OPERATION MANUAL Close Control Units Multi-DENCO. Precise, flexible and efficient

Transcription

1 OPERATION MANUAL Close Control Units Precise, flexible and efficient

2 Table of Contents 1 Overview of Units and Scope of Supply Introduction Model number explained Product series overview DENCO-OfficeCool Scope of supply Accessories and special equipment Directives and regulations References within manual Safety and User Information Availability of the operation manual Scope of the operation manual Document format Signs used within this manual Labelling of safety information Safety-conscious working Proper use Modifications and changes Spare parts Disposal Personnel selection and qualification Noise Environmental considerations Technical Description Unit description Operating limits Operating modes Operating strategies Components Heat rejection systems Shipping and Storage Delivery Handling Storage Installation Requirements and considerations Substructures Unit placement Clearance and Access Installing enclosed accessories Installation of outdoor units Fan touch protection EC Declaration of Conformity Medium Connections Requirements Connecting refrigeration pipework Refrigerant pipework testing procedures Humidifier water connections (optional) Connecting condensate drain PR GB Subject to modifications R3-11/2015

3 Table of Contents 6.6 Connecting water pipework Electrical Connections Requirements Connecting mains power supply Connecting outdoor unit Connecting signal cabling Customer terminals on C5-12 unit controller Commissioning Requirements Pre-commissioning procedure Commissioning procedure Post-commissioning procedure Operation Requirements General operation Alarms and error messages Servicing and Maintenance Maintenance access Servicing Refrigerant leak testing Compressor care Humidifier maintenance (if fitted) Closing down procedure Logbook & EU Regulation Fault Finding and Troubleshooting Common Issues Dismantling and Disposal Dismantling Disposal Appendix Pre-Commissioning Checklist (DQA 880) Pressure Test Certificate (DQA 653) Commissioning Report (DQA 890) PROTECTION NOTICES The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design. PR GB Subject to modifications R3-11/2015 3

4 Unit Type Code The following pages demonstrate the possible type code and options for a unit. The DENCO OfficeCool short type code is listed on page 12. Please note that the type code is subject to updates and addition due to our continuous improvement process, therefore for the latest options available please contact your local office. Basic Unit Product Range Cooling system Unit size Air flow direction Panel configuration Heat exchanger Compressor control Humidifier Filter Fan Heating Power supply D DENCO M A Air cooled C Chilled Water X Split System 010 Size Size Size Size Size 065* 092 Size 092* 130 Size 130* D Downflow U Upflow P Front full height panel F Front air inlet grille panel L Front low level air discharge panel S Standard heat exchanger C CombiCool L Large heat exchanger I Inverter compressor scroll F Fixed speed compressor scroll N Not fitted S Steam humidifier standard conductivity L Steam humidifier low conductivity H Steam humidifier high conductivity N Not fitted 4 Filter G4 7 Filter F7 P EC plug fan E Electric heating T Modulating electric heating N Not fitted R Remote signal 0-10 V 1 3~ 400 V, N, PE, 50 Hz 7 3~ 400 V, N, PE, 60 Hz * Not available for X-Version 4 PR GB Subject to modifications R3-11/2015

5 Unit Type Code Refrigeration Product Range Key Refrigeration Refrigerant Refrigerant circuit arrangement Compressor size Plate heat exchanger Expansion valve Liquid receiver Shut off valve refrigerant Connection type refrigeration Refrigerant leakage detection Compressor soft start Service connections D DENCO M RE Refrigeration D R410A 1 Single circuit N Small compressor C Standard compressor N Not fitted E Electronic expansion valve N Not fitted S Shut off valves compressor and liquid line L Shut off valve liquid line S Solder connections T Twin solder connections L Refrigerant leakage detection N Not fitted N Not fitted C Commissioning front connection points N Not fitted PR GB Subject to modifications R3-11/2015 5

6 Unit Type Code Water Product Range Key Water Shut off valve water Connection type water Water temperature monitoring Valve type Valve actuator Valve kv D M WA S N B G F S N T N Denco Water Shut off valves chilled water Not fitted Threaded pipework connections (BSPT) Flange pipework connections PN06 Flange pipework connections PN16 Solder connections Not fitted Temperature monitoring probes Not fitted 2 2-way water valve P 2-way water valve, pressure independent 3 3-way water valve with bypass B N D 3-way water valve with bypass & regulating valve Not fitted DODC actuator V actuator, drive open, spring return N Not fitted C kv = 1.0 D kv = 1.6 E kv = 2.5 F kv = 4.0 G kv = 6.3 H kv = 10 I kv = 16 J kv = 25 K kv = 40 L kv = 63 M kv = 100 X Y N Small Standard Not fitted 6 PR GB Subject to modifications R3-11/2015

7 Unit Type Code CombiCool Product Range Key CombiCool Shut off valve water Connection type water Water temperature monitoring Valve type Valve actuator Valve kv D Denco M CC CombiCool S Shut off valves chilled water N Not fitted B BSP pipework connections G Flange pipework connections PN06 F Flange pipework connections PN16 S Solder connections N Not fitted T Temperature monitoring probes N Not fitted 2 2-way water valve P 2-way water valve, pressure independent 3 3-way water valve B 3-way water valve with bypass & regulating valve N Not fitted D DODC actuator V actuator, drive open, spring return N Not fitted C kv = 1.0 D kv = 1.6 E kv = 2.5 F kv = 4.0 G kv = 6.3 H kv = 10 I kv = 16 J kv = 25 K kv = 40 L kv = 63 M kv = 100 X Small Y Standard N Not fitted PR GB Subject to modifications R3-11/2015 7

8 Unit Type Code Controls D M CO C N L B E N T N R N W DENCO Controls C5-12 controller Not fitted LonWorks interface BACnet MS/TP interface BACnet I/P, SNMP, Webpage interface Not fitted Touch screen display Not fitted Run status unit Not fitted Product Range Key Controls Water detection, sensor tape and drain pan sensor 1 Water detection, 1 spot sensor and drain pan sensor Controls 2 Water detection, 2 spot sensors and drain pan sensor 4 Water detection, 4 spot sensors and drain pan sensor 6 Water detection, 6 spot sensors and drain pan sensor N Not fitted 1 Return Air T&H sensor 2 Return Air T&H sensor, 10 m cable 7 Return Air T&H + Supply Air Temp sensors 8 Return Air T&H + Supply Air T&H sensors, 10 m cable 9 Return Air T&H + Supply Air Temp sensors, 10 m cable A B N S O N P S N V N E N S N A N M D S N P T Return Air T&H, 10 m cable + Supply Air Temp sensors Return Air T&H, 10 m cable + Supply Air T&H sensors, 10 m cable Not fitted Standard languages Other language (special) Not fitted Floor void air pressure control (APS) Fan speed control cooling demand Not fitted Air volume flow monitoring Not fitted Energy monitoring Not fitted Pump signal CombiCool free-cooling Not fitted Ambient temperature control CombiCool free-cooling Not fitted Main switch Dual power supply (ATS), inbuilt Smoke detection Not fitted Condensate pump Trend BMS interface 1 Condensate pump and Trend BMS interface L N U N LECU Interface Not fitted Uninterrupted power supply controls Not fitted Interface BMS Display Run status Water detection Air sensor Language Fan speed control indoor Air volume flow monitoring Energy monitoring Pump signal Ambient temperature control Main switch Smoke detection Accessories power supply DENCO-Office- Cool Uninterrupted power supply 8 PR GB Subject to modifications R3-11/2015

9 Unit Type Code Casing Product Range Key Casing Connection position Display position Unit colour Filter gauge Air grille unit top Panel Installation wheels Packaging D M CA B S L N R O G N DENCO Casing Pipework bottom entry Standard display position Lower display position Not fitted White Other unit colour (special) Filter differential pressure gauge Not fitted 1 Top air discharge protection grille (Eyelash) 2 Top air inlet protection grille (Eggcrate) D P N S A N S E P F Air damper Prepared for loose air damper Not fitted Standard panels Acoustic insulation panels Not fitted Standard packaging (Domestic) Wooden crate packaging (Export) Standard packaging (Domestic) with unit protection sheet Wooden crate packaging (Export) with unit protections sheets PR GB Subject to modifications R3-11/2015 9

10 Unit Type Code Outdoor Unit * Product Range Key Outdoor unit Outdoor system Coolant Unit size Fan Refrigerant circuit arrangement Compressor size Power supply Winter kit Heat exchanger coating Compressor soft start Unit colour Packaging Airflow direction Number of outdoor units Deliver external unit Liquid receiver Liquid receiver size D DENCO M OU Outdoor unit C Condenser D R410A E EC fan A AC fan with fan speed controller F AC fan 1 Single circuit N Not fitted 1 3~ 400 V, N, PE, 50 Hz 2 1~230 V, N, PE, 60 Hz 3 1~265 V, N, PE, 60 Hz 5 1~230 V, N, PE, 50 Hz 6 3~460 V, N, PE, 60 Hz 7 3~ 400 V, N, PE, 60 Hz W Winter kit, -40 C ambient D Winter kit with double pressure relief valve, -40 C ambient N Not fitted B Blygold heat exchanger coating E Epoxy heat exchanger coating N Not fitted N Not fitted R Aluzinc O Other unit colour (special) S Standard packaging (Domestic) E Wooden crate packaging (Export) H Horizontal airflow V Vertical airflow 1 1 outdoor unit 2 2 outdoor units O External unit is included in package N Deliver without external unit P Liquid receiver with pressure relief valve D Liquid receiver with double pressure relief valve B Liquid receiver with pressure relief valve and pump-down C Liquid receiver with double pressure relief valve and pump-down N Not fitted 1 7L 2 12L 3 15L 4 18L 5 21L 6 25L 7 30L 8 36L A 50L N Not fitted * A-Version, X-Version and H-Version 10 PR GB Subject to modifications R3-11/2015

11 Unit Type Code Accessories Product Range Key Accessories Unit size (indoor) Accessory D DENCO M AC Accessories 010 Size Size Size Size Size Size Size 130 BAS Base stand PLI Plinth PLIO Plinth, other colour (special) TIL Raised floor tile support PUM Condensate pump PUH Condensate pump at humidifier DAM Shut off damper DAMC Shut off damper TRA Underfloor unit drip tray 1WA Horizontal 1 way air discharge 1WAO Horizontal 1 way air discharge, other colour (special) 3WA Horizontal 3 way air discharge 3WAO Horizontal 3 way air discharge, other colour (special) FI4 G4 Spare filter set FI7 F7 Spare filter set FI4C G4 Spare filter set FI7C F7 Spare filter set REM Remote monitoring touch screen display TOU Touch up paint kit D10 Ceiling connection duct 100 mm D15 Ceiling connection duct 150 mm D20 Ceiling connection duct 200 mm D25 Ceiling connection duct 250 mm D30 Ceiling connection duct 300 mm D35 Ceiling connection duct 350 mm D40 Ceiling connection duct 400 mm D45 Ceiling connection duct 450 mm D50 Ceiling connection duct 500 mm D55 Ceiling connection duct 550 mm D60 Ceiling connection duct 600 mm D65 Ceiling connection duct 650 mm D70 Ceiling connection duct 700 mm D75 Ceiling connection duct 750 mm D80 Ceiling connection duct 800 mm D85 Ceiling connection duct 850 mm D90 Ceiling connection duct 900 mm D95 Ceiling connection duct 950 mm D99 Ceiling connection duct 1000 mm TRE Trend BMS interface CEC Central Controller PLV Plant Visor TSD Top-side-down duct PR GB Subject to modifications R3-11/

12 Unit Type Code DENCO-OfficeCool Product Range Cooling system Unit size Air routing Panel configuration Heat exchanger Compressor control Humidifier Filter Fan Heating Power supply D Denco M O Chilled water OfficeCool H Split System OfficeCool 010 Size Size Size Size 045 D Downflow U Upflow P Front full height panel S Standard heat exchanger H Heat pump heat exchanger N Not fitted S Steam humidifier standard conductivity L Steam humidifier low conductivity H Steam humidifier high conductivity N Not fitted 4 Filter G4 7 Filter F7 W Filter washable G4 P EC plug fan N Not fitted 1 3~400 V, N, PE, 50 Hz 6 3~460 V, N, PE, 60 Hz 12 PR GB Subject to modifications R3-11/2015

13 Overview of Units and Scope of Supply 1 Overview of Units and Scope of Supply 1.1 Introduction We would like to thank you for purchasing our products. units are intended and designed for indoor installation for cooling, heating, humidification, dehumidification and filtering of air at atmospheric pressure. The units are designed as refrigeration systems and/or chilled water systems and it is prohibited to use our units for any other purposes. The equipment has been designed and manufactured within a 'Quality Assurance System' within a strict quality controlled environment to ensure that it reaches you in perfect condition. For help, assistance, spares or your local office, please visit the following website for contact details in your region: Model number explained Each product carries an 'Identification Plate' (sometimes referred to as 'serial plate') inside the equipment for indoor units. For outdoor units, this maybe be on the external casing. This identification plate carries information that is important and unique to the unit. Upon receipt of your equipment it is important to check the 'MODEL NUMBER' (a shortened version called 'Model Type Code' is shown on the serial plate) prior to positioning and installation, to ensure it matches your requirements. Any discrepancies should be reported immediately to your representative. Refer to page 4 for the type code of a particular unit. Below shows an example serial plate for a A-Version unit. PR GB Subject to modifications R3-11/

14 Overview of Units and Scope of Supply 1.3 Product series overview There are 3 versions of the product: A-Version, C-Version and X-Version. These versions have some common elements and also individual characteristics. Fig. 1-1: A Unit Common features & options A-Version C-Version X-Version 7 standard box sizes (010, 018, 030, 045, 065, 092 and 130) Cooling capacities up to 150 kw Available with both upflow or downflow air paths Large EC plug fans Integrated or remote temperature and humidity sensors Large surface area for heat exchanger coil Available with full panel doors or with grilles within the doors Humidification and heating options available Standard control software and hardware that is compatible for all versions Building Management System (BMS) interface compatible Refrigeration based cooling R410A used as standard Inverter compressors as standard (fitted in indoor unit) Electronic expansion valve as standard (fitted in indoor unit) Typically supplied with an outdoor condenser Water based cooling Can operate with Glycol A method of heat rejection separate to unit (e.g. Chiller) Can be provided with 3-way, 2-way or 2-way PICV valves and a variety of actuators Refrigeration based cooling R410A used as standard Available for sizes 010 to 045 Inverter compressors as standard (fitted in outdoor unit) Electronic expansion valve as standard (fitted in outdoor unit) Typically supplied with an outdoor condensing unit CombiCool Coil (Optional) A and C-Version units can be upgraded to have inbuilt redundancy. A unit with a CombiCool coil, consists of a primary and a secondary circuit. The primary circuit will be a chilled water cooling circuit. When parameters leave the allowable boundaries (e.g. chilled water inlet temperatures are too high) then the primary circuit will stop and the secondary circuit will be activated (e.g. the A-Version DX circuit) to continue the cooling process. A CombiCool coil can also be used in a FreeCool strategy. 14 PR GB Subject to modifications R3-11/2015

15 Overview of Units and Scope of Supply 1.4 DENCO-OfficeCool DENCO-OfficeCool is a separate version of the design and custommade for use in an office environment or similar requiring comfort cooling. The units consist of one Zone unit to many Local Environmental Control Units (LECUs) to give temperature control through a raised floor. Typically, DENCO-OfficeCool units are in downflow air configuration, but Upflow units can be used with a 'top side down duct'. This can be referred to as 'Underfloor Air Conditioning'. O-Version H-Version Water based cooling Can operate with Glycol A method of heat rejection separate to unit (e.g. Chiller) Can be provided with 3-way or 2-way valves and a variety of actuators Available for sizes 010 to 045 Acoustic insulation and slower fan speeds R410A used as standard Available for sizes 010 to 045 Inverter compressors as standard (fitted in outdoor unit) Acoustic insulation and slower fan speeds Heat pump options available 1.5 Scope of supply A typical order of a unit could consist of (but is not limited to): Indoor unit of configuration with associated internal options preinstalled (unless requiring placement external to the unit or further installation, in which case, hardware is provided loose within the unit) Outdoor unit (Optional) a condenser, condensing unit or drycooler to act as a heat rejection unit for the system Unit documentation A copy of the current operation manual (indoor and/or outdoor) Controller manual Wiring diagrams for both indoor and outdoor units Dimensional drawing Spare part list in the form of a label or a printed sheet Accessories (optional) Any other accessories that may be required for the indoor or outdoor unit, for example; plinths, base stands, ceiling return sections etc. may be provided in separate packaging 1.6 Accessories and special equipment units can be designed with a vast number of accessories and features. To determine the scope of options fitted to your unit, compare the supplied unit 'Model Number' with the unit model number specified in the typecode. 1.7 Directives and regulations We certify that products supplied within the range of conform to, meet and/or exceed the requirements of the following directives and regulations: Directive on Machinery 2006/42/EC Low Voltage Directive 2014/35/EU Electromagnetic Compatibility (EMC) 2014/30/EU Pressure Equipment Directive 2014/68/EU PR GB Subject to modifications R3-11/

16 Overview of Units and Scope of Supply 1.8 References within manual The following references to standards and regulations are made within this manual. These may be updated or revised by the relevant bodies, after publication of this manual. In all instances, review the latest versions for any relevant updates. (EC) No. 842/2006 EN 378 DIN EN ISO /68/EU 2006/42/EC 2014/30/EU 2014/35/EU EN :2010 EN :2006+A1:2012 (EU) No. 517/ /98/EC 2012/19/EU 16 PR GB Subject to modifications R3-11/2015

