Transcript
CHILLED WATER DOWNFLOW AIR CONDITIONING UNITS
BDC
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Before using the unit, read this manual carefully and keep it in a safe place for future reference
IMPORTANT SAFETY NOTICE This unit is built to perform the functions for which it was designed without risk as long as the installation, operation and maintenance of the unit are all carried out according to the instructions in this manual and on the labels on the unit. This unit contains live electrical components, and rotating devices such as the fans. Before accessing the inside of the unit, disconnect it from the electrical power supply. All service and maintenance operations must be performed when the unit is off and must be done by qualified and experienced personnel who are aware of the necessary precautions.
© UNIFLAIR 2002
© Copyright by UNIFLAIR
vers. 2.3 - 18.02.02
UNIFLAIR ITALIA S.p.A. Via dell’Industria, 10 35020 BRUGINE (Padova) Italy Tel. +39 (0)49 9713211 Fax. +39 (0)49 5806906 Internet: www.UNIFLAIR.com E-Mail:
[email protected]
Release:
2.3
Date:
18 - 02 - 2002
Checked by:
Technical Director
2
vers. 2.3 - 18.02.02
INDEX QUICK GUIDE
Start-up of the unit Non-starting of the unit Insufficient cooling Stopping the unit Periodic maintenance GENERAL CHARACTERISTICS IDENTIFICATION PLATE DIMENSION AND WEIGHTS TRANSPORT AND PREPARATION
Receipt of the unit Site transport and storage Positioning Base frame Operational space Air distribution Nominal air volume (standard speed) Nominal air volume (reduced speed) Nominal air volume (low speed)
Control panel High efficiency filter housing Connection to return air ducts
page page page page page page page page page
4 4 4 4 4 5 5 5 6
page page page page page page page page page page page page
7 7 7 7 7 7 8 8 8 9 9 9
ACCESS TO THE UNIT:
Opening and removal of panels Front panel Side panel Rear panel
page 12 page 12 page 12 page 12
WATER CONNECTIONS
Chilled water connections Condensate drain connections Connections of the humidifier CONNECTION TO FRESH AIR INTAKE ELECTRICAL CONNECTIONS
Power connection Mounting and connection of control panel Access to the electrical panel Instruments and alarms Remote control Electrical data Recommended sizes of power supply cables and line fuses
page 13 page 14 page 14 page 14 page 15 page 15 page 15 page 15 page 16 page 17 page 17
START-UP AND COMMISSIONING
Start-up procedure Control and calibration of sensors Calibration of the air flow sensor Calibration of the clogged filter sensor Setting the sensors Electrical current drawn Fan belt tension PULLEYS 3-WAY VALVE AND SERVOMOTOR PREVENTIVE MAINTENANCE FAULT-FINDING GUIDE
vers. 2.3 - 18.02.02
page 18 page 18 page 18 page 18 page 19 page 19 page 19 page 19 page 20 page 20 page 21
3
QUICK GUIDE ATTENTION: the description of the Control System and the operating logic of the unit is contained in the Control System Instruction Manual.
START-UP OF THE UNIT •
Connect power to the electrical panel of the unit: close the main isolator, close the circuit FAN/AUXILIARY of the auxiliary circuit, switch on the power supply and check that the yellow LED lights up as follows: - yellow LED “LINE” on mP3 Control Panel; - yellow LED on mP20 Control Panel.
•
Open the shut-off valves on the chilled water circuit;
•
Check that the chilled water is circulating;
•
•
Start-up the unit by pressing button
on mP3
control panel (or button on mP20 control panel): after a moment the fans will start and the «SYSTEM ON» green LED on the control panel will come on. If an alarm condition arises, displayed on the control panel by the «ALARM» red LED and accompanied by an audible warning, consult the control panel instruction manual.
THE UNIT DOES NOT START If the unit doesnt’start, check that: 1) power is on to the electrical panel and to the auxiliary circuit transformer; 2) the automatic breaker FAN/AUXILIARY on the electrical panel is set; 3) the fuse of the 24V auxiliary circuit is not blown; in the case of units with mP20 control panel, check
the fuse on the interface board (see specific instruction book); 4) the connectors of the control panel are correctly inserted; 5) The yellow LED has turned alternatively for: - yellow LED “LINE” on the control panel mP30; - the yellow LED on the control board mP20.
INSUFFICIENT COOLING (see also para. FAULT FINDING GUIDE) If the ambient temperature is too high after 30 minutes from the starting-up of the unit, verify that chilled water is flowing at the design temperature and check that: 1) the air filters are not clogged and the air flow is not obstructed (see para. AIR DISTRIBUTION); 2) the automatic switches of the electric board are all armed; 3) the control panel does not have an alarm signal (see control panel instruction manual);
4) the room temperature set point is correct (see control panel instruction manual); 5) the fans are rotating in the correct direction; 6) the three-way valve is operating properly (see para. 3-WAY VALVE AND SERVOMOTOR); 7) the heat load is not above the design value.
