Instruction/ maintenance manual of the product FM American Power Conversion
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Operation, Maintenance, and T roubleshooting NetworkAIR ® FM DX Precision Air Conditioner 60 Hz.
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American Power Conversion Legal Disclaimer The information presented in this manual is not warranted by the American Power Conversion Corporation to be authoritative, erro r free, or complete. This publicatio n is not meant to be a substitute for a detailed operational and site specific development plan.
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Content s NetworkAIR FM DX 60 Hz Opera tion, Maintena nce, and Troubl eshooting i General Information................... ...................................... 1 Modules, Systems, and Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Module .
NetworkAIR FM DX 60 Hz Operatio n, Mainte nance, and T roubleshooti ng ii Commissioning Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Initial Inspection Checklis t . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NetworkAIR FM DX 60 Hz Operat i on , Mai nte na nc e , an d Trou bl eshooting iii Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Temperature alarms . . . . . . . . . . . . . . . . . . . . . .
NetworkAIR FM DX 60 Hz Operatio n, Mainte nance, and T roubleshooti ng iv Network Management Card ........ ................... ............... 61 Quick Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Overview .
NetworkAIR FM DX 60 Hz Operat i on , Mai nte na nc e , an d Trou bl eshooting v Troubleshooting .......... ................... ................. .............. 75 Warranty ........................................ ................... .............. 81 One-Year Factory Warranty .
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NetworkAIR FM DX 60 Hz Operati on , Maintenance, an d Tr oubleshooting 1 General Information Modules, Systems, and Group s NetworkAIR Modules and Expansion Modules can be combined electronically to create Systems and Group s .
NetworkAIR FM DX 60 Hz Opera ti o n, Maintenance, an d T roubleshooting 2 Group A Group is a set of two, three or four Systems that work together to provide redundan cy and load sharing capabilities.
3 NetworkAIR FM DX 60 Hz Operati on, Maintenance , and Troublesho oting Safety Symbols Used in this Manual Save these instructions This manual contains important instructions that must be followed when servicing this equipment.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 4 Safety Hazards Lockout/t agout W arning: Make sure to follow the lockout/tagout procedur es for your site to r emove access to a device and physically label the devi ce as intentionally out of service while servicing this equipment.
5 NetworkAIR FM DX 60 Hz Operati on, Maintenance , and Troublesho oting Operation Display Interface Item Function Major Alarm LED When lit, a ma jor alarm condition exists. Minor Alarm LED When lit, a minor alarm condition exists. Check Log LED When lit, at least on e new major alarm or minor alarm or event has occurred.
NetworkAIR FM DX 60 Hz Opera ti o n, Maintenance, an d T roubleshooting 6 Using the Display Interface Scrolling st atus screens The first time you apply power to the Module, the display initializes and runs an LED and alarm- tone test. After start-up, the interface displays the firmware revision number (if the fast start-up is disabled).
7 NetworkAIR FM DX 60 Hz Operati on, Maintenance , and Troublesho oting Main menu screen On any top-level stat us screen, press the E NTER or E SC key to open the main me nu screen. Note: I f the display interface is inactive for ten minut es (the default delay), it will return to the scrolling status screens.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 8 St ar t the Sys t em Path: Main Menu > On/Off T o start the System, select the On/Off option on the main menu and change th e setting to On . The System will run according to the current settings under C o n t ro l E nv i ron m en t .
NetworkAIR FM DX 60 Hz Opera t ion, Maintenance, an d Troublesho oti ng 9 Commissioning After installation, verify that all components are working properly and that the Module is ready to begin operation.
NetworkAIR FM DX 60 Hz Opera ti o n, Maintenance, an d T roubleshooting 10 Power On/Off Procedure Power on 1. T u rn utility power on. 2. Set each main breaker located behind the left door to the “1” (ON) po sition by pushing each breaker lever to the left.
11 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Commissioning Checklist s Initial Inspection Checklist W arning: Review the safe ty and data sheet (M SDS-Material Safety Data Sheet) for R-22 for safe handling of the refrigerant.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 12 Electrical Inspection Checklist Electrical Hazard: All electrical wiring must comply with national and local codes. The equipment mu st be grounded to an earth ground (do not use a water -pipe ground).
13 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Mechanical Inspe ction: Air-cooled Checklist W arning: Air -cooled equipment is shipped from the factory with a nitr ogen holding charge. Remove the nitr ogen holding charge using the multiple Schrader valves located on the internal r efrigerant piping.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 14 St art-up Inspection Checkli st While the equipment is operating, ensure that: The sight glass moisture sensor is green.