17 Safety and User Information 2 Safety and User Information The range is designed in accordance with state-of-the-art technological and engineering standards as well as in conformity with the recognized safety regulations. It must be used in an appropriate manner for suitable purposes, following the details contained within this manual and taking account of safety aspects and potential hazards. Failure to follow the instructions in this manual may result in danger to health and safety, damage to materials and incorrect unit operation. Information within this document advises on, but is not limited to, potential threats or concerns related to health and safety. All users must be, or employ, a trained professional to, assess issues relating to health and safety, before any handling the unit. 2.1 Availability of the operation manual This operation manual contains important information regarding safe and correct operation of the unit. This manual must always be available at the site where unit is operating. Every person working on the equipment must read this manual fully before commencing the work and take note of all relevant information while performing a task. The operation manual is intended to be used by fitting and installation companies, building services engineers, technical personnel or trained persons as well as electrical and refrigeration engineering specialists. 2.2 Scope of the operation manual THIS IS AN ORIGINAL OPERATION MANUAL VERIFIED BY THE MANUFACTURER. This document has been developed by the manufacturer specifically for details relating to the range. Information within this document may be common to other designs or products, but the information contained is exclusive to and non-transferable. The information should not be used as a basis for any other products. Every effort is made to ensure that information contained within this manual is fair and accurate, but DencoHappel endeavours to continuously update and improve all of our products for our customers. Due to this continuous development, some information contained within this manual may become outdated or no longer relevant. If you are in any doubt regarding any information contained within this document, please contact your local sales or support representative who will be happy to assist and enquire further for you. PR GB Subject to modifications R3-11/

18 Safety and User Information This operation manual covers topics in the following areas: Safety and User Information Technical Descriptions Shipping and Storage Installation Mechanical and Electrical Connections Commissioning Operation Servicing and Maintenance Troubleshooting Disassembly NOTE! Please refer to Controls Operation Manual for details about software and control operation of your! NOTE! This manual is valid only for configurations built from our standard catalogue. Any units designed or supplied under special configurations (sometimes referred to as 'Engineering Specials'), may not be covered by previous, existing or future documentation. Please refer to your sales/support contact for any information regarding special designs. 2.3 Document format Significant information for each chapter will be highlighted in the following format: NOTE! Here you will find additional details on using the unit. This symbol is used to indicate normal lists. This symbol indicates instructions to follow. The result of an action is indicated with this symbol. 18 PR GB Subject to modifications R3-11/2015

19 Safety and User Information 2.4 Signs used within this manual Mandatory Signs General Mandatory Sign Refer to manual or documentation Wear ear protection Wear eye protection Wear safety footwear Wear protective gloves Wear protective clothing Wear a protective mask Guards must be used during operation Prohibition Signs General prohibition sign No smoking No open flame, fire, open ignition source PR GB Subject to modifications R3-11/

20 Safety and User Information Warning Signs General warning sign Warning of low temperature Warning of electricity v Warning of suspended loads Warning of toxic substances Warning of hot surfaces Warning of automatic starting machinery Warning of sharp elements Warning of crushing to limbs Possible damage to machinery Environmental damage 20 PR GB Subject to modifications R3-11/2015

21 Safety and User Information 2.5 Labelling of safety information The following symbols and notices are provided in appropriate places throughout this document to designate the safety instructions: DANGER Death/serious irreversible injury Example: Indicates an extremely hazardous situation which will result in death or serious irreversible injury, if the safety instruction is not followed. Electrocution through hazardous voltage will lead to death or serious injury! Disconnect all electric power and ensure the power cannot be inadvertently energized. Verify that all circuits are deenergized, earth, short-circuit and block off all neighbouring live parts WARNING Death/serious injury Example: Indicates a hazardous situation which can result in death or serious irreversible injury, if the safety instruction is not followed. High concentration of refrigerants in the air can result in death or serious injury! High concentration of refrigerants in the air may have an anaesthetic effect and cause unconsciousness. Prolonged exposure may cause irregular heartbeat and sudden death. Very high concentration of refrigerant may cause suffocation by reduced oxygen content in the surrounding air. You should therefore only work in an adequately ventilated environment, and exercise due care and attention when carrying out the work. Wear protective clothing and, if necessary, an autonomous breathing apparatus. PR GB Subject to modifications R3-11/

22 Safety and User Information CAUTION Minor or moderate injury Example: Indicates a hazardous situation which can result in minor or moderate injury, if the safety instruction is not followed. Injury due to sharp cutting edges! While cleaning care should be taken to prevent risk of injury due to thin fins. Wear protective gloves NOTICE Environmental or material damage NOTICE Examples: Indicates actions that can result in equipment or property-damage only accidents. NOTICE Environmental Damage! Dispose of all components and materials (such as water-glycol mix) depending on material type in an environmentally friendly manner and in accordance with the local codes, practices and environmental regulations. NOTICE Damage to the unit! Do not mix up cables during connecting. Use the unit wiring diagram to check electrical cablings. 22 PR GB Subject to modifications R3-11/2015

23 Safety and User Information 2.6 Safety-conscious working The following is initial general advice to consider during various stages of a project. More specific information can be found in relevant chapters in this manual At all times Filters (especially used or dirty filters) are easily flammable. Leaking refrigerant can catch fire and emit noxious substances. No smoking is allowed in direct proximity of any aspect of the system. No open flames near the system. To comply with EN you must wear suitable Personal Protective Equipment (PPE) at any point working on a unit. As a minimum we recommend: Wear safety footwear Wear eye protection Wear protective gloves Wear protective clothing If operating for a prolonged period of time, noise reducing ear protection may be required. Always conduct your own personal risk assessment to evaluate any further requirements During installation & commissioning At these times there are higher risks involved with the handling and operating around a system. Further information is provided in chapters 4 to 8. Always refer to the latest operation manual and support technical documents provided with the unit. Do not make assumptions based on other products design or information. If in doubt, contact your local sales office. Protect against unauthorised access. Do not use or employ un-qualified or inexperienced workers to install or commission the system. During installation there is a higher chance of leaks of refrigerant or glycols. Before adding any cooling medium, ensure: Any system pipework is thoroughly tested for leaks Use non-polluting methods for testing purposes, e.g. Oxygen Free Nitrogen (OFN) PR GB Subject to modifications R3-11/

24 Safety and User Information When unit is operational At any time the unit is operational, rotating machinery and electrically charged components are present. When the unit is not electrically isolated: Ensure all guards and doors are closed. Only remove guards or open doors: When the unit has been electrically isolated. Sufficient time has been allowed for the rotating fan momentum to cease. Sufficient time has been allowed for inverter circuits to discharge. Information regarding 'Fan touch protection' can be found in Chapter 5.7. Further relevant information is provided in chapters 9 to R410A systems EN 378:2008 Part 1 defines R410A refrigerant to group A1. When using refrigerant consider your usage in accordance to Regulation (EC) No 842/2006. NOTE! Refer to 'Field Charge' on the unit serial plate (see chapter 1.2) in regards to system refrigerant volume. NOTICE Always refer to the Material Safety Data Sheet (MSDS) from the supplier. Information relating to hazards, handling and storage, first aid amongst other information is contained within the MSDS. Store these document(s) along with the documents. Features of R410A: Non-combustible No direct toxic effect Colourless and odourless Heavier/denser than air Contains fluorinated greenhouse gases as defined by the Kyoto Protocol Ozone-depleting potential OPD: 0 Greenhouse potential GWP: 1980 Water hazard class WGK: 1, with a slight risk to water Due to the nature of a refrigeration circuit, a system can contain dangerously hot and dangerous cold aspects within the same system or circuit. Failure to wear PPE could result in moderate injury. Review the appropriate chapters for further information. Never touch any part of the refrigeration circuit with unprotected skin. Always conduct your own personal risk assessment to evaluate any further requirements. 24 PR GB Subject to modifications R3-11/2015

25 Safety and User Information Systems containing glycol NOTICE Properties of different glycols can vary significantly between different types of glycols and different manufacturers Always refer to manufacturer s information for usage guidelines Always handle and dispose in accordance with local codes, practices and environmental regulations. General features of glycols: Usually mixed with water. Can reduce the freezing temperature point of the mixture. Reduces cooling capacity when compared to water-only systems. Further information can be found in Chapter 6 and Chapter 8 of this manual. 2.7 Proper use The series are designed as indoor units and for connection to a heat rejection system. They are designed for cooling, heating, humidification, dehumidification and filtering of air at atmospheric pressure. Unless otherwise stated the equipment will not be suitable for use in corrosive atmospheres, for example, areas near large volumes of salt water. Proper use also requires adherence to the operation manual for the controller and suitable and regular inspection and maintenance, following guidelines specified by DencoHappel. Improper use Any use other than that described above is considered improper. The manufacturer/ supplier is not liable for damage arising from improper use. The user alone bears any risk or cost that can be attributed to 'improper use'. It is not allowed to operate units: in explosion risk areas; in areas with strong electromagnetic fields, (electromagnetic immunity as of EMC Directive; refer to the Declaration of Conformity in the unit documentation) in environment with high levels of air contamination, in environments with corrosive and/or aggressive air. 2.8 Modifications and changes Changes or modifications of any units after dispatch from factory shall only be performed following discussion and approval by the sales office. Any works planned that are not covered in this manual must be discussed with, and are subject to approval; non compliance could invalidate the CE conformity and may void the warranty. 2.9 Spare parts Only original spare parts from our spare parts department are allowed. Use of third party spare parts are not allowed and are at the user's own risks. A common spare parts list is enclosed with the unit (either printed or in the form of a sticker). If in any doubt as to the spare part required, please contact your local sales representative who will be able to assist. PR GB Subject to modifications R3-11/

26 Safety and User Information 2.10 Disposal Main and operating supply materials shall be disposed of according to material type in a safe and environmentally friendly manner always refer to your local by-laws and Country specific legislation (also refer to section 12.2 Disposal) Personnel selection and qualification Any individual working on the unit must read and understand all of this manual before starting any works. Any individual working on this system shall be suitably qualified and licensed for the region that the system in installed within. Within the European Union, refrigeration circuit operators shall be in accordance with (EC) No 842/2006 Articles 4 & 5. All personnel involved with the system must understand and observe any local legislation regarding safe working practice Noise The sound power level of the unit can rise up to 98 db(a) according EN ISO 3745 accuracy class Environmental considerations Some versions can use refrigerants, therefore careful and specific attention is required regarding the handling and storage. Consideration must be given to minimise or eliminate any discharge of refrigerant (accidental or deliberate). Chilled water as a cooling medium may contain impurities or chemicals (such as glycol) requiring disposal according to local or regional codes, practices and environmental regulations. DencoHappel highly advises that at all stages of our product lifestyle (purchase, install, maintenance and disposal) carefully consideration is given to any decision to ensure minimal environmental impact. Further information about our policies and values can be found on our website: 26 PR GB Subject to modifications R3-11/2015

27 Technical Description 3 Technical Description 3.1 Unit description Fig. 3-1: Unit, A-Version, Size 092 units are designed for indoor installation (no exposure to outdoor weather) and the system is completed by being connected to an heat rejection system (for example; condenser, drycooler, chiller etc). Typically the units are designed for cooling data centres, though they have a large variety of uses, such as (but not limited to): server rooms, telecom rooms, laboratories, museums, libraries, production environments etc. Heat exchange and airflow is performed vertically; with downflow models receiving warm air from the top of the unit and delivering cold air at the bottom and upflow units taking warm air from the bottom of the unit and discharging cold air at the top. These airflows can be directed at entry and exit of the unit, by using accessories such as: front door grille, ceiling return section, base stands, horizontal discharge sections and dampers. units are available in 7 sizes ranging from (WxDxH) 600x600x1940 mm to 3380x880x1968 mm. These units come with a wide variety of accessories and options meaning that each unit can be tailored to your room's needs. Once you have received your unit, typical onsite tasks include, (but are not limited to): Installation and positioning of units Refrigeration/pipework connections between indoor and outdoor unit Connection of electrical power supply Connection of communication cabling Installation of any accessories provide 'loose' (e.g. water detection tape) Commissioning of the unit Configuration of network settings DENCO-OfficeCool This is a variation of a unit designed specifically to address the needs of comfort cooling. The design is aimed at reducing fan velocities, reduced sound and features for integration with Local Environment Control Units (LECUs) allowing for adjustable environment to suit comfort levels. These are available as direct expansion or chilled water versions. DENCO-OfficeCool design are mostly similar to the requirements and design of units. Within this manual, any differences in the design will be explained. PR GB Subject to modifications R3-11/

28 Technical Description 3.2 Operating limits Unit A-Version C-Version X-Version CombiCool Circuit Indoor Temperature Minimum C Indoor Temperature Maximum C Indoor Humidity (Absolute) Minimum g/kg Indoor Humidity (Absolute) Maximum g/kg Outdoor Ambient Air Temperature Minimum (Standard) C -20 N/A -15 N/A Outdoor Ambient Air Temperature Minimum (with low ambient kit) C -40 N/A N/A N/A Outdoor Ambient Air Temperature Maximum C 55 N/A 46 N/A Condensing Temperature Minimum C 35 N/A 35 N/A Condensing Temperature Maximum C 64 N/A 64 N/A Maximum Operating Pressure (High) MPa Maximum Operating Pressure (Low) MPa 4.32/ N/A 4.15 N/A MPa for unit sizes 010 to MPa for unit sizes 092 & Default configuration for standard design MPa for certain configurations DENCO-OfficeCool Unit H-Version O-Version Indoor Temperature Minimum C Indoor Temperature Maximum C Indoor Humidity (Absolute) Minimum g/kg 2 2 Indoor Humidity (Absolute) Maximum g/kg Outdoor Ambient Air Temperature Minimum C -15 N/A Outdoor Ambient Air Temperature Maximum C 46 N/A Condensing Temperature Minimum C 35 N/A Condensing Temperature Maximum C 64 N/A Maximum Operating Pressure (High) MPa Maximum Operating Pressure (Low) MPa 4.15 N/A 1 Default configuration for standard design. 1.00MPa for certain configurations 3.3 Operating modes Cooling A basic unit only has the capacity to perform cooling, therefore only being able to control the upper limit of the temperature of the room. Heaters and humidifiers can be added to the design to allow for control of both the lower limit of temperature and to control the humidification of the room. The main function of a close control unit is to cool the air within a room to a defined set point. If using refrigerant (A-Version & X-Version), this is achieved by adjusting compressor speed, expansion valve opening and indoor and outdoor fan speed. If using chilled water (C-Version), this is accomplished by adjusting the water valve opening and adjusting the indoor fan speed. Both methods use variable technology to match the heat of rejection by the unit to the volume of heat produced within the room. 28 PR GB Subject to modifications R3-11/2015

29 Technical Description Heating (if fitted) Humidification (if fitted) Dehumidification (if enabled) CombiCool (if fitted) CombiCool FreeCool (if fitted) If the indoor temperatures are too low then the heating function will be activated. There are several options for this operation allowing the heating to be a start/stop operation or variable. When heating is required, the fans can increase their speed. If the humidity levels are below the requirements then the humidifier will be activated to add more moisture to the air. The amount of moisture added to the air varies proportionally to the demand, with the humidifier able to operate between % of its rated capacity. As a default factory settings, dehumidification is a secondary priority compared to temperature control, therefore it will only become active and maintained if the temperature limits are met during the whole operation. If at any point, those limits are not met, the dehumidification operation will be stopped and the unit will operate on a temperature control basis. To perform dehumidification, the unit cools at a higher rate (i.e. over-cools the air) to create condensate on the the heat exchanger coil. Heating options can then be used to re-heat the air before it leaves the unit. Software settings can be changed to deactivate the dehumidification modes, even if components are fitted. The CombiCool options has two separate cooling circuits. CombiCool can be fitted to A- & C-versions of the units. The CombiCool circuit is the primary circuit and is chilled water. The secondary circuit relates to the version (e.g. A-Version, C-Version). The unit will only operate one circuit at a time. If the CombiCool circuit is unable to meet the cooling requirements of the room then the unit changes to use the 'secondary' circuit. When possible, the unit will try to switch back to the 'primary' CombiCool circuit. This feature is ideal to provide internal redundancy to each unit. The unit is fitted with the same CombiCool Coil as above, but can be configured with a FreeCool strategy. When the Cooling Demand is low, the unit will operate with only the FreeCool circuit operating. If this demand increases above a certain threshold, the unit will then activate its secondary circuit (direct expansion or chilled water) and both circuits to operate at the same time to meet the cooling requirements. An ambient sensor can be used to measure the outdoor temperatures. If the ambient temperature is high (above a set value), then the FreeCool circuit will be deactivated and only the secondary circuit will operate. Once the ambient temperature has reduced then the FreeCool circuit will become available again. 3.4 Operating strategies Duty/standby operation 's inbuilt advance software combined with the latest EC variable technology and networking capability, enables the unit to operate with intelligent control strategies to increase performance or maximise energy savings. In most instances we would recommend using a Running Redundancy strategy to help maximise the energy savings possible. Within a room there may be additional units installed as a backup to maintain cooling performance in case there is an alarm or failure on a unit. A common description is an 'N+1' setup, where N describes the number of units required to cool a room. By using the network capability of the unit, upon failure, a signal can be sent to start the standby unit. The network of units can be configured so that the unit designated as 'standby' is changed over after a pre-set period to ensure even wear over their lifetimes. PR GB Subject to modifications R3-11/

30 Technical Description Running redundancy Instead of the standby unit(s) remaining off, running redundancy allows all units to operate at the same time, reducing their cooling requirements. This is can be referred to as 'Hot/Cold Standby'. Each unit will operate on 'part load', reducing the speed of the fans and other variable components. The network would still have backup capability: if a unit developed a fault the other units would use their spare capacity to meet the cooling requirements. By operating in part load, there are significant energy savings when compared to a traditional 'Duty/Standby' operation. The diagram shows an example of savings available: Fig. 3-2: Running Redundancy Example Sensor averaging Automatic Pressurisation System (APS) Sensor averaging can be calculated on temperature, humidity or both, when units are connected in a network. Each unit sends their sensor readings to every unit in the network. Each unit then takes all the values and calculates the average independent of the network units. This gives the advantage of balancing the cooling requirements across all of the units within a room, rather than on individual airflows. The software has features to allow for sensor, communication or unit failure, so that the values do no distort the average value and the unit can change back to 'stand-alone' if necessary. APS ensures a constant pressure in the floor plenum by the unit. This can help reduce hot spots and allows for fast reaction to changes in airflow. This also saves energy as the fans only supply the same amount of air to the floor void, as the amount of air being removed by servers. For datacentres, this feature can be especially efficient when combined with cold-aisle containment. 30 PR GB Subject to modifications R3-11/2015

