Mac 240

INSTALLATION,
OPERATION
&
MAINTENANCE
MANUAL
MOBILE AIR CONDITIONING SYSTEM

Model: MAC-240
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INDEX
Contents Page
GENERAL ................................................................................................................................................................... 3
1. FOREWORD ........................................................................................................................................................... 4
2. STANDARD SPECIFICATION ............................................................................................................................... 4
2.1 BASE CHASSIS AND CONSTRUCTION ........................................................................................................... 4-6
2.2 DIESEL ENGINE GENERATOR ......................................................................................................................... 6-8
2.3 UNIT PHYSICAL DATA ......................................................................................................................................... 9
2.3.1 UNIT SPECIFICATION SUMMARY .................................................................................................................. 10
2.4 AIR CONDITIONING SECTION ........................................................................................................................... 11
2.5 ELECTRICAL ENCLOSURE ASSEMBLY ........................................................................................................... 12
2.6 OPERATING FROM EXTERNAL POWER SOURCE .......................................................................................... 13
3. REFRIGERATION SYSTEM ................................................................................................................................. 13
3.1 GENERAL DESCRIPTION .................................................................................................................................. 13
3.2 REFRIGERATION CYCLE .............................................................................................................................. 13-14
3.3 MAJOR REFRIGERATION COMPONENTS ....................................................................................................... 15
3.3.1 SCROLL COMPRESSORS ......................................................................................................................... 15-17
3.3.2 CONDENSER COIL .......................................................................................................................................... 17
3.3.3 CONDENSER FAN ........................................................................................................................................... 17
3.3.4 CONDENSER FAN MOTOR ............................................................................................................................. 17
3.3.5 EVAPORATOR COIL ........................................................................................................................................ 17
3.3.6 EVAPORATOR FAN ......................................................................................................................................... 17
3.3.7 HOT GAS BY PASS CONTROL ....................................................................................................................... 18
3.3.8 CRANKCASE HEATER .................................................................................................................................... 18
3.3.9 REPLACEABLE CORE FILTER DRIER ........................................................................................................... 18
3.3.10 SIGHT GLASS ................................................................................................................................................ 18
3.3.11 FAN CYCLE HEAD PRESSURE CONTROL .................................................................................................. 18
3.3.12 CONDENSER COIL GUARD .......................................................................................................................... 18
3.3.13 DISCHARGE LINE MUFFLER ........................................................................................................................ 18
3.3.14 VIBRATION ELIMINATOR .............................................................................................................................. 18
3.3.15 SAFETY VALVE .............................................................................................................................................. 18
3.4 REFRIGERATION SYSTEM ASSEMBLY ........................................................................................................... 19
4. CONTROL SYSTEM ............................................................................................................................................. 20
4.1 GENERAL DESCRIPTION .................................................................................................................................. 20
4.2 COOLING CONTROL .......................................................................................................................................... 20
4.2.1 TEMPERATURE SETTINGS ............................................................................................................................ 20
4.2.2 COOLING MODES ............................................................................................................................................ 20
4.2.2a LOW COOL .................................................................................................................................................... 21
4.2.2b MEDIUM COOL .............................................................................................................................................. 21
4.2.2c HIGH COOL .................................................................................................................................................... 21
4.3 SUPPLY FAN SPEED CONTROL ....................................................................................................................... 22
4.3.1 GENERAL DESCRIPTION ............................................................................................................................... 22
4.3.2 VARIABLE FREQUENCY DRIVE ..................................................................................................................... 22
4.4 CONTROL PANEL DESCRIPTION & FUNCTION .............................................................................................. 22
4.4.1 MAIN CONTROL PANEL ............................................................................................................................. 22-24
4.4.2 GENERATOR SET CONTROL PANEL ....................................................................................................... 24-25
4.4.3 SENSORS .................................................................................................................................................... 25-26

Contents Page
5. START-UP & SHUTTING DOWN SEQUENCE .................................................................................................... 26
5.1 VISUAL INSPECTION OF EQUIPMENT (CHECK LIST) ................................................................................ 26-27
5.2 STARTING THE GENERATOR ENGINE ............................................................................................................ 28
5.3 STARTING THE ACU (AIR CONDITIONING UNIT) ............................................................................................ 28
5.4 MACHINE SHUT DOWN ...................................................................................................................................... 29
6. ALARM AND TROUBLE SHOOTING GUIDE ...................................................................................................... 30
6.1 DESCRIPTION OF ALARM ................................................................................................................................. 30
6.2 TROUBLE SHOOTING GUIDE ....................................................................................................................... 31-32
7. PROTECTION DEVICES ...................................................................................................................................... 32
7.1 VOLTAGE MONITORING RELAY ....................................................................................................................... 32
7.2 THERMAL OVERLOAD RELAYS ........................................................................................................................ 32
7.3 CIRCUIT BREAKERS .......................................................................................................................................... 32
7.4 DISCHARGE PRESSURE SWITCH .................................................................................................................... 32
8. ACCESSORIES ..................................................................................................................................................... 33
8.1 FUEL FILL STATION ASSEMBLY ....................................................................................................................... 33
8.2 SERVICE LAMPS ................................................................................................................................................ 33
8.3 ROTARY (BEACON ) LAMPS .............................................................................................................................. 33
9. MAINTENANCE & SERVICING ........................................................................................................................... 34
9.1 GENERAL MAINTENANCE ................................................................................................................................. 34
9.2 INSPECTION & PREVENTIVE MAINTENANCE ............................................................................................ 34-36
9.3 AIR CONDITIONING SYSTEM ............................................................................................................................ 37
9.4 MOISTURE IN A REFRIGERANT SYSTEM ................................................................................................... 38-39
9.5 EVACUATING THE REFRIGERANT SYSTEM ................................................................................................... 40
9.6 REFRIGERANT LEAK TESTING .................................................................................................................... 40-41
9.7 REFRIGERANT LEAK REPAIR ........................................................................................................................... 41
9.8 REFRIGERANT CHARGING & PRESSURE LIMITS ........................................................................................... 42
10. EQUIPMENT DIMENSIONAL DETAILS ............................................................................................................ 43
11. COMPONENT LAYOUT (MAIN CONTROL PANEL) ......................................................................................... 44
12. COMPONENT PARTS LIST (MAIN CONTROL PANEL) .................................................................................. 45
13. PARTS LIST ................................................................................................................................................... 46-51
14. WIRING DIAGRAM ........................................................................................................................................ 52-53
15. SYMBOLS AND LEGENDS ................................................................................................................................ 54
16. PHOTO GALLERY ......................................................................................................................................... 55-66
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

GENERAL
GENERAL STATEMENT
The Zamil Mobile Air Conditioning units are designed & built for the optimum performance. However, it is required that
you become well acquainted with good practices for the proper installation/operation/and maintenance procedures in
order to ensure a safe trouble free operation, year after year.
Please read through the whole manual contents before you attempt to install/operate/ and maintain the unit.
Most of the procedures described in this manual require certain skills and experience. The installation and other mainte-
nance procedures should be performed only by highly skilled and experienced technicians. The end user’s role should be
limited to the cleaning of the filter.
SAFETY ISSUES
There are three degrees of safety hazards that are identified throughout this manual as WARNING (where the situation
will result in personal injury), CAUTION (where personal injury might occur), and ATTENTION (where minor personal
injury and/or property damage could happen). Please understand and respect those identifications.
WARNING: These units operate on a high voltage with moving parts (at high speed) which can lead to serious
injuries and/or damage to the unit. Never attempt to service the unit unless the main electrical power supply has
been disconnected.
CAUTION: Extra care should be observed when installing, test running, adjusting, servicing, or maintaining the
unit as the hazard of explosion, fire, electrical shock, and potential personal injury and property damage are
present.
When performing any task pertaining to the installation and maintenance of the unit, the skilled technician should observe
all the applicable safety measures (wear of safety helmet, boots, gloves, and goggles. Use of proper handling materials
for brazing and use of wet cloth for quenching. A fire extinguisher should be easily accessible etc.). He should also read
all the instructions and information in this Manual prior to attempting to perform any installation or servicing of the unit.
All applicable local codes should also be observed during installation and servicing.

1. FOREWORD
The purpose of this document is to give a brief description of the MAC240 mobile Air Conditioning equipment, its speci-
fication and other relevant information related to maintenance and safe operation of the equipment.
2. STANDARD SPECIFICATION
The Zamil MAC240 mobile air-conditioning equipment consisting of a dual system refrigeration section (condensing
unit), air handling section, and a power generation unit encased in one complete enclosure. The power generator in the
unit is a diesel fed engine which provides power of 460V-3PH-60HZ to the motors in the equipment. The equipment is
mounted on a trailer for the purpose of movements in any area or at any position proper for its safe operation during
installation.
UNIT LEFT SIDE VIEW
2.1 BASE CHASSIS and CONSTRUCTION

The MAC240 Chassis is ruggedly constructed with mild steel base frame and consists of overall system enclosures as
well as trolley’s components and accessories. The enclosure made of double skin heavy gauge (G-90) zinc coated and
galvanized steel by the hot dip process of lock-forming quality conforming to ASTM A 653 commercial weight G-90
followed by baked on electrostatic polyester dry powder coat. Posts and insulated Aluminum outer panels covered
internally by perforated galvanized steel panels filled with standard fiber glass insulation (25mm thick density: 48 kg/m)
as per NEPA 90A standards. The enclosure is constructed of posts and panels.
The MAC240’s enclosure is provided with inner lighting system in various areas to ease the troubleshooting activities
especially in the emergency cases. In addition, it is designed to have the maximum accessibility using access doors as
well as all the enclosure’s panels and posts are removable incase unusual accessibility is needed.
All the service doors are Hinge mounted with air tight turn buckle lock. These light weight aluminum construction doors
allow easy access to components for service and inspection. The main access doors provided are as follow.

UNIT TOP VIEW & ACCESS DOOR LOCATION
• Complete back side access is provided with two easy open lockable latched hinged doors to access the power genera-
tor and its components. The first one is to access the genset’s control panel and provided with outer sight glass
allowing quick visual monitoring to genset operation without the need of opening the access door.
• Air Conditioning discharge side access is provide with two easy open lockable latched hinged doors; the first to reach
the cooling system, the fuel injection’s air filter and belts area of power generator’s engine while the other access door
which is provided with outer sight glass allowing quick visual monitoring is the main maintenance access for the whole
system designed to reach the following components/systems:
!The back side of the power generator and its components.
!The A/C system blower and blower motor.
!The variable frequency dive control box control.
• The front side of the MAC240 is provided with one safe hinged door which can be opened by Allen key to prevent
unnecessary opening to the compressor compartment while the system on operation which result safety cutoff to the
compressors due to the high pressure in the condenser side. (refer to the operation part of the manual for more
information).
• The control box side is having only the access door to the control panel user interface and the control box door allowing
the access to all the electrical and control components. While the fuel filling/monitoring is exposed allowing easer
access.
This type of enclosure’s design provides overall system strength as well as reduces the noise level transmitted to the
outer environment from the internal components of the system especially from the power generator side. Moreover, the
components used are enhancing the enclosure noise damping performance like the heavy duty low noise type con-
denser/outer gen-set cooling fans for quieter operation in addition to the Scroll type compressors equipped.
On the other hand, the enclosure is mounted on a heavy duty trolley system and bolted at four points for each side of the
system. This trolley system is consists of rigid steel structure mounted on two heavy duty axles with total four heavy
machinery wheels; each can carry 2.4 tons while the total trolley system is designed to carry up to 8 Tons.

The trolley system is designed with front turnable axle by means of swivel bearing and both front and rear axles are
mounted on heavy duty leaf springs allowing the required vibration damping to the upper components. This design allows
towing the MAC240 from the front side of the trolley toward the swivel bearing by means of rigid heavy duty beak
supported towing bar as well as it can be lifted by forklift safely. For more towing operation the system is provided with tail
light as well as side reflection lights.
It is very important that the riggers and movers should use designated forklift channels
provided under the trolley. MAC unit can be lifted by a minimum 5 ton load forklift vehicle
using proper forklift channels to handle the complete unit weight.
2.2 DIESEL ENGINE GENERATOR

The diesel engine generator supplies electrical power to compressors, condenser motor, blower motors and controls
respectively. The generator set mounted across the rear of the unit base. The service accessibility of components is
within easy reach through hinged sight glass doors. The generator is fully self-contained including all controls, alarm
indications, and other operating parameters for the engine and generator. The low emission gas generator set is comply-
ing with international safety protection standards. Exhaust muffler mounted on top of the unit is rigidly connected with
spark arrestor silencer.
A. GENERAL Description:
The power generator used in MAC240 is air cooled “DEUTZ” diesel type which consists of 6-cylinder naturally aspirated
engines equipped with advanced injection and combustion system, mechanical governor. And connected to an alternator
to produce 460 Volts 3 phase 60 Hz with a rating of 85.0 KVA running @ NTP (refer to the specification section for more
details). Both the engine and the alternator are controlled by “mecc alte spa” regulator and “DEEP SEA ELECTRONICS”
control system (refer to the components’ appendix and components’ manuals for more information) and located on back
side of the enclosure in top of and to the side alternator respectively.
The power generator of the MAC240 consists of the following components:
1. Cooling fan
2. V-Belts (fan)
3. Optional attachment of hydraulic pumps
4. V-belt washer
5. Tension roller
6. Oil filler neck
7. Fuel pump
8. Fuel change filter
9. Injection pump
10. Oil dipstick
11. Shut-off magnet
12. SAE housing
13. Lube oil filter
14. Air duct hood
15. Cylinder head cove

B. Alternator
This type alternators are brushless, self-regulating and incorporate a rotating inductor with damper cage winding and a
fixed stator with skewed slots. The stator windings have a shortened pitch to reduce the harmonic content of the output
waveform. The alternators are made in compliance with the 98/37, 73/23, 89/336 CEE directives and their amendments,
and the CEI 2-3, EN 60034-1, IEC 34-1, VDE 0530, BS4999-5000, CAN/CSA-C22.2 N°14-95 - N°100-95 regulations.
C. Power Generator Control System:

The power generator control system is an Automatic Mains Failure Control Module. The module is used to monitor a mains
supply and automatically start a standby generator set. The module also provides indication of operational status and fault
conditions, automatically shutting down the genset and indicating failures by means of an LCD display, and appropriate
flashing LED on the front panel.
Selected timers and alarms can be altered by the customer from the front panel. Alterations to the system are made using
the 810 interface and a PC. This interface also provides real time diagnostic facilities.
Easy push-button control

Operation of the module is via push-button controls (with security locking facility) mounted on the front panel with STOP/
RESET, AUTO, MANUAL and START push-button. The first three push-buttons feature LED ‘selected’ indications. Fur-
ther push-buttons provide LCD DISPLAY SCROLL and EVENT LOG VIEW functions.
Microprocessor control
The module features 16-Bit microprocessor control and a comprehensive list of timers and pre-configured sequences. This
allows demanding specifications to be achieved.
Event Log
The instrumentation displays are supplemented further by EVENT LOG VIEW, which shows the last 15 shutdown events
along with date and time of shutdown.
LED indication
‘Hid-‘til-lit’ icons are used to show the presence of alarm conditions detected by the module.
In addition 4 uncommitted LCD segments allow the user to configure the module to provide other status indications from
either internal states or from external digital inputs.
Digital Inputs
The module accepts the following digital inputs:
• Emergency Stop Input - A N/C DC positive input
• Fully configurable warning or shutdown inputs
With the exception of the Emergency Stop Input, these are configurable to be either N/C or N/O contacts connected to the -
Ve DC. The 6 fully configurable auxiliary inputs can be selected to be indication, warning or shutdown inputs either immedi-
ate or held off during start up to allow for use as protection expansion inputs. Alternatively they may be configured to
control extra functions such as Lamp Test or Remote Start input, and many others - refer to appropriate manuals for
details.

