3605 BUFFALO RD

ROCHESTER, NY 14624

Phone: +1-585-594-5050
Fax: +1-585-594-8888
Toll Free: +1-888-723-9230 / 24 hrs.
On the web: www.northernairsystems.com

V036WMADB1SSA00

REV A 08/19/14

1
 TABLE OF CONTENTS
Page 3 System Specifications
Page 4 Sequence of Operation

ELECTRICAL SECTION
Page 5 Input / Output List
Page 6 Dimensional Drawing
Page 7 High Voltage Diagram
Page 8-9 Control Wiring Diagram

REFRIGERATION SECTION
Page 10 Charging Information
Page 11 Refrigeration Piping Diagram

CONTROLLER MENUS AND NAVIGATION

Page 12 Quick Reference Guide
Page 13-16 PLC Menus and Displays

SYSTEM ALARMS AND TROUBLESHOOTING

Page 17-18 System Alarms and Troubleshooting
Page 19-22 Variable Frequency Drive Fault Codes

Page 23-24 Replacement Parts Diagrams

Page 25 Installation Instructions
Page 26-28 Startup Procedure
Page 29 Maintenance Guidelines
Page 30-31 PM Checklist
Page 32 Sensor Calibration Instructions
Page 33 Rigging Instructions

2
 System Specifications

Capacity: 36,000 BTU/hr @ 80F db/67F wb return air, 95F ambient air temperature

Supply Airflow: 1200 CFM @ 0.5”

Heat Capacity: 9 kW
Condenser Airflow: 1800 CFM
Refrigerant: 12 LBS R-134A

POWER:

480 VOLT 3 PHASE 35 AMP MAX CURRENT

1- 0.67 kW Condenser Fan Motor 1.15 FLA

1- 3.00 kW Compressor 10.00 FLA
1- 0.45 kW Evaporator Fan Motor 0.80 FLA
1- 9.00 kW Electric Heaters 20.00 FLA

3
 Sequence of Operations

 System is turned on by the PGD display interface or selector switch

 System reads temperatures, humidity (optional) and system refrigerant pressures, as well as
checks all alarm circuits for faults
 If unit is turned on and no faults are present, the evaporator fan contactor will be activated. The
evaporator fan and condenser fans will run for 30 seconds as a purge cycle. The condenser fans
will be deactivated; the evaporator fan will stay activated.
 Digital Compressor: when the temperature rises 1° above setpoint the compressor starts and runs
modulating to maintain suction pressure set point.(Optional)
o Based on cooling demand the system provides 0 – 10v output to digital compressor.
 Standard Compressor: when the temperature rises 1° above setpoint the compressor will be
activated.
 The condenser fans speed up and down based on pressure using a 0 – 10 volt analog signal to the
drive. The fans are factory set to maintain 230 PSI
 Heating is activated when the temperature drops below set point by 1° and turns off when
temperature is satisfied.(Can be configured through factory)
 If there is a need for heating, the system stops cooling by bringing compressor demand to 0%
and shut off when in cycling mode (optional)
 The unit controllers are linked and communicate via PLAN Network. The units are capable of 4
selectable operation modes: UNIT 1; UNIT 2; ALTERNATING; DUAL.
o When in UNIT 1 mode, only Unit 1 will run
o When in UNIT 2 mode, only Unit 2 will run
o When in DUAL mode, both units will run simultaneously.
o When in ALTERNATING mode, one unit is designated as the lead unit, the other is
designated as the lag unit, only the lead unit will run. In the event of an alarm on the lead
unit, the lag unit will be activated and run.
o When the “Days Until Rotation” setpoint has been reached, the lead unit becomes the lag
unit and vice versa.
o When ALT/DUAL Enable is activated and the temperature has exceeded the ALT DUAL
setpoint, the lag unit will be activated and both units will run until the temperature drops
below the ALT DUAL setpoint. The lag unit will then be deactivated and they will
resume normal operation.
 In the case of high humidity, the system will run cooling and heat at the same time to dehumidify
and maintain temperature set points.(optional)
 In the event of an alarm, the system will display each one with a time and date stamp. This will
be displayed until the problem is solved and alarm is reset by the control pad display.

4
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11
Analog Inputs
AI-1 Low pressure sensor X
AI-2 High pressure sensor X
AI-3 Humidity Sensor (optional) X
AI-4 Room temperature X
AI-5 Suction temperature (optional) X
Total 2 1 2
Digital Inputs
DI-1 Phase monitor X
DI-2 Evaporator fan fault X
DI-3 Condenser fan fault X
DI-4 Low air flow switch or Generator status X
DI-5 Heater fault X
DI-6 Compressor 1 fault X
DI-7 Humidifier fault or Compressor #2 Fault (optional) X
DI-8 On/Off switch X
Total 8
Analog Output
AO-1 Condenser fan VFD 0-10vdc X
AO-2 Evaporator fan VFD 0-10 vdc X
AO-3 Digital compressor demand X
AO-4 Humidifier demand (optional) X
Total 4
Digital Outputs
DO-1 Heater #1 contactor X
DO-2 Heater #2 contactor X
DO-3 Heater #3 contactor (optional) X
DO-4 Evaporator fan contactor X
DO-5 Standard compressor or #2 compressor contactor (optional) X
DO-6 Remote Alarm Contact X
DO-7 Condenser fan VFD enable X
DO-8 Humidifier enable (optional) X
Total 8
Pco Address 1
***When using lead lag option the second unit Pco address will be 2
First Unit Hot Gas EVD Address 3
Second Unit Hot Gas EVD Address 4

