Calorex PORTA TEMP 240 Service Manual

Full Text Searchable PDF User Manual

Page1

AIR CONDITIONING

PORTA TEMP 240/320DX

CAUTION

PLEASE READ THIS LEAFLET CAREFULLY

1. DO NOT APPLY MAINS WATER PRESSURE TO THIS UNIT. WHERE
APPROPRIATE, ACCESS TO THE FILLING POINT FOR THE WATER
CIRCULATING SYSTEM IS REACHED BY THE REMOVAL OF THE FILLER
ACCESS PLATE IN THE ROOM UNIT BACK PANEL.
2. WHEN REMOVING THE UNIT FROM AN INSTALLATION DISCONNECT WATER
QUICK COUPLINGS IN THE ROOM UNIT FIRST.

INTERNAL ACCESS SHOULD BE RESTRICTED TO CALOREX TRAINED STAFF
ONLY.

SD259755 ISS 4

Page 2

BLANK PAGE

Page3

DO NOT LET HEAT EXCHANGER HANG
FROM ITS FLEXIBLE LINE

SUPPORT HEAT EXCHANGER
WEIGHT USING HOOKS
AND CHAINS PROVIDED
OR STAND ON FIRM

GROUND.

DROPS OF CONDENSATE
MAY APPEAR HERE

Fig 1

PAC240 SHOWN

EXTERNAL HEAT EXCHANGER (HEX).

The heat exchanger must stand external to the area
being cooled and, preferably, in the outside atmosphere.
It can stand freely on a flat surface or, in the case of the
PAC.240 may be hung in the upright position from a
sindow sill, balcony etc, see Fig 1. USE THE CHAINS
PROVIDED TO SUPPORT THE HEAT EXCHANGER.
IT WOULD BE HIGHLY DANGEROUS TO SUPPORT
THE HEAT EXCHANGER BY MEANS OF THE
FLEXIBLE LINES ALONE.

CONDENSATE.

In operation, the room unit is constantly condensing water
vapour out of the atmosphere (reducing relative
humidity). This water has to be drained away. An
automatic condensate pump is fitted inside all room
units. The flexible hose outlet from the condensate pump
runs to the outside, inside the flexible sheath , the
condensate is deposited in the base of the heat
exchanger, considerable re-evaporation of this water
takes place on the warm air stream passing through and
around the heat exchanger, but please remember that
there will also be a degree of dripping through the base
of the heat exchanger.

HAVE GREAT REGARD FOR THIS CHARACTERISTIC
WHEN POSITIONING THE EXTERNAL HEAT
EXCHANGER.

The flexible water pipes should be routed so as to avoid
any possibility of kinking or unnecessary restrictions to
the flow of water inside. Also, remember that plastic
and rubber becomes much more flexible when warm
and, as a result, much more susceptible to distortion.

5) MACHINE LINK-UP.

Ensure the mains supply lead to the room unit is
disconnected. A 5m (extendable to 30m) line set to
connect water between the room unit and the external
heat exchanger will have been supplied. The water pipe
connections are by means of “quick connect couplers”.
These are simple “push-on” connectors which, when
disconnected (after pulling back sprung loaded locking
ring), re-seal the water system on either side. The
complete system will have been filled with the necessary
amount of water/antifreeze prior to its arrival on site. A
condensate drain pipe coupler 6mm clear polythene
(push fit), should also be connected. Having made the
couplings, the system is operational immediately.

WARNING !

This unit MUST be transported and operated in the upright
position at all times.

1) COMMISSIONING INSTRUCTIONS

As standard, these units are supplied with a NEMA power
plug attached to the power supply cord. They require a 208/
230volt 1 phase 60Hz supply with the following appropriately
protected current rating:-
PAC.240 20 AMPS
PAC.320 30 AMPS
The size of any extension cable that may be used is as
follows and must be rated above the fuse size also allowing
for voltage drop and be suitable for the environment:
PAC.240

14AWG up to 30 feet
12AWG over 30 feet

PAC.320

10AWG up to 30 feet
8AWG over 30 feet

If the cable is on a "cable drum" then ensure that it is
completely unwound; serious complications will occur
otherwise.

2) SYSTEM DESCRIPTION.

