USER’S MANUAL (PART 1)

AIR CONDITIONER FOR ELECTRIC CABINET

AVC

Division of:
ALFAPLASTIC s.a.s.
Via Della Valle, 39 – 20048 Carate Brianza
Tel. +39 (0362) 903.539 Fax. +39 (0362) 975.133
Mail: [email protected]
www.alfaelectric.com

Document: UMA-CDZ-AVCXXXXXXX-00 Date Name

Description ISSUE 12/07/2011 Ascheri M.
User’s manual for air conditioner AVC series
REV. 01
REV. 02
REV. 03

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TABLE OF CONTENTS

1 - INTRODUCTION page.3

2 - AT TIME OF DELIVERY page.3

3 - AT TIME OF UNPACKING page.3

4 - PRODUCT DESCRIPTION page.4

4.1 - Know the product page.5

5 - UNIT IDENTIFICATION AND CONTROL OF

TECHNICAL REQUIREMENTS page.6
5.1 - Name plate page.6

6 - INSTALLATION page.7
6.1 - Preparation of electric cabinet and installation page.7
6.2 - Start-up page.9
6.3 - Turning off the unit page.9

7 - MAINTENANCE page.9

8 - DISASSEMBLING AND DISPOSAL page.10

9 - CONTROL SYSTEM AND SAFETY page.10

9.1 - Control page.10
9.2 - Security page.10

10 - SAFETY TIPS page.10

11 - FAULTS, LIKELY CAUSES, REMEDIES page.8

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 1 - INTRODUCTION

The purpose of this manual is to guide the customer into the machine, informing him of
the potential of the product in addiction to warnings concerning the proper installation.

Use and maintenance always be carries out by specialist personnel.

It is important to follow all the points listed below:

1) control at the time of delivery, storage and transportation;

2) control at the time of unpacking, storage and transport;
3) identification of the machine and control technical specifications required;
4) preparation of the cabinet;
5) assembly ;
6) starting ;
7) shutdown;
8) maintenance ;
9) disassembly and disposal .

WARNING: point 4, 5, 6, 7, 8, 9 must be carries out by specialist personnel.

2 - AT THE TIME OF DELIVERY

Check on delivery that the package is not damaged or it is not spotted by oil or
refrigerant. Also check the correct position for transport (Fig. 2) required on packing:
any misconduct could seriously affect the operation of the machine.

The compressor must always remain in an upright position to prevent leakage

of lubricant or excessive presence of the same in the compression chamber

The correct position for transport must be respected even when the unloading and
storage.

Fig. 2

3 - AT THE TIME OF UNPACKING

In the pa cking box there are:

 Air conditioner
 Manual
 Test report
 Drilling template
 Gasket
 Fixing screw

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 check when unpack the package contains all the components described above in
addition to their correct position for the reasons already listed above, otherwise pl ease
contact :

ALFA PLASTIC s.a.s.

via Della Valle, 39
20048 Carate Brianza (MI)
tel. +39 0362 903539
fax. +39 0362 975133

Check before you dispose of the packagings that inside there are no components or
documents related to the product
The handling of the product, when unpacked, can be mounting in the appropriate tapped
holes eyebolts threaded placed on top of the air conditioner (Fig. 3).

Check before of the lifting the correct fixing of eyebolts.

Fig. 3

4 - PRODUCT DESCRIPTION

ALFA ELECTRIC air conditioners are designed and manufactured to cooling electrical
cabinet IP54 protection level; these products eliminate problems caused by high
temperature, dirt and humidity which are present in the external air.
The conditioner is composed by f our elements linked together by a circuit, this circuit is
path by refrigerant gas. The four elements are (fig.1):
 compressor ;
 condenser ;
 thermal expansion valve;
 evaporator .

