CLOSE CONTROL TECHNICAL MANUAL AIR AND CONDITIONERS INSTALLATION & ROUTINE SPECIAL MAINTENANCE SYSTEMP Series Series Series Series
SYMBOLS WARNING! This symbol is used to indicate helpful hints for the operator. ATTENTION! DANGER! This symbol is used to indicate situations or operations that may be potentially dangerous or that require the operator’s attention. RISK OF ELECTRIC SHOCK! This symbol is used to indicate situations or operations posing a potential risk of electric shock to the operator. DANGEROUS HANDLING! This symbol is used to indicate situations or operations posing a potential risk of crushing to the operator.
CLOSE CONTROL AIR CONDITIONERS TECHNICAL MANUAL INSTALLATION & ROUTINE AND SPECIAL MAINTENANCE List of revisions Revision Date Author Chapters Descriptions A 04/2011 AF All First version B 12/2011 AF All Revision of contents C 12/2012 AF All Revision of contents D 03/2014 AF All Revision of contents and insertion of R series E 05/2015 AF All Revision of contents for SySmart operation F 05/2016 AF All Revision of contents G 10/2017 AF All Revision of contents H 04/20
CONTENTS WARRANTY CONDITIONS................................................................................................................................................................. 6 WARRANTY RESTRICTIONS.............................................................................................................................................................. 7 SAFETY INSTRUCTIONS.......................................................................................................................
10 11 12 13 EXAMPLES OF WATER AND COOLING CIRCUITS............................................................................................................... 65 10.1 EXAMPLE OF CHILLED WATER CIRCUIT................................................................................................................................................................................65 10.2 TMC AIR-COOLED CONDENSER COOLING CIRCUIT...............................................................................
WARRANTY CONDITIONS All Products of the Manufacturer or bearing the trademark of the Manufacturer are built according to the state of the art techniques, in compliance with the current reference standards, as stipulated in the certificate of conformity provided together with the products. All Products of the Manufacturer or bearing the trademark of the Manufacturer are designed to be installed inside a system that controls them.
WARRANTY RESTRICTIONS The above mentioned warranty conditions are valid as long as the Customer has fulfilled all obligations according to the contract and in particular those relating to payment. A delayed payment or non-payment of the supply, even if partial, suspends any warranty. The warranty does not give the Customer any right to suspend or delay payments, which must be paid in any case according to the stipulations of the order and specified in the written order confirmation.
SAFETY INSTRUCTIONS All the Manufacturer’s Products, or those distinguished by the Manufacturer’s trademark have been designed and built for professional use in accordance with the applicable regulations. Check the complete list of applicable regulations in the EC declaration of conformity reported on the inside back cover of this manual, and supplied together with the product. It is necessary to comply with the regulations of the State where the product will be laid and installed.
RESIDUAL RISK Transport, positioning and installation Area Near product Hazard Risk Faulty lifting system that causes falls Bruising, trauma Unstable or unsuitable support that causes overturning Bruising, trauma Accidental impact with damage and leaking refrigerant Burns, formation of vapours Preventive measures Keep a safe distance from the hazardous area while handling the unit Make sure the product has a suitable support for its weight, and that it is stable and level Keep a safe distance from
1 DESCRIPTION OF UNITS AND OPERATING LIMITS 1.1 P SERIES, G SERIES AND R SERIES UNITS The machines in question are Close Control air conditioners with direct expansion or chilled water coil designed for use in technology centres.
1.3 OPERATING LIMITS WARNING! The Manufacturer tests the hydraulic parts with dried compressed air. This ensures that no water is present in the water circuits, thereby preventing the possibility of freezing during storage prior to installation.
1.4 CONFIGURATION EXAMPLES 1.4.
1.4.
1.4.
1.4.4 R SERIES - HORIZONTAL (HORIZONTAL/FRONT SUPPLY) Standard version with rear suction and front and side 1.4.
2 TRANSPORTATION, POSITIONING AND INSTALLATION PROCEDURES 2.1 OVERALL WEIGHT AND CLEARANCES FOR ROUTINE MAINTENANCE 2.1.1 OVERALL WEIGHT WARNING! If the units are installed on a normal floor, without vibration damping supports, it is necessary to place a layer of vibration damping material (rubber or equivalent material with a minimum thickness of 10 mm) between the machine and the floor to avoid transmitting vibrations to the structure of the building.
2.1.2 DIMENSIONS FOR INSTALLATION AND CLEARANCES The figure below shows the dimensions to be taken into account during installation. For the exact values referring to the dimensions indicated in the figure, refer to the following table and, in any case, to the drawings supplied with the order confirmation. The units must be positioned differently based on the type of unit, and always following the design and manufacturing requirements of the unit.
Clearances G Series B A a H b 1 Plan dimensions Standard models Dimensions (mm) Height Upper Lower Front A B H a b 1 921 1990 1050 2350 921 1990 300 550* 860 1050 2350 921 1990 1320 461 - 612 1490 150 XH 932 230 230 XH Routine maintenance (mm) Depth 70 150 Clearances (mm) Length 1840 2390 2740 1342 3120 300 4020 * Minimum height of ventilating plinth. Check definitive height when placing the order.