05/11/10

5
 8 7 6 5 4 3 2 1

REVISIONS
REV. DESCRIPTION DATE ECN
000 DRAWING RELEASE 4/8/2013

D D

C C

SUPPLY
FILTER/EVAPERATOR ACCESS EVAPORATOR BLOWER ACCESS
FILTER/EVAPERATOR ACCESS
13 5
25 16 " 2 16 " ELECTRICAL ACCESS

7
78"

15
21 16 "

7
15 8 "
B B

3
15 27 8 "
26 16 "

3 REFRIGERATION ACCESS
34 8 "
1
3 OUTSIDE AIR INTAKE 23 16 "
RETURN 39 16 " 28"

REFRIGERATION ACCESS

NAME DATE
UNLESS OTHERWISE SPECIFIED:
DRAWN BY TJF 4/8/2013
CHECKED BY TJF 8/20/2014

A A
DIMENSIONS ARE IN INCHES PROPRIETARY AND CONFIDENTIAL TITLE:
TOLERANCES:
FRACTIONAL 1/16"
THE INFORMATION CONTAINED IN THIS V036WM VER A
BEND 4°
TWO PLACE DECIMAL 0.05" DRAWING IS THE SOLE PROPERTY OF
THREE PLACE DECIMAL 0.010" NORTHERN AIR SYSTEMS. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
CONDENSATE DRAIN SIZE DWG. NO.
NORTHERN AIR SYSTEMS IS
PROHIBITED.
V036WMAEB1SSA00
B
DO NOT SCALE DRAWING
SCALE: 1:32 SHEET 16OF 1
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1

D D

C
C

B B

A PROPRIETARY AND CONFIDENTIAL A

7
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1

D D

Address #XX

Remote Display Screen

C
C

B B

A PROPRIETARY AND CONFIDENTIAL A

8
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1

D D

C
C

B B

A PROPRIETARY AND CONFIDENTIAL A

9
8 7 6 5 4 3 2 1
 CHARGING INFORMATION

Proper Refrigerant charge is critical for proper operation of unit across varying ambient
conditions. System may operate with clear sight glass in warmer temperatures then
charge may be insufficient once ambient temperatures drop.
Service Personnel should be familiar with head pressure control valves and their
operation.
Consequently the only accurate method is to remove all refrigerant and weigh in charge
to system name plate specifications.
If removing refrigerant to weigh, use only clean non contaminated recovery tanks.

10
 8 7 6 5 4 3 2 1

CF-1

D D
CC-1 HPS-1

HPT-1

ORI-1
ORD-1

R-1

C C
HGBS -1
C-1

FD-1 LPT-1

HGB -1 EB-1
VE-1
General Table
SG-1
IDENTIFIER DESCRIPTION
C COMPRESSOR
CC CONDENSER CO IL
CF CONDENSER FAN
B R RECEIV ER HX-1 B
FD FILTER DRYER
SG SIG HT GLASS
HG B HOT GAS BYPASS V ALV E

HX
SUCTION LIQUID LINE
HEAT EXCHANGER
LLS-1
THERMO STATIC
TX V
EXPANSION V ALV E
EC EV APO RATO R CO IL

EB EVAPO RATOR BLO WER

LL S LIQUID LINE SO LENO ID

TXV-1
L PT LO W PRESSURE TRANSDUCER
EC-1
HP T HIGH PRESSURE TRANSDUCER

NAME DATE
H PS HIGH PRESSURE SWITC H
DRAWN BY TMR 6/19/2014

O RI HEAD PRESSURE CONTRO L APPROVED BY TMR 6/20/2014

A A
PROPRIETARY AND CONFIDENTIAL TITLE:
ORD HEAD PRESSURE CONTRO L
THE INFORMATION CONTAINED IN THIS V036WM VER A
DRAWING IS THE SOLE PROPERTY OF REFRIGERATION SCHEMATIC
NORTHERN AIR SYSTEMS. ANY
REPRODUCTION IN PART OR AS A WHOLE
HG B S HOT GAS BYPASS SO LENO ID WITHOUT THE WRITTEN PERMISSION OF
NORTHERN AIR SYSTEMS IS SIZE DWG. NO. CONFIG
PROHIBITED.
V036WM VER A RS-00-12-00001 RS-00
B
VE VIBRATION ELIMINATO R SCHRADER PORT
SCALE: 1:1 SHEET 111OF 1
8 7 6 5 4 3 2 1
 3605 Buffalo Rd.
Rochester, NY 14624
Phone: 585-594-9933
Fax: 585-594-8888
www.northernairsystems.com
QUICK REFERENCE GUIDE

CAREL CONTROLLER: PCO 3 Small

MAIN MENU
 Main Screen – Normal display screens, current running temperature, humidity and pressures.
 On/Off unit – Enables and disables system
 Set Points – Ability to change all temperature and humidity set points.
 Run Times – Displays run hours of all compressors.
 Min/Max reading – Displays min and max temperature and humidity in last 24 hours.
 Factory menu – Factory set and factory authorized changes only
 Network status – Display status of devices on the network.
 Alarm history – Shows all past alarms

VIEW AND CHANGE SET POINTS

 Press “Prg” to view menu list

 Press ↓ to highlight “Set Points”
 Press  TO VIEW CURRENT ALARMS
 Press  to move cursor to password  Press 
 Press ↓ to set password to 9999  Press ↓to view
 Press  (Set points will be displayed)  Press  when prompted to clear current
 Press ↓ until desired set point is displayed alarms
 Press  to move to desired set point
 Press ↑ or ↓to change the set point
 Press  to initialize & save the set point
 Press “Esc” twice to exit set points and return
to the “systems status” screens 
 TO VIEW CURRENT STATUS
VIEW ALARM HISTORY
 Same as above but select “Alarm History”  Press “Esc”
rather than “Set Points”  Press ↑ or ↓ to view
 Press ↑ to view past alarms