The compressor increase refrigerant pressure and refrigerant temperature. Hot ga s

goes to condenser where it transfers heat to condense and become high pressure liquid.
Trough the thermal expansion valve the high pressure liquid decrease; at the end of
thermal expansion valve there is the lowest temperature of cycle; in this point the liquid
trough the evaporator and it absorbs heat from air coming from the cabinet. the
evaporator the refrigerant absorbs heat and it evaporates, at this point the gas is sucked
by compressor and it beginning a new cycle.

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 Fig. 1

4.1 - KNOW THE PRODUCT

The mechanical, electrical and refrigeration component conditioner will be listed and
they will be briefly described. Knowing the machine also means understanding its needs
and avoids incorrect operations that could compromise the operation.

Metal structure
The structure and all components that allow the assembly are constructed of sheet
metal. The cover is made of painted sheet RAL 7035, the frame is made of galvanized
steel.

Compressor
The compressor is rotary or alternative type with security t hermal system that
disconnects the motor from the power line in case of overheating. In suction of the
compressor there is a filter that retains particles of dirt and moisture.

Condenser
In condenser the outgoing gas from the compressor gives way heat s o it becomes liquid.

Thermal expansion valve

Thermal expansion valve is a long copper capillary with a very small internal diameter
(1,63 mm). This component causes a large loss of coolant pressure thus reducing the
temperature.

Evaporator
In evaporator the outgoing gas from the thermal expansion valve absorbs heat from hot
air in the electrical cabinet. The air from electrical cabinet becomes cool.

Gas circuit
Gas circuit is made of copper pipes interconnecting the various components of the
system.

Condenser fan
The condenser fan is a centrifugal type or axial type . This part sucks air from the
environment to facilitate transmission to the condenser heat exchange between gas and
air environment.

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 Evaporator fan
The evaporator fan is an axial type or a centrifugal type. This part sucks hot air from the
electrical cabinet to facilitate transmission to the evaporator heat exchange between gas
and hot air.

Thermostat
The thermostat is a gas loaded mechanical thermostat or digital thermostat depending
on the type of air conditioner series
When the temperature in the electrical panel is higher than that set the air conditioner is
operated. Thermostat is set at 35°C, adjustable 20°C – 45°C.

Pressure actuated fans-peed controller

The pressure actuated fans -peed controller keeps the condensation temperature
constant to get the best air flow trough the condenser.

Low and high pressure cut -outs

The pressure control turns off the power at compressor in case of low pressure inside of
circuit (for example in case of circuit discharge) or in case of high pressure inside of
circuit. These controls ensure a long life at compressor.

Condensate drain pipe

The condensate drain pipe allows removing condensate produced by the evaporator.
It is very important that the pi pe is clean to drain the condensate without
problems: presence of water within the framework could seriously impair
the functioning and security of components.

5 - UNIT IDENTIFICATION AND CONTROL OF TECHNICAL REQUIREMENTS

The identification code of the product is printed on a plate on the side of the air
conditioner, this plate described all technical data. For proper use of the unit, please, at
the time of installation, to respect the values and specific requests.

5.1 - Name plate

Model: Identify the family of the product

Rated voltage : power supply
Dimensions: dimensions in mm
Cooling capacity
(DIN3168): cooling capacity expressed in two different operating
points
L35 L35 (cabinet temperature = 35°C; ambient
temperature = 35°C)
L35 L50 (cabinet temperature= 35°C; ambient
temperature= 50°C)
Maximum rated current: maximum current consumption, running
Delayed fuse: type of fuse to protect the unit
Absorbed electric power : power consumption expressed in two different operating
points
L35 L35 (cabinet temperature = 35°C; ambient
temperature = 35°C)

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 L35 L50 (cabinet temperature= 35°C; ambient
temperature= 50°C)
Refrigerant: type of refrigerant used and quantity (charge)
Max pressure: maximum pressure which the circuit can operate
Operating temperature: operating temperature which the air conditioner can
operate
Protection degree: protection degree IP to the cabinet
Protection degree IP to the ambient
Electrical connection: type of connection
Weight: weight of the air conditioner
Colour: colour under RAL classification
Temperature regulation: temperature set with thermostat.
Conformity: CE

6 - INSTALLATION

6.1 - Preparation of electrical cabinet and installation of conditione r

The conditioner will be mounted on the side of electrical cabinet in the highest position
possible so it can treat more hot air in the electrical cabinet. (fig. 4).

