HELPING YOU TEACH TECHNOLOGY
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1 600V HVAC TK TRAINER OPERATION MANUAL HELPING YOU TEACH TECHNOLOGY
2 600V HVAC TK TRAINER OPERATION MANUAL PRINTED IN CANADA All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. ConsuLab Educatech Inc 4210 Jean-Marchand Street Quebec City (Quebec) Canada G2C 1Y6 Phone : (Canada and USA) (USA) (Canada) Fax : info@consulab.com Web site:
3 TRAINER DESCRIPTION The 600V Stand-Alone Thermo King HVAC Training Bench is a secure, fully operational system. Trainer allows clear visualization of all component operation of the electrically operated HVAC system. The training bench is mounted in compliance with the manufacturer s specifications and standards, and wired according to OEM electrical diagrams. In addition to demonstrating basic system operation, the trainer provides student diagnostic exercises using manually inserted faults.
4 600V HVAC TK TRAINER 5 CONTROL PANEL IDENTIFICATION IntelligAIRE III controller 2. RS-232 programming port 3. Compressor run indicator lamp 4. Boost pump lamp (reheat (rh) mode) 5. Coolant valve lamp (reheat (rh) mode) 6. ATS (Ambient Temperature Sensor) sensor adjustment knob (allows the external temperature signal to be varied for system operation checks) 7. RTS (Return Temperature Sensor) sensor adjustment knob (allows the sensor signal to be varied for system operation checks)
5 NV C 600V HVAC TK TRAINER POWER & PRIME MOVER CONTROL UNIT IDENTIFICATION Main switch 2. A/C system input power lamp indicators 3. Motor starting switch 4. Motor run indicator lamp 5. DC power switch 6. Drive fault indicator lamp
6 DRIVE OPERATION WARNING Motor Control The speed displayed is the compressor speed reading. Drive Programming DISPLAY The drive programming is protected by an access code (code = 999) to avoid any programming change. OPERATION PROCEDURE 1. Plug the power cord into an appropriate power outlet. 2. Make sure that all the emergency stop buttons are disabled. 3. Power on the A/C system input switch. 4. Power on the motor using the key switch. 5. Make sure that the compressor speed reaches 750 rpm. 6. Power on the DC switch. The DC power indicator lamp should be ON. 7. Make sure that ATS and RTS adjustment knobs are set to minimum. 8. Use the IntelligAIRE III module to operate the HVAC system. Note 1: The HVAC system (Model Athena 960-M3) has been modified for half capacity of its operation. A section of the evaporator and another one of the blower motor have been removed, and Fuses F14 and F16 as well. CFM2 and CFM4 fans are disconnected. Note 2: The HVAC system contains half the amount of the refrigerant charge (R134A = 12 lbs). Note 3: The HVAC system is driven by a 15hp electric motor connected to an appropriate power outlet. The motor has been programmed to permit the compressor (Model X640) to reach a speed of 750 rpm.
7 FAULT INSERTION PROCEDURE 1. The manual fault box allows the insertion of single or multiple faults in the system. 2. Faults are inserted by selecting switches for each condition. 3. Use the key to lock the fault box following the fault insertion. FAULT DETAILS EFFECT RTS RTS ON: RTS sensor circuit is open. Forces the evaporator fan to stop. ATS CL COM ATS ON: ATS sensor circuit is open. CL ON: The compressor clutch power supply circuit is open. COM LOSS: The communication is lost. Forces the condenser fan to reach the maximum speed. Forces the compressor to stop. Forces loss of communication between the IntelligAIRE III module and the HVAC system.
8 4210 Jean-Marchand Street Quebec City, PQ Canada G2C 1Y6 Phone: (Canada & USA) (USA) (Canada) Fax: Internet:
HELPING YOU TEACH TECHNOLOGY
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