D. Alarms & Shutdowns:

2.3 UNIT PHYSICAL DATA
MODEL NUMBER MAC240
0
NOMINAL CAPACITY (TONS) @ 95 F AMBIENT 24
CAPACITY (TONS) @ 1150F AMBIENT 21
APPLICATION INDUSTRIAL, 100% FRESH AIR
POWER SUPPLY (V-PH-HZ) 460-3-60
COMPRESSOR Type SCROLL
Part # (Qty.) 800-674-19 (2)
Refrigerant R-22
Operating charge per system, oz 450
RLA/LRA, Amps 19.6/125
CONDENSER FAN & MOTOR Type PROPELLER
Part # (Qty.) 800-226-01 (2)
Nominal CFM 15000
Dia. (mm) 700
POWER SUPPLY (V-PH-HZ) 460-3-60
Motor kW - RPM - FLA - LRA 1.5 - 1000- 2.6- 10
EXHAUST FAN Size (mm) 700
Part # (Qty.) 800-237-03 (1)
kW - RPM - FLA - LRA 1.5 - 1000- 2.6- 17.4
MINIMUM CIRCUIT AMPACITY Amps 74
MAX. FUSE SIZE/CIRCUIT BREAKER Amps 90
UNIT KVA Amps 54.6
CONDENSER COIL Type Inner grooved tubes and enhanced fins
Tube Dia.- Rows - Fins per inch 3/8-5-14
Total face area (Sq. ft.) 25
EVAPORATOR BLOWER Type BACKWARD CURVED
Size (inch) DP/500
Drive type DIRECT DRIVE
Nominal CFM 2400
EVAPORATOR BLOWER MOTOR Motor KW 13.2
FLA/LRA 21 /111
Motor frame IEC
EVAPORATOR COIL Type CORRUGATED FIN & TUBE
Tube Dia.- Rows - Fins per inch 1/2-12-10
Total face area (Sq. ft.) 6
HIGH PRESSURE SETTING OPEN - PSIG 450 ± 10
CLOSE - PSIG 360 ± 15
LOW PRESSURE SETTING OPEN - PSIG 25 ± 5
CLOSE - PSIG 50 ± 5
AIR COOLED DIESEL ENGINE GENERATOR / WESTAC ( DEUTZ) WPDZ72/F6L914 (85KVA / 68KW )
UNIT DIMENSIONS TRAILER MOUNTED - L x B x H (meters) 3.6 x 2.2 x 2.6
UNIT WEIGHT ( WITHOUT FUEL), KG 4000
TRAILER SPEED LIMIT 15 KM / H

2.3.1 UNIT SPECIFICATION SUMMARY
1. GENERAL
• Length (overall): 141.7 inches (3600mm)
• Width (overall): 86.9 inches (2210 mm)
• Height (overall): 104.5 inches (2654mm)
• Weight (approximate): 8800 lbs (4000 kg)
• Storage Temperature: 40°F to 120°F(clean and dry place)
• Fuel Tank Capacity(approximate): 104 gallons (396 I)
2. POWER GENERATING SYSTEM

• Make: WESTAC (DEUTZ) Air cooled diesel engine generator.
• Model: WPDZ72 (WP07-A76217) / F6L914
• Rating: (85KVA/ 68KW @ NTP)
• Voltage: 460 Volts/ 3 Phase / 60HZ
3. AIR CONDITIONING SYSTEM

• Cooling Capacity: 280,000 BTU/hr. @ 95°F ambient temperature
• Cooling Capacity: 250,000 BTU/hr. @ 115°F ambient temperature
• Ambient Operating Temperatures 50°F to 125°F
• Maximum Humidity: 100%
• Airflow=2156 cfm -100% fresh air
• Static pressure= 20" H2O
• Altitude: To 6561 feet (2000m)
• Refrigerant: R22
4. VEHICLE/ UNIT ENCLOSURE

• Completely self contained enclosure, constructed of base rail, post and double skin aluminum and steel panels. The
whole unit is mounted on heavy duty trolley. All the service doors are hinge mounted with air tight turn buckle lock.
These light weight aluminum construction doors are ready to access component for service and inspection.
• Parking drum brakes in trunnion axle wheel is activated by raising the towing bar and deactivated by lowering the
towing bar.
• Maximum operating trolley speed 15km/ hr
10

2.4 AIR CONDITIONING SECTION (ACU)
The factory assembled Air Conditioning unit has cooling or combination of heating (optional) and cooling as a single
package, suitable for mobile applications. The cooling system consists of two stage refrigeration compressors, with each
stage having a closed loop circuit in which the refrigerant is circulated by the pressure differential created by the com-
pressors. The compressor maintains high side condensing pressure and a thermostatic expansion valve separates the
high pressure side from the low pressure side (evaporator). The dual circuit Hermetic scroll compressors run continu-
ously in the ambient temperature of 500C (1220F) at 100% relative humidity environment. Auto refrigeration system
ensures defrost cycle to prevent the system icing.
The unit consists of the following protective devices.

1. High Refrigerant Discharge Pressure Switch
2. Low Suction Pressure Switch
3. Compressor Motor Winding Thermal Overload Protection.
4. Compressor External Overload/ Short Circuit Protection.
5. Blower Motor Overload/ Short Circuit Protection.
6. Condenser Fan Motor Thermal/ Short Circuit Protection
EQUIPMENT EXPLODED VIEW
13
12
11
10
09
01
08
02
03
06 04
07 05
01 GENERATOR 07 FRESH AIR INTAKE PANEL
02 SUPPLY AIR OUTLET 08 COMPRESSOR
03 MOTOR 09 CONDENSOR COIL
04 BLOWER 10 CONDENSOR FAN

C5 EVAPORATOR COIL 11 CONTROL BOX
06 FRESH AIR FILTER 12 EXHAUST MUFFLER - G/SET
13 EXHAUST FAN
11

2.5 ELECTRICAL ENCLOSURE ASSEMBLY
The unit has two electrical enclosures, one for the generator engine’s control and the other serves as the unit’s main control
panel. The main unit control panel enclosure is designed with hinged access door and according to NEMA 4 requirements. The
internal power and control wirings are neatly routed and with cable markers for identification as per NEC regulation.
The engine’s control panel has the following monitoring devices:
a) Engine hour meter gauge
b) Engine oil pressure gauge
c) Engine temperature gauge
d) Fuel gauge
e) Coolant level gauge
f) Ammeter
g) Voltmeter
h) Frequency meter
The main unit’s control panel has the following control devices:
a) Unit (engine) start / stop switch
b) Vent / Cool selector switch
c) Cool mode selector switch
d) Panel lamps for unit status indications
e) User interface control board
f) Re-set button
g) Lamp test button
h) Emergency stop push button switch
ELECTRICAL ENCLOSURE
(MAIN CONTROL BOX)
12

2.6 OPERATING FROM EXTERNAL POWER SOURCE
The equipment may also be operated from an external power source. The power source rating shall be having a nominal
voltage rating of 460V-3PH-60HZ and can adequately handle the equipment’s power consumption of 55KVA.
When the equipment is operated from an external power source, ensure that the generator’s circuit breaker is switched
“OFF” and the output feeder (power conductors from generator) connected to the main circuit breaker (CB6) in the main
control panel is removed. The power feeder (external power source) can then be fixed on the line terminals of the main
circuit breaker. The equipment can now be operated starting with the steps described in “Start-Up Sequence” 5.3(b) in
this manual.
3. REFRIGERATION SYSTEM
3.1 GENERAL DESCRIPTION
In the basic refrigeration cycle, there are four major components: compressor, condenser, expansion valve and the
evaporator. Let briefly review the function of each of these elements.
The standard unit is equipped with heavy-duty high pressure backward radial fan is capable of supplying required airflow
& static pressure. The fan discharge outlet can be connected to a flexible pre conditioned delivery hose. Flexible duct is
constructed by two-ply, abrasion resistant fabrics or PVC coated fabrics and is stowed inside the unit, when not in use.
Compressor
In the compressor, the low pressure refrigerant vapor is compressed to a high pressure refrigeration vapor. The com-
pressor pumps this refrigerant to the condenser and on through the system.
Condenser
The condenser, receives the high pressure vapor from the compressor, cools it with outdoor air, and then causes the
refrigerant vapor to condense into a high pressure liquid. It may also provide storage for liquid refrigerant in the
system.
Expansion valve
The expansion valve provides a control through which high pressure liquid refrigerant pass into the low pressure side of
the system i.e. evaporator.
Evaporator
The evaporator is a heat exchanger which absorbs heat and boils the low pressure liquid refrigerant, thus changing it into
o low pressure vapor. The low pressure vapor is then drawn back into the compressor and the cycle is repeated.
3.2 REFRIGERATION CYCLE

Whenever the compressor is in operation, there is continuous flow of refrigerant within the system. Liquid refrigerant from
the high pressure side of the system is metered by the expansion valve into the evaporator coil. A portion of the liquid
flashes into vapor resulting in a mixture at the valve outlet. The mixture as it passes through the nozzle orifice of the
distributor rushes with velocity, creating turbulence and thorough mixing. A pressure drop accompanies the mixture as it
passes into the low pressure side of the system. The liquid quickly expands extracting the heat from the air passing the
evaporator coil.
The suction action of the compressor draws the heat laden vapor from the evaporator coil. The pumping of the refrigerant
into the condenser raises its pressure and temperature. Air passing over the condenser surface carries the heat, being
expelled by the refrigerant, away from condenser, thereby lowering the temperature the pressure to allow the heat laden
vapor to be condensed into liquid.
The liquid refrigerant is stored in the condenser where additional heat is sub cooled prior to its passing through the
metering device (expansion valve) into the evaporator coil.
13

SCHEMATIC REFRIGERATION DIAGRAM
14

3.3 MAJOR REFRIGERATION COMPONENTS
The model MAC240 is equipped with two Copeland hermetic scroll compressor. The compressors have a rated cooling
capacity of 12 tons each and one compressor is used in each refrigerant circuits. Located in the condensing section and
are accessible through front access door. Compressors are conforming to ARI540 STD.
The compressors are equipped with internal motor protection, factory installed crankcase heaters and rubber vibration
isolators for quiet and efficient operation. Each compressor has lock-out devices to protect it from short cycling when
tripped by safety controls. Each compressor has separate condenser coil with safety controls. The diesel generator-set
drives the compressor integral motor.
3.3.1 Scroll Compressor

Scroll working principal is briefly described as below:
15

The scroll compressor consists of two involutes or Archimedean spirals. One spiral is positioned inside the other to form
a series of crescent-shaped pockets. During compression the upper spiral remains stationary and the lower one, being
eccentrically mounted on the drive shaft, describes an orbital rather than a simple rotary motion.
How a Scroll Compressor works:
Compression in the scroll is created by the interaction of an orbiting spiral and a stationary
spiral. A refrigerant enters the outer openings as one of the spirals orbits.
The open passages are sealed off as gas is drawn into the spiral.
As the spiral continues to orbit, the gas is compressed into two increasingly smaller pockets.
By the time the gas arrives at the center port, discharge pressure has been reached.
Actually, during operation, all six gas passages are in various stages of compression at all
times, resulting in nearly continuous suction and discharge.
16

Refrigerant enters the compressor at the suction connection and flows around the motor’s housing and enters at the
bottom side through the openings.
Oil droplets separate from the refrigerant and fall into the oil sump.
All suction refrigerant passes through the electrical motor, ensuring full motor cooling.
After that the refrigerant enters the scroll elements.
3.3.2 Condenser Coil

Condenser coils are corrugated fin and tube type; constructed of seamless 3/8" diameter inner grooved copper tubes,
mechanically bonded to enhanced louvered aluminum fins for maximum heat transfer efficiency. As the fins have full self
spacing collars which completely cover each tube. The staggered tube design improves the thermal efficiency. End
plates support sheets are heavy gauge galvanized steel, formed to provide structural strength. Each coil is pressure
tested in the factory at not less than 450 psi air pressure. Finally the coils are coated with thermo guard coating for
protection against seashore salty and corrosive environments.
3.3.3 Condenser Fan

Condenser fans are constructed of die cast aluminum blades/hubs with direct driven motors. All fans are statically and
dynamically balanced to operate at minimum noise and vibration. Fan blades are designed with appropriate pitch angle
which result in maximum airflow through the condenser coil.
3.3.4 Condenser Fan Motor

Condenser fans, the impeller and motors are so constructed to form an integral unit. All fan motors shall be three phase
with class ‘’F’’ winding insulation and ball bearings for high ambient application. These fan motors are of totally enclosed
air over type (TEAO) with inherent thermal protection of automatic reset type & specially designed for outdoor applica-
tions.
3.3.5 Evaporator Coil

Coils are made with corrugated fins and seamless ½’’ diameter copper tubes mechanically bounded enhanced fins
enable maximum heat transfer efficiency. Evaporator is tested in the factory at 300 PSI air pressure. Finally the coils are
coated with thermo guard coating for protection against seashore salty and corrosive environments. Coils conform to ARI
standard 410.
3.3.6 Evaporator Fan

Heavy-duty high pressure backward radial fan is capable of supplying required airflow & static pressure. The fan dis-
charge outlet can be connected to a flexible pre-conditioned delivery hose (supplied along with unit). Flexible duct is
constructed by two-ply, abrasion resistant fabrics or PVC coated fabrics and is stowed inside the storage box, when not
in use.
17

3.3.7 Hot Gas By-Pass Control
Hot gas bypass control is provided in the both circuit to permit operation of the system down to 80 % of its unloaded
capacity. Under low ambient condition, it controls temperature by eliminating the need to cycle the compressor on and
off, ensuring narrow temperature swing and lengthen the life span of the compressor.
3.3.8 Crankcase Heater

Each compressor has crankcase heater. The compressor crankcase heater is always on when the compressor is de-
energized. This protects the system against refrigerant migration, oil dilution and potential compressor failure.
3.3.9 Replaceable Core Filter Drier

Refrigerant circuits are kept free of harmful moisture, sludge, acids and oil contaminating particles by the filter drier.
3.3.10 Sight Glass

Moisture indicating sight glass installed in the liquid line. Easy to read color indicator shows moisture contents and
provides a mean for checking the system refrigerant.
3.3.11 Fan Cycle Head Pressure Control

The capacity of air-cooled condensers varies with the difference between condensing temperature and condenser enter-
ing air temperate (ambient temperature). It increases as this difference increases. For a given capacity, a drop in the
ambient temperature will lower the condensing temperatures and if the ambient temperature drops below a given limit,
head pressure control is required. Control shall be set for a minimum of 95°F (35°C) saturated refrigerant condensing
temperature, or to suit the specified application.
3.3.12 Condenser Coil Grills (Guard)

Protect the condenser coil from physical damage.
3.3.13 Discharge Line Mufflers

Discharge line mufflers are installed to eliminate noise due to refrigerant pulsation.
3.3.14 Vibration Eliminator

To eliminate the vibration transmitted from compressor to the piping, unit structure and transportation.
3.3.15 Safety Valve

This valve protects the unit against high discharge pressure in the system due to malfunction of high pressure
switches.
18

