ED Power - Baudiment Technology

Transcription

Air or Water Cooled Direct Expansion
CLOSE CONTROL UNITS
Use and Maintenance
MANUAL
(rev. 2, 08/2013)
ED - Power Line – Use and Maintenance Manual
Emicon A.C. S.p.A. reserves the right to modify its products and the corresponding documentation without
any prior notice.
pag. 2
EMICON A.C. S.P.A. via A. Volta, 49 – 47014 Meldola (FC) – Italy
tel. (+39) 0543/495611 – fax. (+39) 0543/495612 – e-mail emicon@emiconac.it
(rev. 2, 08/2013)
TABLE OF CONTENTS
1.
INTRODUCTION ................................................................................... 7
1.1.
Manual content ..................................................................................................... 8
1.2.
Safety marks ......................................................................................................... 8
1.3.
Referring standards ............................................................................................. 8
1.4.
Identification Tag ................................................................................................. 9
1.5.
Warranty.............................................................................................................. 10
1.6.
Manual’s Readers .............................................................................................. 10
1.7.
Main safety rules ................................................................................................ 10
1.7.1.
General warnings ........................................................................................... 10
1.7.2.
Allowed use.................................................................................................... 11
1.7.3.
Forbidden use ................................................................................................ 11
1.7.4.
Dangerous areas ........................................................................................... 11
1.8.
2.
Personnel’s requirements ................................................................................. 12
DESCRIPTION .................................................................................... 13
2.1.
ED Series description ........................................................................................ 13
2.2.
Available configurations ................................................................................... 13
2.3.
Main components ............................................................................................... 16
2.3.1.
Housing.......................................................................................................... 16
2.3.2.
AC Centrifugal Fans (Standard) ................................................................... 17
2.3.3.
EC Centrifugal Fans (Optional) ..................................................................... 17
2.3.4.
Direct expansion cooling coil with hydrophilic treatment ............................... 18
2.3.5.
Electric heater (optional) ................................................................................ 18
2.3.6.
Humidifier (optional) ....................................................................................... 18
2.3.7.
Scroll Compressor/s ...................................................................................... 19
2.3.8.
Different types of base-frames (optional) ...................................................... 20
pag. 3
(rev. 2, 08/2013)
2.3.9.
Plenum (optional) .......................................................................................... 20
2.3.10.
Electric board ............................................................................................. 21
2.3.11.
Control system ........................................................................................... 21
2.3.12.
Front panels with windows for access/inspection ...................................... 22
2.3.13.
Opening of the electric board ..................................................................... 24
2.3.14.
Internal or external main switch with padlock ............................................. 25
2.4.
Controls and tests .............................................................................................. 26
2.5.
Accessories ........................................................................................................ 27
2.6.
Operational scheme ........................................................................................... 30
2.7.
Wiring diagram ................................................................................................... 33
2.8.
Noise level .......................................................................................................... 33
2.9.
Dimensions ......................................................................................................... 33
2.9.1.
3.
ED Power series’ dimensions ........................................................................ 33
INSTALLATION .................................................................................. 35
3.1.
Identification tag ................................................................................................ 35
3.2.
Reception and inspection ................................................................................. 35
3.3.
Handling .............................................................................................................. 35
3.4.
Unit Positioning .................................................................................................. 36
3.5.
Opening and closing of panels ......................................................................... 38
3.6.
Cooling and hydraulic connections ................................................................. 40
3.6.1.
Cooling connections for ED.X and ED.E ....................................................... 40
3.6.2.
Plate condenser hydraulic connections for ED.H .......................................... 47
3.7.
Condensate drainage connection .................................................................... 48
3.7.1.
Condensate drainage connection .................................................................. 48
3.8.
Fresh air intake connections (optional) ........................................................... 48
3.9.
Humidifier connections (optional) .................................................................... 49
3.10.
pag. 4
Electric connections ....................................................................................... 50
(rev. 2, 08/2013)
3.10.1.
Power supply connection ........................................................................... 51
3.10.2.
Connection to the user terminal board ....................................................... 52
3.10.3.
Condenser or motor-condenser connections ............................................. 54
3.10.4.
Control of the correct sequence of the power supply phases .................... 54
3.11. Tightness test, vacuum and charge execution of the system (only for EDX
and EDE) ....................................................................................................................... 54
3.11.1.
Tightness test ............................................................................................. 55
3.11.2.
Vacuum execution ...................................................................................... 56
3.11.3.
Refrigerant charge execution ..................................................................... 58
4.
OPERATION ....................................................................................... 60
4.1.
Documentation ................................................................................................... 60
4.2.
First start-up ....................................................................................................... 60
4.2.1.
First controls .................................................................................................. 60
4.2.2.
Startup ........................................................................................................... 62
4.2.3.
Switch-off ....................................................................................................... 63
4.3.
Setup ................................................................................................................... 63
4.4.
Microprocessor setting ..................................................................................... 64
4.5.
Steam production setting (unit with humidifier) ............................................. 64
5.
MAINTENANCE .................................................................................. 65
5.1.
Programmed maintenance ................................................................................ 67
5.1.1.
Leak detection ............................................................................................... 67
5.1.2.
Control of the safety pressure switch ............................................................ 67
5.1.3.
Control of the safety valves ........................................................................... 67
5.1.4.
Control of the noise level and vibrations ........................................................ 68
5.1.5.
Periodical operations ..................................................................................... 68
5.2.
Routine maintenance ......................................................................................... 70
5.2.1.
Control of the refrigerant humidity probe ....................................................... 70
pag. 5
(rev. 2, 08/2013)
5.2.2.
Control of the refrigerant overheating ............................................................ 71
5.2.3.
Control of the refrigerant subcooling ............................................................. 71
5.2.4.
Control of the overcurrent protective devices ................................................ 72
5.2.5.
Control of contactors ..................................................................................... 72
5.3.
Troubleshooting ................................................................................................. 73
5.4.
Special maintenance .......................................................................................... 77
5.4.1.
Opening of the cooling circuit ........................................................................ 78
5.4.2.
Refrigerant treatment ..................................................................................... 79
5.4.3.
Operations to be performed after the repair .................................................. 80
6.
DISMANTLING .................................................................................... 80
7.
REFRIGERANT SAFETY DATA SHEET ............................................ 81
pag. 6
1.
(rev. 2, 08/2013)
INTRODUCTION
The range of close control units of ED Power Line has been designed and realised by Emicon A.C. S.p.A. for
bieng used in technological centres, data processing centres, telecom applications and whenever special
thermo-hygrometric conditions are required.
Emicon A.C. S.p.A. presents the following series belonging to ED Power Line :
•
ED.X Series – air cooled precision conditioning unit with direct expansion coil;
•
ED.H Series – water cooled precision conditioning unit with direct expansion coil;
•
ED.E Series – precision conditioning unit with direct expansion coil and remote motor-condenser.
The units of ED Power Line are available in different configurations according to the air intake and
discharge:
o
Up Version (front air intake and upflow air discharge);
o
Version Vertical (bottom air intake and upflow air discharge);
o
Back Version (back air intake and upflow air discharge);
o
Down Version (top air intake and downflow air discharge).
The units of ED.E series need to be connected to the air motor-condensers of MCX Kc or Ka, designed for
external installation.
This diversification can satisfy the customers demands in terms of unit performance, airflow capacity and
energy saving.
The units of ED Power Line are produced using the best technologies and components currently available on
the market, among which the fans with AC (Autotransformer Controlled) motors. The single-inlet AC
centrifugal fans are equipped with an impeller with backward curved blades. They are equipped with an auto
transformer which can control the fan speed rotation.
ED Power Line is built using the panels coating technology. As a matter of fact, the galvanised steel panels
are coated with a protection film in PVC. This technology allows to obtain a high corrosion resistance and
prevents blisters from occurring in cases of high humidity conditions.
pag. 7
(rev. 2, 08/2013)
1.1. Manual content
The present document (hereinafter: The Manual), originally written in Italian, was completed in
compliance with the relevant European laws. It contains all the necessary information to carry out
correctly and without any risk the transportation, the installation, the startup, the operation, the setting,
the maintenance and the dismantling of the unit it refers to.
Before doing any operation on the unit, read the whole Manual and all its annexes which are an integral
part of it, and follow carefully all instructions described in it.
The non respect of the instructions described in the Manual during the installation, the operation, the
maintenance, the repair and the dismantling of the group, can cause serious damage to people, things and
environment.
In case of any doubts on the correct understanding of the instructions contained in the Manual, please
contact Emicon A.C. S.p.A. to get further explanations (hereinafter: The Manufacturer).
The unit must be installed, controlled, submitted to maintenance, repaired and dismantled in conformity with
the local laws into force.
1.2. Safety marks
The following safety marks are used in this Manual to draw the reader’s attention to all useful information
in order to avoid any dangerous situation which could be unsafe and harmful for people, could damage
equipment and environment besides breaking the unit.
It means operation not allowed as it could damage the unit.
It means an important information for the correct unit operation.
It means danger or risk to people, things or environment.
It means an electrical danger to people, things or environment.
1.3. Referring standards
Unless there are different agreements clearly stated on the corresponding order, the unit described in this
Manual has been manufactured in compliance with all the relevant European Directives and in particular, it
meets the essential safety requirements of the following directives:
•
2004/108/CE (Electromagnetic Compatibility Directive),
•
97/23/CE (PED – Pressure Equipment Directive),
•
2006/42/CE (Machinery Directive),
pag. 8
•
(rev. 2, 08/2013)
2006/95/CE (Low Voltage Directive).
As required, the compliance of the unit to the above mentioned directives is certified by the Declarations of
Conformity described in Chapter 8 and it is also attested by the CE mark on the unit identification tag, described
in the following paragraph.
In order to guarantee the unit compliance to the above mentioned directives, the unit is designed, manufactured
and tested according to the instructions established in the harmonised standards listed in the above mentioned
certificates of conformity.
1.4. Identification Tag
The unit is identified by means of a permanent tag attached inside the electrical panel (hereinafter:
Identification Tag). Figure 1.1 shows a facsimile of the Identification Tag with the description of the
information it contains, in conformity with the relevant European norms.
Figure 1.1: Unit Identification Tag
1
Manufacturer’s name and address
7
Refrigerant charge per circuit
2
CE mark and notification number of the Notified Body
8
Transportation weight
9
Maximum allowable pressure (PS) for high and low
who has issued the PED certificate
3
Model
pressure sections
4
Identification number
10
Year of production (when the production cycle has been
achieved)
5
Type of power supply
11
The text "Contains fluorinated greenhouse gases covered
by the Kyoto Protocol"
6
Type of refrigerant
pag. 9
(rev. 2, 08/2013)
1.5. Warranty
The Manufacturer warrants the unit according to what stated on his General Sales Conditions or
according to what else explicitly agreed.
The Manufacturer Warranty is void in case the guidance of this Manual has not been carefully
respected.
The Manufacturer refuses all responsiblity for any damage to people, animals, things or environment caused by
incorrect installation, maintenance or setting, that is to say caused by a misuse of the machine. It is considered
as “misuse” of the machine any use not explicitly allowed in this Manual.
On the first unit startup, duly fill in the relevant Report attached to this Manual and send
the Manufacturer a copy in order to make the warranty valid.
1.6. Manual’s Readers
The Manual and all its annexes are supplied together with the unit they refer to.
The Manual must be kept in a proper place by the owner or by the person in charge of the unit control
(hereinafter: The Owner). To this end, a plastic bag where to store the Manual has been placed inside the
electrical panel so that it can be always easily accessible for consultation and at the same time, it can be
preserved properly.
All people in charge of operating on the unit and in particular, the technicians who must work on the cooling
system, must read all the information and instructions contained in this Manual.
The non respect of the instructions contained in the Manual during any operations of
installation, operation, maintenance, repair and dismantling of the unit can cause serious
damage to people, animals, things or environment.
In case the Manual is lost or deteriorated, a new copy must be requested directly to the Manufacturer.
1.7. Main safety rules
1.7.1. General warnings
Read carefully the whole handbook before performing any operation on the unit. Only
qualified and trained technicians must perform any operation on the unit.
pag. 10
(rev. 2, 08/2013)
Do not touch the machine if with barefeet or with humid or wet parts of the body.
Do not perform any cleaning operation before the main switch is “OFF” and
power line disconnected.
Do not spread, leave unattended or to the reach of children any packaging material (carton
box, staples, plastic bags, etc) as they may be source of danger.
1.7.2. Allowed use
The unit has been designed and produced for air conditioning of technological centres and therefore, it
must be used only for this purpose according to its performing features. All different uses are not allowed
and disclaim all manufacturer’s responsibility for damages caused to environment, people, animals and
properties.
1.7.3. Forbidden use
Do not use the machine:
•
For other use than what described in paragraph 1.7.2;
•
When it is exposed to rainfall;
•
in atmosphere with high risk of fire or explosion;
•
in spaces with corrosive atmosphere.
Any operation on the unit must be carried out in compliance with local technical standards.
1.7.4. Dangerous areas
The machine is closed by case panels, at the exception of the upper part on some models. The dangerous parts
inside the unit are not accessible from outside.