Clearances R Series a 2 H a b B A Front view Top view Plan dimensions Dimensions (mm) Clearances (mm) Standard models 121- 201 20 231 - 361 40 1 Length Depth Height A B H 300 1200 1975 + 70* 600 1222 1985 + 30* Front and side Front intake intake a b 200 315 * Height of the “Wheel kit” accessory 19 Routine Maintenance (mm) Front Rear 1 2 800 800 45
2.2 TRANSPORT, HANDLING AND POSITIONING OF THE UNIT DANGEROUS HANDLING! HEAVY LOADS! Always use suitable equipment to move the unit! 2.2.1 TRANSPORTATION AND RECEIVING THE MACHINES ON SITE During transport the machines cannot be laid down or turned over; hence they must always stay in vertical position. Turning the unit over would cause damage to the internal components.
2.2.2 HANDLING THE UNITS During site handling the machine must be left in its original packaging until it has reached the installation position. The unit must be lifted and transported by means of a forklift truck, pallet truck, winch hoist or through a rope lifting system. In case of rope lifting, the ropes must be slid underneath the pallet the unit is fitted with, and stiff spacers must be arranged to ensure the ropes do not crush the unit's structure during lifting.
2.3 UNIT POSITIONING 2.3.1 UNIT POSITIONING WITH WINCH HOIST To remove the unit from the wood pallet for final positioning, use one or more winch lifters of sufficient capacity (see previous chapters). Proceed as follows for the handling operations: 1) 2) 3) 4) 5) 6) 7) 8) Remove the straps and clamps on the wooden pallet. Push the winch lifters to the edge of the pallet while holding it securely. Make sure the lifting parts of the winch lifters are positioned at the bottom of the unit.
2.3.3 FRONT PANEL LOCKS, PANELS SCREWS AND COVER PLATES SCREWS The front panels feature one-quarter turn safety locks. The type of insert, shown in the following image, requires a special key to be opened. Two copies of these keys are supplied with the unit, one fixed to the outside and one inserted inside the electrical panel as a backup.
3 PLENUMS, VENTILATED PLENUMS AND DUCT SECTIONS (ACCESSORY) Various types of air distribution plenums are available as accessories for both the Under and Over versions of the unit. During plenum and duct section installation it is advisable to place a seal (rubber or equivalent material with minimum 5 mm thickness) between them and the unit so as to guarantee the air-tightness of the element.
3.2 INSTALLATION OF PLENUMS AND DUCT SECTIONS ABOVE THE UNIT Depending on the type of plenum, they are attached in two different ways: • • Unit with sheet metal structure: With bolts inserted in the relative holes. Unit with aluminium profile structure: With brackets. With bracket-mounted models, the brackets need to be attached to the unit’s aluminium uprights with self-drilling screws. The brackets should be attached, in a central position, to each side of the unit.
3.3 INSTALLATION OF PLENUMS AND VENTILATED PLENUMS (G SERIES UNIT) UNDER THE UNIT When installing plenums under the unit, it is advisable to place a layer of vibration damping material (rubber or equivalent material with a minimum thickness of 10 mm) between them and the floor to avoid transmitting vibrations to the structure of the building. The interposition of vibration damping material also enables the recovery of a slight lack of flatness of the floor and to contain the noise level of installation.
4 FREE COOLING PLENUM (ACCESSORY) WARNING! If the Free Cooling plenum is used with chilled water units, it is essential to use glycol if outdoor temperatures below 5°C are expected! Free Cooling plenums can be supplied as an accessory for the Under version units. These plenums make it possible to use outdoor air to cool the environments, and consist of: • • • A structure in galvanised sheet metal or in aluminium sections (depending on the model). Two panels fitted with motorised dampers.
4.2 MOUNTING FREE COOLING PLENUMS 4.2.1 DAMPER POSITIONING Free Cooling plenums are supplied with a standard configuration, for transport, with the dampers positioned at the front and back inside the plenum. When mounting and installing the plenum, the position of the dampers can be changed so that they can be adapted to the system requirements. Position it as follows: 1) 2) 3) 4) Define the position of the dampers (see table below). Remove the screws to take the panels off.
4.2.2 ADJUSTING THE OPENING OF THE DAMPERS If it is necessary to always guarantee a percentage of outdoor air intake or room air recirculation, the opening of the dampers can be adjusted with the servomotors installed on them: Adjust by calibrating the limit switch screws on the servomotor. Adjust as follows: 1) 2) 3) Set the motor at “Service OFF” with the function selector. Adjust the position of the limit switch blocks. Test movement of the dampers with the manual release button.
4.2.4 SETTING UP THE DUCT FOR OUTDOOR AIR INTAKE For optimal operation of the Free Cooling plenum, the outdoor air damper will have to be connected to the outside of the building so that it can draw in outdoor air: The installer will set up the connection duct and outdoor air intake. It is advisable to provide: • • • 4.2.5 An external opening with slots or grilles to prevent rainfall, harmful animals and human entry. An outdoor air filtration system, with G4 efficiency level.
5 ADJUSTABLE AND VENTILATED PLINTHS (ACCESSORY) When installing plinths it is advisable to place a layer of vibration damping material (rubber or equivalent material with a minimum thickness of 10 mm) between them and the floor to avoid transmitting vibrations to the structure of the building. The interposition of vibration damping material also enables the recovery of a slight lack of flatness of the floor and to contain the noise level of installation.
