GB.COOLER.INST.060501 Cooling Unit – Cooler Installation and Maintenance Instructions Sizes 14-60 Sizes 14-18 Sizes 24-60 GB.COOLER.INST.060501 Contents 1.Overview 1.1. General 1.2 Operating Principle 1.2.1 Cooler 14 and 18 1.2.2 Cooler 24, 34, 48 and 60 2 Safety Precautions 2.1 Safety switch/main switch 2.2 Hazards 2.3 Electrical equipment 2.4 User qualification 2.5 Decals 3 3 4 4 5 6 6 6 6 6 6 3Installation 3.1 Unloading/site transport 3.1.1 Transport using a forklift truck 3.1.2 Lifting using a crane 3.2 Mounting 3.2.1 Fitting handles on Unit 3.3 Installation Principle 3.3.1 Installation – Cooler, size 14 3.3.2 Installation – Cooler, size 18 3.3.3 Installation – Cooler, size 24-60 7 7 7 7 7 7 8 9 9 9 4Electrical Wiring 4.1 Wiring to mains power 4.1.1 Cooler – size 14 4.1.2 Cooler – size 18 4.1.3 Cooler – size 24 - 34 4.1.4 Cooler – size 48 - 60 4.2 Other electrical connections 4.2.1 GOLD, Verson B 4.2.2 Other types of air handling unit 10 10 10 10 10 10 10 10 11 5 Ferrit Block, 019 210 12 6 Communication Cable, 019 007 13 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.8.1 6.8.2 Cooling Connections Location Draining the cooling coil Liquid connections Venting nipples Insulating the cooling agent circuits Connection to the cooling unit Safety drain Filling with water/glycol mixture Filling Venting the system 13 13 13 13 13 13 13 13 13 14 14 7 7.1 7.1.1 7.1.2 7.1.3 Commissioning Preparations Before starting for first time Starting up To correct the phase sequence 15 15 15 15 15 www.swegon.se 8 8.1 8.1.2 8.2 8.3 Programming and Managing the Menus Hand-held micro terminal Display and buttons Menu button captions and symbols Menu groups and levels 16 16 16 16 16 9 9.1 9.2 9.3 9.4 9.5 Menus Main menu Information menus Settings menus Test menus Alarm menus 17 17 17 18 19 20 10 10.1 10.2 10.3 10.4 10.5 Alarms General Resetting the alarms Settings Alarm conditions Alarm priorities 20 20 20 21 21 22 11 11.1 11.2 11.3 11.4 11.5 11.6 Maintenance Cleaning Changing the water/glycol mixture Handling the refrigerant Charging with refrigerant Annual inspection Service 23 23 23 23 23 24 24 12 12.1 12.1.1 12.1.2 12.2 12.2.1 Cooling Coil and Cooling Agent Cooler Instructions for BASIC BCKO Cooling agent cooler, 006-014 BCKA Cooling coil, 004-014 Instructions for the GOLD, sizes 11-32 Installing the TBKA, TBKC cooling coil 24 24 24 25 26 26 13 13.1 Connection to Ducting Type of end connection 29 29 14Electrical Data 14.1 Cooling unit 14.2 Power supply 29 29 29 15General Technical Data 30 16 Mechanical Design 16.1 Design 16.1.1 Dimensions and weights 31 31 31 17Other Particulars 32 18Enviromental Compatibility Declaration 18.1 Scrapping 32 32 19 33 Compliance Declaration Specifications are subject to alteration without notice. GB.COOLER.INST.060501 1. Overview 1.1. General Cooling Unit Cooler The Cooler is a complete one-piece cooling unit for comfort cooling in air handling systems. All the refrigeration and electrical components are interconnected and housed in one common casing. The units are test run prior to delivery. The coils are designed for installation in the ducting. The arrangement of piping between the cooling unit and the coils and the electrical wiring of the cooling unit is carried out at the building site. The Cooler can be used together with an air handling unit. The capacities of the six sizes are however matched to the size 08-60 GOLD air handling system and the size 004-014 Basic air handling units. Complete indirect system (sizes 24, 34, 48 and 60) The size 24-60 Coolers have a complete indirect system. Heat/cooling energy is transferred across a heat exchanger from the refrigerant to the circulating water mixed with glycol. Both the brine circuit and the cooling agent circuit must be filled with a mixture of water and 30% ethylene glycol after the unit has been installed. Compressors Sizes 14, 18, 24 and 34 each have two-piston compressors. Sizes 48 and 60 each have two compressors as well, but they are of Scroll-type. Partially indirect system (sizes 14 and 18) The size 14 and 18 Coolers have a partially indirect system. On the warm side, a coil (condenser) is used for directevaporating refrigerant, while on the cold side, there is a heat exchanger, where energy is transferred to the water mixed with glycol (brine) circulated to the cooling coil in the supply air duct. The circuits must be filled with a mixture of water and 30% ethylene glycol after the unit has been installed. The condenser coil is integrated into the cooling unit fitted in the exhaust air duct. Fig. 2 Refrigerant Cooler has double refrigerant circuits which are separate from one another. The refrigerants used are of type R407C and R134A in each circuit respectively, each with its own compressor. On delivery, the refrigerant circuits are charged. These refrigerants do not have any known impact on the ozone layer and there are no known restrictions for their use at this present time. Refrigerant volume See section 14. General Technical Data. Reporting obligation The user is required to submit periodic reports to the local inspectorate only if the total charge volume exceeds 10 kg. Annual inspections Annual inspections by an accredited inspectorate are required if the volume of refrigerant in the one-piece unit exceeds 3 kg. This is applicable to the size 24, 34, 48 and 60 Coolers only. Fig. 1 Specifications are subject to alteration without notice. Quality Management System to ISO 9001 and Environmental Management System to ISO 14001 Swegon maintains documented and certificated Quality Management and Environmental Management Systems that meet the provisions of ISO 9001 and ISO 14001 respectively. www.swegon.se GB.COOLER.INST.060501 1.2 Operating Principle 1.2.1 Size 14 and 18 Coolers HT E1 BT2 RP2:2 M2 SS RP2:1 VVX2 EV2 Cooling coil G1 BT4 SV EK BT3 Condenser coil EV1 VVX1 M1 BT1 RP1:2 RP1:1 Fig. 3 BT1 Hot gas thermostat R134A BT2 Hot gas thermostat R407C BT3 Brine temperature sensor BT4 Extract air temperature sensor RP1:2 High pressure switch R134A RP2:2 High pressure switch R407C RP1:1 Low pressure switch R134A RP2:1 Low pressure switch R407C G1 Brine pump M1 Compressor R134A M2 Compressor R407C VVX1 Evaporator VVX2 Evaporator SV Safety valve EK Expansion vessel E1 Electrical cubicle with safety switch, power section, control card SS Start and control signals EV1 Expansion valve 1 EV2 Expansion valve 2 HT Hand terminal www.swegon.se Operation There are two refrigerant circuits in the cooling unit The circuits are separate from one another and each contains a different type of refrigerant. Each circuit is equipped with its own heat exchanger on the cold side. On the warm side, both circuits are arranged through a condenser coil. The brine (water/ethylene glycol) passes the heat exchanger of both refrigerant circuits. The refrigerant in gas form is compressed by each compressor and then passes to the condenser coil, where it is chilled by the air flowing through the coil, and condenses to liquid form. A reduction in pressure occurs in expansion valve EV. From the expansion valve the refrigerant advances to evaporator VVX where the refrigerant vaporises and absorbs heat from the adjacent medium, i.e. the brine. This chills the brine. Gas leaves the evaporator and flows back to the compressor. Water pump G1 pumps the brine (water/ethylene glycol) in a circuit from evaporators VVX1 and VVX2, where it is chilled by the refrigerant and advances to the cooling coil, which in turn cools the supply air flowing to the air handling unit. The refrigerants are never in physical contact with the brine. Heat and cooling energy are transferred across the heat exchangers in the evaporator and condenser. Control In a response to an ON/OFF control signal, the controller switches in pump G1 and compressor M1. The cooling capacity is controlled by switching in one or two compressors. On increasing cooling load, the controller switches in compressor M2 and at the same time switches out compressor M1. If even more cooling is required, compressor M1 is switched in to operate together with compressor M2. If the temperature of the outgoing brine becomes too low, one of the compressors is switched out. When this condition subsides, it is restarted automatically. Should the pressure become too low, the low pressure switch will trip. The equivalent will occur on the warm side. If the temperature of the exhaust air becomes too high, one of the compressors is switched out. If the pressure still rises, the high pressure switch will trip. Specifications are subject to alteration without notice. GB.COOLER.INST.060501 1.2.2 Size 24, 34, 48 and 60 Coolers HT E1 BT2 RP2:2 M2 VVX2 Cooling agent cooler SV EK VVX3 EV2 BT4 SS RP2:1 Cooling coil G1 BT3 G2 SV EK EV1 VVX1 BT1 RP1:2 VVX4 M1 RP1:1 Fig. 4 BT1 Hot gas thermostat R134A BT2 Hot gas thermostat R407C BT3 Brine temperature BT4 Cooling agent temperature RP1:2 High pressure switch R134A RP2:2 High pressure switch R407C RP1:1 Low pressure switch R134A RP2:1 Low pressure switch R407C G1 Brine pump G2 Heating medium pump M1 Compressor R134A M2 Compressor R407C VVX1 Condenser VVX2 Condenser VVX3 Evaporator VVX4 Evaporator EK Expansion vessel SV Safety valve E1 Ellectrical cubicle with safety switch, power section, control card SS Start and control signal EV1 Expansion valve 1 EV2 Expansion valve 2 HT Hand-held micro terminal Specifications are subject to alteration without notice. Operation There are two refrigerant circuits in the cooling unit. The circuits are separate from one another and each contains a different type of refrigerant. Each circuit is equipped with its own set of heat exchangers