horizontal self contained environmental control unit... · unit part no. rev. cde 09/05/2018...

Cage Code 3C0M7

3390 Farmtrail Road ■ York, PA 17406 Phone 717-854-0005 ■ Fax 717-854-0045

Rev. D 04 January 2019

© 2019 Tekgard Inc. All rights reserved. This document contains information developed by Tekgard, Inc. for Tekgard’s customers. All information contained in this document is proprietary and the property of Tekgard, Inc. This document, in electronic form or hardcopy, is an integral part of the environmental control unit and as such may be distributed through the same chain of custody/ownership as the ECU. It shall not be disclosed, reproduced, transferred, or used outside the chain of custody/ownership in any manner or form without the written consent of Tekgard, Inc.

Horizontal Self Contained Environmental Control Unit

Model #: TEK-H42C4 Part # H42-T104-C

Safety, Operation, and Maintenance Manual

102T197

Cage Code 3C0M7

Model #: TEK-H42C4 P/N H42-T104

Rev. D

04 January 2019 of 40

© 2019 Tekgard Inc. All rights reserved. See cover page for distribution information.

RReevviissiioonnss

Revision

Release Date

Description

Released

By

A 20 June 2016 Initial Release CWG

B 17 October 2017 ECN-826 Changes CWG

C 09 April 2018 ECN-881 Changes CWG

D 04 January 2019 ECN-933 Changes CWG

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CCoonntteennttss

Section

Description

Page No.

Safety General Safety Guidelines

4

Design Parameters

System Description, Design Parameters, Cooling Capacity, Heating Capacity, Physical Dimensions, Power Requirements, Component Factory Settings

9

Theory of Operation Individual Component Operations 12

Operating Instructions Setup and Operation Procedure 17

Maintenance & Repair

Preventive Maintenance Guidelines Air Filter Cleaning Procedure

24

Troubleshooting Guide Troubleshooting Guidelines 30

Replacement Parts List

Recommended Spare Parts and Location Details

32

Drawings & Schematics

(11”x17”)

Interface Control Drawing: H42-T104-C, 088T1104-A Electrical Schematic: 015T718-B Refrigeration Schematic: 015T868-A

Attached

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SSAAFFEETTYY

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SAFETY: The items listed in this section are general safety guidelines. They are provided as information to be used in the absence of related policies and procedures. DO NOT SERVICE OR ADJUST ALONE

Under no circumstances should any person reach into an enclosure for the purpose of servicing or adjusting the equipment except in the presence of someone who is capable of rendering aid.

The US EPA Clean Air Act of 1994 requires personnel working with refrigerants to be certified to the current standards of Section 608.

RESUSCITATION

Personnel working with or near high voltages should be familiar with modern methods of resuscitation. CPR information and training can be obtained from your local Red Cross or American Heart Association.

KEEP AWAY FROM LIVE CIRCUITS

Personnel must at all times observe all applicable safety regulations. DO NOT REMOVE OR REPLACE ELECTRICAL COMPONENTS WITH MAIN POWER CABLE ATTACHED. Dangerous potentials exist when the power cable is attached. To avoid injury to personnel, always remove power by disconnecting power cable, and then use test equipment to confirm that a high voltage circuit is at ground potential before touching it.

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THERE IS NO OFF SWITCH OR POSITION THAT DISCONNECTS LINE VOLTAGE FROM A UNIT WITH A POWER CABLE ATTACHED. 380 VAC IS PRESENT ON THE LINE SIDE OF THE CONTACTORS AND THE 24 VDC CONTROL POWER IS LIVE WHENEVER THE MAIN POWER CABLE IS ATTACHED.

ABNORMAL CONDITIONS

In the event of an abnormal condition not covered by the procedures in this manual, stop work and consult a qualified technician before continuing work.

LIFTING OPERATIONS

USE EXTREME CARE AND UTILIZE A FORKLIFT OR CRANE WHEN LIFTING OR MOVING UNITS OR HEAVY COMPONENTS. STAND CLEAR DURING ALL LIFTING OPERATIONS.

VENTING REFRIGERANTS

The U.S. Clean Air Act Amendments of 1990 prohibit venting refrigerants to atmosphere. The objectives of this Act are to reduce the use and emissions of such substances to the lowest achievable level and maximize the recapture and recycling of such substances. In addition, the amendments establish new standards for the safe disposal of these substances. All emissions must be captured in a suitable container for further

WARNING

WARNING

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recycling or safe disposal. Service personnel or any other individual may not “knowingly vent or otherwise release or dispose of any substance used as a refrigerant in such appliances in a manner which permits such substance to enter the environment.” It is the customer’s responsibility to keep informed of the latest Amendments to this Act.

SMOKING AND OPEN FLAMES

SMOKING OR OPEN FLAMES SHOULD NOT BE PERMITTED WITHIN 50 FT. (15M) OF REFRIGERANT VAPORS.

HIGH PRESSURE SYSTEM

THE UNIT HAS A CLOSED-LOOP, HIGH-PRESSURE REFRIGERANT SYSTEM. DO NOT CLOSE, OPEN OR ADJUST VALVES IN THE REFRIGERANT SYSTEM UNLESS A SPECIFIC INSTRUCTION STATES THAT VALVES MUST BE OPENED, CLOSED, OR ADJUSTED. PERSONNEL COULD BE INJURED OR EQUIPMENT COULD BE DAMAGED.