3.4 REFRIGERATION SYSTEM ASSEMBLY
02
08 04 03
08
06
01
07 05 09 15
01 COMPRESSOR
02 EVAPORATOR COIL
03 CONDENSER COIL
04 EXPANSION VALVE
05 VIBRATION ELIMINATOR
06 HGBP LINE
07 VIBRATION ELIMINATOR
08 MUFFLER
09 BALL VALVE
19

4. CONTROL SYSTEM
4.1 GENERAL DESCRIPTION:
The ACU section control is managed by a 16-bit microprocessor board fixed in the main control panel with a separate
LCD display as user’s interface. The control board completely controls the operation of the refrigeration system; i.e.,
compressors and condenser fan motors, and the variable frequency drive. The variable frequency drive operates in
coordination with the microprocessor board to control the speed of the supply fan motor. Please refer figure below for the
system flow diagram and I/O signals processed by the microprocessor board.
4.2 COOLING CONTROL

In general, the temperature of the supplied air and the CFM are major factors in cooling control. Temperature sensor
(STS) and differential pressure transmitter (DPS) is fixed at the supply air extender of the fan motor to sense the
temperature and pressure of the supplied air. The signals are transmitted to the microprocessor board which will then
manage the operation of the compressors in the unit.
Cooling or compressor operation can only be able to start if the following conditions are met:
a) Supply air CFM is within 10% of the set CFM (set @ 2200) and air pressure is less than the set maximum supply
air pressure (set @ 21”WG).
b) No alarms or system faults.
c) Supply air temperature is as described in 4.2.1
4.2.1 TEMPERATURE SETTINGS

Cooling operation is active if the supply air temperature is 120C and above. The compressors are stopped when supply
air temperature goes down at 30C and re-starts only when temperature goes up to 120C, provided that this condition is
maintained in a span of 3 minutes.
4.2.2 COOLING MODES

Cooling operation is selectable in three different cooling levels; Low Cool, Medium Cool and High Cool modes. The
temperature settings are fixed and as described in paragraph 4.2.1. Each mode differs only in the compressor run
timings. The compressor run timings can be well described by the following representation:
20

Compressor Run/Off Timing in Different Cooling Modes
a) Low Cool Mode – In this mode, cooling is in intermittent operation. Cooling is active for 10 minutes and stops for 3
minutes in every 13 minutes timing interval. Compressors are alternated in a way that at least one compressor in the
unit is running for 10 minutes for every 13 minutes interval. There will be off timing of 3 minutes after each cooling
operation of 10 minutes.
b) Medium Cool Mode – Cooling operation is continuous in this mode. Each compressor will have run timing of 10
minutes and off timing of 3 minutes. Both compressors will operate at the same time in the first 2 minutes and the last
5 minutes in each 13 minutes interval. There will then be 2 compressors running for a total of 7 minutes in each cooling
operation of 13 minutes.
c) High Cool Mode – In this mode, cooling operation is also continuous. One compressor will always be active while the
other compressor will operate intermittently – running for 13 minutes and off timing of 5 minutes in each 18 minutes
interval. Both compressors will then be in continuous operation for a total of 13 minutes in each 18 minutes interval.
The control is having a compressor run time equalization function. After each cooling cycle, the compressor with the least
run time will operate as the lead compressor.
21

4.3 SUPPLY FAN SPEED CONTROL
4.3.1 General description

The supply fan motor is connected to a variable frequency drive device (VFD) to regulate its speed and thereby control-
ling the air flow. At start-up, the motor will gradually increase its speed until the desired or set CFM is met. The device
may give an output to gradually increase or decrease the speed of the motor depending on the analogue signal (0~10V)
coming from the microprocessor board. In case the supply air static pressure reaches the maximum setting, the supply
fan speed will be maintained and prevented to increase further.
4.3.2 Variable frequency drive

The VFD gives power and dictates the speed to the supply fan motor. This also eliminates the high starting current and
torque of the motor, thereby reducing the risk of nuisance circuit breaker trips at start-up.
The VFD’s (Variable Frequency Drive) settings are pre-set in the factory. The LCD display of the device is set to show the
motor speed in RPM and the drive’s output in AMPS. The on/off command is set to be controlled through switching
contacts in the main control panel of the ACU. However, the VFD can also be controlled or operated manually using its
keypad with some changes in its internal parameter settings. Please refer to the product catalogue for the setting proce-
dures.
The keypad with LCD display is attached to the unit and is used for the following:
a) Displaying the operating status of the drive
b) Displaying a fault or trip code
c) Reading and changing parameter values
d) Stopping, starting and re-setting the drive (keypad mode)
QUICK TO CONNECT
Typical Hook-Up Diagram of the Variable Frequency Drive
4.4 CONTROL PANEL DESCRIPTION AND FUNCTION
4.4.1 Main control panel

The main control panel is located beside the generator section. The panel is designed based on specifications equivalent
to a NEMA 4A enclosure. It is here where the major motor control components and the start-up control components are
fixed. The start-up control section of the panel and its component is described in the figure below:
22

Main Control Panel Switches & Indicators
The description and function of each of the switches and lamps are as follows:
1) Temperature LCD Display – This LCD window will display the temperature of the supplied air. In the process of
parameter changing, the LCD will display the data that is being changed – either the parameter number or the
parameter value.
2) Status / Alarm LCD Display – This LCD window displays the status and alarm condition or alarm history of the unit.
The status conditions such as pressure readings in both systems, motor status, supply air CFM, supply fan speed
and other information can be viewed through this LCD window.
3) Up Button – Used to increase the parameter values or changing to the next information displayed on the LCD
window #2.
4) Set Button – Used to enter in set mode and change the set-up parameter values.
5) Down Button – Used to decrease the parameter values or go back to the previous information displayed on the LCD
window #2.
6) ON / OFF Button – Used to shut-off or start the system’s control.
7) Menu Button – Used to access the different menu functions.
8) Escape Button – Used to reset alarm and to quit accessed menu.
9) ON/OFF LED – To indicate system is in start or shut-off condition.
10) Menu LED – To indicate set-up menu is active.
11) Alarm LED – To indicate there is an active alarm in the system.
12) Start Control Switch – To switch on/off the generator engine and start the supply fan motor.
13) Mode Control Switch – To select system mode from fan only mode or cooling mode.
14) Cooling Level Switch – Used to select desired cooling level – Low, Medium or High cooling level. Mode control switch
should be in cool mode position.
15) Generator Alarm Lamp – This lamp will light if there’s a fault in the generator. The nature of the fault (shown in
symbol) will be described in the generator’s control panel LCD. Please refer to the generator’s manual for the
description of the fault.
23

16) ACU Alarm Lamp – This lamp will light if there’s a fault in the ACU system. The nature of the fault will be described
in the LCD window #2 of the ACU’s control panel.
17) Alarm Reset Button – If there’s a fault, pushing this button will re-set the system. The lighted fault indicating lamps
will be turned off.
18) Power ON Lamp – This lamp lights up to indicate power is provided in the ACU.
19) Comp 1 Trip Lamp – This lamp will light up indicating there is a fault in refrigeration system 1. The nature of the fault
will be described in the LCD window #2 of the ACU’s control panel.
20) Comp 2 Trip Lamp - This lamp will light up indicating there is a fault in refrigeration system 2. The nature of the fault
will be described in the LCD window #2 of the ACU’s control panel.
21) No Air Flow Lamp – This lamp will light up if there is no air flow under vent or cool mode condition.
22) Low Fuel Alarm Lamp – If the generator engine’s fuel level goes down at 10% level, this lamp will light up to indicate
low fuel.
23) Lamp Test Button – Used to test the indicating lamps on the control panel. Pushing this button will light up all the
indicating lamps in the panel and also the beacon lamp located on top of the unit.
24) Service Lamp Switch – This switch turns OFF/ON the two service lamps provided in the unit. Generator engine
should be in operation to give power to the lamps.
25) Beacon Lamp Switch – This switch will turn ON/OFF the beacon lamp on top of the unit provided that the fuel level
is more than 30%. If fuel level is less than 30%, then the beacon lamp is lighted up and cannot be turned off by this
switch.
26) Emergency Stop Switch – This is a “push – pull” mushroom head type button switch to shut-off the operating
equipment when pushed. It is located just above the main control panel LCD display to make it accessible whenever
an emergency case arises. The switch is to be “pulled” back to bring the equipment ready to operate.
4.4.2 Generator set control panel

The power generator is provided with a control module which monitors the mains supply indicating the status of the mains
on the module’s integral LCD display. Additionally the module monitors the engine, indicating the operational status and
fault conditions, automatically shutting down the engine and giving a true first up fault condition of an engine failure by a
flashing common alarm LCD indicator (refer to the generator manual for the details of the fault conditions). The exact
failure mode is indicated by combined “hidden until lit” LEDs and the LCD display on the front panel.
The microprocessor contained within the module allows for a range of features incorporated as standard:
a) Graphical icon based LCD display
b) Voltage, current and power monitoring
c) Engine parameter monitoring
d) Fully configurable inputs for use as alarms or a range of different functions
Generator Set Module Panel with LCD Display
24

The description and functions of the control buttons on the module panel are as follows:
1) Stop/Reset Button – This button places the module into its stop/reset mode. This will clear any alarm conditions for
which the triggering criteria have been removed. The fuel supply will be removed and if the engine is running, it will be
brought to a stand still.
2) Manual Mode Button – This mode is used to allow manual control of the generator functions. Once in manual mode
the module will respond to the Start button (5) and start the engine.
3) Auto Mode Button – This button places the module into its “automatic” mode. The module will monitor the remote start
input and once a start condition is signaled the set will be automatically started and placed on load. If the starting
signal is removed the module will automatically shut off the engine after a cooling down delay timer is satisfied.
4) Test Mode Button – This mode allows the operator to perform an “on load” test of the system. Once in test mode, the
module will respond to the start button (5) and start the engine and run on load (for further details please see the more
description of “test operation” in the generator set manual).
5) Start Button – This button is only active in “manual” or “test mode”. Pressing this button in manual or test mode will
start the engine and run off load (manual) or on load (test).
6) LCD Display – To view or monitor all the system operating parameters by the user.
7) Scroll Button – This button is used to display the different instrumentation values (power, voltage, current, frequency,
etc.) on the LCD display. Pressing this button repeatedly will scroll through each individual instrument eventually
returning to the original instrument displayed.
8) Configure/Log Button – This button is used to view shutdown alarm history. The module maintains a log of the last 15
shutdown alarms. The alarm is logged, along with the date and time of the event and shown on the LCD display.
Pressing this button together with the “stop” button (1) will enter the user in configuration mode (for further details on
configuration mode, please see “configuration editor” in the generator manual).
4.4.3 Sensors
Both analogue and digital type sensors are used in this equipment. The signals sent by these sensors are direct inputs
to the microprocessor control board. The locations of these sensors are shown in the figure below:
SENSOR LOCATION
25

The description and function of the sensors are as follows:
a) Air Velocity Sensor – The function of this sensor is to measure the air velocity (mass flow). The working range air
velocity is adjustable up to 20 m/s. Output signal is 0~10V range and transmitted to the microprocessor board which
will in turn send to the VFD for supply fan speed control.
b) Ambient and (5) Supply Air Temperature Sensor – These sensors are PTC type sensors measuring the temperature
of the ambient and supplied air for cooling control. Resistance value is 1Kohm @ 250C.
c) Air Differential Sensor – The function of this sensor is to measure the static pressure (air duct) of the supplied air. The
signal is transmitted to the microprocessor board for cooling and supply fan speed control. Output signal is 0~10V and
differential pressure range is 0~0.1 Bar.
d) Air Flow Switch – This is a SPDT switching type device sensing supply air flow.
e) Discharge Pressure Switch - This is a SPDT switching type device sensing the refrigerant pressure in the discharge
line. It’s function is to stop the compressor from operation at a predetermined pressure (high discharge pressure).
f) Suction and Discharge Pressure Transducers – These are transducer type sensor device with a 4~20ma output
signal. These sensors are fixed in the suction and discharge lines to measure the pressure and transmit the informa-
tion to the processor board. These signals are then processed for safeties function (low suction or high discharge
pressures) and for pressure readings display on the user interface board.
5. STARTING-UP AND SHUTTING DOWN SEQUENCE

Before initiating the start-up sequence, ensure that the emergency stop push button switches are in “pulled” position. The
following steps are to be taken in starting the mobile AC equipment.
5.1 VISUAL INSPECTION OF EQUIPMENT (CHECK LIST)

Before initiating start-up sequence of the unit please check the following points to ensure safe and reliable operation:
a) Check generator engine oil level. Remove engine oil dipstick and check oil level mark on it. Add oil to bring it to “full level” mark.
CAUTION: NEVER OPERATE THE ENGINE WITH THE OIL LEVEL BELOW THE LOW MARK OR ABOVE HIGH
MARK. WAIT AT LEAST 5 MINUTES AFTER SHUTTING OFF THE ENGINE TO CHECK THE OIL. THIS ALLOWS
TIME FOR THE OIL TO DRAIN TO THE OIL PAN.
b) Visually inspect fuel lines and fittings for evidence of fuel leakage. Inspect valve covers, oil pan, and cylinder block for
evidence of oil leakage. Do the necessary correction if leakage is observed.
c) Remove any storage cover, loose hardware or debris found inside the generator and compressor section of the
equipment that may be drawn into the exhaust or condenser fans during operation.
d) Check the engine fuel level (press the fuel level switch and observe the fuel gauge).
WARNING: CHECKING THE FUEL LEVEL IS ADVISED TO BE DONE ONLY WHEN GENERATOR ENGINE IS IN
“STAND-BY” MODE – GENERATOR NOT RUNNING AND DC BATTERY SWITCHED “ON”. IN CASE THE OPERA-
TOR DECIDES TO CHECK THE FUEL LEVEL WHILE THE GENERATOR IS IN OPERATION, THE CONTROLS MAY
STOP THE ENGINE IF THE PUSH-TO-CHECK SWITCH IS NOT PRESSED PROPERLY.
e) Inspect the air conditioning lines and fittings for evidence for breaks or potential failure.
f) Inspect the compressor unit and system components for evidence of oil leakage.
g) Inspect the air conditioner duct for loose connections, leaks, cuts or abrasion that may lead to premature failure during operation.
NOTE: TO CHECK THE REFRIGERANT CHARGE LEVEL FOR THE AIR CONDITIONER, THE UNIT MUST BE
OPERATING. THIS REQUIRES PERFORMING ALL OTHER PREOPERATIONAL CHECKS PRIOR TO START-
ING THE UNIT TO CHECK THE REFRIGERANT CHARGE. IF DESIRE, CHECK THE REFRIGERANT CHARGE
DURING THE FIRST USE OF THE UNIT EACH DAY.
h) Inspect the sight glasses for proper charge level with the unit running, the liquid line sight glasses should show full liquid.
i) Close all the unit access doors.
WARNING: NEVER ENTER THE INTERIOR OF THE UNIT WHILE UNIT IS IN OPERATION. DO NOT STEP ON OR
GRAB HOLD OF WIRING OR REFRIGERANT PIPING.
26