5.1.1 SIZING THE HOLE FOR THE INSTALLATION OF THE PLINTHS IN THE FINISHED FLOOR SURFACE To permit correct installation of the bases a hole must be made in the floor tiles. The dimensions of the plinths are found in the order confirmation or in the following tables for standard models (identified by the code number sequence).
5.2 ADJUSTABLE PLINTH ASSEMBLY Adjustable plinths come unassembled in a specific kit, accordingly it will be necessary to assemble them as explained in the chapters below. 5.2.1 POSITIONING SUPPORT PROFILES Position the metal supporting profiles supplied with the assembly kit on a flat surface according to the diagram below.
5.3 ADJUSTABLE PLINTH HEIGHT DEFINITION AND ADJUSTMENT The adjustable plinth support system is composed of two parts: • • One drilled tubular supporting foot. One threaded tubular support. The height must be adjusted as instructed in the next chapters. 5.3.1 port.
5.4 INSTALLATION OF ADJUSTABLE AND VENTILATED PLINTHS ON FINISHED FLOOR SURFACE ATTENTION! DANGER! DANGEROUS HANDLING! Placing the unit on the plinth before fixing the feet to the slab and positioning the raised floor can cause damage to the supporting feet and a risk of the units falling! The plinths are installed in the finished floor surface as follows: 1) Place the plinth on the slab. With adjusted plinths, attach the feet to the slab with suitable plugs.
6 TMC AIR-COOLED CONDENSER PLACEMENT AND INSTALLATION 6.1 DIMENSIONS FOR INSTALLATION AND CLEARANCES The figure below shows the dimensions to be taken into account during installation of the TMC air-cooled condensers. For the exact values referring to the dimensions indicated in the figure, refer to the following table and, in any case, to the drawings supplied with the order confirmation.
6.2 TMC AIR-COOLED CONDENSER INSTALLATION DANGEROUS HANDLING! HEAVY LOADS! Always use suitable equipment to move the unit! 6.2.1 VERTICAL INSTALLATION (V) TMC air-cooled condensers must be installed according to the following instructions: A A B A B Brackets Vibration damping supports (accessory) A Vertical installation (V) 1) 2) 3) 6.2.2 Remove the condenser from the packaging. Place the condenser in a vertical position.
7 CONNECTION OF CONDENSATE DISCHARGE AND HUMIDIFIER 7.1 CONNECTION OF CONDENSATE DISCHARGE AND HUMIDIFIER RISK OF BURNS! The drainage water of the humidifier may reach temperatures of 100 °C! All air conditioners, whether direct expansion or water chilled coils, require a condensate discharge connection, and the humidifier discharge of the building waste drainage system.
7.2 CONDENSATE BOOSTER PUMP CONNECTION (ACCESSORY) RISK OF BURNS! The drainage water of the humidifier may reach temperatures of 100 °C! All conditioners, both direct expansion and chilled water, can be supplied with a condensation pumping trap (accessory). Condensation booster pump When the unit is installed the drain pipe must be connected to the building's sewage network by the installer. The drainage pipe is flexible and transparent, with an external diameter of 9 mm (internal 6 mm).
8 WATER CIRCUIT CONNECTIONS 8.1 CHILLED WATER CIRCUITS CONNECTION WARNING! If the chilled water unit is used with Free Cooling plenum, it is essential to use glycol if outdoor temperatures below 5°C are expected! It will be necessary to install water inlet and outlet pipes for machines with chilled water coils. The inlet and outlet fittings are identified in the order confirmation or in the following tables for standard models (identified by the code number sequence).
8.1.1 SETTING UP THE CHILLED WATER CIRCUITS The positions of the water inlet and outlet connections are indicated in the figure below. The connections can also be identified by the adhesive labels applied on the pipes of the unit near the connections.
8.2 CHILLED WATER CIRCUITS CONNECTION - TWO SOURCES DESIGN It will be necessary to install water inlet and outlet pipes for Two Sources units as it was for machines with chilled water coils. The inlet and outlet fittings are identified in the order confirmation or in the following tables for standard models (identified by the code number sequence).
8.3 CHILLED WATER CIRCUITS CONNECTION - FREE COOLING DESIGN Machines in Free Cooling execution are supplied with water circuits connected to the pre-set valve and water condenser. Accordingly it will be necessary to set up the circuit water supply and discharge lines. The diameters of the pipes and the inlet and outlet fittings are identified in the order confirmation or in the following tables for standard models (identified by the code number sequence).
8.4 WATER-COOLED CONDENSER WATER CIRCUITS CONNECTION (ACCESSORY) For machines with incorporated water-cooling condenser it is necessary to set up the condenser supply and discharge lines. The diameters of the pipes and the inlet and outlet fittings are identified in the order confirmation or in the following tables for standard models (identified by the code number sequence).
8.4.2 SETTING UP THE WATER-COOLED CONDENSER WATER CIRCUITS The positions of the water inlet and outlet connections are indicated in the figure below. The connections can also be identified by the adhesive labels applied on the pipes of the unit near the connections.