31 Technical Description 3.5 Components Fig. 3-3: Components 1 Casing The casing design gives the unit a high level of air tightness. The side and rear panels are flat and are flush with the edge of the frame. The front doors are curved and are removable during servicing. All doors use a compression locking mechanism to give a high quality seal. The frame members are anodised aluminium and the panels are white PVC coated steel. Other panel colours are available on request. 2 Touch screen display A 4.3" colour touch screen display is mounted into one of the front doors of the unit (standard configuration). Settings are separated into three levels allowing for control of system settings based on passwords. The display is able to switch between several languages and alarms are displayed in plain text. The display has a screen saver function, which changes to signify when there is an alarm present. 3 Microprocessor control The microprocessor can control all the functions for cooling, heating, humidifying and dehumidifying. It can monitor all digital and analogue inputs and outputs and can be linked in a network between units. The C5-12 controller can output to the BMS standard RS485, but other BMS interfaces can be installed into the controller. As an additional option, the C5-12 controller can be fitted with an UPS capacitor to enabling the powering of the controls for over 1 minute during a power outage. This feature removals the start-up time of the unit when the power supply is restored. 4 Cooling coil The cooling coil is inclined within the unit and uses copper tubes and rippled aluminium fins to give high performance. To prevent condensed water entering the supply air, an intermediate drip tray collects water that drains to a larger drip tray, which is mounted to the bottom of the coil. PR GB Subject to modifications R3-11/

32 Technical Description 5 EC fan All units use direct driven, variable speed, high efficiency EC plug backward curved fan with three dimensional profiled blades as standard. The impeller is optimally balanced according to ISO1940 and fan speed modulates on standard settings. The fan is made of a composite material and variable speed regulation is performed using a 0-10 V control signal. An EC drive motor with an internal overload protection is integrated in the fan. Fan operation is monitored using a current relay. In the event of a fan failure, all other functions are interlocked, to prevent their operation. 6 Filters units are provided with G4 class filters as standard, with high efficiency G7 filters or G4 washable filters (limited regions) available. The filters are positioned directly in front of the coil and are replaceable from the front of the unit. Other filters can be supplied upon request. 7 Humidifier An electrode boiler humidifier can be installed into the unit to allow humidity to be controlled. The humidifier generates steam using proportional regulation of untreated mains cold water. Electrode boiler humidifiers generate sterile, odourless steam free of mineral deposits. The humidifier has an inlet hose connection and a water drain connection to remove any remaining water. 8 Electric heater Units with electrical heating are equipped with sturdy sheathed elements with stainless steel finning and rated to operate at black heat in order to prevent annealing conditions and sparking. Overheat protection is provided through a thermostat (Klixon). The available heating duty is sufficient to prevent low supply temperatures in the dehumidification mode. Electric heating can also have an integrated thyristor control to provide variable heating loads and closer control. Low-pressure, hot water options are also available as an alternative heating method. 9 Electronic Expansion Valve (EEV) The electronic expansion valve is an efficient, service friendly, refrigerant metering device that accurately controls the superheat of the refrigerant within the cooling coil. It is controlled through set parameters in the C5-12 controller and software and requires no external adjustment throughout its working life. The EEV has the ability to close itself in the event of a power failure by using a power supply stored within the C5-12 controller. 10 and 11 Compressor and inverter units use variable speed inverter compressors. These operate using R410A and have a high efficiency using a permanent magnet and brushless DC Motors. Within the unit, the configuration can be; single compressor, in tandem with a fixed speed compressor or in tandem with another inverter compressor. The compressors are provided with Neoprene anti-vibrational mounts, motor protection against overcurrent and thermal overload and are able to perform periodical oil reclaim on a cyclical basis. Units using only fixed speed compressors are only available for size 010 and PR GB Subject to modifications R3-11/2015

33 Technical Description 12 Chilled water valve & actuator A variety of modulating ball valves are available with the units: 3-port valve 3-port valve with double regulating valve (DRV) in bypass 2-port valves 2-port pressure independent control (PIC) valves All valves are fully modulating and are placed within the return water pipework. The actuators available come in 2 varieties: Drive Open Drive Close (DODC) 0-10 V control These options, combined with the variety of valves, ensure that you have a valve and actuator combination that meets your needs. The same valves and actuators are used for both the chilled water units (C-Version) and the CombiCool circuits. 3.6 Heat rejection systems A unit needs to be part of a system which includes heat rejection. There are several different methods for heat rejection (depending on your unit) and your local sales office can help you decide the best for your requirements Condensers A-Version units typically use condensers to reject the heat that the unit has absorbed from the room. They consist of a large coil and a fan to condense the R410A gas into a liquid form. Condensers can be supplied with AC or EC fans and can be installed with vertical or horizontal airflow. Nominal duties for condensers range from 5kW to 100kW when using a 15 C temperature differential. The refrigerant gas inlet and liquid outlet pipes are terminated as stub connections, sealed to contain a low-pressure nitrogen holding charge (5 psig/ 0.35 bar). Condensers can be installed either with a direct 1 to 1 relationship with the indoor unit or 2 condensers can be used with a single unit as part of 1 single circuit. This arrangement is refer to as 'twin condensers' Chillers C-Version units are typically used with chillers (usually several are connected to the same chiller). The water inlet temperature and the room set point can determine the capacity of the unit when using chilled water from a chiller. Chillers can bring benefits of several economies of scale for larger operations and allow for multiple functions to source the same chiller for heat rejection. We are able to offer freecooling chillers that can use low ambient temperatures to minimise energy usage. Separate operating manuals are supplied. PR GB Subject to modifications R3-11/

34 Technical Description Condensing units Condensing units perform the same functions as condensers, but they also contain the compressor. Used for the X-Version of and H-Version of DENCO-Office- Cool, usually the indoor unit would be used with 1 condensing unit, but for certain unit sizes, 2 condensing units can be used. 2 circuits are used and the indoor unit has a 'split coil', half the coil operates with 1 condensing unit, the other half of the coil with the other condensing unit. Separate operating manuals are supplied with the outdoor units for this configuration Dry coolers Typically used in CombiCool configurations, our drycoolers are designed exactly the same as our condensers (dimension and build design) but are used to cool water or glycol based fluids. These units can be used for FreeCool strategies also Plate heat exchangers Where installation of A-Version units requires a large distance between the indoor unit and any heat rejection location, a plate heat exchanger can be used to interface between the refrigerant system and a chilled water system. The plate heat exchanger can use the chilled water to condense the refrigerant into liquid form, thereby transferring the heat to the chilled water circuit, which can then be transported to a chiller or similar. We have a vast catalogue and plate heat exchangers available and your local sales office will be able to help you with your options. Separate operating manuals will be supplied. 34 PR GB Subject to modifications R3-11/2015

35 Shipping and Storage 4 Shipping and Storage 4.1 Delivery On receipt, the equipment should be carefully checked against the despatch note and examined for completeness and damage. It is necessary to take photographs of all visible transit damage. NOTE! Missing parts or claims of shipping damage shall only be reported to the transport insurance, if the damage has been confirmed by the delivering carrier. NOTE! We recommend to keep the equipment in the original packaging for protection, ease of handling, shipping and storage. Remove the original packaging only before installation. If the unit is stored for a period of time before installation or commissioning, it must be protected from the elements, build-up of dust and dirt! 4.2 Handling units are heavy and can have a high centre of gravity. Failure to safely secure the equipment may result in death or serious injury. See unit's serial plate or documents for weight information. Always use proper and suitable lifting equipment for each movement. When moving using a fork lift truck or a stack-a-truck secure the unit against tilting. Never stand beneath suspended loads. As a minimum for handling and shipping, we recommend wearing: Safety footwear Protective gloves Conduct your own risk assessment to evaluate the need for any additional PPE. When handling a unit: Only use the designated lifting points. Never attach lifting hooks or similar gear directly to the unit construction. Use proper and appropriate lifting gear. When handling and shipping, do not tilt the unit by more than 15. With the packing pallet and slinging the unit; use spreader bars to prevent damage. PR GB Subject to modifications R3-11/

36 Shipping and Storage Before lifting or shipping the unit, make sure that all mountings are fixed and secured. Only use lifting gear with sufficient load carrying capacity. Never use damaged lifting equipment. Ropes/chains shall not be knotted or be exposed to sharp edges. Only use ropes/chains of the same length. Move the unit carefully without fast irregular movements. Always set the unit down gently, without a large impact. Take steps to avoid twisting the cabinet during positioning. If necessary, use a specialist company to transport the unit. Use slings to secure the unit against tilting! Fig. 4-1: Handling of unit in export packing and wooden crate NOTE! The only valid dimensional drawing is enclosed with the unit documentation. Placement at the installation site is covered by chapter Storage Storage conditions for uninstalled units Air temperature: -20 C to +50 C Air humidity: up to 90 % (relative humidity with no condensation) During storage, the unit and packaging must be in a protected environment and not exposed to the outdoor environment. 36 PR GB Subject to modifications R3-11/2015

37 Installation 5 Installation Note on unit assembly and installation! Placement, installation and assembly should only be carried out by qualified personnel and must observe relevant accident prevention regulations, as well as other recognized health and safety codes of practice. Information on moving the unit! If the units have been moved from one plant/location to another, they will need to be re-commissioned even if the new room layout is similar. As a minimum for handling and positioning, we recommend wearing: Safety footwear Protective gloves Conduct your own risk assessment to evaluate the need for any additional PPE. 5.1 Requirements and considerations Refer to the unit's dimensional drawing for weights and dimensions General requirements The unit must be installed at a location that fulfils the following requirements: NOTICE Dusty environments can damage electronic printed circuit boards. Ensure the unit is protected from dust during installation Clean unit before first use Humidity sensors can be damaged by aggressive vapours (e.g. chlorine or acetone) Ensure possible vapours are removed from the local environment before installation Ensure the room has a good 'air tightness' to prevent any entry of vapours. Ensure that the site is level and that it can support the weight of the equipment, so that no vibrations or operating noise occurs when the unit is operating. The unit should be set in an upright position - level in both directions. Failure to carry out levelling correctly may cause operational problems; particularly to the drainage. Possible misalignment of panels will indicate that the unit is not level. The unit should be installed so that it is only accessible to trained and authorised personnel. Sufficient clearance in front of the unit must be ensured for maintenance and service jobs. (If applicable to local regulation) Check installation site fulfill requirements as defined in EN 378-3:2008+A1:2012. It is recommended that once the the unit is located, then it is fixed in placed (e.g. bolted, bracketed etc) to prevent unwanted movement or vibrations. PR GB Subject to modifications R3-11/

38 Installation Noise consideration at installation site It is important noise has been considered before the installation. Options are available to equip your unit with sound reduction features. Noise is usually a high consideration of DENCO-OfficeCool installations therefore. Ask your local sales representative for details. When planning or installing units, consider: The acoustic properties of the room soft furnishings, curtains and carpets tend to reduce sound reflections. Bare walls and vertical surfaces tend to produce larger sound reflections which result in higher noise levels. Equipment placed alongside a solid wall can transmit noise through and along the wall into adjacent areas. Floors with high deflections e.g. wooden floors, can amplify the noise produced by the unit. To reduce these problems, the following are suggestions, dependent upon site conditions: Ensure that any vertical planes directly in front of the unit are acoustically insulated. Where units are situated in equipment rooms, acoustic treatment of the walls of the equipment room should be considered. Acoustic pads may be placed behind equipment to reduce wall transmissions. Panels and cables in the air flow direction can cause vibrations and produce noise. Rigidly support these components to a solid structure to reduce this effect. Positioning close control air handling units on building columns or supporting elements of the building to try to minimise noise transmission on the building. Steel floor framing for unit equipment may be used for this purpose. Acoustic rubber pads for vibration insulation may be used beneath the equipment. Abrupt bends in pipework should be avoided by fitting long turn elbows or forming long radius bends. Where pipes pass through walls or partitions, an oversize sleeve to be packed with suitable insulation material is recommended. Insulate pipes and rigidly support to a solid structure of a building. 38 PR GB Subject to modifications R3-11/2015

39 Installation 5.2 Substructures Under unit drip tray To protect the floor underneath a unit from any condensation, a drip tray can be mounted underneath. The drip tray can be used in a raised floor (underneath a base frame) or with a plinth. It is design to hold a small volume of water and should be used along with water detection tape or spot sensor to prevent any significant build-up of water. Fig Base stand For units to be used with a raised floor (upflow and downflow), a base stand should be used underneath the close control unit. The height of the base stand can be from a minimum of 300 mm. The base stand comes complete with adjustable feet (+/- 25 mm available). The surface between the base stand and the unit should be lined with a 3 mm semi-hard gasket. For more details or specification please contact your local sales representative. Fig Support plinth For units installed without a raised floor, a plinth should be used to allow for service connections to the unit. The standard plinth is 200 mm tall and uses the same frame and materials as the unit for a consistent look. Panels are removable with a cross-head screwdriver, the same as the unit's panels. Fig Shut off damper Dampers can be provided loose for further installation on site. The control of the damper is linked to the unit's C5-12 controller and can be made to open/close depending on the unit's operation. It can also close if a critical alarm in generated or linked to fire alarm shutdown routines to protect your units. Dampers should not be directly mounted to the air discharge of a fan. At least a 600 mm duct should be in between the damper and the fan. Fig. 5-4 PR GB Subject to modifications R3-11/

40 Installation Ceiling connection duct For units that wish to connect with a suspended ceiling, a connection duct can be used to create an air path. The ceiling connection duct is made of the same material as the unit's panels. The height of ceiling connection ducts are made to specification and they can bolt onto the top of the close control unit through a service panel on either side. Fig Horizontal air discharge For upflow units that do not have ceiling voids, a horizontal air discharge section can be used to change the airflow direction. Fig. 5-6 The design can have a grille on the front panel only (1 way blow) or grilles on the front and sides (3 way blow). The assembly is bolted onto the top of the unit through the frame. This can be accessed via the service panels on either side of the unit (for 3 way blow, remove the grille for access) Protection grille This is the standard grille that is placed directly on top of the unit to protect individuals from the rotating fan blades during operation. The grille design is different for upflow and downflow units. 40 PR GB Subject to modifications R3-11/2015

41 Installation 5.3 Unit placement It is easier for unit placement can be carried out prior to the installation of a raised floor. It is recommended not to remove the transport packing to provide sufficient protection for the unit during placement. units are heavy and can have a high centre of gravity. Failure to safely secure the equipment may result in death or serious injury. Never stand beneath suspended loads. units are heavy and can have a high centre of gravity. The unit, or parts of the unit can, tip and fall. Failure to safely install the equipment may result in death or serious injury. Secure the unit against tipping before removing the unit from the pallet. Do not lean against or lean objects against the unit. Do not expose any part of your body, limbs or hands to the space between the unit and any substructures (see chapter 5.2) or between the unit and the ground. NOTICE During installation and placement, weight loads may be increased or concentrated. Failure to account for this can cause damage to the floor or the unit. Ensure the floor can withstand the weight and forces of the unit, lifting equipment and operators. For installation on a raised floor, ensure flooring can support increased point loads. NOTE! We recommend using two heavy-duty jacks. Always refer to the manufacturer's instructions when operating the heavy-duty jacks. For further advice, consult your local office. Fig. 5-7: Heavy-duty jack PR GB Subject to modifications R3-11/

42 Installation Placement without raised floor The unit could be placed on a lift truck or two to six-wheeled platform and manoeuvred to its installation site. Once in position, check and adjust levelling will need to be conducted. Care should be taken to prevent damage from contacting the unit by the lifting gear/ slings or fork lift truck etc. Lift the unit from the pallet and take care to manoeuvre it. The unit should be lifted from the base frame only with suitable measures to prevent tipping or rolling. NOTE! We strongly recommend using a third party, specialist lifting company to offload and position all equipment Placement on raised floor Perform the levelling of the unit at the installation site. Take good care when manoeuvring the unit during placement using wheeled platform. At the same time secure the unit against tipping. 5.4 Clearance and Access Clearance Fig. 5-8 Size Unit Width mm Nominal Airflow m 3 /s Clearance above unit (A) mm Floor Void (B) mm Service Access (C) mm Distance to first floor grille (D) mm Tab. 5-1: Columns A, B and D are recommended minimum values to ensure satisfactory operation by your unit. Column C is the mandatory minimum values to ensure serviceability for your unit. Note! Column C is ONLY the minimum service requirements and does not reflect any safety requirements that may affect your local region. Refer to your local Health and Safety regulation for aisle clearances and free space requirements to ensure a safe working environment. 42 PR GB Subject to modifications R3-11/2015

43 Installation Access has been designed to be serviceable exclusively through the front doors of the unit (the curved panels). Access to the right hand side panel (as you face the unit) can increase the speed of service, but is not mandatory. units are compact and efficient design, therefore the larger the clearance all around the unit, the easier service and repair work can be conducted. The doors are hinged and removable. Some frame mullions are removable for assisting in removing larger components Removing doors and panels All unit components are accessible through front doors and panels. s Doors and panels can weigh up to 11kg and easily tip and fall. Ensure panels are held in place when fixings are being removed. Ensure doors are properly attended when being removed. Use access platforms for units that are installed above floor height. To open the front doors, use the key supplied with the unit to release the 1/2 turn locks. Before removing a door with an integrated display remove the cable between the C5-12 controller and the display module. Release the upper hinge retainer and remove panel. To reinstall the doors, first lift the panel and clip into the bottom retainer. Release the top retainer, shift the panel upwards to the unit and clip into the top retainer. The rear and side panels can be removed by unscrewing six screws (per panel). It is recommended to, use a vacuum lifting tool for holding panels Ductwork On units where ductwork is to be fitted, ductwork connections must be completed before any pipework and electrical connections are made. Note! Care must be taken when fixing ductwork to the unit that all panels and metal plates can be removed and are not impeded by rivets, 'tec-screws' and other fixings! PR GB Subject to modifications R3-11/

