Temperzone OPA 171/211 RLTFYD (Econex Pro) Air Cooled Packaged Units - Installation & Maintenance
1. General
This document provides instructions for the installation and maintenance of Temperzone OPA Outdoor Air Cooled Packaged units to ensure optimum performance, reliability, and durability. Units must be installed in accordance with all national and regional regulations and bylaws, including National Health and Safety regulations. Local permits must be acquired, and local regulations on maximum boundary noise must be considered. The 'R32 Handling Ducted Packaged Units' pamphlet is part of these instructions.
WARNING: These units use R32 refrigerant (Class A2L), which is mildly flammable. The system must be installed, operated, and stored in a well-ventilated space. Contact with fire may produce poisonous gas. R32 is odorless. If stored indoors, keep away from continuous ignition sources like operating gas or electric heaters. This appliance is not intended for use by persons with reduced physical, sensory, or mental capabilities, or lack of experience, unless supervised. Children should be supervised to ensure they do not play with the appliance.
2. Installation
2.1 Location, Clearances & Service Access
Locate units in areas not accessible to the general public. Refer to the Specification Sheet for minimum clearances. If units are placed side-by-side, allow at least 2m between coil faces.
2.2 Mounting
Fasten the unit to a firm, flat horizontal base using the provided mounting channels. For roof installations, use a substantial structure with vibration-isolating pads or mounts. For ground or concrete pads, use rubber pads or mounts to provide a minimum 20mm ground clearance. Flexible duct connections are recommended. Ensure compressor shipping wedges are removed before starting the unit.
For plant room installations, ensure sufficient ventilation. Discharge air must be ducted away to prevent recirculation, which reduces efficiency. Never install the unit in a totally enclosed room.
2.3 Condensate Drains
Condensate drains should be 'U' trapped outside the unit with a vertical height of at least 100mm. Drain lines must slope at least 1 in 50 and must not be piped above the unit drain pipe. A diagram illustrates the recommended drain setup with a U-trap and vent pipe for long runs.
4.1 Electrical Requirements
Electrical work must be performed by a qualified electrician according to AS/NZS 3000. DANGER: Isolate mains power before working on the unit. Only qualified and trained personnel should perform service and maintenance.
The unit must be wired directly from a distribution board using an appropriately sized circuit breaker. A lockable isolating switch is required near, but not on, the unit. Refer to Appendix VI for cable entry locations and wiring paths. A 24-hour power supply to the compressor crankcase heaters is mandatory for warranty.
4.2 Controls Wiring
A communication cable entry hole is provided. Control methods include Sensors and Inputs, BMS BACnet Interface, BMS Modbus Interface, and Standalone. Section 4.3 provides details on sensor and input requirements for each method.
3. Refrigeration System
3.1 General
These OPA models feature a single inverter compressor for variable speed operation and part-load efficiency. The system is charged with R32 refrigerant.
3.2 Compressor
The compressor is an inverter scroll type, using polyolester oil (POE), which absorbs moisture quickly if exposed to open air.
3.3 External Economiser Function (Option)
The OPA Econex Pro can work with an external economiser damper setup. When outdoor air enthalpy is lower than return air enthalpy, a fresh air damper opens and a return air damper closes for first-stage cooling. Spill air may be needed if the return air damper is closed. The fresh air damper should return to minimum, and the return air damper open before compressors operate for further cooling.
3.4 Fresh Air (Option)
Fresh air flow through the in-duct damper should not exceed 25% of the unit's nominal airflow. Excessive low-ambient fresh air can reduce performance, especially on heating cycles. Adjust fresh air to meet CO₂ sensing requirements. In-duct damper settings depend on return air duct static pressure and design airflow. Airflow balancing is recommended. Excessive fresh air introduction may void the unit's warranty.
4. Wiring
4.3 Sensors & Inputs
A table details sensors and inputs required for different control methods (Sensors and Inputs, BMS BACnet/Modbus, Standalone). It lists inputs like Room Temperature, Room RH%, ID Fan Speed, RA Temp/RH, FA Temp/RH, SA Temp/RH, and CO2, along with their corresponding pins and signal types. Notes clarify sensor fitting, BMS overrides, and requirements for economiser options.
