251010cbmitb848 Exco00-193
251010cbmitb848 Exco00-193
251010cbmitb848 Exco00-193
HVAC SYSTEM
IOM MANUAL
REVISION HISTORY
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INDEX
1 INTRODUCTION.............................................................................................................................. 4
2 REFERENCE DOCUMENT ............................................................................................................. 4
3 TECHNICAL MAINTENANCE MANUAL AIR COOLED CONDENSING UNITGB001 A/B/C ....... 6
3.1 General information ................................................................................................................. 6
3.2 Installation................................................................................................................................ 6
3.3 Preliminary checks .................................................................................................................. 8
3.4 PERFORMANCE................................................................................................................... 10
3.5 CALIBRATION....................................................................................................................... 11
3.6 MAINTENANCE SCHEDULE................................................................................................ 14
3.7 RESEARCH AND FAILURES ANALISYS............................................................................. 17
4 TECHNICAL MAINTENANCE MANUAL AIR HANDLING UNIT GA001 A/B/C .......................... 19
4.1 GENERAL DESCRIPTION.................................................................................................... 19
4.2 INSTALLATION ..................................................................................................................... 19
4.3 PRELIMINARY CHECKS ...................................................................................................... 22
4.4 STARTING............................................................................................................................. 24
4.5 SETTINGS............................................................................................................................. 26
4.6 MAINTENANCE CARD ......................................................................................................... 32
4.7 DEFAULTS RESERARCH AND ANALYSIS ......................................................................... 35
5 CABLE CELLAR EXHAUST FANS 002510006600GA004A / B ................................................. 38
6 BATTERY ROOM EXHAUST FANS 002510006600GA002A / B ................................................ 50
7 TRANSFORMER ROOM ROOF FANS 002510006600GA003A /B ........................................... 134
8 DUCT ELECTRIC HEATERS 002510006600GT001 / 2 / 3........................................................ 147
9 BLAST DAMPERS 002510006600GJ050 / 51 / 52 / 53 ............................................................. 149
10 FIRE DAMPERS ATEX ........................................................................................................... 150
11 FIRE DAMPERS SAFE AREA................................................................................................ 178
12 GASTIGHT DAMPERS ........................................................................................................... 188
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1 INTRODUCTION
This document contains the installation, use and maintenance manuals of the equipments and
instruments installed in the hvac system.
2 REFERENCE DOCUMENT
251010DBQBTB378 ITP for HVAC System
251010CBQBTB849 HVAC System - Quality Control Plan
251010CGEDTB851 HVAC System - Manufacturer data book - Index
251010DACHTB071 HVAC System - Cooling and Heating Load Calculation Report
251010CEDATB837 002510109200EL104 - HVAC POWER & CONTROL PANEL General arrangement
251010CECATB838 002510109200EL104 - HVAC POWER & CONTROL PANEL Calculations (heat dissipation, AUX consumption)
251010DAFMTB074 HVAC System - Duct and Instrumentation Diagram (D&ID)
251010CEDATB866 HVAC System - AHU - General arrangement
251010CEDATB868 HVAC System - ACCU - General arrangement
251010DAFBTB417 HVAC System - Block Diagram
251010DARBTB070 HVAC System - Design basis hold
251010DAGATB087 Technical Data Sheet for HVAC Main Equipment
251010DAGATB099 Technical Data Sheet for Fire Dampers
251010DAGATB105 Technical Data Sheet for Extractor Fans
251010DAGATB111 Technical Data Sheet for HVAC Diffusers and Grilles
251010DAGATB117 Technical Data Sheet for Loose Items
251010DADPTB077 HVAC System - E&I Equipment Layout
251010DADLTB078 HVAC System - Cable Tray Layout & Sections
251010DAEHTB083 HVAC System - Loop Diagrams
251010DADPTB075 HVAC System - Equipment Layout and Details
251010DADLTB076 HVAC System - Ducting Topographic Layout and Details
251010DADQTB084 HVAC System - E&I Equipment Typical installation
251010DADPTB123 HVAC System - HVAC piping layout, section, isometrics, line classes
251010DAEETB079 HVAC System - I/O list
251010DAEBTB090 MTO for HVAC Main Equipment
251010CEDRTB869 HVAC System - ACCU - Electrical & Instrumental Schematic
251010CEDQTB882 HVAC System - Ductwork Typical Installation Detail
251010CEDPTB883 HVAC System - Piping and support Layout and Details
251010DAEPTB080 HVAC System - Cable List
251010CEEHTB839 002510109200EL104 - HVAC POWER & CONTROL PANEL Wiring diagram
251010DACATB072 HVAC System - Ductwork Calculation Report
251010CEFCTB842 002510109200EL104 - HVAC POWER & CONTROL PANEL Logic diagram
251010CIEETB844 002510109200EL104 - HVAC POWER & CONTROL PANEL I-O list
251010DWPGTB404 HVAC Pre-commissioning / commissioning procedure
251010CEEZTB840 002510109200EL104 - HVAC POWER & CONTROL PANEL Spare parts (commissioning and 2 years of operations)
251010CEGATB841 002510109200EL104 - HVAC POWER & CONTROL PANEL Vendor Technical Data Sheet
251010CBQRTB845 HVAC System - FAT Procedure
251010CBQRTB846 HVAC System - SAT Procedure
251010CWPTTB847 HVAC System - Start-Up Procedure
251010CEDRTB884 HVAC System - Instruments - Constructive and electrical Details
251010CECATB885 HVAC System - Electrical Calculation Report
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Shipment
After the units arrival at site, check carefully each components and make sure that there
aren’t transport damages.
