Ice ECUA90, ECUA120, ECUA150, ECUA240, ECUA180 Installation & Operation Manual
ECU Installation & Operation Manual
Vertical Air Conditioners
Models ECUA90/120/150/180/240
Chapter 1 Description ........................... 5
Chapter 2 Installation ......................... 12
Chapter 3 Start-Up ............................. 21
Chapter 4 Troubleshooting ................. 22
Chapter 5 Maintenance ....................... 25
Chapter 6 Warranty ............................ 26
Chapter 7 Start-Up Checklist .............. 27
Industrial Climate Engineering™ Division of AIRXCEL®, Inc.
P.O. Box 5104 • Cordele, Georgia 31010
2002 Hoover St. • Cordele, Georgia 31015
E-mail: icesales@airxcel.com • Internet: www.acice.com
The most current version of this manual can be found at www.acice.com.
Manufactured By:
(229) 273-9558 • Fax (229) 273-5154
Part Number 02118 04/2015 rev.3
How To Use This Manual
This manual is intended to be a guide to Industrial Climate Engineering's 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.
If you are installing the air conditioner rst read Chapter 1 and scan the entire manual before beginning the installation as
described in Chapter 2. Chapter 1 contains general, descriptive information and provides an overview which can speed
up the installation process and simplify troubleshooting.
If a malfunction occurs, follow this troubleshooting sequence:
1. Make sure you understand how the air conditioner works (Chapters 1 & 3).
2. Identify and correct installation errors (Chapter 2).
3. Refer to the troubleshooting information in Chapter 4.
If you are still unable to correct the problem, contact the Factory at 1-229-273-9558 for additional assistance.
Please read the following “Important Safety Precautions” before beginning any work.
Important Safety Precautions
1. USE CARE when LIFTING or TRANSPORTING equipment.
2. TRANSPORT the UNIT UPRIGHT. Laying it down on its side may cause oil to leave the compressor and breakage
or damage to other components.
3. TURN ELECTRICAL POWER OFF AT THE breaker or fuse box BEFORE installing or working on the equipment.
LINE VOLTAGES ARE HAZARDOUS or LETHAL.
4. OBSERVE and COMPLY with ALL applicable PLUMBING, ELECTRICAL, and BUILDING CODES and ordi-
nances.
5. SERVICE may be performed ONLY by QUALIFIED and EXPERIENCED PERSONS.
* Wear safety goggles when servicing the refrigeration circuit
* Beware of hot surfaces on refrigerant circuit components
* Beware of sharp edges on sheet metal components
* Use care when recovering or adding refrigerant
6. Use COMMON SENSE - BE SAFETY-CONSCIOUS
This is the safety alert symbol . When you see this symbol on the air conditioning unit and in the instruction manu-
als be alert to the potential for personal injury. Understand the signal word DANGER, WARNING and CAUTION.
These words are used to identify levels of the seriousness of the hazard.
!
DANGER
!
WARNING
!
CAUTION
Failure to comply will result in death or severe personal injury and/or property damage.
Failure to comply could result in death or severe personal injury and/or property damage.
Failure to comply could result in minor personal injury and/or property damage.
IMPORTANT is used to point out helpful suggestions that will result in improved installation, reliability or operation.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.
© 04/2015 Industrial Climate Engineering™ Div. Airxcel™, Inc.
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WARNING
• If the information in these instructions are not followed exactly, a re 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.
• Installation and service must be performed by a qualied installer or service agency in
accordance with these instructions and in compliance with all codes and requirements
of authorities having jurisdiction.
INSTALLER: Afx the instructions on the inside of the building adjacent to the
thermostat.
END USER: Retain these instructions for future reference.