4.4 BMS - BACnet Interface
Install an Ethernet CAT 5 STP shielded cable between the Carel c.pCO mini controller and the BMS network switch. The default IP address is 192.168.1.10, with a subnet mask of 255.255.255.0. Refer to Appendix II for IP address changes.
4.5 BMS - Modbus Connection
Connect to terminals in the electrical box as per the specifications document. Diagrams show RS485 terminal blocks and shield grounding recommendations for master/slave networks. Information on network configurations, including multiple units and optical isolation, is provided.
4.6 Stand Alone
Option 1: Install an optional Carel pGDN remote display. Option 2: Use the on-board Carel c.pCO mini controller with its digital display.
4.7 Remote on/off
This can be achieved via the optional Carel pGDN remote display or a low-level BMS 24V signal to the 'ENB IN' terminal.
4.8 Economiser Wiring
Refer to the specifications document for wiring schematics. The unit is pre-wired for standalone economiser operation.
5. Economiser
An economiser package includes two external in-duct opposed blade dampers (fresh air and return air) with 0-10V dc controlled damper motors. The system must prevent water ingress. When outdoor temperature and enthalpy are below return air conditions, the fresh air damper opens, and the return air damper closes for first-stage cooling. Refer to Section 4.3 for sensor requirements and Section 6.3 for configuration.
Damper minimum and maximum openings can be adjusted via the Master Controller's Menu/Settings/Damper Config. Settings can be made for occupied and unoccupied modes, and for CO₂ air quality sensors. Local building codes may require 10-15% minimum fresh air. Ensure airflow is equal between full return air and full economiser by adjusting damper stops.
6. Start-Up Procedure
6.1 Before starting the compressors
- Isolate mains power before working on the unit.
- Remove compressor shipping wedge and check mounting.
- Check mains power and controls wiring.
- Check tightness of all electrical connections.
- Check air filters are installed (if applicable).
- Ensure indoor fan motors rotate freely.
- Check supply voltage between phase and neutral.
- Verify in-duct dampers, air diffusers, and ductwork are open.
- Apply mains power by closing the isolating switch.
- A four-hour delay period is required for crankcase heaters to drive liquid refrigerant out of the compressor oil. Mains power must remain on during this period.
6.2 Master Controller Display (Carel c.pCO mini)
The controller display shows system status. Buttons include Alarm (for indication and reset), Menu (to access the main menu), and Esc (to return to previous page or exit). The Main Menu offers options like Information, Settings, Communication, Service, Manufacturer, Alarms Logs, and Scheduler.
Commissioning: A Temperzone Technician is required for commissioning. After the 4-hour delay, use the Commissioning Sheet. Steps involve accessing the Service menu, Manual Control for Indoor Fans (setting airflow) and Compressors (setting capacity), and Fan Config (setting fan mode and airflow). Notes highlight the impact of incorrect fan speeds. Outdoor fans may run on after compressor stops. Indoor fans may reduce speed in heating or latent cooling modes.
7. Operation
7.1 BMS – BACnet
Configure the IP address as per Appendix II. To start the unit via BACnet, write to specific BACnet objects for Unit On/Off, Cooling/Heating Setpoints. If Room Temperature and RH% are measured by BMS, write to corresponding override objects. Airflow can be adjusted via the Air Flow Setpoint object.
7.2 BMS Modbus
Refer to the 'OPA Econex Pro Technical Guide' for Modbus command information.
7.3 Stand Alone Unit
Master controller site set-up: Access the Main Menu via the Program button. Navigate through Settings to Set Points, Occupied/Unoccupied settings, and Deadbands. Options for Dehum Reheat, Night Mode, Unoccupied Time Clock, Fan Control Method (Airflow, Fixed Speed, 0-10VDC), Constant Airflow, and No Load Fan settings are available. Damper configuration for Economy Mode and CO₂ Control is also accessible.