on the warm and cold side respectively. The cooling agent and the brine (water/ethylene glycol) both pass through the heat exchanger of both refrigerant circuits. The refrigerant in gas form is compressed by each compressor and then advances to condenser VVX1 or VVX2, where it is chilled by the cooling agent (water/ethylene glycol) and condenses to liquid form. A reduction in pressure occurs in expansion valve EV and the pressure drops. From the expansion valve the refrigerant advances to evaporator VVX3 or VVX4 where the refrigerant vaporises, boils, and absorbs heat from the adjacent medium, i.e. the brine (water/ethylene glycol). Gas leaves the evaporator and flows back to the cooling compressor. Water pump G1 pumps the brine (water/ethylene glycol) in one circuit from condensers VVX3 and VVX4 where the brine is chilled by the refrigerant and then proceeds to the cooling coil, where it in turn cools the supply air discharged from the air handling unit. Water pump G pumps brine (water and ethylene glycol) in the circuit from condensers VVX1 and VVX2, where the brine cools the refrigerant and further to the brine cooler (the coil in the exhaust air duct). The brine is cooled there where it transfers heat to the exhaust air leaving the air handling unit. After that the brine returns to the condenser. If the cooling agent isn’t chilled adequately, the COOLER will temporarily lower its capacity to avoid a shutdown (shuts off one refrigerant circuit and compressor). The cooling unit will however revert to operating at full capacity again as soon as the operating conditions so permit. Control In response to an ON/OFF control signal, the controller switches in pumps G1 and G2 and compressor M1. The cooling capacity is controlled by switching in one or both compressors. On increasing cooling load the controller switches in compressor M2 and at the same time switches out compressor M1. If still more cooling is required compressor M1 is switched in to operate together with M2. If the temperature of the outgoing brine becomes too low, one of the compressors is switched out. When the condition subsides, it is restarted automatically. Should the pressure become too low, the low pressure switch will trip. The equivalent will occur on the warm side. If the temperature of the exhaust air becomes too high, one of the compressors is switched out. If the pressure still rises, the high pressure switch will trip. www.swegon.se GB.COOLER.INST.060501 2 Safety Precautions 2.3 2.1 Safety switch/main power switch The electrical equipment of the unit is located behind the inspection door in a separate electrical cubicle. The safety switch is located inside the inspection door (right-hand door on the size 24 - 60 units). The safety switch must not be used for starting or stopping the cooling unit. Make sure that the Cooler is switched off by shutting down the air handling unit or by temporarily switching out the cooling unit in the display. Enter SET in the main menu, select SET again, then select PROG and then SHUT OFF. After doing this, the safety switch can be used to isolate the power. Important! Always switch off the safety switch when servicing unless otherwise specified in the relevant instruction. 2.2 Hazards 2.4 Electrical equipment User Authorisation Only a qualified electrician or trained service personnel is permitted to carry out electrical wiring in the unit. Only staff of an accredited refrigeration service company is permitted to modify or repair the refrigerant circuit. Modification or work on the cooling unit may only be carried out by service personnel trained by Swegon. Should the need arise to do any repair work, get in touch with your nearest Swegon service representative, see the last page of these instructions. 2.5 Decals The model number label with type designation, serial number, refrigerant volume, etc. is affixed to the inspection door of the unit. Caution! Make sure that the power has been switched off before carrying out any work inside the unit. Caution! Unauthorized personnel are not under any circumstances permitted to open the refrigerant circuit. The circuit contains gas under high pressure. Hazardous areas where there is refrigerant The entire cooling unit is in principle a hazardous area due to the presence of refrigerant. For particulars of how to deal with leakage, see Section 10.3. The circuits contain type R 407C and R134A refrigerant. Caution! Since the Cooler is located on the pressue side downstream of the air handling unit, the inspection lid must not be opened while the fan is in operation. The door may fly open and cause injury to personnel. (Applicable to the size 14 and 18 units). www.swegon.se Specifications are subject to alteration without notice. GB.COOLER.INST.060501 3 Installation 3.1 Unloading/transport within the building site Important! 3.1.2Lifting using a crane Place two sling spreaders on the upper side of the unit and two on the underside of the pallet or under the unit. Then lift in the pallet (or the unit if the pallet is not to be attached). See fig. 6. The unit should always be horizontal while it is being transported. 3.1.1Transport using a forklift truck Fig. 6 3.2 Fig. 5 Caution! Low centre of gravity! Lift the unit carefully. Mounting The Cooler cooling unit should be located at a suitable spot in the fan room. The unit can be located with its backside against the wall. Adequate open space must be provided outside the inspection door to allow access to the safety isolating switch/main circuit breaker located behind the inspection door in compliance with local electrical safety regulations. 3.2.1 Fitting handles to the unit Fit the handles on the inspection doors. Specifications are subject to alteration without notice. www.swegon.se GB.COOLER.INST.060501 3.3 Installation principle The dimensions and capacity of the cooling coil and the cooling agent cooler are specially suited for connection to the size 08-60 GOLD and size 004-014 Basic air handling units. For a survey of the sizes of cooling unit and their capacities that correspond to each size of air handling unit, see Section 14, General Technical Data. Cooler, sizes 14-18 Venting nipple Power supply Start and control signal Brine Venting nipple Exhaust air Extract air Outdoor air Support legs Supply air Condensate drain Cooling coil Fig. 7 Cooler 24-60 Venting nipples Cooling agent Start and control signal Brine Exhaust air Extract air Outdoor air Cooling agent cooler Power supply Supply air Condensate drain Cooling coil Fig. 8 www.swegon.se Specifications are subject to alteration without notice. GB.COOLER.INST.060501 General The unique Wing fans in the GOLD and Basic air handling units make it possible to connect coils directly against the duct connection of the air handling unit without any pressure losses or nonuniform air distribution. Provision for inspecting and cleaning the GOLD unit must be provided when the unit is installed, such as by fitting inspection covers to the ducting or making the coils withdrawable. The cooling coil can be incorporated into a block or can be located separately at an appropriate spot next to a Basic casing on the supply air side of the unit. 3.3.1Installing size 14 Coolers For GOLD: The cooling coil and the refrigerating machine of the size 14 Cooler have an approved rubber seal for circular connection to the supply air duct and exhaust air duct respectively of the GOLD 08. A 400/500 mm conical transition piece is required on the supply air side of the air handling unit. The cooling unit has a rectangular outlet connection to decrease pressure losses. The connections of the GOLD 14-20 are rectangular and their dimensions are matched to fit this unit. Slip-clamps are used for connection. For the Basic: The cooling unit is connected without any end panel to the exhaust air side downstream of the fan in the Basic. A cover plate must be fitted to the air handling unit since the refrigerating machine is somewhat smaller, see Fig. 9. The cooling coil can be incorporated into a block or can be arranged separately at an optional spot in a Basic casing on the supply air side of the unit . See Section 5 for particulars of the cooling connection. 3.3.2Installing size 18 Coolers For the GOLD: The cooling coil and the size 18 cooling unit have rectangular connections.Slip-clamps are used for connection to the ducting. For the Basic: The cooling unit is connected without any end panel to the exhaust air side downstream of the fan in the Basic. The cooling coil can be incorporated into a block or located separately at an appropriate spot in a Basic casing on the supply air side of the unit. See Section 5 for particulars of the cooling connections. 3.3.3Installing size 24-60 Coolers For the GOLD: Cooling coil and cooling agent cooler for the size 24, 34, 48 and 60 cooling units have rectangular connections. Slip-clamps are used for connection. For the Basic: The cooling coil and cooling agent cooler can be incorporated into a block or can be installed separately in the Basic casing at an appropriate spot on the supply air or exhaust air side of the unit. See Section 5 for particulars of the cooling connections. Fig. 9 Specifications are subject to alteration without notice. www.swegon.se GB.COOLER.INST.060501 4 Electrical Wiring Important! The installation work shall be carried out by an authorized electrician. 