3.2 Installation
Arrangement
Generally, the Units can be located on the floor without block clamps if it is sufficiently robust to
support the weight.
It recommends applying the rubber strips under the base of the unit as a precautionary measure
against the transmission of vibration, by adjusting the height to keep the bubble units.
To allow the access to compressors area, control panel, motor fans and refrigerating components, it is
necessary to have a work space at least of one meter (laterally) and two meters (frontally).
If the floor is not equipped with a drainage pit for the condenser water, it is necessary to make
provision for a conduction pipe to the nearest water drainage pit.
The connection to the condensing drainage is positioned at the bottom of the Unit. We recommend on
the horizontal pipe type to make provision of a stage of a least 5 mm for meter to avoid the backwater
of impurity.
The diameters of the connection are indicated on the drawing of the Unit.
To install the duct fix it with self-threaded screws to the collar and to the holes already pre-drilled, in
case it is not directly fixed the Unit.
To avoid air leakage in ambient we recommended to seal the junction with mastic.
Noise
It is indispensable to make sure that do not exist any acoustic reverberations possibility.
It is necessary to avoid the installation in narrows, in the angle between two walls, in skylight passage
or little rooms which can promote the acoustic reverberations
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The moto-evaporating units are already pre-loaded with the necessary refrigerant R134a, however,
during the first start it is necessary to verify that the refrigerant circuit is charged (indicator clear sight
glass), otherwise it is necessary to make top-up to be performed by skilled personnel.
Warning: the shut-off valve on the liquid line mounted on the liquid receiver is closed as the suction
gas shut-off valve mounted on the compressor. Only after the vacuum and leak test of the cooling
lines that connect the unit condensing the evaporating unit, the valves can be opened
Electric connection
The electrical connections must be made in accordance with the diagram inside the control panel and
the terminal box of the unit.
The units in their standard configuration are equipped with control elements of the installed items. The
protection of the fans switches, control switches, signal lights are placed inside and on the door of
main control panel.
IMPORTANT NOTE: The power source variation mustn’t exceed 5% of nominal value.
Equipotential Bonding
It must be done trough the external terminals, with adequate section cables, with scrupulous respect
of the regulations in force. The grounding of the machine, which is required by law, it is essential to
respect the safety regulations against accidents of electrical origin
The lack, or the incorrect grounding, exempt the manufacturer from any liability for accidents of
electrical origin.
It draws attention to the responsibility of the installer to make active safety systems installed according
to UE guidelines, respecting in particular the rule outlined in 4.7.3
Wiring and all electrical components used in the installation must conform to the IEC and CEI in force.
Warning:
Energize the crankcase heaters at least 24 hours before the first start.
Do not remove the voltage to the heaters during shutdown periods of the machine.
Note: the failure of the crankcase heater allows to the refrigerant an oil entrainment in the circuit
causing the intervention of the safety devices and causing certain times the break for lack of
lubrication. Do not remove the voltage to the heaters during shutdown periods of the machine.
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Fig. 1
OIL LEVEL
To obtain a vacuum in the refrigerant circuit is necessary to have a high vacuum pump, with a flow
rate of at least 30 l / min. the vacuum pump is connected by means of flexible hoses with ¼ SAE
female swivel equipped with vacuum to the sockets on the compressor valves.
Apply an analogical or electronic manomether for the vacuum reading. You will perform also in the
presence of moisture in some circuit. On this occasion you will have to identify and eliminate the
cause that allowed the ingress of moisture.
When the evacuation is completed, close the low-pressure lever of the manifold valve and stop the
operation of the vacuum pump.