8.5 CONNECTION OF THE INTERNAL SUBMERGED ELECTRODE HUMIDIFIER (ACCESSORY) The units may be fitted with a submerged electrode humidifier to control environmental humidification. This type of humidifier exploits the conductivity of the water in the cylinder to produce steam. Applying voltage to the electrodes in the cylinder, current will flow between the electrodes that will heat the water until it reaches boiling point. The humidifier is adjusted with the electronic board installed in the electric panel.
8.5.2 SETTING UP THE SUBMERGED ELECTRODE HUMIDIFIER WATER CIRCUITS The submerged electrode humidifier's supply line shall have the features set out in the table below: A B A Shut-off cock Mechanical filter B Humidifier water supply line To ensure that circuit pipes are installed correctly, we recommend you follow the instructions below: • • • • • • A shut-off cock must be installed on the water supply pipe (A). A 50 μ mechanical filter must be installed on the supply line (B).
9 COOLING CONNECTIONS 9.1 ROUTING OF THE COOLING CIRCUIT PIPES WARNING! Correct pipe routing is crucial for good conditioner operation. It is necessary to be particularly careful in the choice and set-up of the supply and liquid pipes, especially with very long lines. It is important to remember that the pipes should be SHORT AND WITH THE LEAST BENDS POSSIBLE since the cooling capacity of the circuit can be reduced based on its length. 9.1.
9.1.
Installation with condenser down low (Height difference -1 ÷ -10 m) A A B C D F -10 m * E F B D C Unit Supply line Air-cooled condenser (horizontal installation) Air-cooled condenser (vertical installation) Check valve Liquid line * Suggested maximum height difference vertical E E Suggested maximum vertical height difference -10 m Supply pipe precautions Ensure a gradient of 2% along the horizontal sections toward the condenser Supply pipe insulation Internal Required External For aesthet
9.2 COOLING CIRCUIT SIZING 9.2.1 TYPES OF PIPING TO BE USED The pipes must be made of copper that is suitable for direct expansion cooling circuits as required by standard EN 12735-1. Annealed copper coils may be used (diameters up to 7/8"), as well as hard-drawn copper bars.
9.2.3 DIAMETERS OF COOLING CIRCUIT CONNECTION PIPES The diameters of the supply, liquid and suction pipes are identified in the order confirmation or in the following tables for standard models (identified by the code number sequence).
9.3 COOLING CIRCUIT INSTALLATION 9.3.1 COOLING CIRCUIT INSTALLATION PRECAUTIONS In order to correctly implement the cooling circuit, the following precautions need to be complied with: • • • • • • • • 9.4 Do not leave the circuit outdoors for an extended time, to prevent excessive formation of humidity. To prevent copper dust or swarf from getting into the system, the pipes should be cut using a pipe cutter rather than a hacksaw.
9.5 AIR-COOLED CONDENSER CONNECTION The refrigerant inlet and outlet connections on the air-cooled condenser can be identified by their adhesive labels. To facilitate the connection there is a section of pipe approximately 100 mm long, crimped and welded shut on the free end. A check valve (supplied loose) has to be installed on the liquid pipe. When installing the valve, make sure the direction of the arrow matches the direction of flow.
9.5.3 PRECAUTIONS FOR BRAZING RISK OF BURNS! Burn hazard during cooling circuit brazing procedures! WARNING! Check the nitrogen flow during brazing. If brazing is performed without using nitrogen, a strong layer of rust will develop inside the pipes, which may damage the valves and compressor and hinder the unit from operating correctly. When performing brazing while feeding nitrogen into the pipe, the nitrogen must be regulated with a pressure reduction valve at 0.
9.6 COOLING CIRCUIT VACUUM DRYING OPERATIONS WARNING! Remote condenser air conditioners are shipped pressurised with nitrogen. Air-cooled condensers are shipped pressurised with nitrogen. WARNING! Air conditioners with internal water-cooled condensers are supplied FULLY CHARGED with refrigerant. After all connections and seal test operations, included in the previous chapters, have been completed for the cooling circuit, it is necessary the vacuum drying operation of the cooling circuit.
9.7 CHARGING THE COOLING CIRCUIT 9.8 PRECAUTIONS WARNING! This equipment is exclusively meant for professionally prepared operators that know the fundamentals of cooling, cooling systems, cooling gasses and the possible damages that pressured equipment may cause. The compressor must exclusively operate with refrigerants indicated by the manufacturer. Oxygen must never be allowed to enter the inside of the compressor.
Unit refrigerant content Standard models Unit Oil separa- Water-cooled tor condenser kg Hot gas Standard models Unit Oil separa- Water-cooled tor condenser kg Hot gas P Series 071 2.00 0.15 0.25 322 0.30 2.50 0.20 0.40 0.65 141 2.40 0.20 0.25 0.30 422 2.70 0.20 0.40 - 211 2.60 0.20 0.40 0.45 512 4.40 0.20 0.55 - 251 4.15 0.20 0.55 0.45 662 5.20 0.20 0.70 - 301 5.00 0.20 0.70 0.65 852 5.20 0.20 1.45 - 932 7.70 0.20 1.45 - 321 5.00 0.20 0.
9.9 LUBRICATING OIL FILLING IN THE CIRCUIT WARNING! The quantity of lubricating oil necessary for the system to operate must be checked in ALL units, even those with the oil separator. Correct lubricating oil charging is crucial for good operation of the direct expansion circuit, in fact, having no lubricating oil causes problems to the circuit, such as mechanical breakage of the compressor. 9.9.