15 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Final Inspection Checklist Owner Accept ance T o ensure proper unit operation and trouble free op eration the following procedure s must be completed and filed with the custom er for future reference.
NetworkAIR FM DX 60 Hz Opera ti o n, Maintenance, an d T roubleshooting 16 System Configuration The System config uration options are defined both at the factory and durin g the commissioning of the Modules in the System. Caution: Changing the settings inco rrectly can cause serious ma lfunctions and damage to your System.
17 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Humid Ctrl. Indicates the humidity control method. The System can contro l the humidity based on the relative humidity ( RH ) of the return air and the dew point ( DewPt ) of the return air .
NetworkAIR FM DX 60 Hz Opera ti o n, Maintenance, an d T roubleshooting 18 # PCIOMs. Set the number of Programmable Customer Input/Output Modules (PCIOMs) installed in the user interface box. This setting controls the number of input contacts and output relays available in the Input/Output menu.
19 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting System delays Path: Main > Setup > System # > System Config > System Delays The System Delays protect the Modules in the Sy stem from excessive wear and dama ge a nd keep the modes (cooling, rehe at, and de humidi fy) from working against each other .
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 20 Building management Path: Main > Setup > System # > Sy stem Config > Building Management If you are using a build ing management system with your Module, you must set the following values: Address.
21 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Settings for fluid-cooled options Modules using the Economizer or MultiCool options ha ve several settings that must be defined. T o accommodate the heat of the rejection metho d, the valve and piping setti ngs must be configured.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 22 Va l v e t y p e s Path: Main > Setup > System # > System Config > V alve T ypes Flow Switch.
23 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Economizer isolati on valve (optional) When multiple Modules having three- way valves are connected to a common coolant source, coolant flow through a Module exists even when there is no cooling demand.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 24 Coil fluid temperature acti vation threshold and deadband Path: Main > Setup > System # > Sy stem Config > Coil Fluid Options The Coil Fluid Options help control the optional MultiCool coil or Economizer coil in equipped Systems.
25 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Cont act s and Relays The System can monitor external contact clos ure events for the following applications: • Magnetic con.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 26 Action. Set the System controller to respond to the change of status for an input in one of the following ways: Map Description/Function Status Only Displays the event on the Active Alarms screen.
NetworkAIR FM DX 60 Hz Opera t ion, Maintenance, an d Troublesho oti ng 27 Output relays Path: Main >Setup >System # >Input/Output >Output Relays The Main Module supports up to 16 user -defined ou tput relays. Output rela ys respond to internal alarms and events by changing states to notify outside devices.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 28 Module Configuration The Module configuration settings define which comp on en ts are availab le and how the Modu le sh ou ld operate. Caution: The settings in the Module Configurat ion me nu are defined at the factory .
NetworkAIR FM DX 60 Hz Opera t ion, Maintenance, an d Troublesho oti ng 29 Module Control The Module Control op tions are configured an d tuned during the commissio ning of each Module. Caution: The settings in the Module Control menu are defined at the factory .
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 30 Reset V ariable Frequency Drive Paths: Main > Setup > Module > Main Mod ule > Module Control > Reset VFD# Main > Setup > Module > Exp a nsion Mo dule 1 > Module Control > Reset VFD# The Reset VFD option resets the variable frequency driv e (VFD).
31 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Control the Environment The System controls the ro om environment by engagin g one of four modes: Cool, Deh umidify , Reheat, or Humidify . These modes may work differently dependi ng on the options a nd eq uipment installed in the Modules.
NetworkAIR FM DX 60 Hz Opera ti o n, Maintenance, an d T roubleshooting 32 DX Dehumidify . Similar to DX cooling, the output for de humidification is de termined by the difference between the setpoint and the average re turn humidity from each of the Modules in the System (if more than one Module is present).
33 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Setpoint s Path: Main > Control Envir onment > Setpoints Setpoints are the target values each mode will maintain in the room. Th e default setpoints are appropriate for most precision cooling ap plications.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 34 Deadbands Path: Main > Control Environment > Deadbands The deadband is the sensitivity rang e for a setpoint. It is the value ab ove or below the setpoint at which the mode will output at full capacity .
35 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting The following graphic is an example of a two-Module System (with four compre ssors).
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 36 Dehumidify deadband. The Dehumidify mode splits the deadba nd into equal segments according to the number of Modules in the Syst em. A Module is then assigned to each segment of the deadband above the setpoint.
37 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Modes Path: Main > Control Environment > Modes Enable and disable the modes of operation. The four modes are: • C o o l • Reheat • D e h u m i d i f y • H u m i d i f y Modes can only be enabled or di sabled using the service password.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 38 PID controls Path: Main > Setup > System # > System Config > PID Controls The Proportional plus In tegral plus Derivative (PID) loop is used to con trol the output of the LiquidCool, reheat, and dehumidify modes.