CAUTION

WARNING

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ELECTROSTATIC DISCHARGE (ESD)

WHEN WORKING IN THE ECU CONTROL BOX, MAINTENANCE AND REPAIR TECHNICIANS SHOULD EXERCISE GOOD ESD PREVENTION PROCEDURES. THE USE OF (A) GROUNDING WRIST STRAP(S) WHEN REMOVING AND/OR REPLACING COMPONENTS IS STRONGLY ENCOURAGED.

WARNING

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DDEESSIIGGNN PPAARRAAMMEETTEERRSS

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DESIGN PARAMETERS: GENERAL This manual defines Environmental Control Unit (ECU), Tekgard model TEK-H42C4, Part Number H42-T104. This ECU is designed for use on a shelter powered by a generator or shore power. The basic design of the ECU is a self-contained electric motor driven, air-cooled unit. Total system capacity is 52,000 BTU/HR at an ambient temperature of 125°F. DESIGN PARAMETERS The ECU is designed to meet the following requirements for physical dimension, weight, mobility, power requirements, and performance.

COOLING: Total Cooling Capacity: 52,000 BTU/HR @ +125°F

Ambient Maximum Ambient Temperature: +131°F Design Return Air Dry Bulb Temperature:

+90°F 50%RH

Approximate Supply Airflow Rate: 1,400 CFM @ 0.75” ESP Fresh Airflow Rate: 0-180 CFM

HEATING: Total Heating Capacity: 9.75 KW ( BTU/HR) Minimum Ambient Temperature: -40°F

PHYSICAL DIMENSIONS: Height: 33.50” Width: 69.50” Depth: 35.48” Weight: 470 Lbs.

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POWER REQUIREMENTS: Voltage: 230 Volts

Tolerance Recommended ±10%

Number of Phases: 1 Phase Frequency: 50-60 Hz Maximum Power Draw: 10.5 kW

Control Circuit: 24 VDC

COMPONENT SETTINGS: TXV Setting - Super Heat Factory set between 9°F and 15°F Low Pressure Cut Out Switch Opens @ 5 psig & closes @ 20

psig High Pressure Cut Out Switch 700 psig - Manual Reset High Pressure Relief Valve 750 psig Heater Hi Temp Cut Out Switch 185°F Refrigerant Charge (R-410A) 6 lbs 4 oz +/- 8 oz

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TTHHEEOORRYY OOFF OOPPEERRAATTIIOONN

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THEORY OF OPERATION: INDIVIDUAL COMPONENT OPERATIONS COMPRESSOR

The compressor raises the pressure of low pressure, low temperature refrigerant gas producing high pressure, high temperature refrigerant. High and low pressure cutout switches are utilized in the system to prevent unsafe operation and protect the compressor from damage.

Vibration eliminators have been installed to reduce transmission of compressor-induced vibration through the system. The vibration eliminators are located on the compressor inlet and outlet lines.

CONDENSER COIL

The condenser is an air cooled heat exchanger designed to lower the temperature of the refrigerant that is being discharged by the compressor as a high pressure/ high temperature vapor. A properly sized and functioning condensing coil will have little effect on the pressure; however the temperature of the refrigerant will be lowered enough to cause the refrigerant to condense into a liquid.

CONDENSER FAN

The condenser fan provides air flow through the condenser coil allowing the coil better exchange heat.

CONTACTORS

Contactors have a set of high current carrying contacts for conducting line voltage to the load and a magnetic holding coil, which closes the line voltage contacts whenever the control circuit voltage (115 VAC) is applied.

Contactors are used to turn on and off the compressor, heaters and fan motors. Motor Starter Protectors or Circuit Breakers are also used to protect the load devices. The compressor has an internal temperature protection module and an internal pressure relief port. In addition to the circuit breakers, the heaters have a manually resettable high temperature cut-out switch.

ELECTRICAL WIRING

The wiring of the unit and the control panel is described in the wiring schematic mounted on the inside of the electrical panel. The schematic is also shown in the attached Drawings & Schematics included with this manual.

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EVAPORATOR COIL

As the refrigerant passes through the Thermostatic Expansion Valve (TXV), its pressure and therefore temperature is reduced. The evaporator is a heat exchanger designed to allow the refrigerant to absorb heat from the circulation air. As the circulation air gives up its heat to the refrigerant, the refrigerant “boils” from a liquid to a gas and the circulation air temperature is lowered.

EVAPORATOR FAN

The evaporator fan moves shelter air across the evaporator coil and heating elements.

FILTERS

Each of the ECUs is equipped with washable return air filters. The return air filters are installed just inside the return air opening (See spare parts photos). The filters are pleated electrostatic washable filters; see Maintenance & Repair for filter cleaning procedure.

FILTER DRIER

The filter drier removes solid contaminants such as metal filings and brazing slag from the system. It also removes soluble contaminants such as moisture and acid that could damage sensitive components in the system.

Note: The filter drier should be replaced any time the refrigeration system is opened to the atmosphere.

HEATING ELEMENTS

The ECU contains electric resistance heating elements to provide heat at those times when the shelter temperature is below the desired set point. The coil assembly is staged with two different heat outputs based on the amount of heat needed to reach the desired set point. The heating elements also provide temperature stabilization during dehumidification outside of normal cooling operations.

HI-PRESSURE CUT OUT

The hi-pressure cut out is a mechanical switch that disconnects the power to the compressor in the event an over-pressurization of 700 psig is sensed. If the hi-pressure cut out is tripped it must be manually reset.

