should be away from the barrier to ensure the air blowing through the chamber.
• The installation location should leave sufficient space for commissioning and maintenance.
• The water inlet & outlet pipe of the condenser should be connected as per the shown mark on the plant.
• The water inlet & outlet pipe should be fitted with a valve for cleaning it.
• The packaged air conditioner has a condensate water connection to ensure the water drain out thoroughly.
• The safety valve outlet should be connected with a copper tube and lead to the outside.

## The checked items after installation

Items to be checked Accidents due to improper installation
Whether the installation is firm? The plant may have some vibration or noise.
Whether the condensate water drain out well? The plant may have some drops and wet the floor.
Whether the voltage comply with the nameplate? The plant may have some malfunctions or parts damaged.
Whether the water inlet & outlet pipe of condenser connects correctly? The plant can not work or have high pressure alarm.
Whether the cables comply with the drawings? Cables will be burnt or the plant have malfunctions.
Whether air inlet & outlet has barrier? It wll cause insufficient cooling capacity(heating capacity)

## Attentions of operation

Confirm the power supply wire is connected firmly, otherwise it will cause electric shock or fire, don’t damage the wire or use other type cable.

Ground: ground reliably, earth wire should be connected to the special ground device onboard.

When istall the packaged air conditioner, there have bolt holes on top of backside to fix the top.

Don’t put your fingers or bar into air outlet of indoor unit, otherwise it will damage the AC or personnel injury.

Regulae the setting temperature to proper value.

Don’t pour the water to AC or flush it by water, otherwise it will result in malfunction or cause electric shock.

## Notice for operation

• Cooling mode  When cooling, the compressor runs, the fan also runs, indoor ventilates, AHU will absorb the inside heat and reduce the ambient temperature.
• Heating mode   The fan runs, electric heating will work, indoor ventilates, Packaged air conditioner releases the heat and increases the ambient temperature.
• Anti cold air:    Under”heating” mode, the fan will not start immediately, it will blow out heat air after one minute of preheating.
• Unmormal working conditions of Packaged air conditioner
• “Auto”mode, indoor temperature is beyond 24℃, AC will auto begin to cool, when indoor temperature is lower than 24℃, AC will auto begin to heat.
• “Cooling” mode, indoor temperature is lower than 18℃, it will not cool.
• When humidity is above 80%(door and window open), it continues to cool, air outlet will have dew drops.
• Start/stop instructions of compressor
• To prolong the compressor life, computer board will auto control the start/stop of compressor, it will appear when ambient temperature reaches to setting value, it will stop with time delay. When protection shutdown appears, compressor will start with 3min delay even the malfunctions are reset.

## Components name

1 compressor
2 condenser
3 expansion valve
4 evaporator
5 liquid charge vavle
6 drier filter
7 high & low pressure controller
8 temp sensor
9 control panel
10 air outlet
11 terminal box
12 Condenser water inlet & outlet flange connection
13 air inlet & filter mesh

## Operation method of PAC

First  Provide the power supply

Open the terminal box

Close the air switch.

Second Operation of control panel

Press On/Off switch to select “ventilation” mode and fan will run.

Press On/Off switch to select “cooling” mode and fan will run. Regulate temp▲▼ switch, set temp is 24℃, compressor will run and blow out the cold air.

Press On/Off switch to select “heating” mode. Regulate temp▲▼ switch, set temp is 28℃,wait for 1min, fan will run and blow out the hot air.

Press “swing” switch to change the direction of air outlet.

Press “speed” switch to change the air speed.

## Maintenance

1 How to check the system leak?

The needed materials and tools: the bottled nitrogen, relief valve, 3 long ¢6 copper tube, DN4 copper joint flare expand tool, spanner, soap water, sprinkling can and screwdriver.

Disassemble the panel of air inlet ,fill the soap water into sprinkling can, one end of copper tube is welded to relief valve,the other end is sleeved with DN4 copper joint, then expand the flare, mount the relief valve on the nitrogen bottle, open the liquid valve, balance the high & low pressure gauge to 1.5MPa, then stop pressing, close the nitrogen bottle valve and liquid valve. Use sprinkling can to aim at the connection of copper tube and check one by one, the leak place will have some bubbles, repair it.

