ComPac® I and ComPac® II Air Conditioner Product Manual Vertical Wall-Mount Air Conditioners with Front Control Box Panel Models AVPC 24-30-36-42-48-60-72 R-407c Chapter 1 Description............................ 5 Chapter 2 Installation.......................... 18 Chapter 3 Start-Up.............................. 30 Chapter 4 Troubleshooting.................. 31 Chapter 5 Maintenance........................ 34 Chapter 6 Warranty............................. 35 Parts List & Exploded Views.................
How To Use This Manual This manual is intended to be a guide to Marvair's ComPac® line of vertical air conditioners. It contains installation, troubleshooting, maintenance, warranty, and application information. The information contained in this manual is to be used by the installer as a guide only. This manual does not supersede or circumvent any applicable national or local codes.
WARNING • If the information in these instructions are not followed exactly, a fire may result causing property damage, personal injury or loss of life. • Read all instructions carefully prior to beginning the installation. Do not begin installation if you do not understand any of the instructions. • Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
Table of Contents Chapter 5 Maintenance 5.1 Scheduled Maintenance..........................................................................................................................34 Chapter 6 Warranty 6.1 Limited Product Warranty.......................................................................................................................35 Parts List and Exploded Views......................................................................................................................
Chapter 1 Description & Specifications 1.1 General Description The Marvair® ComPac® I and ComPac® II air conditioners are designed to cool electronic and communication equipment shelters. The AVPC models use R-407c refrigerant and a unique combination of controls and components to operate in extremely cold and high ambient conditions. The series includes multiple sizes with nominal cooling capacities from 24,000 to 72,000 BTUH. Electric resistance heating are available in various wattages.
1.2 Model Identification The model identification number is found on the data sticker. Rating plate located on side panel. ••• C • AC • • • • Refrigerant C = R-407c Nominal Cooling 24 = 24,000 BTUH 30 = 30,000 BTUH 36 = 36,000 BTUH 42 = 42,000 BTUH 48 = 48,000 BTUH 60 = 60,000 BTUH 72 = 72,000 BTUH Model AVP 1.
Figure 1a. Dimensional Data - Models AVP24/30/36 ComPac® Air Conditioner L.H. SIDE MODEL IN MM IN MM A 39-3/8 1000 44-9/16 1132 FRONT AIR OUTLET D 8 203 8 203 E 20-1/2 521 18 457 1.500 FLANGE WIDTH F 12 305 14 356 R.H. SIDE AIR INLET 0 4.188 3-9/16” (91mm) 1-1/16” (27mm) 0.000 4-9/16” (116mm) 5/8” (16mm) 0.
Figure 1b. Dimensional Data - Models AVP42/48/60 ComPac® Air Conditioner 8 ComPac 5.2011 AVP42-60 MODEL IN MM B C D E F 117 mm 38 mm 57 mm G R.H. SIDE H 502 mm I 1054 mm J 502 mm K SIDE FRESH AIR VENTS ONLY ON UNITS WITH VENTILATION CONFIGURATIONS "C", "B", "Y", & "Z" 10 mm 45-1/8 22-5/8 86.00 10.00 30.00 16.00 26-1/2 30.
Figure 1c. Dimensional Data - Model AVP72 ComPac® I & ComPac® II Air Conditioners 9 ComPac 5.
1.5 General Operation Refrigerant Cycle (Cooling Mode) The ComPac® I & ComPac® II A/C use R-407c refrigerant in a conventional vapor-compression refrigeration cycle to transfer heat from air in an enclosed space to the outside. A double blower assembly blows indoor air across the evaporator. Cold liquid refrigerant passing through the evaporator is boiled into gas by heat removed from the air. The warmed refrigerant gas enters the compressor where its temperature and pressure are increased.
Delay on Break If the compressor is de-energized due to a loss of a cooling “Y” call or the first fault, the unit re-start will be delayed 3 minutes from the time the contactor is de-energized. (Note: There is no delay on break if the lockout condition is reset.) Delay on Make On initial power up only, the unit will wait 0.03 to 10 minutes from the cooling “Y” call before allowing the contactor to energize. The delay can be adjusted by the DOM wheel on the board. Factory recommended wait is 3 minutes.