Table of Contents
Chapter 1 Air Conditioner Description & Specications
1.1 General Description .................................................................................................................................5
1.2 Model Identication .................................................................................................................................5
1.3 Serial Number Date Code ........................................................................................................................5
1.4 Air Flow, Weights and Filter Sizes ...........................................................................................................6
1.5 General Operation ....................................................................................................................................6
1.6 Electronic Control Board Mode of Operation ..........................................................................................7
1.7 Optional Controls and Packages ..............................................................................................................8
1.8 Electrical Operation .................................................................................................................................9
Chapter 2 Installation
2.1 Equipment Inspection .............................................................................................................................12
2.2 Installation Requirements .......................................................................................................................12
2.3 Installation Materials ............................................................................................................................13
2.4 Porting and Duct Work ..........................................................................................................................15
2.5 Top Flange Installation ..........................................................................................................................15
2.6 Installing the Lifting Brackets ................................................................................................................16
2.7 Mounting the Unit .................................................................................................................................16
2.8 Electrical Connections ...........................................................................................................................17
Chapter 3 Start-Up
3.1 Check-Out of Cooling Cycle .................................................................................................................21
3.2 Check-Out of Heating Cycle ..................................................................................................................21
Chapter 4 Troubleshooting
4.1 Overview ................................................................................................................................................22
4.2 Failure Symptoms Guide ........................................................................................................................22
4.3 Compressor Troubleshooting .................................................................................................................23
4.4 Control Board Diagnosis ........................................................................................................................24
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Table of Contents
Chapter 5 Maintenance
5.1 Scheduled Maintenance .........................................................................................................................25
Chapter 6 Warranty
6.1 Limited Product Warranty ......................................................................................................................26
Chapter 7 Start-Up Check List
7.1 Start-Up Check List ................................................................................................................................27
Illustrations
Figure 1a. Typical Electrical Schematics for Units with One Compressor ............................................. 10
Figure 1b. Typical Electrical Schematics for Units with Two Compressors ........................................... 11
Figure 2. Top Flange and Lifting Bracket Installation .......................................................................... 16
Figure 3. Wall Mounting Detail ............................................................................................................. 17
Figure 4a. Thermostat Connection Diagram ........................................................................................... 20
Figure 4b. CommStat™ 3 Wiring Detail ................................................................................................. 20
Tables
Table 1 Cooling Performance and Air Flow ......................................................................................... 6
Table 2 Return Air Filter Sizes .............................................................................................................. 6
Table 3 Shipping Weights & Dimensions ............................................................................................. 6
Table 4 Minimum Clearances ............................................................................................................. 13
Table 5 Voltage Limitations ................................................................................................................ 13
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Chapter 1 Description & Specications
1.1 General Description
Industrial Climate Engineering's (ICE) Environmental Control Units (ECU) are a series of vertical
wall-mounted air conditioning systems that provide heating, cooling, and ventilation for electronic
equipment shelters, process control centers, E-Houses, and other applications with high internal heat
gains. The series includes multiple sizes and nominal cooling capacities from 90,000 to 240,000 BTUH.
Resistance heating elements are available in various wattages.
Industrial Climate Engineering ECU's feature an exclusive electronic control board.
The control board consolidates several of the electrical components, improves the air conditioner’s
reliability and has LED’s to indicate operating status and fault conditions to assist the service technician.
A complete description of functions of the control board is in Section 1.6
Other standard components include:
• Hot gas by-pass valve to allow operation in cold temperatures
• Thermal expansion valve to improve both efciency and capacity over a wide range of ambient
temperatures
• Phase monitor to prevent operation if the unit is not properly phased
The ECU's are designed for easy installation and service. Major components are accessible for service
beneath external panels.
All units have internal disconnects. Depending upon state and local code requirements, this feature
may eliminate the need for an external breaker or disconnect.
1.2 Model Identication
The model identication number is found on the data sticker. Rating plate located on side panel.
ECU D A ••• AC • ••• • • U A5 •••
D = Dual
Compressors
Environmental
Control Unit
1
The standard conguration is with one compressor. Add "D" to the model number to indicate dual compresssors.
2
The standard conguration is with the supply (conditioned) air at the top of the unit and the return air below it. In the reverse air ow conguration, the return
is at the top and the supply air below it.
3
Filter acces in the standard conguration is through the hinged, sheet metal panel on the exterior of the air conditioner. The "I" conguration allows access to
the lter from inside the building through the return air grille.