44 Installation 5.5 Installing enclosed accessories Below is a list of items or options that could be supplied with your unit. The accessories could be inside of the unit on delivery or as a separate package. The below items will need further installation once the unit is in place Interface cards There are several versions of the interface cards available, these all install directly into the controller within the unit. Installation and configuration of these cards must only be conducted by a suitably qualified person. Fig Air sensor If a temperature and humidity sensor is supplied as an remote accessory item, it must be positioned in the reference air flow and must not be subjected to direct sunlight. The sensor cable is already connected to the unit and can be extended to a maximum of 30 m by using a cable of the same specification. Fig Note! Take care when locating the remote air sensor as the unit will attempt to control the conditions of the room based on the sensor location. Do not place the sensor in areas of draft or anywhere near a heat source that could provide a 'false reading'! Floor void air pressure control (APS) Fig The air differential pressure sensor is mounted within the unit. But the two hoses must be connected to the sensor during installation to enable the sensor to read the air pressures. Two hose ports are available: '+' (high pressure), which needs the hose to be positioned within the floor void. The other hose, '-' (low pressure) which needs to be installed within the room space. Air hose opening in the raised floor must be positioned at the right angle to air flow, in order to prevent measurement of dynamic pressure.this can also be achieved if the hoses are enclosed in perforated boxes. The pressure test point must be placed at least 2 m away from the unit. It is optimal to run multiple pressure test points in one closed circular line, shown in figure Fig APS can also be used to monitor pressure difference between a hot and cold aisle. If multiple units used within a room, use a BMS system must be used to calculate an average value and then use the BMS to adjust the fan speed. Fig. 5-12: Showing multiple pressure test points in a floor void. 44 PR GB Subject to modifications R3-11/2015

45 Installation Water detection Important Note! The water detection tape should be installed prior to commissioning and the end user should be made aware that, upon contact with water, an alarm is generated by the controller as an indication of the presence of water. This alarm is not critical to the unit's operation, therefore the unit will continue to operate. The alarm does not protect the unit from water build up, it simply highlights the issue, therefore at every occurrence of the alarm it should be investigated to find the cause and rectify the issue. If an under unit drip tray is supplied it is ideal to mount the sensors within the drip tray (see Fig. 5-1 on page 39). Water detection tape The water detection tape will be delivered connected to the unit's controller. The tape will be collected together and should be unwound once the unit is in it's final position (see Fig. 5-13). Fig Fig The sensor tape should be routed on the floor where it is likely to come into contact with any leaking water. If possible, run the tape around the perimeter of the unit around the base stand feet (if fitted). The water sensor needs to be fitted to the floor in such a way that it maintains a contact with the surface at all times but will not come into contact with any vibrating parts that could cause damage to the sensor. A quick curing, non-conductive epoxy resin or silicone sealant is an effective way to keep the water sensor in its correct location. Water detection spot sensors Spot sensors are also available for water detection. These should also be installed in the under unit drip tray (if included). Distribute the sensors evenly to help ensure all areas under the unit can detect a water build up. PR GB Subject to modifications R3-11/

46 Installation Condensate pump When a humidifier is fitted, condensate collected in drip trays and condensate pumps can be at near boiling temperatures. This condensate, or surfaces that it has been in contact with, can cause scalding or burns. The installer must install condensate tubing suitable for these temperatures. The installer must ensure individuals cannot come in contact with this fluid, tubing or affected regions. When installing a condensate pump: Never run power supply cables for the condensate pump together with control cabling Position the condensate pump carefully and secure it against slipping Where ever possible consider future servicing needs where this pump may have to be removed and cleaned as part of a maintenance program Fitting the condensate pump outside of the unit casing offers the best access Care must be taken that condensate inlet and outlet are not placed beneath the fan Ensure that no power or water hoses can contact the fan, if necessary, suitable condensate hose bracketing should be installed For cold water condensate pumps (units without a humidifier): Pump Capacity: Max. Discharge Height: Max. Flow Rate: 0.85 litres 9 metres 40 litres per hour for 1 metre discharge height 28 litres per hour for 9 metre discharge height For hot water condensate pumps (units with a humidifier): Pump Capacity: Max. Discharge Height: Max. Flow Rate: 5 litres 6 metres 480 litres per hour for 1 metre discharge height 120 litres per hour for 6 metre discharge height Remote monitoring touch screen display The display can be mounted up to 50 m away from the C5-12 controller within the unit. A 24 VAC supply is required, local, to power the display, together with a two core screened data cable that networks the display to the plan connection on the C5-12 controller. For further details refer to the wiring diagram. Fig PR GB Subject to modifications R3-11/2015

47 Installation 5.6 Installation of outdoor units Note! It is mandatory to connect the indoor unit to a heat rejection unit. This is achieved typically in five different forms, depending on the version used: Condensers (DMOUCD) Condensing units (DMOUUD) (including heat pumps) Chiller Drycoolers Plate heat exchangers This chapter covers only the condensers (DMOUCD). Condensing units (DMOUUD) has a separate installation manual that can be provided on request and is provided with the delivery of the equipment. For all other varieties or equipment not purchased with a unit, please refer to their independent manuals. Outdoor condensers use exposed heat exchanger coils, which have thin metallic fins. These fins can cause cuts to limbs. Ensure cut protective PPE is worn. Do not handle the condenser in the region where the coil is exposed. All warnings found in chapter 5.3 Unit placement also apply Requirements Condensers are design for outdoor installation As standard, condensers can operate in temperatures as low as -20 C Winter kits are available for very low ambient conditions (down to -40 C) For condensers to be installed in a coastal region or an area of high corrosion, ensure: The unit is supplied with epoxy or Blygold coated coil The outdoor unit has sufficient housing and protection from the elements of the local environment All pipework and interconnecting electrical cables are insulated and protected from the environment Separation The separation between the indoor unit and the outdoor condenser must be within the following limits for the interconnecting pipework requirements: No more than 35 m above the height of the indoor unit No more than 10 m below the height of the indoor unit The interconnecting pipework between the indoor and the condenser must be less than 100 m For more details about interconnecting pipes, please see chapter 6. PR GB Subject to modifications R3-11/

48 Installation Positioning The condenser must be installed on a level surface that can support the weight of the equipment and allowing for access from all sides. If multiple condensers are used for 1 indoor unit, the condensers must be installed on the same level and the same distance to the indoor unit. Whenever possible, shelter condensers from winds and avoid prevailing winds blowing directly onto the fan(s) or the heat exchanger. Always bolt down units to ensure secure fixing to location. Consideration should also be given to minimising the noise created by the condenser. Pipework and cabling running underneath the unit should be configured so as not to obstruct airflow. Pipework and cabling underneath the unit can cause a reduction in airflow as well as an increase in noise as air passes around the obstruction. All outdoor units should be fixed to a rigid structure using the holes provided (wherever possible). If the units are in an exposed situation and normal bolting is not practical, then alternative brackets, fixings or adhesive should be used. Condensers are delivered with the mounting legs loose, allowing for installation on site to decide the orientation of the unit (vertical or horizontal). The legs have been designed to maximise the clearances onto the coil, so it is essential they are installed correctly. The hot gas discharge line MUST be positioned at the top of the condenser for horizontal airflow (labelled as 1 on the diagrams below). Therefore, the liquid line (labelled as 2) will be at the bottom of the unit. Vertical airflow condensers must not be installed upside down. Horizontal Airflow Vertical Airflow Fig PR GB Subject to modifications R3-11/2015

49 Installation Clearances Condensers must be located in an unobstructed position to ensure adequate air circulation through the cooling coil. Care must be taken to avoid air recirculation from one unit to another. Horizontal airflow Clearances around the condensers must be in accordance with condenser specific drawings supplied in the unit documentation. Fig Vertical airflow Definition of 'L' and 'W' Y must be greater than 2X Requirements if more than one unit is installed by a solid wall. Solid obstructions along any two walls. When multiple units are located with solid obstructions along any three sides, the open side must give free air to each of the units. When multiple units are located alongside two solid obstructions and two louvered sections: C + D > L The total free area of the louvres should not be less than 70%. Fan discharge should be level with the top of the louvres. When multiple units are located alongside one solid obstruction and three louvered sections: B + C + D > L The total free area of the louvres should not be less than 70%. Fan discharge should be level with the top of the louvres. Fig PR GB Subject to modifications R3-11/

50 Installation 5.7 Fan touch protection On Downflow units: On Upflow units: It is extremely important that no one can come into contact with the fans within the units during operation or immediately after operation. Users must wait 5 minutes after turning off a unit before removing any safety guard, to ensure fans have come to a complete stop. Full Height Panels these units are typically used with a raised floor. The floor tiles must be unremovable without the use of tools for sufficient protection. If this is not the case, then the installer must install additional fan protection grille below the unit to prevent access to the fans. Low Level Discharge Grille these units are typically used with a plinth. The plinth's design means that the panels are unremovable without the use of tools. If the unit used with a raised floor then the same conditions apply as for Full Height Panels. If the unit isn't supplied with one of the following accessories then the installer must build a touch protection device on the top of the unit. The accessories are: Top air outlet protection grille (Eyelash) Ceiling connection duct Horizontal 1 way air discharge Horizontal 3 way air discharge 5.8 EC Declaration of Conformity Note! ANY installation of a unit that is labelled as CAT II under the Pressure Equipment Directive 2014/68/EU (see serial label on unit), within the EU, MUST be completed by an installer that is certified with a notified regulatory body. Outside of the EU installers must comply with local legislation and regulations. We strongly recommend that anyone involved with any installation of units reviews and understands all the necessary legislation, in particular, the Pressure Equipment Directive 2014/68/EU. For any installation of equipment that requires interconnecting pipework, it is the responsibility of the installer to produce an EC Declaration of Conformity, if installed within the European Economic Area (EEA). Outside of the EEA there may be similar, separate requirements by different nations. To assist with these requirements, we have prepared a short guide. This guide is NOT exhaustive and care should be taken by the installer that the EC Declaration of Conformity that is produced, conforms to the necessary requirements. Guidelines on producing a Declaration of Conformity Since the installation is the concept/design of the installer, the EC Declaration of Conformity of the whole system needs to be prepared and completed by the installer. This will require the creation of a technical file along with suitable documentation of safety and design to meet the legal requirements. 50 PR GB Subject to modifications R3-11/2015

51 Installation It is the responsibility of the installer to carry out the assessment and to prepare the EC Declaration of Conformity. For the installation of the interconnecting pipework and electrical cabling, the declaration must then be signed by your legally responsible representative (which may be the Managing Director of the Company). The installer will need to consider some or all of the following: 1. Machinery Directive 2006/42/EC 2. EMC Directive 2014/30/EU 3. Low Voltage Directive 2014/35/EU 4. Pressure Equipment Directive 2014/68/EU 5. EC type examination certificate: 6. Applied Harmonised Standards: 7. Safety of machinery: Electrical equipment: 8. Safety of machinery: Basic design, concept and technical principle: 9. EMC emissions for residential, commercial and light industrial environments: 10. EMC immunity for industrial environments: 11. Refrigerating Systems: 12. Pressure equipment for refrigerating systems and heat pumps (General piping) 13. Applied National Standards/Technical Specifications: This assessment will need to include creating a technical file including: 1. Description of the equipment, accompanied by block diagram. 2. Wiring, circuit diagrams, and cable sizing information. 3. Pipework layout drawing. 4. List of standards applied. (See above). 5. Records of risk assessments and assessments to standard's 6. Description of control philosophy/logic. (Controls Manual) 7. Materials list including source traceability on pressure related components e.g. pipework, fittings, and brazing materials etc. 8. Copies of any markings and labels. 9. Copy of this manual. 10. Test reports e.g. pressure test certificates, wiring test certificates. 11. Commissioning records. 12. Declaration of Conformity. PR GB Subject to modifications R3-11/

52 Medium Connections 6 Medium Connections NOTE! When routing pipework, take due care that air flow is not obstructed as this may reduce the efficiency of the system. 6.1 Requirements Short line lengths Liquid receivers (For refrigeration circuits) Only pipe sizes recommended by DencoHappel are allowed. Incorrect pipe sizing can cause compressor damage and void the warranty. Every part of all circuit(s) (cooling and heating) must be designed and installed to national and local standards and regulations. Piping must be properly sized to meet the design requirements. Mechanical connections shall only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes. Only copper refrigerant lines meeting EN :2010 standards shall be used for refrigeration pipework installation. R410A is the standard refrigerant used within units, ensure that pipework used is suitable for the higher pressures used with this refrigerant. The relevant requirements of the standard, especially apply to: Quality of internal surfaces Sealed pipe ends Pipe labelling Testing Pressure resistance Keep the pipe length as short as possible. The greater the distance between the air handling unit and the outdoor heat rejection unit, the greater the pressure drops in connected pipes, resulting in reduced energy efficiency of the unit. Installing a refrigerant receiver is not mandatory. With long pipe runs and low ambient temperature operation of the unit it is, however, recommended to install a refrigerant receiver. If a receiver is not installed, the refrigerant should be selected and charged with extreme care. When charging the unit with refrigerant at low ambient temperature, ensure that the system is not overfilled and the unit can be trouble-free operated at high ambient temperature as well. Consider the manufacturer's instructions on layout of a refrigerant receiver and installation manual on mounting a receiver. 6.2 Connecting refrigeration pipework Pipework All pipework must be installed in accordance with EN and with recognised good refrigeration practices in a tidy manner. Any further local legislation may vary, but must be observed. Within the EU, certain systems may be subject to mandatory requirements of the Pressure Equipment Directive 2014/68/EU. To know the classification of your equipment, refer to the serial plate on each unit. Details of the maximum lengths of interconnecting pipework are in chapter PR GB Subject to modifications R3-11/2015

53 Medium Connections Material quality For refrigeration pipework: Copper tube quality must be the equivalent of EN Refrigeration grade copper must be used Pipework must be cleaned and dehydrated Use of joints, bends or sets must be kept to a minimum Bends or sets are to be machine pulled to approved radius at all times Only properly swaged joints can be used (butt joints are not allowed) Manufactured bends are not recommended It is recommended to use half-hard straight lengths of copper instead of coils Sizing NOTE! Prior to installation it is particularly important to check the correct size refrigeration pipework is being installed. Contact your local representative if you are unsure. NOTE! Only the pipe sizes listed below are ALLOWABLE for each size. ONLY these sizes MUST be used for both horizontal and vertical risers. This table is for REFERENCE ONLY. A-Version Pipe sizing NOTE! FINAL and ULTIMATE responsibility for pipe sizing is of the contractor or installer. The below table is for GUIDANCE ONLY to specify the range of sizes applicable. It is necessary that suitably qualified engineers conduct their own, separate calculations to determine the sizing suitable for the application. When sizing pipework, consideration should be given with regards to adequate oil return during all conditions. It is also important that the pressure drops in pipework are minimised to avoid unnecessary decreases in capacity. Larger pipe sizes reduce gas velocity and make oil return more difficult to accomplish. Smaller pipe diameters increase oil velocity, but will be more susceptible to high pressure drops. Metric (mm) x 22 2 x 28 Imperial (Inch) 3/8 1/2 5/8 3/4 7/8 1-1/8 1-3/8 1-5/8 2 x 7/8 2 x 1-1/ Tab. 6-1 Liquid Discharge Liquid Discharge Liquid Discharge Liquid Discharge Liquid Discharge Liquid Discharge Liquid Discharge Discharge Line: Recommended pressure drop = 1.0K, Max pressure drop = 2.5K Liquid Line: Max pressure drop = 1.5K PR GB Subject to modifications R3-11/

54 Medium Connections X-Version & H-Version (DENCO-OfficeCool) Metric (mm) x 12 2 x 22 Imperial (Inch) 3/8 1/2 5/8 3/4 7/8 2 x 1/2 2 x 7/8 010 Expansion 1 x PUHZ-ZRP100YKA Suction 018 Expansion 1 x PUHZ-RP200YKA Suction 030 Expansion 1 x PUHZ-RP250YKA Suction 045 Expansion 2 x PUHZ-RP250YKA Suction Tab. 6-2 Only valid for unit combination listed within table. For any other version please contact your local sales/service support Installation with 2 condensers NOTE! For condensing units, see separate installation manual. On Fig. 6-1 and Fig. 6-2 the labels are as follows: 1 Discharge line (hot gas) from the indoor unit 2 Branches of discharge line 3 Liquid Line returning to the indoor unit 4 Branches of liquid line For any installation with 2 condenser in tandem configuration: Both must be placed on the same level If this is not possible, an external liquid receiver must be installed Pipes 2 and 4 (pipework after the 'T-Joint') should be 1 pipe diameter size smaller than pipes 1 and 3 respectively (see tab 6.1 and 6.2) Ensure that A = A and B = B For Horizontal Airflow: A + B < 5 metres For Vertical Airflow: A < 5 metres and B < 5 metres 54 PR GB Subject to modifications R3-11/2015

55 Medium Connections Horizontal airflow Isometric View Top View Fig. 6-1 Vertical airflow Isometric View Side View Fig. 6-2 PR GB Subject to modifications R3-11/

56 Medium Connections Thermal expansion All pipework, which is subject to changes in temperature, expands and contracts. The routing and joining of the pipework must be capable of absorbing this movement. An example of the rate of expansion on a unit is as follows: Pipe Pipe Operating Temperature C Expansion in 0 C Temperature mm/m Expansion in 21 C Temperature mm/m Hot Gas Line Liquid Line Suction Line Tab. 6-3 Pipework with multiple bends and where any straight lengths are short prevents issues with expansion. If long, straight pipework is unavoidable, the following methods can be used: Expansion loops Offsets Anacondas (see manufacturer's datasheets for details) If using expansion loops or offsets, the following minimum dimensions must be observed: Expansion Loops Offset Fig. 6-3 Tube Outer Diameter Size of expansion movement [mm]: Length (L) of required loop or offset [mm]: 1/2" or 12 mm /8" or 16 mm /4" or 18 mm /8" or 22 mm /8" or 28 mm /8" or 35 mm /8" or 42 mm Tab PR GB Subject to modifications R3-11/2015

57 Medium Connections Insulation For insulating pipework: All insulation (e.g. Armaflex or equivalent) shall be class O minimum 3/8" wall thickness All joints and edge splits must be glued or taped on suction lines Vapour sealing is not required on hot gas lines Any painting of insulation installed outdoors must be completed in line with manufacturer's guidelines A-Version: X-Version: Each site must be individually assessed depending on pipework exposure, position, length and accessibility to pipework, but for units: Discharge lines and liquid lines do not need to be insulated, but may be required due to site conditions and accessibility to pipework. We recommend insulating the liquid line in the raised floor to avoid heating the cold air. Both lines (suction and expansion) MUST be insulated Cutting tubes Where appropriate, pipework and cables shall be sleeved when passing through building walls or roof structures. When cutting copper tubing or pipe, care must be exercised to prevent the filings or cuttings from entering the pipe. Some effective means should be used to clean out the small particles of copper when they do enter the tube or pipe. When cutting copper tubing with a wheel cutter, it is extremely important to use sharp wheels. The copper wears the edge of the wheels more quickly than might be expected; therefore the condition of the wheel must be checked regularly. Always ream the tube ends to remove burrs. NOTE! We recommend using a wheel cutter as the best method for cutting pipework Brazing Brazed joints are to be made with Easy-Flo or similar copper alloy rod. Flux is not required for joining copper to copper. When bronze or brass is involved, Silver-Flow self-fluxing rod or similar is required. NOTE IMPORTANT! When soldering or brazing, purge a small amount of dry nitrogen through the pipe to prevent oxidation and scaling internally. Failure to purge nitrogen whilst brazing will result in scale build up and this WILL block the Electronic Expansion Valve (EEV). Any subsequent scale found within the valve body may result in voiding of warranty! PR GB Subject to modifications R3-11/