Fig. 4

The ALFA ELECTRIC conditioner must be mounted exclusively upright

position and in the same packaging, do not mount on top of the wall or
upside down or slanted.

Before the installation make sure that the cabinet is disconnected from the
electrical supply.

Check before mounting that:

1) power supply is disconnected ;
2) the required e lectrical specifications (voltage, phase, frequency) are respected;
3) the wall of the electrical cabinet on which you installed the air conditioner is free
from internal and external components that may affect the proper installation;
4) the electrical cabinet is IP54;
5) the internal space and external space are enough to install and maintenance of air
conditioner (fig. 5);

Fig. 5

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6) inside the cabinet is clean;
7) the area surrounding electrical cabinet isn’t effected by flows of hot air and too
dirty;
8) the inlet of the air conditioner fan must remain sufficiently far away from objects
which might reduce the flow of air;
9) for mounting on the door check that the hinges are sufficiently strong to bear the
weight ;
10) the condensate is not discharged to damage electrical circuits or other ;
11) the weight of the air conditioner will not jeopardize the stability of the framework .

Once these checks have been made you can proceed with the installation:

1) apply the drilling template that is contained in the box on the wall that will conditioner
making sure that the holes, screws, cables etc. not going to invade the equipment of
the framework or compromise the operation. The template includes, in addition to the
holes for the mounting screws, two cuts for the passage of air and the outlet of the
conditioner; (fig. 6);
2) makes holes as indicated

Fig. 6

3) apply the adhesive gasket, that is contained in the box, on the perimeter wall of the
air conditioner in contact with the cabinet;
4) screw the eyebolts;
5) fix the air conditioner w ith the screws on the wall of electrical cabinet;
6) remove the cover of the air conditioner, unroll the hose and putting it into the hole
on the bottom;
7) replace the cover;
8) insert the power plug;
9) close the cabinet;
10) restore the power of the cabinet.

The unit is connected to the mains by pin socket. The female is already wired
to the air conditioner, the male is provided in the bag supplied and it is up to
the installer to provide wiring (Fig. 7)

Fig. 7

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 Powering the air conditioner, evaporation fan is ope rated automatically
and, unlike the other components, it is always in rotation, this to allow the
recirculation of air inside the cabinet even in conditions where the temperature is
still not likely to operate the entire condition. Compressor and condenser fan are
regulated by the thermostat, then begin to function when it reaches the
temperature at which it is programmed.

6.2 - Start-up

If the preliminary operations and assembly are carried out properly the air conditioner is
ready for operation.
At this point, if the panel temperature is lower than the temperature set on the thermostat,
will operate only the fan of evaporator, otherwise the compressor and the condenser fan
will start.

Compressor and condenser fan is regulated by the thermostat calibr ated by

ALFA ELECTRIC at 35°C.
Any changes to this value are to be performed by qualified personnel after
removing tension.

6.3 - Turning off the unit

The unit is switched of by removing the tension in the system, or installs switch isolation
from the ma ins.

7 - MAINTENANCE

ALFA ELECTRIC conditioner is designed for use in industrial environments thus requires
little maintenance but it is important that small measures are met so as to ensure
maximum performance and proper operation.
These operations ca n be performed even by unskilled personnel after power failure.

Clean of condenser
This operation should be done with non -powered air conditioner. The condenser fins are
subject to fouling because hit by air from the external environment, simply rem ove the lid
and blow with compressed air across the battery of condensation (Fig. 8). Any impurities
will fall down, give a clean the whole unit and replace the lid.