Be sure to carry out the evacuation for at least 30 minutes duration which varies according to the
length of the cooling lines, and check that the pressure gauge on the low pressure side indichi- 76cm
Hg (-1.0x105Pa)
Warning:
Never wash with trichlorethylene or similar products: these liquids would make subsequent
dehydration very difficult.
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Connect the gas bottle to the load placed on the liquid line, venting a bit 'of gas to purge the air in
the first connecting pipe tighten the attack.
Turn the bottle and introduce the liquid refrigerant in the condenser. In this way it can be loaded
about 75% of the total charge.
After the introducing 75% of the refrigerant charge, connect the bottle to the suction valve taking
care to vent the air from the charge hose.
Start the group, open the gas cylinder holding it upright and introduce the refrigerant in the circuit
observing the sight glass located on the liquid line freon.
The attainment of the required charge is indicated by the total absence of gas bubbles in the liquid
indicator. The verification must be carried out with the plant in operation at full load after at least 30 'at
a constant speed operation.
Care It must be take care, do not introduce to much refrigerant. The charge is exact when the
temperature of the liquid line is of 4/7 ° C (under cooling) lower than the condensing temperature.
For under-cooling we mean the difference between the condensing temperature indicated by the
manometer inserted in the flow and the temperature of the upstream of the thermostatic valve liquid
measured with a contact
The detection of the liquid temperature is performed through a contact thermometer, while the
condensation temperature is detected by the pressure gauge.
In a similar way, since the compressor suction gas superheat temperature indicates the correct
operation of the thermostat. Superheat, measured with a contact thermometer, must be of 4/7 ° C
higher than the evaporation temperature on the gauge.
After one hour of operation the indicator lamp will not indicate the liquid flow passage of the gas
and the humidity indicator bubbles should have a GREEN colour (anhydrous facility).
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3.4 PERFORMANCE
The start-up is directly controlled by the selectors on the control panel. The set point is fix to the
electronic regulator on the door of the control panel which start the compressor with two (2) minutes
delay.
The unit will operate until it has reached the predetermined temperature on the display, at this point
will stop the compressor. A series of indicator lights indicate the status of various machine
components.
Operations check
4. Make sure that the humidity indicator inserted in the flow indicator has green colour
Seal Test
ATTENTION:
Never use oxigen instead of azote, because ther is a severe danger of explosion.
The bottle of azote shall be provided of pressure reducer.
It is also very important not to exceed the max pressure of 10 bar.
If during the test there are leakages in the welded junctions, let out the pressure before doing
maintenance operations.
Do not effect weldings on circuit containing refrigerant gas to prevent the forming of toxic gas
extremly dangerous (deadly!).
The junctions on pipes shall be repaired with Argent Castolin 1802 alloy with low point of
fusion or equivalent.
After reparing, do again the seal test unitil obtain positive results.
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3.5 CALIBRATION
Safety setting
The safeties are setted in workshop so is not necessary any other check. However the check to the
safeties intervention is possible, but shall be done only by specialized personnel.
Their intervention opens the circuit. The reset is manually made with the reset button positioned on the
proper unit used for the oil and high pressure switch and thermic protection.
The low pressure switch have an automatic reset.
It’s very important that during the safety intervention the reset and restart of the Units carryed out only
after that have been checked and solved the cause of the abnormal functioning.
Each valve is adjusted to an average superheat of 4: 5 ° C. If the valve is set to a too low superheat,
you will have an excessive amount of liquid to the evaporator; the suction pipe will be too cold and you
will have a return of liquid to the compressor with possible internal damage to the compressor.
A setting for an excessive overheating will cause, on the contrary, an insufficient flow of refrigerant to
the evaporator; the suction pipe will be too hot and the thermal output of the group will lower.
WARNING: an excessive heating can cause in the long-term an engine burn.
Overheating check-out
1. Measure the temperature of the suction pipe next to the bulb of the expansion valve.
2. Detect the suction pressure of the suction pressure gauge of the circuit to be checked
3. Convert the pressure obtained in step 2) in temperature, using a conversion table pressures
depending on temperatures of the refrigerant used from the machine.
4. Calculate the difference between the two temperatures in points 1) and 3); this difference is
the superheat value. Normally this value must be maintained at around 4: 5 ° C.
Note: This check must be performed with chilled water temperature regime and with the unit operating
at 100%.
Overheating setting
Note: this adjustment must be performed with chilled water temperature to scheme (monitor the load
losses) and the unit operating at 100%.