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HI-TEMP PRESSURE RELIEF

The hi-temp pressure relief is a valve that releases refrigerant from the system in the event of over-pressurization. The valve acts as a final safety mechanism to prevent damage to the system should the other installed safeties fail. Once opened, the valve must be replaced and the system evacuated and re-charged.

HI-TEMP PROTECTION

The heating elements have a high temperature safety switch mounted in close proximity to the heating coils (see spare parts photos) which will de-energize the heaters in the event air flow is interrupted or at any time the temperature of the heaters rises above a safe preset temperature. The safety switch must be manually reset when the temperature returns to a safe range.

LOW PRESSURE CUT OUT

The low pressure cut out is used to protect the compressor from excessively low suction pressures that could possibly damage it.

LIQUID LINE SOLENOID VALVE

The liquid line solenoid valve, when energized, stops the flow of refrigerant to the evaporator coil. This allows cooling to be stopped without the need to cycle the compressor.

REFRIGERATION SYSTEM

The refrigeration circuit of the unit is described in the refrigeration schematic diagram located on the outside of the electrical panel. The schematic is also shown in the attached Drawings & Schematics included with this manual.

SERVICE PORTS

The service ports are used in maintenance and to take pressure readings. The top port is the high pressure liquid side of the system and the bottom port is the low pressure gas side of the system.

SIGHT GLASS

The sight glass is helpful when determining if the system is properly charged with refrigerant or contains moisture.

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THERMOSTATIC EXPANSION VALVE

The thermostatic expansion valve (TXV) is a modulating valve that regulates the flow of refrigerant through the system. It is controlled by two measurements taken at the discharge of the evaporator coil. The first measurement is the temperature of the refrigerant leaving the coil. The second measurement is the pressure leaving the coil. The relationship between these two measurements is called the “superheat”. The valve is adjusted at the factory to maintain an optimal superheat.

UNLOADER VALVE

The Unloader Valve is the device that allows a digital scroll compressor to vary its capacity. With the Unloader Valve open the compressor motor still spins, but no refrigerant is moved through the system. By varying the time that the valve is open a precise amount of refrigerant can be circulated into the system varying the cooling that can be induced.

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OOPPEERRAATTIINNGG IINNSSTTRRUUCCTTIIOONNSS

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OPERATING INSTRUCTIONS: STARTUP AND OPERATION

THERE IS NO OFF SWITCH OR POSITION THAT DISCONNECTS LINE VOLTAGE FROM UNIT WITH A POWER CABLE ATTACHED. 230 VAC IS PRESENT ON THE LINE SIDE OF THE CONTACTORS AND THE 24 VDC CONTROL POWER IS LIVE WHENEVER THE MAIN POWER CABLE IS ATTACHED. Note: These procedures must be accomplished by qualified personnel. STARTUP

1. Perform a visual inspection to make sure all fasteners are secure and the unit is stable.

2. Attach plenum to ECU along with the air filter that accompanies it. 3. Check for leaks that are evident by an accumulation of oil and that there are

no loose, cracked or broken wires or other physical damage. Make all necessary repairs prior to powering the unit.

4. Connect 230V/50-60Hz/1Ø power source to main disconnect/breaker. 5. Make sure the unit is sufficiently grounded. 6. Check for proper drainage of the condensate drain line. 7. Check and remove any obstructions in the ductwork that may limit the air

flow. 8. Replace and/or close all access and service panels. Tighten fasteners as

necessary. CONTROL OPERATION:

WARNING

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THEORY OF OPERATION

This ECU operates on supply air control. A resistive temperature device located in

the supply air stream measures the supply air temperature. The ECU adjusts the compressor cycle time (unloader valve) to maintain the supply air set point. The supply air set point adjusts between 75°F and 45°F based on the return air temperature compared to the HMI return air set point. If the return air temperature is greater than the return set point for 10 seconds, .5°F is subtracted from the supply air set point. If the return air temperature is less than the return set point for 30 seconds, .5°F is added to the supply air set point.

Evaporator Fan – The evaporator fan (shelter fan) runs when the ECU is on at a constant speed.

Condenser Fan – The condenser fan may run any time the ECU is in “AUTO” or “TRANSPORT” mode. The condenser fan speed varies based on refrigerant pressure. A pressure below 200 PSIG stops the fan. As the pressure increases the fan speed increases until the maximum speed is reached at a pressure of 501 PSIG. In load bank mode the condenser fan runs full speed.

HMI DISPLAY AND MODES OF OPERATION

The ECU is controlled by the HMI screen on the remote control (088T1104). There are 4 screens on the HMI: Home, Status, Fault, and Transport. The Home, Status, and Fault screens can be selected by pressing the desired screen’s tab in the lower part of the HMI display. The Transport mode screen is the only screen accessible when in Transport mode.

Home Screen (Fig.1) - Displays the current running status, Set Temperature, and Shelter Temperature of the ECU. This screen also displays if the ECU is receiving a generator running signal, the amount of minutes left in the add load cycle and the minutes left in the load cycle. Home Screen is where the operator can select the ECU mode as well as adjust the Set Temperature.

Status Screen (Fig.2) - Displays system pressures, both supply and return temperatures reported from the RTDs, and load bank times.

Fault Screen (Fig.3)- Displays the status of any detected system faults.

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Transport Screen (Fig.4)- Displays the transport mode status when the system is running in transport mode.