The system comprises a room unit cooling section, an
external heat exchanger and the two are inter-connected
by means of flow and return water pipes and an electrical
supply to the heat exchanger fan.The room unit is fitted
with an automatic condensate disposal pump which
discharges the condensate via a small plastic pipe

into

the base of the external heat exchanger

and all

interconnecting pipes and electrics are enclosed in a flexible
plastic sheath. In addition, both ends of each pipe are fitted
with "quick connect" couplings that open on coupling but
reseal to become water tight on disconnect.

3) AIRFLOW

The angled outlets at the top of the room unit are fitted with
air grilles that allow the angle of air outlet to be adjusted
vertically and horizontally and, in conjunction with the fan
speed control switch, the air velocity and direction can be
carefully set up to obtain maximum coverage of the area
being cooled without causing drafts. Care should be taken
to avoid outlet air being obstructed as this will cause the air
to "eddy" around the unit resulting in recirculation and short/
inaccurate cycling of the machine. Ideally, cold air should
be directed to create a "blanket" all across the ceiling area
allowing natural convection to drop the air over the whole
area at very low velocity.

4) SITING

Ideally, the room unit should be positioned equidistant along
the shortest wall in the room

blowing down the length of

the room. If there is more than one unit in the same area,
then they would normally be positioned side by side, and
equidistant along the long wall, all pointing in the same
direction. Sometimes it may be necessary to position units
around the perimeter of an area but, in this case, great
care should be taken to avoid one unit blowing cold air
straight into another which will adversely affect the machine
operation. Good and correct air flow is, perhaps, the single
most important aspect of satisfactorily applying portable
air conditioners. If in doubt seek the advice of your supplier.

Page 4

6) ROOM UNIT WATER LEVELS

The water system in the room unit will be to the correct
level when delivered. However if for some reason the level
has fallen, antifreeze (33%) and water will have to be added.
The header tank filler and level indication is located to the
rear of the room unit and can be accessed by removing the
two screws holding the security plate over the filler tank
cap, see Fig 2. Ensure the machine is running in cooling
mode before removing the header tank cap, and as with all
pressure caps, remove slowly. It is recommended that a
mixture, by volume, of one part antifreeze to two parts water
is utilised, this will prevent freezing down to an external
temperature of -30°C/-5ºF. The approximate total volume
the systems, room unit with external heat exchanger and
lines is as follows:-

DO NOT APPLY MAINS WATER PRESSURE TO THE
SYSTEM.

Fig 2

10
C

THERMOSTAT

KNOB

MAINS LIGHT

(RED)

MODE

SWITCH

FAN ONLY
POSITION

COOLING

POSITION

FAN SPEED

SWITCH

FAN SPEED

HIGH

FAN SPEED

LOW

COOLING LIGHT

(GREEN)

ATTENTION LIGHT

(AMBER)

HIGH

PRESSURE

RE-SET

LOW

PRESSURE

RE-SET

DEFROST

LIGHT (WHITE)

OFF

POSITION

7) OPERATING INSTRUCTIONS.

The Control Panel on the room unit is illustrated below,
see Fig 3.
a) Revolve thermostat knob fully CLOCKWISE to the
number "8" position.
b) Plug in the room unit mains cable, and switch on
electricity, red mains light will illuminate.
c) Select "Fan Only" with the mode switch. The fan will
start.
d) Select "Fan Speed", with the fan speed switch, high or
low depending on air velocity required.
e) Select "Cooling" with the mode switch, and revolve the
thermostat knob fully ANTI-CLOCKWISE to the number
"1" position. If fitted the external heat exchanger fan and
the water pump in the room unit will start. After a delay of
10mins the green "Cooling" light will illuminate and the
machine will proceed to cool the air.
f) Monitor the room temperature and when it has reduced
to the desired level, very slowly revolve the thermostat knob
back, clockwise, until the green "Cooling" light goes out.
The room unit will now control the room temperature cooling
automatically at this setting.

Fig 3

LINESET LENGTH Total Volume

Units

16FT

2.65

U.S Gallons

21FT

3.07

U.S Gallons

32FT

3.25

U.S Gallons

48FT

3.85

U.S Gallons

64FT

4.45

U.S Gallons

80FT

5.05

U.S Gallons

Page5

8) ROUTINE MAINTENANCE

The air filter must be kept clean, never allow to become
choked with dust or dirt. If allowed to do so, the performance
of the unit will become impaired, resulting in loss of air flow,
freezing up of the evaporator coil and possible component
damage.