4.1 Wiring to the mains power The power cable must be arranged through the front panel of the unit. A permanent cable gland has been factory-fitted to the side of the inspection door. The location of the gland varies slightly depending on the size of cooling unit. The incoming cable for 400 V power (5-wire system) must be connected directly to the safety switch, which has four normally-closed contact functions. The safety switch is installed in the built-in electrical cubicle. The terminal block for incoming earth is situated adjacent to the safety switch. If a 4-wire system is used, a jumper should be fitted between the earth and zero terminal blocks in the Cooler. For access to the connections of the safety switch, the safety guard above the electrical cubicle components has to be dismantled. 4.1.1 Size 14 Coolers The cable gland is located to the right at the top of the front panel. The fuse for the cable shall be rated for 20 A(T). When sizing the cable, take into account the ambient temperature and how the cable will be arranged. See Fig. 10. 4.1.2 Size 18 Coolers The cable gland is located at the bottom edge of the front panel. Fuse for the cable should be rated for 25 A(T). When sizing the cable, take into account the ambient temperature and how the cable will be arranged. See Fig. 10. 4.1.3 Size 24 and 34 Coolers The cable gland is located uppermost and to the right on the front panel. The fuse for the cable shall be rated for 32/35 A (T) for the size 24 Coolers and 35 A(T) for the size 34 Coolers. When sizing the cable, take into account the ambient temperature and how the cable will be arranged. See Fig. 10. 4.1.4 Cooler sizes 48 - 60 The cable gland is located uppermost and to the right on the front panel. The fuse for the cable shall be rated for 63 A(T). When sizing the cable, take into account the ambient temperature and how the cable will be arranged. 10 www.swegon.se Fig. 10 4.2 Other electrical connections 4.2.1GOLD, Version B General The Cooler is supplied with two alternative accessories for controlling the cooling load. Extra interference protection is required for the Cooler variants operating where the cooling load is controlled by an external 0 –10 V DC signal. To meet the provisions stipulated in the EMC Directive, concerning insensitivity to interference, the analogue inputs must be protected by a Ferrit block, 019 210. Communication cable 019 007 is the accessory, that must be used when the Cooler operates together with the Version B GOLD ventilation unit. See the individual instructions. Design The ferrit block, 019 210, is designed for snapping around wires. The block consists of two ferrit-halves, enclosed in a plastic casing that can be opened. The plastic casing has ”hinges” and a simple lock that make it easy to open and close around relevant wires. Dimensions: H = 15 mm, W = 15 mm, L = 29 mm and diameter of the openings = 6.6 mm. Communication cable 019 007 is a 5 m long flat cable, with a type RJ 1 modular connection fitted at both ends. The cable transfers normal communication signals between the control unit and the GOLD unit (Version B), but not 4 V DC. Both types of control have their own 4 V DC supply. Important: Do not use an ordinary bus cable! If the 4 V DC connections are interconnected, this will cause malfunctions. Specifications are subject to alteration without notice. GB.COOLER.INST.060501 Connection of the control and regulation cable to the air handling unit. Only one communication cable is required for transmitting information between the Cooler and the GOLD control systems. All the operating conditions and alarms are transmitted across this cable. Communication: Communication between the Cooler and the GOLD unit takes place by means of a special communication cable (PM part number 019 007). Installation in the GOLD: Connect communication cable 019 007 to any of the ABC Bus outlets on the control unit. For the Gold (Version B) see Fig.11! Use one of the holes in the oval rubber-covered cable glands on the backside of the electrical cubicle’s junction hood, for running the cable in to the control unit. See Fig. 12! Move a part of the cable gland to the side to insert the Modular connection through it. Connect the cable to a bus connection on the control unit. Adjust the cable length inside the electrical cubicle and adjust the cable in the cable gland. Refit the cable gland in its correct position. Lay the communication cable in a safe manner from the plastic hood on the top panel of the GOLD unit (Version B) to the Cooler unit. Installation in the Cooler: Connect communication cable 019 007 to any of the ABC Bus outlets on the control unit. For the Cooler, see Fig. 11b! Remove the safety guard over the electric cubicle of the Cooler. Loosen the oval cable gland on the front side of the electrical cubicle just so much to enable you to push the quick connector on the communication cable through the opening. See Fig. 12! Fasten the connector in any of the connections for ABC Bus/communication on the control circuit card ABC Bus ABC-Bus Fig. 11 Specifications are subject to alteration without notice. Dip switch SW1 ABC Bus Fig 11b. Hand-held Micro Terminal Connect the quick connector of the hand-held micro terminal to one of the connections on the control circuit card, i.e. to the centre outlet up to the left or any of the 6 right-hand modular connections at the lower edge of the control circuit card. Lead the cable through the cable gland in the same manner as the communication cable, described above. hand-held micro terminal of the Cooler can also be connected to any vacant ABC Bus connection on the circuit card or hand-held terminal of the GOLD unit. Commissioning At the lower edge of the control unit in the Cooler there is a red block with four DIP switches that have to be set to appropriate settings. For communication with the GOLD unit, set all 4 switches to the ON position (up). Use the hand-held terminal to set the cooling unit function to the auto operation mode. Do this under SETTINGS. See the Operation and Maintenance Instructions for the GOLD. 4.2.2Other types of air handling unit Instructions for the Cooler with 0-10 V controller Connection of the control and regulation cable to air handling units other than the GOLD version B. DIP-switch settings: At the bottom of the control unit in the Cooler there is a red block with 4 DIP switches, which have to be set. If 0-10V control is used, set the switch no. 1 to the OFF position (down) and switch nos. 2 – 4 to the ON position (up). See Fig. 11b! Hand-held micro terminal: The hand-held micro terminal is connected to one of the ABC-Bus-connections on the control circuit card,The centre outlet up to the left (Fig. 13) or one of the 6 right-hand modular connections at the lower edge of the control circuit card (Fig. 11). www.swegon.se 11 GB.COOLER.INST.060501 Mounting: Dismantle the safety guard over the electri- In-operation Indications cal cubicle of the Cooler. Loosen the oblong cable gasket on the front of the electrical cubicle, just so much that the quick connector of the communication cable can be inserted through the opening. See Fig. 12. A common cable can be used for both the signals. The existing cable glands can be used if the diameter of the cable does not exceed 6.5 mm. If a thicker cable is used, wire it through any of the lead-throughs to the side of the cable gland. There is no external operation input in the GOLD unit. Ferrite block 019 210 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 P N L - + - + - + - + - + - + - + 25 27 29 31 33 35 37 39 41 43 45 47 49 51 26 28 30 32 34 36 38 40 42 44 46 48 50 52 Fig. 12 Fig. 13 Start signal free normally-open contacts for cooling, on/off Connect to terminal blocks 45 and 46. 0-10 V control signal for regulating the cooling capacity The control signal must not exceed 10 V +10 %. Connect to terminal blocks 47 (−) and 48 (+). 5 FERRITE BLOCK 019 210 Important! Both signal inputs must be connected. Type A and B Group alarms Priority A group alarms are indicated on a closure of the potentialfree relay contacts between terminals 9 and 10. Priority A group alarms are indicated on a closure of the potentialfree relay contacts between terminals 11 and 12. In-operation indication Indication that the pumps are in operation can be obtained by an alternating potential free relay contact. Terminal block 15(NC), 16(Com) and 17(NO). A common cable may be used for all signals. The existing cable gasket may be used if the cable diameter does not exceed 6.5 mm. If a thicker cable is used, it will have to be run through one of the cable glands to the side of the cable gasket. Installation in the GOLD, Version C. Run the cable(es) into the electrical cubicle via the cable gland, or via lead-throughs on the backside of the top panel hood. Start signal Connect to terminal numbers 7 and 8. 