Only qualified and trained personnel is allowed to remove the covering panels because inside
the unit there are parts with high risk of electric shock, areas with high temperature and
working mechanical components.
Inside the unit there are some parts which might be dangerous because of the following elements:
•
Elements submitted to electrical tension,
•
Working mechanical components,
pag. 11
(rev. 2, 08/2013)
•
High temperature surfaces,
•
Sharp corners or cutting elements,
•
Components containing high pressure fluid.
When possible, the dangerous areas are protected by suitable equipement so as to make them unaccessible.
Only qualified and trained personnel can remove this protection equipment.
When there is no protection equipment, the dangerous areas are clearly and properly marked.
1.8. Personnel’s requirements
Any operation on the unit and in particular, on the cooling circuit, must be performed only by a qualified and
trained personnel, duly equipped with individual protection garments and trained to the use of refrigerant
liquids in compliance with local standards in force.
All maintenance and repair operations which require the intervention of personnel having different specific
skills (like welders, electricians, programmers, etc.) must be carried out with the supervision of a personnel
expert in cooling systems.
The personnel working with refrigerant fluids must be properly trained to acquire the required skills related
to the security aspects for dealing with this kind of substances. Besides the topics indicated in the local
standards in force, training must also include the following topics:
•
•
•
Knowledge of local legislation, norms and standards in force concerning the refrigerants;
In-depth knowledge and suitable training concerning the use of refrigerants and of the necessary
individual protection equipment;
Knowledge and training to prevent leaks, to use the cylinders for the charge, to detect leaks, to
recover and treat the refrigerants.
The personnel must be able to understand and put the applicable local standards into practice.
In order to maintain these skills, the personnel must be submitted regularly to a suitable training in
compliance with the local laws in force.
pag. 12
2.
DESCRIPTION
2.1.
ED Series description
(rev. 2, 08/2013)
The following scheme shows the meaning of the elements composing the unit acronym.
ED - X - 10 - 1 - U - Kc
Kc = R 410° or Ka = R 134a
U = front air intake, upflow discharge
V = down air intake, upflow discharge
D = up air intake, downflow discharge
B = back air intake, upflow discharge
Number of cooling circuits
* Cooling Capacity in kW
X = air cooled
E = water cooled
H = with remote motor-condenser
ED = Direct Expansion Unit
* The cooling capacity is calculated with a temperature of 27°C with 50% of relative humidity.
2.2.
Available configurations
The units are available in different configurations according to the air intake and discharge.
The following pictures show the possible unit configurations according to the transfer path of the air inside the
unit before being discharged into the working room at the desired temperature.
pag. 13
(rev. 2, 08/2013)
Figure 2.1: Air transfer path for ED.X and ED.H series
pag. 14
(rev. 2, 08/2013)
Figure 2.2: Air transfer path for ED.E series
pag. 15
(rev. 2, 08/2013)
2.3.
Main components
The units of ED Power Line series are made of the following main components:
•
The housing is made of press-formed and welded sections, covered with epoxy paint.
•
Galvanised steel sheet panels coated with a protection film in PVC.
•
Fans with Autotransformer Controlled (AC) motor (standard).
•
Fans with Electronically Commutated (EC) motor (optional).
•
Scroll compressor/s.
•
Soundproof panels with acoustic material of HF – UL94 class mounted inside the panels. On demand,
it is also possible to have acoustic material of class 1 (option IS1).
•
Direct expansion cooling coil with hydrophilic treatment.
•
Braze-welded plate exchanger (only for ED.H series).
•
Double front panels with access/inspection windows.
•
Drain pain made up of peraluman (an aluminium-magnesium casting alloy).
•
Electronic thermostatic valve.
•
Regenerable air filters with efficiency grade G4 for the standard model or F5, F6, F7, F9 as optional.
•
Immersed electrode humidifier (optional).
•
Electric board in compliance with CE regulations provided with main switch with padlock (fig. 2.8),
automatic switches, contactors, motor circuit breakers, auxiliary low voltage circuits, terminal board
and control by microprocessor.
•
Electric board with key lock (figure 2.5).
•
Internal (fig. 2.8 - standard) or external (optional - fig.2.9) main switch with padlock.
The following paragraphs describe the characteristics of the main components of the unit. The figure 2.3 shows
as an example a scheme to detect the main components of the unit. It must be noted that in the ED.E series the
compressor/s is /are present only in the motor-condenser/s MCX.
2.3.1. Housing
The unit housing is made of press-formed sections in galvanised steel sheets, covered with RAL 9004 epoxy
paint.
The structural elements are assembled together in order to build a strong housing able to support both the
components of the unit and any eventual mechanical stress which might occur during the unit handling and
operation.
The components are placed inside the unit in such a way to be easily accessible from the front and to make
the startup and maintenance operations safe.
Figure 2.3: Main components of the UW series
pag. 16
(rev. 2, 08/2013)
Air
Filters
Refrigerant
Filter
TEV Valve
Liquid
receiver
Hydrophilic cooling
coil
Scroll
Compressor
Electric
heater
Fan
Steam
distributor
Humidifier
Micro
processor
Electric
board
AC Centrifugal Fans (Standard)
The units are equipped with single-inlet centrifugal fans having an impeller with
backward curved blades. They are provided with an auto-transformer (see the picture
aside) which can control the fan speed rotation. Fans are connected to the power supply
by means of the auto-transformer which can change the power tension and, therefore, the
fan speed rotation.
Thanks to the new motors, to the backwards curved blades and to the building materials,
the AC fans allow to have a low noise level, high airflow and above all a low energy
consumption.
2.3.2. EC Centrifugal Fans (Optional)
As an optional, the units can be also supplied with centrifugal fans having an impeller with
backwards curved blades and a high efficiency EC brushless motor. The electric motor is
pag. 17
(rev. 2, 08/2013)
suitable to operate at a variable rotation speed which can be regulated by microprocessor through a 0-10 V
signal. The backwards curved blades have been suitably designed to maximise the unit efficiency and to
reduce the noise level. They are directly coupled with the electronically commutated motor provided with
internal thermal protection.
For further details on the EC fan (to adjust the airflow and the static back pressure), refer to the
microprocessor manual.
2.3.3. Direct expansion cooling coil with hydrophilic treatment
The cooling coil has been designed with a large front surface in order to have a high SHR (Sensible Heat
Ratio) and a low airlfow speed in order to avoid the condensate to detach, to reduce the air pressure drop and
to guarantee a higher efficiency of the heat exchange both during the cooling process and the
dehumidification process.
The evaporating coil is composed of copper tubes mechanically expanded on hydrophilic treated aluminium
fins. By reducing the surface tension between water and metal surface, it allows a film condensation and
avoids condensate to drain outside the drip tray.
Coils are leak tested and cleaned before being installed by the Manufacturer.
2.3.4. Electric heater (optional)
The precision air conditioning units of ED Power
line can have, as an optional, the installation of
electric heaters for postheating the discharge air in
order to compensate the system sensible cooling
during the dehumidification phase.
The electric heaters are installed by the manufacturer on the discharge air side of the coil and are controlled
by the microprocessor on the unit.
2.3.5. Humidifier (optional)
The ED Power Line series has been designed and realised to be suitable for the eventual
installation (optional) of the humidifier with immersed electrodes. The humidifier is
supplied with the fill and drain valves and their corresponding tubes. The operation is
completely automatic thanks to the humidifier control system which controls the charge
and discharge phases of the humidifier according to the water conductivity.
Frame
1
pag. 18
Model
71
81
EDX
EDH
EDE
U-V-B U-V-B U-V-B
x
x
x
x
x
x
Humidifier
model
1,5-3KGH
230V/1F
Nominal
Steam
Prodution
Setting
Absorbed
Absorbed
Nominal
Current
Capacity
kg/h
kW
A
1,5
1,12
5
(rev. 2, 08/2013)
2
3
4
5
6
7
8
101
131
161
181
211
231
261
271
281
282
331
332
371
372
421
422
461
462
501
502
551
552
591
592
642
771
772
852
921
922
952
991
992
1022
1112
1122
1442
1462
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
1,5-3KGH
230V/1F
3
2,25
10
5-8 KG/H
400V/3F
5
3,75
5,5
5-8 KG/H
400V/3F
8
6
8,7
5-8 KG/H
400V/3F
8
6
8,7
5-8 KG/H
400V/3F
8
6
8,7
5-8 KG/H
400V/3F
8
6
8,7
5-8 KG/H
400V/3F
8
6
8,7
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Models which are not marked by an “x” do not exist.
2.3.6. Scroll Compressor/s
All models have Scroll compressors working with refrigerant R410A and R134a.
All compressors are mounted on rubber antivibration dampers and are supplied
with:
•
Direct startup motors, cooled down by the refrigerant;
•
Crank-case heater on which the electric heater is installed;
•
Integrated thermistor protection relays to protect motors from overheating;
pag. 19
(rev. 2, 08/2013)
•
Charge with polyester oil;
•
The compressors terminal board has an IP54 protection rate.
The unit microprocessor can activate and disactivate the compressors and in this way it can also regulate the
heating-cooling capacity supplied.
2.3.7. Different types of base-frames (optional)
There are several types of base frames available for the ED Power Line units so as to satisfy any customer
demands. In the list of accessories at chapter 2.6, you can find the description of several base frames.
The different base frames are the following:
•
Adjustable base frame (B);
•
Adjustable base frame with conveyor (BN);
•
Adjustable base frame with ON / OFF damper (BS);
•
Adjustable base frame with conveyor and ON / OFF damper (BSN).
In the following pictures it is shown, as an example, how to fix the adjustable base frame “B”, see figure
2.4. This procedure is the same for all types of base frames. The correct position of the fixing points are
shown in the unit drawing attached to the manual.
Figure 2.4: How to fix the base frame
2.3.8. Plenum (optional)
The distribution plenum is complete with a double-row finned adjustable grid for a better distribution of the
discharge air (only for versions U, V and B).
Figure 2.5 shows, as an example, how to fix the plenum.
pag. 20
(rev. 2, 08/2013)
Figure 2.5: How to fix the plenum
2.3.9. Electric board
The unit electric board is in compliance with the European regulations in force 2006 / 95 / CE and has been
realised inside a metal compartment having an IP54 protection degree. This compartment is separated from
the airflow compartment.
The main characteristics are the following:
•
Three-phase power supply 400V / 3ph + N / 50Hz on all units, unless different special
requests are demanded;
•
Auxiliary circuit in low tension 24Vac with isolation transformer;
•
Main switch (the mechanical interlock is an optional);
•
Circuit breakers; magnetothermic protection on transformer of the auxiliary circuit;
•
Terminal board for signal and control free contacts.
All units undergo a safety cycle with continuity tests on protection conductors, insulation resistance and
withstanding test.
2.3.10.
Control system
The unit is controlled by electronic microprocessor by means of a control software developped by
Emicon AC.
The microprocessor is composed of:
•
•
A control electronic card with the terminal board for the transmission of the operating parameters
and the enabling of the control devices;
A user terminal board with 6 backlit keys to modify the parameters. Semi-graphic and backlit
display LCD 64x120 pixel to visualise the operation status and the alarm messages.
pag. 21
(rev. 2, 08/2013)
The electronic card controls the various devices
installed
on the unit according to the values shown by the
operational variables and it also carries out the
following main functions:
•
Unit ON/OFF from the keyboard or from a
remote position;
Control and memorisation of alert and alarm
status.
•
Furthermore, the display of the microprocessor user
interface also allows to visualise the following information:
•
•
•
•
values of set regulation parameters,
values of operating variables,
status of digital and analogical inlets and outlets,
status of unit operation,
alert and alarm signals.
•
2.3.11.
Front panels with windows for access/inspection
The ED Power Line units have been designed and realised with double front panels so as to be able to carry
out a visual inspection and access of the inner components (compressors, evaporating coil, thermostatic
valves, etc), but also the connection of devices during the startup. This is possible without need of stopping
the unit, but simply by removing the external panel (see par. 3.5 – figure 3.3) and moving the little door
covering the inspection window. Figure 2.6 shows the inspection windows.
pag. 22
(rev. 2, 08/2013)
Figure 2.6: Windows for access/inspection
Once the operation is finished, proceed backwards (with reference to figure 2.6) to shut the inspection
window and the outside panels.
pag. 23
(rev. 2, 08/2013)
2.3.12.
Opening of the electric board
On ED Power Line units, the panel of the electric board (if present) is provided with a lock key and another
one without lock key. Figure 2.7 shows the lock key.
It is advisable to close the electric board panel by means of the lock key. In particular, during the
maintenance operations, it is recommended to stop the unit by means of the main switch by
moving it in position OFF and shut the electric board by lock key.
Figure 2.7: Lockable electric board
pag. 24
2.3.13.
(rev. 2, 08/2013)
Internal or external main switch with padlock
The ED Power Line units use both internal (standard) and external (optional) main switches with padlock.
This device is necessary to block the main switch on OFF position during the maintenance operations in
order to be able to work on the unit on safety conditions.
To lock the internal or external main switch, follow the instructions shown in figures 2.8, 2.9 and 2.10.
