Water Cooled Fcu Piping Details

8/10/2019 Water Cooled Fcu Piping Details

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CONTENTS

Installation

CONTENTS

Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

Dimensional Drawing - - - - - - - - - - - - - - - - - - - - - 2

Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

Piping Works - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

Electrical Connections & Diagrams - - - - - - - - - - - 6,9-13

Operation and Start-Up - - - - - - - - - - - - - - - - - - - - 6

Refrigerant Charging - - - - - - - - - - - - - - - - - - - - - - 7

Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

Trouble Shooting - - - - - - - - - - - - - - - - - - - - - - - - - 13

INSTALLATION

UNPACKING Move unit to final location. Remove plastics wrapfrom unit being careful not to damage or cause scratch to the unit.Check the shipment against shipping list and remove unit protectivecovering. If the unit has been damaged, file claim with transportationcompany and immediately notify Concepcion-Carrier or its authorizedDealer.

CEILING MOUNTED INSTALLATION

Select a suitable location for the unit. For example, useKitchen or Bathroom ceiling spaces. (See Fig. 6)

Make sure that there is enough ceiling clearance between unitand slab. Check units dimensional drawing. Clearance shouldalso be allowed for ceiling acoustic treatment and piping.

To design steel frame for units base, do not place unit directlyon the ceiling. Use a strong hanging suspension wheninstalling the steel frame to slab.

Ensure there is sufficient clearance between hanging rodsand cabinet access panels, so that service work can becarried easily. See the back page drawing for details.

Place the unit onto the steel frame and make sure that theunit is leveled. Use vibration isolators between unit and steelframe. Do not use rubber blocks as isolators.

Vibration isolators are also required for water pipe andrefrigerant tube connections. Care should be taken withrefrigerant piping to avoid any transmission of noise andvibration to the ceiling or walls. Provide enough pipe flexibilitybefore fixing unit to the structure.

Provide access panel in ceiling. Make sure the panel islocated near the unit for easy maintenance and servicing.

After the unit is installed and pipe work are completed, besure to insulate the units surroundings with acoustictreatment. An acoustic type insulation can be used foradditional sound reduction.

CAUTION Consult local building and National Electrical codes forspecial installation requirements. Check that electrical data on unitsnameplate correspond to job site electrical supply. Check that fieldpower supply is sized for the units and additional accessories like waterpumps, cooling towers and indoor units.

FLOOR MOUNTED INSTALLATION

Select a suitable location for the unit. For example, usekitchen or balcony spaces. (See Fig. 7)

Make sure that enough space clearance for unit. Check unitsdimensional drawing. Clearance should be also allowed foracoustic treatment and piping.

To design a compartment complete with access panel or doorfor maintenance and servicing the unit.

Use vibration isolators between the unit and floor. Do notplace the unit directly onto the floor.

After the unit is installed and pipe works are completed, besure to insulate the units internal compartment with acoustictreatment.

ConcepcionCarrierAir condi tioningCompany

07KHP WATERCOOLEDSPLIT CONDENSING UNIT

INSTALLATION MANUAL, START-UP &SERVICE INSTRUCTIONS

PRIOR TO INSTALLATION OF THE 07KHPUNITS, REVIEW THE FOLLOWING IMPORTANTPOINTS

However, for applications such as hotel rooms, care needs tobe taken to prevent break out noise from the immediatesurroundings into the room below.


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TABLE 1 SPECIFICATIONS

mm07KHP

01207KHP

01807KHP

02407KHP

04007KHP

06007KHP

090

H 508.0 623.0

H1 355.0 549.0

H2 254.0

H3 179.0H4 105.0

L 569.0

W 680.0

W1 329.0

W2 179.0

W3 130.0

W4 420.0

07KHPMODEL

013 018 024 040 060 090

RATED CAPACITY (TONS) 1.0 1.5 2.0 3.0 5.0 7.5

CDU POWER INPUT (kW) 1.08 1.75 2.22 3.15 5.15 6.45

NET WEIGHT (kg) 52 54 63 70 78 93

Type R-22REFRIGERANT

Charging method By Superheat Method

Type Rotary Scroll

Compr. Model RH189NRAT RH277NHDT PH39NPBT NH52NAHT ZR61KC-TF5 ZR81KC-TF5

RLA (A) 4.8 7.8 12.6 16.8 20.7 25.0LRA (A) 35 47 66 91 139 179

COMPRESSORS

Refill Oil Charged (lit. / oz) 0.52 / 17.6 0.52 / 17.6 0.90 / 30 1.30 / 44 1.83 / 62 1.66 / 56