WARNING: NEVER SMOKE OR ALLOW AN OPEN FLAME WITHIN THE IMMEDIATE VICINITY OF THE UNIT
WHILE SERVICING FUEL. NEVER SERVICE UNIT WITH THE ENGINE OPERATING. FAILURE TO COMPLY MAY
RESULT IN POTENTIAL HAZARD
WARNING: POTENTIAL FOR FUEL FIRE OR FUEL EXPLOSION CAUSING SEVERE EQUIPMENT DAMAGE AND/
OR SEVERE INJURY, EVEN DEATH TO PERSONNEL FROM SKIN BURNS. TO PREVENT SPARKING BETWEEN
FILLER NOZZLE AND FUEL TANK, ALWAYS MAINTAIN METAL TO METAL CONTACT BETWEEN FILLER AND
FUEL TANK AND GROUND THE UNIT TO A CERTIFIED GROUND POINT.
j) Service with diesel fuel as required. The fuel tank has drains in the side of the tank. Drain water and foreign material
at least weekly.
k) Remove the air-conditioning duct from storage box located below the trailer and near to supply/ blower out let. Attach
the service coupling to the aircraft. Ensure the air-conditioning duct is securely fastened to the aircraft. If not securely
fastened, the duct may detach from the aircraft when the air conditioner is started, causing injury to personnel or
damage to equipment or aircraft.
WARNING: POTENTIAL FOR INJURY TO PERSONNEL AND OR TO EQUIPMENT OR AIRCRAFT. ENSURE THAT
THE AIR DELIVERY DUCT IS SECURELY FASTENED TO THE AIRCRAFT PRIOR TO STARTING THE UNIT.
POTENTIAL FOR AIR-DELIVERY DUCT RUPTURE OR INADEQUATE SUPPLY OF AIR FLOW TO THE AIRCRAFT.
ALWAYS STRAIGHTEN THE AIR DUCT TO PREVENT SEVERE BENDS OR KINKS THAT COULD IMPEDE OR
BLOCK THE AIR FLOW.
WARNING: NEVER SWITCH THE UNIT TO BLOWER WITHOUT HAVING THE AIR HOSE FIRMLY AND PROPERLY
CONNECTED TO THE AIRCRAFT OR UTILITY. FAILURE TO ADHERE COULD RESULT IN SEVERE INJURY TO
PERSONNEL OR EVEN DEATH.
WARNING: PROLONGED EXPOSURE TO HAZARDOUS NOISE MAY RESULT IN PERMANENT HEARING LOSS. EAR
PROTECTION DEVICES MUST BE USED WHEN WORKING WITHIN A CLOSE PROXIMITY OF THIS EQUIPMENT.
INSTRUCTIONS
DOWN DISCHARGE APPLICATION (OPTIONAL)
PLENUM EXTENSION
MAKE SURE, THIS PART TO BE
FIXED INSIDE DISCHARGE OPENING
AS SHOWN , FOR DOWN DISCHARGE
APPLICATION PRIOR TO FIX SPIRAL
FLEXIBLE DUCT CONNECTION.
PLENUM EXTENSION
FIXING BOLTS
(MIDDLE TWO BOLTS ONLY)
27

5.2 STARTING THE GENERATOR ENGINE
a) Switch “ON” the isolating switch of the DC battery in the generator set section. The “lever” should be
pointing towards the operator to be in “ON” position.
b) Turn the key provided in the generator module to switch “ON” power to the module. The module’s LCD display will be
illuminated and information appearing on it.
c) Set the module in “auto” mode by pressing first the “Stop/Reset” button then followed by the “Auto Mode”
button .
d) In the main control panel, set the “Start Control Switch” to “GEN ON” position. The generator engine
should then start at this point.
5.3 STARTING THE ACU (AIR CONDITIONING UNIT)

a) Switch “ON” the mains circuit breaker (in the generator section) and ACU circuit breaker (inside the main control
panel). At this point, the LCD display of the user interface board in the main control panel will be illuminated and the
power button will be lighted up.
b) Turn the “Start Control Button” to “FAN” position to bring the ACU system in standby mode.
c) Push the “ON/OFF” button on the user interface board to bring the system’s control in the operation mode.
The “ON” LED positioned above right of the button will light up and the LCD display will show “STARTING”. After a
minimum time of 1 minute, the supply fan motor will start.
d) Turn the “Mode Control Switch” to "COOL" position to operate the compressors (cooling mode). The
cooling system will be allowed to start if the conditions described under 4.2.1 “Cooling Control” in this manual are
satisfied.
e) Select the desired cooling level (Low, Medium or High) through the “Cooling Level Switch”.
28

5.4 MACHINE SHUTDOWN
a) The system is stopped by pressing again the ON/OFF” button on the user interface board. The “ON” LED
is switched “OFF” and on the LCD display will show the status “STOPPING”. All the compressors will stop and the
supply fan shuts off after a pre-set timing of 30 seconds.
b) To bring the generator to stop, turn the “Start Control Switch” in “OFF” position. The generator engine will
come to a halt after the cooling pre-set timing of 5 minutes (cooling down timer) is satisfied.
Note: The generator can be forcibly stopped by pressing the “STOP/RESET” button on the engine’s module.
29

6. ALARMS AND TROUBLESHOOTING GUIDE
6.1 DESCRIPTION OF ALARMS (FAULT)
This section describes the various alarms that can be shown in the LCD display of the user interface board in the main
control panel. The alarms are handled only if the controller is in “ON” status. Once the alarm condition has been reset the
error message disappears automatically or, in some particular cases, will remain until the ESC button is pressed. Please
refer to the trouble shooting guide for the nature and remedy for each alarm condition.
The description of each alarms are as follows:

a) NO AIR CIRCULATION – This fault is brought about by a “no air flowing” condition sensed by the air flow switch
sensor after a delay timing of 75 seconds, when a signal is already present for the supply fan motor to run. With this
condition, the supply fan motor will be switched “OFF” and LED indicator “NO AIR FLOW” on the panel is lighted. After
the fault condition is corrected, re-set by pressing the re-set button on the panel.
b) LOW AIR FLOW – This alarm serves as a message that the sensed CFM is 10% less than CFM set point. Usually
this may appear during start-up and compressors may not start immediately. Once the CFM has reached the target
set point, the compressors will then start.
c) LAT TR OUT OF RANGE – This fault is caused by an “open” or “shorted” temperature sensor (leaving air temperature
sensor). Compressors are stopped or will not be able to operate. Re-sets automatically after the condition is cor-
rected.
d) TAE TR OUT OF RANGE – This fault is caused by an “open” or “shorted” temperature sensor (ambient air tempera-
ture sensor). Compressors are stopped or will not be able to operate. Re-sets automatically after the condition is
corrected.
e) ADP TR OUT OF RANGE – This fault is caused by an “open” or “shorted” air differential pressure sensor. Supply fan
motor and compressors are switched OFF or will not be able to operate. Re-sets automatically after the condition is
corrected.
f) VFD TR OUT OF RANGE – This fault will appear if the VFD’s feedback signal to ST1 terminal in the microprocessor
board is in “shorted” or “open” condition. This is only a warning and supply fan motor may operate but speed will not
be modulating. Re-sets automatically after the condition is corrected.
g) # SP TR OUT OF RANGE - This fault is caused by an “open” or “shorted” suction pressure transducer. Compressors
are stopped or will not be able to operate. Number shown with the fault corresponds to the particular system where the
fault occurred. Re-sets automatically after the condition is corrected.
h) # DP TR OUT OF RANGE - This fault is caused by an “open” or “shorted” discharge pressure transducer. Compres-
sors are stopped or will not be able to operate. Number shown with the fault corresponds to the particular system
where the fault occurred. Re-sets automatically after the condition is corrected.
i) LOW FUEL – This alarm serves as warning when the fuel level goes down to 30%. The equipment still continues to
operate and the beacon lamp on top of the unit is lighted.
Note: If this warning is not attended and the fuel level goes further down to 10% level, then the generator engine will shut down.
j) # BREAKER FAULT – This fault appears when the compressor circuit breaker is in switched “OFF” condition or has
tripped. The number mentioned with the displayed fault signifies the compressor number where the fault is. Compres-
sor operation is stopped and the “ESC” button on user interface board is to be pressed to re-set after correction has
been done.
k) # HIGH PRES SWT FAULT – This fault will appear if any of the following safety contacts open:
• High Pressure Switch
• External Overload Relay of Compressor
• Thermal Protection Contact of Condenser Fan
The system (particular to the system number where the fault appeared) is stopped and the “ESC” button on user
interface board is to be pressed to re-set after correction has been done.
l) # SUCTION PRES LOW – If the suction pressure goes down to the pre-set level and timing for low suction pressure
alarm (25 psi for 90sec), then this fault description will appear on the LCD display. The compressor operation of the
system where the fault appeared (described by number with the fault description) will be stopped. Re-setting is
through the “ESC” button after the fault condition is corrected.
m) # DISCHARGE PRES HIGH - If the discharge pressure reaches the pre-set level for high discharge pressure alarm
(400 psi), then this fault description will appear on the LCD display. The compressor operation of the system where
the fault appeared (described by number with the fault description) will be stopped. Re-setting is through the “ESC”
button after the fault condition is corrected.
30

6.2 TROUBLE SHOOTING GUIDE
FAULT DESCRIPTION PROBABLE CAUSE CORRECTIVE MEASURE
SYMPTOM LCD DISPLAY
Supply Fan No Air Circulation a) Loosed wiring connections on relay - Check and Re-tighten wiring connec-
Motor Stopped AR4-3B (NC) terminal to terminal A11 tion.
or Not Starting of MB board.
b) Clogged or crimped hose fixed at high/ - Remove the clog or straighten the
low pressure outlet of air flow switch. hose.
c) Defective AR4 relay. - Replace Relay.
d) Defective time delay switch (TDS) - Replace time delay switch.
VFD Fault VFD Fault Check VFD LCD display for error code
and refer VFD manual for possible cause
and corrective measure.
ADP Tr Out of a) Open or loosed wiring connection of air - Check and re-tighten connection.
Range pressure sensor to terminal RH of MB
board.
b) Shorted or defective sensor - Replace sensor
Supply Fan VFD Tr Out of Open or loosed wiring connection of VFD’s Check and re-tighten connection.
Motor Speed Range feed back signal to terminal ST1 of MB
not Modulating board.
Compressor LAT Tr Out of a) Open or loosed wiring connection of - Check and re-tighten connection.
Stopped or Range supply air temperature sensor to ter-
Not Starting minal Tout of MB board.
TAE Tr Out of a) Open or loosed wiring connection of - Check and re-tighten connection.
Range ambient air temperature sensor to
terminal TAE of MB board.
SP Tr Out of a) Open or loosed wiring connection of - Check and re-tighten connection.
Range suction pressure transducer to termi-
nal S1 or S2 of MB board.
DP Tr Out of a) Open or loosed wiring connection of - Check and re-tighten connection.
Range discharge pressure transducer to ter-
minal D1 or D2 of MB board.
b) Shorted or defective sensor. - Replace sensor
# Breaker Fault a) Compressor circuit breaker is “OFF” - Switch breaker to “ON”
b) Breaker auxiliary contact wiring to A2 - Check and re-tighten connection.
or A7 terminal of MB board is loose. - Check ampere setting of breaker and
c) Compressor circuit breaker has adjust to proper setting.
tripped. - Compressor winding could be shorted
or grounded. Replace compressor.
# High Pressure a) High pressure switch opened - Check pressure switch setting and
Switch Fault adjust. Replace if defective.
b) External Overload Relay Contact of - Check overload setting and adjust correctly.
compressor opened - Check compressor contactor contact points for
carbon deposits. Clean or replace contactor.
c) Cond. Fan motor thermal contact is - Thermal contact may close automatically when
open. cooled. Check condition of motor winding. Re-
place fan if winding is damaged.
31

FAULT DESCRIPTION PROBABLE CAUSE CORRECTIVE MEASURE
SYMPTOM LCD DISPLAY
Compressor # Suction Pres- Low Refrigerant pressure - Check hot gas by-pass solenoid if not
Stopped or sure Low getting activated, replace if damaged
Not Starting - Check for leaks in suction line, re-
pair and add refrigerant charge.
# Discharge High pressure at discharge line - Check expansion valve and replace
Pressure High if defective.
- Reduce refrigerant charge if system
is overcharged.
Mains Power Generator Fault on generator - Check error code on LCD of genera-
Loss tor set module. Refer generator’s
manual for nature of fault and pos-
sible corrective measure.
Low Fuel Fuel Level is Low (10%) - Switch “OFF” the engine and add
fuel.
No Control - 1. No control power (24V circuit) - Check control fuses F5/F6 and re-
Power (LCD 2. No Control Power (230V) place if blown.
not Illumi- 3. Serial cable (UIB to MB) loose or - Check control fuses F1 to F4 and
nated) Defective replace if blown.
- Check emergency stop button and
pull if it is in “pushed” position.
- Replace cable
7. PROTECTION DEVICES
7.1 VOLTAGE MONITORING RELAY
This device protects the motors in the equipment from faults such as; under or over voltage, phase imbalance, and phase
reversal of the main supplied voltage. When the device sensed such faults, it will cut-off the power supply in the control
circuit thereby cutting OFF power to the motors. The voltage monitor relay will re-set automatically when power is brought
back to normal conditions. The trip settings and other details are shown in the table below:
TRIP & RE-SET VOLTAGE (% OF SET POINT)
LINE VOLTAGE
UNDER VOLTAGE OVER VOLTAGE PHASE IMBALANCE
RANGE
TRIP RE-SET TRIP RE-SET TRIP RE-SET
190 - 480 VAC 90% 93% 110% 107% 6% 4.5%
7.2 THERMAL OVERLOAD RELAYS

Each compressor and condenser fan motor in the equipment is having internal thermal protection for its winding and an
external overload relay is provided to protect the motor against overload. The external overload relay is set to trip when
the motor drawn current reached up to 20% more than its rated current.
7.3 CIRCUIT BREAKERS

Circuit breakers are devices designed to open and close a circuit by non-automatic means, and to open the circuit
automatically on a predetermined over current due to abnormal circuit conditions such as a short circuit. All the motors in
the equipment, the ACU section, and the generator output are provided with circuit breakers.
7.4 DISCHARGE PRESSURE SWITCH

Each refrigeration system of the equipment is provided with a protection from excessive discharge pressures. The unit’s
control cuts-off the compressor’s operation at a pre-set discharge pressure value. Aside from the pressure sensor
(transducer), an added pressure switch is also provided for additional protection in each system in case of high discharge
pressures.
32

8. ACCESSORIES
8.1 FUEL FILL STATION ASSEMBLY
The Diesel fuel fill station assembly is mounted on the side of the unit. This assembly contains a Protecto-Seal cap, an
electrically operated fuel level gauge with “push-to-check” switch and a level gauge to indicate fuel quantity available in
the tank.
FUEL FILL STATION ASSEMBLY
The Diesel fuel should be used this unit should content with less than 0.5% Sulphur and not to be mixed with petrol. For
the purpose of low ambient, add an appropriate amount of Kerosene prior to fill with Diesel. Refer Generator Engine
manual for more information.
NOTE:
Checking the fuel level is advised to be done only when the generator engine is not running or in “stand-by” mode. If in
case the generator engine is running and the operator decides to check the fuel level, the generator controls may stop the
engine if the “push-to-check” switch is not pressed properly.
8.2 SERVICE LAMPS

Two 60watts/220 volt service lamps are provided in the unit located in the supply fan motor section and in the generator
engine section.
8.3 ROTARY (BEACON) LAMP

A rotary lamp is fixed on top of the equipment for the purpose of providing the operator a warning signal when the
generator fuel has reached to a critical level. At 30% (preset) fuel level, this lamp will be switched “ON” as a low fuel
warning while the equipment is in continuous operation. When fuel level reaches 10%, then the equipment shuts down.
This lamp may also be switched “ON” manually through the toggle switch on the equipment’s main control panel.
33