Figure 2.8: Lockable main switch inside the electric board
a)
Figure 2.9: Lockable main switch outside the electric board (<100 A)
pag. 25
(rev. 2, 08/2013)
a)
Figure 2.10: Lockable main switch outside the electric board (>100 A)
2.4. Controls and tests
Once the unit is finished, the circuit is tested according to the procedures established in the Warranty System
of the Manufacturer’s Quality. In particular, it is submitted to a test of mechanical resistance to pressure and
to a tightness test to detect evenual leaks.
pag. 26
(rev. 2, 08/2013)
Before shipment, the unit undergoes a complete operational test.
2.5. Accessories
Here below you can find a list of the main accessories which can be installed on ED Power Line units.
OPTION
ED.X ED.H ED.E
Accessory description
AA
●
●
●
Flooding detector: placed in the downflow units, it is already wired and detects water
in the false floor. The positioning under the unit must be carried out by the personnel in
charge of the installation.
AE
●
●
●
Electrical power supply different from standard: mainly, 230 V three-phase, 460
V three-phase. Frequency 50/60 Hz.
AL
●
●
●
Smoke alarm: it consists of a sensor detecting smoke inside the unit and activating an
alarm signal which stops the fans.
B
●
●
●
Base-frame: it is adjustable from 170 mm to max 600 mm for installation on raised
floors. It is provided with adjustable feet.
●
Hot water coil: 1-row or 2-row water coil, it is placed after the cooling coil for the reheating and/or the heating of the treated air. Provided with modulating actuator and
with three-way valve, it is controlled by the microprocessor on board.
●
Hot gas coil: placed after the cooling coil, it makes the re-heating of the treated air and
is provided with a 3-way valve (ON/OFF) controlled by the microprocessor on board.
It is available only with the dehumidification control (DH option). (Alternative to BC
and not available with HG).
●
Base-frame with conveyor: it is provided with a suitable conveyor facilitating the
airflow and remarkably reducing the pressure drop in case of horizontal airflow. It is
adjustable in height from min 400 mm to max 800 mm. (only for D version)
BC
BG
BN
●
●
●
●
●
●
BS
●
●
●
Base-frame with ON / OFF motorised damper: this device prevents the air return
from the unit when it is not working or in case some units are working close to it.
Available only for D version; for other versions, being a special execution, please
contact the Sales Dept.
BSN
●
●
●
Base-frame with conveyor and ON / OFF motorised damper: one base-frame with
both options BN and BS to optimise the efficiency and the space.
CI
●
●
●
Soundproofing jacket on compressors: made of soundproofing material,
wrapped all around the compressors so to further reduce the overall sound level of
the unit.
CS
●
●
●
Compressor inrush counter: electromechanical device positioned inside the
electrical board, recording the total inrush starts of compressors.
DH
●
●
●
Dehumidification control system: managed by microprocessor, through the
electronic thermostatic valve, it operates on two parameters ensuring that the
dehumidification process is carried out with a constant air flow, without
partializing the evaporating coil. This will optimise the air distribution throughout
the room.
DP
●
●
●
Double panels: for shutting off the compartments affected by the air flow, they are
made from pre-painted and galvanised steel plate, ensuring a reduction in the noise
transmitted through the panels and a better air tightness even without the external
pag. 27
(rev. 2, 08/2013)
panels so that the access is guaranteed with the doors open also during the maintenance
operation, such as the filters replacement.
EC-LP
& HP
●
●
●
Single-inlet EC (electronically commutated) centrifugal fans with backwards
curved blades (LP not available for D version) made of high performance
composite material, directly coupled to a three-phase electronically commutated
external rotor, they allow a continuous speed regulation by means of 10V signal,
sent and integrated to the control. The fans are fixed on suitable supports reducing
the transmission of vibrations to the frame and the impeller is statically and
dynamically balanced with long-life bearings. Thanks to their technology, the EC
fans ensure a lower electrical aborption and sound level, if compared to the
traditional centrifugal fans. It is possible to adjust their air flow to the head
pressure requested on site.
In case of IT electrical supplies, Emicon AC s.p.a. must give,
prior assessment, the authorisation to the wiring connection.
F5,F6,
F7, F9
●
●
●
Higher efficiency air filters: pleated filters with F5, F6, F7, F9 efficiency,
supplied as an alternative to standard G4 filters.
FR
●
●
●
Spare filter kit (G4) as a replacement to the ones on board of the unit.
●
Humidifier: of immersed-electrode type for the modulating production of steam. It
is composed of a steam cylinder, a steam distributor, water inlet and outlet valves
and a maximum level probe. The microprocessor on board indicates when the
steam cylinder must be replaced. The electrical protection is ensured by a
magnetothermic switch.
H
●
●
HG
●
●
●
Hot gas by-pass: it is a mechanical device for modulating the cooling capacity, so
to reduce the ON/OFF of compressors and therefore to wait for the re-starting
timing, with influence on the condensing temperature. It is not available for sizes 1,
2, and 3 and with options BG or DH.
IE
●
●
●
Fumigated wooden crate packing: available on request for critical transports, so
to assure a suitable protection to the unit.
IH
●
●
●
RS485 serial interface: electronical card to be connected to the microprocessor to
allow communication between the units and a Carel supervision system. In this way, it
is possible to fully control the unit from remote. For connection to other supervision
systems, the protocol of the controlled parameters is available on demand. (the
supervision system and the management software are not included in the supply –
please contact the Manufacturer to check the available communication protocols).
IM
●
●
●
Seawood packing: fumigated seawood case and protection bag with hygroscopic
salts, suitable for long sea transports.
IP
●
●
●
Magnetothermic switches for auxiliary circuits: installed in replacement of the
fuses, as a protection of the auxiliary circuits.
IS1
●
●
●
Class 1 insulating material compliant to the main European standards.
MF
●
●
●
Phase monitor: electronic device controlling the correct sequence and/or the
eventual lack of one of the 3 phases, switching off the unit if necessary.
Lack of neutral for power supply 400/3/50: general unit power supply without
neutral conductor.
MN
pag. 28
●
●
●
In case of IT electrical supplies, Emicon AC s.p.a. must give,
prior assessment, the authorisation to the wiring connection.
PB
●
●
(rev. 2, 08/2013)
●
Condensing water pump: Micro pump discharging the condensing water
produced by the unit, it is factory installed.
PBH
●
●
●
Condensing water pump and humidifier: Micro pump discharging the condensing
water produced by the unit and the water present in the humidifier, it is factory
installed.
PL
●
●
●
Distribution plenum: with front grid and a double row of adjustable fins for a better
air distribution (only for U, V and B versions).
PQ
●
●
●
Remote microprocessor: remote terminal allowing to display the temperature and
humidity values detected by probes, the alarm digital inputs, the outputs and the remote
ON/OFF of the unit, to change and program the parameters, the sound signal and the
display of the present alarms.
PR
●
●
●
Fresh air inlet: external fresh air inlet with filter, placed on side for the renewal
of the treated air (standard on the left), with circular connection. (Ø 100 mm)
RE
●
●
●
Electrical heaters: made in aluminium and installed after the cooling coil, for the
re-heating and/or heating of the treated air. The heating capacity is split on 3 steps
max, so to reduce the energy absorption. They are controlled by the microprocessor
on board of the unit. The electrical protection is ensured by a magnetothermic
switch.
REM
●
●
●
Oversized electrical heaters
RF
●
●
●
Power capacitor (available only for compressors): compressors
power factor correction system cosФ > 0,9
RV
●
●
●
Personalised frame painting in RAL colour
SL
●
●
●
Main switch with external padlock.
ST
●
●
●
Manual calibration damper in galvanised steel sheet and opposite fins
movement. By a manual drive, it is possible to adjsut the air flow accurately.
●
Motorised calibration damper in galvanised steel sheet and opposite fins
movement. By a modulating servomotor (0-10V), it is possible to adjust the air
flow accurately.
●
Gravity overpressure damper for ducted units, to prevent the air return when the
units are not operating, where the several units are installed in the same room.
Available for U, V, B versions; for D version, being a special execution, please
contact the Sales Dept.
STM
SV
●
●
●
●
VCP
●
Pressure control valve : 3-way valve
VP
●
2-way pressostatic valve: it is placed on the plate exchanger and it controls the
water flow following the condensing pressure of the unit.
WG
●
●
●
Electronic card for interfacing to BMS with SNMP or TCP / IP protocols.
pag. 29
(rev. 2, 08/2013)
2.6. Operational scheme
Here below it is shown the standard refrigerant schemes of the units; an eventual specific scheme is attached to
the Manual.
AC
AIR HEAT EXCHANGER
PRV
OVERPRESSURE DISCHARGE DEVICE
BC
HOT WATER COIL
PSH
HIGH PRESSURE SWITCH
BG
HOT GAS COIL
PSL
LOW PRESSURE SWITCH
BW
LOW TEMP. OPERATION UP TO -40°C (ON CR)
PT
PRESSURE TRANSDUCER
CM
COMPRESSOR
RE
ELECTRIC HEATER
DH
DEHUMIDIFIER
RV
MODULATING VALVE
OVERSIZED ELECTRIC HEATER
EF
FAN
REM
EHC
CRANK-CASE HEATER
SV
SHUT-OFF VALVE
EV
SOLENOID VALVE
TS
SAFETY THERMOSTATIC VALVE
FSR
FAN SPEED REGULATOR
TT
TEMPERATURE PROBE
H
HUMIDIFIER
TWV
3-WAY VALVE
HG
HOT GAS
VP
EVAPORATOR
HT
HUMIDITY PROBE
VT
THERMOSTATIC EXPANSION VALVE
LF
DEHYDRATING FILTER
WC
WATER COIL
LS
SIGHT GLASS
YVCA
HUMIDIFIER FILL VALVE
LT
LIQUID RECEIVER
YVSA
HUMIDIFIER DRAIN VALVE
NR
NON-RETURN VALVE
pag. 30
(rev. 2, 08/2013)
Figure 2.11: Refrigerant scheme with n°1 circuit and n°1 compressor
Figure 2.12: Refrigerant scheme with n°1 circuit and n°2 compressors
pag. 31
(rev. 2, 08/2013)
Figure 2.13: Refrigerant scheme with n°2 circuits and n°2 compressors
Figure 2.14: Refrigerant scheme with n°2 circuits and n°4 compressors
pag. 32
(rev. 2, 08/2013)
2.7. Wiring diagram
Attached to the Manual you can find the wiring diagram related to the power and control of the unit, to the
terminal board together with the corresponding table key summarising the characteristics of the main
components used.
2.8. Noise level
The unit does not require the presence of any technician as it is able to work automatically and autonomously.
Therefore, it is not necessary to provide the noise level data in the control position. However, in the “General
Catalogue for technological centres” and in the technical specification sheet, it is indicated the average sound
pressure level, measured in A-weighting at 2 m of distance from the unit in open field with ducted air discharge
and suction (at the exception of U version); the data refer to the condition of standard airflow and avaialble
pressure and also with standard airflow but higher external available pressure.
2.9. Dimensions
The following table show the dimensions and weight of the ED Power Line units related to figure 2.15.
2.9.1. ED Power series’ dimensions
1
2
3
4
5
Model
FRAME
Dimensions
71
81
101
131
161
211
231
261
271
281
282
331
332
371
372
421
422
461
462
501
502
Weight
Compressors
Length
(A)
Width
(C)
Height
(B)
Weight
"U" full
opt (with
RE)
Weight
"V" full
opt (with
RE)
Weight
"B" full
opt (with
RE)
Weight
"D" full
opt (with
RE)
mm
mm
mm
kg
kg
kg
kg
171
171
171
176
1
1
550
550
1980
182
182
182
187
1
1
185
185
185
190
1
1
233
233
228
228
1
1
238
238
233
233
1
1
286
291
297
297
1
1
294
299
304
304
1
1
338
343
348
348
1
2
294
299
304
304
1
1
750
980
1160
1860
550
750
850
850
1980
1980
1980
1980
N° of
cooling
circuits
N° of
compressors
363
358
363
363
1
1
399
394
399
399
2
2
363
358
363
363
1
1
399
394
399
399
2
2
373
368
373
373
1
1
409
404
409
409
2
2
396
391
396
396
1
1
409
404
409
409
2
2
500
510
520
530
1
1
513
523
533
544
2
2
502
512
522
532
1
1
514
524
534
544
2
2
pag. 33
(rev. 2, 08/2013)
6
7
8
551
552
591
592
642
771
772
852
921
922
952
991
992
1022
1112
1122
1442
1462
2210
2565
3100
850
850
850
1980
1980
1980
520
530
540
550
1
1
532
542
552
562
2
2
523
534
544
554
1
1
550
560
571
581
2
2
550
560
571
581
2
2
628
639
644
654
1
1
615
625
630
640
2
2
660
670
675
685
2
2
746
756
766
761
1
2
745
756
766
761
2
2
761
771
781
776
2
4
777
787
797
792
1
2
776
786
796
791
2
2
793
803
813
808
2
4
830
840
850
845
2
4
784
794
804
799
2
2
978
978
988
1009
2
4
1017
1017
1027
1047
2
2
Figure 2.15: General Dimensional Drawing of ED Power Line series
pag. 34
(rev. 2, 08/2013)
3. INSTALLATION
The unit position must be chosen taking into account the local regulations in force.