* AT ANY TIME THE ESC KEY TO GET BACK TO THE MAIN “SYSTEMS DISPLAY SCREENS”

12
 PLC MENUS AND DISPLAYS
MENU DISPLAY OPTIONS DESCRIPTION
SYSTEM STATUS
ROOM TEMP X DEG F Displays current room temperature
HIGH PRESSURE X PSI Displays current high pressure
LOW PRESSURE X PSI Displays current low pressure
HUMIDITY X% Displays current relative humidity (optional)
HEAT DEMAND X% Displays current heating demand
COOL DEMAND X% Displays current compressor demand
COND FAN DEMAND X% Displays current condenser fan demand
EVAP FAN SPEED X% Displays current evaporator fan speed
HUMIDITY DEMAND X% Displays current humidification demand (optional)
HEAT STAGE X Displays current heating stage
TEMP SETPOINT X DEG F Displays current room temperature set point
Displays current room humidification set point
X%
HUM SETPOINT (optional)
Displays current room dehumidification set point
X%
DEHUM SETPOINT (optional)
UNIT MODE Multiple Displays the current mode of operation
ON / OFF by
STATUS switch Displays the position of the unit ON/OFF switch
UNIT ON/OFF
System ON / OFF by
ON/OFF STATUS switch Displays position of unit ON/OFF switch
X MIN Allows fans to run for X amount of time before starting
STARTUP DELAY: the compressor
UNIT ADDRESS X Displays the units Plan communication address
UNIT MODE Multiple Allows selection of unit mode of operation
SETPOI
NTS
PSWD:
9999 TEMPERATURE X DEG F Controls temperature setpoint
HUM SETPOINT: X% Controls humidification setpoint (optional)
DEHUM SETPOINT: X% Controls dehumidification setpoint (optional)
Number of degrees above or below setpoint
X DEG F
DEHUM STOP BAND dehumidification starts and stops
FACTORY MENU / CONFIGURATION
X PSI Controls the high pressure at which the condenser fan
COND VFD SETP is set to maintain
High pressure set point used to enable the condenser
X PSI
COND VFD EN fan VFD
Percentage at which condenser fan will run during
X%
COND VFD START purge cycle on start up
LEAD/LAG ENABLE OFF Not used
ALT DUAL ENABLE OFF Not used
ALT DUAL SETUP X DEG F Not used. DO NOT CHANGE
X MIN Compressor will shut down after having zero demand
DEMAND SD TIMER for this amount of time
XV Output voltage to compressor controller at zero
MIN COMP RUN V demand while running
XV Output voltage to compressor controller while
COMP OFF VOLT compressor is not running
X MIN Minimum amount of time in minutes that the
COMP MIN OFF compressor cannot be off

13
 CYCLYING
COMP TYPE Not used
X PSI Low pressure set point the compressor is modulating
LP SETPOINT to maintain during cooling operation
COOL ON SETP X DEG F Degrees above set point when cooling is activated
DIG TANDEM COMP NO Not used
For use on systems with evaporator fan VFD
X%
EVAP VFD SPEED DO NOT CHANGE
PI control loop settings for condenser fan, DO NOT
MULTIPLE
COND VFD TUNING CHANGE
PI control loop settings for compressor, DO NOT
MULTIPLE
COOLING TUNING CHANGE
PI control loop settings for heating, DO NOT
MULTIPLE
HEATING TUNING CHANGE
PI control loop settings for humidification, DO NOT
MULTIPLE
HUMIDIFIER TUNING CHANGE
CLOCK TIME/DATE Allows user to set the time and date
TEMPERATURE UNITS °F / °C Allows change of temperature unit of measure
PRESSURE UNITS PSI Displays the pressure unit of measure
CHANGE PASSWORD
SERVICE
XXXX Allows change of service level password
CHANGE FACTORY
PASSWORD
XXXX Allows change of factory level password
FACTORY MENU / I/O CONFIGURATION
LOW PRESSURE MULTIPLE Low pressure sensor set up & calibration
HIGH PRESSURE MULTIPLE High pressure sensor set up & calibration
HUMIDITY MULTIPLE Humidity sensor set up & calibration (optional)
TEMPERATURE MULTIPLE Temperature sensor set up and calibration
SUCTION TEMP MULTIPLE Suction temp sensor set up & calibration (optional)
PHASE MONITOR MULTIPLE Phase monitor input set up
EVAP FAN FAILURE MULTIPLE Evap fan failure input set up
COND FAN FAILURE MULTIPLE Condenser fan fault input set up
Optional airflow switch can be used to indicate dirty
MULTIPLE
AIR FLOW SWITCH filters
HEATER FAILURE MULTIPLE Heater failure input set up
COMPRESSOR OVERLOAD MULTIPLE Compressor fault input set up
Humidifier fault input set up (optional) If humidifier CP4 board faults,
MULTIPLE this alarm will be activated. See troubleshooting guide in humidifier
HUMIDIFIER FAILURE section in this manual
ON/OFF SWITCH MULTIPLE ON/OFF switch input set up
REMOTE PANEL OPR MULTIPLE Remote panel operations input set up
GENERATOR STATUS MULTIPLE Generator input set up (optional)
FACTORY MENU / MANUAL CONTROL
COND VFD AUTO/HAND % Allows manual operation of the condenser fan VFD
Only used on systems equipped with evaporator fan
AUTO/HAND %
EVAP COND VFD VFD. Allow manual control of evaporator fan VFD
Allows manual operation of the modulating
AUTO/HAND %
MOD COMP compressor
HUMDIFIER AUTO/HAND % Allows manual operation of the modulating humidifier
AUTO/HAND Allows manual operation of the stage 1 heater
HEATER 1 ON/OFF contactor (optional)
AUTO/HAND Allows manual operation of the stage 2 heater
HEATER 2 ON/OFF contactor (optional)
AUTO/HAND Allows manual operation of the stage 3 heater
HEATER 3 ON/OFF contactor (optional)
AUTO/HAND Allows manual operation of the evaporator fan
EVAP FAN ON/OFF contactor