0-10 V control signal Connect to terminal numbers 42 (-) and 43 (+). Group alarm A and possibly group alarm B Connect alarms from the Cooler to the External Alarm 1 or the External Alarm 2 terminals. The alarm in the Cooler is factorypreset with priority A, which means that only group alarm A normally needs to be connected. Connect the conductors from terminals 9 and 10 in the Cooler controller to terminal numbers 50 and 51, or 52 and 53, in the GOLD control unit. Instructions for the Cooler with 0-10 V Controller General The Cooler is supplied with two optional accessories for controlling the cooling load. Extra interference protection is required for the Cooler variants for which the cooling load is controlled by an external 0 –10 V DC signal. To comply with the provisions of the EMC Directive that deals with insensitivity to interference, analogue inputs must be protected by a Ferrite block, 019 10. Communication cable 019 007 is the accessory that must be used if the Cooler operates together with the GOLD ventilation unit, Version B. See individual instructions on this topic. Design Ferrite block, 019 10 is designed to snap on around cables. The block consists of two ferrite halves that rest in a plastic casing that can be opened. The plastic casing has ”hinges” and a simple lock that simplifies opening and closing it around relevant conductors. Dimensions: H= 15 mm, W= 15 mm, L= 9 mm and diameter of openings = 6.6 mm Installation After installing the relevant cables for operating and controlling the Cooler, fit the ferrite block. Fit the ferrite block around the conductors connected to terminals 47 – 48 (0-10 V control signal) and the conductors on terminals 43 – 44 (steady 10V output signal), if used. Position the ferrite block as near as possible to terminals 47 – 48. Ferritblock 019 210 P N L - + - + 43 45 47 44 46 48 Fig.26 12 www.swegon.se Specifications are subject to alteration without notice. GB.COOLER.INST.060501 6 Communication Cable 019 007 6 Instructions for the Cooler Connection of the cooling coil and the cooling agent cooler to cooling unit General 6.1 The Cooler is supplied with two optional accessories for controlling the cooling load. Communication cable 019 007 is the accessory that must be used if the Cooler operates together with the GOLD ventilation unit, Version B. See individual instructions on this topic. Extra interference protection is required for the Cooler variants for which the cooling load is controlled by an external 0 –10 V DC signal. In these cases, the ”Ferrite block” accessory should be used. See individual instructions. The cooling coil shall be located in the supply air ductwork. Sizes 14 and 18: Install the refrigerating machine in the exhaust air ductwork down-stream of the fan. Sizes 24, 34, 48 and 60: install the cooling agent cooler in the exhaust air ductwork. The cooling unit is designed to stand alone in the fan room. Design Communication cable 019 007 is a 5 m long flat cable, with a type RJ 1 modular connection fitted at both ends. The cable transfers normal communication signals between the control unit and the GOLD unit (Version B), but not 4 V DC. Both types of control have their own 4 V DC supply. If an ordinary bus cable is used, the 4 V DC connections will be interconnected and this will cause malfunctions. Installation Connect communication cable 019 007 to any of the ABC Bus outlets on the control unit. Use one of the holes in the oval rubber-covered cable glands on the backside of the electrical cubicle’s junction hood, for running the cable in to the control unit. Move a part of the cable gland to the side to insert the Modular connection through it. Connect the cable to a bus connection on the control unit. Adjust the cable length inside the electrical cubicle and adjust the cable in the cable gland. Refit the cable gland in its correct position. Lay the communication cable in a safe manner from the plastic hood on the top panel of the GOLD unit. Insert and connect the cable correspondingly in the Gold control unit. Commissioning Set the Dip switches on the control unit in the Cooler for communication with the GOLD. Set Dip switches SW1, 1– 4 = On (up). The Cooler controller will then operate as a ”slave”. On delivery, Dip switch SW1, 1 = Off and 2 – 4 = On. The Cooler controller is then a “master”. Use the hand-held terminal to set the cooling unit function to the auto operation mode. Do this under SETTINGS. See the Operation and Maintenance Instructions for the GOLD. Dip switch SW1 ABC Bus Fig. 14 ‘ Specifications are subject to alteration without notice. 6.2 Cooling Connections Location Condensate from cooling coil The cooling coil is equipped with a drip tray with drain connection (to collect condensate from the coil). A drain pipe should be arranged from the condensate drain connection to a floor gulley. Size 14 units with the size 08 Gold unit: use the connection on the outlet air side and plug the connection by the inlet air. 6.3 Liquid connections Liquid is conveyed by means of pipework. The coils have female-threaded connections and the Cooler has smooth connections for brazing or compression ring fittings. The liquid circuits should be connected in a counter-flow mode to enable maximal cooling capacity. Shut-off valves should be installed in the pipework leading to and from the cooling coil to avoid having to drain the whole system of fluid if work is necessary (such as having to replace a circulation pump). 6.4 Venting nipples Fit venting nipples at the highest point of the connecting pipework at both the outlet and inlet of the cooling coil and the cooling agent cooler respectively. Locate the nipples where the water is on its way downstream. See illustrations in Section 3.3. 6.5 Insulating the brine circuit Insulate the brine circuit of the cooling coil in compliance with local standards. 6.6 Connection to cooling unit Connect the cooling coil and the cooling agent cooler to cooling unit as illustrated in Section 3.3. 6.7 Safety drain Safety valves for relieving the water circuits are fitted to the expansion vessels. The safety valves open if the pressure in the system is too high, i.e. they open if the pressure reaches 1.5 bar. The drain pipe from the safety valve should be extended to a receptacle; not directly to a floor gulley since the liquid circuit contains glycol. One (sizes 14-18) or two hoses (sizes 4-60),13 mm i.d., is/ are run from the safety valves and out through the casing to be fitted with an extension to a collecting tank, see Fig. 7 and 8. www.swegon.se 13 GB.COOLER.INST.060501 6.8 Filling with water/glycol mixture Caution! The ethylene glycol used is toxic and must never be consumed! Accessories used • Mixing vessel. • Filling pump for pipes and coils. 5.8.1 Filling For particulars of the volume to be filled, see information for the relevant size in the charts in Section 11. • Blend water/glycol (with 30% admixture of glycol) into an appropriate mixing vessel and stir. • Connect the filling hose to the tap in the unit. Important! The system must be vented, see Section 6.8.2. It is essential to evacuate all the air out of the system. It is advisable to run the pumps with connection to an open vessel and to alternately vent the unit and hoses, and fill up. See fig. 15.2. 6.8.2 Venting the system Vent the system as follows: • Set the safety switch of the cooling unit in the ON position. • Start the pumps. Important! If you are starting the unit for the first time, first follow the directions in Section 6, Commissioning. Strainer Strainer Pump Pump Return from coil Fig. 15.1 • • • • 14 Open the tap. Use an appropriate filling pump with hose. Fill up the water/glycol mixture until the plastic vessel is filled halfway (cold side). On the hot side the expansion vessel can be filled until the safety valve opens. See Fig. 15.1. Shut-off the tap. www.swegon.se Return from coil Fig. 15.2 • • • • Press button 3 TEST in the main menu for 5 seconds. Press the arrow button to advance down to Brine pump press button 4 PROG, press button + so that the value will be 1, do the same for the cooling agent pump. Open venting plugs by cooling coil and cooling agent cooler. Cooling coil only on sizes 14 - 18. Open the venting nipples on the water connections Specifications are subject to alteration without notice. GB.COOLER.INST.060501 • • • • • The venting holes shouldn’t be completely open, but only slightly to allow the air to be forced out. To remove all the air from the cooling unit, start the pumps to transport any air remaining in the circuit to the venting nipple. Always check that there is positive pressure in the system (check the manometer), otherwise the air cannot be forced out. If the pressure isn’t positive, fill up with more of the water/glycol mixture. The system should maintain a positive pressure of about 0.5 bar while you are venting it. If there is still air in the system, repeat the venting procedure as many times as necessary until there is no air left in the system. When the system reaches the correct pressure, close the tap and take away the filling pump. 7 Commissioning 7.1 Preparations 7.1.1 Before starting up for the first time • The water circuits shall be filled and vented. • The power supply must be connected. • The external control signal or communication cable of the GOLD unit must be connected. • Check the Dip-switch settings on the control card. For communication via bus with the GOLD unit, all switches (1 - 4) should be in the ON position. For control via external 0 - 10 V DC signals, switch 1 should be OFF and switches 2 - 4 should be ON. • The hand-held micro terminal must be connected. • Check that all fuses and motor protection circuit breakers are switched in. The control system of the unit has a preprogrammed factory setting, which makes the unit ready to use when basic settings have been entered. 