ACCESSING THE FILTER

Lift open the return air grille on the front face of the unit,
Fig 4. On refitting the filter ensure that it is correctly
positioned covering the whole rear face of the grille. The
filter (see Fig. 4) can be washed in warm, soapy water,
rinsed and shaken dry before replacement. Frequency of
cleaning depends upon application and can only be
determined by the user. However, you should never allow
more than two months to elapse between cleaning. The
probable life of the filter will be about one year and spares
are available from the supplier of the unit itself. Failure to
have filter fitted during operation will cause serious damage.

FIG 4.

The refrigeration circuit inside the room unit is fitted with a
HIGH and a LOW pressure sensing switch. They are both
manually re-settable. A pencil or screwdriver with gentle
pressure on the knob behind is all that is required to re-set.
Necessary access is provided through the control console.
HOWEVER, DO NOT ATTEMPT TO RE-SET WITHOUT
FIRST DISCOVERING WHY THE TRIP
OCCURRED IN THE FIRST PLACE

LIFT AND REMOVE AIR FILTER

UNSCREW RETAINERS AND OPEN PANEL TO REMOVE FILTERS

9) MACHINE NOT WORKING?

ONLY A COMPETENT ELECTRICIAN SHOULD
ATTEMPT TO RECTIFY ELECTRICAL SUPPLY
PROBLEMS. DO NOT REMOVE ANY PANELS FROM
THE MACHINE.

Problem

- No air flow from room unit.

Diagnosis

-Red "MAINS" light off.

Cure

- Turn on electricity and/or check mains supply

fuse.

Problem

- No air flow from room unit.

Diagnosis

- Red "MAINS" light on, White "DEFROST"

light on.

Cure

- Machine in defrost mode, do not adjust anything,

machine will revert to normal run after 10 mins.

Problem

- Insufficient air flow from room unit.

Diagnosis

- Blocked air filter.

Cure

- Clean filter

Problem

- No cooling.

Diagnosis

- Green "COOLING" light off.

Cure

- Revolve thermostat knob fully anti-clockwise to

"1". Wait 10 minutes for time delay on start-up

Problem

- No cooling.

Diagnosis

- Amber "ATTENTION" light illuminated.

High pressure trip.

Cure

- Press "+" button to re-set and check for :-

Lack of water flow ... kinked hoses? Shortage of
water ... top up.
External heat exchanger unit mounted in very high
temperature? Water frozen? Add glycol (33%).
External heat exchanger coil blocked with dirt ... clean.

Problem

- No Cooling.

Diagnosis

- Amber "ATTENTION" light illuminated.

Low pressure trip.

Cure

- Press, "-" button to re-set and check for :-

No air flow, blocked filter?
Evaporator blocked with ice. Very low external
temperature?

Problem

- No Cooling.

Diagnosis

- Amber "ATTENTION" light illuminated.

Low pressure trip.

Cure

- Condensate pump not reducing water level.

Kink in Condensate tube between room unit and heat
exchanger? Leak inside room unit. Sump filter inside
room unit blocked. Condensate tube frozen.

Page 6

HE
X

WA
T

PU
M

HEX UNIT

ST
AT

1 4

HP
L

FS
1

FS
2

AU
X

min
s

SUMP HEATER

COOL

FAN ONLY

LOW

HIGH

CO
M

OU
T

PUMP

CONTROLLER

TIME

DELAY

K 1

DO NOT SCALE PRINT

10 FLOAT SWITCH COAXIAL LEADS REMOVED

3 SUPPRESSORS ADDED TO RELAYS No2 & 3

4 W/R & W WIRES TO FLOAT SWITCHES WERE BLACK

5 CONTACTOR CHANGED

SUPPRESSORS DELETED

FLOAT SWICHES

COAX LEAD ADDED

6 2 off RELAYS DELETED & PUMP CONTROLLER ADDED

7 PUMP CONTROLLER CLARIFIED ON CIRCUIT DIAGRAM

8 FLOAT SWITCH FS1 TURNED AROUND 180 deg

PLUG LEAD COLOURS ADDED.