9.9.5 CHECK OF CORRECT LUBRICATING OIL LOAD AND EVENTUAL CIRCUIT TOP-UP It is always necessary to check whether lubricating oil needs to be added to the cooling circuit. The quantity of lubricating oil depends on the total refrigerant load and system characteristics.
9.9.7 CHARGING THE CIRCUIT WITH REFRIGERANT WARNING! Cooling circuit recharging operations need to be carried out with the unit running. Make sure that the electrical connections are correct. Always charge the refrigerant in its liquid state. Make sure that the connections between pipes and cylinder are always set up correctly. Before charging the circuit, check that the refrigerant cylinder is equipped with a dip tube for the liquid refrigerant.
9.10 TMC CONDENSER PRESSURE REGULATOR (ACCESSORY) As accessories, speed regulation systems are available, installed inside the unit, for the remote condenser fans. Two different types of regulation are available, depending on what type of condenser is used. 9.10.1 ELECTRONIC CUT-OFF (AC) FAN SPEED REGULATORS Electronic cut-off speed regulators are normally used to proportionally and continuously vary the speed of condensers with AC fans, with 230 Vac power supply, suitable for cut-off control.
9.11 CHECKING THE REFRIGERANT LOAD AND COOLING CIRCUIT OPERATION WARNING! The compressor needs to be started up a few minutes prior to running the checks! Correct plant operation, which depends on the choice of fundamental components and the dosage of the refrigerant load, can be checked from the cooling circuit operating values.
9.12 PRECAUTIONS AGAINST REFRIGERANT LEAKS The direct expansion units operate on R410a refrigerant. R410a refrigerant is completely safe, non-toxic and non-flammable. This notwithstanding, it is considered a fluorinated greenhouse gas subject to the Kyoto Protocol, with a Global Warming Potential (GWP100) of 2088. According to the REGULATION (EC) no.
10 EXAMPLES OF WATER AND COOLING CIRCUITS 10.1 EXAMPLE OF CHILLED WATER CIRCUIT The following image represents the water circuit of chilled water units. E D A B C D E F G H I C C B F G H Water inlet Inlet water temperature (accessory) Manual air vent valves Chilled water coil Fan Outlet water temperature (accessory) Water flow measuring device (accessory) 3-way ball valve Water outlet * 2-way ball valve (accessory) I A 10.
10.3 COOLING CIRCUIT WITH SINGLE COMPRESSOR AND REMOTE CONDENSER The following image represents the cooling circuit in units with single compressor and remote condenser.
10.4 COOLING CIRCUIT WITH SINGLE COMPRESSOR AND WATER-COOLED CONDENSER The following image represents the cooling circuit in units with single compressor and air-cooled condenser.
10.5 COOLING CIRCUIT WITH DOUBLE COMPRESSOR AND REMOTE CONDENSER The following image represents the cooling circuit in units with double compressor and remote condenser.
10.6 COOLING CIRCUIT WITH DOUBLE COMPRESSOR AND WATER-COOLED CONDENSER The following image represents the cooling circuit in units with double compressor and water-cooling condenser.
10.7 TWO SOURCES WATER CIRCUIT WITH CHILLED WATER CIRCUITS The following image represents the water circuit of chilled water two sources units.
10.8 TWO SOURCES COOLING CIRCUIT WITH SINGLE COMPRESSOR AND REMOTE CONDENSER The following image represents the cooling circuit in two sources units with single compressor and remote condenser.
10.9 er.
10.10 TWO SOURCES COOLING CIRCUIT WITH DOUBLE COMPRESSOR AND REMOTE CONDENSER The following image represents the cooling circuit in two sources units with double compressor and remote condenser.
10.11 TWO SOURCES COOLING CIRCUIT WITH DOUBLE COMPRESSOR AND WATER-COOLED CONDENSER denser.
10.12 COOLING CIRCUIT WITH FREE COOLING AND SINGLE COMPRESSOR The following image represents the cooling circuit of the free cooling units with single compressor.
10.13 COOLING CIRCUIT WITH FREE COOLING AND DOUBLE COMPRESSOR The following image represents the cooling circuit of the free cooling units with double compressor.
11 ELECTRICAL CONNECTIONS WARNING! It is necessary to always refer to the electrical diagram supplied with the unit. The electrical wiring diagram suggests dimension values for the electricity line and the corresponding protective devices.
11.1 RS485 SERIAL COMMUNICATION BOARD CONNECTION (Modbus RTU - BACnet MS/TP) The SySmart3 microprocessors can be connected to a supervision and/or BMS (Building Management System) network, which adopts the Modbus RTU (Standard) or BACnet MS/TP (Accessory) protocol through a dedicated RS485 serial board. Using this type of board it is also possible to connect the gateways necessary to interface the SySmart3 with networks that use different protocols to those available as accessories.
11.2 ETHERNET RJ45 PORT CONNECTION (Modbus TCP - BACnet IP - Web Server) The SySmart3 microprocessors can be connected to a supervision and/or BMS (Building Management System) system, which adopts the Modbus TCP (Standard) or BACnet IP (Accessory) protocol through a dedicated RJ45 serial board. ry).