9) MAINTENANCE & SERVICING
9.1 GENERAL MAINTENANCE
This section contains instructions for Servicing, Inspecting, and Preventive Maintenance on the Model MAC240 Air
Conditioner unit.
To ensure that the unit is kept in correct operating condition, inspect and maintain it on a regular basis. Proper replace-
ment of filters, lubricating oil, etc.., at recommended intervals help prevent damage or failure of the unit, and provide
optimum performance.
Overhaul Intervals: Under normal operating conditions and with proper preventive maintenance practices, the Model
MAC 240 Air Conditioner Unit provides years of excellent service. Typically 7,000 to 10,000 hours (depending upon local
conditions). After this 7,000 to 10,000 hour interval, major component overhaul, i.e.., diesel engine, may be required.
A. Engine Oil Change Schedule:

Time schedules indicated in preventive maintenance inspection schedule are based on average operating conditions. It
may be necessary to change oil and air filters more frequently under severe operating conditions, such as operating in
dry, hot, dusty climates (desert), areas of high humidity (tropical), excessive periods of heavy load or frequent intermit-
tent operations. Refer to Genset Manual for Engine Oil Change Instructions.
B. Refrigeration System:
The refrigerant system oil is sealed within the compressor and requires no checking.
C. Engine oil specifications:

Refer to the Genset Manual for engine lubrication specifications and requirements.
D. Fuel
Refer to the Genset Manual for engine fuel specifications and requirements.
9.2 INSPECTION & PREVENTIVE MAINTENANCE

Establish and maintain a periodic Preventive Maintenance Inspection Schedule as per table below. The criteria listed
meet the minimum requirements necessary to ensure safe reliable service under normal operating conditions. Modify it
as required to meet varying operating and environmental conditions.
PREVENTIVE MAINTENANCE SCHEDULE

This Preventive Maintenance Schedule is only for quick reference and not replacing the manufacturer manual by any means which shall be followed
by the users. Therefore, please read and follow the manufacturer manual before and during operation without any responsibility on Zamil Air Condi-
tioners. For more information, please refer to the manufacturer directly.
NOTE: repeat the schedule every 1000 HR.
# Operation 50 Daily 125 250 500 1000 12000 1 2

hour hour hour hour hour hour year year
E10 E20 E30 E40 E50 E60 E70

Engine Lubricant
1 Check engine for leaks (visual inspection) X
2 Check oil level X

3 Check Top up lube oil if necessary (also with separate container) X X
4 Change Lube oil (oil change intervals depending on engine use),
see 6.1.1/6.1.2 of the engine manual attached for engine model
F6L914 (Naturally aspirated engine type). X X X
5 Replace Oil filter cartridge (at each lube oil change) X X X
6 Check Oil bath air filter X
7 Replace Bypass - oil filter X
34

# Operation 50 Daily 125 250 500 1000 12000 1 2
hour hour hour hour hour hour year year
E10 E20 E30 E40 E50 E60 E70

Fuel System
8 Inspect for leaks X
9 Replace Fuel filter cartridge X
10 Clean Fuel pre-cleaner X
11 Drain sediment from tank X X X X
Engine Cooling System (Air Cooled)
12 Inspect air intakes for restrictions X
13 Check or clean cooling system (see the manual for more information) X X
14 Clean Intake air cleaner/dry type air cleaner (If available, maintain
according to maintenance indicator) (Inspect daily). X X
15 Check the operation for the cooling fans. X
16 Check the oil temperature after operation. X

Exhaust System
17 Inspect for leaks X
18 Inspect system for restrictions X
19 Inspect clamps for tightness X
20 Inspect for corrosion X
21 Inspect muffler for security X X X X
Power Generator Electrical System
22 Inspect that battery electrolyte level covers plates X
23 Check Battery and cable connectors X
24 Check battery state of charge X X X X
25 Inspect battery hold-down X
26 Inspect battery terminals for safety X
27 Check Engine monitoring system, warning system X
Engine Related Systems
28 Adjust Valve clearance (set if necessary, earlier if noises occur) X X
29 Check V-belts (re-tension or replace if necessary) X
30 Replace V-belts X
31 Check Sheathed glow lamps X
32 Replace Sheathed glow lamps X

33 Check Engine suspension (replace if damaged) X
34 Fastenings, hose connections / clamps X
35 Basic overhaul X
35

# Operation Every time Frequency of maintenance, Months
used 1 3 6 12
Air Conditioning System
36 Clean Pre- & Final air filters & replace if required. X
37 Clean evaporator coil, drain pan & drain line. X
38 Clean condenser coil. X
39 Lubricate blower motor/condenser motor. X
40 Check/clean electrical connections, controls & control box. X
41 Check all electrical control components, wiring terminals etc. for
spark, overheating & loose connections. Replace/correct as necessary. X
42 Check compressors & blowers insulation flanking. Repair/replace as required. X
43 Check loose bolts/screws & tight as necessary. X
44 Check for rusted/dented/damaged body parts & repair/repaint as necessary. X
45 Check flexible ducts duct and clamps. Repair/replace as required. X
46 Run test all motors and check the amperage, abnormality etc. X
47 Run test compressors and check the amperage, noise, pressure etc.
and correct them accordingly. X
48 Check the main control system devices for correct operation
calibrate/ re-adjust as required. X
49 Check the operation of the fault lights in the control panels and
beacon light in the top of the machine. X
50 Apply corrosion inhibitor/contact cleaner as required. X
51 Check all pressures/temperatures as applicable and satisfy the
operation & performance. X
General System Assembly
52 Ensure that the towing bar is in the vertical position and locked. X
53 Ensure that the machine is secured by wheel stoppers. X
54 Inspect overall system assembly for damages or missing items. X
55 Inspect system for restrictions for all access doors and openings. X
56 Keep minimum 2 meters clearance all around the system X
57 Inspect overall assembly leakages and any up-normal conditions
below the system. X
58 Inspect and remove any accumulated on the roof of the system. X
59 Check the wheels’ deflections if not normal recharge the tires. X
60 Ensure that the compressor compartment access door is closed
during the operation of the machine. X
NOTE: Change engine oil and filter after the first 50 hours of use, then after every 250 hours of use or every six months, whichever is
the most frequent.
WARNING: POTENTIAL FOR SERIOUS INJURY OR DEATH. USE EXTREME CAUTION WHILE MAKING SERVICE INSPEC-
TIONS WITHIN THE UNIT. DO NOT WEAR LOOSE CLOTHING OR JEWELRY WHEN THE UNIT IS IN OPERATION. NEVER
SERVICE THE UNIT ALONE - ALWAYS HAVE A SAFETY PERSON PRESENT DURING SERVICING OPERATIONS.
36

9.3 AIR CONDITIONING SYSTEM
The Model MAC240 Air Conditioner Unit provides reliable operation while requiring a minimum of service and mainte-
nance. This chapter contains information on servicing and maintaining the unit for optimum performance. Detailed ser-
vice and maintenance procedures on the diesel engine generator set may be found in the manufacturer’s publication
manual.
A. General Tools and Equipment:

Certain general tools are required to perform the routine preventative maintenance and servicing procedures outlined in
this manual. The following tools are recommended for use when servicing this equipment.
(1) Open end wrench set
(2) Socket set and drive ratchet
(3) Adjustable wrench
(4) Screwdriver set, flat head and Phillips
(5) Allen wrench set
(6) Canopy lock (key set)
B. Special Tools:
To service the refrigerant system, the following tools are required in addition to the general tools listed above.
(1) Compressor oil pump
(2) Refrigerant leak detector
(3) Vacuum pump
(4) Refrigeration ratchet
(5) Manifold gauges
(6) Refrigerant recovery and recycle system
(7) Micron gauge
(8) Nitrogen cylinder with L.P. regulator
(9) R-22 refrigerant bottle
(10) Scales (for weighing refrigerant cylinder)
(11) Refrigerant recovery and storage tank
C. Refrigerant System:
This unit utilizes refrigerant type R-22 only.
NOTE:
1. In accordance with the Montreal Protocol, venting refrigerant to the atmosphere is not permitted. Never vent refriger-
ant from the system or Freon cylinders to atmosphere. Always use a refrigerant recovery and recycle system.
Observe all local and national statutes concerning the handling of refrigerant chemicals.
2. Each refrigerant system in the Model MAC240 Air Conditioner Unit is an independent circuit. The servicing proce-
dures set forth in this manual are directed toward the servicing of a single refrigerant circuit. Therefore, if more
than one circuit is to be serviced, follow the procedure entirely on one refrigerant circuit before proceeding to the next.
D. Checking Refrigerant Charge:

With the unit running in the cool mode, observe the R-22 refrigerant charge using the refrigerant sight glasses. There is
one sight glass for each refrigerant circuit located in the piping leading to the evaporator coil for that system. A proper
refrigerant charge is evident by the absence of bubbles or the presence of very few bubbles in the refrigerant flow when
viewed through the sight glass. If there are many bubbles in the refrigerant flow, recharge the system must. Each
refrigerant circuit in the Model MAC240 Air Conditioner Unit is independent of the other as stated earlier. When checking
the refrigerant charge for the entire system, be sure to observe the liquid refrigerant flow in each sight glasses.
Whenever the refrigeration system is opened, take care to prevent the entry of moisture and air into the system.
37

9.4 MOISTURE IN A REFRIGERANT SYSTEM:
The filter drier in the system removes particles and small amounts of moisture which may enter the system during minor
servicing or fault conditions. Major moisture intrusion through fault or contamination may require complete system evacu-
ation for moisture removal.
Moisture in a refrigerant system is directly or indirectly the real cause of more problems and complaints than all other
causes combined. Moisture in a system can be visible or invisible. Rarely is liquid water found in a system, normally all
intrusive moisture is in the form of vapor. A single drop of moisture in a system can cause “freeze-ups.” Moisture can be
picked up by the refrigerant and be transported through the lines as a fine mist, causing ice crystals to form at the point
of expansion (expansion valve). These ice crystals retard or stop the flow of the refrigerant, causing a reduction or
complete loss of cooling. As the expansion valve warms due to the lack of refrigerant, the ice melts and passes through
the expansion valve. The moisture then cycles through the system until it again returns to the expansion valve, and the
cycle is repeated. The result is intermittent cooling. Moisture can also cause corrosion, which can present serious
problems, often not apparent until severe damage has occurred. Moisture, combined with refrigerants, can create acids
which in turn greatly increase the corrosion of metals and copper plating.
Refrigerant oil has an attraction for moisture absorbs it rapidly if left open to the atmosphere. Water formed acids mix with
refrigerant oil, the two forming a closely bonded mixture of fine globules. The effect is called “sledging” and greatly
reduces the lubricating ability of the oil. The corrosion caused by the presence of this moisture in the form of “sludge” can
plug fine strainers, expansion valves and capillary tubes. Because it usually contains acids, sludge corrodes whatever it
clings to, accelerating system damage. Only use fresh oil from unopened containers. Previously opened oil provides too
great a danger of system moisture intrusion.
The most effective means in removing moisture from a system is to utilize a high (deep) vacuum pump. A high vacuum
pump is capable of removing all moisture from a hermetic system by reducing internal system pressures to the boiling
point of water at normal temperatures. The vacuum pump does not “suck out” the liquid moisture, but rather causes it to
boil into a vapor state at which time it can be harmlessly removed from the system and exhausted through the vacuum
pump.
The ideal vacuum pump evacuates the system to at least 500 microns and is capable of holding that vacuum throughout
the dehydration process. It pulls that vacuum on the entire system and not simply at the intake of the pump; it removes
moisture at an ambient temperature of 80°F or over.
Table- 2 provides the boiling temperature of water compared to the evacuation of a system. The higher the vacuum, the
lower the boiling point, the greater the system evacuation.
To reduce pumping time as well as prevent early pump failure, use only a pump properly sized to the system. Table-1
provides pump sizing-to-system requirements. A larger than recommended pump is perfectly acceptable, but avoid using
a smaller than recommended pump. Multiple vacuum pumps equaling the single size required may be utilized by placing
them at various points on the system. Be sure that all valves are open to allow complete evacuation of the system.
Change the vacuum pump oil every time the pump is used; clean oil enhances pump efficiency.
TABLE-1: SUGGESTED HIGH VACUUM PUMP SIZE

System Size Suggested High Vacuum Pump Size
Up to 7 tons 1.2 CFM
Up to 15 tons 2.2 CFM
Up to 30 tons (MAC240 air conditioning system) 4.5 CFM
Up to 100 tons 15 CFM
38

TABLE-2: BOILING TEMPERATURES OF WATER AT CONVERTED PRESSURE
Temperature in Degrees Inches of Vacuum Microns,, Pounds Per Square Inch

Fahrenheit (°F) (Pressure)
212° 0.00 759,968 14.696
205° 5.00 535,000 12.279
194° 9.81 525,526 10.162
176° 16.02 355,092 6.866
158° 20.80 233,680 4.519
1400 24.12 149,352 2.888
122° 26.36 92,456 1.788
104° 27.83 55,118 1.066
86° 28.75 31,750 .614
80° 29.00 25,400 .491
76° 29.10 22,860 .442
72° 29.20 20,320 .393
69° 29.30 17,780 .344
64° 29.40 15,240 .295
59° 29.50 12,700 .246
53° 29.60 10,160 .196
45° 29.70 7,620 .147
32° 29.82 4,572 .088
210 29.90 2,540 .049
6° 29.95 1,270 0245
-90 29.97 500 .019685
-24° 29.99 254 .0049
-35° 29.995 127 .00245
-60° 29.999 25.4 .00049
-70° 29.9995 12.7 .00024
-90° 29.9999 2.54 .000049
Remaining pressure in system in micron:

1.000 inch = 25,400 microns = 2.540 cm = 25.40 mm .100 inch = 2,540 microns = .254 cm = 2.54 mm 039 inch = 1,000 micron = ,100 cm = 1.00 mm
39

9.5 EVACUATING THE REFRIGERANT SYSTEM
Anytime the compressor or refrigerant system is exposed for long periods of time to atmospheric air, becomes contami-
nated, or requires removal of the refrigerant charge, evacuate the system using the procedures that follow.
CAUTION:
POTENTIAL FOR SERIOUS DAMAGE TO THE MOTOR WINDINGS IN THE COMPRESSOR. DO NOT START
THE COMPRESSOR OR ATTEMPT TO OPERATE THE UNIT WHILE THE SYSTEM IS UNDER HIGH VACUUM.
Use a small portable vacuum pump designed for R-22 refrigerant system evacuation. Do not use the refrigerant system
compressor as a vacuum pump. This could result in severe damage to the compressor.
It is possible to use the manifold gauges to connect the vacuum pump to the service valves on the refrigerant system. For
larger systems and larger vacuum pumps, copper tubing or vacuum hoses of 1/4" minimum inside diameter are recom-
mended for high vacuum work. The procedures that follow are for use with a small vacuum pump connected through
manifold gauges.
Triple evacuation is strongly recommended for all field installed systems.