Low Pressure Switch The low pressure switch is mounted on the compressor suction line. It is designed to open if the refrigerant pressure drops to 35 PSIG; it resets when the pressure rises to 60 PSIG. The switch protects the unit if airflow through the indoor blower is impeded, if the blower motor fails, or if there is a loss of refrigerant. POST PURGE WHEEL LEDs DELAY ON MAKE (COMPRESSOR TIME DELAY) WHEEL 1.
until the thermostat is satisfied. This assures the environment temperature is maintained as first priority and humidity control is second. In applications where a shelter has redundant air conditioning units and is controlled by a lead lag controller (Marvair's LL357D4 or CommStat3 Controller), most times the dehumidification option is only necessary on one of the two units. It is possible for one unit to be operating in the cooling mode while the unit with dehumidification is operating at the same time.
1.8 Electrical Operation The compressor and condenser fan are energized with a contactor controlled by a 24 VAC pilot signal. Some compressors incorporate an internal PTC crankcase heater that functions as long as primary power is available. The heater drives liquid refrigerant from the crankcase and prevents loss of lubrication caused by oil dilution. Power must be applied to the unit for 24 hours before starting the compressor. The condenser (outside fan) motor is energized by the same contactor.
Figure 2a. Typical Electrical Schematic - ComPac® I A/C 15 ComPac 5.
Figure 2b. Typical Electrical Schematic - ComPac® II A/C 16 ComPac 5.
1.9 Economizer Components (ComPac® II A/C Only) Damper Actuator: The damper actuator is a 24V motor that modulates the position of the damper blade. It is capable of driving a full 90 degrees within 90 seconds. The assembly has a spring return to close the damper during power outage. Controls: The economizer is controlled by the H205A enthalpy control.
Chapter 2 Installation WARNING Failure to observe and follow Warnings and Cautions and these Instructions could result in death, bodily injury or property damage. Read this manual and follow its instructions and adhere to all Cautions and Warnings in the manual and on the Marvair unit. 2.1 Equipment Inspection Concealed Damage Inspect all cartons and packages upon receipt for damage in transit. Remove cartons and check for concealed damage. Important: keep the unit upright at all times.
standards. Marvair® strongly recommends referring to the current edition of the National Fire Protection Association Standards 90A and 90B before designing and installing duct work. The duct system must be engineered to insure sufficient air flow through the unit to prevent over-heating of the heater element. This includes proper supply duct sizing, sufficient quantity of supply registers, and adequate return and filter areas. Duct work must be of correct material and must be properly insulated.
P/N Description S/04581 CommStat 3 Controller, Solid State Lead/Lag Controller S/07846 CommStat 4 Controllers, Solid State Lead/Lag Controller S/07529 LL357D4, Lead/Lag Controller with T'stat & Sub-Base; Controls 2 A/C Units 50123 Digital thermostat. 1 stage heat, 1 stage cool. 7 day programmable. Fan switch: Auto & On. Auto-change over. Keypad lockout. Non-volatile program memory. 50107 Digital thermostat. 2 stage heat, 2 stage cool. 7 day programmable. Fan switch: Auto & On. Auto-change over.
Warning FIRE HAZARD Improper adjustment, alteration, service, maintenance or installation could cause serious injury, death and/or property damage. Installation or repairs made by unqualified persons could result in hazards to you and others. Installation MUST conform with local codes or, in the absence of local codes, with codes of all governmental authorities have jurisdiction.
BASIC MODEL AVP24 AVP30/36 AVP42/48/60 AVP72 MAXIMUM TOTAL STATIC .30 .40 .50 .50 MINIMUM FILTER AREA 2.75 3.33 5.50 6.00 Table 6. Maximum Static Pressure (For units with 2" Pleated Filters) 2.5 Fresh Air Hood (ComPac I air conditioners only) The fresh air hood is located on the inside, behind the slots on the bottom front panel. To access the hood, remove the screws that hold the front panel.
2.7 Mounting The Unit 1. For wiring into the back of unit, locate the lower of the two knockouts on the wall side of the unit. Drill a one inch hole in the shelter wall to match this opening. Allow sufficient clearance to run 3/4" conduit through the hole and to the unit. 2. Using an appropriate and safe lifting device, set the unit on the bottom support bracket mounted on the wall.