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Maintenance Schedule
Safety systems
The essential safety requirements, stipulated in the EEC Directives and to which this machine is in
compliance, should be checked at least every 90 days. The check shall confirm the correct operation
of the safety devices and their reliability as follows:
1. detecting, from the documentation supplied with the machine, devices and adopted
constructive measures;
2. using all the necessary precautions, with regular working machine, causing the intervention of
the safety devices, one by one, checking the immediate power cut to all parts of the machine
and its stop (for example, open inspections as an at time); repeat the operation twice, not
consecutive, for the whole series of safety devices installed;
3. If there is an interior lighting, check that, during the previous trial, the opening of inspection
panels light up the points interior light.
4. check the correct positioning of the static safety systems, or passive, and their stable fixing to
fixed parts; in particular, the protections of the moving parts that need only be rigidly attached
and removed with specific tools.
Coils
During filters cleaning or replacements, check the status and integrity of the finned packs. It may be
that, the impurities have clogged the finned packs for failure or delay in maintenance to filters
or damage to them.
In this case, do not use tools that could damage the fins, but use a jet of compressed air blown in the
opposite direction to the flow of operation. If there are deformations to the fins, restore with
special combs.
When for serious failures, leaks or other, the battery must be removed, proceed as follows:
1. close the valves, the inlet and outlet, and drain the battery by opening vent and drain;
2. remove the collectors from the supply circuit;
3. remove the cover panel of the same collectors and, inside, side plates;
4. ensure that the outdoor space available is sufficient for the entire length of the battery, as
prescribed in paragraph 4.2. Free space;
5. lift the side manifolds and drag the battery outward, sliding it on the guides, possibly lubricated
with grease;
6. if the machine needs to continue the service without the faulty battery, replace the cover panel
collectors plugging the outlet holes.
For the assembly of the repaired battery, proceed in reverse with the above operations, taking
care to seal the exit of the collectors from the panel.
If the unit should remain stationary for long periods, it should necessary use a few simple precautions:
1. remove the power supply from the general framework, signaling downtime;
2. turn off the water supply;
3. empty the basins and clean them as in 6.4.1 .;
4. close the shut-off valves and drain the batteries;
5. close all dampers;
6. if the machine is equipped with absolute filters, dismantle them and close them in sealed
containers;
7. periodically, approximately every 30 days, to run motors, fans and pumps for a few seconds in
order to avoid damage to the bearings
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Calibration checks
Condensing unit See wiring diagram manual stop for the excess drive of the
thermic relay fan motor absorption
Low pressure switch 0,5 bar automatic (at 2,5 ferma il compressore al
bar) diminuire del-la pressione di
aspirazione
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Check absorptions *
of electric motors
Check voltage *
power supply and
auxiliary
Check calibration of *
controllers (not
included in the unit)
Check contactors *
status of motors and
fans
Locking of all *
electrical
connections
Cleaning of the *
condensation wash
basin
NOTE: Above operations could be subjected at variation at the above intervals depending on the
installation location and climatic conditions.
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Check *
absorptions of
electric motors
Check voltage *
power supply and
auxiliary
Check calibration *
of controllers (not
included in the
unit)
Check contactors *
status of motors
and fans
Locking of all *
electrical
connections
Cleaning of the *
condensation
wash basin
Figuring paint *
where needed
NOTE: Above operations could be subjected at variation at the above intervals depending on the
installation location and climatic conditions
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Machine Register
DATE CONTROL OR FAILURE RESULT INTERVENTION SIGN
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The electric heating coil does not operate with a switch in running
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Considerations
The air handling units must be installed and operated according to the instructions contained in this
manual. The strict observance of these instructions is a prerequisite for:
eliminate or reduce downtime for unexpected failures;
Improving the performance of the components, resulting in energy savings;
Increase the life of components and the whole unit;
Decrease maintenance costs.
This machine is built in compliance with the safety standard of the Machinery Directive 2006/42
/ EC, Directive 2006/95 / EC Low Voltage Directive, and Directive 2004/108 / EC Electromagnetic
Compatibility and therefore complies with the 'essential requirements of safety and of
"prescribed by the same Directives health protection.
At this scope, the machine is equipped with a series of prevention and safety devices described in
detail in documentation. The installer is required to connect and activate all these components
installed and verify its functions
The system, or the machine, in which this unit will have to be incorporated, must also be in
compliance to the above guidelines.
The end user, or who subsequently manage the system, will have to periodically check the
functionality and efficiency of safety devices.
The non-activation, or the removal or inhibition of active safety systems, as well as the removal of the
passive safety systems, constitute the manufacturing company. any liability regarding any accidents or
damage, direct or indirect, to people and / or things, attributable to his machine.
Warning!!!
For the of spare parts request please indicate always the type, serial number and the machine
code reported over the name plate.