11.3 CANbus LAN CONNECTION (ACCESSORY) SySmart3 microprocessors can be interconnected in a CANbus LAN (Accessory) that allows several units to run so as to optimise the regulation of the air-conditioned rooms. To create a LAN, simply connect the units from the terminals on it (see wiring diagram for further information). Refer to the next chapter for connecting the remote terminal. A D C B E D F E D A B C D E E F F Unit 1 Unit 2 End unit (max.
11.4 REMOTE CONTROL TERMINAL CONNECTION (ACCESSORY) If the terminal is to be panel or recess-mounted, the maximum thickness of the panel must be 6 mm; if the terminal is to be recess-mounted in a wall, it is necessary a square recess-mounted resin box for 6 (3+3) modules (506E BTicino type). The dimensions and drilling template are as follows: Remote terminal dimensions In order to power the remote display through the unit, it needs to be enabled for such connection through the dedicated accessory.
11.5 WALL-MOUNTED TEMPERATURE AND HUMIDITY PROBE CONNECTION (ACCESSORY) The supplied temperature and humidity probe allows managing the room temperature and humidity detection in systems where return detection is not real or satisfying like, for example, systems with partial outside air introduction in the return. The supplied probe is of wall installation type. It is recommended to position the probe at a minimum height of 1600 mm off the floor for the most reliable temperature readings.
11.6 DUCTED TEMPERATURE AND HUMIDITY PROBE CONNECTION (ACCESSORY) The supplied temperature and humidity probe allows managing the room temperature and humidity detection in systems where return detection is not real or satisfying like, for example, systems with partial outside air introduction in the return. The supplied probe is the duct installation type. It is recommended to position the probe at the centre of the duct for the most reliable temperature readings.
11.7 CONNECTION OF THE SMOKE AND FLAME DETECTORS SUPPLIED (ACCESSORY) The smoke and flame detectors supplied detect the presence of smoke or flames in the environment. The supplied probe is of wall installation type. The connections must be made as indicated in the electrical wiring diagram supplied with the unit. The terminal board for connecting the sensor is shown in the figure below.
11.8 WATER DETECTION PROBE CONNECTION (ACCESSORY) The accessory for detecting the presence of water provides an alarm if the probe, supplied with the device, is even partially covered with water. The probes are comprised of an anti-corrosive metal container (local probe) or a fabric belt (belt probe). Inside the probes there are two stainless steel metal electrodes to read the alarm condition.
11.9 CONNECTION OF FREE COOLING PLENUM MOTORISED DAMPER ACTUATORS (ACCESSORY) The Free Cooling plenum accessory has two motorised dampers controlled by the regulator through a 0-10 Vdc signal. The damper actuators are supplied mounted on the dampers, and equipped with 3 metres of pre-wired cable in the actuators.
11.10 AIR-COOLED CONDENSER POWER SUPPLY AND REGULATION CONNECTION (ACCESSORY) Air-cooled condensers can be supplied with two types of electric power supply and regulation, as an accessory: 1) 2) A 230 Vac power supply with cut-off regulation, dedicated to condensers with AC fans. A 230 Vac or 400 Vac protected line (depending on the type of condenser) and a 0-10 Vdc signal line for the regulation of condensers with EC fans.
12 ROUTINE AND SPECIAL MAINTENANCE WARNING! The product must be serviced by skilled personnel who fulfil the adequate requisites for the task as defined by the regulations in the country where positioning and installation of the product take place.
12.1 ROUTINE MAINTENANCE 12.1.1 CONTROL MICROPROCESSOR MAINTENANCE For further and more detailed information concerning regulation, see theMICROPROCESSOR OPERATING MANUAL. The microprocessor requires periodical checks to verify operational statuses and the presence of possible alarms in components that may compromise proper unit operation. For further information concerning alarms and operations, see the installed microprocessor operating manual. 12.1.
12.1.3 AIR FILTER REPLACEMENT To replace the air filters the following instructions must be observed, as well as full compliance with safety obligations regarding use of the equipment: 1) 2) 3) 4) 5) 6) Set the main switch to "0". Open the panels via the relevant safety locks. Remove the filter support by turning the screws. Replace the dirty filters with clean ones. Position the support and secure it with the screws. Close the panels and return the main switch to “I”.
12.1.4 MAINTENANCE OF INTERNAL HUMIDIFIER ATTENTION! DANGER! Risk of immediate start-up after resetting the main switch if used as an emergency stop! The main switch can be used as an emergency stop when the operator is near the machine (during startup, operation and maintenance). In this case, resetting the main switch will allow the machine to immediately restart, without any additional action by the operator.
12.2 SPECIAL MAINTENANCE RISK OF ELECTRIC SHOCK! Set the main switch to "0" before every activity RISK OF BURNS! Some parts of the cooling circuit may be hot! RISK OF CUTS! Sharp parts! ATTENTION! DANGER! Risk of immediate start-up after resetting the main switch if used as an emergency stop! The main switch can be used as an emergency stop when the operator is near the machine (during startup, operation and maintenance).
12.2.3 FAN MAINTENANCE For fans maintenance the following instructions must be observed, as well as full compliance with safety obligations regarding use of the equipment: 1) 2) 3) 4) 5) 12.2.4 Check the general condition: corrosion, fastening, cleanliness. Verify the noise of the motor. Check the impeller: vibrations, unbalancing. Verify the absorbed current. Clean the impeller and the motor.