For installations inside the European Community, it must be taken into account that the unit can be
considered as a Direct System according to the EN 378-1 standard (par. 4.1.2, 4.4.1.1 and fig. 1 a). The kind
of refrigerant and the charge present in the cooling circuit are shown in the unit Identification Tag.
3.1. Identification tag
The unit can be identified by means of an Identification Tag, shown in fig. 1.1 and described at par. 1.4. The
tag is applied inside the electrical panel.
The correct unit identification by means of the serial number is essential for the execution of
any operation to carry out on the unit. The serial number must be always advised whenever
submitting a request of technical service support to the Manufacturer.
3.2. Reception and inspection
It is very important to check the packing integrity immediately upon delivery through a visual inspection. In case
the packing is found damaged, it is necessary to accept the goods with reservations and to indicate on the
consignment note the condition of the received goods and let the driver countersign it for confirmation.
Any claim regarding the delivered material must be sent to the Manufacturer within 8 days from
the goods reception, by e-mail, fax or registered letter.
3.3. Handling
The handling of the unit must be carried out by expert personnel, equipped with appropriate equipment in
relation to the weight and dimensions of the unit. During the handling, the unit must be always kept upright, that
is to say, with the base-frame parallel to the floor.
It is advisable to remove the packaging only when the unit is finally installed, and possibly, only after the unit is
positioned on the place of its final installation.
Even if packed, it is forbidden to put the units one on another. If the unit is stocked after
reception, even if packed, it must be sheltered against bad weather.
The weight of some models might be unbalanced, therefore check the unit stability before
starting to handle it.
Lift the unit vertically, without jerks and at a suitable speed to the charge so as to not
jeopardize the structure integrity.
pag. 35
(rev. 2, 08/2013)
In case the fork lift is employed, the forks must be spaced out to the maximum allowed by the pallet size.
Please follow the instructions illustrated on Figure 3.1 to move the
unit.
If the unit is lifted by means of a crane, it is important to avoid that
cables and belts exert a too high tractive effort on the unit that might
cause damages or break.
Figure 3.1: Lifting sheme
The lifting devices, such as cables and belts, used to handle the unit must be compliant
to the local regulations into force.
Before starting to handle the unit to place it, it is advisable to identify first the best way to arrive to its
final position, taking into consideration the dimensions and weight of the unit and its options, and the
available equipment.
3.4. Unit Positioning
The unit installation is under the responsibility of the Owner who must supervise the execution operations. A
correct installation presupposes that a plan has been drawn up by an expert and that is carried out by skilled
and trained technicians who have all the necessary information.
pag. 36
(rev. 2, 08/2013)
The place where the unit is installed must be free of any aggressive substances or, in general, of
any incompatible substances to copper, carbon steel, aluminium and all the other materials used
to realise the unit. In case of any doubt, carry out specific chemical analysis and send the results
to the Manufacturer so as to find the necessary measures.
The unit installation must be carried out in compiance with the local regulations into force.
Before placing the unit, the following points must be checked:
•
The floor where the unit is positioned must bear the total weight of the unit under normal operation;
•
Enough room must be left around the unit to allow the routine and special maintenance (such as the
replacement of compressors and exchangers) as shown in Figure 3.2;
•
Connections for cooling, electrical, hydraulic and condensate/humidifier drainage circuits must be
done.
The unit has been designed for internal installation and operation (like for example a technological data centre).
During the operation, the unit base-frame must be horizontal: the maximum acceptable
slope is 5° in length and width directions.
The unit does not need any special foundation as it can be simply laid down on the surface.
In case of units provided with downflow air discharge, it is necessary to take into account that the floating
floor height might greatly influence the unit performance.
In order to avoid high noise level and/or inacceptable reductions of air flow, the floating floor height should
never be inferior than the unit width.
Make sure that the value of the pressure drop of the air distribution system is not higher than the unit available
pressure in its standard configuration. If this is the case, then adjust by auto-transformer (AC fan) or by 0-10V
signal (EC fan).
Make sure that the number and the characteristics of the air suction and distribution grids are suitable for the
unit air flow capacity.
For the installation of any spare accessory, strictly follow the attached instructions to each of them.
pag. 37
(rev. 2, 08/2013)
Figure 3.2: Service areas
* It is necessary to respect the distances shown in the picture also in case of lateral hydraulic connections or
in case option PR is installed.
Before proceeding with the installation, make sure that the unit characteristics described in
the documentation attached to this Manual are compatible with the characteristics of the
project.
3.5. Opening and closing of panels
Figure 3.3 gives a graphic description of how to open and close the external panels of the units of ED Power
Line. The electrical board panel is hinged, while the panels for inspection and maintenance of the unit
components are removable (follow the instructions here below).
pag. 38
(rev. 2, 08/2013)
Figure 3.3: Opening of external panels
pag. 39
(rev. 2, 08/2013)
To close the panels, follow the above graphic description backwards.
3.6. Cooling and hydraulic connections
3.6.1. Cooling connections for ED.X and ED.E
These units are supplied with dry air charge (10 bar). Discharge pressure carefully only before carrying out
the cooling connections.
Designed to work with air cooling system, copper pipes must be employed for the connections to their ventilated
condenser units which are installed outdoor.
The piping scheme is shown in Figure 3.4 (ED.X) and Figure 3.5 (ED.E).
Even if refrigerant is not classified as a toxic substance, pay the maximum attention during
the refrigerant charge operation and strictly follow the security requirements in compliance
with D.Lgs 81/08 ; in particular, the appropriate and necessary equipment must be worn to
avoid contact, inhalation and ingestion.
If any of the above mentioned cases occurs, it is advisable to consult the security
specifications for the operations of first aid and emergencies concerning the employed
refrigerant.
In case it is necessary to go to the doctor, it is advisable to bring these refrigerant
specifications with you.
The pipe installation must be performed by a skilled refrigeration technician.
pag. 40
(rev. 2, 08/2013)
Figure 3.4: Piping diagram ED.X
Figura 3.5: Schema tubazioni ED.E
pag. 41
(rev. 2, 08/2013)
Figure 3.5: Piping diagram ED.E
pag. 42
(rev. 2, 08/2013)
The piping path must be as shortest as possible in order to reduce the quantity of refrigerant gas and oil
circulating and to reduce the pressure drop. If copper pipes have to cross electric wires, it is advisable to
isolate the tubes in order to avoid the danger of inducted current.
If the discharge pipes go through rooms where people normally live, it is advisable to install rubber vibration
dampers and a sound attenuator as nearest as possible to the compressor.
The piping insulation, except for special requirements, can be applied on the following parts only:
•
Suction pipes (ED.E);
•
Discharge pipes (ED.X), where pipes are lapped by the unit air discharge (in the
suspended floor); where pipes can be accessible to unauthorised people so that any
damage or skin burn can be avoided.
During the piping installation, the refrigerant tubes must be sealed to prevent humidity and dirt from going inside.
The piping arrangement must consider easy access for operations like bracket insertion, tube welding and inspection.
Figure 3.6: Connections diagram
It is here reminded that the total piping length is the result of its geometrical calculation plus the length of valves,
bents and fittings present on the line itself. If failing to have more accurate information, you can obtain the total
length by multiplying the geometrical length of the line by 1,5 or 2.
pag. 43
(rev. 2, 08/2013)
Copper pipes must be adequately supported by brackets so as to make them secure and fasten, and at the same time
allow thermal expansion of the copper tubes.
Lines must be realised with pickled and clean copper pipes specific for cooling circuits, and must have the
diameters indicated in Table 1 ( ED.X 1-circuit ), Table 2 (ED.X 2-circuits), Table 3 (ED.E 1-circuit) and
Table 4 (ED.E 2-circuits).
Table 1
Pipes diameter for ED.X 1-circuit
pag. 44
Ф Liquid connection (mm)
Ф Discharge pipe (mm)
Ф Liquid pipe (mm)
Ф Liquid pipe (mm)
Ф Liquid pipe (mm)
2
10
12
12
16
16
16
16
16
22
22
22
22
22
22
22
22
22
28
28
10
10
10
12
12
12
12
12
16
16
16
16
16
16
16
16
16
22
22
12
12
12
16
16
16
16
16
18
18
22
22
22
22
22
22
22
28
28
10
10
10
12
12
12
12
12
12
12
16
16
16
16
16
16
16
18
22
12
12
12
16
16
18
18
18
18
18
22
22
22
22
22
22
28
28
28
10
10
10
12
12
12
12
12
12
16
16
16
16
16
16
16
18
22
22
12
12
16
16
18
18
18
18
22
22
22
22
28
28
28
28
28
35
28
10
10
10
12
12
16
16
16
16
16
16
16
18
18
18
18
18
22
22
2
28
22
28
22
28
22
28
22
Number of compressors
71
81
101
131
161
211
231
261
271
281
331
371
421
461
501
551
591
771
921
991
Number of circuits
ED.X
Ф Discharge connection (mm)
Equivalent length
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10 metres
20 metres
40 metres
(rev. 2, 08/2013)
Table 2
Pipes diameter for ED.X 2-circuits
Ф Liquid pipe (mm)
Ф Liquid pipe (mm)
Ф Liquid pipe (mm)
4
16
16
16
16
16
22
22
22
22
22
22
22
22
22
22
22
22
28
12
12
12
12
12
16
16
16
16
16
16
16
16
16
16
16
16
22
2x16
2x16
2x16
2x16
2x16
2x18
2x18
2x18
2x22
2x22
2x22
2x22
2x22
2x22
2x22
2x22
2x22
2x28
2x12
2x12
2x12
2x12
2x12
2x12
2x12
2x12
2x16
2x16
2x16
2x16
2x16
2x16
2x16
2x16
2x16
2x18
2x16
2x16
2x18
2x18
2x18
2x18
2x18
2x18
2x22
2x22
2x22
2x22
2x22
2x22
2x22
2x22
2x28
2x28
2x12
2x12
2x12
2x12
2x12
2x16
2x16
2x16
2x16
2x16
2x16
2x16
2x16
2x16
2x16
2x18
2x18
2x22
2x16
2x18
2x18
2x18
2x22
2x22
2x22
2x22
2x22
2x22
2x28
2x28
2x22
2x28
2x22
2x22
2x28
2x28
2x12
2x12
2x12
2x16
2x16
2x16
2x16
2x16
2x16
2x16
2x18
2x18
2x18
2x18
2x18
2x18
2x18
2x22
2
28
22
2x28
2x18
2x28
2x22
2x35
2x22
Number of compressors
282
332
372
422
462
502
552
592
642
772
852
922
952
992
1022
1112
1122
1442
1462
Number of circuits
ED.X
Ф Discharge connection (mm)
Equivalent length
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
4
2
2
2
4
2
4
2
2
2
2
10 metres
20 metres
40 metres
pag. 45
(rev. 2, 08/2013)
pag. 46
Ф Suction pipe
(mm)
Ф Liquid pipe
(mm)
Ф Suction pipe
(mm)
Ф Liquid pipe
(mm)
Ф Suction pipe
(mm)
Ф Liquid pipe
(mm)
10
10
10
12
12
12
16
16
16
16
16
22
22
16
18
18
22
22
22
28
28
35
35
35
42
42
10
10
10
12
12
12
12
16
16
16
16
18
22
16
18
18
22
28
28
28
28
35
35
42
42
42
10
10
10
12
12
12
16
16
16
16
18
22
22
16
18
22
22
28
28
35
35
35
42
42
54
54
10
10
10
12
12
16
16
16
18
18
18
22
22
1
42
22
42
22
54
22
54
22
1
1
1
1
1
1
1
1
1
1
1
10 metres
20 metres
40 metres
Ф Suction pipe
(mm)
Ф Liquid pipe
(mm)
Ф Suction pipe
(mm)
Ф Liquid pipe
(mm)
Ф Suction pipe
(mm)
Ф Liquid pipe
(mm)
Pipes diameter for ED.E 2-circuits
ED.E
332
422
502
642
852
922
1122
1462
1
16
16
16
22
22
22
28
28
35
35
35
42
42
1
Equivalent length
Ф Suction connection
(mm)
Table 4
71
81
101
131
161
211
271
331
421
501
591
771
921
991
Number of circuits
ED.E
Ф Suction connection (mm)
Pipes diameter for ED.E 1-circuit
2
22
22
28
28
35
35
35
12
12
16
16
16
16
16
2x22
2x22
2x28
2x28
2x35
2x35
2x35
2x12
2x12
2x12
2x16
2x16
2x16
2x16
2x22
2x28
2x28
2x35
2x35
2x35
2x42
2x12
2x12
2x16
2x16
2x16
2x16
2x18
2x22
2x28
2x28
2x35
2x42
2x42
2x42
2x12
2x16
2x16
2x16
2x18
2x18
2x18
2
42
22
2x42
2x18
2x42
2x22
2x54
2x22
Number of circuits
Table 3
2
2
2
2
2
2
Equivalent length
10 metres
20 metres
40 metres
(rev. 2, 08/2013)
Once pipes are placed, before carrying out the connections to the unit, the circuit must be leak tested by means of
pressurised nitrogen or dry air. It is recommended to mark the pressure test value on a pressure gauge.