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Shipment
4.2 INSTALLATION
PLACEMENT:
Normally, the units can be placed on the floor without lock brackets, if it is strong enough to support
its weight.
It recommends applying the rubber strips under the base of the unit as a precautionary measure
against the transmission of vibration, by adjusting the height to keep the bubble units
To allow the access to the compressor compartment, to the control panel, the electric fans and to the
various components of the cooling circuits, it is necessary keep a minimum space of work one (1)
meter laterally and two (2) meters from the front.
If the floor area is not able to receive and discharge the condensation water, it is necessary to provide
a conveyor line to the nearest well.
The attack for the condensate drain is located externally to the units and in the embodiment is
recommended in the horizontal sections of the pipe to provide a slope of the pipe at least 5 mm per
meter in order to avoid the stagnation of impurities. The condensate drain diameters are indicated on
the unit's design.
To install the duct with self-tapping screws to the collar and the holes already drilled in the case is not
directly attached to the unit. To avoid leakage into the environment it is recommended to seal the
joints with putty.
NOISE
FILTERS EXTRACTION
The air treatment sections are furnished with bag filters F7 and washable filters efficiency G4.
The filters extraction is through the front opening of the dedicated compartment. The filters must be
frequently checked to assure the functional condition.
They can to be cleaned blowing or suctioning air in reverse to normal flow or washing them with a
detergent solution in hot water at 40-50°C.
It is necessary in this case to provide a complete drying of the filter (48 hours at 40°C) to assure the
complete drying, in particular of the layer of needful that could make blobs with the dust kept during
the filtration phase.
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CONDENSATE DISCHARGE
The sections are equipped with a condense drain pan placed under the cooling coil.
The discharge connection of the pan is constituted of a threaded female nipple 1”.
The drains must be equipped with a siphon that, in the more common situation of the basin in
depression, must have a swing dimensioned according to the maximum negative pressure existing in
the section where there is the same basin. To simplify, it is assumed as a reference the total pressure
of the fan and in the figure shows the dimensions of the casement and simple relations with such
pressure.
The evaporating units have been pre-loaded with the refrigerant necessary quantity of R134a for the
operation, however, during the first start you need to verify that the refrigerant circuit is charged (LED
indicator clear passage), otherwise you need to make top-up to be carried out by qualified personnel.
FREON TAPS
The taps installed on the refrigerant circuit for condensing units are intercepted, the tap on the liquid
receiver and the sull'aspirante tap the compressor that will be opened only after realizing the
emptiness of the pipes connecting the evaporating unit to be implemented in construction site.
ELECTRICAL CONNECTION
The electrical connection must be made in accordance with the wiring diagram placed inside the
control panel and terminal dedicated to the unit.
The units, in their standard configuration, contain control elements. In this case, the circuit breakers of
the fans, control switches, signal lights are placed inside and the door command of main electrical
panel.
IMPORTANT: The supply voltage fluctuations can not be greater than 5% of the nominal value.
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GROUNDING
It must be done through the terminals supplied externally with cables of adequate section, respecting
scrupulously the rules in force. The grounding of the machine, required by law, is a fundamental
requirement to comply with safety standards against an electrical accident.
The lack or incorrect connection to the ground, relieve the manufacturer from any
responsibility or liability for accidents of electrical origin. It draws attention to the
responsibility in making active safety systems installed in accordance with EC Directives,
particularly respecting the principle described in 4.7.3 .. The wiring and all electrical
components used in the installation must comply with regulations IEC and CEI in force.
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Verify that in the vicinity of rotating parts (transmissions, rotors, snails, roll filters) and in the
rooms of the various sections there are no foreign bodies or dirt;
Verify that the electrical connections of the auxiliary circuit power has been performed in
accordance with the standards specified in the wiring diagrams
With the main isolators open, tighten all clamps of the electrical connections and check that all
moving parts of the contactors move freely
Check the oil level in the compressors. Before starting the engine, this level should cover at
least 3/4 of the light (see Fig.1).
To obtain a vacuum in the cooling circuit it is necessary to have a high vacuum pump, with a flow rate
of at least 30 l / min. the vacuum pump must be connected by flexible pipes with ¼ SAE female swivel
accompanied by depressor to the sockets on the compressor taps
For the vacuum reading apply an analogical or electronic manomether. You will have to perform well
in the presence of moisture in some circuit. On this occasion you will have to identify and eliminate the
cause that allowed the ingress of moisture.
After the evacuation is completed, close the low pressure level of the manifold valve and stop the
operation of the vacuum pump. Be sure to perform the evacuation for 30 minutes or more (time that
varies according to the length of the refrigerant lines) and check that the pressure gauge on the low
pressure side -76cmHg (-1.0x105Pa).