Quantity 1PLATE HEAT EXCHANGER(STAINLESS STEEL)

Water Inlet / Outlet ,mm (in.) 25.4 (1) FPT

Suction,mm (in.) Flare Type 12.7 (1/2) 12.7 (1/2) 15.8 (5/8) 15.8 (5/8) 19.05 (3/4)S-28.6(1-1/8)REFRIGERANT CONNECTIONS

Liquid, mm (in.) Flare Type 6.35 () 6.35 () 9.52 (3/8) 9.52 (3/8) 9.52 (3/8) S-15.8 (5/8)

High Press (PSIG) 426 7 / 320 20CONTROL PRESSURESTAT SETTINGS(Open / Close pressure settings) Low Press (PSIG) n.a. 27 4 / 67 7

POWER SOURCE (V-Ph-Hz) NOMINAL (V) 208/230 - 1 - 60 230 - 3 - 60

PERMISSIBLE MIN-MAX VOLTAGE (V) 197 - 253

REFRIGERANT CONTROL DEVICE IN UNIT Capillary Tube Capillary*/Accurator**

RLA : Rated Load Amps LRA : Locked Rotor Amps Data rated at 29.5 Water Out, 27C/19C Indoor Condition

* - Capillary tube located at FCU on model ASBFM0360-060 (Floor Standing)** - Accurator is located at FCU on model 42AR0036-060 (Ceiling Type), 42GKX036-060(Cassettetype), 42LX036-060(Ceiling-Ducted). 7.5TR system normally uses TXV metering device.

Note: Refill oil charge is for service use after compressor has been drained. This value is differentand less than Factory oil charged. Use only corresponding compressor maker approved specs.(S) under refrigerant connections section means Sweat Type connection.

FIG. 2 DIMENSIONAL DRAWING

FRONT VIEW

TOP VIEW


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PIPING WORK

REFRIGERANT PIPING

Use correct size and good condition field supply tubing ofrefrigerant grade.

Run refrigerant tubes as straight as possible. Avoidunnecessary turns and bends.

Suspend refrigerant tubes so that they do not transmitvibration to structure.

Also when passing refrigerant tubes through wall, sealopening so vibration is not transmitted to structure.

Leave some slack in refrigerant tubes between structure andunit to absorb vibration.

NOTE:The longer the interconnecting piping, the lower thecooling capacity of the unit. See table 2.

Table 2 Reduction in capacity vs increase in pipe length

EQUIVALENGHT PIPING LENGTH (ONE WAY)MODEL07KHP 5m 10m 15m 20m 25m

012 0 1.7% 2.7% 3.7% 4.8%

018 0 1.6% 2.8% 3.8% 4.9%

024 0 1.7% 3.0% 4.0% 5.4%

040 0 1.8% 3.0% 4.2% 5.6%

060 0 2.1% 3.8% 4.7% 5.9%

090 0 2.5% 4.3% 5.2% 6.3%

The permission piping for recommended combinations as per Table 3and fig. 3.

Table 3 Vertical and horizontal separation between fan coil andcondensing unit.

MAX. LIFT, H m (ft)

MODEL07KHP

MAX. DISTANCE, Lm (ft) CDU ABOVE

FCUCDU BELOW

FCU

012 15 (50) 7.5 (25) 5.0 (16)

018 15 (50) 10 (33) 7.5 (25)

024 15 (50) 10 (33) 7.5 (25)

040 18 (60) 10 (33) 7.5 (25)

060 18 (60) 10 (33) 7.5 (25)

090 18 (60) 15 (50) 10 (33)

SIGHT GLASS AND FILTER DRIER

Sight glass and filter drier are factory supplied and field installedapplicable for model 07KHP036,048, 060 and 090 only. Warranty will bevoided if these models were not fitted with external filter drier in the fieldinstallation.