4
Three wire
5
Four wire
1
Refrigerant
A = R410A
Nominal Cooling
90 = 90,000 BTUH
120 = 120,000 BTUH
150 = 150,000 BTUH
180 = 180,000 BTUH
240 = 240,000 BTUH
System Type
Air Conditioner
Power Supply
D = 460V,3ø,60Hz
E = 380V,3ø,50Hz
C = 208/230V,3ø,60Hz
Z = 575V, 3ø,60Hz
Electric Heat – kW
000 = No Heat
090 = 9 kW
150 = 15 kW
180 = 18 kW
4
5
4
1.3 Serial Number Date Code
A = January E = May J = September D = 2014
B = February F = June K = October E = 2015
C = March G = July L = November F = 2016
D = April H = August M = December
Special Option Code
F = Reverse Air Flow
I = Factory Installed
Filter Rack Allows
Changing of Filters
from the Return Air
3
Grille
Ventilation
A = No Outside Air
(standard)
C = Economizer
2
Compressor
U = Scroll Compressor
Cabinet Color
116 = Beige
216 = Gray
(standard)
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1.4 Weights and Filter Sizes
Complete electrical and performance specications and dimensional drawings are in the Product Data
Sheet.
Model Number ECUA90 ECUA120 ECUA150 ECUA180 ECUA240
Cooling BTUH
Rated Air Flow (CFM2) 3,500 4,000 5,000 6,000 8,000
ESP3 @ Rated Conditions 0.25 0.30 0.35 0.35 0.40
1
Cooling rated at 95°F (35°C) outdoor and 80°F DB/67° WB (26.5°C DB/19.5°C WB) return air
2
CFM=Cubic Feet per Minute
3
ESP=External Static Pressure
Ratings are with no outside air. Performance will be affected by altitude.
Ratings are at 230 volts for 208/230 volt units (“C” models), 460 volts for “D” models, 380 volts for “E” models, 575 volts for “Z”
models. Derate performance by 17% for ACE (380v. 3ø, 50 Hz) models
Operation of units at a different voltage from that of the rating point will affect performance and air ow.
MODEL Description INCHES MILLIMETERS PART NO. FILTERS PER UNIT MERV RATING
ECUA90/120/150 Exterior Access Return Air Filter 25" x 16" x 2" 635 x 406 x 51 80137 3 8
ECUA90/120/150 Interior Access Return Air Filter 15" x 20" x 2" 381 x 508 x 51 92365 3 8
ECUA180/240 Exterior Access Return Air Filter 25" x 16" x 2" 635 x 406 x 51 80137 4 8
ECUA180/240 Interior Access Return Air Filter 24" x 18" x 2" 610 x 457 x 51 81257 4 8
1
94,000 125,000 150,000 170,000 235,000
Table 1. Cooling Performance and Air Flow Ratings
Table 2. Return Air Filter Sizes
MODEL
ECUA90
ECUA120
ECUA150
ECUA180
ECUA240
1.5 General Operation
Refrigerant Cycle (Cooling Mode)
The air conditioners use R-410A refrigerant in a conventional vapor-compression refrigeration cycle to
transfer heat from air in an enclosed space to the outside. A motorized impeller 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. The hot refrigerant gas condenses to liquid as heat is transferred to outdoor
air drawn across the condenser by the condenser fan. Liquid refrigerant is metered with a thermal
expansion valve (TXV) into the evaporator to repeat the cycle.
Heating Mode
Unit Weight
LBS KG LBS KG Inches MM Inches MM Inches MM
1,053 478.6 1,178 535.5 98 2,489 56 1,422 42 1,067
1,160 527.3 1,285 584.1 98 2,489 56 1,422 48 1,219
1,166 530 1,291 586.8 98 2,489 56 1,422 48 1,219
2,307 1,046 2,420 1,098 98 2,489 76 1,930 51 1,295
2,523 1,144 2,636 1,196 98 2,489 76 1,930 51 1,295
Shipping
Weight
Height Width Depth
Shipping Dimensions
Table 3. Shipping Weights & Dimensions
A wall-mounted thermostat controls the heating cycle of models which incorporate resistance heating
elements. On a call for heat, the thermostat closes the heat relay to energize the indoor fan and the
resistance elements.
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1.6 Electronic Control Board Mode of Operation
Normal
24 VAC power must be continuously applied to “R” and “C”. Upon a call for cooling “Y” and with
the high pressure switch (HPS) closed, the compressor will be energized. (Note: See the delay on
make feature.) The compressor will remain energized during the 3 minute timed low pressure by-pass
cycle. If the low pressure switch (LPS) is open after the 3 minute by-pass cycle, the compressor will
de-energize.