11 GREY FLOAT SWITCH LEADS WERE BLACK.

ISS

DRAWING CHANGE

12 TERMINAL BLOCK ADDED FOR WATER PUMP

U.C.C.

CALOREX HEAT PUMPS LTD

MATERIAL

FINISH

1024 CJW 08:02:01

GSM 3:6:97

GSM 23:6:97

952 GSM 23:1:98

961 GSM 4:6:98

961 GSM 3:12:98

JAC

1004

1050 CJW 29:06:04

C/N

APPD

DATE

1084 CJW 15:04:05

LP SWITCH

HP SWITCH

TERM BLOCK

EARTH STUD

FAN CAP

COMP RUN CAP

HARD START CAP

COMPRESSOR

SUMP HEATER

BASE EARTH

B 1,5

BR 1,5

B 0

BR 0,5

B 0,5

GR/B 0,5

L 0,

R 1,5

BL 1,5

P 1,5

PLUG

MAINS LEAD

FAULT

G/Y 1,5

BLACK FLYING LEADS

G/Y 1,0

BRO

EEN

L 0,

W 0,5

FAN MOTOR

SOCKET

G/Y 1,5

G/Y 1,0

BR 0,5

LAMP

TERMINAL BOX

G/Y (G USA)

BR (BL USA)

B (W USA)

GSM 3:8:98

08:02:01

SOCKET TO HEX UNIT

B 0,5

BR 0,5

B 0,5

G/R GREEN/RED

GRUN/ROT

VERT/ROUGE

BL
B
BR
GR
O
P
R
W

G/Y GREEN/YELLOW

WHITE

RED

PINK

ORANGE

GREY

BROWN

BLUE

BLACK SCHWARZ

BLAU
BRAUN
GRAU
ORANGE
ROSA
ROT
WEIB

GRUN/GELB

NOIR
BLEU
MARRON
GRIS
ORANGE
ROSE
ROUGE
BLANC

VERT/JAUNE

V VIOLET

VIOLETT VIOLETTE

G GREEN

GRUN

VERT

HEX

UNI

O/BK 0,5

P 0,5

GR/B 0,5

L 0,

Page7

---

GSM 9:4:97

NTS

B
FT
S1

HP
LP
D
K
MC
MV
C1
C2

Y
AT

CONTACTOR

DEFROST THERMOSTAT

FAN MODE SWITCH

LOW PRESSURE SWITCH

DELAY TIMER

RELAY

COMPRESSOR MOTOR

FAN MOTOR

COMPRESSOR CAPACITOR

FAN CAPACITOR

SOLENOID VALVE
AIR THERMOSTAT

HIGH PRESSURE SWITCH

SCHALTSCHUTZ

VEREISUNGSSCHUTZTHERMOSTAT

GEBLASESCHALTER

HOCHDRUCKSCHALTER

NIEDERDRUCKSCHALTER

VERZOGERUNGSRELAIS

RELAIS

KOMPRESSORMOTOR
VENTILATORMOTOR

KONDENSATOR KOMPRESSOR
KONDENSATOR VENTILATOR

MAGNETVENTIL

LUFTTHERMOSTAT

CONTACTEUR

THERMOSTAT DE DEGIVRAGE

SELECTEUR DE MODE DU VENTILATEUR

REINITIALISATION DEFAUT HAUTE PRESSION
REINITIALISATION DEFAUT BASSE PRESSION

TEMPORISATEUR

RELAIS

COMPRESSEUR

MOTEUR DU VENTILATEUR

CONDENSATEUR DU COMPRESSEUR
CONDENSATEUR DU VENTILATEUR

VANNE ELECTROMAGNETIQUE

THERMOSTAT AIR

CONDENSATE PUMP

KONDENSATPUMPE

POMPE A CONDENSAT

FAULT LAMP

LAMPE 'FEHLER'

VOYANT PANNE

DEFROST LAMP

LAMPE 'ENTEISEN'

VOYANT DEGIVRAGE

CHILL LAMP

LAMPE 'KUHLEN'

VOYANT REFROIDISSEMENT

MAINS (OR RUN) LAMP

LAMPE 'STROM EIN' ODER 'LAUF'

VOYANT SECTEUR (FONCTIONNEMENT)