Warning: Never wash with trichlorethylene or similar products: these liquids would make
subsequent dehydration very difficult.
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Connect the gas cylinder attack charge placed on the liquid line, venting a bit 'of gas to purge
the air in the connecting pipe before tighten the attack.
Spilling the cylinder and in this position to introduce the refrigerant in the condenser in liquid
form. In this way it can be reduced about 75% of the total charge
After introducing about 75% of the refrigerant charge, connect the bottle to place the suction
valve always taking care to vent the air contained in the first charging hose.
Start the group, open the gas cylinder holding it in normal vertical position and introducing
gaseous refrigerant in the circuit by observing the passage of mail indicator on the line of the
liquid freon.
The attainment of the required charge is indicated by the total absence of gas bubbles in the liquid
indicator. The verification must be carried out with the plant in operation at full load after at least 30 'in
steady-state operation.
Be careful not to introduce excess refrigerant.
The charge is correct when the temperature of the liquid line is 4/7 ° C (under cooling) lower than the
condensation temperature. For under cooling means the difference between the condensation
temperature indicated by the manometer inserted in the flow and the temperature of the upstream of
the thermostatic valve liquid measured with a contact thermometer
The detection of the liquid temperature is carried out through a contact thermometer, while the
condensation temperature is detected by the pressure gauge. In a similar manner, from the
compressor suction gas superheat temperature indicates the correct operation of the thermostat. The
overheat measured with a contact thermometer, must be of 4/7 ° C higher than the evaporation
temperature read at the manometer.
After about one hour of operation indicator lamp don’t indicate the liquid flow passage of the gas
and the humidity indicator bubbles should have been made a GREEN (anhydrous facility).
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4.4 STARTING
Warning:
Energize the crankcase heaters at least 24 hours before the first start.
Do not remove the voltage to the heaters during shutdown periods of the machine.
Note: the failure of the crankcase heater allows to the refrigerant an oil entrainment in the circuit
causing the intervention of the safety devices and causing certain times the break for lack of
lubrication. Do not remove the voltage to the heaters during shutdown periods of the machine.
The star-tup unit is controlled directly by the selector switches on the electric control panel. The set
point is set to the electronic regulator mounted on the door of the control panel. These start the
compressor which will start with a delay of two (2) minutes. The unit will operate until it has reached
the predetermined temperature on the display, at this point will stop the compressor. A series of
indicator lights indicate the status of various components of the machine.
In the case of the refrigerant circuit repairs perform the following steps:
Leakage test.
Drying and vacuum in the refrigerant circuit.
Load.
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Pressure test
In the case of losses due to damage during transport it is necessary to do the test of the entire cooler
seal.
To do this it will be enough to load refrigerant in the circuit (keeping the cylinder in a vertical position)
until the pressure reaches the value of about 1 bar.
To find leaks, use a halide plus propane lamp or an electronic leak detector.
Warning:
Under no circumstances use oxygen instead of nitrogen, as they incur in serious danger of explosion.
If during the test were identified leaks in welded joints, relieve pressure before carrying out the repair
work.
Do not weld on containing gas refrigerant circuits to prevent the formation of extremely dangerous
toxic gases (lethal!).
The joints on the pipes must be repaired with silver alloy Castolin 1802 low melting point or equivalent.
After the repair, repeat the leak test until you get positive results.
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4.5 SETTINGS
Safety setting
The safeties are settled in workshop so is not necessary any other check. However the check to the
safeties intervention is possible, but it shall be done only by specialised personnel.
Their intervention opens the circuit. The reset is manually made with the reset button positioned on the
proper machine used for the oil and high pressure switch, antifreeze thermostat and thermal
protection.
The low pressure switch and air flow switch have an automatic reset.
It’s very important that during the safety intervention the reset and restart of the Unit is carried out only
after have been checked and eliminated the cause of the abnormal functioning.
Each valve is settleded by manufacturer for a overheat of 4: 5 ° C: If the valve is set to a too low
overheat, you will have an excessive quantity of liquid to the evaporator; the suction pipe will be too
cold and you will have a liquid return to the compressor with dangerous liquid slugging.
A setting for an excessive overheating will cause the contrary, an insufficient flow of refrigerant to the
evaporator; the suction pipe will be too hot and the yield of the group will subside.
WARNING: excessive heating can cause long-term engine burn.
Overheating check
1. Measure the temperature of the suction pipe next to the bulb of the expansion valve.
2. Determine the suction pressure on the suction pressure gauge of the circuit to be check
3. Convert the pressure obtained in step 2) in temperature, using a conversion table pressures -
depending on temperatures of the refrigerant used from the machine.