14
 AUTO/HAND Allows manual operation of the condenser fan VFD
COND EN ON/OFF enable
AUTO/HAND
HUMID EN ON/OFF Allows manual operation of the humidifier enable
AUTO/HAND Allows manual control of compressor#2 only used on
COMP2 ON/OFF systems equipped with 2 compressors
AUTO/HAND Allows manual control of remote alarm output. Used to
ALARM ON/OFF test light bulb and/or siren
FACTORY MENU / ALARM SET POINTS
Delay on start up only before hi or lo temp alarm is
X MIN
TEMP AL DELAY allowed
Degrees above set point when hi room temp alarm is
X DEG F
HI ROOM TEMP activated
Degrees below set point when lo room temp alarm is
X DEG F
LO ROOM TEMP activated
Low pressure alarm set point that compressor will
X PSI
LO PR SHUTDOWN shutdown
Frequent low pressure alarm set point no comp
X PSI
LO FREQUENT PR shutdown
LO PR TIMEOUT X MIN Delay before alarming on frequent low pressure alarm
High pressure alarm set point that compressor will
X PSI
HI PR SHUTDOWN shutdown
Frequent high pressure alarm set point no comp
X PSI
HI FREQUENT PR shutdown
Delay before alarming on frequent high pressure
X MIN
HP TIMEOUT alarm
The amount of time in seconds the PLAN network is
X SECONDS
PLAN ALARM DLY off line before alarm is activated
Relative humidity at which high humidity alarm is
X%
HIGH HUMIDITY activated
Relative humidity at which low humidity alarm is
X%
LOW HUMIDITY activated
FACTORY MENU / HUMIDIFY/DEHUM
HUMIDIFIER ENABLE ON/OFF Activates humidification control option
DEHUM ENABLE ON/OFF Activates dehumidification control option
Controls RH% at which dehum is activated and
X%
DEHUM BAND deactivated
FACTORY MENU / HEAT SETUP
HEAT STAGE DELAY X MIN Delay time between stages of heat activation
HEATING OFFSET X DEG F Degrees below set point when heating is activated
X% Controls the demand for heat at which each stage is
STAGING activated and deactivated.
FACTORY MENU / VALVE SETUP
Allows the enabling of electronic hot gas bypass valve
NO
ENABLE HOT GAS EVD controls. Not used DO NOT CHANGE
Allows the enabling of electronic pressure regulating
ENABLE SPRHT EVD NO valve controls. Not used DO NOT CHANGE

RUN TIMES
HEATER 1 X HRS Displays current total hours of operation (optional)
HEATER 2 X HRS Displays current total hours of operation (optional)
HEATER 3 X HRS Displays current total hours of operation (optional)
EVAPORATOR FAN X HRS Displays current total hours of operation
COND FAN EN X HRS Displays current total hours of operation
HUMIDIFIER EN X HRS Displays current total hours of operation (optional)
COMPRESSOR X DEG F Displays current total hours of operation
MIN/MAX READINGS

15
 Displays min and max readings over past 24 hours of
X PSI
HIGH PR operation
Displays min and max readings over past 24 hours of
X PSI
LOW PR operation
Displays min and max readings over past 24 hours of
X%
HUMIDITY operation (optional)
Displays min and max readings over past 24 hours of
X DEG F
TEMP operation
NETWORK STATUS

NONE Displays current network status an component

NETWORK STATUS address
ALARM HISTORY
Displays all past alarms with time and date stamp.
ALARMS Also the power supplied from generator or shore
ALARMS during the fault (optional)

16
 SYSTEM ALARMS & TROUBLESHOOTING
DISPLAY DESCRIPTION & TROUBLESHOOTING TIPS

Low pressure is nearing the low pressure shutdown setpoint: check for
accurate pressure sensor reading, dirty evaporator coil or air filters.
FREQUENT LOW PRESSURE
Make sure liquid line solenoid is open and liquid line filter drier is not
plugged. Check for proper refrigerant charge & leak check.

Low pressure has reached the low pressure shutdown setpoint and has
shut down the compressor: check for accurate pressure sensor
LOW PRESSURE SHUTDOWN reading, dirty evaporator coil or air filters. Make sure liquid line solenoid
is open and liquid line filter drier is not plugged. Check for proper
refrigerant charge & leak check.
High pressure is nearing the high pressure shutdown setpoint: check
FREQUENT HIGH PRESSURE for accurate pressure sensor reading, dirty condenser coil or lack of air
flow through the condensing coil.
High pressure has reached the high pressure shutdown setpoint and
has shut down the compressor: check for accurate pressure sensor
HIGH PRESSURE SHUTDOWN
reading, dirty condenser coil or lack of air flow through the condensing
coil.
(Optional) The relative humidity level is below the alarm set point,
LOW HUMIDITY check the humidifier, humidifier water supply tank and pump for proper
operation. Also check for accurate humidity reading.

(Optional) The relative humidity level is above the alarm set point,
HIGH HUMIDITY check for accurate humidity reading, if dehumidification is needed
ensure that the dehumidification option is activated in the factory menu.