Upon power up, or after a loss of power, the ECU will start up in AUTO mode after a 2 minute delay. The ECU changes operating modes by touching the “OFF” button on the HMI display (Fig.1). The first press puts the ECU in Vent mode and runs the evaporator fan only. The second press puts the ECU in Auto mode. In auto the ECU cools, or heats, based on the difference between the HMI set temperature and the

Fig.1 Fig.2

Fig.3

Fig.4

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shelter return temperature. A third press puts the ECU in Transport mode. The next press turns the ECU off.

Low Heat – If there is no fault, low heat is energized 3 seconds after the return temperature drops more than 2°F below the set temperature and the compressor has been off for at least 2 minutes. Low heat is also energized when high heat is energized. Low heat is de-energized when the return temperature reaches the set temperature.

High Heat – If there is no fault, high heat is energized when the return temperature is less than the set point minus 4°F and low heat has been energized for at least 2 minutes. High heat remains on as long as the return temperature is less than or equal to the set temperature minus 2°F.

Cooling – The compressor is energized when the return temperature reaches 1°F above the set temperature and heat has been de-energized for at least 2 minutes. The compressor is de-energized when the return temperature drops to 2°F below the set temperature for 5 minutes continuously. There is a 24 second compressor on delay. The percentage of cooling is controlled by the unloader valve and internal supply air set point.

Vent Mode – In vent mode the evaporator fan will be energized to move ambient air only. No conditioned air via heating or cooling is being provided in this mode.

Transport Mode – Transport mode will automatically heat or cool as required to maintain the set temperature that was set in Auto mode. The transport mode is used to operate the ECU while the ECU is in motion. The ECU capacity will be reduced if the condenser fan cannot supply sufficient cooling. To prevent damage the compressor may cycle on/off based on the head pressure of the ECU.

WARNINGS

High Pressure Warning – The high pressure warning occurs when the refrigerant pressure reaches 645 PSIG. Normal operation returns when the pressure drops below 600 PSIG. The high pressure warning resets the unloader cycle to 10 seconds and resets the unloader cycle clock, unloading the compressor immediately.

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High Pressure Warning in Transport mode – The high pressure warning occurs when the refrigerant pressure reaches 600 PSIG. Normal operation returns when the pressure drops below 525 PSIG. The high pressure warning resets the unloader cycle to 10 seconds and resets the unloader cycle clock, unloading the compressor immediately. In transport mode the compressor shuts down at a pressure of 625 PSIG and turns back on at 450 PSIG.

Suction Pressure Warning – A suction pressure warning will occur when the average suction pressure is less than 100 PSIG for 10 minutes. This warning sets the max unloader off time to 4 seconds. If this condition continues for an additional 10 minutes the compressor will turn off. The suction pressure warning will clear when the average suction pressure rises above 100 PSIG.

FAULTS

All faults, except the door switch, latch electronically and must be reset from the HMI.

High Pressure Fault – occurs with any of the following conditions:

1. The discharge pressure transducer reads less than 5 PSIG.

2. The discharge pressure transducer reads greater than 650 PSIG.

3. The HPC switch is open. This is a manual reset switch.

Low Pressure Fault – occurs with any of the following conditions:

1. The suction pressure transducer reads less than 5 PSIG.

2. The suction pressure transducer reads greater than 600 PSIG.

High Temperature Fault – occurs when the high temperature switch is open. This is a manual reset switch.

Supply RTD Fault – occurs if the reading is greater than 200°F or less than 55°F. Return RTD Fault – occurs if the reading is greater than 200°F or less than 55°F. Door Switch Fault – occurs if the door switch is not closed.

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DEHUMIDIFICATION

This ECU has a shelter temperature dead band of +/- 2°F. If the relative humidity in the shelter (sensed in the ECU return air stream) is above the relative humidity switch setting (factory set at 50% but is adjustable in the electrical panel), the unloader valve is cycling, and the shelter temperature is within the dead band, Dehumidification turns low heat on. If the high pressure is below 500 psig the low heat is on continuously. With a high pressure above 500 psig the low heat cycles with the unloader valve.

LOAD BANK CONTROL Note: Load Bank Control is not active in Transport mode.

This function is intended to have the ECU serve as a load bank for the generator. The ECU receives an input when the generator is running (indicated on the home screen). Located on the status screen are the user-adjustable times for the Time Between Load Bank (in hours) and the Load Bank Mode Duration (in minutes).

When the ECU is powered by the generator, run time will be accumulated regardless of ECU mode. The ECU will only operate in load bank mode when indexed to the Auto mode. The Time Between Load Bank and the Load Bank Mode Duration time will be remembered if the ECU loses power or the generator run signal is removed. In Load Bank Mode if heating is required, the unit is forced into high heat. If heating is not required, the compressor is energized, the condenser fan is turned on full speed, and Dehumidification is enabled. The unloader valve is still under normal control to maintain set temperature.

The load bank timers and user-adjustable set times are maintained during a generator shut down and power cycling of the ECU.

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MAINTENANCE AND REPAIR:

MAINTENANCE, PREVENTIVE by Operations Personnel

Item No.

Interval

Item to be Checked or

Serviced

Procedure “Not Fully Mission

Capable If”

1

Before Operation

and/or Daily

Coil (Condenser

Coil)

Inspect for dirt or obstruction to coil. Remove obstruction or notify unit maintenance to clean as necessary.

Coil is obstructed or dirty to the point of impeding airflow.

2

Before Operation

and/or Daily

Panels

Inspect panels for tight fit and/or loose hardware. Notify unit maintenance to repair as necessary.

Panels loose to the point that airflow is being diverted from

shelter.

3

Before Operation

and/or Daily

Condenser Fan

Inspect for foreign object(s) in fan.

Remove foreign object(s).