2 How to vacuum?

The needed material and tools: vacuum pump, liquid pipe, spanner and screwdriver.
Disassemble the panel of air inlet, screw off the plastic cap of liquid valve and cock of DN4 copper joint, connect the liquid pipe: one end is connected to liquid valve, the other end is connected to suction of vacuum pump, open all stop valves of the system, open the vacuum pump, then close the liquid valve till reaches to 720mmHg, close the pump.

3 How to add the refrigerant?

The needed material and tools: bottled refrigerant, liquid pipe, special valve spanner for cooling, short jumper and screwdriver
Disassemble the panel of air inlet, screw off the plastic cap of liquid valve and cock of DN4 copper joint, connect the liquid pipe: one end is connected to the refrigerant bottle, the other end is connected to liquid valve and tight it. Upside down the refrigerant bottle, remove the plastic cover of high & low pressure controller, short connect two terminals inside the controller, start it in cooling mode, when compressor is running, the pressure of low pressure gauge will be low, open the liquid valve, the liquid refrigerant will enter into the system, the charge capacity is different due to different models, please refer to the following:

auto low speed middle speed high speed
AC modelRefrigerantcharge capacity(kg)
CLD-15R404A2.5

4 How to adjust the expansion valve, clean the expansion valve filter mesh and change the expansion valve?

The needed material and tools: screwdriver and spanner
Disassemble the panel of the air inlet, screw off the cap of the expansion valve, when seeing the flow adjust nut, use spanner or cross screwdriver to adjust, in clockwise, the flow will be reduced, in counter-clockwise, the flow will be increase.

Clean the expansion valve filter mesh

The needed material and tools: screwdriver, spanner, hex spanner, vacuum pump, liquid pipe and short jumper
Disassemble the panel of air inlet, screw off the plastic cover of high & low pressure controller, short connect the two terminals of controller, close the outlet valve of condenser, select cooling mode, compressor will run, when low pressure gauge indicates 0.01Mpa, it will shutdown and cut off the power. Use spanner to disassemble the nut at inlet of expansion valve, separate the copper tube and expansion valve, now you can see that the filter mesh is inserted at the inlet of expansion valve, draw out the filter mesh and clean it. Reinstall it after cleaned. Open the liquid valve, connect the liquid pipe and vacuum pump, start the pump, when low pressure gauge reduces to , then close the liquid valve, open the outlet valve of condenser. Use the soap water to check the disassembled connections to check the leak.

Change the expansion valve

The needed material and tools: new expansion valve, screwdriver, spanner, hex spanner, vacuum pump, liquid valve and short jumper
Disassemble the panel of air inlet, screw off the plastic cover of high & low pressure controller, short connect the two terminals of controller, close the outlet valve of condenser, select cooling mode, compressor will run, when low pressure gauge indicates 0.01Mpa, it will shutdown and cut off the power. Use spanner to disassemble the nut at inlet and outlet of expansion valve, or use hex spanner to loose off four screws on expansion valve base, pay attention not to damage the cushion inside the expansion valve when changing, the temp bulb should be installed to previous location, after changed, recover all the connections, open the liquid valve, connect the liquid pipe and vacuum pump, start the pump, when low pressure gauge reduces to , then close the liquid valve, open the outlet valve of condenser. Use the soap water to check the disassembled connections to check the leak.

5 How to change the control screen and computer board?

The needed material and tools: the new control screen, computer board and screwdriver
Cut off the power supply, disassemble the panel of air inlet and outlet, cover of electric box, the control screen is on the panel of air inlet, draw out the signal wire of control screen from the electric box, disclose the rubber insulation on the rear of the air inlet panel, screw off the screws on the cover of control screen, you will see the control screen, change it and recover them. Pull off all plugs on the computer board, remove the four fixed screws on it, change the new one and then recover the plugs as per the previous order.

6 How to change the electric heating superheat protector?

The needed materials and tools: screwdriver
Disassemble the panel of air inlet and outlet, and decoration strips on both sides of the air conditioner casing, on the bottom of the electric heater have two screws to connect with the frame, screw them off, draw out the fan and electric heater integrally, then change the new superheat protector.