7.1.2 Starting up • Set the Cooler safety isolating switch to the ON position. • Take the hand-held terminal and enter the TEST mode by pressing the TEST pressure button and holding it pressed in for about 5 seconds. • Start the pump/pumps to run for a few minutes to check that the liquid control systems are free from air. Start the pumps by pressing the PROG button to advance to the control position. Use the ”arrow right” and ”arrow left” buttons to move the marker and press the ”+” button to highlight ”1” (operation) or the ”--” button to highlight ”0” (stop). • • • • • • • • Repeat the same procedure to start the compressors in the next menu image. (The pumps must be in operation). Size 48 and 60 Coolers: the direction of rotation of the compressors is important. Start one compressor at a time and advance 2 menus, to the temperature reading image. Check that BRINE TEMP drops and that COOLING AGENT TEMP rises after just a few minutes of operation. If this does not occur, the direction of rotation may be wrong. If this is the case, change the sequence of the power supply phase wires, see Section 7.1.3. Repeat this check to make sure that the direction of rotation is correct. Set the compressors and pumps to 0 (stop). Press the RET button to return to the main menu. From there, press the SET button to advance to the settings mode. Press button 2 for Auto operation and confirm by pressing the SET button. The Cooler is now ready for operation and will operate whenever the connected control signal calls for cooling. Remove any impurities that may have collected in the strainer(s)! 7.1.3 Correcting the phase sequence Caution! To be carried out by an authorized electrician or trained service personnel only. • • Stop the Cooler by selecting SWITCHED OFF under the settings mode. Then switch off the safety isolating switch on the Cooler. Important! Isolate the power supply to the unit. • • • • Transpose the two phase power supply conductors to obtain the correct direction of rotation. Switch on the power supply to the unit. Turn the safety isolating switch to the ON position. Start the Cooler as described under Starting up, see Section 7.1.2. Commissioning Report www.swegon.com Specifications are subject to alteration without notice. www.swegon.se 15 GB.COOLER.INST.060501 8 8.1 Programming and ManaGIng the Menus The hand-held micro terminal The GOLD Cooler has a hand-held micro terminal with menus viewing settings, readings and possible alarms. The hand-held terminal consists of a sealed control box with a bus cable connection. The bus cable supplied is 3 m long and its one end is designed for connection to the control circuit card in the electrical cubicle of the Cooler. If a communication cable is used for connecting the Cooler to a GOLD unit, the hand-held terminal of the Cooler can also be connected to a free bus connection on the control circuit card or hand terminal of the GOLD. The hand-held terminal has a four line display screen and 4 push-buttons The right-hand button contains an alarm LED. 8.1.2 Display and Buttons All settings can be read in clear text in the display. All information is presented in various menus. The main menu normally appears in the display, if no other menu has been selected. If no return to the main menu is manually keyed, the display will automatically return to the main menu after about 30 minutes. The functions of the four buttons change depending on which menu is shown. The function of the buttons is explained by the caption or symbol shown in the display right above each button. For explanation, see Section 8.2. 16 www.swegon.se 8.2 Menu button captions and symbols The most common button functions are described below. In some of the separate menus, the buttons have other functions. These different functions are explained in the relevant menu section. ↓ Advance 1 step to the next menu in the group. ↑ Go back 1 step to the previous menu in the group. RET Return to preceding menu level (main or start menu). PROG Changes to the submenu of the menu shown (alter settings level). + Increases the value of the highlighted figures. − Decreases the value of the highlighted figures. → Advance to highlight new figures/line. After the last figure/line, the image changes back to the readings level in the menu. ← Go back to highlight previous figures/line. After the last figure/line, the image changes back to the readings level in the menu. 1-4 Used to select a function if numbered options appear in the image displayed. SET Confirms your choice and changes the image back to the readings level in the menu. 8.3 Menu groups and levels The menus of the hand-held micro terminal are broken down into various menu groups. The four menu groups can be selected in the main menu by pressing the buttons identified by their captions: INFO, SET, TEST and ALARM. Menus and functions are explained under each group as specified in Section 9. Specifications are subject to alteration without notice. GB.COOLER.INST.060501 9 Menus 9.1 Main Menu OPER LEVEL indicates the present cooling load, as in the main menu. BRINE PUMP shows the pump status. 1 = On and 0 = Off. COOLING AGENT PUMP shows the status of the pump. 1 = On and 0 = Off. (Size 14 and 18 Coolers: this line is empty). COMPRESSOR.1 COMPRESSOR.2 : :: 1 1 RET : ▼ *COOLER* TUES 12:49 . . : 100% AUTO OPER INFO : INST : : TEST : LARM COMPRESSOR.1 shows the status of compressor 1. 1 = On and 0 = Off. COMPRESSOR.2 shows status of the compressor 2. 1 = On and 0 = Off. ▼ Fig. 16 The COOLER image indicates type of unit, the present day of the week and the time. The second and third lines indicate the in-operation status of the cooling unit. SWITCHED OFF is shown when the control circuit card has not received an operation command. STOP is shown when operation command has been given, but the cooling load signal is 0. A percentage figure that may vary between 0–100% together with the text AUTO OPER indicates the cooling capacity at which the unit is operating. The text DELAYED START and the percentage figure are alternately displayed when any of the cooling compressors are unable to start, because the restart delay time has not run out. 9.2 Information Menus *COOLER* TUES 12:49 . . : 100% AUTO OPER INFO : INST : : TEST : LARM ▼ BRINE temp COOLING AGENT temp PROGRAM VERSION : : : RET -7,9˚c 34,6˚C : 1.14 : ▼ BRINE TEMP shows the present temperature of the brine medium. COOLING AGENT TEMP shows the present temperature of the heat carrying medium. (Size 14 and 18 Coolers: CONDENSER TEMP is displayed). PROGRAM VERSION shows the current program version of the control equipment. *oper time Day and night* cOMPRESSOR 1 2999 cOMPRESSOR 2 1998 : :: RET : OPER TIME DAY AND NIGHT shows current operation time for each compressor. The time is measured in minutes but specified in day and night, due to limited space in the display. Main menu. OPER LEVEL BRINE PUMP COOLING AGENT PUMP : :: RET 100% 1 1 : ▼ Specifications are subject to alteration without notice. www.swegon.se 17 GB.COOLER.INST.060501 9.3 Settings Menus * COOLER * TUES 12:49 STOP AUTO OPER INFO : INST : : TEST : LARM ▼ * ACTTUAL TIME * WED TIME 07:30 DATE 17/03 - 2003 : : :RET * språk/LANGUAGE * ENGLISH : PROG : ▼ The preset operating mode is shown on the second line. Pressing PROG changes the image to the settings menu. 1 = SWITCHED OFF and 2 = AUTO OPER. Select appropriate number and confirm by pressing SET. * REGULATION SPEED* STAGE TIME 600S : :RET : PROG ▼ : :RET Preset value for the STAGE TIME, delayed switching in from compressor stage 1 to stage 2 and vice-versa. Same delay also applies to switching between stage 2 and stage 3. Pressing PROG changes the image to the settings menu. The step time can be set between 0 and 600 s. *** COOLER *** SIZE 24 : :RET : PROG ▼ : PROG ▼ Shows preset LANGUAGE. The second line shows current language selected. Pressing PROG changes the image to the settings menu. Press the arrow up or down to advance to the desired language from the current list and confirm by pressing SET. If the Cooler is connected to the GOLD unit by means of a communication cable, same language appears in both displays. FACTORY SETTING : : PROG ▼ ** OPER MODE ** AUTO OPER : :RET Shows preset ACTUAL TIME. The second line shows the current day of the week and time. The third line shows current date. (dd/mm – year) Pressing PROG changes the image to the settings menu. Main menu. : : : : 0 :RET : PROG Activating the FACTORY SETTING. The factory setting function resets all the parameters back to their original settings. This function should only be used when problems with settings have arisen. Pressing PROG changes the image to the settings menu. Set the value to 1, confirm by pressing SET. The parameters will be reset when the display image returns to the Main Menu. The preset COOLER SIZE is shown on the second line. The preset size must agree with current unit size and should only be changed if the control circuit card is replaced. Pressing PROG changes the image to the settings menu. The sizes 14, 18, 24 , 34, 48 and 60 can be set. 18 www.swegon.se Specifications are subject to alteration without notice. GB.COOLER.INST.060501 9.4 Test menus Whenever any of the menus under TEST is selected, the control system will leave the normal in-operation status and go over to manual test run status. Warning! The various ouputs are now controlled by the operator in fully manual mode. The safety functions are switched off and the operator assumes all responsibility. The only provision is that the pumps must be in operation before any compressor can be started. *COOLER* TUES 12:49 SHUT OFF INFO : INST : : TEST : LARM ▼ : : :RET : 00% 1 1 : PROG ▼ OPER LEVEL indicates the current percentage, the same as in the main menu. BRINE PUMP and COOLING AGENT PUMP shows the status for each pump in the manual mode. Pressing PROG alters the image to the settings menu. (Cooler 14 and 18: Line 3 is empty. Specifications are subject to alteration without notice. 