12.2.6 MAINTENANCE OF WATER CIRCUITS For the water circuit maintenance the following instructions must be observed, as well as full compliance with safety obligations regarding use of the equipment: 1) 2) 3) 4) 5) 6) 12.2.7 Check circuits for leaks. Bleed air from circuits. Check circuit temperatures and pressures. Check operation of the 3-way valves. Check the amount of glycol in the circuit. Make sure the water circulates properly.
12.2.8 REPLACEMENT OF WATER VALVE ACTUATORS WITH RING NUT CONNECTION To replace the actuators of the water valves, proceed as follows: 1) 2) 3) 4) 5) 6) 7) 12.2.9 Set the main switch to "0". Open the panels via the relevant safety locks. Disconnect the electrical connections from the actuator. Remove the actuator by means of the ring nut. Do not use equipment. Replace with an original spare. Make the electrical connections of the actuator as per the wiring diagram.
12.2.10 COOLING CIRCUIT MAINTENANCE For the cooling circuit maintenance the following instructions must be observed, as well as full compliance with safety obligations regarding use of the equipment: 1) 2) 3) 4) 5) 6) 7) Check the work pressures and temperatures from the screen of the SySmart controller microprocessor. Check overheating, sub-cooling and desuperheating from the screen of the SySmart controller microprocessor. Check the condition of the liquid sight glass filter.
12.2.12 COMPRESSOR REPLACEMENT ATTENTION! DANGER! Neither the circuit nor the compressor must be left in open air for more than 15 minutes to avoid humidity contaminating the oil. To replace the compressor the following instructions must be observed, as well as full compliance with safety obligations regarding use of the equipment: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) Set the main switch to "0". Open the panels via the relevant safety locks.
12.3 MAINTENANCE OF TMC AIR-COOLED CONDENSERS 12.3.1 MAINTENANCE OF TMC AIR-COOLED CONDENSER FANS For air-cooled condenser fans maintenance the following instructions must be observed, as well as full compliance with safety obligations regarding use of the equipment: 1) 2) 3) 4) 5) 12.3.2 Check the general condition: corrosion, fastening, cleanliness. Verify the noise of the motor. Check the impeller: vibrations, unbalancing. Verify the absorbed current. Clean the impeller and the motor.
12.3.3 CLEANING THE COILS OF THE TMC AIR-COOLED CONDENSERS Notes for correct cleaning: 1) 2) 3) Use a flat or "fan-shaped" spray nozzle. Maximum water pressure: < 2 bar with tap water and 80÷100 bar with pressure washer. Keep the water spray at right angles to the fin edge both vertically and horizontally.
13 DEACTIVATION, DISMANTLING AND DISPOSAL WARNING! The product must be dismantled by skilled personnel who fulfil the adequate requisites for the task as defined by the regulations in the country where positioning and installation of the product take place. For the deactivation, dismantling and disposal of the units, the following must also be considered: • • • 13.1 The direct expansion units contain R410a refrigerant, a fluorinated greenhouse gas subject to the Kyoto Protocol.
13.1.1 LIST OF THE MATERIALS CONTAINED IN THE UNITS The following table lists the materials used, upon shipment, to produce the units.
14 APPENDIX 1: RECOMMENDED EQUIPMENT The table below lists the equipment required to perform unit installation, start-up and maintenance.
15 APPENDIX 2: PRELIMINARY CHECKS AND FIRST START-UP WARNING! The product must be installed and started up by skilled personnel who fulfil the adequate requisites for the task as defined by the regulations in the country where positioning and installation of the product take place. 15.1 PRELIMINARY CHECKS 15.1.1 VERIFICATION OF POSITION AND INSTALLATION Description 1 Check that the units received comply with the order and transport documents.
15.1.4 CHECKS ON THE WATER CONDENSED DIRECT EXPANSION CIRCUIT Description 1 Make sure the cooling circuit valves are open. 2 4 Verifying the water circuit connections. Check that all liquid supply pipes have manual shutoff taps just outside the machine, and that these taps are open. Verify that the hydraulic circuits have been adequately cleaned. 5 Verify that there is no air in the hydraulic circuits.
15.1.6 CHECKS OF THE VACUUM OF THE AIR CONDENSED DIRECT EXPANSION CIRCUIT Description 1 Make sure the cooling circuit valves are open. 2 Check opening of the solenoid valve (if present on circuit). 3 Check the seal of the cooling circuit. 4 Check the high and low side pressure gauges connection in VACUUM position. 5 Check the vacuum level of the cooling circuit. 15.1.7 1 Check the high and low side pressure gauges connection in CHARGING position.
15.1.9 1 2 3 4 5 6 7 8 9 10 11 12 13 VERIFY CONNECTIONS TO ROOM PROBE, REMOTE TERMINALS, LAN AND RS485 SERIAL BOARD (IF PRESENT) Description Make sure the RS485 board is wired as indicated on the wiring diagram and in the installation manual. Check the activation of the terminating resistance of the RS485 network. Check connection of LAN cable as indicated in the electrical wiring diagram and the installation manual. Check the activation of the opening and terminating resistance of the LAN.