7 Compressor run pressure and protection pressure

The air conditioning system can select different refrigerants, which have different working pressures and protection pressure.

pressureR404ATemp
run high pressure value1.5Mpa30℃
run low pressure value0.5Mpa30℃
protection high pressure value2.1Mpa30℃
protection low pressure value0.2Mpa30℃

## Operation method of remote controller

Put the battery on the remote controller, aim it at the connection of far infrared ray of control panel, regulate the function of AC as per the requirements.

## Maintenance

Clean

After AC is put into the run, clean the condenser 2-3 times every year.

Clean method: stop the cooling water pump, close the water inlet & outlet valve, screw off the water drain valve of condenser to discharge all water, use wrench to loose all the bolts on both sides of condenser to remove the cover, then you can see a copper tube, use soft brush to stretch into the tube and drag back and forth to clean it. When reinstall, pay attention to the direction of cover and cushion, wrong installation will make AC not work or high pressure alarm.

When AC is not used, close the water inlet & outlet valve of condenser to drain the cooling water inside the condenser to prevent the freeze broken.

Filter mesh at air inlet should be cleaned in schedul, too much dust on the mesh will reduce the air flow and result in sufficient cooling(heating) capacity.

Clean method:disassemble the air inlet panel of AC, use dust colletor to aim at the filter mesh, open the dust collector, reset it after cleaned.

Rust proof

After AC is run for a time, the unit will have some rust, customer should be cleaned frequently, repair the damaged paint.

Maintenance method: use sand paper to polish the rusted place, use the same paint to repair.

## Malfunction removal

Malfunction: open-air switch, the control panel has no display.

Removal: disassemble the fixing screw of the terminal box and open it, measure the voltage of terminals L1, L2 and L3 with a multimeter, if it is zero, the power should be supplied by switchboard onboard, if it is normal, the power may have wrong phase sequence, over-voltage, under-voltage, lack phase, then disassemble the air inlet panel, baffle of the electric box, check the LED lamp on power monitor, if phase sequence is wrong, exchange the wiring of L1 and L2, if the voltage is over or under, the ship should provide the working voltage, which is ±10％of rated one, if phase lack, check cables are good or not.

Removal:

cut off the power, disassemble air inlet panel, baffle of electric box, screw off the cover of fuse, measure the fuse resistance with multimeter, if it is zero, fuse is good, if the resistance is infinite, fuse is bad, change new one.

After AC is run for a time, the unit will have some rust, customer should be cleaned frequently, repair the damaged paint.

Maintenance method: use sand paper to polish the rusted place, use the same paint to repair.

## Malfunction removal

Malfunction:Malfunction: control panel display the malfunction code and can not cool.

Malfunction codeMalfunctionChecked itemRemovalRemark
E1high pressure alarmWhether cooling water flow is sufficient.Open all water valves on cooling piping, clean it.After all defects are removed, push the green reset button on high & low pressure controller by hand to cancel the E1 code.
E1high pressure alarmCondenser internal cooling pipingCondenser clean refer to Page 10.
E1high pressure alarmwhether refrigerant is too muchRelease it
E1low pressure alarmWhether liquid stop valve is openedOpen itAfter malfunctions are removed, low pressure will reset to normal, E1 code will disappear.
E1low pressure alarmWhether refrigerant is leakUse leak detector to check all connections,repair it, refer to Pag e 7
E1low pressure alarmFilter mesh and temp sense bulb of expansion valveDisassemble the temp bulb, clean the mesh, if the bulb is broken, change it and refer to Page 7-8

Malfunction: after start up, control panel display normal, in “cooling” mode, but it still does not cool.

Malfunction codeMalfunctionChecked itemRemovalRemark
E5contact defectContact jack or contactFix the jack or change contact
Malfunction: after start up, control panel display normal, in “cooling” mode, but it still does not cool.
Malfunction Checked item Removal
Temp is not set improperly. Set temp should be lower than the ambient temp. Reduce the set temp.
Shutdown without water pressure. The water pressure gauge should indicate 0.12MPa, if lower than 0.07MPa, compressor can not work. Increase water pressure, but water flow should meet with requirements.

Malfunction: after start-up, control panel displays normal, in “heating” mode, but it still does not heat.

MalfunctionChecked itemRemark
Temp is not set improperly.Set temp should be higher than the ambient tempRise the set temp
Overheat protectionheater has overheat protector, when temp is over70℃, it will force to stop

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