39 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting 6. Note the time, in minutes, betw een the peaks of the oscillations. This is the Ult i mate Period, P U. 7. Note the value of the proportional co nstant. This is the Ultimate Gain, G U.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 40 Alarms Set alarms to alert you to abnormal temperatures or humidity levels and the number of hours the components have b een in operation. See “Respond to Alarms” on page 52 for info rmation on how to correct these conditions.
41 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Component name. Scroll through the components to view the maintenance intervals: • B l o w e r 1 • B l o w e r 2 • Heater • H u m i d i f i e r • V a riable Frequency Drive 1 (VFD 1) • V a riable Frequency Drive 2 (VFD 2) • Compressor 1 • Compressor 2 Alarm.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 42 Group Up to four Systems can be connec ted to form a redundant Grou p. Jo ining Systems together to form a Group provides the .
43 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Comm Loss Failover . Decide if the Group considers a System in the Comm Lost state to be in a failed state. • Off —The Group will assume that the System is still operating normally .
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 44 System Role Assignment. The System Role Assignment settings depend on th e Run-time Balance ( Run-time Bal ) setting.
45 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Display Set display settings including the ti me and date, temperature units, pa sswords, and time-out settings. Y ou can also reset settings to their defa ult values and download new firmware.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 46 Adjust display Path: Main > Se tup > System > Display > Display Ad just Set the LCD contrast. Adjust the visibility of the screen text. Lower numbered settings provide darker text; higher numbers provide light er text.
47 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Reset to default s Path: Main > Setup > System # > Display > Reset to Defaults Reset User Parameters . Return settings that can be modified with the user password to their factory default settings.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 48 Network Configuration Configure the network settings for the Network Ma nagement Card from the di splay interface. The management card allows remote cont rol and configuratio n of the System.
49 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting V iew S t atus Readings The display interface has several options for vi ewin g the statu s of the System, its Modules, and the environment bein g co ntrolled.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 50 System st atus Path: Main > St atus > System # The System status screens include information about the entire System.
51 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting V iew Event Log The event log saves status information and a messag e each time a change in the System is detected. Alarms and ev en ts are re co rde d in the log. However , status events (informational) are only displayed on the active alarm s sc ree n.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 52 Respond to Alarms When an alarm is triggered, the Main Module alerts you through th e display by the foll owing methods: • A.
53 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Alarm messages and suggested actions Displayed Alarm Message Action Required Air Block Interlock Open • V erify that the air block panels are in place. • Confirm that the wiring connections fo r the air block in terl ock switches are secure.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 54 Condensate Pump Fail • V erify that the condensat e pump circuit breaker has not been tripped. • Ensure that the wiring between the float switch for the condensate pump and the controller is secure.
55 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Env T emperature Low • V erify that no supply air is fed directly back into the return air . • Ensure th at the alarm delay is not set too low . The delay should be long enough to allow the room temperat ure to stabilize after start-up.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 56 Group Configuration Invalid • Check that the # Sy stems setti ng ( Path: Main > Setup > Gr oup > Gr oup Config ) agrees with the actual number of Systems connected to the Group.
57 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Humidifier Cylinder Depleted • R eplace the disposable cylinder . • Clean the reusable humid ifi er cylinder (optional). Humidifier Cyli nder Full When Off • Check the humidifi er fill and dr ain valves for clog ging.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 58 MultiCool Coil No Coolant Flow • V erify the flow from the chilled water supply . • Check the operation of the flow switch. • Check the electrical connect ions to th e flow switch.
59 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Supply Humidity High • V erify that the suction pressure is not below 5 8 psig (4 00 kPa). • Ensure th at the alarm delay is not set too low . The delay should be long enough to allow the Module to contro l the hu mitity after start-up.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 60 System Comm Lost • Check that the System is receiving power . • Check the external CAN bus connections. • Check th e System ID DIP switch settings of every Main M odule in the Group.
NetworkAIR FM DX 60 Hz Operat i on , Mai nte na nc e , an d Trou bl eshooting 61 Network Management Card Quick Configuration The NetworkAIR FM DX is shipped with a Network Management Card that enables you to manage the air conditioner over y our network.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 62 APC Device IP Configuration Wizard Y ou can use the APC Device IP Configu ration W izard at a computer running Microsoft W indows 2000, W indows 2003, or W indows XP to configure a Network Management Card.
63 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting 2. When the Network Management Card rebo ots, the BOOTP server provides it with the TCP/IP settings. – If you specified a bootup file name, the Netwo rk Management Card attemp ts to transfer that file from the BOOTP server using TFTP or FTP .