N.B.: in the case of a unit malfunction, call a qualified service engineer.
STOPPING THE UNIT •
Stop the unit by pressing push button
on mP3
control panel (or button on mP20 control panel): after a moment all the components of the unit will stop and the «SYSTEM ON» green LED on the control panel will go off. •
4
N.B.: Manual starting and stopping operations are deactivated in room units equipped with mP20 control panel if the microprocessor has been programmed either for remote control or for time controlled start/stop (see mP20 Instruction Manual).
For long shutdown periods it is advisable to disconnect the power supply and to open the isolator on the electrical panel.
vers. 2.3 - 18.02.02
PERIODIC MAINTENANCE (see also para. PREVENTIVE MAINTENANCE) •
Check that the room conditions displayed on the control panel are normal;
•
Check periodically that the air filters are not clogged; change the filters when the specific alarm comes on;
•
Check that the noise of the unit is normal;
•
Check the free flow of condensate to the main drain;
•
Check the tension of the fan belts.
GENERAL CHARACTERISTICS The following general characteristics are relevant to standard units and may change in case of special or modified versions. Model Belt driven fans Number of motors Number of poles
3010
3310
3510
3 1 4
3 1 4
3 1 4
standard speed Nominal power. (each.)
-kW
5.5
5.5
5.5
Nominal power. (each.)
-kW
4.0
4.0
4.0
2.2 3 750x750 150 300
2.2 3 750x750 150 300
2.2 3 750x750 150 300
27 9 3
27 9 3
27 9 3
9.4 6.9
9.4 6.9
9.4 6.9
2” 1.1/4” 1.1/2”
2” 1.1/4” 1.1/2”
2” 1.1/4” 1.1/2”
reduced speed low speed Air filter
Electric Heaters Humidifier
Nominal power. (each.) -kW Number Dimensions -mm Thickness of E U4 Filter (standard) Thickness of EU5 filter (optional) Total Capacity -kW Number of elements Number of stages Nom. steam product. Nom. absorbed power
-kg/h -kW
Chilled water valve Hot water valve (on request) Dehumidification valve (on request)
IDENTIFICATION PLATE MODEL
SERIAL No.
POWER SUPPLY VOLTAGE ELECTRICAL CURRENT
OA
FLA
LRA
KW TOTALI
The unit identification plate is placed in the electrical panel compartment and gives the following information: - Unit model and serial number; - Power supply (voltage, number of phases); - Current and power absorption; - Set point of instruments;
SETTING OF SAFETY DEVICES REFRIGERANT
vers. 2.3 - 18.02.02
5
DIMENSIONS AND WEIGHTS
FIG. 1
A A1 B C C1 D G H
3010 2370 2330 1970 850 845 700 2270 790
3310 2370 2330 1970 850 845 700 2270 790
3510 2370 2330 1970 850 845 700 2270 790
kg
650
665
680
Weight of unit (no packing) Maximum tolerance on height, see figure 1. - point B, is of ± 5mm. The other dimensions have no tolerance indications, average precision grade according to EN 22768-1 standards.
B
D
C1 C 1
60
FIG. 4
A1 A
N
FIG. 2
H 30
M O G
FIG. 3
A1
C1
3010 2440 2135 920
3310 2440 2135 920
3510 2440 2135 920
kg
700
715
730
Weight of unit with packing
X2
6
M N O
vers. 2.3 - 18.02.02
TRANSPORT AND PREPARATION RECEIPT OF THE UNIT On receiving the unit, check that it is complete and in perfect condition; immediately notify the carrier in writing of any damage that might be have been caused in transit.
SITE TRANSPORT AND STORAGE The unit should not be turned on its back or upsidedown, or exposed to atmospheric agents, and should be carried as near as possible to the place where it is going to be installed before removing the cardboard packing and the pallet. The unit can be lifted: - with a fork-lift, placing the forks in the appropriate slots of the pallet;
- by the application of belts passed under the unit, making sure that the belts do not create pressure on the upper rim of the unit. The unit must be stored, preferably in its packing, under cover and protected from excessive humidity (< 90% R.H.) and temperature (< 50°C).
POSITIONING The unit is light in weight and can be placed directly on the raised floor where a hole has been previously made as indicated in fig. 2 to allow the discharge of conditioned air and the installation of water and electrical connections; make sure that the floor can hold the weight of the unit (see ‘DIMENSIONS AND WEIGHTS I’). Apply a flexible gasket to the perimeter of the base to avoid air leakage and transmission of vibrations.