4. Calculate the difference between the two temperatures in points 1) and 3); this difference is the
superheat value. Normally this value must be maintained at around 4: 5 ° C.
NOTE:
This check must be performed with chilled water temperature regime and with the unit operating at
100%.
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Overheating setting
Between a feed and theother, wait for the unit's operating conditions to stabilize (about 10
minutes). Turn the screw clockwise to increase the superheat and counterclockwise to
decrease it.
Note:
this adjustment must be performed with chilled water temperature to scheme (monitor the load
losses) and the unit operating at 100%.
THERMOSTATIC VALVE
Maintenance Schedule
Safety systems
The essential safety requirements, stipulated in the EEC Directives and to which this machine is in
compliance, should be checked at least every 90 days. The check shall confirm the correct operation
of the safety devices and their reliability as follows:
1. detecting, from the documentation supplied with the machine, devices and adopted
constructive measures;
2. using all the necessary precautions, with regular working machine, causing the intervention of
the safety devices, one by one, checking the immediate power cut to all parts of the machine
and its stop (for example, open inspections as an at time); repeat the operation twice, not
consecutive, for the whole series of safety devices installed;
3. If there is an interior lighting, check that, during the previous trial, the opening of inspection
panels light up the points interior light;
4. check the correct positioning of the static safety systems, or passive, and their stable fixing to
fixed parts; in particular, the protections of the moving parts that need only be rigidly attached
and removed with specific tools.
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The motors and fans bearings are permanently lubricated and do not require any intervention. On
selected large size fans they are mounted on bearings with supports with greaser; in such cases, the
lubrication, with lithium grease for bearings, must be done once a year by the procedure specified:
1) Carefully wipe the outside of the lubricator, before connecting the pipe of the grease pump, to
avoid introducing dirt inside;
2) Introducing the fat with moderate pressure to avoid, absolutely, that the same bait from seals;
3) After the operation, turn the fan for a few seconds.
Every 30 days to observe the state of belts wear and check the their tension as below instruction:
Apply to the center of the free section a force "F", within the values indicated in the table of Fig. 7, a
function of the assembled belt section.
4) Measure the arrow "C", at the center of the free section, which must be equal to 1.5 mm per
100 mm of length D ( C = 1,5 x D/100);
5) If "C" is lower (too tensioned belt) act on the screw "A" (see Fig. 8), approaching the motor to
the fan, if "C" is greater (too slow belt) always act on the screw "A" by removing the engine
from the fan;
6) When the force "F" and the arrow "C" are within the prescribed values, refit the cover fixed on
the transmission, blocking yourself with the screws provided
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At the motor engine, it is, in any case, adjust a slippage of the belts for 1-2 seconds. The correct
tension of the belts is important in order to avoid premature wear (lens belts) or overloading on motor
bearings and fan (belts too tight). To prevent service interruptions, change the belts at least every 12
months, without waiting for their complete wear.
The operations to be performed for the replacement are similar to those described above for
recording, keeping in mind that:
1) for replacement is necessary to act on the screw "A" up to be able to easily remove the straps from
their seat;
2) the tension of the new belt must be made with a force F1 = F x 1,3;
3) after a short operation (12-24 hours), recheck the voltage and bring it within the values established
by the Fig. 7 table (page before).
Air filters
a) Since the duration of the filters depends on the environmental working conditions, proceed
every 15 days to a their control to ensure the possibility of arriving at normal maintenance
intervals.
b) Every 60 days cleaning or replacement of the cells; if they are regenerable, they should be
cleaned by means of suction or typing, or with a wash in warm water and detergent; if they are
in pockets or absolute no recovery is not possible and must be replaced.
c) When a differential pressure gauge is installed to detect the loss of load, clean or replace the
cells when the loss of such value reaches the maximum level indicated by the manufacturer
(usually 200 Pa - 20 mm for corrugated filters, 300 Pa-- 30 mm - for those pockets, 500 Pa -
50 mm for absolute), regardless of the operating period.
d) In the roll filters, replace the rollers soon as they arrive at the stroke end
Warning, the lack of maintenance of filtering systems has serious disadvantages for the efficiency
with:
- increase of the load losses in the air circuit and reduction of air flow;
- Resulting in reduced yields of the machine and the worsening environment in comfort;
- Possible damage to the refrigeration system with direct expansion coils.
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Coils
During filters cleaning or replacements, check the status and integrity of the finned packs. It may be
that, the impurities have clogged the finned packs for failure or delay in maintenance to filters or
damage to them.