FAN SPEED SWITCH

SCHALTER VENTILATORGESCHWINDIGKEIT

COMMUTATEUR VITESSE VENTILATEUR

F1 CONTROL

FUSE

KONTROLLSICHERUNG

FUSIBLE

PRINCIPAL

CONDENSATE FUSE

KONDENSATSICHERUNG

FUSIBLE CONDENSAT

HARD START CAPACITOR

HARTSTARTKONDENSATOR

CONDENSATEUR DEMARRAGE DIRECT

FS1

FLOAT SWITCH HIGH LEVEL

SCHWIMMERSCHALTER HOHER STAND

INTERRUPTEUR A FLOTTEUR NIVEAU HAUT

FS2

FLOAT SWITCH LOW LEVEL

SCHWIMMERSCHALTER NIEDRIGER STAND

INTERRUPTEUR A FLOTTEUR NIVEAU BAS

C4 SUPPRESSOR

SUPPRESSEUR

ENTSTORUNGSELEMENT

D355550

WIRING DIAGRAM

PAC240/HEX240

TOLERANCE UNLESS SPECIFIED

HOLES TO BS 4500 E12

INSPECTION LEVEL

DIMS

SHT No.

CONT'

DRAWN

DRG No.

APPROVED

DATE

SCALE

TITLE

AIR STAT

3 POSN SWITCH

A B

DELAY TIMER

1 4

2 3

DEFROST STAT

FAN MOTOR

SOLENOID VALVE

CONDENSATE

FLOAT SWITCH
HIGH LEVEL

FLOAT SWITCH

LOW LEVEL

MAINS

DEFROST

CHILL

BR 1

B 0,5

CONTACTOR B

AUX

B 0,5

BL/W 0,5

RELAY No 1

L 0

P 0,5

P 0

P 0,5

L 0,

O 0,5

GR/B 0,5

B 0

R 0,5

GR 0,5

BR 0,5

R/B 0,5

R/BL 0,5

BLUE FLYING LEAD

BLACK FLYING LEAD

WHITE

BROWN

BR 0,5

RED NOT USED

R 1

FLYING LEAD

SUMP

GREY

R/B

BR 0

L 0

BR 1

W/R 0,5

B 0,5

W/R 0,5

G/Y 1,0

B 0,5

O 0,5

B 0,5

G/Y 1,0

PUMP

W/R 0,5

W 0,5

BR 0

FAN ONLY

COOL

W/BL LINK

GR 0,5

B 0,5

N/C

CL DL RL

FS1

FS2

NOTE ORIENTATION OF SWITCHES

B 0

1,5

0,5

B 0

8 COM

7 N/C

6 N/O

5 FAULT SIGNAL

4 OUT

3 SIGNAL IN

2 L

1 N

B 0

PUMP CONTROLLER

2 POSN SWITCH

FAN SPEED

CONTROL FUSE 7A

CONDENSATE FUSE 1A

BR 1,5

BR 0,5

G/R 0,5

LAB

L D

355

551

D355550

E 1

FLYING LEADS

IF IN DOUBT ASK

DRG No.