The unit must be perfectly levelled with a maximum difference of 5 mm between the base extremities: an imperfect levelling could cause the overflow of condensed water from the condensate tray. ATTENTION: the unit must be installed indoors and in a non-aggressive atmosphere.
BASE FRAME To allow positioning of the unit before installing the raised floor and to dampen any vibrations, it is advisable to use a base frame, available as optional extra, whose dimensions are shown in fig. 3.
Place a flexible gasket, at least 5 mm thick, between the panels of the raised floor and the frame, which should also be insulated from the metal floor substructure.
The height of the standard base frames, shown as X2, is adjustable between 200 and 600 mm (±25 mm); higher types are available upon request.
OPERATIONAL SPACE To allow easy maintenance of the unit it is necessary to leave some free space at the front (see dimension D in the drawing 1); lateral access is not required.
fan assembly); in this case, if there is no room at the sides, the operation can be carried out by partially turning or moving the unit forward.
N.B.: lateral access would only be necessary in the unlikely event of replacement of the cooling coil or the
AIR DISTRIBUTION The conditioned air is delivered into the raised floor cavity and distributed through it into the room. Since the cooling capacity of the unit depends on the air flow, it is necessary to take care of: a) space between the top of the unit and the ceiling; a gap of less than 600 mm may affect the air flow rate; b) the connection hole between the room unit and the raised floor; a hole has to be made in the raised floor, as shown in fig. 2 ; the outlet section of the fans must not be obstructed, even partially, by portions of panels, stringers, pipes or other items;
c) free air flow within the raised floor cavity; the cavity under the raised floor must be sufficiently high (at least 200-250 mm not including the thickness of panels and the stringers of raised floor) and free from obstructions, especially near the unit; d) the grilles and holes for air distribution into the room; the air flows out of the floor through holes (for cooling of machines) or through grilles (for conditioning the ambient).
vers. 2.3 - 18.02.02
7
The air velocity at outlets should be between 1 and 2.5 m/s. The total free area (the sum of the sectional areas of the holes and of the grilles) necessary for each model should be calculated dividing the total air flow rate (in 3 m /s: see the enclosed table) by the specified outlet velocity (in m/s).
The position and the total area of the holes and grilles should be adjusted according to the lay-out of the heat load and of the machines to be cooled.
ATTENTION: an insufficient free flow sectional area will reduce the delivered air volume and the performance of the unit.
NOMINAL AIR VOLUME (in m3/s) (standard speed) MODELS
20 Pa
40 Pa
60 Pa
800 Pa
100 Pa
120 Pa
140 Pa
160 Pa
180 Pa
200 Pa
BDC 3010
23080
22640
22170
21690
21180
20650
20090
19500
18870
18190
BDC 3310
22900
22450
21990
21500
20990
20460
19900
19310
18670
17980
BDC 3510
22710
22270
21800
21310
20810
20280
19710
19120
18480
17790
NOMINAL AIR VOLUME (in m3/s) (reduced speed) MODELS
20 Pa
40 Pa
60 Pa
800 Pa
100 Pa
120 Pa
140 Pa
160 Pa
BDC 3010
19040
18500
17910
17290
16600
15870
15060
14130
BDC 3310
18880
18330
17750
17120
16440
15700
14880
13950
BDC 3510
18720
18170
17590
16960
16270
15530
14710
13770
NOMINAL AIR VOLUME (in m3/s) (low speed)
8
MODELS
20 Pa
40 Pa
60 Pa
800 Pa
100 Pa
BDC 3010
15030
14300
13500
12600
11520
BDC 3310
14890
14160
13360
12450
11370
BDC 3510
14760
14030
13230
12310
11220
vers. 2.3 - 18.02.02
CONTROL PANEL The unit is delivered with the control panel packed separately to prevent any damage during transport.
For mounting see para. «MOUNTING CONNECTION OF CONTROL PANEL».
AND
The packing containing the control panel is placed on the right-hand side of the unit, inside the fan compartment protecting panel.
HIGH EFFICIENCY FILTER HOUSING In order to conceal the high efficiency filters, which are deeper than the standard type and therefore would protrude from the top of the unit, a special housing,
available as an optional extra, can be fitted on the top of the unit. The housing, 200 mm high, does not allow access from the front for removal of the filters.
CONNECTION TO RETURN AIR DUCTS The air intake may be connected through an extension hood to the false ceiling or through a return air duct.
Top edge details necessary for fastening the extension hood for the return air are shown in the detail G .