The room temperature is below the low temperature alarm set point,
LOW TEMPERATURE
check heater operation.
The room temperature is above the high temperature alarm set point,
HIGH TEMPERATURE
check air conditioning operation.
The evaporator fan has possibly overheated: If fan contactor is pulled
in and running check the fan contactor for defective auxiliary contacts.
EVAPORATOR FAN FAULT If the fan contactor is not pulled in check all wiring connections to the
fan contactor and fan motor. Check fan for high motor temperature and
or seized bearings replace fan if necessary.
The condenser fan has possibly overheated: Check all wiring
CONDENSER FAN FAULT connections to the fan VFD and fan motor. Check fan for high motor
temperature and or seized bearings replace fan if necessary.
Phase protection monitor has faulted: Check for 3 phase line voltage to
be within the setting on the phase monitor & adjust phase monitor if
PHASE MONITOR FAULT required. If 3 phase line voltage is within the setting, check wiring
connections to phase monitor from the PCO controller, replace monitor
if necessary.
The condenser fan VFD has faulted: Read VFD display for a fault code,
check fault code within this manual to diagnose. If no fault code is
CONDENSER FAN VFD FAULT present, check all wiring connections to the fan VFD from PCO
controller, if VFD display is off check for line voltage; if power is present
to the VFD but no display is present replace the VFD.

17
 The electric heaters have possibly overheated: If heat contactor is
pulled in and running check the heat contactors for defective auxiliary
contacts. If the heat contactors are not pulled in check all wiring
HEATER FAULT connections to the heat contactors and heat elements. Check the auto
reset high limit switch for closure, if open and plenum is below 145
degrees replace the automatic high limit switch. Also ensure the one
shot high voltage cut out switches are closed.

(Optional) The humidifier CP4 board has faulted: count the red flashing
HUMIDIFIER FAULT light on the CP4 board for a code, look in this manual for the humidifier
fault codes and explanations.

The digital compressor controller has faulted or the manual reset high
pressure switch has tripped: Push the high pressure switch reset
button located on the compressor discharge, If compressor starts then
look for dirty condenser coils or lack of air flow through condenser coil.
If switch was not tripped check the compressor body for excessively
COMPRESSOR FAULT
high temperature, if compressor is truly overheated check refrigerant
DIGITAL COMPRESSOR ONLY
charge for 10 degree sub cooling and proper 12 degree superheat,
adjust charge accordingly and leak check. If compressor is not hot
check wiring to the compressor and the compressor controller. Count
the red flashing light on the digital compressor controller and refer to
this manual for the compressor controller fault codes and explanations.

The PLAN communication network between controllers has been

interrupted. Check for loose connections at terminal J11 on both PCO
controllers. Check the cable running between the controllers for
damage or broken wires. If all connections are ok check controller
pLAN FAILURE
addresses as follows: cycle power to controllers, on power up press
PCO #1 OFFLINE
and hold the  and  simultaneously. Once the controller boots up it
PCO #2 OFFLINE
will display the controller address. Be sure one of the unit’s controller
address is set to address 1 and the other unit’s controller address is set
to address 2. If addresses are correct and there are no broken
communication wires, replace controller as needed.

LOW PRESSURE SENSOR FAIL

HIGH PRESSURE SENSOR FAIL
HUMIDITY SENSOR FAIL (optional)
The PLC has lost the input signal from the sensor. Check for broken
ROOM TEMPERATURE SENSOR FAIL
wires, loose connections or terminations. Replace sensor as needed.
SUCTION TEMPERATURE SENSOR FAIL
(optional)

18
VFD Troubleshooting and Diagnostics
Status / Warning Cause Remedy
DC-Injection brake activated
Deactivate DC-Injection brake
 Activation of digital input
DC-Injection brake  Deactivate digital input
br (P121…P124=18)
active  Automatically after P175 time
 Automatically (P110=2,4...6)
expired
 Automatically (P111=1,3)
 Verify motor data (P302…P306)
The drive ID(P502) stored on the and perform Auto Calibration
bF Drive ID Warning EPM does not match the drive  Set drive mode (P300) to 0 or 1
model  Reset the drive (P199 to 3 or 4)
and reprogram
Motor Auto-Calibration Motor Auto-Calibration is being
CAL Refer to P300, P399
Active performed
An EPM that contains
Parameter settings can only be
valid data from a
An attempt was made to change changed after the EPM data is
cE previous software
parameter setting converted to the current version
version has been
(P199=5)
installed
 Increase P171
CL Current Limit Reached Motor Overload  Verify drive/motor are proper size
for application
If drive trips into HF fault:
The drive has stopped
 Increase P105, P126
decelerating to avoid tripping
dEC Decel Override  Install Dynamic Braking Option
into HF fault, due to excessive
motor regen (2 sec max)
Invalid data was entered, or
Err Error
invalid command was attempted
Verify drive/motor are proper
FCL Fast Current Limit Overload
size for application
Flying Restart Attempt
FSE P110= 5,6
After Fault
An attempt was made to change In OEM Settings mode
OEM Settings Operation
GE parameter settings while drive is (P199=1), making changes to
Warning
operating in OEM settings mode parameters is not permitted
An attempt was made to use, or
OEM Defaults Data reset to, the OEM default setting Install an EPM containing valid
GF
Warning (P199=1 or 2) using an EPM OEM defaults data
without valid OEM data
The drive has attempted 5  Drive requires manual reset
LC Fault Lockout restarts after a fault; all attempts  Check fault history (P500) and
were unsuccessful correct fault condition
PID setpoint has finished its
Pdec PID Deceleration Status ramp but the drive is still
decelerating to a stop
Drive has been put into PID
PI d PID Deceleration Status Refer to P200
mode
SLP Sleep Mode Active Refer to P240…P242