58 Medium Connections It is necessary to create a positive pressure inside the pipe. Before applying heat to pipes, remove Schraeder valve cores and open any other valves, solenoids etc. which will cause a build-up of pressure in the line and, therefore, blowholes in the joint. Also, any valve seats, gaskets, capillaries etc. that may be damaged by heat, flux or dry nitrogen must be removed or protected, (e.g. wrap in a cold damp cloth.). When making soldered or brazed joints, it is essential that the surfaces to be joined are clean. Unclean metals do not take the flux properly, which results in bare spots over the brazing alloy and will not flow. Thin films of soldering alloy make the strongest joints. Clearances of between 0.02 mm to 0.07 mm are all that are required. Too much clearance prevents the proper capillary action, wastes alloy, promotes a weak joint and allows ingress of soldering material in the lines. After completion of joints ensure that all surplus flux is thoroughly cleaned off. Flux left on the pipes looks unsightly and can cause oxidisation, pitting and prematurely age the tubing Oil traps Fig. 6-4: Requirements of discharge lines on units 58 PR GB Subject to modifications R3-11/2015

59 Medium Connections If the condenser(s) are installed ABOVE the unit, for the discharge line: The condenser must be NO MORE than 35 m above the unit 'P' traps must be installed at the bottom of EVERY vertical riser in the discharge line, including pipework outside of riser cupboards (Detail 1) For every max. 5 m of vertical pipework, and 'S' trap must be installed (Detail 2) At the top of every riser a bend should be used to prevent oil return (Detail 3) Use a 1% slope in the direction of refrigerant flow (Detail 3 & 4) NOTICE Failure to install sufficient oil traps can cause a lack of lubrication in a compressor resulting in poor performance or failure. The last trap (detail 3 in Fig. 6-4) prevents liquid refrigerant travelling backwards to the compressor outlet. Ensure suitable oil traps are installed as per Fig When the condenser is located BELOW the unit, oil traps are not required. Consideration must be given to ensure that the liquid line pressure losses are not excessive (see chapter 'Sizing' for more information) Tube support (clamping) It is recommended: All tubing should be independently clamped in position using a cushion based vibration absorption clamps Supports should be spaced at no more than 1.5m separation A thermal break should be provided between suction pipes and any support brackets Fan removal to aid installation On certain downflow units, access to the refrigeration pipework connections can be difficult (especially if there is no side access to the unit). units are designed to allow for the removal of fan closest to the pipework to make installation easier. NOTE LABELLING OF ELECTRICAL WIRES! It is very important to observe and label any electrical wires for the fan being removed to ensure a correct re-installation. Fig. 6-5 PR GB Subject to modifications R3-11/

60 Medium Connections Each fan assembly is heavy and can weight up to 36 kg (special designs could weigh more). Conduct a risk assessment and plan any manoeuvre before starting any work. Ensure a safe lifting procedure is observed. 1 Remove the 2 x 4.8 mm self-tapping screws that connect the mullion to the horizontal frame. 2 Remove the 2 x 4.8 mm self-tapping screws that connect the mullion to the bracket and vertical frame 3 Loosen the fan inlet ring (6 x M6x25 bolts) but DO NOT REMOVE THE BOLTS 4 Remove the bolts used to fix the fan assembly to rails. Once unscrewed, remove the assembly by pulling it towards the front of the unit as far as possible. Then lift the assembly up and remove it from the unit. 6.3 Refrigerant pipework testing procedures On completion of the refrigeration pipework the equipment must be pressure tested with dry nitrogen, at a pressure relevant to the refrigerant used. This should be completed by a competent person holding the relevant refrigerant handling qualification. NOTE! The procedures below are according to EN 378 and are the minimum standards expected during leak, pressure and strength testing. Always refer to your country/ region specific legislation. Leak testing Certification A thorough leak test must be performed to ensure that the system is 'leak tight'. It must be carried out at pressure, using oxygen-free nitrogen. This can be carried out at relatively low pressures (see below) in accordance with safe methods of working and good refrigeration practice On all new installations once the system is found to be leak free, a label stating date and time and final pressure reading is to be attached to the pipework inside the unit. A pressure test certificate must be signed, witnessed and passed to the commissioning engineer. NOTE! The use of 'tracers' or 'dyes' are not permitted on units under any circumstances. NOTE! Depending upon your commercial agreement, you may be required to perform the vacuuming and oil and refrigerant pre-charging of the system, before the commissioning engineer's arrival. For details of this 'Pre-Commissioning Procedure' please see chapter 8 'Commissioning' and in particular chapter 'Initial charge for refrigerant circuits'. Important safety information is listed at the start of chapter 8, therefore read the whole chapter IN FULL before commencing any work. 60 PR GB Subject to modifications R3-11/2015

61 Medium Connections A-Version: Size 010 to 065 For standard units, all devices fitted to the low pressure side of the system are sufficiently pressure rated and can remain connected to the system during pressure testing. 1: Ensure that the adjacent area is clear of non-essential staff, complete a risk assessment and establish an exclusion zone for safety purposes. 2: Insert 3.5 bar nitrogen into the unit to identify first fix leaks, if leaks occur, release the nitrogen, repair the issues and re-insert nitrogen to 3.5 bar. 3: Complete a strength test by pressurising system with dry nitrogen to 47.6 bar and leave on test for a minimum of 60 minutes. 4: On completion of the strength test drop the pressure down to zero by using the relief valve on the nitrogen regulator or charging manifold. 5: Repair any leaks found and then repeat steps. 6: If the client or end-user requires witnessing the pressure test, carry out this witness at this point making notes of dates, times and pressures. 7: At the completion of the pressure test, the Oxygen-Free Nitrogen charge should be safely purged away leaving a holding charge prior to the evacuation process. Ensure you have recorded the holding charge in your records at this point. 8: On completion, prepare and sign the 'Pressure Test Certificate' (chapter 13.2) A-Version: Size 092 & 130 NOTICE During the pressure test, system pressures exceed the maximum values specified by the supplier. Exceeding these pressures could damage the sensors resulting in incorrect operation by the unit. Ensure low pressure switches are disconnected before pressure testing. 1: Ensure that the adjacent area is clear of non-essential staff, complete a risk assessment and establish an exclusion zone for safety purposes. 2: Low side strength test; Complete a strength test on the whole system by pressurising with dry nitrogen to a maximum of 33.0 bar and leave on test for a minimum of 30 minutes. 3: High side strength test; On completion of step 2, CLOSE THE SUCTION LINE SHUT OFF VALVE, and increase the dry nitrogen pressure to 47.6 bar and leave on test for a minimum of 30 minutes. 4: Decrease the pressure to 17.2 bar by using the relief valve on the pressure regulator or manifold. Re-fit the LP switches, open the suction line valve and complete a bubble test on the LP switch joints. 5: On completion of step 4, reduce the pressure to zero by using the relief valve on the nitrogen regulator or charging manifold. 6: Repair any leaks that are found and then repeat steps 1 to 5. 7: If the client or end-user requires witnessing the pressure test, carry out this witness at this point making notes of dates, times and pressures. 8: At the completion of the pressure test, the Oxygen-Free Nitrogen charge should be safely purged away leaving a holding charge prior to the Evacuation process. Ensure you have recorded the holding charge in your records at this point. 9: On completion, prepare and sign the 'Pressure Test Certificate' (chapter 13.2). PR GB Subject to modifications R3-11/

62 Medium Connections X-Versions and DENCO-OfficeCool H-Versions For guidelines on how to perform pressure testing for these installations, please refer to the separate installation manual. Some condensing units may be delivered with a 'pre-charge' of refrigerant: ensure this is not released during pressure testing. 6.4 Humidifier water connections (optional) The humidifier unit must be connected to a standard piped cold water supply. All mains water pipework to humidifiers must be installed to national and local standards, in particular, local water authorities' regulations and requirements. Supply water quality Connect the humidifier using a fitted flexible hose and a compression fitting. The water supply should have a stop cock adjacent to the unit. The earth bonding (supplied) must be connected to the incoming water supply and also to the drain line if electrically conducting tubing is used for instance copper pipe. In general the water supply feed to the humidifier must be normal quality drinking water but must comply with the following parameters: Water feed pressure between 0.1 and 0.8 MPa (1 and 8 bar) Temperature between 1 and 40 C Hardness not exceeding 400 ppm equalling CaCO3 (40 fh) Conductivity 125 to 1250 µs/cm (microsiemens/cm) (depending on bottle used) No organic substances In operation, the humidifier can produce hot water vapour. The vapour, tubing that it is directed through and areas that it has been in contact with can be hot and will cause scalding or burns. Always allow time for the humidifier and affected regions to cool sufficiently before starting any work Do not touch affected regions with unprotected skin. 62 PR GB Subject to modifications R3-11/2015

63 Medium Connections NOTICE ON WATER USE! Under no circumstances should the water supply be fed from a water softening system. Do not add disinfectants or anti-corrosive substances (irritants). It is not recommended to use industrial water or chemically and bacteriologically polluted water for cooling circuits. Do not use demineralised water (e.g. osmosis/purified water) Where a salt exchange plant is in use at a site, the feed water to the unit should by-pass this. Water feed quality Unit Normal tap water Water with low salt content Min. Max. Min. Max. Activity of hydrogen ions (ph) 7 8,5 7 8,5 Specific conductivity 20 C (σr,20 C) μs/cm Dissolved solid materials (cr) mg/l (1) (1) (1) (1) Solid residue at 180 C (R180) mg/l (1) (1) (1) (1) Total hardness (TH) mg/l CaCO (2) (2) 160 Temporary hardness mg/l CaCO 3 60 (3) (3) 100 Iron + manganese mg/l Fe+Mn = 0,2 = 0,2 Chlorides mg/l Cl- = 30 = 20 Silica mg/l SiO 2 = 20 = 20 Residual chlorine mg/l Cl 2 = 0,2 = 0,2 Calcium sulphate mg/l CaSO 4 = 100 = 60 Metal contamination mg/l Dissolvents, thinners, detergents, lubricants mg/l (1) = General values, depending on specific conductivity: C R 0,65 x σr,20 C; R 180 σr,20 C (2) = Not below 200 % of chloride content in mg/l Cl (3) = Not below 300 % of chloride content in mg/l Cl Tab. 6-5 PR GB Subject to modifications R3-11/

64 Medium Connections 6.5 Connecting condensate drain Drainage stack Fig. 6-6: Air break Drip tray Air handling unit Condensate humidifer drain Condensate drain The following should be considered during installation: Drainpipe runs shall be 22 mm OD or larger of water carrying quality of either copper or high temperature rigid plastic and should be adequately supported at regular intervals and have a slope of at least 2 % to ensure drainage. If the run is long and has a number of bends, the tube should be adequately sized and suitable cleaning (rodding) eyes installed at bends. If an air handling unit is fitted with a humidifier, drain pipework must be designed as temperature-proof to withstand up to 100 C. Upon completion of the installation, drain pipework should be leak tested. Depending on unit type, condensate traps may be in-built into the unit or the pipework may be provided loose - review unit design before completing installation. Condensate trap must be filled with water prior to commissioning and after long inactive periods. Electrically conductive drain pipework should be earthed at a point adjacent to the unit. NOTE! Some units will have two separate drains to connect (humidifier/condensate). NOTICE Local and regional legislation will require a minimum quality standard for drainage. Ensure the drainage system is reviewed during installation and assessed for possible issues, such as, blockage, overflow, contamination and Legionella. NOTE! Direct connection to a waste network is not allowed. Ensure drain has an air break fitted as shown in Fig PR GB Subject to modifications R3-11/2015

65 Medium Connections 6.6 Connecting water pipework Mechanical connections shall only be carried out by qualified licensed staff or other individuals with professional training and experience in the relevant accident prevention regulations. Chilled water pipework connections are placed at the bottom of the unit and are terminated with flanges, BSP connectors or just copper tubes (solder connection). Please refer to the unit dimensional drawing. When connecting: Entire chilled water circuit must be designed and installed to national and local standards and regulations. Piping and pump must be properly sized to meet the design volume flow. Non-compliance can cause operational malfunctions. All chilled water and dry-cooler water pipework must be vapour sealed and insulated to avoid condensation and capacity losses. The exterior surface of steel piping must be protected against corrosion using protective paint. Hydraulic devices such as solenoid valves, modulating valves or hand shut off valves may cause hydraulic hammer. This condition should be avoided. Beware of any residual glycol solution that may be left in the hydraulic circuit following testing. Residual glycol solution must be disposed of in an environmentally-friendly manner. Whenever possible it is recommended that "reverse return" piping (Tichelmann system) be used for multiple installations to ensure an easily balanced system. Regulating valves (preferably with pressure test points for measurement of volume flow) should be used before each unit to enable balancing of water flow rates. This regulating valve should be installed before each unit. NOTICE The chilled water circuit must be protected from fouling, freezing or solid materials. Failure to do so may result in poor performance or system failure. Install at least 1 water strainer per hydraulic circuit Provide frost protection though glycol or trace heating on external pipework Chemically treat condenser water served by an open evaporative cooling tower. Ensure filtration of solid materials within the circuit We recommend using a plate heat exchanger for system separation. Separate isolating valves should be provided at all equipment to enable servicing to be carried out without draining the water circuit system. Thermometers and pressure gauge test points should be located in supply and return lines of air handling units, heat rejection unit or chillers for commissioning and normal service checks. All high points and coils of the water circuit must be provided with vent cocks to enable system venting to prevent air locks. Your unit is already provided with a vent at the top of the coil. All coils and low points of the water circuit must be provided with drain cocks to enable complete draining. Pipe expansion and contraction should be allowed for by the installation of expansion bellows and loops (where necessary). A closed type expansion tank must be provided for the hydraulic system. Pipework must be properly cleaned and flushed. Pressurisation may be required to ensure a static head pressure is always available to protect the circulation pump from cavitation. PR GB Subject to modifications R3-11/

66 Medium Connections AIR HANDLING UNIT CASING RECOMMENDED CHILLED WATER RETURN TO CHILLED WATER MAIN/CHILLER M EXPANSION TANK HUM RECOMMENDED WATER FILL CONDENSATE TRAY/DRAIN CHILLED WATER SUPPLY FROM CHILLED WATER MAIN/CHILLER CONDENSATE / HUMIDIFIER DRAIN HUMIDIFIER WATER SUPPLY (IF FITTED) LINE TYPES: CHILLED WATER SUPPLY CHILLED WATER RETURN CONDENSATE / HUMIDIFIER DRAIN P/W TO EXPANSION VESSEL UNIT ON SITE Fig. 6-7: Hydraulic circuit example 66 PR GB Subject to modifications R3-11/2015

67 Medium Connections Water quality Recommendation on water quality for chilled, warm and condensing water circuits/heat exchanger: Parameter Unit Value ph-value (at 20 C) Conductivity (at 20 C) μs/cm < 700 Dissolved solid materials (cr) O 2 mg/l < 0.1 Total hardness (TH) dh 1-15 Dissolved sulphur S not detectable Sodium Na + mg/l < 100 Iron Fe 2+, Fe 3+ mg/l < 0.1 Manganese Mn 2+ mg/l < 0.05 Ammonium content + NH 4 mg/l < 0.1 Chloride Cl - mg/l < 100 Sulphate 2- SO 4 mg/l < 50 Nitrite - NO 2 mg/l < 50 Nitrate - NO 3 mg/l < 50 Tab. 6-6 A good water quality e.g. salt and lime free drinking water considerably increases the service life and efficiency of the unit and the connected secondary system. Check the limit values in the table once a year to avoid damage to the hydraulic system components Glycols Glycols and other anti-freeze materials can be harmful for humans and animals. Prior to use, refer to the supplier's Material Safety Data Sheet (MSDS). If ingested, seek urgent medical help. NOTE! The following recommendations are based on using the brands Antifrogen N for ethylene glycol and Antifrogen L for propylene glycol. Other suppliers and variety may have different properties or hazard warnings. Always refer to the supplier's information and the MSDS. Water-glycol mixtures have different thermodynamic and physical properties to wateronly chilled water systems. If glycol is mixed with a medium, the resultant mixture has: Lower specific heat capacity Higher viscosity Increase flow rate Increased pressure drops Increased power and current consumption of a pump Lower cooling capacity Larger thermal expansion when compared with water-only PR GB Subject to modifications R3-11/

68 Medium Connections When using glycol: Water-glycol mixture does not have a burst effect starting from frost resistance of - 20 C, as slush ice forms when the mixture is cooled below the freezing point. Use only one type of glycol, do not mix different types. Only charge the system with a prepared water-glycol mixture. Do not use Teflon seals if using water-glycol mixtures. Add glycol concentration to match the ambient temperatures to ensure energy consumption of the pump is not excessively increased. Once a system is filled, always double check the water-glycol concentrations. Minimum concentrations to prevent corrosion: Ethylene glycol = 20% by volume Propylene glycol = 25% by volume. NOTICE Excessive volumes of glycol within a chilled water system can result in poor heat transfer, increased viscosity and possible damage to pumps and valves. Glycol content must be less than 50% of total system content Connecting chilled water pipework NOTICE Incorrect fitting of water inlet and outlet connections can result in leaks and cooling capacity reduction. Counter hold connection fittings to prevent damage. We recommend using a pipe wrench. Access to water pipe connections can sometimes be difficult if there is no side access. The procedure to remove indoor fans to allow easier access to the connections is in chapter NOTE! There are three different available connections depending on the size of the equipment (see unit type code) 'BSP pipework connections' 'Flange pipework connections' 'Solder connections' Connect the piping system, to the chilled water inlet/outlet in accordance with best practice and conforming to and local and national regulations. 68 PR GB Subject to modifications R3-11/2015