TUBING CONNECTIONS AND LEAK TEST

Both suction and liquid are equipped with flare typeconnections. (except for Model 090 uses sweat connection).

Assemble flare joint by aligning tubing with machine surfaceof fitting. Start run onto threads by turning backwards firstthen forwards.

All lines should be assembled with type L or quarter harddrawn refrigeration grade copper tubing and not with copperwater pipe.

Use the following brazing alloys:

Copper to Copper -------------- 5% Silver Alloy (no flux)Copper to Steel or Brass ---- 35% Silver Alloy (no flux)

Remove cap and Schrader core from service port to protectseals from heat damage. Wrap service valve with wet ragbefore applying heat. Flow dry nitrogen into a service port andthrough the tubing while brazing to prevent pipe oxidation.

Pressurize line set and coil through service fittings with drynitrogen to 150 psig maximum (or refer to Carrier StandardService Techniques Manual, chapter 1, section 1-6) If a leakis found, recover pressure and repair all leaks.

WARNING:DO NOT USE OXYGEN TO PURGE LINES OR PRESSURE SYSTEMFOR LEAK TEST. OXYGEN REACTS VIOLENTLY WITH OIL, WHICHCAN CAUSE AN EXPLOSION RESULTING IN SEVERE PERSONALINJURY OR DEATH.

PIPING INSULATION

Insulate both suction and liquid lines as per Fig. 4

FIG. 4 PIPING INSULATION


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EVACUATION AND DEHYDRATION

Evacuation is the most important part of the entire service procedure.The life and efficiency of the equipment is dependent upon theevacuation and dehydration thoroughness exercised by theserviceman.

Air in the system causes high condensing temperature and pressure,resulting in increased power consumption and at the same time itreduces system efficiency. Moisture chemically reacts with therefrigerant and oil thus forming corrosive acids which attacks motorwindings and metal parts, causing early breakdown.

After the system has been leak checked and proven leak free, connectthe vacuum pump and evacuate system to 29 Hg vacuum. It isadvisable to connect both vacuum pump hose to the high-side and low-side of the system to have a better and faster evacuation.

FINAL LEAK TEST

After the unit has been properly evacuated and charged, use a halogenleak detector to check system for leaks. In the absence of this device

water-soap solution is acceptable. All piping within the condensing unit,evaporator, and interconnecting tubing should be checked for leaks. If aleak is detected, the refrigerant should be recovered before repairing theleak. This is in compliance with the Clean Air Act.

WATER PIPING

Water inlet and outlet are equipped with 25.4mm or 1 (FPT)female pipe thread.

Make sure that internal water piping is clean.

Use correct size wrenches and proper sealing for water inletand outlet connections.

Do not over tighten the connections.

Suspend or use vibration isolators on water pipes, for pipesnot to transmit vibration.

Field install air bleed valve and dirt leg pipes (for backwashingpurposes) in water piping system.

Field install water supply and return line connection and checkfor water pressure drop and flow rates.

Water piping accessories, water strainer (screen assemblies

of 20 to 40 mesh) and water flow switch to be field suppliedand installed.

Water system needs to be chemically treated in order tomaintain water cleanliness and minimize scale build-up.

After all the water piping is completed, be sure to flush all pipework prior to start-up.

Condenser water inlet need to be controlled at 29.5C(85F).It is advisable to always maintain the water inlet temperature inthis region. This can be accomplished by using a thermostat tocontrol the cooling tower fan and water temperature in thebasin of the tower.

FIG. 5 TYPICAL PIPING & WIRING WORKS


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REFRIGERANT CHARGING

The 07KHP units are packed with refrigerant holding charge only.Proper refrigerant charge is determine using Superheat method.

IMPORTANT

For accurate system performance, charge by superheat method asshown in table 6 and 7.

To check and adjust charge, follow the following procedures:

1. Operate unit for a minimum of 30 minutes before checkingcharge.

2. Measure suction pressure by attaching a gauge to suctionline service port.

3. Measure suction line temperature by attaching a servicethermometer to unit suction line near suction valve. Insulatethermometer for accurate readings.