Fig. 8

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Checking the condensate drain
The condensate drain has the important task of removing the condensation water from air
conditioner and then from the cabinet. It is essential that the drainage pipe is free from
any fillings or showing no folds affecting the normal flow of condensate. It is important to
remember that the amount of con densation
depends on moisture in the air. So periodically check the proper state of drainage pipe
and more frequently if you operate in very damp ambience.

After long stopping of function is wise to make a general cleaning of the air
conditioner to be a ble to reactivate and thus have the highest performance.

8) DISASSEMBLING AND DISPOSAL

The unit disassembling from the electrical enclosure must be exclusively to non -powered
air conditioner.
After removing tension predispose eyebolts in the appropriate locations on the upper wall
and hook the unit so that it can be safely released from the painting. In the painting
inside, unscrew the screws and release the air conditioner.
Disposal of the product must be performed by authorized bodies.

ALFA ELECTRIC conditioner does not have liquids, gases or hazardous or toxic
materials

9 - CONTROL SYSTEM AND SAFETY

9.1 - Control
The system control unit is characterized by a mechanical thermostat gas charge or digital
thermostat described above. The value of temper ature which is set to represents the
value at the compressor and condenser fan start receiving consent. This value is set by
ALFA ELECTRIC during assembly.

9.2 - Security

1) Thermal safety on the engine: it cuts the power supply when the motor windings h eat
up excessively.
2) Pressure actuated fans -peed controller that keeps the condensation temperature
constant to get the best air flow trough the condenser.
3) Low and high pressure cut -outs: they cut off the power in low and high pressure

10 - SAFETY TIPS
The air conditioner is a system under pressure with the presence of various electrical
components, thus avoiding damage to the pipes of the coolant and check for leaks.

No maintenance when the unit is energized, disconnect the power before

any intervention.

Never appears soldering operations on pipes before they have fully downloaded from the
refrigerant circuit;
Not to operate the air conditioner without the cover, there are rotating parts, such as fan,
which may represent, if exposed, serious dan ger to people.

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 12 - FAULTS, LIKELY CAUSES, REMEDIES

Fails to cool

1) check that unit is connected

1) No part
to the mains
(fan, compressor,..) → Lack of voltage to the unit →
2) check that doors and switches are
working
closed

Cooling system interrupted or

2) components working → → 1)contact technical ALFAELECTRIC
out of gas

1)power fan interrupted

3) Compressor and evaporator 2)fan damaged 1) restore power
fan working, → 3)fan capacitor damaged → 2) replace fan
condenser fan not working (where present) 3) replace capacitor

1)power fan interrupted

4) Compressor e condenser 2)fan damaged 1) restore power
fan working, 3)fan capacitor damaged (where
→ → 2) replace fan
evaporator fan present) 3) replace capacitor
not working

1)compressor power interrupted 1) restore power

5) Fans working, 2) capacitor of compressor 2) replace capacitor

compressor not → damaged →
working 3)thermal protection of 3) replace thermal protection
compressor damaged
4)compressor damaged 4) contact technical ALFAELECTRIC

Fails to cool sufficiently

1)thermostat damaged
1) Compressor and condenser 1) replace thermostat
fan working intermittently, → →
2)loose connection to the
evaporator fan working 2) restore connections
thermostat

2) Compressor working intervention of thermal

→
intermittently, fans working protection of compressor

1)motor windings overheats 1) replace compressor

2)excessive pressure inside 2) contact technical ALFAELECTRIC

3) Intervention of compressor
→ circuit →
thermal protection
3)temperature inside the cabinet 3) contact technical ALFAELECTRIC
too high
4)ambient temperature too high 4) ventilate the area

4) Every parts working → heat exchange coils dirty → clean heat exchange coils

cabinet with a degree of

5) Condensate over protection
→ less IP54
production

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NOTES

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