Do not exceed 20 bar when pressing with nitrogen.
Dry air also enables the circuit to dry up. If the circuit pressure drops, this means that the circuit is not sealed off.
It is then necessary to let in a small quantity of refrigerant so that it is possible to locate the leak by means of
appropriate detectors. If a leak is detected, after the repair, a new test leak, the vacuum and the charge of the
system must be carried out again following the instructions as described in par. 3.11
3.6.2. Plate condenser hydraulic connections for ED.H
The units are designed to work with tower water. It is necessary that the refill water for the evaporating
tower is adequately treated in order to avoid corrosion problems, limestone deposit and algae
microrganism proliferation.
It is also possible to use water from water city systems adequately treated.
In these cases, the water condenser is equipped with a pressostatic valve as optional (VP or VPC): when
calculating the circulation pump size, the pressure drop of this component must be also kept into account. On
demand, the condensers can be sized to be able to employ a water and ethylene glycol mixture in a closed
circuit cooled by a forced ventilation coil exchanger (dry-cooler) which dispels the heat into the atmosphere.
The use of glycoled water allows the cooling circuit to also work at low outdoor temperatures. The
percentage of ethylene glycol to be used is indicated in Table 5.
Table 5
Percentage of ethylene / propylene glycol
Percentage of
ethylene glycol
(Vol %)
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
Freezing
temperature
-1,72
-3,63
-6,10
-8,93
-12,10
-15,74
-19,94
-24,79
-30,44
-37,10
Percentage of
propylene
glycol (Vol %)
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
Freezing
temperature
-1,70
-3,43
-5,30
-7,44
-9,98
-13,08
-16,86
-21,47
-27,04
-33,72
When employing this mixture, the condenser must be equipped with a temperature control device of the antifreeze mixture.
If the anti-freeze mixture contains a lower ethylene glycol percentage than above recommended, there could
be risks of freezing, while a higher percentage can reduce the unit performance. At the beginning of every
pag. 47
(rev. 2, 08/2013)
winter, it is recommended to check the correct concentration of glycol in the system; please only use inhibited
ethylene glycol in order to avoid rusting of the hydraulic circuit.
Do not use anti-freeze liquids unsuited to copper, stainless steel and to all other materials present in the
system.
It is recommended to install a filter with grid not larger than 1mm on the condenser water inlet.
It is also advisable to install a ball check valve on the condenser inlet and outlet so that it is possible to shut
off the conditioning unit in case of special maintenance operations: the installation of a three-piece joint
between the valves and the conditioning unit will ease these operations.
The water system pressure must range between 1,5 and 3,5 bar.
3.7.
Condensate drainage connection
3.7.1. Condensate drainage connection
The air conditioning unit is provided with a stainless steel (peralluman) tank collecting the condensate and placed
under the coil. The tank must be connected to the drainage collector by means of a flexible pipe with siphon having
internal diameter of 19 mm. The pipe shall be placed with a slight slope downwards (about 1%) towards the
outlet direction.
To guarantee a correct condensate drainage, it is necessary to set up a siphon on the
drainage collector.
3.8.
Fresh air intake connections (optional)
The fresh air intake optional is installed inside the conditioning units of ED Power Line on the left side or, on
demand, on the right side.
The new air intake duct is connected to the nearest external intake through a coupling of Ø 100 mm mounted on
the side panel of the unit.
The fresh air intake optional is equipped with a pleated air filter easily removable for cleaning or replacement
purpose by removing the cap by means of screws as shown in figure 3.5.
pag. 48
(rev. 2, 08/2013)
Figure 3.7: Fresh air intake with internal filter
3.9.
Humidifier connections (optional)
On request, the unit can be supplied with an optional steam humidifier with immersed electrodes (Fig. 3.8)
having an appropriate capacity.
Figure 3.8: Humidifier connections
pag. 49
(rev. 2, 08/2013)
The humidifier must be connected to a supply water line (preferably sanitary water) and to a drain water line
provided with a shut-off valve to collect the eventual condensate and drainage water.
Even if the humidifier is provided with a filter, it is advisable that the supply water does not have any
impurity bigger than 100 micron.
Do not use demineralised water (suggested hardness 15-40° F, with conductivity 300-1250
µS/cm). The supply water pressure must range between 0,8 and 7 bar.
On demand, it is available a device which can work with specific conductivity between 125 and 500 µS/cm.
For further details on chemical characteristics of the supply water following the specific conductivity,
please read the Humidifier Use and Maintenance Manual.
The supply water must not be treated with softeners because they can cause electrodes
corrosion and can generate foam, thus compromising the correct operation of the unit.
It is not advisable to use well water, process water coming from the cooling circuits or, in
general, that may contain polluted chemicals or bacteria that could be spread in the
environment together with the produced steam.
It is also inappropriate to use supply water containing disinfectants or anticorrosion
compounds because they are potentially irritant.
The drain water contains the same substances as the supply water, but in higher concentration because of
the steam production. This water can be therefore discharged to a collecting clear wastewater system.
Once the installation is completed, wash the supply water piping making the water running for
few minutes directly in the drainage line (without entering into the humidifier); this will help to
eliminate any waste or installation remains which could cause a bad operation of the unit.
3.10. Electric connections
The wiring diagram for the unit power supply must be sized by a certified engineer and realised by an expert
personnel on behalf of the Owner and in compliance with the local regulations into force.
The power cable of the unit must be protected by means of an automatic switch having appropriate
size and characteristics and in compliance with the local regulations into force.
The system must be realised in such a way so as to be able to shut off the unit without interrupting all the other
services, like lightening, ventilation, alarms and security systems.
In case of IT electrical supplies, Emicon AC s.p.a. must give, prior assessment, the
authorisation to the electrical connection.
pag. 50
(rev. 2, 08/2013)
Only authorised and trained personnel can carry out any operation on the electrical wiring
in compliance with the existing local regulations.
Before working on the unit wiring circuit, it is necessary to check the wiring diagram
attached to this Manual.
Make sure that the power tension and the frequency are the same as stated on the unit
indentification tag and on the wiring diagram attached to this Manual.
It is necessary to use a power cable of appropriate size and of moderate length in order to avoid voltage drops.
Please refer to the data indicated in the wiring diagram attached to this Manual to calculate the
cross section of the power cable, the size and the intervention value of the automatic switch.
Make sure there is no humidity trace inside the electrical panel and on all electric and
electronic components. In case humidity is found, detect and eliminate the cause of the
infiltration.
Make sure the circuit and the electric components have not been damaged during the
transportation, handling and positioning. If any damage is detected, proceed with the
repair;
Make sure the electrical wires are properly tightened; if necessary, tighten adequately any
loose wire.
3.10.1.
Power supply connection
The unit must be powered by means of a 5-pole cable (3 phases + Neutral + GND), if the power supply tension is
400V / 3ph / 50Hz + neutral + GND (standard). On demand, it is also possible to have special power supplies
(check the identification tag and the wiring diagram).
Inside the electrical board, connect the phases and the neutral to the terminals of the main switch and the
earth wire to the corresponding terminal. Use a power supply cable of adequate cross section and of
moderate length to avoid voltage drops.
Protect the power supply cable by means of an automatic differential switch of
appropriate size and features. The cross section of the power supply cable and the size
of the automatic switch can be found on the attached wiring diagram where it is also
pag. 51
(rev. 2, 08/2013)
indicated the main switch size.
The input position for the power supply cable is indicated in the dimensional drawing of the unit attached to this
Manual. The power cable input must be adequately protected in
compliance with the existing local regulations.
Before operating on the wiring circuit, check visually that the
unit wiring circuits have not been damaged during the
transportation. In particular, make sure that all screws of
terminals are correctly tightened and that the cable insulation is
intact and in good condition.
The power cable phase conductors must be connected to the
free terminals upstream the main disconnecting switch; the
grounding conductor must be connected to the appropriate
terminal (marked by PE).
If the power cable comes from the top wiring box, perform a bend
on the cable as shown in the picture on the right.
3.10.2.
Connection to the user terminal board
A user terminal board is available (Figure 3.9) with free contacts designed for:
1. generic alarm state (1);
2. unit remote ON/OFF (2).
pag. 52
(rev. 2, 08/2013)
Figure 3.9: Example of user terminal board
Check the wiring diagram for the exact correspondence of the terminal numbers.
Inside the electrical board there is a terminal board where digital and analogical inputs are made available with
reference to the unit operation. Since the terminal configuration can vary according to the unit, please refer to the
configuration shown in the wiring diagram attached to this Manual.
Figure 3.10 shows, as an example, the available terminals for the free contacts described here below.
Figure 3.10: Example of contacts present in the user terminal board
(1)
Digital input
(free contact)
(2)
Digital output (free contact)
U2-30
U9-U10
Remote ON/OFF:
• Open = unit OFF
• Closed = unit ON
General alarm: NO contact (Closed = alarm)
pag. 53
(rev. 2, 08/2013)
3.10.3.
Condenser or motor-condenser connections
The condensers (remote for ED.X) or the remote motor-condensers (for ED.E) must be connected to the
appropriate wire terminals in the indoor unit using an electrical cable having an adequate size and features
related to the capacity and the environment.
3.10.4.
Control of the correct sequence of the power supply phases
The rotation direction of all electrical motors installed on the unit (fans, compressors) is checked and
harmonised during the operational test carried out in the factory (at the exception of those groups which
cannot be started, like for example those having a special power supply), if not previously agreed.
Once the unit has been connected to the power supply, it is necessary to check that the phases have been
connected in the correct sequence. On this purpose, check that all electrical motors rotate in the foreseen
direction.
In case of three-phase units, if the rotation direction of some components is not correct, this means that all
motors rotate in the wrong direction and, therefore, two out of three phases must be inverted in the terminals
of the main switch.
In order to avoid any connection mistakes, do not disconnect other conductors than those
concerned in the operation.
After inverting the phases, if some components still rotate in the wrong direction, it is necessary to check and
eventually to correct the sequence of the power supply conductors of each component, as described above.
3.11. Tightness test, vacuum and charge execution of the system (only for EDX
and EDE)
The units ED.H are supplied with the refrigerant and antifreeze oil charge, therefore they must
be submitted to the operations described here below only after having carried out an operation
on the cooling circuit.
For a correct and reliable operation of the system, once the connection lines between the indoor and the
outdoor units are carried out, it is extremely important to clear the circuit of any air, humidity, noncondensable gas and, in general, of any polluting substance before executing the refrigerant charge.
The presence of solid particles, such as metal dust, welding debris and dirt of small dimensions that cannot
be detected by the mechanical filters, can cause serious damages to the surfaces in motion and involve a
reduction in efficiency and of compressor life.
Do not perform any holes in the cooling circuit, the complete removal of metal
particles produced would be then prevented.
If excessive humidity persists inside the cooling circuit, negative consequences can arise. Humidity can
freeze inside the thermostatic valve and can even clog it up, causing the unit stop because of the low pressure
pag. 54
(rev. 2, 08/2013)
alarm. A significant amount of humidity can saturate the filter drier in a very short time and it will be
necessary to replace it (with consequent operating interruption of the system).
Humidity interacts chemically with the refrigerants and especially with polyester lubricant oils (normally employed
with refrigerant type R407C, R134a, R404A, etc.). This interaction creates acid substances that, if present in fair
amount, can damage the compressor electric motor insulation causing motor burns and rusted copper pipes that can
generate solid impurity.
Reduce as least as possible the exposure of the circuit and its parts to the
atmosphere, especially if compressors are charged with polyester oil.
If non-condensable gases are not eliminated accurately from the circuit, they can gather inside the condenser
and the liquid receiver. If gases are in the condenser, they can cause a reduction of the useful thermal
exchange surface, meaning a condensing temperature increase and, consequently, a reduction of the energy
efficiency and of the system reliability. In worst cases, the unit can be stopped by the activation of the high
pressure switch.
Big amounts of non-condensable gases gathered in the liquid receiver can cause the malfunctioning of the
thermostatic valve, since it might be fed not only by the liquid refrigerant, as it should be, but also by a
mixture of refrigerant and non-condensable vapours. If this occurs, there will be a strong reduction of the
evaporating temperature up to the activation of the low pressure switch in worst cases, thus involving a
reduction of the unit cooling capacity and a reduction of the system efficiency and life.
The operations to be carried out are:
a) Tightness test
b) Vacuum and dehydration
c) Refrigerant charge
3.11.1.
Tightness test
In order to detect any eventual leak in the cooling circuit, follow these operations:
a) Charge the cooling circuit with refrigerant gas up to a pressure of 1 bar.
b) Add dry nitrogen by means of bottles with reducer up to a pressure of 15 bar.
c) Locate the eventual leaks by means of a leak detector having a realiable calibration (5 gr/year or
better) with reference to the employed refrigerant. In particular, check the joints concerned by the
repair.
d) In case a leak is detected, discharge the cooling circuit, carry out the repair and repeat again the leak
test.
Do not use oxygen, hydrogen or any other types of reactive and inflammable gases to
pressurise the cooling circuit: only use dry nitrogen.
pag. 55
(rev. 2, 08/2013)
It is forbidden to charge the circuit and, in particular, the low pressure side, at a pressure
higher than 16 bar.