4. Measure entering water temperature with a secondthermometer.

5. Measure indoor coil air inlet wet-bulb temperature with a slingpsychrometer.

6. Refer to table 4. Find entering water temperature and wet-bulb temperature entering indoor coil. At this intersection,note the superheat.

7. Refer to table 5. Find superheat and temperature and suction

pressure, note suction line temperature.8. If unit has higher suction line temperature than chartedtemperature add refrigerant until charted temperature isreached.

9. If unit has lower suction line temperature than chartedtemperature, bleed refrigerant until charted temperature isreached.

10. If entering water temperature or pressure at suction linechanges, charge to new suction line temperature indicated onchart.

11. This procedure is valid independent of indoor air quantity.

MAINTENANCE

Remove units access panels for internal servicing and maintenance.

LUBRICANT

Compressor contains factory oil charge. Replace oil when lost. See

table 3 for oil recharge and refer to Carrier Manual Chapter 1, page 1-21for oil recharging procedure.

CLEANING HEAT EXCHANGER

Use a tank with 5% phosphoric acid. Pump the cleaning liquid throughthe plate heat exchanger at 1.5 times normal flow rate for optimumcleaning, preferably in back flush mode. Then, rinse with large amountof fresh water to get rid of all the acid before starting up the systemagain. Clean at regular interval.

TABLE 4 AIR AND WATER LIMITS

LIMITS STANDARD TEMPERATURE

AIR (C)

Min. Ambient Air 21

Rated Ambient Air 27

Max. Ambient Air 43

Min. Entering Air at Evap 21

Rated Entering Air, DB/WB 27/19

Max Entering Air, DB/WB 32/23

WATER (C)

Min. Entering Water 15

Normal Entering Water 29.5

Max Entering Water * 35

TABLE 5 WATER FLOW LIMITATIONS

UNIT MODEL NO. - 07KHP MAX / MIN L/S (GPM)

0130.25 / 0.1(4 / 1.5)

0180.38 / 0.14

(6 / 2.3)

0240.5 / 0.19

(8 / 3)

0400.76 / 0.28(12 / 4.5)

0601.26 / 0.47(20 / 7.5)

0901.89 / 0.72(30 / 11.5)

CAUTIONTO PREVENT PERSONAL INJURY, WEAR SAFETY GLASSESAND GLOVES WHEN HANDLING REFRIGERANT. DO NOTOVERCHARGED SYSTEM. THIS CAN CAUSE COMPRESSOR

FLOODING.

CAUTIONBEFORE PERFORMING RECOMMENDED MAINTENANCE, BESURE UNIT MAIN POWER SWITCH IS TURNED OFF. FAILURETO DO SO MAY RESULT IN ELECTRIC SHOCK OR INJURY.

*At maximum water flow conditions only as shown on Table 5below

NOTE: Water flow must be sufficient to obtain a maximum 10Ftemperature rise across the water-to-refrigerant heat exchanger whenoperating in the cooling mode. Water flow rates greater than 4.0 GPMper nominal ton or water velocities of 10 ft/sec or more may causeerosion damage to the water-to-refrigerant heat exchanger.


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Superheat Charging Table (English)

(Superheat Entering Suction Service Valve)

INDOOR COIL ENTERING AIR (F) WET-BULBENT.WATER

TEMP(F) 50 52 54 56 58 60 62 64 66 68 70 72 74 76

55 9 12 14 17 20 23 26 29 32 35 37 40 42 45

60 7 10 12 15 18 21 24 27 30 33 35 38 40 43

65 - 6 10 13 16 19 21 24 27 30 33 36 38 41

70 - - 7 10 13 16 19 21 24 27 30 33 36 39

75 - - - 6 9 12 15 18 21 24 28 31 34 37

80 - - - - 5 8 12 15 18 21 25 28 31 35

85 - - - - - - 8 11 15 19 22 26 30 33

90 - - - - - - 5 9 13 16 20 24 27 31

95 - - - - - - - 6 10 14 18 22 25 29

100 - - - - - - - - 8 12 15 20 23 27

105 - - - - - - - - 5 9 13 17 22 26

110 - - - - - - - - - 6 11 15 20 25

115 - - - - - - - - - - 8 14 18 23

Symbol dash (-) means: Do not attempt to charge system under these conditionsor refrigerant slugging may occur.