(1) Attach the common connection on the manifold gauges to the suction connection on the vacuum pump.
(2) Connect the high and low pressure connections on the manifold gauges to the service valves on the high and low
sides of the system respectively.
(3) With the valves on the manifold gauges closed (front-seated), open the service valves and adjust to a point approxi-
mately midway between the front-seat and backseat position.
(4) Start the vacuum pump and gradually open the valves on the manifold gauges. It may be necessary to restrict the
vacuum pump suction pressure using the manifold gauges to avoid overloading the vacuum pump motor.
(5) Continue evacuation until obtaining the desired vacuum reading on both gauges.
(6) When evacuation is complete, close the valves on the manifold gauges tightly, remove the line from the vacuum
pump and connect it to an R-22 refrigerant cylinder.
(7) Loosen the common hose connection at the manifold gauges, crack the refrigerant cylinder valve to purge the hose
and retighten the hose connection.
(8) Crack the valves on the manifold gauges until the system pressure rises to 2 psig.
(9) Close the refrigerant cylinder valve and the valves on the manifold gauges.
For triple evacuation, perform the above procedure three times, evacuating twice to 500 microns and the last time for
eight hours to ensure complete system evacuation.
When triple evacuation is complete, the system is ready for recharging. If it is not to be charged immediately, seal the
system by back-setting the service access valves and plugging or capping all open gauge ports or connections.
9.6 REFRIGERANT LEAK TESTING
WARNING:
WHEN WORKING WITH REFRIGERANTS, ALWAYS WEAR GOGGLES. CONTACT WITH REFRIGERANT MAY CAUSE INJURY.
A leak-free system assures trouble-free system operation and performance. Loss of refrigerant reduces system effi-
ciency and capacity. It also causes repeated activation of system safety monitors, shutting down the unit. Perform leak
testing at scheduled intervals and after doing any work on the unit.
A leak may spread refrigerant throughout the interior of the unit, making locating the leak difficult. Air the interior of the
unit prior to testing. If a leak is detected but it is difficult to pinpoint the location, use compressed air to blow the area free
of vapor then immediately retest before the leaking vapor spreads.
Use a draft free area when leak testing to prevent the loss of vapor from small leaks. Ensure the testing area is free of
compressor oil, which may contain dissolved refrigerant, giving false test indications.
40

(1) TESTING METHODS
(a) Electronic Leak Detector:
This is the easiest method for leak detection. Electronic leak detectors can be used in areas where an open flame is not
permitted. Pass the detecting probe over the area of the suspected leak. If a leak is present, the detector sounds a high
frequency alarm or signals by a flashing light, depending on the model used.
(b) Soap Bubble Testing:

Applying a generous amount of common dish washing detergent to the suspected areas creates tell-tale bubbles if a
large leak is present.
CAUTION:
DO NOT USE THE COMPRESSOR TO BUILD UP PRESSURE IN THE SYSTEM. DO NOT OVERCHARGE THE
SYSTEM.
(2) TESTING PROCEDURES

(a) Charge the system to 10 psig with refrigerant. Add dry nitrogen (do not use oxygen) until the system pressure is 150
psig. Check for leaks with a halide electronic leak detector (Preferred method).
OR
(b) Charge the system with dry nitrogen (do not use oxygen) to 150 psig and use the soap- bubbles test to find large leaks
(Alternate method).
9.7 REFRIGERANT LEAK REPAIR
WARNING:
ENSURE ADEQUATE VENTILATION DURING REPAIRS. PHOSGENE GAS, A DEADLY POISON, IS GENERATED
WHEN REFRIGERANT IS EXPOSED TO FLAME.
(1) Locate leak as described above.

(2) Using a refrigeration recovery system compatible with R22, pump refrigerant from the system and dispose.
(3) Replace drier if necessary, see sight glass for moisture indication.
(4) Correct leak as described below.
(5) If no leaks are present, pump out system and then evacuate system to at least 500 microns, hold for 30 minutes.
Break vacuum with R22 and raise system pressure to 0 to 5 psig. Re-evacuate system to 500 microns.
Repeat this for a total of three (3) times, then charge the system with R22 as per unit name plate or refer the below
paragraph.
(6) Leak Repair Procedure:
(a) Thoroughly clean paint, dirt and oil film from adjacent piping. Use a wire brush, sand cloth or sandpaper.
(b) Wrap nearby parts with water-soaked cloths to protect them from heat damage during repairs.
(c) If a solder joint requires repair, disassemble the joint and clean away any refrigerant oil which may be present;
oil traces prevent making leak-proof solder repair. After cleaning, reassemble the parts and solder.
d) Reassemble and tighten any connections previously loosened.
(e) After opening the plumbing system for repair, evacuate the system previously open to a vacuum of 750 microns.
Add refrigerant gas until pressure within the system is at least 5 psig. Follow with dry nitrogen to raise pressure
to 150 psig.
(f) Open all previously closed valves.
(g) Perform a pressure check for leaks as previously discussed.
41

9.8 REFRIGERANT CHARGING & PRESSURE LIMITS
If the air conditioning unit is to provide the proper amount of cooling, the refrigerant system needs to be adequately
charged with R-22 refrigerant. A shortage of refrigerant is evident by a loss of cooling effect, a low suction pressure, and
many bubbles present in the sight glass.
The necessity to add refrigerant is not considered routine maintenance. The loss of any portion of the refrigerant charge
indicates a refrigerant leak and thereby a need for service.
A liquid sight glass is located in the refrigerant piping just ahead of the expansion valve. When the refrigerant charge is
low, bubbles are evident in the liquid refrigerant flowing through the sight glass. Add refrigerant until the bubbles are
eliminated or only an occasional bubble is noticed.
WARNING:
DO NOT OVERCHARGE THE REFRIGERANT SYSTEM. OVERCHARGING THE SYSTEM CAN DAMAGE THIS
UNIT. THE ORIGINAL REFRIGERANT CHARGE FOR THIS UNIT IS LISTED BELOW.
A. REFRIGERANT CHARGE QUANTITY

Model MAC240 Air Conditioner Unit:
System-1 charge-R22: 450 oz (12.75 kg)
System-2 charge-R22:450 oz (12.75kg)
If the system has lost its charge completely, evacuate prior to recharging. Use the following procedure to add or replace
the refrigerant.
(1) Using a platform scale, weigh the R-22 Freon cylinder and its contents. Record this weight for later reference.
(2) Using a copper connecting tube or other appropriate charging hose, loosely connect the outlet of the Freon cylinder
to the charging valve.
(3) Position the R-22 Freon cylinder so that the top is at a higher level than the bottom. This is necessary to ensure the
release of the refrigerant in the gaseous state.
(4) Slightly open the valve on the R-22 Freon cylinder.
(5) Purge the charging line and tighten the connection.
(6) Check the tubing connections between the R-22 Freon cylinder and the charging valve for leaks.
(7) Open the valve on the Freon cylinder approximately halfway.
(8) Open the charging valve.
(9) Close the refrigerant valve on the liquid line to the expansion valve. Be sure the compressor suction and discharge
valves are open.
(10) Tip the R-22 Freon cylinder so that the outlet valve is at the lowest point allowing liquid refrigerant to flow through the
charging hose.
(11) Operate the compressor. The tubing connecting the R-22 Freon cylinder to the charging valve is not of sufficient
size to supply enough refrigerant to prevent the system from pumping down into a vacuum. Watch the suction
gauge and do not allow suction pressure to go below zero. The ideal pumping is to approach a vacuum without
actually pumping into a vacuum.
(12) If the system has lost its charge completely, charge only the specified weight of refrigerant into the system. DO NOT OVER-
CHARGE. Check that the refrigerant charge is free from bubbles and completely fills the sight glass.
(13) If the system has a partial charge, charge the system with only 10 pounds of R-22 Freon at a time. Stop the
charging operation and operate the unit in cool mode. Observe the refrigerant charge in the sight glass as stated
above. Repeat the procedure until the correct refrigerant charge is obtained without overcharging.
Compressor Oil
NOTE: The compressors are sealed and do not require oil servicing.
B. REFRIGERANT PRESSURE SWITCH LIMITS

The refrigerant pressure switches are set properly to control the unit within the design parameters and are not adjustable.
If any refrigerant pressure switch fails to operate, replace the switch. The refrigerant pressure switch limits settings
are as follows:
High Pressure Switch (HPS) - 450 psig
Low Pressure Switch (LPS) - Cut-Out 25 psig, Cut-In 50 psig
42

10. EQUIPMENT DIMENSIONAL DETAILS
Model No.: MAC240FZ600
43

11. MAIN CONTROL PANEL COMPONENT LAYOUT
44

12. MAIN CONTROL PANEL COMPONENT PARTS LIST
45

13. PARTS LIST –MAC240
ZAMIL Part No. Description Uom Qty
04940003 REFRIGERANT – FREON 22 (PER SYSTEM) LB 28
60020008 WRG DGM MOBILE AC/MAC240 FZ601 460V-3-60 HZ EA 1
80000502 AIR FLOW SWITCH EA 1
80000934 FUSDEL DUAL ELEMENT 2 AMP 250V EA 2
80000937 FUSDEL DUAL ELEMENT 3.5AMP 250V EA 2
80000961 FUSDEL DUAL ELEMENT 5 AMP 500V EA 2
80001214 TRANSF 208/230/460 VAC TO 24 VAC 50/60HZ 75VA EA 1
80001230 TRANSFORMER 30VA QUIK CONNECT 208/230 TO 24V EA 1
80001345 VOLTAGE MONITOR-230/380/415/460V-3-50/60 HZ EA 1
80001600 TRAILER MAC - 240 EA 1
80001603 ELECT OPERATED - 12V DC (10-180 Ohms) FUEL LEVEL EA 1
80001651 DIESEL GENERATOR POWER SYSTEM; 480-3PH-60Hz EA 1
80002701 INSULATED SPRIAL (PCA) DUCT 14" x 30' EA 1
80002765 CORDRI RC4864 CORE DRIER EA 2
80002792 CLAMP TUBE 5/8 IN DIA EA 2
80002838 HANDLE LATCH KIT [CCW] EA 1
80002861 KNOB PLASTIC 3/4" DIA EA 1
80002862 DOOR HINGES - WELD ON TYPE EA 2
80002874 WING NUT (STAINLESS STL 3/8"DIA) S/S EA 8
80002994 DOOR STOP WITH PANEL MOUNTING DEVICE EA 6
80003215 SCREW 3/8 #8 32TPI EA 40
80003280 SCREW 5/16 DIA 7/8"LG HEX HD 18TPI TAPTITE EA 53
80003404 SCREW .400" #8 PHL TRUSS HD 16TPI SELF T EA 40
80003420 WING HEAD THUMB SCR 5/16-18 X 3/4L EA 2
80003503 TERMIN QUICK CONNECT K2/4"ARK3000H19A EA 21
80003504 TERMIN PIGGY BACK 3/4"Q/C ARK 3000H21A EA 5
80003532 INSULATED HOOKED BLADE TERMINAL 16-14AWG EA 35
80003535 INSULATED PIN TERMINAL 16-14AWG EA 34
80003558 TERMIN LUG #8 AWG 1/4" HOLE EA 14
80003561 TERMIN LUG #2 AWG 1/4" HOLE EA 14
80003563 TERMIN LUG #12-10 AWG 1/4" HOLE EA 50
80003564 TERMIN LUG #16-14 AWG 1/4" HOLE EA 18
80003619 FUSE CARRIER-1POLE,32A,600V [CLOSED TYPE] EA 6
80004020 PLASTIC PIPING CLAMP WITH NUT & BOLTS (DIA. 5/8) EA 18
80004021 PLASTIC PIPING CLAMP WITH NUT & BOLTS (DIA.7/8) EA 8
80004023 PLASTIC PIPING CLAMP WITH NUT & BOLTS (DIA.1 3/8) EA 6
80005040 TIE WIRE PLASTIC EA 40
80005074 CLAMP CABLE NYLON 7/8 IN EA 4
80005076 CLAMP CABLE NYLON 1-1/4 IN EA 4
80005086 TUBE THERMOPLASTIC 3/8"OD FT 35
80005087 PLASTIC INSUL’N PROTECTIVE SLEEVE-TRANSPARENT[1/4"] EA 26
46

PARTS LIST –MAC240
80006200 CANOPY LOCK [S/S] EA 4
80006201 END COLLAR [S/S] S.A. OUTLET EA 1
80006202 PULL HANDLE EA 2
80006204 STKADH TOWING INSTRUCTION EA 1
80006205 SCREW MACHINE PAN HEAD (SS) EA 44
80008300 LUGGND EA 3
80008615 COUPLING S.STEEL 3/4 SIZE EA 1
80008630 COUPLING # 3000 STEEL HALF (D.B.#CPL279) EA 4
80008729 THERMAL MAGNETIC CIRBKR 3P 9In 32-40A 500v 50/60Hz EA 2
80008733 THERMAL MAGNETIC CIRBKR 3P 9In 80-100A 500v 50/60Hz EA 1
80009840 AUX.CONTACT BLOCK [L&T] 1 NO + I NC [L] EA 2
80009851 3P CONTACTOR 9A 220V COIL 50/60HZ [L&T] EA 3
80009859 3P CONTACTOR 32A 220V COIL 50/60HZ [L&T] EA 2
80009861 3P CONTACTOR 40A 220v COIL 50/60HZ [L&T] EA 1
80009890 3P THERMAL OLR MNX R3 20.0-33.0A [L&T] EA 2
80009906 CAP COPPER 1 5/8" DIA {WELD TYPE} EA 4
80014220 NON-METALLIC LIQ TIGHT FLEXIBLE CONDUIT [NMUA-3/8] FT 15
80014222 NON-METALLIC LIQ TIGHT FLEXIBLE CONDUIT [NMUA-3/4] FT 10
80014223 NON-METALLIC LIQ TIGHT FLEXIBLE CONDUIT [NMUA-1] FT 7
80014224 NON-METALLIC LIQ TIGHT FLEXIBLE CONDUIT [NMUA-1-1/4] FT 25
80014634 CONDUT L.T. CONCTR STR. 1-1/4" EA 6
80014703 CONDUT BX CONCTR CORD GRIP 3/8" NOM EA 4
80014711 NON-METALLIC LIQ TIGHT CONDUT FITTINGS [NMLT-3/8] EA 4
80014713 NON-METALLIC LIQ TIGHT CONDUT FITTINGS [NMLT-3/4] EA 4
80014714 NON-METALLIC LIQ TIGHT CONDUT FITTINGS [NMLT-1] EA 4
80017100 VIBELE ELIMINATOR 1 3/8" EA 4
80017105 VIBRATION ELIMINATOR 7/8" EA 6
80018479 EXPANSION VALVE 15 TONS NOM 7/8"x1-3/8"DIA EA 2
80019009 NOZORI EA 2
80019602 DISTRIBUTOR 1115 TYPE 1/4"DIA EA 2
80019754 AUXILIARY SIDE CONNECTOR ASC-9-5 1-1/8 SIZE EA 2
80020000 SIGHT GLAS SA 155 5/8 SWT EA 2
80020101 SIGHT GLASS 2870 A203 OBP30 FOR 30" PANEL EA 3
80020708 VALACE MADEN VU 53-346. ACCESS VALVE EA 24
80020725 VALACE 1/4 MPT ACCESS VALVE EA 2
80021220 STKADH ZAMIL ALUM. FOIL EA 1
80022601 FAN ASSY ZIEHL (700mm) FC071 6DQ 6K5 460/400-3-60/50 EA 2
80023703 FAN ASSY [710mm]OD, SINGLE SPEED, 230/460/400-3-60HZ EA 1
80024910 AL. FILTER - [ 23 1/2"x 19 1/2"x 7/8"] EA 2
80029888 TERBLK 310A 16395-3 600VAC EA 1
80029894 DUST COVER CPDB-3 FOR 3 POLE TERM.BLOCK EA 1
80030070 TERM BLOCK SCREW CLAMP TYPE 4SQ.MM WIRE RANGE EA 35
80030071 TERM BLOCK END STOP PLASTIC 8MM WIDTH EA 20
80030073 TERM BLOCK END COVER 3MM THICK 4SQ.MM EA 4
80030075 TERM BLOCK CROSS CONNECTN 10 POLE INSULD 4SQ.MM EA 1
80030076 TERMINAL BLOCK RAIL 7.5 DEPTH 2M LTH MT 1
80030081 TERM MARKER TAG # 1 SYMBOL (10NOS./STRIP) EA 0.7
47