4

Before Operation

and/or Weekly

Sight Glass

Inspect sight glass for cracks and note center indicator color. If cracked or center indicator color is YELLOW, notify unit maintenance.

Sight glass cracked or center indicator color is YELLOW.

5 During

Operation Weekly

Condensate Drain Hose

When in cooling mode, check that water is dripping from the hose end. If water is dripping from any other place, notify unit maintenance.

Water is pooling in drain pan.

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Item No. Interval


Serviced Procedure “Not Fully Mission

Capable If”

6 During

Operation Weekly

Air Filter

Check that the filter is clean and free of dirt or other obstructions. Clean as necessary.

Dirt is resulting in choked air flow

7 Monthly Contactors Check for worn or burned contact points.

Contacts are burned or worn

8 Monthly Outside

Surface of Unit

Inspect for cracks or dents in the frame or panels. Check for chipped or missing paint and any evidence or corrosion. Notify unit maintenance.

9 Monthly Data Plates

Check that identification plates are securely attached to unit and can be easily read. Notify unit maintenance to attach if loose or replace if hard to read.

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MAINTENANCE, PREVENTIVE by Maintenance Personnel

NOTE: The following procedures are to be performed by trained qualified technicians and should not be attempted without authorization.

Item No. Interval


Serviced Procedure

“Not Fully Mission

Capable If”

1

Quarterly (More

often in dusty

climates)

Condenser Fan

Clean condenser fan as necessary and inspect for any cracks or damage. Replace if damaged.

Condenser fan is damaged or dirty enough to cause reduced airflow.

2 Semi-Annually

Wires, Cables,

Harnesses and

Electrical Connections

Open cover and panels as necessary to access component connections. Check wires, cables and harnesses for breaks, cuts or frayed insulation. Check that all electrical connections are secure. Tighten if necessary. If terminals are missing or damaged, repair or replace.

Any wire, cable or harness is damaged. Any electrical connection is loose, missing or damaged

3 Semi-Annually

Electric Box Wiring

Open cover and/or panel necessary to access electric box. Inspect for frayed or damaged insulation over visible portion of wires. Check for loose electrical connections. If frayed, damaged or loose connection, notify maintenance.

If any wire is frayed, damaged or loose connection..

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Item No. Interval


Serviced Procedure

“Not Fully Mission Capable

If”

4 Semi-Annually

Electrical System

Components

Open cover and panels as necessary to access components. Check components for damage or evidence of overheating. Replace any damaged components per appropriate procedure.

Electrical system component damaged or overheated.

5 Semi-Annually

Refrigeration System

Components, Tubing and

Fittings

Open cover and panels as necessary to access components. Check components for damage or evidence of refrigerant leak. Notify direct support maintenance if damaged or leak is suspected. Check components for damage or evidence of refrigerant leak. Notify direct support maintenance if damaged or leak is suspected.

Refrigeration system component

damaged or leaking.

Tubing or fittings are damaged or

leaking.

6 Semi-Annually

Evaporator Coil

Check evaporator coil for any visible damage or evidence of leaking. Notify direct support maintenance if leaking or damaged. Clean any accumulated dirt from coil.

Coil leaking or damaged.

Coil dirty enough to

obstruct airflow.

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CLEANING INSTRUCTIONS FOR RETURN AIR FILTERS

To clean a dirty filter: Rinse the filter with a moderate-to-heavy stream of warm water in the direction opposite of the air flow. See the tag at the end of the filter for intended direction of airflow. If the filter is especially dirty presoaking the filter in a solution of warm water and mild detergent prior to rinsing is acceptable. Any liquid dishwashing detergent can be used in the presoak. NOTE: High-powered steam cleaning or chemical dips are unnecessary and not recommended and will reduce the life of the filter.

Rinse Water Flow Direction

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TTRROOUUBBLLEESSHHOOOOTTIINNGG GGUUIIDDEE

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TROUBLE SHOOTING GUIDE:

CONDITION POSSIBLE CAUSE CORRECTIVE ACTION

Evaporator Fan does not energize

System set-up Make sure power and remote cables are connected between remote and ECU

Phase Sensing Relay detects power that is not acceptable: Voltage out of range, phases are out of sequence, or a phase is missing

Verify Power supply is phased correctly and within spec

Evaporator Fan Circuit Breaker is tripped

Reset Circuit Breaker and verify nothing is obstructing fan before attempting to start

ECU does not cool/ Compressor does not energize

Temperature sensed is not above set point

Verify controller in remote shows measured temperature above set point

High Pressure Cut-out is tripped Reset High Pressure Cut-out

Compressor Circuit Breaker is tripped

Reset Compressor Circuit Breaker

Compressor internal overload is tripped

Allow ECU to cool down and wait for internal overload to reset

ECU does not cool/ Compressor does not remain energized

Condenser fan does not come on, causing High Pressure Cut-Out to trip

Verify condenser fan circuit breaker is not tripped - reset as needed

Low Pressure Cut-Out is tripping (automatic reset device)

Verify ECU has sufficient refrigerant charge. Monitor suction and liquid pressures while unit operates

ECU does not heat

Temperature sensed is not below set point

Verify controller in remote shows measured temperature as lower than set point

High Temperature Cut-Out is tripped Reset High Temperature Cut-Out

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REPLACEMENT PARTS LIST

The identified replacement parts are not necessarily based upon frequency of failure; they are also based on availability. Some replacement parts have lead times of 14 to 18 weeks. Tekgard can provide a spare parts kit for this unit. This kit is customer specific and is based on the number of ECUs ordered, life cycle of components & availability of parts. For more information contact: [email protected]

mailto:[email protected]