69 Medium Connections Hot water heating (optional) The L.P.H.W. (low pressure hot water) coil is fitted with a modulating three port valve, which is wired and fitted within the unit casing. It is important to consider the fitting of commissioning sets in the supply/return pipework to allow accurate water measurements and flow adjustments. These should be supplied and fitted in accordance with the manufacturer's recommendations. The installation of the hot water pipework is similar to that of the chilled water pipework (chapter 6.6.3). PR GB Subject to modifications R3-11/

70 Electrical Connections 7 Electrical Connections When making an electrical installation, the installer must: be qualified and licensed according to local and regional regulation. Observe regulation relating to electrical power supply for the installation region Observe the Low Voltage Directive 2014/35/EU Provide potential equalisation Equipped, and any connected component, must be wired with an earth connection. Unmade or partly made electrical connections have a high hazard of creating an electrical potential on other materials. This can lead to death or serious injury. When installing electrical connections: Ensure all power supplies are disconnected including existing connections and power to new connections to be made Ensure any power supply cannot be inadvertently energised by 'locking' the power supply. NOTICE The electrical wiring must be installed fully and correctly. Failure to do so may result in damage to components and failure to operate. Always refer to the 'unit-specific' wiring diagram. Never connect multiple units to the same mains power supply. Failure to follow these instructions can invalidate warranty. 7.1 Requirements Before making electrical connections, check the following: The mains power supply properties comply with EN :2006+A1:2009 and the power requirements of the unit. Mains power supply voltage tolerance should not exceed ± 10% with a maximum phase difference of 3%. NOTE! We recommend installing power surge protection devices in areas of poor quality electrical supply. 70 PR GB Subject to modifications R3-11/2015

71 Electrical Connections 7.2 Connecting mains power supply Cable requirements A suitable 3-phase mains supply (with earth and neutral) shall be available to connect the unit (voltage and frequency must be according to the unit identification plate). The power supply line must be equipped with necessary protective devices; in particular, fuses must be of type D Electrical protection requirements The pre-fuse size should be determined on the basis of the wiring diagram or unit identification plate and must not exceed the size specified in the above-mentioned documents. For further information contact your local sales office Cable connection Connect the main power supply cable to the isolator provided within the unit. ALWAYS refer to electric wiring diagram supplied with the unit. NOTE! When connecting the supply voltage, make sure to observe the clockwise rotating direction! If the rotation direction is incorrect, an adjustment shall be performed by changing the phases using the main connection of the unit. Change the phase sequence of the power supply lines through other. Never change the wiring in the unit control cabinet. NOTE! If NO door interlocked isolator is fitted to the unit, a multi-core cable must be used for unit power (to avoid cable breaks by the hinged cabinets) and a means of isolation must be provided meet country specific regulations. Always refer to local and country specific electrical regulations when installing power supplies. A maximum distance of 1m from the unit is recommended. If the unit is supplied with an "Automatic Transfer Switch (Dual Power Supply)", this will be in a different location to the isolator Cable routing inside unit units are designed for cable entry from the BOTTOM of the unit. Secure any interconnecting cables within the unit and ensure that the cables cannot make contact with the fan or any hot components. Do not remove any unused rubber glands or blanking plugs. Do NOT drill any holes in the top panels of ANY electrical cabinets. Cable routing must consider that some electrical panels can pivot on hinges. PR GB Subject to modifications R3-11/

72 Electrical Connections 7.3 Connecting outdoor unit NOTE! We STRONGLY recommend that the outdoor unit should be connected to the indoor unit for its power supply A-Version Condensers (DMOUCD) that are supplied with A-Version units are provided with their OWN SEPARATE ISOLATOR. For condensers, the following power and controls layouts are possible: Fig. 7-1: EC fan installation 1 Condenser 2 Condenser Control Power Control Power AC Fans Not Required 2 Core + Earth Not Required AC fans with Winter Kit Not Required 3 Core + Earth Not Required 2 Core + Earth Separate Power** 3 Core + Earth Separate Power** EC Fans* 2 Core Screened 3 Core + Earth 2 Core Screened 3 Core + Earth EC Fans with Winter Kit* 2 Core Screened 4 Core + Earth 2 Core Screened 4 Core + Earth * Not available in size 008 ** For AC units, Fig. 7-1 does not apply. Power cables must be installed for each condenser and connected to the indoor unit separately. We recommend any 2 core screened data cable for control wiring, for example: Beldon 8761 Alpha 2401C BICCH PR GB Subject to modifications R3-11/2015

73 Electrical Connections X-Version & DENCO-OfficeCool H-Version Fig. 7-2: Note 1: External isolator provided by others. Power Control (24 VDC) 1 Phase Power Supply 2 Core + Earth 3 Core + Earth 3 Phase Power Supply 4 Core + Earth 3 Core + Earth Tab. 7-1 NOTE! Power supply is dependent on outdoor unit's size. See electrical drawing for details. X-Version and DENCO-OfficeCool units are provided with PAC interface control boards to allow for control of condensing units. If 2 outdoor units are required, 2 boards will be provided. Designated terminal blocks are available within the controls cabinet for connecting of the outdoor condensing unit for power supply. For further details please see the unit specific electrical contract drawing. PR GB Subject to modifications R3-11/

74 Electrical Connections 7.4 Connecting signal cabling NOTE! This chapter is for C5-12 controls only. NOTE! For all electric connections ensure that control and safety signals (24V AC) are run in a separate cable to the mains power cable (e.g. 400V AC/230V AC). Where power and signal/control cables have to run together, then a minimum gap of 30 mm between each category is to be maintained. Ideally, power and signal/control cables should never cross, but if unavoidable, ensure that they cross at Signal cable installation Maximum cable length: Minimum cable cross-section: 100 m 1.5 mm 2 units are designed for cable entry from the BOTTOM of the unit. Secure any interconnecting cables within the unit and ensure that the cables cannot make contact with the fan or any hot components. Do not remove any unused rubber glands or blanking plugs. Do NOT drill any holes in the top panels of ANY electrical cabinets. Cable routing must consider that some electrical panels can rotate on hinges. Signal cables must enter the controls cabinet at the side of the cabinet, through the rubber grommets provided Remote display For a remote/dual display, provided with a unit, the electrical requirements are: 2 core screen cable for data signal to the unit's C5-12 controller A 24V AC power source (this can be from the unit) The remote display can be installed up to 50m away from the unit. In all installations, consider the effect of signal attenuation and voltage drop. 74 PR GB Subject to modifications R3-11/2015

75 Electrical Connections Unit networking When multiple are located within the same cold space, it is best practice to set them up in a network. Creating a network has the advantages of being able to perform sensor averaging or rotating standby units. Details of how to network your units are available in the electrical drawing provided with the unit and also within the Controls Manual. NOTE! If networking multiple units together it is strongly recommended that this is carried out by an experienced DencoHappel engineer due to its complex nature. Your local office can help you arrange this Network wiring Up to a maximum of 15 units on the network Unit 1 Unit 2 Unit 8 Fig. 7-3 A recommended cable specification to use for the network wiring is 22 AWG (0.326 mm²) stranded conductors, polyethylene insulation, twisted pair with 22 AWG (0.326 mm²) drain wire and aluminium foil outer shield, covered in a PVC jacket. Examples of this style of cable are: Beldon 8761 Alpha 2401C BICC H8082 PR GB Subject to modifications R3-11/

76 Electrical Connections 7.5 Customer terminals on C5-12 unit controller Unit Network/Remote Display/Unit Display Air intake sensor Air discharge sensor C5-12 CONTROLLER TERMINALS Serial Card Interface Card (Optional) CUSTOMER TERMINAL BLOCKS Remote contact on/off * Emergency off (Fire Alarm) * Critical Alarm # Maintenance Alarm # Condensate Pump * (Optional) Run status # (Optional) Terminals Notes 6 5 Remote On/Off for activating and deactivating the unit via a normally open volt free contact by others. 3 5 Emergency Off, a volt free contact (supplied by others) opening, deactivates the unit (e.g. used in a fire alarm system) The unit's critical alarm indication e.g. HP/LP, Airflow, High Temperature The unit's maintenance alarm indication e.g. Dirty Filter, humidifier Alarm contact of condensate pump (optional accessory) Indication of unit s operation (i.e. fans enabled) +VDC GND U1 U2 Air intake sensor +VDC GND U3 U8 Air discharge sensor (optional, only if the item is fitted). Serial Card Interface cards for building management (optional). Rx-/Tx- - Rx+/Tx+ - GND Unit s network terminals for connecting multiple units. Displays already connected to these terminals Cabling provided by others. # Volt free contacts (voltage or signal to be provided by others). * On-site volt free contacts must be provided (if function is required remove jumper). Tab. 7-2 NOTICE Wiring that is not isolated from active (live) components of non-selv or non- PELV circuits may induce power than can cause damage to control boards. This may cause poor operation or system failure. Use double or reinforce insulation on electrical wiring external to the unit. 76 PR GB Subject to modifications R3-11/2015

77 Commissioning 8 Commissioning 8.1 Requirements NOTICE READ ALL OF THIS CHAPTER BEFORE STARTING ANY WORK. Different options can require different commissioning procedures (e.g. winter kit). This chapter applies to initial commissioning as well as re-commissioning due to extended shut down periods or relocation. Only R410A can be used in systems. Refrigerants poses hazardous risks: Refrigerant cylinders can be heavy. Refrigerant cylinders can have unstable centres of gravity. Refrigerants are stored or used at high pressures. Systems using refrigerants can be operating with very high and very low temperatures. Refrigerant released into an enclosed space could cause asphyxiation and death. During commissioning: Ensure a full risk assessment has been conducted. Ensure only qualified individuals conduct work on the system. Establish an exclusion zone from the system for non-essential individuals. Ensure that the room is well ventilated Commissioning report A sample of the Commissioning Report is available in this manual (chapter 13.3) An electronic version can be provided upon request The report must be completed, during commissioning, by a Service representative or an appointed contractor Once completed, the report MUST be sent to your sales/service representative Failure to send the completed report, may invalidate warranty PR GB Subject to modifications R3-11/

78 Commissioning Suggested equipment It is important that all equipment is safe to use, is calibrated and is portable appliance tested (PAT) where appropriate. Below is a list of recommended equipment to be able to fully commission a unit: Electrical test meter Phase rotation meter Current measuring device Airflow measuring device Digital thermometer (If humidifier is fitted) water conductivity meter Suitable R410A refrigerant gauge manifolds and gauge lines Oil pump Vacuum pump (must be able to achieve 2.66 mbar) Fresh vacuum pump oil Digital refrigerant cylinder weighing scales 8.2 Pre-commissioning procedure For all checks, we recommend following EN 378-3:2008+A1:2012. Ensure all protective clothing and equipment is worn. In particular: Suitable eye protection Suitable hand/finger protection Protective cloths for entire body including safety footwear Pre-commissioning checklist We recommend that the "Pre-Commissioning Checklist" is completed, by the installer/contractor, prior to the commissioning engineer attending site. A copy of this checklist can be found in chapter Please present this completed checklist to the commissioning engineer on or before their arrival. If the site does not meet the requirements or information required in the checklist, the engineer may be unable to conduct the commissioning and may abort the commissioning. 78 PR GB Subject to modifications R3-11/2015

79 Commissioning General checks AFTER all installation work has been completed and the pre-commissioning checklist has been completed, the following checks should be completed BEFORE mains electrical supply power is applied to the unit: Documentation Check that the unit configuration (listed on the serial plate) matches what has been ordered Check the "Pre-Commissioning Checklist" (chapter 13.1) has been completed and has been filed appropriately Check that a copy of this manual is available Check a copy of the electrical drawings/wiring diagrams are available unit Check the unit internally and externally for any damage Photograph and record any damage (including shipping damage) and inform the end user Check the unit has the minimum clearances available (chapter 5.1) Check that the fans inside the unit can rotate freely Check the unit is mounted suitably within the room (e.g. if on a base frame) Check that the entire heat exchanger is protected by the air filter(s) (If fitted) check the humidifier is supplied with water and that the earth bonding device is secured to the incoming pipework Check that the condensate drain is connected correctly and water can drain freely, for both coil condensate and humidifier (if fitted) Room Check interconnecting services, Mechanical and Electrical, have been installed as per requirements in chapter 6 & 7 respectively Check the dimensions of raised floor is sufficient for airflow (if used) Check floor tiles do not prevent the opening of panels and doors (If used) check all dampers (including fire protection) are fully open (For humidity control) check the control space/installation room is vapour sealed and fresh air is not supplied excessively Outdoor unit Check the unit is installed with appropriate clearances and the fans and coils are free to operate (chapter 5.6.4) (If powered from indoor unit) check the unit's isolator is set to the 'ON' position If separates power supply, leave isolator in the OFF position PR GB Subject to modifications R3-11/

80 Commissioning Checking refrigerant circuits (A-Version, X-Version & H-Version) Check the oil traps are installed and to specifications (chapter 6.2.9) Check that pipework is sized correctly and within the limits (e.g. length between indoor and outdoor unit) (chapter 5.6.2) Check appropriate insulation has been added to pipework Check pipework for cleanliness and tidiness Checking water circuits (C-Version, O-Version, CombiCool, Hot Water Heating) Check the hydraulic connections have been made correctly Check the hydraulic circuit is fitted with a water filter Check the water pipework is clean and has been flushed Check all shut off valves within the unit are open Check all filling valves and vent cocks are closed Check any water circuit safety devices for proper function Checking electrical connections Untested or unused electrical systems poses higher risks of faults. Unsafe operation on these systems can lead to death or serious injury. Before conducting the following checks: Ensure all electrical connections are isolated and interlocked to prevent accidental activation Check the unit is voltage free Switch off all circuit breakers (MCBs) NOTE! When commissioning a unit with the option: "Automatic Transfer Switch (Dual Power Supply)" it is important to check the electrical supply of BOTH the incoming supplies. Both electrical supplies must match the requirements of the unit nameplate. Also the phase rotation of both incoming supplies must be checked. Select a primary supply using the supplied key and test that the dual power supply changes over when the primary supply is lost. Then select the other supply to be the primary power supply and carry out the test again. Check any electrical installation has been conducted as per the unit specific contract electrical drawing Check all electrical connections are tight Check earth conductors are connected correctly and the earth terminals are secured tightly Check any signal and mains power cables are segregated Check inside of the control cabinet for loose connections or damaged components Tighten all supply terminals in the motor terminal clamps Ensure temperature and humidity sensors are adequately protected by their enclosures ONLY when all the above checks been completed can the unit's circuit breakers (MCBs) can be set to the ON position. 80 PR GB Subject to modifications R3-11/2015

81 Commissioning Initial charge for refrigerant circuits NOTE! It is recommended a triple evacuation is thoroughly conducted. If the system cannot be evacuated to the levels defined below, you must NOT add any refrigerant and the system installation must be checked and corrected. Once completed, re-conduct the procedure and ensure requirements are achieved. Incorrect or inadequate evacuation resulting in moisture or contamination within the system will void warranty. NOTE! No refrigerant commissioning can commence until the commissioning engineer has reviewed the 'Pressure Test Certificate' (chapter 13.1) and ascertained what gas and pressure the system is at. NOTE! Any work on the refrigerant system must only be carried out by suitably trained and qualified personnel. Refer to local and national regulations and guidelines. The recommended procedure requires a triple evacuation, whilst adding any addition oil before adding the initial charge. It is as follows: Initial evacuation Connect the service manifolds to the system in an appropriate and safe manner. Make sure that all system valves are open (i.e. shut off valves) If the system contains Oxygen-Free Nitrogen (OFN), carefully purge the gas to atmosphere in accordance with safe working practices Connect the vacuum pump to the service manifolds Achieve a vacuum of at least two Torr (2.6 mbar) Adding oil If the interconnecting pipe length (one-way) is greater than 20 metres, it is likely that more oil would be required for the system. Your local representative can advise on the amount of oil required (if supplied with the required information). Add the required oil to the system (under vacuum) via the discharge line. NOTICE Excessive oil added to a stationary compressor may cause a hydraulic lock and damage the unit during start up. This will void warranty. During evacuation, oil must be added into the discharge line. Non-return valves are installed in the compressor discharge line to prevent the oil travelling against the flow direction (into the compressor). PR GB Subject to modifications R3-11/

82 Commissioning NOTE! units can contain two different types of compressors each with their own oil type. Please follow the below recommendations: A-Version - Size FV50S Emkarate RL68H Mobil Arctic EAL68 A-Version - Size POE 160SZ Emkarate RL32H Alternative oils are compatible with the original oil type used, therefore these can be mixed and alternatives can be used as "top up". For X-Version & H-Version units, refer to the separate condensing unit installation manual for compatible oil types. Emkarate Typical Properties Property and Procedure RL32H RL68H 40 C (cst), ASTM D C (cst), ASTM D Typical SUS 100 F Viscosity Index, ASTM D Pour Point ( C), ASTM D C (g/ml), ASTM D Flash Point (COC) ( C), ASTM D Acid Value (mgkoh/g), ASTM D-974 modified 0.02 <0.02 Water Content (ppm), ASTM E <50 <50 Refractive 28 C Tab nd and 3 rd vacuum Shut off the vacuum pump and add oxygen free nitrogen to a system pressure of 1bar. Safely release the gas to just above atmospheric pressure Evacuate the system to at least 2 Torr (2.6 mbar) Again, shut off the vacuum pump and add oxygen free nitrogen to a system pressure of 1 bar Safely release the gas to just above atmospheric pressure and once again evacuate the system to at least 2 Torr (2.6 mbar) Once achieved, turn the vacuum pump off and observe that the system maintains a vacuum for at least 30 minutes to prove the tightness of the circuit. On completion of evacuation, the gauge manifold should be closed off and isolated from the vacuum pump, then connected to a refrigerant cylinder, the gauge lines should be carefully purged of any air. 82 PR GB Subject to modifications R3-11/2015