Figures 5a. and 6. Show the dimensions of the air intake plenums for return air.
N.B.: if high efficiency filters (EU5), deeper than the standard ones, are used, the return air duct should have an access hatch P , 400 mm high, just above the unit in order to allow removal of the filters (fig. 6.).
The plenum, an optional accessory, is available in a sound absorbing version with removable panels used for frontal filter access. The height of the plenum is customised to fit the installation required. The application of a plate F , available as an optional extra, in front of the air filters is necessary to guarantee air tightness (see fig. 5b.).
In figure 8.a. - 8.b. the horizontal motorised damper, with dimensions. For all electrical connections see electrical drawing SE OP .... 20 CV
CV
62
61
MS
Damper servomotor
0
vers. 2.3 - 18.02.02
9
FIG. 5a A B H1 H2
25
H1
A
SUCTION PLENUM 3010 3310 2330 2330 810
3510 2330
300-600 without filter extraction door 600-1200 with filter extraction door
FRONT OF UNIT
B
G
5 20
FIG. 5b FIG. 6
F A
P
H2
1 FIG. 7 B
E
2
A B H1
A D
0
10
H2 min
C
B
vers. 2.3 - 18.02.02
SUCTION PLENUM (silenced version) 3010 3310 3510 2330 2330 2330
810 600 without filter extraction door (standard filters) 1100 with filter extraction door (high capacity filters)
F MAX 145
2115 1910
60
20 17,5 N.4 ASOLE ø8X15 20 17,5
17,5 17,5
A B
17,5
850
C D 20 17,5
20
3010
3310
3510
A
2160
2160
2160
B
2125
2125
2125
C
810
810
810
D
775
775
775
E
2600
2600
2600
F.max
2225
2225
2225
E OPTIONAL motorised intake damper
vers. 2.3 - 18.02.02
FIG. 8
11
ACCESS TO THE UNIT OPENING AND REMOVAL OF PANELS The unit is accessible on all sides by removing the covering panels (see fig. 7).
FRONT PANELS Front panel removal does not require the use of tools. The main panel A (fig. 7.), is hinged and opens on release of handle B when pressed at the indicated point; this operation also frees the panel on the left side C . The locking pressure of the panel can be adjusted by means of the screw in the internal catch.
The remaining panels are engaged at the bottom and held to the front of the unit by spring-loaded catches; for removal, pull the top edge of the panel forward to release the catches (operation 1) and lift (operation 2). Do the opposite for assembly.
SIDE PANELS They are both fixed with five internal screws as follows: - three screws D distributed on the front side uprights, accessible after removal of the front panels; - two screws E on the backside uprights; the screws are marked with the symbol shown in fig. 9 and accessible at the bottom of the filter compartment (with the filters removed) and at the end of the fan compartment.
FIG. 9
REAR PANELS The rear panels are fixed with screws on each side.
12
vers. 2.3 - 18.02.02
Fig. 10.a.
Fig. 10.b.
WATER CONNECTIONS CHILLED WATER CONNECTIONS Check the chilled water pipe sizes and the circulating pump characteristics: an insufficient water flow affects the performance of the unit. Connect the unit to the piping system making sure that chilled water flows into the unit through the lower connection and comes out from side connection (see fig. 10.a. resp. points I and U ); seal the holes where the pipes pass through the base of the unit in order to avoid by-pass of air. It is recommended to use: - flexible hoses to avoid the transmission of vibrations; I U
3010 2” 2”
- 3 piece unions, close to the connections, to permit possible removal of the unit; - shut-off valves to isolate the unit from the water circuit: if possible use full flow ball valves to minimize the water pressure drop. Insulate all the chilled water pipes with closed cell insulating material (e.g. Armaflex or equivalent) to avoid condensation; insulation must allow access to valves and joints.
3310 2” 2”
vers. 2.3 - 18.02.02
3510 2” 2”
13
CONDENSATE DRAIN CONNECTIONS The condensate drain tray and – (in unit types D and H, with humidifier ) the humidifier drain connection must be connected to the drains of the building recommended to use a 25mm internal diameter plastic or rubber pipe (resistant to 100 °C ) to be connect with the drain pipe found under the humidifier. (see fig. 10.a., point C under humidifier).
Ensure that there is a trap in the tube and maintain a minimum gradient of 1% downstream of the trap. If used, the condensate drain pump (optional extra) must be installed at a lower level than the drain connection. Check that the pump head pressure is sufficient for the height of the drain connection.