3.11.2.
Vacuum execution
Do not use the compressor for carrying out the vacuum inside the cooling circuit.
Make sure that all valves are open in order to avoid that some circuit parts result cut off.
To obtain a sufficient vacuum, it is necessary to use a two-stage pump with adequate features.
Normally, vacuum is considered to be adequate if when starting the unit the humidity presence in the
refrigerant is below 100 ppm; as a matter of fact, under this value, during the operation, the drier filter can
keep this value below 20 ppm.
Once the cooling lines are completed and checked that no leaks are present, the vacuum must be carried out
as described here below:
a) Connect a vacuum pump of a suitable water flow capacity (a two-stage pump able to keep a pressure
of 0,02 mbar) to the circuit by using the charge connections present on discharge and liquid receiver
(if the latter one is not present, the charge connection is placed on the suction pipe). The positions of
charge / discharge are properly marked by means of adhesive labels, see following figure.
b) Let the vacuum pump work until the pressure shown on the appropriate vacuum meter does not go
below 0,04 mbar.
Vacuum must be checked by placing the vacuum meter on the circuit and not on the pump.
c) Isolate the pump from the circuit by means of the appropriate cut-off valves and wait for 30 min.
d) If pressure goes on increasing during the pump stop period or if it is impossible to reach the desired
pressure value, it means there is a leak in the circuit. It is necessary to detect and repair the leak, and
after that, repeat again the procedure starting from step b).
e) If pressure goes up until it reaches a climax value, it means the circuit contains a big amount of
humidity. In this case, it is necessary to let in nitrogen in the circuit (up to about 2 bar) and repeat
steps b), c) and e) for at least twice; then proceed with step f).
f) If pressure stabilises after a short increase, it means the circuit is leak proof and reasonably dried. Start
up again the pump after the shut-off valves are open and let it operate for 2-4 hours according to the
circuit size after pressure has returned below 10 mbar.
While the circuit is vacuum, do not let the compressor operate nor carry out any kind
of test.
pag. 56
(rev. 2, 08/2013)
If the cooling circuit was open only for few time, usually operations described in steps a), b) and c) are
enough to obtain an adequate vacuum.
If the appropriate equipment is not available or if the circuit was open for long time, it might be necessary to
repeat steps b) and c), by using the refrigerant instead of the nitrogen to break the vacuum.
Figure 3.11: Example of vacuum in a cooling circuit
pag. 57
(rev. 2, 08/2013)
3.11.3.
Refrigerant charge execution
Do not use a different refrigerant than the one indicated in the Identification Tag.
Avoid any refrigerant gas release in the environment during the charge operations.
If the refrigerant is a mixture of several components, such as R410A or R134a, make sure to
introduce it in the circuit in a liquid state to avoid the components separation. On this
purpose, bottles are provided with two distinct valves: one for vapour and one for liquid.
Once vacuum is completed, the circuit must be charged with the correct quantity of refrigerant and, if necessary,
of antifreeze oil.
a) Connect the refrigerant cylinder to a 1/4” SAE male (7/16” – 20 UNF) charge connection placed
on the liquid refrigerant line.
b) Let a small quantity of liquid go out in order to eliminate the air from the connection pipe.
c) Open the cylinder valve and let the refrigerant enter the cooling circuit for pressure difference;
replace the refrigerant bottle when it is empty.
d) If pressure reaches a climax value at room temperature, the refrigerant cannot flow naturally from
the cylinder. Therefore, it is necessary to connect the bottle to a charge connection placed on the
suction line.
e) Clear the connection pipe of any air as indicated at step b).
f) Start up the compressor, open the bottle valve and complete the charge. Replace the bottle when
necessary.
g) Charge small quantities of refrigerant at a time, by checking each time the pressure and the
operating temperatures to avoid an overload of the system.
h) Complete the charge by comparing the quantity of refrigerant introduced with the value indicated in
the Identification Tag (only on EDH).
i) Check that the quantity of refrigerant introduced in the circuit is correct by checking the sight glass
and by measuring the liquid subcooling and the suction superheat.
The connection pipes must be as shortest as possible and must be provided with valves so as to reduce the
possibility of refrigerant leaks.
To facilitate the charge operation, the following tables show, as an indication, the necessary amount of
refrigerant to charge the different types of indoor units and the corresponding connecting pipes. For a correct
calculation of the refrigerant quantity, it must be also taken into account the volume of the outdoor unit cooling
circuit and of any other component installed (such as additional liquid receivers, oil separators, etc.).
Use only new refrigerant or recycled refrigerant whose composition is known and having suitable
characteristics to be used in cooling circuits.
pag. 58
(rev. 2, 08/2013)
The recovered refrigerant in liquid state can be re-used in the same unit, if in the circuit there is no presence
of inert gas or any other pollutants.
Before charging the refrigerant from a cylinder, it is necessary to check the quality and the quantity of fluid it
contains.
The amount of refrigerant charged in the cooling circuit must be measured by weight or by volume. It is
good practice to charge the refrigerant in liquid state.
In case the cooling lines are very long or in case the oil separators are installed on the compressors discharge, a fair
quantity of antifreeze oil must be added.
Make sure the employed oil is compatible with the one charged in the compressor
(check the compressor identification tag).
In case oil separators are employed, add the lubricant quantity suggested by the Manufacturer.
It is advised to add 1 kg oil for each 10 kg refrigerant loaded in the circuit.
An overload oil charge can lead to a system efficiency drop and to compressor breaking.
pag. 59
(rev. 2, 08/2013)
4.
OPERATION
Before starting the unit, the personnel must be informed and trained through the Manual
about the unit construction, management, operation and maintenance, about the security
measures and the regulations to comply to, about the eventual individual protection
garments to wear.
4.1.
Documentation
The Owner of the unit must require the authorisations and prepare the documentation for the unit installation
and operation as foreseen by the applicable local regulations. In particular, he must acquire and put the
necessary documentation available to confirm that the installation has been carried out following the project
specifications, according to what required by the local regulations.
The necessary information to keep a reliable and safe system must be visible, close to the unit and in a protected
position, in compliance to the existing local regulations.
4.2.
First start-up
The first start-up of the unit must be carried out by an expert technician authorised by the
Manufacturer.
4.2.1. First controls
Before starting the unit, an expert technician must perform a visual inspection, including the following
points:
a) Check if any damage has occurred during the transportation, the stock or the handling of the unit;
b) Compare the circuit with the hydraulic and wiring diagrams;
c) Check the foreseen security devices and its corresponding documentation;
d) Check the certificates, the identification tags and, in general, all foreseen documentation;
e) Check that the accessible pipes cannot cause any accidental damage to people;
f) Check that the power supply is adequate to the system’s requirements in terms of characteristics and
capacity;
g) Check the placement and the condition of valves and shut-off valves;
h) Check that brackets and fixing devices are adequate;
i) Check the quality of weldings, brazings and joints;
j) Check that the protections against mechanical damages, heat and devices in motion are adequate;
k) Check the unit is accessible for inspection, maintenance and repair of main components;
l) Check if the sound insulation is present and in good condition;
The technician who has carried out these controls must report them in compliance with the existing local
pag. 60
(rev. 2, 08/2013)
regualtions.
Before starting the unit, on its first start-up or after a long unit stop, check the wirings and
the connections to the protection conductors. In case defects are detected, do not start the
unit.
Before starting the unit, check that the following conditions are respected:
•
The ground wiring has been carried out correctly and has been connected to an efficient system;
•
The electrical power supply is protected by an automatic switch of adequate size and features;
•
The parameters related to temperature and antifreeze alarm are set correctly on the microprocessor.
For EDH units, the following conditions must be also checked:
•
•
The hydraulic system has been duly cleared of any dry air by means of the appropriate air discharge
valves;
The condensing water flow and temperature are correct;
During the unit operation, it is advisable to keep the pressure in the hydraulic circuit between
1,5 and 3,5 bar.
•
The hydraulic connections have been carried out correctly and do not present any leak;
•
If necessary, the hydraulic circuit must contain the antifreeze mixture in the required concentration;
Once the operations are completed as described above and in paragraphs 3.10 and 3.11, the unit is ready for the
start-up. Make sure the valves are open according to the following instructions:
a) Unscrew the stylus protection cap (figure 4.1);
b) Turn the stylus anti-clockwise until the end (figure 4.2)
c) Turn the stylus clockwise for one turn, if the manometer plug 1 is employed
d) Screw the cap tightening it firmly, so to avoid any gas leakage.
pag. 61
(rev. 2, 08/2013)
4.2.2. Startup
Before starting the unit, for the first time or after a long unit stop, check if the parameters set on the
microprocessor correspond to the foreseen operating conditions.
To start the unit, turn the main switch to ON position.
Make sure the unit is OFF from the keyboard.
Wait at least 3 hours before starting the unit to allow the oil sump heater to pre-heat the oil.
Once the unit is started, after a short period needed to the microprocessor for an auto-test, push the ON/OFF
button on the microprocessor keyboard, switching it to ON. At this point, all system components will start
working automatically according to the selected and detected thermal and humidity parameters.
In case of 3-phase motors, check the rotation direction of fans and compressors; if
rotation is reversed, two out of the three phases must be inverted in the terminals of the
main switch (see par. 3.10.4)
Once the unit has reached steady operation conditions, the technician performing the first start up must
check the operational parameters and report them in the appropriate First Startup Form, attached to the
Manual.
Send the Manufacturer a copy of the First Startup Form, duly filled in in all its parts in order to
make the unit warranty valid.
During the first startup operations, the technician must check that the safety and control
devices are working correctly.
pag. 62
(rev. 2, 08/2013)
4.2.3. Switch-off
To stop the unit, push the ON/OFF button on the microprocessor keyboard, switching it to OFF position.
If the unit does not work for more than 24 hours, turn the main switch to OFF position to cut off the power
supply.
If any technical faults are found during the unit operation, they must be set up as soon as
possible, so to avoid they show again on the next startup.
4.3.
Setup
The setup must be performed when the unit is operating in conditions as close as possible to the nominal
ones.
Make sure:
•
The thermal load is adequate;
•
Doors and windows are closed;
•
Surrounding spaces are clean.
The thermostatic valve heating setting is already adjusted in the factory at 5°C. If different values are detected,
then check the correct value on the microprocessor. Then, check the suction gas heating as described here below
and, if necessary, adjust the thermostatic valve setting. When the unit is working at the nominal conditions,
connect a manometer on the low pressure side. Check the temperature on the compressor intake (Fig.4.4) by
means of a contact thermometer (Fig. 4.3).
If superheating is over 10°C, the thermostatic valve must be opened, while if it is below 5 °C, the valve must be shut
off (Fig. 4.5 cap removal and Fig. 4.6 opening adjustment).
Valve adjusting operations must be always carried out with caution, turning the adjusting screw only half
turn each time; wait for few minutes before every new adjustment in order to allow the unit to reach steady
conditions.
The electronic thermostatic valve adjustment is a very delicate operation, therefore it must
be carried out by a skilled technician.
pag. 63
(rev. 2, 08/2013)
4.4.
Microprocessor setting
If the preset parameters need to be changed, follow the instructions described in the microprocessor
documentation, attached to the Manual.
Only skilled technicians authorised by the Manufacturer can change the parameters set on the
microprocessor. As a matter of fact, if wrong parameters are set up, the unit could work in
different operation conditions than foreseen, thus involving possible damages to the unit and
the circuit.
4.5.
Steam production setting (unit with humidifier)
Steam production must not exceed 60 -70% of humidifier maximum capacity in order to guarantee a long
operating life of the unit.
To set and modify the operating parameters, check the humidifier manual (here attached).
pag. 64
(rev. 2, 08/2013)
Table 8
Safety devices setup
OFF (barg)
High pressure safety valve
ON (barg)
43,4±3%
High pressure switch
39,1±1
33±1,5
Low pressure alarm (software management)
4±0,4
6±0,4
NB: After 3 resets, the low pressure alarm makes the unit stop working.
5.
MAINTENANCE
The Owner must make sure that the unit is submitted to an adequate maintenance as described in the Manual
and in compliance with the existing local regulations.
The unit maintenance must be carried out only by qualified and trained personnel, equipped
with individual protection devices as established by the existing local regulations.
In general, any person involved in the refrigerant handling must be equipped at least with protection
gauntlets and glasses.
When performing the unit maintenance, make sure about the following:
pag. 65
(rev. 2, 08/2013)
a) limit as much as possible the risk of accidents to people and of damages to things,
b) the system components are not damaged,
c) the system functionality and availabilty are not compromised,
d) reduce as much as possible the energy consumption,
e) detect and repair any eventual refrigerant leak.
The maintenance operations not involving specific refrigeration skills can be carried out by personnel having
adequate competence, charged by the Owner.
During the maintenance operations, only the authorised and concerned personnel can stand close to the unit.
During the maintenance operations, all labels and warnings on the system and on its components must be
checked. All deteriorated and unreadable texts must be replaced.
Do not make modifications to the unit or replace its components without the prior Manufacturer’s
authorisation.