Required Suction Tube Temperature (English)(Entering Suction Service Valve)

SUCTION PRESSURE AT SERVICE PORT (psig)SUPERHEATTEMP (F) 61.5 64.2 67.1 70.0 73.0 76.0 79.2 82.4 85.7

0 35 37 39 41 43 45 47 49 51

2 37 39 41 43 45 47 49 51 53

4 39 41 43 45 47 49 51 53 55

6 41 43 45 47 49 51 53 55 57

8 43 45 47 49 51 53 55 57 59

10 45 47 49 51 53 55 57 59 61

12 47 49 51 53 55 57 59 61 63

14 49 51 53 55 57 59 61 63 65

16 51 53 55 57 59 61 63 65 67

18 53 55 57 59 61 63 65 67 69

20 55 57 59 61 63 65 67 69 71

22 57 59 61 63 65 67 69 71 73

24 59 61 63 65 67 69 71 73 75

26 61 63 65 67 69 71 73 75 77

28 63 65 67 69 71 73 75 77 79

30 65 67 69 71 73 75 77 79 8132 67 69 71 73 75 77 79 81 83

34 69 71 73 75 77 79 81 83 85

36 71 73 75 77 79 81 83 85 87

38 73 75 77 79 81 83 85 87 89

40 75 77 79 81 83 85 87 89 91

Superheat Charging Table (Metric)(Superheat Entering Suction Service Valve)

INDOOR COIL ENTERING AIR (C) WET-BULBENT.

WATERTEMP(C)

10 11.1 12.2 13.3 14.4 15.6 16.7 17.8 18.9 20 21.1 22.2 23.3 24.4

12 5 6.7 7.8 9.4 11.1 12.8 14.4 16.1 17.8 19.4 20.6 22.2 23.3 25

15.5 3.9 5.6 6.7 8.3 10 11.7 13.3 15 16.7 18.3 19.4 21.1 22.2 23.9

18.3 - 3.3 5.8 7.2 8.9 10.6 11.7 13.3 15 16.7 18.3 20 21.1 22.8

21.1 - - 7 5.6 7.2 8.9 10.6 11.7 13.3 15 16.7 18.3 20 21.7

23.9 - - - 3.3 5 6.7 8.3 10 11.7 13.3 15.6 17.2 18.9 20.6

26.7 - - - - 2.8 4.4 6.7 8.3 10 11.7 13.9 15.6 17.2 19.4

29.4 - - - - - - 4.4 6.1 8.3 10.6 12.2 14.4 16.7 18.3

32.2 - - - - - - 2.8 5 7.2 8.9 11.1 13.3 15 17.2

36 - - - - - - - 4.4 5.6 7.8 10 12.2 13.9 16.1

37.8 - - - - - - - - 3.3 6.7 8.3 11.1 12.8 15

40.6 - - - - - - - - 2.8 5 7.2 9.4 12.2 14.4

43.3 - - - - - - - - - 3.3 6.1 8.3 11.1 13.9

46.1 - - - - - - - - - - 4.4 7.8 10 12.8

Symbol dash (-) means: Do not attempt to charge system under these conditionsor refrigerant slugging may occur.

Required Suction Tube Temperature (Metric)(Entering Suction Service Valve)

SUCTION PRESSURE AT SERVICE PORT (KPaG)SUPERHEATTEMP (K)