In this case, do not use tools that could damage the fins, but use a jet of compressed air blown in the
opposite direction to the flow of operation. If there are deformations to the fins, restore with special
combs.
When for serious failures, leaks or other, the battery must be removed, proceed as follows:
1) close the valves, the inlet and outlet, and drain the battery by opening vent and drain;
2) remove the collectors from the supply circuit;
3) remove the cover panel of the same collectors and, inside, side plates;
4) ensure that the outdoor space available is sufficient for the entire length of the battery, as
prescribed in paragraph 4.2. Free space;
5) lift the side manifolds and drag the battery outward, sliding it on the guides, possibly lubricated with
grease;
6) if the machine needs to continue the service without the faulty battery, replace the cover panel
collectors plugging the outlet holes.
For the assembly of the repaired battery, proceed in reverse with the above operations, taking care to
seal the exit of the collectors from the panel
Dampers
Every 180 days to control the complete ride with regularity, without harsh or jams points, particularly in
the types booster.
When the control is manual, check the correct operation of the lock in place.
If the unit should remain stationary for long periods, it should necessary use a few simple precautions:
1) remove the power supply from the general framework, signaling downtime;
2) turn off the water supply;
3) empty the basins and clean them as in 6.4.1 .;
4) close the shut-off valves and drain the batteries;
5) close all dampers;
6) if the machine is equipped with absolute filters, dismantle them and close them in sealed
containers;
7) periodically, approximately every 30 days, to run motors, fans and pumps for a few seconds in
order to avoid damage to the bearings.
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Calibrations check
CHECKS CALIBRATION RECONNECTION FUNCTION
Condensing See wiring manual stop for the excess
unit thermic diagram drive of the fan motor
relay absorption
Disconnector See wiring Short circuit protection
diagram
Differential Adjustable automatic alarm status when the
pressure switch clogging of the filter
dirty filter section causes
excessive depression
Low ariflow fixed automatic status of each fan
differential alarm when it detects
pressure switch the absence of
depressure (flow rate)
Safety Adjusted in fabric manual It disengages the
thermostat resultant electrical
heating resistors and
stops the unit, in case
of air-temperature is too
high (fire)
High pressure 23 bar manual Stop the compressor at
switch the pressure supply
increase
Low pressure 0,5 bar automatic (at 2,5 Stop the compressor at
switch bar) decrease of suction
pressure
Compressore See wiring manual Stop the compressor at
motor thermic diagram an excessive power
relay absorption
Internal automatic Stop the compressor
protection running when the
winding motor refrigerant isn’t enough
compressor
Oil pressure 1 bar manual stop the compressorer
gauge in case of lubricant lack
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Check absorptions of *
electric motors,
compressors and fans
Check operation *
compressor heater
crankcase
Condensers cleaning *
NOTE:
Above operations could be subjected at variation at the above intervals depending on the installation
location and climatic conditions.
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Check absorptions *
of electric motors
Check voltage *
power supply and
auxiliary
Check calibration of *
controllers (not
included in the unit)
Check contactors *
status of motors
and fans
Locking of all *
electrical
connections
Cleaning of the *
condensation wash
basin
Figuring paint *
where needed
NOTE:
Above operations could be subjected at variation at the above intervals depending on the installation
location and climatic conditions
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Machine Register
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The electric heating coil does not operate with a switch in running
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Considerations
The air handling units must be installed and operated according to the instructions contained in this
manual. The strict observance of these instructions is a prerequisite for:
eliminate or reduce downtime for unexpected failures;
Improving the performance of the components, resulting in energy savings;
Increase the life of components and the whole unit;
Decrease maintenance costs.
This machine is built in compliance with the safety standard of the Machinery Directive 2006/42
/ EC, Directive 2006/95 / EC Low Voltage Directive, and Directive 2004/108 / EC Electromagnetic
Compatibility and therefore complies with the 'essential requirements of safety and of
"prescribed by the same Directives health protection.
At this scope, the machine is equipped with a series of prevention and safety devices described in
detail in documentation. The installer is required to connect and activate all these components
installed and verify its functions
The system, or the machine, in which this unit will have to be incorporated, must also be in
compliance to the above guidelines.
The end user, or who subsequently manage the system, will have to periodically check the
functionality and efficiency of safety devices.
The non-activation, or the removal or inhibition of active safety systems, as well as the removal of the
passive safety systems, constitute the manufacturing company. any liability regarding any accidents or
damage, direct or indirect, to people and / or things, attributable to his machine.
Warning!!!
For the of spare parts request please indicate always the type, serial number and the machine
code reported over the name plate.
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