2.8 Electrical Connections WARNING ELECTRICAL SHOCK HAZARD Failure to follow safety warnings exactly could result in serious injury, death, and/or property damage. Turn off electrical power at fuse box or service panel BEFORE making any electrical connections and ensure a proper ground connection is made before connecting line voltage. Important All electrical work must meet the requirements of local codes and ordinances. Work should be done only by qualified persons.
Dual Unit Phasing For applications where one controller operates two units, e.g., the CommStat 4 or LL357D. The LL357D4 and the LL357D3 do not require unit phasing. However, if other devices are connected to the control system, phasing of the air conditioner is required. Earlier models; i.e., LL357, LL357A, LL357D2 require the unit to be properly phased. 1. Wire each unit as described in steps 1 through 4 above. 2. Test for proper phasing as follows: A. Power up the units. B.
environmental control units. See CommStat 3 Product Data Sheet for installation and programming instructions. LL357D4 Lead/Lag Controller (See Figure 6c) The Marvair® LL357D4 is a complete control package designed to operate a fully or partially redundant air conditioning system. It consists of a two-stage heat and two-stage cool electronic thermostat and a solid state timer.
Figure 6a. Humidistat (P/N 50254) Wiring to a ComPac Air Conditioner with Reheat. Figure 6b. Thermostat Connection Diagram 27 ComPac 5.
Figure 6c. LL357D4 Wiring Diagram & Thermostat Keys 28 ComPac 5.
CommStat 3 +24v.
Chapter 3 Start-Up 3.1 Check-Out of Cooling Cycle Important: Be sure that the crankcase heater (if used) has been energized for at least 24 hours before starting the unit(s). Double-check all electrical connections before applying power. ComPac® air conditioners with scroll compressors running on 3Ø power must be checked for proper rotation during the initial start-up. Please refer to Section 2.8 for determining if the 3Ø compressors are rotating correctly.
Chapter 4 Troubleshooting 4.1 Overview A comprehensive understanding of the operation of the ComPac® A/C is a prerequisite to troubleshooting. Please read the Chapter 1 for basic information about the unit. Marvair's ComPac® air conditioners are thoroughly tested before they are shipped from the factory. Of course, it is possible that a defect may escape undetected, or damage may have occurred during transportation. However, the great majority of problems result from installation errors.
PROBLEM/SYMPTOM C. Unit cycles on high/low pressure limit. D. Unit blows fuses or trips circuit breaker. LIKELY CAUSE(S) CORRECTION 1. Loss or restriction of airflow. 1. Check blower assembly for proper operation. Look for airflow restrictions, e.g.. the air filter. Check blower motor and condenser fan. 2. Restriction in refrigerant circuit. 2. Check for blockage or restriction, especially filter drier and capillary tube assembly. 3. Refrigerant overcharge (following field service) 3.
3. Motor Winding Resistances: Using a digital volt-ohm meter (VOM), measure the resistance across the compressor windings as shown below. SINGLE PHASE C R2 S R1 R3 R R3 > R2 > R1 R3 = R2 + R1 THREE PHASE T1 R2 T2 R1 R3 R3 = R2 = R1 T3 Resistance can be measured as shown above. Any deviation from above values could indicate a defective compressor. 4. High Voltage/Insulation Test: Test internal leakage with a megohmeter.
Chapter 5 Maintenance 5.1 Scheduled Maintenance Marvair® strongly recommends that the air conditioner be serviced a minimum of twice a year – once prior to the heating season and once prior to the cooling season. At this time the filters, evaporator coil, condenser coil, the cabinet, and condensate drains should be serviced as described below. Also at this time, the air conditioner should be operated in the cooling and heating cycles as described in Chapter 3, Start-Up.
Chapter 6 Warranty 6.1 Limited Product Warranty If any part of your Marvair® Air Conditioner, Heat Pump or Unit Ventilator fails because of a manufacturing defect within fifteen months from the date of original shipment from Marvair or within twelve months from the date of original start-up, whichever is the earlier date, Marvair will furnish without charge, EXW Cordele, Georgia, the required replacement part.
EXPLODED VIEWS AND PARTS LISTS Current parts lists and exploded views of the unit can be found on our web site at www.marvair.com. Click on the Service and Parts in the menu on the left hand side of the Home page. From the drop down menu, select Exploded Views. Once here, you can select your air conditioner or heat pump. The units are grouped by model and by the refrigerant – R-22, R-410A or R-407c. 36 ComPac 5.