CONNECTION OF THE HUMIDIFIER The humidifier feed valve (see fig. 10.a. , point F ) must be connected to the building water main using the 6 mm internal diameter flexible plastic pipe supplied with the unit: The feed water characteristics should comply with the following values: Characteristic Feed water pressure Electrical conductivity at 25°C Impurity size
Minimum 1 bar 125 mS/cm -
Maximum 10 bar 1250 mS/cm 0.1mm
It is recommended to install a shut-off valve and a mechanical filter with a mesh size less than 50 µm. Do not use demineralized or softened water. The drain pipe should be connected as indicated in the previous paragraph. Further details regarding the humidifier are contained in the hP3 or in the mP20 control system instruction manual. C F
HYDRAULIC CONNECTIONS Condensate drain pipe Humidifier feeder pipe
CONNECTION TO FRESH AIR INTAKE (optional extra) Connect the intake of the fresh air filter (see fig. 11.) to the nearest external air inlet with a flexible hose (100 mm minimum diameter) following the shortest and straightest path. Secure the hose to the fresh air intake with a fastening collar.
mP3
hP3
Inlet for return air: Ø 100 mm opt.
300
925
FIG. 11.
14
vers. 2.3 - 18.02.02
TYPE Ø 25 mm Ø 6 mm
ELECTRICAL CONNECTIONS A correct electrical connection, carried out accurately and in compliance with local regulations, is extremely important in order to prevent accidents and to ensure a long troublefree operation.
POWER CONNECTION Before working on the electrical parts of the unit, make sure that the power is off and that the isolator on the electrical panel is open (position «O»). After checking that the mains voltage corresponds to the nominal data of the unit (voltage, phases, frequency) shown on the protective cover of the electrical panel, pass the electrical supply cable through the hole in the bottom of the unit and up to the main isolator IG on the electrical panel (see fig. 12.). Fix the ends of the supply cable wires to the upper terminals of the isolator in the electrical compartment; tighten up the terminal screws. The power supply must be within ± 6% of the nominal value, in the case of a three-phase power supply – the max difference between the phases must not be higher than 2%: unit operation out side of these limits will annul the warranty on the unit.
70
70
FIG. 12.
MOUNTING AND CONNECTION OF CONTROL PANEL The control panel should be placed in the hole (in the two holes in the case of mP3+hP3 system) on the front left panel. Fasten the control panel(s) into position following the instructions enclosed in packing and insert the cable
connectors in the respective slots without forcing them (see also the control panel instruction manual). ATTENTION: the connection of the control panel must always be carried out when the power is off (isolator on the electrical panel in position «O»).
ACCESS TO THE ELECTRICAL PANEL The power section of the electrical panel, at mains voltage, is protected by a plastic cover. To remove it:
- turn off the isolator to release the handle blocking the hatch; - unscrew the four fixing screws.
INSTRUMENT AND ALARMS The unit is equipped with the following instruments (see fig. 13.): - Room temperature and humidity sensor STU; made up of: a) a NTC sensor on the mP3 unit, plus a humidity sensor on the hP3 panel (if fitted); b) a single combined sensor equipped on units with mP20, an alternative version in respect to the two sensors described in point (a); - Air flow sensor FS - differential pressure switch in the electrical panel; - Clogged filters sensor PFS - differential pressure switch in the electrical panel; - Electrical heaters safety thermostat TSR - in the fan compartment with access to manual reset pushbutton without removal of the internal panel. The following optional instruments can be connected to every room unit (see fig. 13.):
b) RAS sensor (or sensors, connected in parallel) to be placed at the points to be monitored; - High/low room temperature sensors ATA and BTA: to be installed close to the room unit; - High/low room humidity sensors AUA and BUA: to be installed close to the room unit; - Fire and smoke sensors SFF: to be installed in the ambient or in the raised floor cavity, in a low airspeed zone.
- Under floor flooding detector consisting of: a) SAS instrument inserted in the appropriate socket of the electrical panel; vers. 2.3 - 18.02.02
15
The following optional instruments can be connected to units with mP20 panel (see mP20 instruction manual): - External air temperature sensor (for reading only): to be installed outdoor - in the shade; - Chilled water temperature sensor (for reading, for the «intelligent dehumidification» cycle and for high chilled water temperature): to be inserted in a pocket on the chilled water supply pipe to the unit; - Hot water temperature sensor (for reading and control of hot water reheating): to be inserted in a pocket on the hot water supply pipe to the unit; - Air discharge temperature sensor (for reading and control of the room unit cooling capacity as a function of the discharge temperature): to be placed downstream of the fan outlet; - Chilled water flow sensor (for lack of chilled water flow alarm): flow switch to be inserted in the chilled water piping.
STU PFS
SI mP3 mP20
FS SAS TSR
RAS
FIG. 13.