19
 The drive has tripped into a fault To disable auto- restart, set
SP Start Pending
and will automatically restart P110=0…2
Drive has been taken out of PID
SPd PID mode disabled
mode. Refer to P200
Output frequency = 0Hz Stop has been commanded from
Apply start command (start
StoP (outputs U,V,W the keypad, terminal strip or
control source depends on P100)
inhibited) network
Drive Configuration Messages
When the mode button is pressed and held, the drive’s display will show a 4 digit code that indicates
how the drive is configured. If the drive is in the STOP state when this is done, the display will also
indicate which control source commanded the drive to STOP. The two displays will alternate every
second.
Configuration Display
X = Control Source: Y= Mode: ZZ= Reference:
L= Local Keypad S= Speed Mode CP= Keypad
t= Terminal Strip P= PID Mode EU= 0-10 vdc (TB-5)
r= Remote Keypad t= Torque Mode E 1= 4-20mA (TB-25)
n= Network C= Sequencer Mode JG= Jog
Format= x.y.zz
nt= Network
OP= MOP
P1___P7= Preset 1….7
P I___16= Sequencer
Segment
Example:
L_S_CP= Local Keypad Start control, Speed mode, Keypad speed reference
t_P-EU= Terminal Strip Start control, PID mode, 0-10vdc setpoint reference
t_C_12= Terminal Strip Start control, Sequencer Operation(Speed mode),
Seg# 12
n_t_P2= Network Start control, Vector Torque mode, Preset Torque #2
reference
n_5_03= Network Start control, Speed mode, Speed reference from sequencer
segment #03
Stop Source Display
L_StP= Stop Command came from Local Keypad
t_StP= Stop command came from Terminal Strip
Format= x_StP
r_StP= Stop command came from Remote Keypad
n_StP= Stop command came from Network

Fault Messages- The messages below show how they will appear on the display when the drive trips.
When looking at the fault history(P500), the f_ will not appear in the fault message.
Fault Cause Remedy(*)
High Temperature  Reduce drive load
F_AF Drive is too hot inside
Fault  Improve cooling
 Make sure the assertion level
 Assertion level switch is changed
switch and P120 are both set for
during operation
F_AL Assertion Level Fault the type of the input devices
 P120 is changed during
being used, prior to setting P100
operation
or 121…P124.

20
F_bF Personality Fault Drive Hardware  Cycle power
 Power down and install EPM with
An EPM has been installed that valid data
F_CF Control Fault
is either blank or corrupted  Reset the drive back to defaults
An EPM has been installed that (P199=3,4) then re-program
Incompatible EPM
F_cF
Fault
contains data from an  If problem persist, contact factory
incompatible parameter version support
(*) The drive can only be restarted if the error message has been reset.
TROUBLESHOOTING AND DIAGNOSTICS-(Drive can only be restarted if the error message has
been reset)
Fault Cause Remedy(*)
 Increase active decal time
Dynamic Breaking Dynamic braking resistors are
F_dbf (P105,P126,P127)
Fault overheating
 Check mains voltage and P107
 P121…P124=21 and that digital
 Correct the external fault condition
inputhas been opened
F_EF External Fault  Make sure digital input is set
 P121….P124=22 and that digital
properly for NC or NO circuit
input is closed
F_F1 EPM Fault EPM is missing or defective Power down and replace EPM
F_F2
thru Internal Faults Contact Factory Technical Support
F_F12
F_Fnr Control Configuration The drive is setup for REMOTE Set P400= 1; or P600= 1
Fault KEYPAD control(P100=2 or 5)
but is not setup to communicate
with a remote keypad
The drive is setup for Set P400 or P600 to a valid
NETWORK ONLY network communications protocol
control(P100=3) but is not setup selection
for network communications.
Loss of 4-20mA signal 4-20 mA signal (at TB-25) is
F_FoL Check signal and/or signal wiring
fault below 2 mA(P163= 1)
Drive is powered up with P199= Install an EPM containing valid
OEM Defaults data
F_GF 1 and OEM settings in the EPM OEM Defaults data or change P199
fault
are not valid to 0
F_HF High DC Bus Voltage Mains too low Check main voltage and P107
Fault
Increase active decel
Decel time is too short, or too
time(P105,P126, P127)or install
much regen from motor
dynamic braking option
Low DC Bus Voltage
F_LF Main Voltage Too Low Check Main Voltage
Fault
F_IL Digital Input More than one digital input set Each setting can only be used once
Configuration Fault up for the same function (except settings 0 and 3
(P121…P124) Only one digital input
One input must be set to MOP Up;
configured for MOP function
another must be set to MOP Down
(Up, Down)
PID mode is entered with Change PID setpoint reference
setpoint reference and feedback (P121… P124) or feedback
source set to the same analog source(P201)

21
 signal
One of the digital inputs Reconfigure digital inputs
(P121…P124) is set to 10 and
another is set to 11…14
One of the digital inputs Reconfigure digital inputs
(P121…P124) is set to 11 or 12
and another is set to 13 or 14
PID enabled in Vector Torque PID cannot be used in Vector
mode (200= 1 or 2 and P300= 5) Torque mode
F_JF Remote Keypad Fault Remote Keypad disconnected Check remote keypad connections
An attempt was made to start the
drive in Vector or enhanced See P300-P399 for Drive Mode
F_ntF No Motor ID Fault
V/Hz mode prior to performing setup and calibration
the Motor Auto- Calibration
F_nF 1 Refer to the module
thru Network Faults documentation for causes and Check module connections
F_nF 9 remedies
F_DF Output Fault: Output short circuit Check motor and/or motor cable
Transistor Fault Acceleration time too short Increase P104, P125
Severe Motor Overload, due to:  Check machine/system
 Mechanical Problem  Verify drive/motor are proper size for
 Drive/motor too small for application application
Boost values too high Decrease P168,P169
 Use shorter motor cables with lower
Excessive capacitive charging current charging current
of the motor cable  Use low capacitance motor cables
 Install reactor between motor and drive
Failed Output Transistor Contact factory technical support`
F_OF I Output Fault: Ground Grounded Motor Phase Check motor and cable
Fault Excessive capacitive charging Use shorter motor cables with
current of the motor cable lower charging current
 Verify proper setting of P108
Excessive motor load for too
F_PF Motor Overload Fault  Verify drive and motor are proper
long
size for application
Controller was unable to
synchronize with the motor
F_rF Flying Restart Fault Check motor/load
during restart attempt (P110=5
or 6)
F_SF Single Phase Fault A main phase has been lost Check main voltage
 Must wait at least 2 seconds after
Start command was present
power-up to apply Start command
F_UF Start Fault when power was
 Consider alternate starting method
applied(P110=0 or 2)
(P110)
(*) The drive can only be restarted if the error message has been reset.