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Item # Part # Nomenclature

Qty

Schematic Reference

1 008T170 COMP, D SCROLL, 54K BTU, R410A 1.00 CMP-1023 2 009T186

HEATER, ELECTRIC COIL, 2 STG, 3.75KW/6KW 9.75 KW TOTAL 1.00 EHC-1083

3 025T164 EVAP COIL, 24 X 25.50, 3R, 12 FPI, H42-T101 1.00 EC 4 025T238

COIL, CONDENSER, MICROCHANNEL (LARGER OF THE 2 COILS) 1.00 CC1

5 025T239 COIL, CONDENSER, MICROCHANNEL(TOP COIL) 1.00 CC2 6 054T158-01 CONFIGURED FOR H42-T104 EVAP FAN 1.00 EF-1192 7 057T114

SWITCH, HI PRESSURE CUT OUT, 700 PSI, MANUAL RESET 1.00 HPC-1581

8 089T303 TRANSFORMER, 240V/24V 1.00 TX-1361 9 081T127 GUARD, CONDENSER COIL, END, 304 SS 1.00

10 021T201 LATCH, COMPRESSION, LIFT & TURN, SEALING W/ CAM TYPE 8 10.00

11 081T159

GRILLE, CONDENSER COIL, TOP, 304 SS, H42-T103 1.00

12 098T063-01 CONFIGURED FOR H42-T104 CONDENSER FAN 1.00 CF-1262

13 005T103 SIGHT GLASS, 1/2 ODF 1.00 SG

14 009T132 SENSOR, HIGH PRESSURE TRANSDUCER, 0-10V, 0-650 PSI SAE #4, 7/16" INTERNAL 2.00

SPT-1541, DPT-1571

15 053T255 VALVE, PRESS RLV, 750 PSIG 1.00 HPR

16 053T246 VALVE, TXV. 1.00 TXV

17 053T188 VALVE, UNLOADER W/SOLENOID COIL, R-410A COMPRESSOR 1.00 UV-1342

18 005T112 FILTER DRIER, CATCH ALL, ½ IN AND OUT 1.00 F/D

19 063T103 ABSORBER, VIBRATION, 7/8 OD TUBING X 6" SUCTION SIDE 1.00 VE1

20 063T105 ABSORBER, VIBRATION, 5/8 OD TUBING X 7-1/4 1.00 VE2

21 065T609 ACCESS VALVE BODY, BRASS (SCHRADER) 2.00 SP

22 065T611 ACCESS VALVE CAP, NEOPRENE SLEEVE SEAL 2.00 SP

Cage Code 3C0M7


Rev. D




Qty

Schematic Reference

23 065T612 VALVE, CORE 1/4" 2.00 SP

24 009T126 CUT-OUT, KLIXON, OPENS AT 185°F, MANUAL RESET WITH 24" CAPILLARY TUBE 1.00 HTC-1651

25 029T116 HUMIDISTAT ASSEMBLY 1.00 HS-1631

26 089T328 SENSOR, RTD, 100 OHM, 2 INCH PROBE TEFLON INSULATION (.084) 2.00

RTD-1501, RTD-1471

27 089T603 HMI (089T380) CONFIGURED 1.00 HMI-1781

28 089T550 SWITCH, POSITION, W/ROLLER CRANK ADJ. 1NO/1NC 1.00 LSW-1601

29 024T161

FILTER, FRESH AIR, 5.625 X 5.625 X , 875, ELECTROSTAT MEDIA, AL PROTECTIVE GRILLE & FRAME 1.00 F2

30 089T172 RELAY, COIL, 3 POLE, 24VAC/DC, 120VAC 1.00 LBR-1763

31 089T273 HOUR METER, DC 1.00 HM-1511

32 089T360-004 CONTROLLER, PLC, PROGRAMMED W/087T138 & 087T139 1.00 PLC-1441

33 089T363

PLC TERMINAL, 24VDC DIGITAL OUTPUT, ME IB IL 24 DO 4-ME 1.00 PLC-1441 C1

34 089T364

PLC TERMINAL, ANALOG INPUT, V OR I IB IL AI 2/SF-ME 1.00 PLC-1441 C3

35 089T366

RELAY, PLC, SPDT, 6A, 24 VDC PLC-RSC-24DC/21 6.00

CFR-1551, CMR-1582, EFR-1531, H1R-1632, H2R-1652, UVR-1611

36 089T381

PLC TERMINAL, RTD TEMP INPUT IB IL TEMP 2 RTD-PAC 1.00 PLC-1441 C4

37 089T861 CAPACITOR, RUN, COMPRESSOR 1.00 C-1031

38 089T860 CIRCUIT BREAKER, 2P, 40A, 400V, D, 10KA 1.00 CB-1081

39 089T449 PLC TERMINAL, INLINE ANALOG OUTPUT, V OR I IB IL AO 2/UI-PAC 1.00 PLC-1441 C2

40 089T492

POWER SUPPLY, 120-240VAC, 24VDC, 4.2A STEP-PS/ 1AC/24DC/4.2 1.00 PS-1381

41 089T542

RELAY, PLC, 2PDT, 6A, 24 VDC PLC-RSC-24DC/21-21 1.00 HTCR-1671

42 089T637

POE INJECTOR / SPLITTER, W/SURGE PROTECTION DIN RAIL MTG 1.00 POE-1702

43 089T665 CIRCUIT BREAKER, 2P, 6A, 400V, D, 10KA 3.00