REMOTE CONTROL Every unit is equipped with a volt-free contact for remote signalling of any alarm condition. The mP3 control panel is capable of being connected to a remote control and monitoring system. It can: - be started and stopped from a remote control system by the addition of an optional extra ancillary relay R1 which must be fitted as shown in fig 14.a.; - trasmit to a remote location a general alarm signal by means of the changeover relay with which the control panel is equipped as standard. For more details on the above, check the unit wiring diagram and the control panel Instruction Manual. 20
mP20 microprocessor controls are programmed for the automatic management of two units of which one in operation (base) and one in stand-by, without the need of remote systems. This is possible through the connections of the relay terminals NC10-C10 of second level alarms (addressable). The fist unit connects to terminals 20-50 remote of the other unit and vice-versa. The terminals used for the interconnection of the two units have been numbered.
20
R1 20 G(19)
mP3 G0(20)
22
alarm relay
20
ON-OFF remote
ON-OFF Remote
50 50
21 23
mP20 0
R1
ID1 IDCM1
2 0
FIG. 14.a.
16
NO10
FIG. 14.b.
vers. 2.3 - 18.02.02
nd
C10 NC10
level alarm
ELECTRICAL DATA COMPONENTS
COMPLETE ROOM UNIT
BELT DRIVEN FANS MOTORS Standard speed (a) MODEL
VOLTAGE No. kW
Reduced speed (a)
Electric Heaters
Electrode Humidifier
ROOM UNIT VERSION C
Low speed (a)
ROOM UNIT VERSION T
ROOM UNIT VERSION D
ROOM UNIT VERSION H
Belt driven fans - Standard speed
OA FLA LRA No. kW OA FLA LRA No. kW OA FLA LRA kW
OA
kW
OA
OA (b)
OA (b)
OA (b)
OA (b)
BDC3010 400V/3ph
1
5.5 10.8 12.0 84.0 1
4
8.2 9.1 55.5 1
2.2 4.7 5.2 26.0 27.0 39.0
6.9
10.0
10.8
49.8
20.8
59.8
BDC3310 400V/3ph
1
5.5 11.2 12.0 84.0 1
4
8.5 9.1 55.5 1
2.2 4.8 5.2 26.0 27.0 39.0
6.9
10.0
11.2
50.2
21.2
60.2
BDC3510 400V/3ph
1
5.5 11.6 12.0 84.0 1
4
8.8 9.1 55.5 1
2.2 5.0 5.2 26.0 27.0 39.0
6.9
10.0
11.6
50.6
21.6
60.6
NOTES
LEGEND kW: nominal power; OA: nominal operating current; FLA: full load current; LRA: locked rotor current;
VERSION C: cooling only; VERSION T: cooling + electrical heating; VERSION D: cooling + humidity control; VERSION H: temperature control and humidity.
(a): data referred to each piece; (b): max current of the most loaded phase at nominal operating condition;
RECOMMENDED SIZES OF POWER SUPPLY CABLES AND LINE FUSES ROOM UNIT VERSION C
ROOM UNIT VERSION T
ROOM UNIT VERSION D
ROOM UNIT VERSION H
MODELS
LINE
FUSE (a)
LINE
FUSE (a)
LINE
FUSE (a)
LINE
FUSE (a)
BDC3010
3x2.5+2.5PE
30A
3x16+16PE
80A
3x2.5+2.5PE
30A
3x16+16PE
80A
BDC3310
3x2.5+2.5PE
30A
3x16+16PE
80A
3x2.5+2.5PE
30A
3x16+16PE
80A
BDC3510
3x2.5+2.5PE
30A
3x16+16PE
80A
3x2.5+2.5PE
30A
3x16+16PE
80A
NOTES Data refers to units fitted with belt driven fans – standard speed. (a): supply line back-up protection suitable for Isc up to 50kA
START-UP AND COMMISSIONING START-UP PROCEDURE a) Check that the auxiliary transformer is supplied through the terminal (220, 240, 380, 415) corresponding to the actual mains voltage; b) check that power is on to the electrical panel of the unit: close the isolator on the unit, set the automatic breaker FAN/AUXILIARY of the auxiliary circuit and check that it is turned on: - the yellow LED “LINE” on the control panel mP3; - the yellow LED on the control board mP20. c) open the shut-off valves of the chilled water piping; d) check that the chilled water circulating pump is working properly;
e) start-up the unit by pressing button
on mP3
control panel (or button on mP20 control panel): after a moment the fans will start and the «SYSTEM ON» green LED on the control panel will come on. In the event of an alarm condition (shown on the control panel) «ALARM» red LED and accompanied by an audible warning sound, consult the control panel instruction manual.