Before performing any operation on the unit, switch off the electrical board by turning the main
switch to OFF position and put a padlock to the main switch as described at par.2.3.14
Inside the unit there might be high voltage areas: all operations demanding the access to these
areas can be carried out only by a qualified and trained personnel in compliance with the
existing local regulations.
The surface of components on the compressor discharge line and on the liquid line can
reach high temperatures and they can cause burns in case of contact.
On the unit there are some sharp or cutting parts which can hurt and cut if accidentally hit.
Only a trained personnel can carry out operations on the compressor.
Before performing any operation on compressors, disconnect the power supply. If an
intervention on the power capacitors is needed, it is necessary to discharge completely the
power capacitor.
In case of any doubt on the trouble detected or on the actions to be taken to solve it, please
contact the Manufacturer.
Do not smoke during the maintenance operations.
pag. 66
5.1.
(rev. 2, 08/2013)
Programmed maintenance
The Owner must make sure that the unit is submitted periodically to adequate inspections, controls and
maintenance operations according to the type, size, age and function of the system and according to what is
stated in the Manual.
The maintenance operations during the unit life operation and, in particular, the periodical leak detections,
the controls of the safety devices, must be carried out in compliance with the existing local regulations.
If any device for the leak detection is installed on the circuit, it must be controlled at least
once per year to make sure it is working correctly.
5.1.1. Leak detection
In absence of more precautionary requirements, the unit must be leak tested at least every three months (1).
During the test, if the minor doubt arises that a refrigerant leak is present (for example, following a reduction
of the cooling capacity or following the measurements of the overheating and subcooling), it is necessary to
detect it through the appropriate devices, repair it and make a new leak test in accordance to the existing
national law.
The result of the tests and the measures taken must be written on the Register.
The personnel performing the leak test are not allowed to use naked flame or any other potential source of
fire ignition.
Any eventual refrigerant leak must be detected and repaired as soon as possible by a certified personnel in
conformity with the existing local regulations.
5.1.2. Control of the safety pressure switch
In absence of more restrictive local regulations, high pressure safety switches must be inspected on the spot
at least every twelve months to make sure they work correctly and, in case they are manually set, check they
are set correctly and installed in compliance with the applicable laws.
5.1.3. Control of the safety valves
Lack of more severe regulations, the external safety valves must be controlled at least every six months (as
per table 5.1) to check their tightness. If a leak is detected, the valve must be replaced.
1
( ) For the units installed on the territory of the European Community, the leak test must be carried out
following the instructions described in the Commission Regulation (EC) 1516/2007.
pag. 67
(rev. 2, 08/2013)
Every five years check the valves to make sure they are in good condition, the adjustment pressure printed on
the valve is readable, they are installed and they have the appropriate features to guarantee the system
security in compliance with the local regulations.
5.1.4. Control of the noise level and vibrations
At least every month, check that the unit does not emit weird noises and that pipes do not have strange
vibrations which might cause a break.
5.1.5. Periodical operations
Table 5.1 shows in summary all operations of programmed maintenance and the corresponding frequency the
unit must be submitted to in order to guarantee a correct and reliable operation in time.
All operations having a daily and monthly frequency can be carried out directly by the Owner of
the circuit. All the other operations can be carried out only by a trained and qualified personnel.
Do not touch the unit if barefooted or with humid or wet parts of the body.
Do not perform any cleaning operation before disconnecting the power line by rotating the main
switch in OFF position and put the padlock as described at par.2.3.14.
Only trained and qualified technicians in compliance with the existing local regulations can
carry out any operations on the cooling circuit.
When working on the unit, it is necessary to be equipped with the required individual protection
devices. In particular, it is necessary to wear at least the protection glasses, the gauntlets, the
helmet and the safety shoes.
Table 5.1: Periodical maintenance operations
FREQUENCY
OPERATION TO BE PERFORMED
Every
Every
Every 2
Every 6
Every
Every 5
When
day
month
months
months
year
years
necessar
ELECTRIC CIRCUIT AND CONTROL DEVICES
Check that the unit is working regularly and that there is no
alarm signals
X
Make a visual inspection of the unit
X
Check the unit noise level and vibrations
X
Check that the safety and interlocking devices are efficient
X
Check the unit performance
X
pag. 68
(rev. 2, 08/2013)
Check the current absorption of the various components
X
(compressors, fans, etc.)
Check the unit power supply
X
Check cables are fixed in the corresponding terminals
X
Check the insulation material of the electric cables is intact
X
Check the contactors are in good condition and efficient
X
Check the microprocessor and the display are working
X
Check the values of the set parameters on the
X
microprocessor
Clean the electric and electronic components from any
X
eventual dust
Check the regulation and functioning of probes and
X
transducers
COIL, FANS and COOLING CIRCUIT
Check visually the evaporating coil
X
Clean the finned coil
X
Clean / replace the air filters *
X
Clean the condensate tank/s to check the drainage
X
Clean the humidifier cylinder *
Check the water flow
X
Check the fans noise level and vibrations
X
Check the fans power supply
X
Check the electric connections of fans
X
Check the regulation and functioning of the fan speed
X
regulator system (auto-transformer or 0-10V signal)
Check if the 3-way valve is working properly (if option BC
X
is present)
Check if the pressostatic valve is working properly (if
X
present)
Check if the hydraulic circuit is air free
X
COMPRESSORS
Check visually the compressors
X
Check the compressors noise level and vibrations
X
Check the compressors power supply
X
Check the electric connections of compressors
Check that the compressors electric cables are in good
conditions and are fixed correctly in the corresponding
terminals
•
X
X
The control of the cleaning condition of the air filters and of the humidifier cylinder depends on the kind of
installation.
pag. 69
(rev. 2, 08/2013)
5.2.
Routine maintenance
If a fault compromising the reliability of the unit operation is detected, it must be eliminated
before starting the unit.
During its operation life, the unit must be submitted to inspections and controls according to the existing
local laws and regulations. In particular, in absence of more severe requirements, follow the instructions
described in the Table 5.2 (see EN 378-4, annexe D), with reference to the described situations.
Table 5.2: Inspections and tests
Situation
Visual inspection
Pressure test
Leak test
(par. 4.2, steps a – l)
A
X
X
X
B
X
X
X
C
X
X
D
X
X
Inspection following an operation which might have possible effects on the mechanical resistance, or
following a change of use, or following a unit stop of more than two years; all components which are
no more appropriate must be replaced. Do not perform a test at a higher pressure than that one of the
project.
A.
Inspection following a repair or a substantial change to the system or to its components. It is possible to
test only the components involved in the operation, but if a refrigerant leak is detected, a leak test must
be carried out on the entire system.
B.
C.
Inspection following the unit installation in a different position than the original one. If possible effects
on the mechanical resistance are likely, please refer to point A.
D.
Leak test following a founded suspicion of refrigerant leak. The system must be inspected to detect the
leak through either direct measures (use of leak detectors) or indirect measures (deduction of the leak
presence following the analysis of the operating parameters), concentrating on the most subject parts
(i.e. the joints).
5.2.1. Control of the refrigerant humidity probe
The sight glass and humidity probe mounted on the refrigerant liquid line, downstream the dehydrating filter,
allows two types of controls:
1) Following the colour of the sensible material present in the sight glass, it is possible to deduct if the
humidity in the refrigerant is within acceptable limits: usually the light glass is bright green if the
humidity amount is sufficiently low; while it migrates towards yellow as the refrigerant becomes
more humid (in any case, please refer to the indications on the sight glass).
pag. 70
(rev. 2, 08/2013)
If an excessive presence of humidity is detected in the circuit, it could be necessary to replace the
dehydrating filter or, in the worst cases, the refrigerant contained in the circuit.
If the unit was stopped for long time, check the colour of the humidity probe at least after
one hour of operation to allow the dehydrating filter to eliminate part of the humidity
present in the refrigerant.
2) By observing the sight glass, it is also possible to understand if the refrigerant charge in the circuit is
adequate: usually, the refrigerant charge is considered sufficient if after 10 minutes of operation at
the nominal conditions there are no vapour bubbles through the sight glass.
5.2.2. Control of the refrigerant overheating
To measure the refrigerant overheating on the evaporator outlet while the unit has been working at the
nominal conditions at least since 10 minutes, it is necessary to measure:
•
The evaporating pressure by means of a manometer connected to one of the appropriate connections
placed on the suction line;
•
The suction temperature by means of a contact thermometer placed on the low pressure side at about
20 cm of distance from the evaporator.
If necessary, to measure the temperature, partially remove the insulation material covering
the suction pipe. The detector must be preferably placed on a horizontal tract, at 10 o’clock
poisition compared to the pipe axis. The contact between the probe and the surface can be
improved by using the appropriate conductive paste.
The refrigerant overheating is the difference between the suction temperature, estimated by means of a
contact thermometer, and the saturation temperature (dew value in case of zeotropic blends, that is to say
characterised by a temperature glide) corresponding to the evaporating pressure shown on the manometer.
All units are direct expansion with finned coil. The superheating values are set on the
microprocessor at the factory (5 ÷ 7 °C)
If the superheating value is below 5 K or over 7 K, it is necessary to change the parameters of the
thermostatic valve (see the Microprocessor Manual here attached) to let it stabilise around 5 ÷ 7 K.
5.2.3. Control of the refrigerant subcooling
To measure the refrigerant subcooling on the condenser outlet, while the unit has been working at the
nominal conditions since at least 10 minutes, it is necessary to measure:
•
The condensing pressure by means of a manometer connected to one of the appropriate connections
placed on the liquid line;
pag. 71
(rev. 2, 08/2013)
•
The liquid refrigerant temperature by means of a contact thermometer placed on the refrigerant line,
on the unit inlet (EDX, EDE) or at about 10 cm from the plate condenser outlet (EDH).
The contact between the probe and the surface can be improved by using the appropriate
conductive paste.
The refrigerant subcooling is the difference between the saturation temperature (the bubble value in case of
zeotropic blends, that it to say characterised by a temperature glide), corresponding to the condensing
pressure measured by a manometer, and the refrigerant temperature, measured by a contact thermometer.
If the subcooling value is below 3 K or over 10 K, it could be necessary to change the refrigerant quantity
charged in the circuit to let it stabilise around 5 ÷ 7 K.
5.2.4. Control of the overcurrent protective devices
The overcurrent protective devices must be inspected to make sure they are intact and working.
Fuses can be replaced only after disconnecting the unit from the power supply, rotating the
main switch on OFF position and put a padlock on the main switch as explained at
par.2.3.14.
It is forbidden to by-pass the fuses used on the unit or to replace them with other fuses having
a bigger size.
Fuses can reach very high temperatures and they can cause burns if not handled with the due
precautions.
In case of adjustable devices (thermal relays or motor overload protections), make sure the
absorption value set is not higher than the value indicated in the identification tag of the
component to be protected.
5.2.5. Control of contactors
The contactors used to activate the electrical loads must be inspected to make sure they are intact, contacts are
in good condition and the electric coil is working.
Check also that the electrical cables are fixed correctly and firmly in the appropriate terminals.
When necessary, remove any eventual dust and debris which might cause a noisy and unreliable functioning
of the device.
pag. 72
(rev. 2, 08/2013)
5.3.
Troubleshooting
The troubleshooting is realised by the unit control microprocessor which activates an alarm and shows on its
display the type of fault occurred.
Table 5.3 describes the most commun faults which might occur on the unit and for each of them the most possible
causes and solutions are stated.
In case of an alarm signal, before proceeding with any repair, it is advisable to check the following:
•
The operational conditions must correspond to the foreseen ones and, in any way, they must be
compatible with the unit operational limits;
•
All electric cables of the concerned components must be fixed in the corresponding terminals (see the
Wiring Diagram here attached);
•
The set values for the concerned parameters must be coherent with the operational conditions (refer to
the Microprocessor Manual here attached).
Table 5.3: Common faults
FAULT
POSSIBLE CAUSE
CORRECTIVE ACTION
Check the electric tension of each phase of the power
a.
The electric panel is not powered
supply line
Check the main switch is closed (ON position)
Check the fuses of the auxiliary circuit (see the Wiring
b.
The auxiliary circuit is not powered
c.
The microprocessor does not start the
Check the electric connections to the microprocessor
unit
Check the set value of the temperature
Diagram)
1. The unit does not
work
Check the remote ON/OFF contact is closed (see the
d.
The external impulse fails at the
Wirinig Diagram)
starting of the unit
Enable the external impulse from the user terminal
(display) when the unit starts
a.
The unit does not work
b.
The control system setting is not
2. Room temperature
too high (high room
correct
See point 1
Check the setting of the control system
c.
The air flow capacity is too low
See point 6
d.
The compressor does not work
See point 10
e.
The compressor output is not sufficient
temperature alarm
signal)
See point 13
See point 14
pag. 73
(rev. 2, 08/2013)
See point 15
f.
The reheating system is not working
properly (if present)
g.
The control system does not work
Consult the Microprocessor Manual here attached
h.
Thermal load higher than estimated
Check the room thermal load
a.
The control system setting is not
correct
3. Room temperature
too low (low room
b.
temperature alarm
signal)
The reheating system is not working
properly (if present)
high (high room
See point 7 and/or 16
c.
The control system does not work
d.