15.2 FIRST START-UP WARNING! Starting up or checking machines with cooling circuit requires the units to be powered on for at least two hours prior to the arrival of the technician, in order to allow the compressor's crankcase oil heater to reach working temperature and allow evaporation of any refrigerant deposited in it and guarantee correct compressor operation. The crankcase heaters switch on automatically when the machine is powered on. 15.2.
15.2.5 CHECKING COOLING CIRCUIT OPERATION Description 1 Evaporation pressure 2 Evaporation temperature 3 Suction temperature 4 Overheating 5 Compression ratio 6 Discharge temperature 7 Condensation pressure 8 Condensation temperature 9 Desuperheating Value Positive Negative Value Positive Negative 10 Liquid temperature 11 Sub-cooling 15.2.6 CHECKING CORRECT COMPONENT OPERATION Description Fans 1 Check fan current consumption. 2 Check flow sensor operation.
15.2.7 MAKE SURE THE UNIT IS OPERATING CORRECTLY Description 1 Ensure that the set temperature is reached. 2 Ensure that the set humidity is reached. 3 Check correct general operation of the unit. 15.2.
16 APPENDIX 3: FAULT DIAGNOSIS WARNING! Maintenance operations must be carried out by professionally trained technicians This chapter contains information to assist the operator in tracing any faults that may arise with the machine. Starting with a description of the nature of the problem, we provide indications on the probable causes and possible solutions.
16.
16.
NO AIR CHECK AERAULIC CIRCUIT COOLING CIRCUIT EMPTY CHECK FOR LEAKS AND CHARGE CIRCUIT FILTER-DRIER CLOGGED REPLACE FILTER-DRIER EXPANSION VALVE FAULTY REPLACE VALVE PROBLEMS WITH STARTUP IN WINTER OUTDOOR TEMPERATURE TOO LOW - INSTALL LAC VALVE PRESENCE OF ICE ON EVAPORATOR CHECK AIR FLOW RATE AND REFRIGERANT LOAD COOLING CIRCUIT EMPTY CHECK FOR LEAKS AND CHARGE CIRCUIT LOW CONDENSATION PRESSURE CHECK CONDENSER FILTER-DRIER CLOGGED REPLACE FILTER-DRIER EXPANSION VALVE FAULTY REPLACE VALV
LOW SUBCOOLING HIGH PRESSURE SAFETY TRIGGERED CONDENSER DIRTY WASH CONDENSER AIR OR INBOUND WATER TEMPERATURE TOO HIGH CHECK FOR ANY RECYCLING OF AIR OR WATER CIRCUIT COOLING CIRCUIT EMPTY CHECK FOR LEAKS AND CHARGE CIRCUIT CONDENSER DIRTY WASH CONDENSER AIR OR INBOUND WATER TEMPERATURE TOO HIGH CHECK FOR ANY RECYCLING OF AIR OR WATER CIRCUIT FANS NOT WORKING CHECK SPEED REGULATOR FANS DAMAGED REPLACE FANS NO WATER CHECK WATER CIRCUIT AND ADJUSTMENT VALVE COOLING CIRCUIT TOO FULL CHECK AN
16.
16.
16.
PRESENCE OF ELECTRIC ARCS IN CYLINDER CYLINDER CLOGGED WITH LIMESCALE CLEAN CYLINDER AND REPLACE IF NECESSARY WATER CONDUCTIVITY HIGH INSTALL CYLINDER WITH HIGH CONDUCTIVITY PRESENCE OF SALT SOFTENERS REMOVE SOFTENERS CYLINDER BURNT OUT REPLACE CYLINDER DISCHARGE SOLENOID VALVE BLOCKED CHECK VALVE AND REPLACE IF NECESSARY NO ELECTRICAL POWER SUPPLY CHECK ELECTRONIC CONTROL BOARD NO CONTROL SIGNAL CHECK ELECTRONIC CONTROL BOARD WATER CONDUCTIVITY LOW INSTALL CYLINDER WITH LOW CONDUCTIVITY WA
CONTINUOUS OR INTERMITTENT WATER DISCHARGE WATER OVERFLOWS FROM TANK DURING DISCHARGE CYLINDER BURNT OUT REPLACE CYLINDER DISCHARGE SOLENOID VALVE BLOCKED CHECK VALVE AND REPLACE IF NECESSARY WATER CONDUCTIVITY HIGH INSTALL CYLINDER WITH LOW CONDUCTIVITY PRESENCE OF FOAM IN CYLINDER USE UNTREATED POTABLE WATER DISCHARGE PIPE BLOCKED REMOVE BLOCKAGE DISCHARGE PIPE VERY SMALL REPLACE DISCHARGE PIPE WITH SUITABLY SIZED TYPE PRESENCE OF SIPHONS ON DISCHARGE LINE REMOVE SIPHONS NO ELECTRICAL POWE
17 NOTES 120
EC DECLARATION OF CONFORMITY The manufacturer declares, under its own responsibility, that the equipment covered by this manual: • Is intended for installation in air conditioning systems. It is prohibited to place this equipment into operation before the system has been declared as compliant with the provisions of the applicable Directives.
The Manufacturer adopts a policy of continuous development and therefore reserves the right to make changes and improvements to any product described in this document without prior notice. Technical data and dimensions are not binding.