B 0

R 1.0

BL 1.0

WATER PUMP

TERM BLOCK
IN TERM BOX

B 0,5

O/BK 0,5

GR/B 0,5

R/B 0,5

G/Y 1,0

BR 1,5

B 1,5

Page 8

RED FLYING LEAD
RED FLYING LEAD

L 0,

BL 0,5

R/B 0,5

2 CHANGES TO SUIT EXISTING PAC22 LOOM

05:11:03

10A

INSIDE

VIEW

R/BL 0,5

1 AS DRAWN

19:01:02

BL
B
BR
GR
O
P
R
W

G/Y GREEN/YELLOW

WHITE

RED

PINK

ORANGE

GREY

BROWN

BLUE

BLACK SCHWARZ

BLAU
BRAUN
GRAU
ORANGE
ROSA
ROT
WEIB

GRUN/GELB

NOIR
BLEU
MARRON
GRIS
ORANGE
ROSE
ROUGE
BLANC

VERT/JAUNE

V VIOLET

VIOLETT VIOLETTE

G GREEN

GRUN

VERT

TERM BLOCK

30A

EARTH/GROUND STUD

FAN CAP

COMP RUN CAP

HARD START CAP

SOCKET TO HEX UNIT

COMPRESSOR

SUMP HEATER

BASE EARTH

B 2,5

BR 2,5

B 0,

B 0,5

BR 0,5

B 0,5

BR 0,5

BL 0,5

R 2,5

BL 2,5

P 2,5

G/Y 2,5

PLUG

MAINS LEAD

G/Y 2,5

BLK FLYING
LEADS

B 0,5

G/Y 1,0

TERMINAL BLOCK

G/Y 2,5

G/Y 1,0

BR 0,5

GND

GR/

LP SWITCH

HP SWITCH

GR/B 0,5

L 0

FAULT

V 0

LAMP

G/Y (G USA)

BR (BL USA)

B (W USA)

HEX

WA
T

PU
M

HEX UNIT

ST
AT

1 4

HP L

FS
1

FS2

S R

AUX

SUMP HEATER

10A

COOL

FAN ONLY

LOW

HIGH

COM

OU
T

PUMP

CONTROLLER

TIME

DELAY

K 1

FAN SPEED CAP

ISS

C/N

APPD

DATE

U.C.C.

CALOREX HEAT PUMPS LTD

MATERIAL

FINISH

DO NOT SCALE PRINT

DRAWING CHANGE

Page9

CONTROL FUSE 10A

B 0,5

B 2,5

R/BL 0,5

B 0,5

)

BLK

D355552

LABEL D64355553

D355552

WIRING DIAGRAM

PAC320DX/HEX320D

ISSU

E 2

HEX UNIT

---

CJW 19:01:02

NTS

AIR STAT

3 POSN SWITCH

A B

DELAY TIMER

1 4

2 3

DEFROST STAT

FAN MOTOR

SOLENOID VALVE

CONDENSATE

FLOAT SWITCH

HIGH LEVEL

FLOAT SWITCH

LOW LEVEL

MAINS

DEFROST

CHILL

BR 2,

BR 2,5

B 0,5

CONTACTOR B

AUX

BR 0,5

B 0,5

BR 0,5

R/BR 0,5

BL/W 0,5

RELAY No 1

/BL

P 0,5

O 0,5

GR/B 0,5

B 0

R 0

R 0,5

W 0

GR 0,5

GR 0

BR 0,5

BLACK

BROWN

BR 0,5

BLUE

R 2

FLYING LEAD

SUMP

GREY

/BL

B 0

B 2

W/R 0,5

B 0,5

W/R 0,5

G/Y 1,0

B 0,5

B 0

O 0,5

B 0,5

G/Y 1,0

PUMP

W/R 0,5

W 0,5

R 0

B 0

FAN ONLY

COOL

W/BL LINK

GR 0,5

B 0,5

WATER PUMP

BR 1,0

N/C

CL DL RL

FS1

FS2

NOTE ORIENTATION OF SWITCHES

B 0,

W 0

2,5

0,5

B 0,

8 COM

7 N/C

6 N/O

5 FAULT SIGNAL

4 OUT

3 SIGNAL IN

2 L

1 N

B 0

B 0,

PUMP CONTROLLER

PUMP

FAN MOTOR

BASE PLATE

EARTH

SUPPL

GND

WHT

BLK

GRN

GRN/YEL 1,50

BRN

WHT 1,00

MAINS

START

WATER STAT

BLK

)

WIRED TO RUN COUNTER CLOCKWISE

EVE

G PLU

YEL(WHT)

/WHT

BLK

T Z

CONTROL FUSE 10A

CONDENSATE FUSE 1A

BR 0,5

G/R 0,5

FLYING LEADS

BLK 1,00

WHT

YEL(WHT)

BLK

GRN
GRN (GRN/YEL)

GRN

G/Y

2 POSN SWITCH

FAN SPEED

HIGH

LOW

TOLERANCE UNLESS SPECIFIED

HOLES TO BS 4500

E12

INSPECTION LEVEL

DIMS

SHT No.

CONT'

DRAWN

DRG No.

APPROVED

DATE

SCALE

IF IN DOUBT ASK

TITLE

DRG No.

Page 10

BLANK PAGE

Page11

BLANK PAGE

Page 12

BLANK PAGE

PDF User Manual

PORTA TEMP 320DX

Full Text Searchable PDF User Manual