Check the thermal loss value
a.
The setting of the control system is not
correct
4. Room humidity too
See point 7 and 16
b.
Latent load higher than estimated
c.
The compressor does not work when in
humidity alarm)
dehumidification phase
d.
The control system does not work (if
option DH is present)
Check the room latent load
See point 10
Consult the Microprocessor Manual attached
a.
Check if the humidifier is present
If the humidifier is absent, proceed with its installation
b.
The humidity set-point is set at a too
Increase the humidity set-point value
5. Room humidity too
low (low room humidity
low value
alarm)
6. Low or no air flow
capacity (flow or fans
c.
The humidifier does not work
Consult the Humidifier Manual here attached
a.
Fans are not powered
Check the fans electric circuit
b.
Clogged filters
Clean or replace the filters
c.
Obstruction in the air duct or excess of
Check the total pressure drop and compare it with the
pressure drop in the air ducts
unit available pressure
alarm)
7. The 3-way valve does
d.
The fan thermal protection is activated
a.
The c ontrol system does not work
b.
The valve servomotor does not work
c.
The valve is blocked mechanically
not work (present in
case of options BC or
BG)
pag. 74
Check the fan winding resistance (after the reset, check
the tension and electric absorption).
Check the electrical connections and eventually replace
the servomotor, if defective
Try to unblock manually the valve or replace it
a.
The control system of the condensation
pressure is not working properly (if
present)
b.
c.
(rev. 2, 08/2013)
Make sure the control system of condensation is set and
it works
One or more condensing fans are out of
Check the internal heat protection of the out of order
order (ED.X and ED.E)
fans: replace the defective fans
The high pressure switch is not
properly set
Replace the high pressure switch
8. High pressure switch
is activated
d.
Output pressure too high
See point 14
e.
The condensation water flow capacity
Make sure all valves are positioned correctly
is not sufficient (ED.H)
Make sure there is no air in the circuit
Water to the plate condenser too hot
Check the capacity of the cooling system of the
(ED.H)
condensation water
g.
Encrusted plate condenser
Clean the exchanger with specific products
a.
The low pressure switch is not set
f.
9. Low pressure switch
correctly
Replace the low pressure switch
is activated
b.
Suction pressure too low
See point 13
a.
The automatic switch is activated
Reset the automatic switch, check the short circuit pause
Check the compressor winding resistance (after the
10. The compressor does
b.
not work
The compressor internal protection is
reset, check the tension and electric absorption)
activated
Make sure the operational paarameters go back to the
nominal values
11. The compressor is
c.
The contactor does not work
Check the contacts and the contactor coil
a.
Liquid return to the compressor
b.
The compressor is damaged
Replace the compressor
a.
Check the room thermal load value
b.
Discharge pressure too high
See point 14
Check the functioning and the overheating of the
expansion valve
noisy
12. Compressor suction
Make sure the overheating of the thermostatic valve is
correct
high pressure
c.
Liquid
refrigerant
return
to
the
compressor intake
Check that the pressure transducer and the temperature
probe of the electronic thermostatic valve are well
placed, fixed and insulated
a.
Room temperature too low
b.
The air flow capacity is too low or
See point 3
13. Compressor suction
low pressure (possible
absent
See point 6
pag. 75
(rev. 2, 08/2013)
frost on the coil battery)
c.
Clogged refrigerant filter
d.
The
Check the refrigerant filter
Check the setting of the electronic valve parameters, in
electronic
thermostatic
valve
particular
parameters are not set correctly
Make sure the thermostatic element is intact
Check the presence of an eventual leak and re-establish
e.
Insufficient refrigerant charge
f.
Discharge pressure too low
a.
the charge
See point 15
pressure is not working properly (if
present)
14. Compressor high
b.
Air to the condenser too hot
c.
Insufficient
condensation
Check the setting and functioning of the condensation
control system
Check the presence of any condensation air re-cycle
air
flow
Make sure there is no obstruction to the air flow in the
capacity
finned exchanger coil
d.
Suction pressure too high
See point 12
e.
Clogged fins of the condenser coil
Remove the clogging material
f.
Circuit
High refrigerant subcooling: remove some refrigerant
charged
with
too
much
refrigerant: condenser partially flooded
pressure output
from the circuit
The flow sight glass presents gas bubbles. The
g.
Non condensable air or gas
in the
circuit
compressor discharge temperature is high: the cooling
circuit must be discharged and charged again after the
vacuum execution
Check the capacity of the condensation water cooling
h.
Too hot water to the condenser (EDH)
i.
Insufficient condensation water flow
Check the circuit pressure drop and compare it with the
capacity (EDH)
pump available pressure
j.
Encrusted plate condenser (EDH)
Clean the exchanger with specific products
a.
Check the setting and functioning of the condensation
pressure is not working properly
control system
b.
Suction pressure too low
See point 13
a.
The set-point temperature is too low
Increase the set point temperature
b.
Magnetothermic switch disconnected
15. Compressor low
system
pressure output
16. The electric heater
does not work (if
present)
Make sure there is no short circuit.
Reset the disconnected switch.
Check the current absorption
pag. 76
(rev. 2, 08/2013)
Air flow capacity too low: see point 5.
c.
Safety thermostat activated
Check the safety thermostat is working and, if
necessary, replace it.
d.
The contactor does not work
Check the contacts and the contactor coil
Check the hot water source.
a.
Hot water flow capacity is insufficient
Check the duct and make sure there is no leak or
obstructions
17. The hot water coil
does not work (if option
BC is installed)
18. Probe alarm
19. The fan does not start
b.
The discharge hot water temperature is
too low
c.
The set point temperature is too low
Increase the set point temperature
a.
The probe corresponding to the alarm
Check if the defective probe is connected and working.
code is defective or disconnected
If necessary, replace the probe.
a.
Current black out
Check the main switch and the power cable
b.
Protection switch is open
c.
Transformer protection activated
Check eventual short circuits on the auxiliary circuit
d.
Defective contactor
Repair or replace the contactor
e.
Fans are not powered
Check the fans electric power supply
f.
The fan thermal protection blocks its
Check if the rotor is blocked, or if the power supply is
operation
not sufficient or if there is a phase loss
g.
Microprocessor not powered (display
OFF)
h.
5.4.
Check the hot water distributor
Unit OFF (OFF position)
Reset the protection switch and check the motor
amperage and absorption
Check eventual short circuits on the auxiliary circuit
Set ON position on the keyboard
Special maintenance
The unit repair operations must be carried out by adequately trained and informed personnel, equipped with
individual protection devices in compliance with the existing local regulations.
If brazings and weldings must be performed in presence of the refrigerant, besides the individual protection
devices necessary for the fluid handling, the concerned personnel must also wear a respirator with a specific
protection filter for possible decomposition compounds.
pag. 77
(rev. 2, 08/2013)
The cooling circuit contains high pressure refrigerant. Before performing any operation on
the cooling circuit, discharge the pressure completely and with precaution.
When necessary, comply the existing national regulations in terms of refrigerant
transportation.
Do not modify the unit or replace its components without the explicit Manufacturer
authorisation.
The operations carried out by a personnel having different qualifications (like welders, electricians,
programmers, etc) must be carried out under the supervision of a personnel having the necessary competence
on air conditioning.
Welding and brazing operations must be performed only by adequately trained personnel, in conformity with
the qualified procedures, only after the concerned section of circuit has been discharged of refrigerant and
flushed with nitrogen.
During the welding and brazing operations, remove all those parts which might be damaged by
heat or protect them by wrapping the components with wet cloths.
In case of operations requiring the dismantling of shut-off valves, it is advisable to replace
the gaskets with new tight elements.
In absence of more restrictive requirements, the repair of the cooling circuit components must be carried out
according to the following phases, when applicable:
a) Analysis and assessment of the risk for the operation,
b) Training of the maintenance team,
c) Disconnection and protection of the components to be repaired,
d) Refrigerant recovery and vacuum execution,
e) Cleaning by flushing with dry hydrogen,
f) Authorisation to the repair,
g) Repair execution,
h) Check and test of the repaired parts (pressure test, tightness test, operational test),
i) Remounting, vacuum execution and refrigerant charge.
5.4.1. Opening of the cooling circuit
Before operating on the cooling circuit, make sure the following precautions are put into place:
pag. 78
(rev. 2, 08/2013)
a) Obtain the authorisation for the execution of the job (if necessary);
b) Make sure that in the working area there are no flammable materials or fire ignition sources;
c) Make sure that suitable fire and protection devices are available;
d) Before starting to work on the cooling circuit and before performing any welding or brazing, make
sure the working area is properly ventilated;
e) Make sure all the personnel in charge of the operation is adequately trained.
When an operation involving the cooling circuit discharge is carried out, it is necessary to collect the refrigerant
gas in an appropriate recuperator for the environment safety.
During the operations requiring the refrigerant handling, make sure the ventilation is adequate and in the
proximity there is no naked flame or other fire ignition sources.
The equipment for the refrigerant recovery must be compliant to the existing local regulations and must be in
good maintenance condition; it is advisable they can operate up to a pressure of 0,3 bar.
Once the repair on the cooling circuit is achieved, the following procedures must be carried out:
a) Tightness test (see par. 3.11.1) ,
b) Vacuum and dehydration (see par. 3.11.2),
c) Refrigerant charge (see par. 3.11.3).
5.4.2. Refrigerant treatment
In absence of more specific local regulations, during the refrigerant handling operations, follow the
instructions described here below.
The operations involving the refrigerant use must be carried out so as to reduce as much as possible any
release in the atmosphere.
Charge the refrigerant in the cooling circuit only after that the cooling circuit has succeeded a tightness test.
Do not connect the refrigerant cylinder to a higher pressure system, when a reflux situation
is likely.
The refrigerant cylinders must be disconnected from the system as soon as the fluid transfert operation is
terminated.
The refrigerant cylinders must not be beaten, hit, let fall or exposed to heat sources during the operation.
They must be visual inspected to check their condition.
Do not charge in the cylinders a bigger quantity of refrigerant than the maximum foreseen
which must be clearly stated on the cylinder.
pag. 79
(rev. 2, 08/2013)
Do not introduce refrigerant in cylinders intended for a different substance; the compound
present in the cylinders must be clearly indicated on them.
To avoid to mix different refrigerant qualities (new, re-cycled, re-used), the refrigerant quality must be
clearly indicated on the cylinders.
It is forbidden to connect more refrigerant cylinders between them by means of a collector.
The refrigerant cylinders must be conserved in an appropriate area, far from any fire source, protected from
heat sources or from direct sun exposure.
The cylinders must be handled with precaution to avoid mechanical damages; if necessary, they must be
secured to avoid they can fall.
The cylinders valve must be closed and protected. Gaskets must be replaced when necessary.
5.4.3. Operations to be performed after the repair
After each repair operation, the following operations must be performed:
a) Check all safety, control and measurement devices and make sure they work properly;
b) Make a leak test on the concerned sections of the cooling circuit;
c) Check and re-establish the refrigerant charge;
d) Make sure the safety devices are working;
e) Check if there is any refrigerant presence in the fluid to be cooled.
After each repair operation, check and record the functioning of eventual security systems, such as for
example the refrigerant detector and the systems of mechanical ventilation.
All lost or unreadable labels on the components of the cooling circuit must be replaced.
After the repair is finished, an operational test must be carried out; if a refrigerant leak is detected, the entire
system must be submitted to a tightness test.
Report on the Register the quantity and type of refrigerant employed.
The unit tightness must be checked again within one month from the repair to check if the operation was
effective.
6.
DISMANTLING
When the unit has to be dismantled, it is necessary to separate all its components and to ship them to a separate
waste collection area. This activity must be carried out by a specialised company in compliance with the existing
local regulations.
pag. 80
(rev. 2, 08/2013)
Before dismantling the unit, it is necessary to drain the cooling circuit and collect the refrigerant by means
of an appropriate receiver in compliance with the local existing regulations.
The operations of refrigerant recovery, re-usage, re-cycle, regeneration and diposal must be
carried out only by a trained, qualified and equipped personnel, in compliance with the
existing local regulations.
The refrigerant pressure present in the cooling circuit can be elevated, therefore discharge
it with caution.
The refrigerant fluid released in a sudden way can cause burns in case of contact, due to the
low temperature.
The refrigerant filters used can contain residual quantities of fluid which must be eliminated
before their disposal.
If the unit has worked with an antifreeze mixture, it is necessary to collect all the fluid
contained in the unit and deliver it to a specialised centre for waste disposal.
Do not release in the atmosphere the antifreeze mixture present in the unit.
Do not release the refrigerant in the environment.
7.
REFRIGERANT SAFETY DATA SHEET
pag. 81
(rev. 2, 08/2013)
pag. 82
(rev. 2, 08/2013)
pag. 83
(rev. 2, 08/2013)
pag. 84
(rev. 2, 08/2013)
pag. 85
(rev. 2, 08/2013)
pag. 86
(rev. 2, 08/2013)
pag. 87
(rev. 2, 08/2013)
pag. 88
(rev. 2, 08/2013)
pag. 89
(rev. 2, 08/2013)
pag. 90

ED Power - Baudiment Technology

Transcription

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