83 Commissioning Adding refrigerant The initial 'charge' of refrigerant that is added to the system is not an exact measure, but a volume of refrigerant to enable the system to start initially. This first charge should always go into the liquid line of the unit and be approximately 75% of the planned charge amount. Your sales/support representative should be able to give you an estimate of total system charge (if supplied with the required information). Add an 'inital-charge' of refrigerant R410A until 'high' and 'low' side pressures are equal. Be careful that no liquid refrigerant is injected into the compressors. Close off the manifold valves and record the quantity of refrigerant added. NOTE! It is important that the volume of refrigerant added during the initial charge is recorded accurately. When commissioning it is a LEGAL REQUIREMENT for the total refrigerant weight to be added to the unit's nameplate. Ensure the pre-charge measurement is accurate and this information is provided to the commissioning engineer. 8.3 Commissioning procedure NOTE! Due to the complex nature of the product, we strongly recommend that a DencoHappel commissioning engineer is employed to carry out the commissioning procedure. Contact your local representative for assistance with this Room considerations During commissioning, it is important to understand the heat load and the ambient temperature in relation to: Initial design conditions Current conditions (during commissioning) (Possible) future conditions For example, attempting to commission a A-Version unit in a room with no heat source is difficult, as you would not be able to give a consistent operation to observe refrigerant charge. Alternatively, commissioning a unit on a cold day could result in lower condensing temperatures, which may cause over-charging of a unit. Wherever possible, attempt to recreate the required conditions needed by the end user, so that the unit is configured for the appropriate operating range. Always consider that the ambient temperature on initial design conditions, may only be 'peak' temperature and that the unit will probably be operating at lower temperatures for a significant percentage of operation. PR GB Subject to modifications R3-11/

84 Commissioning Calibration of refrigeration devices Before finishing commissioning, but after the initial charge has been added, various refrigeration devices/sensors must be calibrated to ensure accurate operations. This will require the controller/display to be enabled, but the cooling circuit must remain disabled (i.e. compressors are off). This can be achieved by the controller or through disabling MCBs. These devices and the suitable commissioning devices are as follows: Suction transducer(s) with a refrigeration gauge Suction pipe temperature probe(s) with a temperature touch probe Discharge transducer with a refrigeration gauge Discharge pipe temperature probe with a temperature touch probe NOTICE Refrigeration devices that are not calibrated can result in safety and protection features being disabled. Failure to calibrate during commissioning will void the warranty Enabling the unit NOTE! For chilled water units, review and complete requirements of chapter before enabling the unit. Once the electric power supply is connected and energised, there is a risk of electric shock during commissioning. Also inverter circuits may store electrical energy for some time after isolation. Once isolated, allow time for stored energy to fully decay before operating on inverter based circuits. With the initial charge added and the devices calibrated the unit can be enabled by the following order: Enable any isolator or circuit breakers in the main power distribution board (both boards for units with dual power supply) Ensure the outdoor unit's isolator is set to 'ON' (if applicable) Enable any 'in-line' isolation for the unit Set the door interlock isolator (if fitted) to the 'ON' position Wait 1-2 minutes for the unit to start up When display is active, press the 'Enable' button in the bottom left corner of the display The unit will now being to operate and control to the default settings in the C5-12 controller. 84 PR GB Subject to modifications R3-11/2015

85 Commissioning Calibration of control sensors Recommendation: If suitable cooling demand can be provided to the unit from within the controlled space during commissioning, then at this point in the procedure would be appropriate to change the set-point and other variables to the requirements of the end-user. Details of how to change values in the C5-12 controller are available in the controls manual. Once the unit is enabled and operating, calibration of control sensors is vital to ensuring an accurate and efficient operation of your unit. These sensors include (but are not limited to): Control temperature and humidity sensors all fitted within the unit and/or remotely Pipework pressure and temperature sensors Floor void air pressure control (APS) sensors Ambient temperature sensor These sensors must be calibrated accurately to allow for a successful commission to be completed. Failure to calibrate these sensors may lead to inefficient operation or possibly alarms and non-operation Commissioning refrigerant circuits NOTE! When commissioning a refrigerant circuit for a unit it is important that the compressors are operating at a high speed. Once the high speed is achieved, time should be allowed for the system to stabilise. Consideration and Targets Below are the commissioning targets for an optimum system charge: Superheat: 7-9 K (Default set point = 8 K) Sub-cooling: 5-8 K Discharge superheat: Compressor(s) at Low Speeds (< 50 RPS) = 15-25K Compressor(s) at High Speeds (> 50 RPS) = 25-35K NOTE! If fitted, it is important to consider the state of BOTH compressor speeds to understand the unit's operating level. For example, an inverter compressor may be operating at low speeds (< 50 RPS), but if the other compressor is active then the unit will be operating at above 50% capacity. Compressor speeds can be viewed in the 'Engineering level' of the C5-12 controller display. All 3 of these variables must be considered together for a successful commissioning. You must also consider/witness what these variables will be at different operating conditions (e.g. low demand vs high demand). PR GB Subject to modifications R3-11/

86 Commissioning Procedure With a stable system, additional refrigerant can be progressively added to the circuit to bring the system to the required charge. When adding refrigerant, the following procedure and advice applies: Refrigerant should be added to the suction line as liquid A metering valve on a set of manifold gauges should be used Any refrigerant should be added as lightly/slowly as possible NOTICE Large concentration of liquid refrigerant entering the compressor can cause 'hydraulic lock' and permanently damage the compressor. Add refrigerant in no more than 0.5 kg additions. Allow the system to stabilise after each addition. It may take several minutes for the system to stabilise. Adding refrigerant too quickly can cause an 'over-charged' condition. To stop the charging, close the LP manifold valve Observe the state of the liquid in the Electronic Expansion Valve (EEV) sight glass Wait several minutes for the system to settle before proceeding further Observe the system to see if the unit charge is suitable and effective Observe superheat, sub-cooling and discharge superheat against targets listed earlier in this chapter If fitted/required, adjust the fan speed controller settings to modify the sub cooling settings If overcharge, remove refrigerant from system NOTICE Refrigerant is damaging to the environment. Never discharge refrigerant to the atmosphere. Recover any refrigerant and dispose of according to national/regional requirements. If refrigerant circuit charge is to your satisfaction, re-perform the 'Calibration of refrigeration devices' (chapter 8.3.2) to ensure proper operation of control devices. If good operation is observed, record the total charge of the system, check the oil and perform the safety procedure as detailed in the next sections. 86 PR GB Subject to modifications R3-11/2015

87 Commissioning Oil level check Size Size Before the system can be left as fully charged, the oil level within the system must be checked a final time. There are 2 different procedures depending upon your size of unit: For these sized units there is no oil level sight glass available, therefore the temperature of the oil reservoir within the compressor must be taken. With stable running conditions, the reservoir temperature must be 10 K more than the running evaporating temperature for example: If evaporating temperature equals 10 C then the oil reservoir temperature must be greater than 20 C. In these units, an oil balance sight glass is fitted, allowing for visual inspection of the system. There are also sight glasses on each compressor which should be reviewed. The below table describes what should be observed in the sight glass when at optimum conditions: Unit stopped * For this scenario, this must be observed in the sight glass for the fixed speed compressor. If either scenario requires additional 'top-up' of oil, ensure this is conducted whilst the unit is off and deactivated. Function Test of Safety Device(s) Both compressors operating Size 092 ½ to ¾ full ¼ to ½ full Size to ¼ full ½ full * Tab. 8-2 units are fitted with High Pressure (HP) switch(s) to mechanically protect the refrigeration circuit. After charging, these MUST BE TESTED. For details of the procedure, please refer to the controls manual. This test requires system pressure to be continually increased to check safety devices of the system. If the devices fail the test and appropriate actions are not taken to stop further pressure increases, there is danger of pipework ruptures and catastrophic failures. Failure to follow recommendations may lead to death or serious injury. Do not allow the system pressures to rise above the Maximum Operating Pressure (MOP) stated on the unit's nameplate. If the High Pressure (HP) switch fails to deactivate the compressors and the pressure continues to rise; DEACTIVATE THE UNIT IMMEDIATELY (for example, isolate the power supply). Before re-enabling the unit; Mechanically measure the pressure within the system Wait until the pressures have reduced to normal standby conditions Ensure the condenser fan MCB(s) have been re-enabled. PR GB Subject to modifications R3-11/

88 Commissioning Commissioning chilled water circuits The following procedure applies to any water circuit used within a system (C-Version, CombiCool circuit, O-Version etc). Procedure Check for an established water flow Check that any temperature sensors are securely fastened to the correct pipework Take readings of water temperature sensors and compare these values with the values displayed on the C5-12 controller: all probes and sensors MUST be calibrated Check for correct rotation in the water pump and any air within the water system is being removed by the pump or by air purge valves (If applicable) add, as required, pressure to any expansion vessels (If applicable) sample and check Glycol concentration (more details below) Record all details to the commissioning report Glycol and corrosion inhibitors We recommend using a hand held refractometer (for example Kittiwake, RHA-21ATC) for measuring glycol concentrations. It is able to give accurate readings from a very small sample of fluid and covers both Ethylene Glycol and Propylene Glycol. It is important to ascertain the quality and quantity of any glycol and corrosion inhibitors (see chapter 'Glycols' on page 67). Pumps must never have a negative pressure or vacuum on their inlet. Automotive inhibitors and anti-freeze MUST NOT BE USED as nearly all automotive anti-freeze contains silicate-based inhibitors, which gel and foul, coating heat exchanger surfaces and reducing energy efficiency. These silicates have also been shown to significantly reduce the lifespan of pump seals. NOTICE Low levels of glycol or inhibitors can cause corrosion of steel or iron components. Ensure minimum concentration of inhibitor is above 20%. Coolant concentrations are determined by first deciding what freeze and/or burst protection is appropriate for the application, based on operating temperatures or ambient temperatures. Fig. 8-1: Kittiwake hand held refractometer Freeze protection Burst protection This is imperative when a system requires pumping. It is achieved when glycol concentrations in a system are sufficient to prevent ice crystals from forming when the fluid experiences the lowest temperature for its application. This is achieved when the concentration of glycol in a system is high enough to prevent the fluid from freezing solid. The glycol concentration will be lower than that of a 'Freeze Protected' system, therefore it can form ice crystals at low temperatures (being a semifluid state) and will no longer be pump-able. When ice crystals being to form the solution will expand. 88 PR GB Subject to modifications R3-11/2015

89 Commissioning The table refers to general percentage concentration of Ethylene Glycol. Always contact the manufacturer for specific values for their variant of Glycol: Tab. 8-3 Temperature Percentage concentration needed for (%): C Freeze Protection Burst Protection Ethylene glycol gives added protection against system damage from bursting: On freezing water expands about 9% This volume change may rupture piping and cause catastrophic system failure Adding ethylene glycol significantly reduces the expansion the solution upon freezing, thus reducing the likelihood of system pipes bursting The higher the ethylene glycol concentration, the less the expansion Pure ethylene glycol does not expand at all upon freezing Refer to the Tab. 8-3 for freeze and burst protection. In a system not operational in winter, it may be sufficient to choose a lower fluid concentration, one that merely protects against bursting, since some crystal formation in the fluid will not be harmful Water balancing 3 & 2-port Drive Open Drive Close Valves (DODC) Ensure the valve is '100% open' during water balancing; failure to follow this may result limited capacity of the unit To force the valve to be 100% open, use the controls to modify the set-point temperature (supply or return) so that it is below the water temperatures within the chilled water circuit 2-port Pressure Independent Control Valves (PICV) NOTE! The following instructions are for 2-port PICV valves used with C5-12 controllers in units. For all other configurations or equipment please see separate manuals or contact your local office. PR GB Subject to modifications R3-11/

90 Commissioning To set up the maximum design chilled water flow rate, on site: The unit must be powered on, pre-commissioned and running under automatic control The chilled water pump must be operating to provide pressure differential across the unit of 100 kpa (minimum 50 kpa, maximum 350 kpa) Force the chilled water valve to 100% open by reducing the set-point temperature (supply or return) to below the water temperatures within the chilled water circuit Measure the chilled water flow rate using a hydronic manometer with the hoses connected to the local orifice plate in the external chilled water pipework supplying the unit (supplied/fitted by others) To adjust the maximum chilled water flow rate to design conditions, adjust the setting PIC Valve Max Value % to achieve the design maximum flow rate (see the C5-12 controller manual for instructions on how to do this) Record the maximum flow rate and PIC Valve Max Value % Variances for winter kit Units operating in low ambient temperatures may be fitted with a winter kit. The system operates as a 'liquid backup'. At high ambient temperatures, the system regulates so that liquid refrigerant is stored in the liquid receiver. At low ambient temperatures liquid refrigerant is stored/backed-up in the condenser coil instead. The components of the winter kit are: Electronic Regulation Valves (ERV) Condenser fans Liquid receiver with trace heating Control circuit transformer for controlling the ERVs (Evolution Driver) Control panel heater Mains Circuit Breaker (MCB) in the indoor units electrical panel (power supply to the winter kit) Commissioning engineers must observe the good practices with the following additional requirements for winter kits. 90 PR GB Subject to modifications R3-11/2015

91 Commissioning Procedure 1. Calculate the 'system refrigerant'. This is the refrigerant required to charge a standard system without a winter kit option (indoor/outdoor unit and interconnecting pipework). 2. Calculate the refrigerant required to fill the liquid receiver to 80% (see Tab. 8-4). NOTICE Overfilling of liquid receivers can result in poor system performance or failure. The liquid receiver should never exceed 80% full. Condenser Size Liquid Receiver 100% Capacity Litres 100% Filled R410A kg 80% Filled R410A kg DMOUCD DMOUCD DMOUCD DMOUCD DMOUCD DMOUCD DMOUCD Tab. 8-4 At average condensing temperatures of 41 C with 6 K sub-cooling; 35 C liquid temperatures. Density = 1 kg/l Before adding refrigerant, set the condenser fans to minimum speed and lowest pressure setting. This is to allow the liquid receiver to be assessed whilst the fans are operating. NOTICE To change the required settings for C5-12 controls, you must use the display of the unit, which requires the unit to be enabled. To perform safely you must observe the following: Enable power to the unit and set the local isolator to the 'ON' position Wait for the unit to finish its start-up procedure DO NOT press the 'Enable' button on the home screen (bottom left hand corner) Navigate to the condenser settings (Advanced Level) Modify settings as advised Navigate to the home screen Set the local isolator to the 'OFF' position and remove power from the main power distribution board The unit is now ready for charging 4. Add the initial refrigerant. ONLY add 75% of the 'system refrigerant' (excluding the liquid receiver refrigerant) should be added initially (see 'Initial charge for refrigerant circuits' chapter 8.2.6). Enable the unit and set the compressors to operating at high speed (chapter 8.3.5) Add refrigerant in amounts no larger than 0.5kg into the suction line: using the metering valve on appropriate service gauges. After each addition, allow the system to stabilise and check conditions before adding any more. Monitor the sight glass throughout the process - when flashes of liquid are observed stop adding refrigerant PR GB Subject to modifications R3-11/

92 Commissioning 5. When liquid is observed, you will find that you have not use all of the estimated refrigerant (system and liquid receiver) You will have only filled the liquid receiver to its minimum level (Fig. 8-2) Required level Level when 'liquid flashes' are observed. Fig. 8-2 Add ALL the remaining estimated refrigerant to the system to fill the liquid receiver further. 6. Once all the refrigerant has been added, the liquid receiver needs to be checked. Measure the ambient temperature on the face of the condenser coil. Take several measurements at different positions and calculate an average value. Using the average temperature, the level of the liquid receiver should match Tab. 8-5 For example; if the temperature is above 20 C, the liquid receiver should only be 80 % full (no liquid refrigerant in the condenser coil) Otherwise; if ambient temperature is 0 C on the day of commissioning, then the liquid receiver should be about 30 % full (lots of liquid refrigerant in the condenser coil) Tab. 8-5 Ambient Temperature C Liquid Receiver Fill Level % Using a touch probe on the receiver shell (under the insulation) measure every 5 to 10 mm to determine the liquid receiver fill level. If the level does not match, add/remove refrigerant to meet the values in the table. 7. Once the refrigerant level is correct, perform standard calibration checking (chapter 8.3.4). 8. The condenser fan settings should then be restored to 24 Bar and left on 'Minimum Speed' control. 92 PR GB Subject to modifications R3-11/2015

93 Commissioning Common commissioning issues If the discharge pressure is unstable, adjust the set-points and proportional bands of the condenser until the discharge pressure stabilises. The condenser(s) should be left on 'Minimum cut-off' wherever possible. If the electronic expansion valve(s) (EEV) do not open during start-up, and no alarm or status message is shown, check the EEV transducers and the temperature probe for functionality. (Size 010 to 065 units) if during charging there is an 'Overcurrent' alarm from the inverter drive, potentially too much liquid is entering the compressor. Throttle back the manifold gauge to reduce liquid entering the system. 8.4 Post-commissioning procedure Nameplate Once the commission has been successfully completed, it is a LEGAL REQUIRE- MENT that the total refrigerant charge for the whole system is written onto the unit's nameplate. You will see space for this to be written on the bottom left corner of the serial plate Saving controller settings After commissioning, we recommend that your service technician saves the unit configurations to the controller. This can allow for the system settings to be restored, back to the configuration made during commissioning. More details of this feature are available in the controller manual Commissioning report As mentioned previously, it is very important that you submit a copy of the ' Commissioning Report' (chapter 13.3) to your local sales/service representative, so that this can be retained against the project. Failure to do so may invalidate warranty Configuration of accessories Depending upon what design options have been selected, you may be required to continue with configuration of specific accessories (for example, humidifier or condensate pump). Refer to initial design selection or the serial plate within the unit to establish if all necessary parts have been commissioned and configured. NOTE! For filter switches, we recommend the following settings: G4 = 0.7mbar (70 Pa) G7 = 1.2 mbar (120 Pa) These values are based on standard pressure drops when fans operating at max velocity. Different values may be required if fans are operating at lower speeds (as alarm may not occur until fan increases speed to compensate for dirty filters). PR GB Subject to modifications R3-11/