1 1 : :RET : PROG ▼ COMPRESSOR 1 and COMPRESSOR 2 show the status of each compressor in the manual mode. Pressing PROG alters the image to the settings menu. Important! The pumps must be in operation before the compressors can be started. GROUP ALARM A OPER INDICATION OPER INDICATION : Main menu The TEST button must be held in for 5 s. before the image will change. OPER LEVEL BRINE PUMP COOLING AGENT PUMP COMPRESSOR.1 COMPRESSOR.2 : 1 :RET B 0 1 10V : PROG ▼ GROUP ALARM A, B and OPER INDICATION show the status of each relay output in the manual mode. Pressing PROG alters the image to the settings menu. BRINE temp -2,6˚c COOLING AGENT temp 34,6˚C : :: RET : BRINE TEMP and COOLING AGENT TEMP show present temperatures. (For the size 14 and 18 Coolers: BRINE TEMP and CONDENSER TEMP is shown). www.swegon.se 19 GB.COOLER.INST.060501 9.5 Alarm menus * COOLER * TUES 12:49 SWITCHED OFF INFO : INST : : TEST : LARM ▼ 10 Alarms 10.1 General The alarm number and cause is displayed in clear text on the screen. A red lamp incorporated into button number four also flashes on the hand-held micro terminal. Typical alarm text in the display. Main menu L1 l2 * ALARM HISTORY * NR 55 17/02 12:15 nr 54 14/02 12:11 : :: RET : ▼ L3 l4 * ALARM HISTORY * NR 52 12/01 22:47 nr 52 11/02 02:30 : :: RET : * * * ALARM 50 * * * HIGH PRESSURE SWITCH COMPRESSOR. 1 TRIPPED ▼ ALARM HISTORY shows the 4 most recent alarms initiated in the system. L1 shows the most recent one. The alarms are shown with the number of the alarm and the date and time when it was initiated. * PRESET Alarm * NR 50 PRIORITY ALARM IND 1 STOP : : :RET : : PROG : RES Fig. 17 10.2 1 1 : : To reset alarms Manual reset means, unless otherwise indicated, that the RES button on the hand-held terminal is pressed. Automatic reset means that the control unit resets the alarm after the fault has been remedied. PRESET ALARM is the reading and settings menu for the 12 different alarms that have been present in the system. By pressing PROG the image changes to the menu for setting the alarm numbers. From here you can advance to the desired alarm number. By pressing SET the image changes over to the level for setting of the current priority and condition of the alarm. PRIORITY can be selected for 1 or 2. ALARM INDICATION can be selected to 0 (no indication on the hand terminal) or 1. STOP can be selected by marking 0 (when alarm the unit continues) or 1 (when alarm the unit is switched off). 20 www.swegon.se Specifications are subject to alteration without notice. GB.COOLER.INST.060501 10.3 Settings Priority, Indication and Stop All alarms have factory preset options for priority, indication on/off and stop. Some of these settings can be altered. None of the alarms can be completely blocked. Priority option 1 = The alarm has priority A and initiates group alarm A 2 = The alarm has priority B and initiates group alarm B Alarm indication, on/off 0 = The alarm indication on the hand terminal is shut off. 1 = The alarm indication on the hand terminal is active. Alternative for Stop 0 = The cooling unit will not stop when the alarm is initiated. 1 = The cooling unit will stop when the alarm is initiated Delay Delay implies that the alarm will not trip immediately when a fault is registered, but firstly after the fault has lasted a certain period or repeated itself a certain number of times. Action The cause of the alarm is given, and possible sources as well as a few simple spots to check for fault tracing. Other Particulars The alarms are not activated in the programming menus. 10.4 Alarm conditions Alarm 50 HIGH PRESSURE SWITCH COMPRESSOR.1 TRIPPED The alarm is initiated if input 25-26 is interrupted and if BT4 >45°C. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 1 s. The alarm can only be reset locally i.e. via hand terminal, not via communication system or similar remote control, due to regulations in the cooling standards. Alarm 52 CONTACTOR REPLY COMPRESSOR. 1 TRIPPED The alarm is initiated when input 35-36 is interrupted while compressor 1 is operating or when the input is closed while compressor 1 is switched out. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 3 s. The alarm can only be reset locally i.e. via hand terminal not via communication system or similar remote control due to regulations in cooling standards. Alarm 53. LOW PRESSURE SWITCH COMPRESSOR. 1 TRIPPED The alarm is initiated if input 25-26 is interrupted and if BT4 <45°C. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 1 s. The alarm can only be reset locally i.e. via hand terminal not via communication system or similar remote control due to regulations in cooling standards and that low pressure - high pressure switches are connected in series. Alarm 54 LOW PRESSURE SWITCH COMPRESSOR. 2 TRIPPED The alarm is initiated if input 29-30 is interrupted and if BT4 <45°C. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 1 s. The alarm can only be reset locally i.e. via hand terminal not via communication system or similar remote control due to regulations in cooling standards and that low pressure - high pressure switches are connected in series. Alarm 51 HIGH PRESSURE SWITCH COMPRESSOR.2 TRIPPED The alarm is initiated if input 29-30 is interrupted and if BT4 >45°C. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 1 s. The alarm can only be reset locally i.e. via hand terminal, not via communication system or similar remote control due to regulations in the cooling standards. Specifications are subject to alteration without notice. www.swegon.se 21 GB.COOLER.INST.060501 Alarm 55 CONTACTOR REPLY COMPRESSOR. 2 TRIPPED The alarm is initiated when input 37-38 is interrupted while compressor 2 is operating or when the input is closed while compressor 2 is switched out. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 3 s. The alarm can only be reset locally i.e. via hand terminal not via communication system or similar remote control due to regulations in cooling standards. Alarm 56 EXCESS TEMP COMPRESSOR. 1 TRIPPED The alarm is initiated if input 27-28 is interrupted while Compressor.1 is operating. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 5 s. Alarm 57 EXCESS TEMP COMPRESSOR. 2 TRIPPED The alarm is initiated if input 31-32 is interrupted while Compressor.2 is operating. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 5 s. Alarm 58 PUMP FUSE F1 TRIPPED The alarm is initiated when input 50 does not receive a signal stronger than 5 V DC. When the alarm has been initiated, neither the pumps nor the compressors can start. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 3 s. The alarm can only be reset locally i.e. via hand terminal not via the communication system or similar remote control due to regulations in cooling standards. Alarm 60 COOLING AGENT SENSOR (CONDENSER SENSOR, SIZE 14-18) DEFECT The alarm is initiated if communication is not obtained with the (BT4) cooling agent sensor. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 5 s. The alarm resets itself automatically. Alarm 61 BRINE SENSOR DEFECT The alarm is initiated if communication is not obtained with the (BT3) brine sensor. The alarm has factory settings: Priority A, Indication 1, Stop 1. Time delay: 5 s. The alarm resets itself automatically. 10.5 Alarm Priorities Setting of Priority, Indication and Stop: All alarms have factory preset options for priority, indication and stop. Some of these settings can be changed. None of the alarms can be entirely blocked. Possible Settings: Priority: For all alarms priority 1 (A) or 2 (B) can be selected. Indication: For all alarms, option on the hand terminal: 0 (alarm LED doesn’t light at all) or 1 (LED flashes in the event of an alarm). Stop: No alarm can be selected for continued operation. The cooling compressors will stop if any alarms are initiated. If alarm 59 is initiated, the pumps will continue to operate. Alarm 59 BRINE TEMP EXCEEDS ALARM LIMIT The alarm is initiated if (BT3) the brine temperature >15°C for more than one hour while one or more compressors are operating. The pumps continue operating after alarm has been initiated. The alarm has factory settings: Priority 1, Indication 1, Stop 1. Time delay: 1 hour. The alarm resets itself automatically. 22 www.swegon.se Specifications are subject to alteration without notice. GB.COOLER.INST.060501 11 Maintenance Clean the inside of the unit whenever necessary. Carry out a visual inspection at least twice a year. 11.1 • • • • Cleaning Stop the Cooler by shutting down the air handling unit or by setting the cooling unit to ”0” in the cooling menu image in the air handling unit terminal (i.e. alternate the ON/OFF signal). Then shut off the safety isolating switch of the GOLD Cooler. Open the inspection door. Vacuum clean the space and wipe with a damp cloth. 11.2 To change the water/glycol mixture The need for filling or changing the liquid arises only if leakage is detected, or if you fear that the water doesn’t contain enough glycol. To fill the circuit, follow the directions in Section 5.8. The correct mixture is 30% ethylene glycol, 70% water. Do not forget to vent the system! 11.3 Handling refrigerant Type R 407C and R134A refrigerant is used in the Cooler. The refrigerant circuit has been charged at the factory. Caution! 