Unit Power ON/OFF: From the Home screen, select the ON/OFF symbol and confirm to turn the unit on. Controller Info displays software version and other status.
8. Maintenance
WARNING: Isolate all power supplies before performing maintenance.
8.1 Monthly
- Check and clean/replace air filters.
- Check condensate drain for free drainage.
- Inspect compressor compartment for oil stains indicating refrigerant leaks.
- Check system operating pressures via the Carel c.pCO controller.
8.2 Six Monthly
- Check tightness of electrical connections.
- Check for corrosion on electrical connections, especially in high salt atmospheres.
- Check tightness of fan motor mountings.
- Check system operating pressures via the Carel c.pCO mini controller.
- Check condensate drain for free drainage.
8.4 Yearly
- Inspect refrigerant piping for chafing and vibration.
- Check air supply at all diffusers.
- Check for excessive noise and vibration.
- Inspect insulation and ductwork for damage.
- Check sensor values and adjust offsets if necessary.
- Check system operating pressures via the Carel c.pCO mini controller.
- Clean outdoor coil fins with a soft brush or low-pressure water spray. Increase frequency in corrosive environments.
- Touch up any paintwork damage.
9. Troubleshooting
9.1 Room temperature varies significantly
Possible causes include incorrect unit sizing, drafts affecting the sensor, or poor air circulation.
9.2 Air conditioner not delivering heat
Check heating capacity at design conditions, consider heat losses. Units have de-icing cycles that may temporarily reduce heating.
9.3 New building performance
New buildings with significant concrete or structural materials may take time to heat properly due to stored cold and moisture.
9.4 Unit leaking water
Check drain trap, vent, and slope. Reduce maximum fan speed if water carry-over occurs. Ensure the fresh air damper is not open by BMS when raining.
9.5 Air conditioner runs excessively
Check for open windows/doors, blocked outdoor coils, incorrect sensor location, or duct leaks.
9.6 Unit displays an error code
Refer to the UC8 Controller label, the www.temperzone.biz website, or press the Alarm button on the controller for fault information.
10. Warranty
Refer to the separate warranty document supplied with the unit or visit www.temperzone.com for details. Contact information for Australia and New Zealand is provided.
Appendices
Appendix I: Controls Set-up: Menus Map
Details the menu structure of the Master Controller, including Information, Settings, Communication, Service, Alarms Logs, and Scheduler sub-menus.
Appendix II: Controls Set-up: IP Address
Instructions for changing the default IP address of the controller, including network settings like IP, Mask, GW, and DNS.
Appendix III: Master Controller: System Information
Explains how to access UC8 controller information screens, showing variables like suction superheat, expansion valve position, and providing a key to abbreviations.
Appendix IV: UC8 Protection Functions
Details various protection functions implemented by the UC8 controller, including High Pressure (HP), Low Pressure (LP), Indoor Coil Frost Protection, High Discharge Line Temperature (Hi-t), High Discharge Superheat (Hi-dSH), Low Discharge Superheat (LO-dSH), High Evaporation Temperature / High Suction Line Temperature (Hi-SL), other alarms, Lock-out conditions, and Safety Timers (Minimum off time, run time, cycle time, mode change-over time).
Appendix V: Air Handling Performance
Presents graphs illustrating available external pressure versus airflow for OPA 171 and OPA 211 units at various fan speeds (indicated by voltage or current). Notes advise on selecting airflow and coil face velocity to avoid water carry-over, especially in high humidity conditions.
Appendix VI: Connection Wiring Paths
Provides diagrams and notes on wiring connections, emphasizing the separation of low and high voltage wiring. It shows typical power supply and BMS communication cable routing and connection points.
Commissioning Check List
A checklist for installers to complete during unit commissioning. It includes checks for unit mounting, drain trap, water drains, access, electrical terminals, compressor blocks, refrigeration leaks, and airflow balance. It also includes sections for marking UC8 dip switch positions and recording monitored conditions during operation.
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