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 64 Remote access to the control console From any computer on the same subnet as the Netw o rk Management Card, you can use ARP an.
65 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Control console After you log on at the contro l console, as desc ribed in “Remote access to the control console” on page 64: 1. Choose Network from the Control Console menu.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 66 Access a Configured Unit Overview After the NetworkAIR FM DX is running on your ne twork, you can use the interfaces summarized here to access the NetworkAIR FM DX. See the User ’ s Guide for more information on the interfaces.
NetworkAIR FM DX 60 Hz Operat i on , Mai nte na nc e , an d Trou bl eshooting 67 SSH for high-security access. If you use the high security of SSL for the W eb interface, use Secure SHell (SSH) for access to the control consol e. SSH encrypts user names, passwords, and transmitted data.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 68 Recover From a Lost Password T o acces s the control console, you can use a local co mputer (a computer that connects to the Network Management Card or other de vice through the serial port).
69 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Maintenance Monthly Preventive Maintenance The following pages can b e photocopied and used du ring the maintenance procedures. After they have been filled out, save for future reference.
70 NetworkAIR FM DX 60 Hz Operatio n, Maintenance, and Troubl eshooting Mechanical Check the evaporator fans and motors. All componen ts should be moving freely with no signs of binding or damage. Check the condenser fluid cooler motors, fan blad es, and fan guards.
71 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Quarterly Preventive Maintenance * Perform all the Monthly Preventive Main tenance items and the items below .
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 72 Functional test s V erify the following modes of opera tion: • Full cool in g • Full reheat • Humidification • Deh.
73 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Semi-Annual Preventive Maintenance * Perform all the Monthly/Quarte rly Prev entive Ma intenance items and the items below .
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 74 Functional test s Measure the refrigerant pressures. Check the operation of the thermal expansion val ve.
NetworkAIR FM DX 60 Hz Operat i on , Mai nte na nc e , an d Trou bl eshooting 75 T roubleshooting Problem Possible Cause Corrective Action Airflow too low • Blower set ting too low • Dirty or bloc.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 76 Compressor fails to start • Cooli ng mode disabled • Cooli ng setpoint too high • Compressor circuit breaker is tripped .
77 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Compressor noisy • Compressor or compressors may be rotating in the wrong direction • Liquid slugging • High head pressure • V erify the pressure differential across the suction and dischar ge for each compressor .
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 78 Head pressure too low • L ow refrigerant charge • Conden ser fan settings too low • Conden ser water regulating valve malfunction • System requ ires flooded condenser control during lo w ambient conditions • Check subcoo ling and ensure it i s at least 10-15 ° F .
79 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting Suction pressure too low • D irty or blocked evaporator coi l • Dirty or blocked air filters •L o w a i r f l o w • Low return air temperature • Low refrigerant charge • Liquid line filter drier is b locked • High evaporator superheat • Clean evaporator coil.
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NetworkAIR FM DX 60 Hz Operati on, Maintenance , and Troublesh o oting 81 W arranty One-Y ear Factory W arranty The limited w arranty provided by American Power Conversion (A PC ® ) in this Statement of Limited Factory W arranty applies only to products you purch ase for your commercial or industrial use in the ordinary course of yo ur business.
NetworkAIR FM DX 60 Hz Opera tion, Maintenanc e, and Troubles ho oting 82 IN NO EVENT SHALL APC, ITS OFFICERS, DIRECTORS, AFFILIA TES OR EMPLOYEES BE LIABLE FOR ANY FORM OF INDIRECT , SPECIAL, CONSEQU.
83 NetworkAIR FM DX 60 Hz Op erati on, Maintenance , and Troublesho oting W arranty Procedures Claims T o obtain service under the warranty , contact APC Cu stomer Support (see the ba ck cove r of this manual for contact information). Y ou will ne ed the model number of the Product, the serial number, and the date purchased.
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10/2007 990-3127 *990-3127* APC W orldwide Customer Support Customer support for this or any other APC product is available at no char ge in any of the following ways: • V isit the APC W eb site to acce ss documents in the APC Knowledg e Base and to submit customer support requests.
An important point after buying a device American Power Conversion FM (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought American Power Conversion FM yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data American Power Conversion FM - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, American Power Conversion FM you will learn all the available features of the product, as well as information on its operation. The information that you get American Power Conversion FM will certainly help you make a decision on the purchase.
If you already are a holder of American Power Conversion FM, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime American Power Conversion FM.
However, one of the most important roles played by the user manual is to help in solving problems with American Power Conversion FM. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device American Power Conversion FM along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