11.4 Charging with refrigerant Type R 407C and R134A refrigerant is used If a low pressure alarm is initiated, this have been caused by too low a volume of refrigerant. Caution! Always wear protective goggles and protective gloves when working with refrigerant. Contact with skin and eyes may cause frostbite. Caution! If the refrigerant is exposed to fire or is intensely heated in some other way, toxic gases will form. Important! Charging with refrigerant must be carried out according to the refrigerant manufacturer’s recommendations. Whenever possible, employ working methods that prevent refrigerant contact directly with skin. Arrange adequate ventilation/local extraction. Wear tight-fitting protective goggles, protective gloves and an overall. Under no circumstances shall unauthorized personnel be permitted to open the refrigerant circuit. The circuit contains gas under high pressure. The refrigerant circuit may only be modified or repaired by qualified personnel from an accredited refrigeration company. If refrigerant comes in contact with eyes Use an eye douche to flush the eyes (alternatively with lukewarm water) for 20 minutes. Seek a doctor. Important! If refrigerant causes frostbite Seek a doctor. If you detect any refrigerant leakage, get in touch with your nearest Swegon Service representative. Specifications are subject to alteration without notice. If refrigerant comes in contact with skin Carefully wash with soap and lukewarm water. www.swegon.se 23 GB.COOLER.INST.060501 11.5 Annual inspection Annual inspection by an accredited inspectorate is required if refrigerant volume in a one-piece unit exceeds 3 kg per circuit. This is thus not required the for size 14 and 18 units, but on the other hand it is for the size 24, 34, 48 and 60 units. Obligation to file reports Obligation to report to a local supervisory authority is only required if the total volume of refrigerant in the company exceeds 10 kg. 11.6 Service Only service personnel trained by Swegon shall be permitted to do any work on the cooling unit. If any repair work is needed, get in touch with your nearest Swegon service representative, see the backside of these user instructions. 12 Cooling Coil and Cooling Agent Cooler Cooling coil and cooling agent cooler are sized to match the size 08-60 Gold and the size 004-014 Basic units. The coils consist of copper tubes and profiled aluminium fins. The casing is made of hot galvanized sheet steel. The headers are made of steel. 12.1 Instructions for the BASIC unit Installation The coil must be vented before the system is commissioned, thus a venting valve should be fitted to the venting nipple. The BCKO Cooling agent cooler should be connected for cross-flow mode as indicated by the arrows on the connection branches. If a shunt unit is fitted, make sure that it is installed so as not to block inspection of the other functional sections. Care Check whether cleaning is required at least twice a year. The unit should be cleaned in the following way only: Blow with compressed air towards the ordinary direction of airflow and then vacuum clean the side facing the ordinary direction of airflow using a soft nozzle. Wet cleaning can be carried out by flushing with water. If a solvent is used, it must be of a quality that doesn’t corrode aluminium or copper. Cover adjacent functional sections to protect them before you begin cleaning. After you’ve finished cleaning, blow the surfaces with compressed air to remove all traces of detergent. Swegon detergent, sold by Swegon Service is recommended. While cleaning, check for trapped air in circuits, the glycol content and density, if necessary. BCKO Dimensions L P 12.1.1 BCKO, 006-014 Cooling agent cooler The BCKO cooling agent cooler is finned tube coil. Water is used as the heat carrier, usually mixed with glycol. The BCKO is made of copper tubes with aluminium fins. The headers and connections are made of steel. Specification The design, size, etc. of the cooler are specified in the delivery documents. BCKO 24 BASIC COOLER 004 14 006 18 006 24 25 20.1 009 24 32 23 009 34 32 23 014 34 32 30 014 48 32 37 www.swegon.se R dia. VOLUME/L K Fig. 18 BCKO 004-014 B H L 004 1039 546 453 006 1259 656 453 009 1459 756 453 014 1759 906 453 Specifications are subject to alteration without notice. GB.COOLER.INST.060501 12.1.2 BCKA 004-014 COOLING COIL Specification Design, size etc. is specified in the documents supplied. BCKA BASIC COOLER RØ VOLUME/L 004 14 25 5 006 18 32 8,5 006 24 40 11 009 24 40 12 009 34 50 22 014 34 65 32 014 48 65 39 Installation The coil must be purged of air before it is commissioned, because a venting valve must be fitted on the venting nipple. The BCKA is designed for horizontal airflow, the cooling section should be mounted with the circuit pipes horizontal to access for venting and draining. Brine connection (Water) The BCKA should be installed in accordance with the airflow direction arrows on the inspection side. The piping should be connected for counter-flow circulation as indicated by the arrows on the connection pipes. Parallel circulation is wrong and will lead to a substantial reduction in capacity. Keep in mind that the connection pipes must not be in the way and hamper inspection in other unit sections. Height A (the distance between the runoff level in the unit section and the run-off level in the water trap) must be at least just as large in mm as the negative pressure in the unit is in mm gauge. Height B (the distance between the runoff level in the water trap and the uppermost point in the bend of the Upipe) must be at least just as large in mm as half the negative pressure is in mm gauge. A set of connection parts that fit the condensate connection are also included when a water trap is ordered from Swegon. BCKA dimensions S P X K Fig. 19 BCKA B H X L 004 1039 546 215 453 006 1259 656 215 453 009 1459 756 215 453 014 1759 906 215 453 Pipe connections Make sure that the deadweight and/or expansion forces of the piping system will not be applied to the connections. Use appropriate sealant for sealing the thread of the coil connections. Installing the water trap The water trap must be filled with water before the unit is started up. The drain pipe should discharge in such a way that the adjacent unit sections and the building structure won’t sustain damage. The drain pipe must be insulated against the cold if it is run through a cold space. A heating cable may be required. If the coil is fitted on the suction side of the fan, it is especially important to fit a water trap. Specifications are subject to alteration without notice. www.swegon.se 25 GB.COOLER.INST.060501 12.2 Instructions for size 08-60 GOLD units Coils with rectangular connections The coil can be fitted to the ductwork or directly to the unit. The coil should be jointed by means of slip clamps for so-called PG connection and a sealing strip designed for this purpose. 11.2.1Installation of TBKA, TBKC cooling coils A. The coils shall be connected to the ducting as follows: Coils with round connection spigots: The coil is designed for direct connection to spiro ducts. The coil should be secured to the duct by means of pop rivets. G 30 Ø 500 630 H 500 30 A E C B Fig. 21 500 105 688 105 50 Fig. 20 If a duct bend or some other unit section is situated upstream of the cooling coil, the distance to the coil should be adequately long for avoiding a non-uniform air distribution across the coil. The design of the duct bend fitted upstream of the coil must also be aerodynamically correct. Cooling coil For Cooler size Type A 14 TBKA-2-100-040-3 400 18 TBKA-2-100-040-4 400 24 TBKA-2-100-040-5 24 B C E G H RØ Wgt. in kg, excl. liquid Filling volume, L 1295 1000 148 113 625 25 89 9 1295 1000 148 113 625 32 95 12 400 1295 1000 148 113 625 32 101 14 TBKA-2-120-050-3 500 1595 1200 198 133 765 32 130 18 24 TBKA-2-140-060-3 600 1885 1400 243 170 940 32 172 25 34 TBKA-2-120-050-4 500 1595 1200 198 168 835 40 156 28 34 TBKA-2-140-060-4 600 1885 1400 243 170 940 32 184 31 48 TBKA-2-120-050-5 500 1595 1200 198 168 835 32 165 32 48 TBKA-2-140-060-5 600 1885 1400 243 170 940 40 197 37 60 TBKA-2-140-060-6 600 1885 1400 243 170 940 40 220 48 E G H RØ Wgt. in kg, excl. liquid Filling volume, L Cooling agent cooler For Cooler size Type A 24 TBCO-1-100-040-1 400 1191 1000 82 70 540 25 98 20 24 TBCO-1-120-050-1 500 1330 1200 30 20 540 25 58 20 24 TBCO-1-140-060-1 600 1530 1400 30 20 640 25 65 22 34 TBCO-1-120-050-2 500 1575 1200 188 158 815 32 153 32 34 TBCO-1-140-060-2 600 1875 1400 238 175 950 32 186 38 48 TBCO-1-120-050-3 500 1575 1200 188 158 815 32 162 36 48 TBCO-1-140-060-3 600 1875 1400 238 158 915 32 195 43 60 TBCO-1-140-060-4 600 1875 1400 238 158 915 32 208 47 26 www.swegon.se B C Specifications are subject to alteration without notice. GB.COOLER.INST.060501 Fig. 22 Cooling coil For Cooler size Type 48 TBKA-2-160-080-3-0-1 60 TBKA-2-160-080-4-0-1 B H L Wgt. in kg, excl. liquid Filling volume, L 2311 1141 510 215 39 2311 1141 510 230 46 Cooling agent cooler For Cooler size Type 48 TBCO-1-160-080-1-x 60 TBCO-1-160-080-2-x B L RØ Wgt. in kg, excl. liquid Filling volume, L 2311 1141 510 32 225 46 2311 1141 510 32 250 53 Specifications are subject to alteration without notice. H www.swegon.se 27 GB.COOLER.INST.060501 B. The coil should be located as follows: The coil is desiged for horizontal airflow. Double drain connections enable an optional direction of airflow. The tubes of the liquid circuit shall be horizontal to enable venting and drainage. The coils with round connection spigots are fitted with double drain connections which enable optional directin of airflow. C. For the TBKA – coil for cold water – the capacity of the coil is conditional on the direction of airflow through the coil and the connection mode. For best capacity, the coil shall be connected for counter-flow water circulation. See Fig. 21a-b. The lower connection shall be used for filling with water. Vent the coil before commissioning. G. The temperature sensor for the supply air should be fitted as far downstream of the coil as practically posible (at least 1.5 meter) to avoid incorrect readings, caused by layering in the air downstream of the coil. However, the bulb of the temperature sensor should be located opposite the connections. See Fig. 22a and 22b. Round connection Temperature sensor Zone within which the temperature sensor should be vertically positioned Fig.24a Fig. 23a Rectangular connection Temperature sensor Fig. 23b D. The coil section shall be installed where it is accessible for replacement and inspection. On coils with round duct connection spigots, the inspection side can be dismantled. E. The cooling coil shall be insulated in accordance with local regulations for ventilation ducts and connected pipework in accordance with local trade standards. F. On coils with round duct connection spigots, the drain pipe shall be connected to the connection branch on the outgoing air side of the coil. The connection on the ingoing air side shall be plugged. 