80030090 TERM MARKER TAG UPPER CASE LETTER A (10NOS./STRIP) EA 0.2
80030091 TERM MARKER TAG UPPER CASE LETTER B (10NOS./STRIP) EA 0.2
80032106 TRANSF 500VA 240/480 TO 120/240VAC EA 1
80035370 AIR VELOCITY TRANSMITTER 0-10V/4-20mA 24V AC/DC EA 1
80035371 PRESSURE TRANSMITTER 0-20BAR/4-20mA 0-10V DC EA 1
80035380 PUSH BUTTON SWITCH (N.O.) EA 1
80035381 PUSH BUTTON SWITCH (N.C.) EA 2
80035382 PILOT LIGHTS 24V AC/DC (GREEN) EA 1
80035383 PILOT LIGHTS 24V AC/DC (RED) EA 5
80035384 PILOT LIGHTS 24V AC/DC (YELLOW) EA 1
80035385 PUSH BUTTON SWITCH / EMERGENCY STOP (N.C.+ N.O) EA 1
80035386 SELECTOR SWITCH / 3-POSITION (N.O + N.O) EA 2
80035387 ROTORY WARNING (BEACON)LIGHT.220/230V-1PH-50/60 HZ EA 1
80035389 SELECTOR SWITCH/ 2- POSITION (1 NO+1NC) EA 1
80035390 N.O CONTACT BLOCK,HARMONY STYLE 4,3A/240V EA 3
80035391 N.C. CONTACT BLOCK,HARMONY STYLE 4,3A/240V EA 1
80035654 RELAY DPDT-2 FORM C 24V 50/60HZ EA 6
80035656 RELAY DPDT-2 FORM C 240V 50/60HZ EA 4
80035660 RELAY PLUGIN TYPE 4PDT 24V COIL 50/60Hz EA 3
80037419 SCREW MACH RIB SHOULDER 10-32TPI 3/8 EA 1
80037421 SCREW TAPTITE 1/4-20TPI X 3/4"L EA 16
80037514 SCREW M/C(FLAT HEAD) M4x0.7x8MM-CH EA 30
80037515 STUD-UIB MTG PLT M3 x 16 EA 21
80037516 STUD-UIB MTG PLT M4 x 10 EA 22
80039101 HEAT SHRINK TUBE SM3-35 1/4" FLEXIBLE POLYOFIN WHITE EA 0.021
80040015 GROMMET 1-1/2"OD x 1-1/8"ID EA 8
80040016 GROMMET 1-1/8"OD x 7/8" ID EA 8
80040057 GROMMET 2-18"OD x 1-3/4" ID EA 4
80040151 GASKET SEAL- CONTROL PANEL FT 2
80043701 LABEL ADHESIVE AR9 EA 1
80043702 LABEL ADHESIVE AR10 EA 1
80043731 LABEL ADHESIVE “CB6” EA 1
80043732 LABEL ADHESIVE “CB7” EA 1
80043820 LABEL ADHESIVE ‘SW5’ EA 1
80044265 LABADH COMPONENT IDNT “SW1” EA 1
80044266 LABADH COMPONENT IDNT “SW2” EA 1
80044276 LABEL SELF ADHESIVE “OLR1” EA 1
80044277 LABEL SELF ADHESIVE “OLR2” EA 1
80044419 STKADH LABEL SELF ADH, CB1 EA 1
80044420 STKADH LABEL SELF ADH , CB2 EA 1
48

80044421 LABADH CB3 EA 1
80044422 LABADH CB4 EA 1
80045026 LABADH 7/16" x 1/2" F1 EA 1
80045027 LABADH 7/16" x 1/2" F2 EA 1
80045028 LABADH 7/16" x 1/2" F3 EA 1
80045029 LABADH 7/16" x 1/2" F4 EA 1
80045057 LABADH 7/16" x 13/16" CB5 EA 1
80045140 LABADH ADHESIVE 7/16"x13/16" LPS3 EA 1
80045141 LABADH ADHESIVE 7/16"x13/16" LPS4 EA 1
80045301 LABADH ADHESIVE 7/16" X 13/16" CC1 EA 1
80045302 LABADH ADHESIVE 7/16" X 13/16" CC2 EA 1
80045310 LABADH ADHESIVE 7/16" X 13/16" FMC1 EA 1
80045319 LABADH ADHESIVE 7/16" X 13/16" BMC EA 1
80045338 LABADH ADHESIVE 7/16" X 13/16" UVM EA 1
80045342 LABADH ADHESIVE 7/16" X 13/16" HVTB EA 1
80045345 LABADH ADHESIVE 7/16" X 13/16" LUG EA 1
80045354 LABADH ADHESIVE 7/16" X 13/16" CR1 EA 1
80045367 LABADH ADHESIVE 7/16" X 13/16" AR1 EA 1
80045375 LABADH ADHESIVE 7/16" X 13/16" LR1 EA 1
80045379 LABADH ADHESIVE 7/16" X 13/16" TDS EA 1
80045384 LABADH ADHESIVE 7/16" X 13/16" ATB EA 1
80053141 FILTER DRIER REPLACEABLE CORE 5/8 EA 2
80053303 HOTGAS BYPASS VALVE 5/8"OD EA 2
80054018 DISCHARGE LINE MUFFLERS 7/8 ODS EA 2
80055729 LO PRESS SWITCH (ADJ) W/1/4" FLARE CONN EA 2
80055800 CONTRL HI-PRESS CONTROL 450 PSIG EA 2
80056440 TOGGLE SWITCH SPDT 3 AMPS EA 2
80060853 MINIATURE CIRCUIT BRKR 3P 6A 480VAC EA 3
80060860 MINIATURE CIRCUIT BRKR 3P 40A 480VAC EA 1
80062290 RETURN AIR GRILLE ALUM - 610Wx1010H EA 1
80062300 RELAY ARTISAN #438 TIME DELAY 24V-240V EA 1
80063803 ARMAFLEX INSULATION SHEET 7/8" THK SF 17.986
80064274 ROTOLOCK SERVICE VALVE ADAPTER SET W/ACCESSORY EA 2
80064634 CHILLER - CTRL BOX LATCH (W/O LOCK) EA 3
80064645 MICRO CONTL’R MICRO SMART- III for RECIP&SCREW COMP EA 1
49

80064650 USER INTERFACE CARD-CH [PJE] EA 1
80064655 PTC TEMP SENSOR (L=7M) FOR LWT&RWT CH(PJE) EA 2
80064656 RELATIVE PR TRANSDUCER (0TO40BAR)(FOR DP)[PJE] EA 2
80064658 RELATIVE PR TRANSDUCER (-05TO10BAR)(FOR SP) [PJE] EA 2
80064659 CONNECTOR SERIAL INTERFACE RJ45 -CH EA 2
80064660 CABLE FLAT SERIAL INTERFACE 4WIRE -CH FT 4
80064661 SHIELDED ROUND CABLE FOR TRANSDUCERS FT 80
80064662 STUD MOUNTING #8 UNC EA 40
80064664 STICKER ART WORK UIB - CLASSIC-CH EA 1
80064667 KIT-SPACERS,WASHERS & NUTS - CH-PJE EA 4
80066308 COPPER REDUCING ‘TEES’ EA 2
80067419 COMPRESOR ZR144 460-3-60;380/415-3-50 HZ, COPELAND, EA 2
80070540 VALBAL 5/8" DIA. EA 10
80070601 VALPRE RELIEF VALVE 3/8 A15512 EA 2
80101400 BLOWER KIT-DP500/5-S4 (RD270°) INDUST.H/P RADIAL FAN EA 1
80103811 RUBBER ISO ROUND 60ShoreD60/H45M10 [CT # 2750A120] EA 4
80104191 Electrostatic Perm.Washable AIR FILTER - 490x592x48m EA 2
80104300 AHU-TURNBUCKLE LOCK SET 30mm EA 4
80104306 TOGGLE SCREW [for ‘C’ CLAMP] EA 7
80104400 P-RUBBER SEAL TAPE 15x6 S-ADHESIVE MT 25
80104506 LBL SUPPLY FAN SECTION EA 1
80104513 LBL-FILTER SECTION EA 1
80104640 HEXAGON NUT M6 x 5mm - S/S DIN 934 EA 20
80104653 WASHER M6 x 6.4mm - S/S DIN 125 EA 20
80106000 BLOWER MOTOR 13KW 460-3-60hz.TEFC ptc. ; 3600RPM EA 1
80106900 UNIT KEY 6Kw HANDLE 6MM L=E EA 1
80106923 DRIP ELIM BLADE,RAU-PP1381,ART613992, 6M LG EA 4.2
80107138 HEXAGON BOLT M6x25 VZ EA 219
80107150 HEXAGONAL BOLT M8 x 30mm - GAL DIN 933 EA 29
80107161 HEXAGON BOLT M10x20 VZ EA 2
80107176 HEXAGON BOLT M12 x 50 VZ EA 8
80107223 CSK SLTD HEAD SCREW M5 x 16mm - GAL DIN 963 EA 16
80107244 CSK PHILIPS HEAD SCREW M6 x 50mm - GAL DIN 965 EA 26
80107310 SLOTTED CHEESE HEAD SCREW M8x16 VZ EA 2
80107493 SELF TAPPING SCREW 4.8x19 VZSW 8 EA 150
80107494 SELF TAPPING SCREW 6,3x22 VZSW10 EA 50
80107526 VARIABLE FREQUENCY DRIVE 380-480V 3PH 50-60HZ / 15K EA 1
80107713 HEXAGON NUT M5 x 4.0mm GAL DIN 934 EA 8
80107714 HEXAGON NUT M6 VZ DIN 934 EA 12
80107715 HEXAGON NUT M8 VZ GAL EA 12
80107716 HEXAGON NUT M10 VZ DIN934 EA 12
80107717 HEXAGON NUT M12 VZ DIN 934 EA 8
80107803 C-B RIVET NUT M6 SKO 1.5-3MMA2 EA 175
80107809 F-B RIVET NUT M6 FKO 5.5-8MM EA 60
80107814 F-B-RIVET NUT M8 FKO 0.5-3MM EA 13
80107818 F-B RIVET NUT M10 FKO 1-3.5mm EA 8
80107870 POP RIVET 3.2x9.5ST/ST 1.1-4.0 EA 446
50

80107915 WASHER M10 DIN 9021 A2 EA 20
80107918 WASHER M5 x 5.3mm - GAL DIN 125 EA 8
80107919 WASHER 6.4 VZ DIN 125 EA 64
80107920 WASHER 8.4 VZ EA 19
80107921 WASHER 10.5 DIN 125 VZ EA 2
80107930 WASHER M12 VZ DIN9021 EA 183
80107947 SPRING WASHER M5 x 5.1mm - GAL DIN 127 EA 16
80107948 SPRING WASHER B-6 VZ EA 159
80107949 SPRING WASHER B-8 VZ GAL EA 19
80107950 SPRING WASHER B-10 VZ EA 8
80107951 SPRING WASHER VZ DIN 127-B-12 EA 8
80108510 HANDLE 117 GN 528 BLACK EA 1
80108521 3D-HINGE RIGHT 217-9405 EA 4
80108522 3D-HINGE LEFT 217-9406 EA 8
80108523 HINGE BLACK FOR BELT GUARD DOOR EA 6
80108813 LAMP BODY WITH STEEL COVER EA 2
80108815 INCANDESCENT BULB 220V, 60 WATTS THREADED TYPE EA 2
80108825 GROMMET 110 x 40MM (1-5/8") EA 1
80108903 MEMBRANE CABLE BUSHING DG16 EA 2
80300135 HUCKBOLT PIN 3/8" DIA. EA 12
80300136 HUCK COLLAR EA 12
51

14. WIRING DIAGRAM
POWER SUPPLY
SCHEMATIC DIAGRAM MAC 240
460V-3PH-60HZ 2-FAN MOTOR LAYOUT
CB6 HVTB
L1 L1 C1 F1 C2 F2
POWER SUPPLY L2 L2
(GEN SET PANEL) L3 L3 CONTROL
PANEL
VFD CONTROL CONNECTIONS
LUG/ETB CB1 CB2 CB3 CB4 CB5
ST1 27A
(MB)
L1E
L2E
L3E
T1
AO3(-) 79
L1A
L2A
L3A
L1B
L2B
L3B
(MB) T2
100
101
102
103
104
105
BMC T3
AO3(+) 78
FMC1 ATB T4
CC1 CC2 FMC2 (MB)
L1F
L2F
L3F
UVM CONNECTION 15 T5
L1 L2 L3 OLR1 OLR2 AR2 47 T6
ST1 26A
T1A
T2A
T3A
T1B
T2B
T3B
L1 L2 L3 B1
(MB)
35A
36A
37A
35B
36B
37B
80 B2
Ø Ø Ø VFD
L1 L2 L3 UVM
1 UVM-1 8 COMP COMP B3
FM1 FM2 U V W BMR1-1A 81
1 2 B4
B5
68
69
70
TO ATB 1
TO HVTB TO HVTB B6
TO ATB 1A
L1 L3 B7
BM
UVM-1 ES TRANS1
F3(5A) (500VA)
3 4 F4(5A)
460V
ATB F1(3.5A) 5 F2(3.5A) ATB CRANKCASE HEATER CONNECTION SERVICE / BEACON LAMP CONNECTION
6 2
1 1A 1B 230V COMP1
C.HTR1
SW1 L1 L2
GEN SET PANEL
ATB ATB
OFF 15 COMP2
REMOVE C.HTR2 1 2
GEN RUN
JUMPER L2 L3 SW6
FAN 18
LT9
(GEN SET START) 40 83A
41 EMERGENCY STOP SWITCH CONNECTION
72 ATB 1A ES ATB 1B LT10
A14 83B
TO MB
42 CR1 SW7
SW2
ATB
VENT 67
GEN SET CONTROL PANEL
COOL
ES (gen set)
CR1-1A 9 TO MB
A13 84 17 3
43
85 19
SW3
LOW COOL
MED COOL
HIGH COOL TO ATB TO ATB
15 24V ac 17
44 TO MB
A19
45 TO MB
A20 SW5
(LAMP TEST) 57 AR9
CR1-2A 46 BMC
AR10
AR1
AR1-1A 58 LT1
F5(2A) TRANS2 F6(2A) POWER ON
14 (30VA) 16 AR9-1A
230V
ATB ATB AR3-2A 59 LT2
56 AR8-1B 24V ACU COMMON FAULT
15 17
GND AR9-2A
T5 T6 AR4-2A 60 LT3
NO AIR FLOW
TO VFD AR9-3A
47 AR2 VFD READY/FAULT
RELAY AR5-2A 61 LT4
8C 8NO LOW FUEL
AR9-4A
TO MB 48 AR3 ACU COMMON FAULT
RELAY AR6-2A 62 LT5
COMP1 TRIP
AR3-1A AR10-1A
AFS TDS AR7-2A 63 LT6