22
NORTHERN AIR SYSTEMS
+1-888-723-9230
ELECTRICAL PARTS LIST
DESCRIPTION: PART NUMBER: QTY
Controller, PCO3 Small 20EPCO3000ES0 1
Variable Frequency Drive, Condenser Fans 20EESV112TXB 1
Transformer 20E694M2A 1
Contactor, 24v, 18 amp 20G56201 3
ON/OFF Selector Switch 20G56901 1
ON/OFF Selector Switch Base 20G57001 1
Pressure Sensor Cables 20C13601 2
Pressure Sensor 0-5v 20C12101 2
Crank Case Heater, Compressor, 480v 20E018004102 1
Solenoid Coil, 24vac, MKC-2 20SMKC2 2
High Pressure Switch, Manual Reset- 375psi 20RSMR375 1
Temperature Sensor, Wall Mount- NTC 20C11901 1
Remote Display, Wall Mount- PGD1(option) 20EPGD1 1
Evaporator Blower 20M122823 1
Condenser Fan 20MTT72A1 1
HEATER PARTS LIST QTY
Heater Element, 4.5 kW, 480v 20ETT72A2 2
High Temperature Cutout, 300°, One Shot 20EL300F 2
High Temperature Cutout, 150°, Auto Reset 20ETT72A3 1

23
NORTHERN AIR SYSTEMS
+1-888-723-9230
REFRIGERATION PARTS LIST
DESCRIPTION: PART NUMBER: QTY
Compressor 20RZR48K5ETFD130 1
Power Cable with Plug, Compressor 20E529006024 1
Liquid Receiver 20R3392 1
Sight Glass, 1/2" 20S43102 1
Solenoid Valve, Hot Gas By-Pass 20RME9S240 2
Solenoid Valve, Liquid Line 20RME6S140 1
Drier, Liquid Line, 1/2”, Sweat 20SC164S 1
Suction Liquid Line Heat Exchanger 20RHXR150 1
Thermostatic Expansion Valve 20RERJE3CP60 1
Head Pressure Control Valve 20S45601 1
Pressure Differential Valve 20R0RD425 1
Hot Gas Bypass Valve 20S45401 1
Coil, Evaporator 20R12X26EVAPR 1
Coil, Condenser 20RCC21X25 1
Refrigerant, 134A 20R134A 12 LBS
Filters, Return Air, Pleated- 30x12x1 20M6U581 1
Filter, Aluminum Mesh, 8x8x1 20M8X8MESH 1
Door Latch, Slotted, Tool Access 20M12265A53 3

24
 Installation Instructions
To prevent warranty voiding installation and start up is to be performed by factory approved and
trained personnel. These instructions are reference only.

 CONDENSATE DRAIN CONNECTIONS:

Connect all condensate drains with a minimum of ¾” line size and a 4” trap on each.

 MAIN ELECTRICAL CONNECTIONS:

Supply proper power using unit nameplate in electrical compartment conforming to local codes and
ordinances. Install cover after connections are made.

 INSTALL TEMP SENSORS:

Mount and wire temperature sensors in proper location based on system design wiring diagram to
show wire terminations.

 MOUNTING TEMP/HUMIDITY SENSOR (When equipped)

Connect temp/humidity sensor for room to designated 18/4 conductor cable off the front of A/C unit.
Electrical diagram in this manual will show connections. Mount sensor in proper location based on
system design.

 CALIBRATE ALL SENSORS FOR HUMIDITY AND TEMPERATURE

 TEST AND RUN HEATING SYSTEM (When equipped)

 CHECK FLOW RATES AND CIRCUIT SETTER OPERATION (When equipped)

Chillers Only

25
 Unit Model No.
Job Number
Unit Serial No.

START UP PROCEDURE

Initials

_____ Check for loose wiring on all high voltage VFD’s, phase monitor, distribution
block and contactors by tightening each screw terminal and inspecting the wire
terminations.

_____ Check all low voltage wiring connections on low voltage terminal block. Check
by pulling on each individual wire ensuring that all orange terminal tabs are
secured in the locked position. Be sure all screw terminals on PCO controller and
compressor controller are tight.

_____ Inspect both A/C coils for damaged or bent fins. Use coil comb to repair as
needed.

_____ Inspect or connect the condensate drain hose to the system.

_____ Verify the high voltage distribution block cover has been installed.

_____ Make sure there is no continuity from L1, L2 or L3 to ground. (note: secondary of
transformer is grounded and can show L1 or L3 grounded)

_____ Power up high voltage to unit.

_____ Check to make sure all items power up properly.

_____ Check crankcase heater for operation.

_____ Manually push evaporator fan contactor in to check fan motor rotation.

_____ Check room temperature sensor for an accurate reading against a digital
temperature meter and adjust as needed in “I/O configuration” under “factory
menu”. (Password is 9230)

26
_____ Check for any alarms and troubleshoot as needed.