CB-1191, 1261, 1341

44 089T683

BLOCK, POWER DISTRIBUTION, 3 POS, 115A 4 HOLE SECONDARY 1.00 PDB-1041

Cage Code 3C0M7


Rev. D




Qty

Schematic Reference

45 089T697 CONTACTOR, 25A, 35A, 24VDC, 2 POLE WITH DIN RAIL MOUNT ADAPTER 2.00

HC1-1712, HC2-1732

46 089T700 CONTACTOR, 40A, 50A, 24VDC, 2 POLE WITH DIN RAIL MOUNT ADAPTER 1.00 CMC-1692

47 024T127

FILTER, RETURN AIR, 19-7/8 X 11-7/8 X 1, NOMINAL, ELECTRO,AL, PLEATS RUN PAR TO 11-7/8 DIM, WASHABLE. (NOT SHOWN. INSTALLED IN SHELTER) 1.00 F1

Cage Code 3C0M7


Rev. D



17

1

14

14

15

28

19

20

4 5

Cage Code 3C0M7


Rev. D



29

13

24

2

16

3

21 23 22

INSIDE

7

18

Cage Code 3C0M7


Rev. D



45

46

31

42

8

45

34 36 25 32 33 39

35

41

40

35

35

35

35

35

43

38

30

43

43

37

44

Cage Code 3C0M7


Rev. D



6

26

26

3

27

Cage Code 3C0M7


Rev. D



11 9

12

10

TOLERANCES

PAGE 1 OF 2

PROJECTIONH42-T104

D

C

B

AA

B

C

D

12345678

8 7 6 5 4

DECIMALS: X.XX 1

WHETHER IN THE UNITED STATES

EXPORT CONTROLLED - THIS

10/22/2018

TEKGARD CUSTOMERS. ALL INFORMATION CDEDEVELOPED BY TEKGARD, INC. FOR

OR ABROAD REQUIRES AN UNLESS OTHERWISE SPECIFIED.CONSENT OF TEKGARD, INC. H42-T1043C0M7

DRAWN BY

CHECKED BY

DATE

DATEC.A.G.E. CODE

TEK-H42C4UNIT MODEL NO.

CUNIT PART NO.

DRAWING NO.

REV.

WHOSE EXPORT/TRANSFER/

THIS DOCUMENT CONTAINS INFORMATION

DIMENSIONS ARE IN INCHES,

DISCLOSURE IS RESTRICTED BY CONTAINED IN THIS DOCUMENT IS PROPRIETARY AND THE PROPERTY OF

3 2

BEND

ANY MANNER OR FORM WITHOUT THE WRITTEN

UNLESS OTHERWISE SPECIFIED.

REPRODUCED, TRANSFERRED, OR USED IN

1

EXPORT LICENSE.

TEKGARD, INC. IT SHALL NOT BE DISCLOSED, UNITED STATES LAW. DISSEMI-

09/05/2018DOCUMENT CONTAINS DATA

NATION TO NON - US PERSONS .06

1/16 .5

FRACTIONAL:ANGULAR: MACH. THIRD ANGLE

MWK

PERFORMANCECOOLING CAPACITY:

RETURN AIR CONDITION DB:CONDITIONED AIR SUPPLY:

FRESH AIR SUPPLY:HEATING CAPACITY:

MAX OPERATING AMBIENT:RATING AMBIENT:

MIN OPERATING AMBIENT (HEATING):

52,000 BTU/HR90 F / 50% RH1400 CFM MIN. @ 0.75 ESP0-180 CFM (FRESH AIR FILTER 024T161)9.75 kW+131 F+125 F -40 F

MECHANICALREFRIGERATION STAGES:

COMPRESSOR TYPE:REFRIGERANT TYPE:

EVAPORATOR COIL MATERIALS:CONDENSER COIL MATERIALS:

EXPANSION VALVE TYPE:CIRCULATING/EVAPORATOR FAN:

CONDENSER FAN TYPE:RETURN GRILLE AND FILTER:

FRAME AND PANEL MATERIAL:

FINISH: WEIGHT:

MULTIPLEDIGITAL SCROLLR-410ACOPPER TUBE / ALUMINUM FINMICROCHANNEL ALUMINUMTHERMOSTATICMOTORIZED IMPELLER (VARIABLE SPEED)MOTORIZED AXIAL (VARIABLE SPEED)081T129 & 024T127, PROVIDED LOOSE5052 ALUMINUM W/ MIL-DTL-5541CONVERSION COATINGBLUE PEARL, NAVISTAR 6H31APPROX. 470 LBS.

DUCT CONNECTIONS

ELECTRICAL

YESNONONO

SUPPLY:RETURN:

16" X 12"12" X 20"

MOBILITYFORK POCKETS:

PNEUMATIC CASTERS:PULL HANDLE:

BRAKING SYSTEM:

FEATURESYESNONOYES*NOYES

DEHUMIDIFICATION:HOT GAS BYPASS:

PHASE PROTECTION:REMOTE CONTROLS:

EMI SUPPRESSION:EXTERNAL SERVICE PORTS:

YESNOYESNONOYES

COMPRESSOR START DELAY:FILTER WARNING LIGHT:

ELAPSED TIME INDICATOR:MAIN POWER DISCONNECT:

MOTORIZED FRESH AIR DAMPER:GENERATOR LOADING:

VOLTAGE/PHASE/HZ:MAX POWER DRAW:

MOTOR PROTECTION:COMPRESSOR PROTECTION:

HEATING STAGES:COOLING CONTROLS:

HEATING CONTROLS:MODE SELECTOR SWITCH FUNCTIONS:

COOLING SAFETY SWITCHES:HEATING SAFETY SWITCHES:

230V±10%/1PH/50 OR 60 HZ10.5 KWBREAKER & CONTACTORSINTERNAL THERMAL PROTECTION & MOTOR CONTACTOR2 STAGES THERMOSTAT - RETURN AIR SENSINGTHERMOSTAT - RETURN AIR SENSINGAUTO-OFF-VENTSTD - HI & LO PRESSURE SWITCHES AND HI PRESSURE RELIEFSTD - HI TEMPERATURE CUT-OUT (BIMETAL DISC TYPE) W/MANUAL RESET

*HMI REMOTE 088T1104 PROVIDED W/ ECU

REVISIONS

REV. REVISED BY DESCRIPTION DATE ENG. Q.C.

C CDE ECN 933 10/22/2018 MWK DJG

RC01 CDE AS BUILT 01/02/2019 MWK DJG

4 SPACES @8.00 = 32.00

68.00

8 SPACES @ 8.00 = 64.00 2.00

12.00RETURN

5.63 16.00

SUPPLY

8.30 .75

7.50

20.00RETURN

.75

12.00SUPPLY

18.23

1.50

33.50

69.50

28X .33 THRU

1/4" NPT DRAINCONNECTION

POWER & CONTROLKNOCKOUTS

4.08

9.00

9.71

3.00

4.09

.79

.98

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THIS DOCUMENT CONTAINS INFORMATION DEVELOPED BY TEKGARD, INC. FOR TEKGARD CUSTOMERS. ALL INFORMATION CONTAINED IN THIS DOCUMENT IS PROPRIETARY AND THE PROPERTY OF TEKGARD, INC. IT SHALL NOT BE DISCLOSED, REPRODUCED, TRANSFERRED, OR USED IN ANY MANNER OR FORM WITHOUT THE WRITTEN CONSENT OF TEKGARD, INC.

C.A.G.E. CODE3C0M7

DRAWN BY

CHECKED BY

DATE

DATE

UNIT MODEL NO.

TEK-H42C4DRAWING NO.

CUNIT PART NO.

REV.

09/05/2018CDE

PAGE 2 OF 210/22/2018

EXPORT CONTROLLED - THIS DOCUMENT CONTAINS DATA WHOSE EXPORT/TRANSFER/DISCLOSURE IS RESTRICTED BY UNITED STATES LAW. DISSEMI-NATION TO NON - US PERSONS WHETHER IN THE UNITED STATES OR ABROAD REQUIRES AN EXPORT LICENSE.

DIMENSIONS ARE IN INCHES,UNLESS OTHERWISE SPECIFIED.

1/16 .5 1 .06

FRACTIONAL:ANGULAR: MACH. BENDDECIMALS: X.XX

TOLERANCESUNLESS OTHERWISE SPECIFIED.

THIRD ANGLEPROJECTION

H42-T104

H42-T104

MWK

1.77

31.32

33.50

35.55

DETAIL ATYP 12 PLACES

1.50

R.17

A

31.32 26.63

2 SPACES @10.98 = 21.97

5.13

3 SPACES @ 20.00 =60.00

21.81 INSIDEFORKLIFT

4.75

2.22 21.81INSIDEFORKLIFT 2.40

8.31

2.83

2.13

3.94 4.00

8.75

6.31

9.50

.314x

4.62 6.00

1.75 3.50

SHOWN WITHOUTLID

ETHERNET CONNECTION

REVISIONS

REV. REVISED BY DESCRIPTION DATE ENG. Q.C.

A BSS INITIAL RELEASE 05/25/2016 MWK JAV

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THIS DOCUMENT CONTAINS INFORMATION DEVELOPED BY TEKGARD, INC. FOR TEKGARD CUSTOMERS. ALL INFORMATION CONTAINED IN THIS DOCUMENT IS PROPRIETARY AND THE PROPERTY OF TEKGARD, INC. IT SHALL NOT BE DISCLOSED, REPRODUCED, TRANSFERRED, OR USED IN ANY MANNER OR FORM WITHOUT THE WRITTEN CONSENT OF TEKGARD, INC.

C.A.G.E. CODE3C0M7

DRAWN BY

CHECKED BY

DATE

DATE

UNIT MODEL NO.

H42-T104DRAWING NO.

AUNIT PART NO.

REV.

05/25/2016BSS

PAGE 1 OF 105/25/2016MWK

088T1104EXPORT CONTROLLED - THIS DOCUMENT CONTAINS DATA WHOSE EXPORT/TRANSFER/DISCLOSURE IS RESTRICTED BY UNITED STATES LAW. DISSEMI-NATION TO NON - US PERSONS WHETHER IN THE UNITED STATES OR ABROAD REQUIRES AN EXPORT LICENSE. 088T1104DIMENSIONS ARE IN INCHES,

UNLESS OTHERWISE SPECIFIED.

1/16 .5 1 .06

FRACTIONAL:ANGULAR: MACH. BENDDECIMALS: X.XX

TOLERANCESUNLESS OTHERWISE SPECIFIED.

THIRD ANGLEPROJECTION

CALC. WEIGHT:BSCALE:

TITLE:

DRAWING NO.:

SHEET OF

horizontal self contained environmental control unit... · unit part no. rev. cde 09/05/2018...

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