COMP2 TRIP
NC 51 AR4
BMR1-2A 50 NO AIR FLOW AR10-2A
49 RELAY
NO
AR4-1A AR10-3A
GEN SET COMMON ALARM
RELAY CONTACT
LOW FUEL SENSOR RELAY CONTACT (in gen set control panel)
(in gen set panel)
11 14
11 14 AR5 LOW FUEL
52 RELAY R3
R1
AR1-2B LT7
AR5-1A +12V dc 64 65 66 GEN SET FAULT
(gen set battery) JP
17C 17O (remove JP if gen set fault contact is connected)
TO MB TO ATB
53 AR6 COMP1 TRIP
RELAY 1
AR6-1A 230V ac
AR5-4A LT8
18C 18O 2 67 LOW FUEL
AR10-4A (BEACON LAMP)
TO MB 54 AR7 COMP2 TRIP
RELAY
AR7-1A
MODEL
SW4
(RE-SET) 55 AR8
MAC240FZ601
PN:- REV 04
60020008 SHEET 01 OF 02
52

WIRING DIAGRAM
POWER SUPPLY
SCHEMATIC DIAGRAM EXHAUST FAN POWER AND CONTROL CONNECTION
460V-3PH-60HZ
L1G
TO GEN SET CB L2G
(SUPPLY SIDE) L3G
CB7
L2H
L3H
LIH
TO ATB TO ATB FMC3
1 230V ac 2
35C
36C
37C
ATB
16
FM3
TRANS3
14 (75VA)
230V ATB TK(FM3) FMC3 ATB
1 11C 12C 2
24V
15A 17A FUEL GAUGE CONNECTION

GEN SET FUEL GAUGE
24V AC PE CONTROL PANEL SW8
A1 (SSPS-1) LAMP
CB1A-1 21A 22 90
A2 (CB-1) R
JP13
A3 (OL-1) 91 92
JP14
HPS1 10A OLR1-1 11A TK(FM1) 12A AO4 21 94
A4 (HPS-1) TO VFD + S
P 78 T4 PINK (4)
A5 (FCB-1) 93 -
AO3 79 (0~10V)
A6 (SSPS-2) T1 95
CB2A-1 21B A7 (CB-2) (FROM FUEL SENSOR) NOTE: R = 80~100 ohm
A8 (OL-2) AO2
HPS2 10B OLR2-1 11B TK(FM2) 12B A9 (HPS-2) PRESSURE SETTINGS
P
A10 (FCB-2) AO1 DESC. CUT-OFF (PSIG) CUT-IN (PSIG)
AR4-3B 86 A11 (AIRFLW) LOW PRESSURE 25 --
BMCA-1A 71
A12 (S. FAN ENABLE) HIGH PRESSURE 400 --
FROM SW2 43 A13 (COOL / VENT) HPS1 & 2 450 ± 10 360 ± 15
FROM SW1 72 A14 (GEN RUN FDBCK)
AR5-3B (GEN RUN) HGS 47 40
73 A15 (LOW FUEL)
AR8-2A 74 A16 (ALARM RE-SET) JUMPER SETTINGS - MB BOARD
AR2-2A 75 A17 (VFD FAULT) JU1 - CLOSED JU12 - CLOSED (1,2)
76 A18 (VFD RUN FDBCK) JU2 - CLOSED JU13 - CLOSED (2,3)
44 A19 (COOL MODE-LOW)
FROM SW3 45 JU3 - CLOSED (1,2) JU15 - CLOSED (2,3)
A20 (COOL MODE-HI)
JU4 - CLOSED (1,2) JU19 - CLOSED (1,2)
AC (DIGITAL COM)
R1(DIG OUT) 3A CC1
1C 1O
COMP1 CONTACTOR JU7 - CLOSED (2,3) JU17 - CLOSED (2,3)
R2(DIG OUT) JU8 - CLOSED (2,3)
2C 2O
R3(DIG OUT) HGS1 JU9 - CLOSED (1,2) TU1 - CLOSED
3C 3O 4A HOT GAS BY-PASS SOLENOID
(COMP1) JU10 - CLOSED (1,2) TL1 - OPEN
R4(DIG OUT) 3B CC2
4C 4O COMP2 CONTACTOR JU11 - CLOSED (2,3) TD1 - CLOSED
R5(DIG OUT) DIP SWITCH SETTINGS - MB BOARD
5C 5O
R6(DIG OUT) HGS2 1 2 3 4

6C 6O 4B HOT GAS BY-PASS SOLENOID S1
(COMP2) ON OFF OFF OFF
R7(DIG OUT)
7C 7O
ATB R8(DIG OUT) 8NO
8C 48 LEGEND
15 AR3 COMMON FAULT INDICATION
8NC (VOLT-FREE CONTACT) AR AUXILIARY RELAY
ATB AUXILIARY TERMINAL BLOCK
R9(DIG OUT) 9NO 18A FMC1 BM BLOWER (SUPPLY) FAN MOTOR
C
FM1 CONTACTOR BMC VFD POWER CONTACTOR (BM)
R10(DIG OUT) 10NO BMCA BMC AUXILIARY CONTACT
CB CIRCUIT BREAKER
R11(DIG OUT) 11NO 82 BMR1 CC COMPRESSOR CONTACTOR
BLOWER MOTOR CCA CC AUXILIARY CONTACT
JP11
JP12
R12(DIG OUT) 12NO (VFD) RELAYS C.HTR CRANKCASE HEATER

COMP/C COMPRESSOR
C R13(DIG OUT) 13NO 18B FMC2 CR CONTROL RELAY
FM2 CONTACTOR ES EMERGENCY STOP PUSH BUTTON SWITCH
R14(DIG OUT) 14NO F FUSE
AIR VELOCITY SENSOR FM FAN MOTOR (CONDENSER)
(JUMPER SETTINGS) R15(DIG OUT)15NO FMC FAN MOTOR CONTACTOR
HGS HOT GAS BY-PASS SOLENOID
R16(DIG OUT) 16NO HPS HIGH PRESSURE SWITCH
J J (0~20 m/S) HVTB HIGH VOLTAGE TERMINAL BLOCK
R17(DIG OUT) 17NO 53
ATB 17C AR6 (COMP1 TRIP) JP JUMPER
R18(DIG OUT) 18NO L1/L2/L3 POWER LINES
15 18C 54 LPS LOW PRESSURE SWITCH
(I) (U) AR7 (COMP2 TRIP)
EE65 J
LUG LUG GROUND
28A SPT1
S1 - - MB MICROSMART CONTROL BOARD
1 V+ 22A + (A5-SP1) 29A
COMP1 OLR OVER LOAD RELAY
23A ST2 + SUCTION PRESSURE TRANSDUCER
AIR VELOCITY SENSOR 3 - SH + SW SWITCH
AV TDS TIME DELAY SWITCH
2 SH DPT1
D1 - 30A TK MOTOR (PROTECTION) THERMAL CONTACT
GND - COMP1
TO VFD (A6-DP1) 31A TRANS TRANSFORMER
AO-MTR SPEED B1
26A
ST1
+
SH
+ DISCHARGE PRESSURE TRANSDUCER UVM VOLTAGE MONITOR RELAY
(0~+10V) 27A (A1-ST1) VFD VARIABLE FREQUENCY DRIVE
T1 O1 - SPLICE-CLOSED END
(A7-OP1)
24A + DISCONNECT TAB-1/4"
LEAVING AIR TEMP. SENSOR 25A T.OUT
(PTC : -10 ~ +50 C) SH SPT2
TERMINAL BLOCK OR
SH S2 - 28B TERMINATION POINT
SH - COMP2
(A8-SP2) 29B SUCTION PRESSURE TRANSDUCER INDICATOR LIGHTS
1 22B + + +
DIFF. AIR PRESSURE SENSOR 23B RH SH JUNCTION OF WIRES
2
- 30B DPT2
SH D2 - - COMP2 CROSSING OF WIRES
SH (A9-DP2) 31B NO CONNECTION
24B + + DISCHARGE PRESSURE TRANSDUCER
AMBIENT AIR TEMP. SENSOR SH
(PTC : -10 ~ +50 C) 25B TAE SH EARTHING / GROUND
USER INTERFACE BOARD SH
S1
NOTES
On/Off * O2 - 1. ANY WIRE REPLACEMENT, SHOULD BE OF THE
ON DIP
(A10-OP2) 90°C TYPE OR ITS EQUIVALENT.
SERIAL CABLE +
SET MENU * 2. USE COPPER CONDUCTORS ONLY.
TOUT=10°C TIN=15°C 1 2 3 4
COOLING 75% 3. COMPRESSORS ARE PROVIDED WITH INTERNAL
ESC * COM1 GND LINE BREAK THERMAL PROTECTION.
4. REMOVE GEN SET 12V BATTERY WIRE CONNECTION
WHEN UNIT IS NOT IN USE.
5. USE A DISCONNECT TAB OR WIRE NUT ONLY
WHEN REQUIRED FOR EXTENDING ORIGINAL WIRES.
MODEL
MAC240FZ601
PN:- REV 04
60020008 SHEET 02 OF 02
53

15. SYMBOLS AND LEGEND
ES
EMERGENCY STOP
COMPRESSOR # CONTACTOR PUSH BUTTON SWITCH S1
COMP FMC # CONDENSER FAN TOGGLE SWITCH
MOTOR A/CR_# (NORMALLY CLOSE CONTACT)
# MOTOR
HGS HVTB
FMC# CONTACTOR COIL SOLENOID VALVE L1 TERMINAL BLOCK
CONDENSER FAN # HGS# - HOT GAS BY-PASS L2 (MAIN POWER CONNECTION)
MOTOR CONDENSER FAN
FM # MOTOR (SYSTEM #) L3
# PT # PRESSURE TRANSDUCER LVTB

FM # - SPT# SUCTION PRESSURE TRANSDUCER
TK THERMAL CONTACT (SYSTEM #) # TERMINAL BLOCK
CC # CONTACTOR CONDENSER FAN MOTOR # + DPT# DISCHARGE PRESSURE TRANSDUCER (CONTROL WIRING)
COMPRESSOR # (NORMALLY CLOSED) (SYSTEM #) #
OPT# OIL PRESSURE TRANSDUCER
(SYSTEM #)
A/CR_# ATB
CC# CONTACTOR COIL RELAY COIL F#
COMPRESSOR # (GENERAL PURPOSE RELAY) FUSE # AUXILIARYTERMINAL BLOCK
(CONTROL WIRING)
MB
## MICROPROCESSOR BOARD
CC#A -1B CONTACTOR (AUXILIARY CONTACT) A/CR# - 1A EARTHING
RELAY CONTACT (MAIN BOARD) (GROUND CONNECTION)
(NORMALLY CLOSED)
COMPRESSOR # (NORMALLY OPEN)
AB
## MICROPROCESSOR BOARD
CC#A -1A CONTACTOR (AUXILIARY CONTACT) A/CR# - 1B (AUXILIARY BOARD) JUNCTION OF WIRES
(NORMALLY OPEN) RELAY CONTACT (CONNECTED)
COMPRESSOR # (NORMALLY CLOSED)
TRANS #
OLR # EXTERNAL OVERLOAD C.HTR # CRANKCASE HEATER ### CONTROL TRANSFORMER CROSSING OF WIRES
RELAY (COMPRESSOR #) (NO CONNECTION)
###
SW#
SELECTOR SWITCH LT# LED INDICATING LAMPS
OLR# - 1 EXTERNAL OVERLOAD HPS_#
RELAY CONTACT (NORMALLY OPEN CONTACT) DISCHARGE PRESSURE SWITCH
(NORMALLY CLOSED) P
(NORMALLY CLOSED) LT# SERVICE / BEACON LAMP
(NORMALLY CLOSE CONTACT)
F-1
FRESH AIR VENTS FRESH AIR FILTER COMPRESSOR MCP MAIN CONTROL PANEL
# SYSTEM #
DATA POINT
SUPPLY AIR FAN CP GENERATOR SET CONTROL PANEL
AI 8 1 ANALOGUE INPUT
I / O TABLE
AO 1 ANALOGUE OUTPUT
DI 8 DIGITAL INPUT AMBIENT AIR TEMPERATURE AIR VELOCITY

DIGITAL OUTPUT ATS SENSOR AVS SENSOR
DO 11
SUCTION PRESSURE DISCHARGE PRESSURE HIGH PRESSURE DIFFERENTIAL PRESSURE

SPT TRANSDUCER DPT TRANSDUCER HPS SWITCH DPS TRANSMITTER
F (FAIL)
UIB USER INTERFACE BOARD VFD VARIABLE FREQUENCY DRIVE PANEL INDICATOR LAMPS CB # A AUXILIARY SWITCH
(COMPRESSOR CIRCUIT BREAKER)
R (RUN)
54

16. UNIT OVERALL VIEW
55

UNIT REAR SIDE (GENERATOR SECTION)
56

OPTIONAL DOWN DISCHARGE PLENUM EXTENSION (FLEXIBLE DUCT STORAGE BOX)

57
DIESEL FILLING POINT & FUEL GAUGE
58

COIL SECTION
59

FAN & MOTOR ASSEMBLY
60

CONDENSER SECTION
61

OPERATIONAL PANEL
62

MAIN CONTROL BOX
63

VFD & GENERATOR
64

GENERATOR DISPLAY PANEL
65

GENERATOR SECTION
66

Mac 240

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Mac 240

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INSTALLATION,

MOBILE AIR CONDITIONING SYSTEM

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CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

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UNIT LEFT SIDE VIEW

2.1 BASE CHASSIS and CONSTRUCTION

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2.2 DIESEL ENGINE GENERATOR

The power generator of the MAC240 consists of the following components:

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C. Power Generator Control System:

Easy push-button control

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CAPACITY (TONS) @ 1150F AMBIENT 21

APPLICATION INDUSTRIAL, 100% FRESH AIR

POWER SUPPLY (V-PH-HZ) 460-3-60

COMPRESSOR Type SCROLL

Part # (Qty.) 800-674-19 (2)

Operating charge per system, oz 450

RLA/LRA, Amps 19.6/125

CONDENSER FAN & MOTOR Type PROPELLER

Part # (Qty.) 800-226-01 (2)

Nominal CFM 15000

Dia. (mm) 700

POWER SUPPLY (V-PH-HZ) 460-3-60

Motor kW - RPM - FLA - LRA 1.5 - 1000- 2.6- 10

EXHAUST FAN Size (mm) 700

Part # (Qty.) 800-237-03 (1)

kW - RPM - FLA - LRA 1.5 - 1000- 2.6- 17.4

MINIMUM CIRCUIT AMPACITY Amps 74

MAX. FUSE SIZE/CIRCUIT BREAKER Amps 90

UNIT KVA Amps 54.6

CONDENSER COIL Type Inner grooved tubes and enhanced fins

Tube Dia.- Rows - Fins per inch 3/8-5-14

Total face area (Sq. ft.) 25

EVAPORATOR BLOWER Type BACKWARD CURVED

Size (inch) DP/500

Drive type DIRECT DRIVE

Nominal CFM 2400

EVAPORATOR BLOWER MOTOR Motor KW 13.2

Motor frame IEC

EVAPORATOR COIL Type CORRUGATED FIN & TUBE

Tube Dia.- Rows - Fins per inch 1/2-12-10

Total face area (Sq. ft.) 6

HIGH PRESSURE SETTING OPEN - PSIG 450 ± 10

CLOSE - PSIG 360 ± 15

LOW PRESSURE SETTING OPEN - PSIG 25 ± 5

UNIT DIMENSIONS TRAILER MOUNTED - L x B x H (meters) 3.6 x 2.2 x 2.6

UNIT WEIGHT ( WITHOUT FUEL), KG 4000

TRAILER SPEED LIMIT 15 KM / H

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2. POWER GENERATING SYSTEM

3. AIR CONDITIONING SYSTEM

4. VEHICLE/ UNIT ENCLOSURE

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The unit consists of the following protective devices.

EQUIPMENT EXPLODED VIEW

01 GENERATOR 07 FRESH AIR INTAKE PANEL