CONTROL AND CALIBRATION OF SENSORS (see also para. INSTRUMENTS AND ALARM)
The settings for regulation devices and alarms preset in the factory are shown in table ”SETTING VALUES These settings must be checked twice a year – without being modified (unless necessary).
Room relative humidity: see control panel instruction manual. Rif
Description
TSR
Safety thermostat (optional)
TEMPERATURE SETTINGS - Room temperature: see control panel instruction manual;
Intervention Differenz.
320 °C (opening)
-
Reset
Manual reset
SETTING THE AIR FLOW SENSOR The differential pressostat FS must intervene in the event that fan operation is interrupted (if there is only one) or of at least one fan if there are two working. The factory set point of the air flow differential pressure switch FS is 1 mbar (=100 Pa). Being the pressure difference across the fans function of the air flow, it might be necessary to reset the instrument during the commissioning, checking that the contact closes when the fans are in operation
Setting the pressure switch: • Simulate a fan system fault by stopping the fan (stop the fan – if only one – or one of the fans fitted) and check that the pressostat intervenes; • If the pressostat does not intervene, slowly raise the set value. The differential pressostat FS is adjustable on a scale from 0.5 to 5.0 mbar (da 50 a 500Pa).
SETTING THE DIRTY FILTER SENSOR (OPTIONAL) The optional PFS differential pressostat must be set as a function of the pressure drop and is sensible to the state of the filter as well as to the actual air flow rate across the unit and therefore should be adjusted during the commissioning. Proceed as follows when the filter is clean:
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- set PFS at 1,5 mbar (=150 Pa); - cover progressively the front surface of the filter and check that the contact cuts when the filter is approx half covered; - lower the set point in case of no change-over; raise the set point in case of early change-over.
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SETTING OF THE SENSORS Temperature thresholds are regulated by the mP20 microprocessor control (if equipped on the unit) (see. Instruction manual mP20). The setting is adjusted by 0.1 °C the maximum temperature range is between -9.9°C and +9.9 °C.
ELECTRICAL CURRENT DRAWN Check that electrical current consumption corresponds to the values given in the «ELECTRICAL DATA» table.
FAN BELT TENSION 6-8mm
Check the fan belt tension. At the centre of each belt span, apply a force (perpendicular to the span) of 20 N (2 kg): the belt should deflect 6-8 mm (see fig. 15); otherwise, adjust the regulation screw.
20N
Excessive belt tension can cause an unbalanced rotating mass leading to early bearing wear while slack belts will slip and overheat. FIG. 15.
PULLEYS A
The transmission pulleys are fixed with an elastic ring keyed onto the motor and fan shafts.
B
DISASSEMBLING Unscrew the two securing screws and take out the pulley from the elastic ring making use of the extraction screw (fig. 16. A ).
ASSEMBLING Slip the elastic ring onto the shaft, put the pulley onto the ring and tighten the two securing screws (fig. 16. B ).
FIG. 16.
3-WAY VALVE AND SERVOMOTOR ATTENTION: disconnect power before working on the servomotor. The motorized valve (in the chilled water and eventually in the hot water circuits) shall be: 1) of the floating type in the units fitted with mP3 control panel. The floating servomotor moves in the opening or in the closing direction connecting alternatively the terminals of the two wirings as indicated in the electrical diagram; the servomotor automatically stops: - at the end of its stroke; - in the position in which it is situated whenever power is disconnected.
2) of the modulating type in units fitted with mP20 control panel. When supplied at 24 Vac, the servomotor takes a position proportional to the control signal variable between 0 and 10Vcc; the servomotor automatically stops: - at the end of its stroke; - in the balance position corresponding to the control signal; - in the position in which it is situated whenever power is disconnected. The instructions regarding the valve and servomotor are explained in the attached technical data sheet.
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PREVENTIVE MAINTENANCE The following operations are recommended for periodic preventive maintenance. 24 HOURS AFTER THE START-UP: - check the tension and the operating temperature of the fan belts. WEEKLY CHECK THAT: - the room conditions displayed on the control panel are normal; - the supply voltage is within the design limits; - - the noise of the unit is normal; - the air filters are not clogged; clean or change the filters when the specific alarm comes on.
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MONTHLY CHECK THAT: - the tension and the operating temperature of the fan belts are normal; - the cylinder and the feed and drain valves of the humidifier are not clogged: replace the cylinder when the specific alarm comes on (see hP3 instruction manual); - the flow of the condensate to the main drain is free; EVERY THREE MONTHS CHECK THAT: - the electrical terminals are tightened and in good condition; - the fan and motor bearings do not overheat.
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FAULT-FINDING GUIDE Fault finding is made easier by the display on the control panel; consult the control panel instruction manual particularly when an alarm condition is displayed.