424 443 463 483 503 524 546 568 591

0 1.7 2.8 3.9 5 6.1 7.2 8.3 9.4 10.6

1.1 2.8 3.9 5 6.1 7.2 8.3 9.4 10.6 11.72.2 3.9 5 6.1 7.2 8.3 9.4 10.6 11.7 12.8

3.3 5 6.1 7.2 8.3 9.4 10.6 11.7 12.8 13.9

4.4 6.1 7.2 8.3 9.4 10.6 11.7 12.8 13.9 15

5.6 7.2 8.3 9.4 10.6 11.7 12.8 13.9 15 16.1

6.7 8.3 9.4 10.6 11.7 12.8 13.9 15 16.1 17.2

7.8 9.4 10.6 11.7 12.8 13.9 15 16.1 17.2 18.3

8.9 10.6 11.7 12.8 13.9 15 16.1 17.2 18.3 19.4

10 11.7 12.8 13.9 15 16.1 17.2 18.3 19.4 20.6

11.1 12.8 13.9 15 16.1 17.2 18.3 19.4 20.6 21.7

12.2 13.9 15 16.1 17.2 18.3 19.4 20.6 21.7 22.8

13.3 15 16.1 17.2 18.3 19.4 20.6 21.7 22.8 23.9

14.4 16.1 17.2 18.3 19.4 20.6 21.7 22.8 23.9 25

15.6 17.2 18.3 19.4 20.6 21.7 22.8 23.9 25 26.1

16.7 18.3 19.4 20.6 21.7 22.8 23.9 25 26.1 27.2

17.8 19.4 20.6 21.7 22.8 23.9 25 26.1 27.2 28.3

18.9 20.6 21.7 22.8 23.9 25 26.1 27.2 28.3 29.4

20 21.7 22.8 23.9 25 26.1 27.2 28.3 29.4 30.6

21.2 22.8 23.9 25 26.1 27.2 28.3 29.4 30.6 31.7

22.2 23.9 25 26.1 27.2 28.3 29.4 30.6 31.7 32.8

TABLE 6

TABLE 7


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FIG. 8 WIRING DIAGRAM 07KHP012

FIG. 9 WIRING DIAGRAM 07KHP018 & 024


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FIG. 10 WIRING DIAGRAM 07KHP040 & 050



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FIG. 13 RECOMMENDED SERVICE CLEARANCES


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NO COOLING ORIN-SUFFICIENT

COOLING

COMPRESSORRUNS BUT

INSUFFICIENTCOOLING

INCORRECTMETERING DEVICE

DIRTY AIRFILTERS

LOW SUCTIONPRESSURE

AIR TRAPPED INWATER CIRCUIT

BLOCKED WATERCIRCUITS HEAT

EXCHANGER

NO WATER FLOWTHROUGH HEAT

EXCHANGER

COMPRESSOR RUNSBUT CYCLES ON

INTERNALOVERLOAD

COMPRESSORWILL NOT RUN

CONTACTOROPEN

CONTACTORCLOSED

FAULTY POWERSUPPLY

OPEN CONTROLCIRCUIT

DEFECTIVETIME DELAY

LOOSEELECTRICAL

CONNECTION

INTERNAL

OVERLOAD OPEN

CONTACTOR ORCOIL DEFECTIVE

OPENHP PRESSURE

SWITCH

FAULTY STARTGEAR (1PH)

LOOSE LEADSAT COMPRESSOR

COMPRESSORSTUCK

COMPRESSORPOWER

SUPPLY OPEN

COMPRESSORINTERNAL

PROTECTIONOPEN

OVERCHARGED ORNONCONDENSABLES

IN SYSTEM

OPEN, SHORTEDOR GROUNDEDCOMPRESSOR

MOTOR WINDING

HIGHSUPERHEAT

COMPRESSORBEARINGS

DEFECTIVE FANCAPACITOR

LINE VOLTAGE TOOHIGH OR LOW

LOW REFRIGERANTCHARGED

RESTRICTEDDISCHARGE LINE

INTERNALPRESSURE RELIEF

OPEN

DEFECTIVECOMPRESSOR

VALVES

CONDENSER ENT.WATER TEMP.

TO LOW

LIQUID LINESLIGHTLY

RESTRICTED

SLIGHTLYLOW ON

REFRIGERANT

HIGH SUCTIONLOW HEADPRESSURE

INCORRECTMETERING DEVICE

METERING DEVICERESTRICTED

INDOOR COILFROSTED

DAMPER PARTLYCLOSED

DUCTRESTRICTED

HIGH SUCTIONLOW SUPERHEAT

UNITOVERCHARGED

INDOOR COILSTAINER

RESTRICTED

TROUBLESHOOTING CHART-COOLING CYCLE


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Water Cooled Fcu Piping Details

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