_____ (Optional) Connect PGD display to the unit and verify operation.

_____ Raise room temperature set point 10 degrees above current room temperature.
When heating starts take an amp reading on the heater contactors load side to
ensure heater is functioning. Let heat run full out for five minutes.

NOTE: If two stage heat, take amp reading on both stages.

_____ Lower the set point 5 degrees below current house temp. Cooling will start.

_____ Check for proper compressor & condenser fan operation and rotation.

_____ Calibrate pressure gauges and connect them to the suction and discharge lines,
check to make sure the display is reading pressures accurately. Calibrate in the
“factory menu” under “I/O configuration” as needed to correct minor differences.

_____ Disconnect the gauges from the suction and discharge.

_____ Verify all pressure port caps and service valve caps are seated and tight,
including receiver service valve.

_____ Take amp draws of each component listed below and compare to the name plate
ratings on the electrical door or panel cover. Actual readings shall be less than
FLA on the name plate.

Compressor amps

Evaporator fan amps

Condenser fan amps

_____ Let the unit continue to run while periodically checking for any alarms,
troubleshoot if needed.

_____ Set the set point back to 70 degrees or customer desired set point.

_____ Turn unit off from the ON/OFF switch or let it run based on customer needs.

_____ Make sure all doors and panel covers are secure.

_____ Install new return air filters as needed.

27
_____ Startup is now complete.

Date Completed: ______________________

Name: ______________________________

28
 MAINTENANCE GUIDELINES

General
Restricted airflow through the evaporator & condenser coils will reduce the operating
efficiency of the unit and can result in high temperatures and loss of cooling or heating.
Clean all coils of debris that will inhibit air flow. This can be done with compressed air or
an environmentally safe commercial coil cleaner. Thoroughly rinse the coil to remove
any cleaner residue. Check for bent or damaged fins and repair as necessary. In winter, do
not permit snow to accumulate around the sides or underneath the condenser coil. Snow
or ice accumulations on the fan blades will cause them to be out of balance.
Condenser Fans
Inspect the motor & fan assembly to ensure bearings are free and motor is secure within
its mount.
Evaporator Fan Section
Check air filters after initial run period and monthly thereafter, replacing as necessary.
Replace with the same size, and type filters as originally furnished. Periodic checks of the
blower package include: motor mounts, fan bearings and wheels.
Refrigerant Piping
Visually inspect all refrigerant lines for signs of oil leaks, an indicator of a refrigerant
leak. Check the refrigerant charge at the system sight glass. A bubbling sight glass does
not always mean low charge. Use good troubleshooting methods to determine a leak
location or possible restrictions leading to this condition. Check all piping for vibration
isolation and support as necessary. Also check all roto-lock connections for tightness on
compressors.
Electrical
Check and record all running amperage of all fan motors, heaters and compressors. Also
look for signs of heat and loose connections. Make sure line voltage is switched off while
tightening wires.

29
 Date
Unit Model No.
Trailer No.
Unit Serial No.

A/C PM Service Checklist

This form is to be filled out and signed by the person performing the
preventive maintenance service procedure.

Check for loose wiring on all high voltage breakers, variable frequency drives,
overload starters and contactors by tightening each screw terminal and inspecting the
wire terminations.

Inspect and tighten all wiring compressors.

Inspect all low voltage wiring connections to the low voltage terminal
block, control boards and controllers. Check by pulling on each
individual wire ensuring that all connections are secure.

Inspect all mounting hardware for tightness on all fan motors,

compressors, doors, all metal skins and covers.

Inspect refrigerant piping for any signs of leaks and repair as

necessary.

Inspect the humidifier (if equipped) for any signs of water leakage.

Inspect the humidifier canister for excessive debris and sediment build
up. Canister must be replaced at least once a year. If Canister fills
more than ¾ full of water before producing steam and/or is impossible
to see into, then replace the canister.(if equipped)

Make sure all seams are caulked and sealed tight on the exterior
portion of the A/C unit.

Inspect condenser mounting hardware, Isolators, fan blades, motor

brackets and fan guards.

30
 Inspect refrigerant pipe insulation and repair as necessary.

Inspect all isolators: make sure they are not twisted, or

deteriorated

Clean both A/C coils with coil wash solution as necessary.

Inspect both A/C coils for damaged or bent fins and repair as necessary.

Replace the air filters in the A/C unit. Use only high grade pleated filters.

Check all sensors for accurate readings, including the pressure sensors.
Calibrate sensors as needed.

Check for any alarms and troubleshoot as needed.

Company:_________________________________________

Print Name:________________________________________

Signature:_________________________________________

Date:_____________________________________________

31
 SENSOR CALIBRATION INSTRUCTIONS

1. Press esc key until you see “system status” screen

2. Arrow down to “factory menu”
3. Press enter 2 times (left arrow key)
4. Arrow down to set password 9230
5. Press Enter
6. Arrow down to “I/O configuration”
7. Press Enter
8. Arrow down to the sensor screen that needs calibrating
9. Press Enter
10. Arrow up or down to set cal. Offset +/- degrees as needed
11. Press Enter
12. The actual temperature reading is on the bottom of the screen
13. Press esc twice to get back to main temperature screens

****Do this for all sensors as needed to get accurate readings****

32
 RIGGING INSTRUCTIONS

To prevent possible damage to the system:

Please use the Factory supplied lifting jig or qualified personnel to field
install.

Contact factory for further instructions.

585-594-5050

Attention Service Personnel

Please Read!
Report all service calls to factory
+1-585-594-9933 24 hours a day

Before working on this system you should be familiar with the products in this system. It
is imperative that you understand the charging procedure for head pressure control valves
for proper winter and summer operation. Only use exact replacement O.E.M. parts. The
electrical control system has special characteristics and factory support should be utilized.
Failure to call will void warranty and might delay repairs.

33