28 www.swegon.se Zone within which the temperature sensor should be vertically positioned Fig. 24b H. To prevent frost damage on the TBKA water coil, antifreeze must be added to the water. If for some reason anti-freeze cannot be used, other measures to protect the coil from freezing must be taken. Specifications are subject to alteration without notice. GB.COOLER.INST.060501 13 Connection to Ducting The cooling coils for size 14 Coolers have - if they are to be connected to a GOLD 08 unit - circular duct connections fitted with a rubber gasket. The coils designed for connection to GOLD 14-60 units have rectangular duct connections with rigidly mounted slip clamps. The cooling coils for size 18 Coolers have - if they are to be connected to a GOLD 14-60 - rectangular duct connections with rigidly mounted slip clamps. The cooling coils and cooling agent coolers for size 24-60 Coolers have - if they are to be connected to a GOLD rectangular duct connections with rigidly mounted slip clamps. If the cooling coils are to be connected to the Basic air handling unit, they are incorporated with other components as standard cooling coils for the Basic. 13.1 for COOLER 14 and 18. All items are supplied in kit form. Included in the supply COOLER size For end connection wall facing the air handling unit For end connection wall facing the exhaust air duct For end connection wall facing the exhaust air duct 14 GOLD 08 Inlet end connection wall with 400 mm dia. connection Connection frame with slip-clamp joint, 800x400 mm1 — 14, 18 GOLD 14-60 Connection frame with slip-clamp joint, 1000x400 mm Connection frame with slip-clamp joint, 1000x400 mm — 14 BCEA/BASIC 004 Supplied without end connection wall Sealing plate for BCEA/BASIC2 Supplied without end connection wall Connection frame with slip-clamp joint, 850x350 mm (TBXZ-108503523) For air handling unit Accessory 18 BCEA/BASIC 006 Supplied without end Supplied without end connection wall connection wall 1) This end connection wall does not have a circular connection; this minimises the pressure drop. If connection is made to a circular exhaust air duct, use a conical adapter as a transition piece. Connection frame with slip-clamp joint, 1100x500 mm (TBXZ-111005022) 2) A sealing plate is required for connection to the BCEA/BASIC 004 because the COOLER has smaller dimensions. 14Electrical Data 14.1 Cooling unit The Cooler unit has pre-wired internal electrical connections and is test run prior to delivery. All electrical equipment is housed in the electrical cubicle behind the inspection panel. Incorporated components: • Safety isolating switch. • Control circuit fuse. • Contactors and motor protection/fuses for compressors and pumps. • Terminal blocks for internal/external connections. • Circuit card for necessary functions and communication with hand-held micro terminal. Specifications are subject to alteration without notice. www.swegon.se 29 GB.COOLER.INST.060501 15General Technical Data COOLER size 14 18 24 14 7,6 18 24 9,6 11,8 34 48 60 Capacity Cooling capacity, kW1 Power demand, kW2 34 48 60 16 20 22 Brine Type of evaporator Plate heat exchanger Plate heat exchanger Plate heat exchanger Plate heat exchanger Plate heat exchanger Plate heat exchanger Number 2 2 2 2 2 2 Brine flow (l/s) 0,7 1,0 1,1 1,4 1,35 1,63 Max. available external pressure, kPa 50 70 40 50 60 70 Compressor Type of compressor Piston Piston Piston Piston Scroll Scroll Number 2 2 2 2 22 Capacity control, stages 3 3 3 3 3 3 Condenser/ Cooling agent cooler Type Direct Direct expansion expansion Number Cooling agent flow (l/s) Max. available external pressure, kPa Plate heat exchanger Plate heat exchanger Plate heat exchanger Plate heat exchanger – – –2 2 2 2 – 0,62 0,83 0,95 1,17 – – 10 12 3025 Cooling agent Type R134a/ R134a/ R134a/ R134a/ R134a/ R407c R407c R407c R407c R407c Number of circuits2 2 2 2 2 Volume, R134a, Kg 2,3 2,9 2,3 4,5 5,4 Volume, R407c, Kg 2,1 3,0 4,0 4,9 8,0 R134a/ R407c 2 8,2 8,0 Electrical connections Power supply, Volt 400 400 Frequency, Hz 50 50 Fuse, A (delayed/delta-characteristic)20 25 400 50 32/35 400 50 35 400 50 63 400 50 63 Suitable for airhandling unit GOLD 08, 14/20 14/20 BCEA/BASIC 004 006 1) The cooling capacities tabulated above are applicable to the following data: Supply air upstream of the cooling coil 28 °C, 50% RH. Exhaust air upstream of the COOLER (14 and 18) or cooling agent cooler (24-60) 32 °C. These data presuppose cooling energy recovery by means of a rotary heat exchanger which then provides an outdoor temperature of 32 °C, 40% RH and an extract air temperature of 26 °C. 2) Applicable to operation under conditions described in footnote 1) above. 30 www.swegon.se 14/20, 25/30, 25/30, 35/4025/30, 35/40, 35/40 50/60 006, 009 009, 014 014 35/40, 50/60 – Sizing Many factors influence which size of cooling unit and which coils are required. The new cooling unit is designed for meeting a variety of conditions. For sizing, it is recommendable to utilize the unit selection program called PMWIN. Specifications are subject to alteration without notice. GB.COOLER.INST.060501 16 Mechanical Design 16.1.1 Dimensions and weights See Fig. 23 - 25 and the table below. 16.1 Design The refrigerating machine is incorporated into a casing consisting of a framework of torsion resistant profiled sections made of form rolled 1 mm thick aluminiumzinc plated sheet steel, Env. Class C4. The wall, top and bottom panels are made of aluminium-zinc plated sheet steel, Env. Class C4. They are constructed according to the sandwich principle: 0.7 mm thick sheet steel + 50 mm thick insulation + 0.7 mm thick sheet steel. The size 14 and 18 Coolers are to be connected to the exhaust air connection of the air handling unit by means of slip clamps. The larger units stand alone and alongside the air handling unit. Wgt., kg R1 Ø R2 Ø 546 1666 - 28 18 1595 656 945 - 24 975 1075 1759 35 34 975 1075 1759 35 35 48 975 1200 1759 35 35 625 592 60 975 1200 1759 35 42 675 638 Size B 14 985 H Cooler 14 B L At site Excl. packaging incl. water and water 306 300 28 325 318 35 445 415 555 523 Electrical connections L H R2 End facing the air handling unit End facing the exhaust air duct Hose from safety valve Fig. 25 Cooler 18 B L H End facing the air handling unit R2 R2 Electrical connections End facing the exhaust air duct Hose from safety valve Fig. 26 Cooling Agent Cooler Cooling Coil Electrical connections Cooler 24, 34, 48, 60. B L R1 R1 R2 R2 H Fig. 27 Specifications are subject to alteration without notice. Hose from safety valve www.swegon.se 31 GB.COOLER.INST.060501 17Other Particulars Serial number Every cooling unit has a specific serial number which together with its type designation forms a unique identification number for each unit. The serial number is stamped on the identification plate affixed on the inspection cover of the unit. Standards The electrical equipment meets the provisions of Electrical Safety Standard ELSÄK-FS 1999:5 and is CE-labelled in accordance with PED and the Low Voltage Directive 73/23/ EEC with Harmonization Standard EN 60204-1. Interference level The Cooler is designed for installation in electical environments where the Low Voltage Directive specifies interference levels in accordance with the standards for electromagnetic radiation in dwellings, offices, shops and similar environment as well as in industrial environments. 18Environmental Documentation 18.1 Scrapping The design of the unit makes it easy to dismantle and sort according to the various types of material used in its manufacture. When the unit has outlived its useful service life, an accredited re-cycling firm should be engaged. 95% of the GOLD Cooler is re-cyclable. Swegon AB is affiliated with REPA, Reg. no. 5560778465. Get in touch with Swegon AB, phone: +46 (0)512-32200 if you have any questions on dismantling and scrapping the GOLD Cooler or the unit’s environmental impact. 32 www.swegon.se Specifications are subject to alteration without notice. ANNEX IIA (Storbritannien, Irland) GB.COOLER.INST.060501 Compliance Declaration We at: DECLARATION OF CONFORMITY We, Swegon AB Box 300 S-535 23 KVÄNUM assure on our own responsibility that the air handling unit of the following type: BC (fitted with control system) CACA CoolDX GA (fitted with control system) GOLD GOLD Cooler LBTA LLVC LLVD LMTA LPMA-1 LTCE LTCW (fitted with control system) TA (fitted with control system) VVVA VVRV covered by this declaration, comforms to the following Standards: EN 292-1, 2; EN 294; EN 60204-1; EN 61000-6-2; and EN 61000-6-3 according to the provisions in Directives: 98/37/EG , 89/336/EEC and 73/23/EEC. This assurance is applicable only if the air handling unit has been installed according to the instructions and if the air handling unit has not been altered in any way. Kvänum, February 20, 2006 Thord Gustafsson, Quality and Environmental Policy Manager Specifications are subject to alteration without notice. www.swegon.se 33 GB.COOLER.INST.060501 www.swegon.com Swegon AB, Box 300, SE-535 23 Kvänum +46 512 32200 www.swegon.com