PROBLEM NO POWER
When necessary, call the nearest service centre describing the nature of the fault as displayed by the controller.
POSSIBLE CAUSE A) No power to the unit electrical panel
(The yellow LED on the mP3 or MP20 B) No power to the auxiliary circuit board is off).
THE UNIT DOES NOT WORK
A)The control panel does not start the unit. B) Check the control panel for alarms
CHECK / REMEDY Check that power is on and the unit main switch on the electrical panel is closed. 1) Check that the IM automatic circuit breaker on the AUX circuit is set. 2) Check the auxiliary circuit 24V fuse; check the fuse on MP20 board. Check that the control panel connectors are correctly located in their sockets; see control panel instruction manual. See the control panel instruction manual
ROOM TEMPERATURE TOO HIGH (high room temperature alarm)
A) The unit is not working.
See “THE CONDITIONER IS NOT WORKING ”. B) The parameter settings on the control Check the room temperature setting; see panel are not correct. control panel instruction manual C) Lack or zero air flow. See ”Lack Of Air Flow”. D) The 3-way valve is not working Check the electrical connections of the servomotor valve (see paragr. SERVOMOTOR VALVE) E) Insufficient chilled water flow Check the chilled water supply; check that the shut-off valves are open F) Chilled water temperature too high Check the chilled water function G) The microprocessor control system is See Control panel Instruction manual not working. Check that the control panel and the sensor. H) Heat load higher than expected. Check: fresh air conditions and volume, external air infiltration and latent load, particularly with dehumidification.
ROOM TEMPERATURE TOO LOW (Low room temperature alarm)
A) The parameter settings on the control panel are not correct. B) The 3-way valve of the chilled water circuit is blocked open C) Insufficient power supply to the electric heaters or the heaters are not working.
Check the room temperature setting; see the control panel instruction manual Check the functioning of the 3-way valve (see paragr. VALVE AND SERVOMOTOR) 1) Check electric heater operation.
2) Check electric heater power supply. 3) If there is a heater alarm, remove the cause and re-set the safety thermostat. D) The hot water coil is not working 1) Check the flow of hot water properly. 2) Check the function of the regulation valve (see Valve and Servomotor).
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PROBLEM
POSSIBLE CAUSE
CHECK / REMEDY
E) The control system is not working See control panel instruction manual; check properly. that control panel and/or sensors work properly. F) Thermal leakage higher than expected Check thermal leakage and entry of external air. G) High latent load (dehumidification The heating capacity is too low to maintain without cooling) the temperature threshold during dehumidification. Lower the latent load (example. Lower the air flow of the external air) or increase the heating. ROOM HUMIDITY TOO HIGH (High room humidity alarm)
A) The parameter settings on the control panel are not correct. B) Latent load higher than expected C) The control system is not working.
ROOM HUMIDITY TOO LOW (Low room humidity alarm)
LACK OF AIRFLOW
ELECTRIC HEATER SAFETY THERMOSTAT INTERVENES
A) The parameter settings on the control Check the room temperature setting; see panel are not correct. also the control panel instruction manual. B) Latent load lower than expected. Check: quantity of the latent load, fresh air conditions and volume, external air infiltration C) The humidifier is not working. 1) Check water supply pressure 2) Check function of manual control system and steam production group (see microprocessor control manual). D) The control system is not working. See control panel instruction manual; check that control panel and/or sensors work properly. A) No power to the fans. B) The filters are dirty.
Check power supply to the fan motors. Shake dust out of the cartridge and clean with a vacuum cleaner. Change filter if blocked. Check correct setting of the dirty filter pressostat. C) The fans are rotating in the wrong Swap two power supply phases and check direction. correct rotation direction. (See electrical diagrams, RSF phase sequence relay). D) The airflow is obstructed. Read the section on Air Distribution E) Intervention of fan thermal protection. Check the resistance of the fan windings. Re-set then measure voltage and current.
A) Insufficient airflow B) Thermostat interrupted
connection
C) The safety thermostat is faulty
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Check room humidity settings; see the control panel instruction manual. Check: latent load, fresh air conditions and volume, external air infiltration See control panel instruction manual; check that control panel and sensors work properly.
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See Low Airflow wire
is Check the continuity of the connection between the safety thermostat and the control system Change the thermostat.
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Via dell’industria, 10 35020 BRUGINE (Padova) - Italy Tel. +39 (0)49 9713211 Fax +39 (0)49 5806906
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Internet: www.UNIFLAIR.com E-mail:
[email protected]
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Manual code @ digit: 06MM020@00B0230
UNIFLAIR ITALIA S.p.A.