Lock-out
If either of the fault conditions (LPS or HPS) occurs twice during the same call for cooling, the control
board will enter into and indicate the lockout mode. In the lockout mode, the compressor is turned off.
If there is a call for indoor air ow “G”, the blower remains energized, the alarm output is energized and
the status LED will blink to indicate which fault has occurred. When the lockout condition is cleared, the
unit will reset if the demand for the thermostat is removed or when the power is reset. With the control
board, the user can now have either normally closed or normally open remote alarm dry contacts. The
air conditioners are factory wired to be normally open.
Delay on Break
If the compressor is de-energized due to a loss of a cooling “Y” call or the rst 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 By-Pass Time
When starting, the low pressure switch (LPS) fault condition will be by-passed for 3 minutes before
the contactor is de-energized.
Post Purge
Upon a call for indoor airow “G” the blower will energize immediately. When in the cooling mode,
the blower will remain energized for 10 to 90 seconds (adjustable) after the compressor has been deenergized. The time period can be changed by fan purge wheel on the board. Factory setting is 90 seconds.
LED Indicator Lights
COLOR TYPE STATUS DESCRIPTION
Green Power Contstant On 24 VAC power has been applied
Red Status Contstant On Normal operation
Red Status 1 Blink High pressure switch has opened twice
Red Status 2 Blinks Low pressure switch has opened twice
High Pressure Switch
The high pressure switch is mounted on the liquid line. It is electrically connected to a lockout circuit
on the board which shuts down the system if the refrigerant pressure rises to 650 PSIG. This protects
the unit if airow through the condenser is blocked or if the outdoor fan motor fails.
Although the contacts of the high pressure switch close when the refrigerant pressure falls to approximately 450 PSIG, the system must be manually reset once the lockout circuit is activated. A manual
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ECU 04/2015 rev.3
reset is necessary to prevent harmful short-cycling. To reset switch, turn primary power off, then back
LEDs
POST PURGE
WHEEL
DELAY ON MAKE
(COMPRESSOR TIME DELAY)
WHEEL
on or turn thermostat system switch off, then back on.
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 40 PSIG; it resets when the pressure rises to 60 PSIG. The switch protects the unit if
airow through the indoor blower is impeded, if the blower motor fails, or if there is a loss of refrigerant.
1.7 Optional Controls & Packages
Protective Coating Packages
Two corrosion protection packages are offered- one for the condenser section (the Coastal Environmental
package) and the other for the entire unit (the Coat-All Package).
The condenser protection package includes:
• Corrosion resistant fasteners
• Sealed or partially sealed condenser fan motor
• Two layer epoxy/urethane applied to all exposed internal copper and metal in the in the condenser
section
• An impregnated polyurethane on the condenser coil
The Coat-all package includes all of the above but also includes an impregnated polyurethane on the
evaporator coil and the two layer epoxy/urethane on all exterior and interior components and sheet metal.
(Note: the internal sheet metal which is insulated and the internal control box are not coated).
Dirty Filter Indicator
A diaphragm type of indicator measures the air pressure on either side of the lter and when the pressure
drops below the set point, a red LED is illuminated. The set point is adjustable.
Protective Coil Coatings
Either the condenser or evaporator coil can be coated. For harsh conditions, e.g., power plants, paper mills
or sites were the unit will be exposed to salt water, the condenser coil should be coated. Note: Cooling
capacity may be reduced by up to 5% on units with coated coils.
Cabinet Color and Material
The air conditioners are available in two standard cabinet colors -the standard grey with beige as an option.
The standard cabinet’s sides, top and front panels are constructed of 16 gauge painted steel. Contact your
ICE representative for color chips, custom colors and 316 stainless steel cabinets.
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Fresh Air Damper
Allows introduction of outside air into the building to provide positive pressurization. Field installed
on either the left or right hand side of the unit.
Dual Compressors With Lead/Lag Operation
Freeze Sensor On Indoor Coil
Prevents frost on the indoor coil caused by a loss of air ow or restrictive duct work. Field installed.
Filter Access From Return Air Grille
Factory or eld installed lter bracket allows changing and access to the lters from the return air grille.
See model ID, special option code “I”.
Reverse Air Flow Conguration
Location of Supply and Return Air Openings are reversed.
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.
The indoor evaporator fan motor is controlled by the fan purge on the electronic control board.
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