94 Operation 9 Operation More comprehensive details and explanation on the control and regulation of the units are available in Controller Manual. This manual does not cover control of units that have been provided "without controls". 9.1 Requirements Prior to using a unit, a full and safe installation and commission must have been conducted by a suitably qualified personnel and a record of both processes must be stored. The commissioning report (chapter 13.3) must have been sent to your local sales office to validate warranty during operation. Before use all operators MUST be familiar with the following: The contents of this manual Safety assessment for the location where the unit is situated Location of the associated outdoor unit (if applicable) Location of power distribution board isolator Location of the mains isolator Either fitted within the door of the unit or within 1m of the unit Location of circuit breakers (MCBs) inside the unit Shut off (isolation) valves for the unit including (if applicable): Refrigerant circuit Chilled Water Circuit Hot Water Circuit Humidifier Circuit 9.2 General operation Close control units, like, are designed for continuous operation to cover the 8760 hours in a year, thus allowing constant indoor temperatures to be maintained Enabling the unit To enable the unit to operate, you must: Switch the isolator to the 'ON' position at the mains distribution board Switch the isolator to the 'ON' position on isolator fitted to the unit (or within 1 m) Switch the isolator to the 'ON' position for the outdoor unit (if applicable) Wait for the unit to begin its start-up procedure (approximately 45 seconds) Enable the unit by keyboard (see the next chapter for details) 94 PR GB Subject to modifications R3-11/2015

95 Operation The home screen (C5-12) 1: Unit ON/OFF (by keyboard) 9: Unit Number (for networking) 2: Unit Status 10: Model Reference 3: Alarms Page 11: Icon if any alarms are active 4: Unit Graphs 12: Date 5: Login 13: Unit function Icons 6: Status Information 14: Network Status 7: Current Temperature (depending on control sensor) 8: Current Humidity (depending on control sensor) 15: Time 16: Help/additional information Screen saver If you do not use the touch screen for 15 minutes, a screen saver is displayed. To turn off the screen saver simply touch the display. The screen will show a bright red alarm symbol, if the unit has an active alarm during screen saver mode Physical operation and access NOTICE During operation: Do not open any doors. Do not remove any panels of an operating unit. Do not remove any floor tiles near to the unit. Do not conduct any work above or below the unit. Do not insert any tools through any of the grilles of the unit. PR GB Subject to modifications R3-11/

96 Operation Stopping the unit units use fans which are regulated independently by the main control board. Removing guards whilst unit is operational risks death or serious injury. Inverters also store energy for a period of time after isolation. Disable the unit. Electrically isolate the unit. Wait AT LEAST 5 minutes. Once fan momentum has ceased and the inverter energy discharged, you can open the doors and conduct work. To stop the unit, simply press the ON/OFF button on the home screen. The screen will display 'UNIT OFF BY KEYBOARD' if successful Disconnecting from power supply units use fans which are regulated independently by the main control board. Removing guards whilst unit is operational risks death or serious injury. Inverters also store energy for a period of time after isolation. Disable the unit. Electrically isolate the unit. Wait AT LEAST 5 minutes. Once fan momentum has ceased and the inverter energy discharged, you can open the doors and conduct work. Having deactivated the unit (chapter 9.2.5) and waiting AT LEAST 5 MINUTES, you can disconnect the unit by: Switch the isolator to the 'OFF' position for the outdoor unit (if applicable) Switch the isolator to the 'OFF' position on isolator fitted to the unit (or within 1m) Switch the isolator to the 'OFF' position at the mains distribution board When the isolator fitted to the unit (or within 1 m) is in the OFF position, the first half of the isolator could still be live (with electrical power). To ensure safe operations, ensure that the circuit has been isolated in the OFF position at the mains distribution board and suitably locked to prevent inadvertent re-connection of electrical power. 9.3 Alarms and error messages Details and explanation of the alarms by units are available in controller manual. Chapter 11 'Fault Finding and Troubleshooting' has details of typical issues than can be encountered. NOTICE Resetting of alarms without rectifying the cause can lead to extended unit damage, which may result in the voiding of the warranty. 96 PR GB Subject to modifications R3-11/2015

97 Servicing and Maintenance 10 Servicing and Maintenance Regular preventative maintenance of your equipment is strongly recommended to ensure that it is kept in excellent operating condition. Along with equipment recommended in Chapter 2, we recommend that a protective mask is worn during service and maintenance. Review your cleaning equipment's guidelines for the required properties of your protective mask. Ensure your working area is well ventilated. Conduct your own personal risk assessment to evaluate any further requirements. NOTE! We recommend a maintenance contract with DencoHappel or an approved service company. Maintenance shall only be undertaken by authorized and fully qualified staff with the required Country specific qualifications in refrigerant handling and a sound knowledge of the operation and the dangers involved with inverter technology and other electrical services. Ensure all incoming electrical connections are isolated and cannot be inadvertently energised. Inverter technology and rotating fans required at least 5 minutes from electrically isolating the unit before any doors or panels can be removed. Units fitted with and humidifier may have hot water condensate and hot pipework/metal work Refrigeration circuits may have both very hot and very cold sections within the same system. Whilst cleaning, thin fins present a risk of cutting. Panels and doors can be heavy and present a crushing risk when being removed. Do not touch the coil with unprotected skin. Ensure doors are properly attended when being removed. Use access platforms for units that are installed above floor height. NOTICE Damaging fins or louvres during the cleaning process will reduce the unit's cooling capacity. PR GB Subject to modifications R3-11/

98 Servicing and Maintenance 10.1 Maintenance access All panels can be removed to perform maintenance. However, all main components are accessible from the front Servicing Routine, planned maintenance visits will be required throughout the year to maintain efficiency and may also be a legal requirement depending on Country specific legislation. The intervals of service will depend entirely on the operating conditions of your room. This can be as often as once per month for critical, production essential equipment. Your DencoHappel representative will be able to assist you with arranging a maintenance contract that will suit your needs. During maintenance and servicing: Do not allow the system pressures to rise above the Maximum Operating Pressure (MOP) stated on the unit's nameplate. If the High Pressure (HP) switch fails to deactivate the compressors and the pressure continues to rise; DEACTIVATE THE UNIT IMMEDIATELY (for example, isolate the power supply). Before re-enabling the unit: Mechanically measure the pressure within the system Wait until the pressures have reduced to normal standby conditions Ensure the condenser fan MCB(s) have been re-enabled. NOTE! Items of equipment attached to the refrigerant circuit, for instance the H.P. switch (Fig. 10-1), are often protected by a schrader core. If this is the case the connecting nut is painted red. If the connecting nut has no red paint then you must assume that no Schraeder core is present and therefore the whole system refrigerant charge will have to be recovered before the component can be removed Fig Example Maintenance schedule Below show an example maintenance schedule for a unit. We advised the below is the minimum requirements. Most situations will require further actions and a shorter time interval to ensure good operating conditions. After every inspection, any relevant information must be recorded into the logbook. Certain countries have specific legislation regarding record keeping (e.g. Fluorinated Greenhouse Gases Regulation (EU) No 517/2014). Please refer to chapter 10.7 'Logbook & EU Regulation' for more details. 98 PR GB Subject to modifications R3-11/2015

99 Servicing and Maintenance Interval Daily Weekly Monthly Every Three Months Every Six Months Yearly After 5 years of operation Action 1: Check for any outstanding alarms. 2: Check display for good operation. 3: Visual inspection of exterior condition of the unit. 4: Visual inspection in and around the unit for the presence of refrigerant oils, which may show signs of a leak. 1: Inspect outdoor heat exchanger for freedom of airflow. 2: Inspect gaskets, leaks, insulation, fan bearings and water drain of the unit, pay attention for any unusual noises. 1: Check cleanliness of filters inspect for break up and suitable sealing. Replace if necessary. 2: (If fitted) check cleanliness of grilles. 3: Check cleanliness both inside and outside of the unit. 1: Check that the evaporating and condensing pressures are acceptable. 2: Check safety protection features, such as low pressure and temperature alarms, operate correctly. 3: Check capacity control for correct operation and configuration. 4: Check electrical connections for tightness. Repair or replace all damaged terminals. 5: Check all component electrical currents are within acceptable limits. 6: Check refrigerant sight glass. 7: Check condensate drain for free flow and drainage. 8: Check for refrigerant leaks 1 : Inspect all accessible refrigeration pipework with an electronic leak detector paying particular attention to flexible tubes, capillary tubes etc. Check all accessible pipework fixings for tightness and security. 9: Inspect oil charges and levels to identify any loss since last inspection rectify as necessary. 10: Inspect fan touch protection devices for compliance and functionality. 11: Check operation of on-board electrode steam boiler humidifier (if fitted): Check drain down and fill function, disposal pumps and bottle current. Replace any expired bottles. 1: Check contactors for damage or eroding. 2: Check that the electrical contactor overloads functions are set correctly. 3: Check any crankcase heaters (if fitted) for correct operation. 4: Check the evaporator fans can rotate freely. 5: Check conditions of evaporator coils and clean as required. Inspect heat exchangers for free airflow, cleaned and combed where necessary. 6: If not conducted within the last 6 months; change air filters. 7: Check colour code of sight glass moisture indicator. 8: Check compressors for smooth operation. 9: Check anti-vibration mountings (outdoor unit) for damage. 10: Check pipework and insulation for damage (indoor, outdoor and interconnecting pipework). 11: The glycol content should be checked (if applicable) then adjusted and recorded as necessary (water-based circuits). 12: Check the condition of the water pipework, water volume flow, valve operation, and the cleanliness of all the strainers (water-based circuits). 13: Check the calibration and functionality of the unit controller. 14: Check casing and connected ducting for any air leakage repair where required. 15: Check room conditions required and adjust unit settings as necessary. 16: Clean unit inside and out with vacuum cleaner and wipe down with moist cloth. 17: Check proper function of the refrigerant leakage detection system (if fitted) either through use of a service tool or use of testing refrigerant. 1: Test the high pressure safety switch cut out and adjust/replace as necessary (see chapter 'Commissioning refrigerant circuits' on page 84). 1: (If fitted) it is recommended that the pressure relief valve is replaced. Tab The equipment should be thoroughly tested to ensure there are no refrigerant leaks to comply with EN 378-4:2008+A1:2012 Associated equipment should also be service in accordance with manufacturer's specifications. PR GB Subject to modifications R3-11/

100 Servicing and Maintenance 10.3 Refrigerant leak testing Leak testing on the equipment is required: After any strength affecting work (e.g. Brazing) If the unit has not operated for longer than two years Changes or extensions to the system Suspicions of refrigerant leakage On systems with a R410A refrigerant charge of kg (equivalent 5-50 tonnes CO 2 ) a yearly leak test is mandatory. On systems with charges of kg (equivalent tonnes CO 2 ) then it is mandatory to perform a leak test twice a year. Within one month of fixing a refrigerant leak 10.4 Compressor care NOTICE Following advice received directly from the manufacturers of compressors, we DO NOT allow the use of additives (for example Quickshot ) with ANY system. ANY USE WILL INVALIDATE WARRANTY. On new systems, if installed and commissioned correctly, no acids are present. units are fitted with molecular sieve type of drier to help moisture content be at an extremely low level. If the system has operated under adverse conditions for some time, weak acids may appear from the oil and refrigerant by system heat and electrical arcing. This acid will remain INERT until moisture is added to the system, for example, via air ingress into the system during service work. NOTE! During any service or at any time that the refrigeration system is opened, a replacement filter drier (molecular sieve type) should be fitted. These can contain a proportion of activated oxides that absorb weak acids and remove them from the system Humidifier maintenance (if fitted) As the humidifier usually operates in automatic mode and the relevant wear of the device is displayed, a standard maintenance interval is usually sufficient. Cylinder life will be dependent on the quality of the water supplied and the length of time the cylinder will be active. Each cylinder is equipped with an integrated filter in the drain pipe. With every cylinder replacement this filter must be changed also. 100 PR GB Subject to modifications R3-11/2015

101 Servicing and Maintenance 10.6 Closing down procedure It is essential for starting, closing down, emergency operation and fault finding to know the location of the following components: Location of isolator for power distribution to the unit Main Isolator (integral to unit or local position) ON/OFF icon on the display of the unit All valves likely to affect water supply to humidifier (when fitted) NOTE! The units are designed for continuous operation and it is recommended that the system is kept running overnight and at weekends to maintain stable room conditions. Short periods Long periods Indefinitely Should you require the equipment to be closed down for the weekend or Bank Holidays, no special precautions are required. Each unit may simply be turned off by pressing the On/Off icon. Alternatively, the "On/Off Times" can be configured in the controller software. If the plant is to be shut down for longer periods (up to a month) this can be done by switching off at the on/off icon, then opening the Main Isolator, and closing the local mains water supply to the humidifier. When re-starting the plant, follow the same instructions but in the reverse order. When the equipment is to be taken out of service for an indefinite period we recommend a qualified air conditioning engineer. An engineer will also be required for the restarting of the equipment. For units fitted with chilled water cooling and/or hot water heating, the mains power should remain "ON" for at least the stroke time of the valve actuator to ensure that the valve closes fully Freeze prevention of water pipework If water piping is installed where the temperature may drop below freezing, it must be completely drained. Water coils are difficult to drain therefore it is advisable to remove any remaining water by using compressed air. If systems are to remain out of operation for long periods, this can result in corrosion of the inner surfaces of the piping and coils. Therefore we recommend that the hydraulic system be refilled with an anti-freeze solution. The anti-freeze solution should contain inhibitors. Refer to chapter and ask your anti-freeze supplier for advice. On re-commissioning the equipment, the anti-freeze solution must be drained and properly recycled. PR GB Subject to modifications R3-11/

102 Servicing and Maintenance 10.7 Logbook & EU Regulation A logbook should be available throughout the working life of the equipment. In the EU this is a legal requirement if the system charge is 2.3 kg or above. The logbook needs to be updated after each maintenance to comply with EN 378-4:2008+A1:2012 and should include the following information: Initial refrigerant charge following commissioning Details of any maintenance or repair work Quantities of new, re-used or recycled refrigerant additions or removals If there is details of re-used refrigerant, the results should be kept in the logbook also The refrigerant source should also be recorded Changes and replacements of any components of the refrigeration system Results of all periodic, routine tests The periods of any significant non-use Members of the EU must also comply with the Fluorinated Greenhouse Gases Regulation (EU) No 517/2014, alongside any further country specific legislation. This regulation places responsibility for record keeping and leak detection on the owner/operator of the equipment and the company that services it. Information required for this regulation is more comprehensive than a simple logbook and a required period for record keeping, therefore all parties involved should have an understanding of the regulations implications. Furthermore, individual countries can impose stricter rules than those set within the regulation. 102 PR GB Subject to modifications R3-11/2015

103 Fault Finding and Troubleshooting 11 Fault Finding and Troubleshooting The range is designed to perform its primary function: cooling of the controlled space, for as long as possible. As long as a consistent and suitable power supply is given to the unit, only 'Critical' alarms will stop the unit performing its primary function. Other alarms or faults may deactivate additional features of the unit (e.g. turn off the humidifier etc). This chapter provides information on fault finding and remedies to problems found with your unit. Fault finding shall only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes. Provided that a high quality, thorough and planned maintenance program is maintained, a unit should provide years of smooth and problem-free operation. NOTE! A quality, routine, planned maintenance program should be implemented from commissioning. Failure to have a maintenance program in place during the warranty period may invalidate the warranty. NOTE! In the event of persistent faults, room conditions going out of specification or possible refrigerant leaks you must contact competent maintenance & service technicians to rectify your problems. Your local representative should be able to help you with this. If you find that your room conditions are outside of design specifications, there are some simple areas that you can check to gather valuable information: Have conditions within the room changed? Has the equipment been recently moved? Has the airtightness of the room been compromised (e.g. door/window open)? Is there new equipment with higher/lower heat load? Is the air path temporarily blocked? Has additional cooling equipment been added to the room? Have the grille tiles been moved? Observing the unit status: Has the unit got power from the main distribution board? Is the unit isolator in the ON position? Is the unit display working? What does the unit status description say? Is the unit controlled via BMS? What are the current commands? Is the unit a part of a network is it currently in duty or standby mode? Can you hear the fans operating? Observe what previous alarms have been made (and dismissed) Have the set-points been modified? When was the last service? PR GB Subject to modifications R3-11/

104 Fault Finding and Troubleshooting These simple questions and observations give important information to an engineer to be able to appreciate a situation before attending site. The more information you can provide, the more likely the issue will be solved in a fast and timely manner Common Issues NOTE! The advice in the following section assumes the unit has been operating consistently for a significant amount of time with appropriate design conditions, application and all necessary resources are supplied to the unit (electrical power, water, free airflow etc.). units use fans which are regulated independently by the main control board. Removing guards whilst unit is operational risks death or serious injury. Inverters also store energy for a period of time after isolation. Disable the unit. Electrically isolate the unit. Wait AT LEAST 5 minutes Once fan momentum has ceased and the inverter energy discharged, you can open the doors and conduct work. Below is a list of conventional alarms or issues that, if initially installed and commissioned properly, have a small chance of occurring. Before addressing the fault and possible remedy, please observe the following: Always refer to the correct electrical drawing for the equipment. Regular maintenance is the most effective measure to preventing any issues. Refrigerant leak testing must only be conducted by suitably qualified engineers If troubleshooting requires adjustments to the controller's settings, please refer to the separate controller manual before proceeding. All person(s) must know the location of protection features for the unit (e.g. isolation points) before conducting any work For water based circuits; plant hydraulic settings should not be altered as this may affect the balance of the complete system. Rebalancing of a system can be a costly operation, therefore any adjustments must be conducted by qualified individuals with full knowledge of the system design and requirements. The following table contains a sample list of mechanical issues and possible remedies to fix them. A list of common control issues can be found in the separate controller manual. NOTE! Due to the relationship between temperature and humidity, high temperature and low humidity or alternatively low temperature and high humidity can occur at the same time. To resolve such situations, always address the temperature first, before taking measures to resolve humidity. Fault Possible Reason Possible Remedy Low pressure in refrigeration system (low pressure alarm) Tab Possible leak in pipework Investigate location of leak and repair. Once repair perform pressure tests and re-commission 104 PR GB Subject to modifications R3-11/2015

105 Fault Finding and Troubleshooting Fault Possible Reason Possible Remedy High pressure in refrigeration system Too much refrigerant within system Outdoor fans may not be operating Fuse or relay fault Outdoor heat exchanger is blocked/dirty Refer to commissioning report and compare current conditions with conditions during commissioning. If significant changes then perform re-commission the unit. See Fault below Review the unit to check for damage to any fuse or relay that is part of the refrigeration circuit operation Clean heat exchanger fins and clear debris in and around unit Indoor fans not operating Blocked filter alarm Check the coil filters for cleanliness, clean or replace as appropriate Fan motor failure Fan relay not activating The fan and the motor are a dynamic pair, therefore the fan assembly must be replaced Check the fan relays (1 relay per fan) Unit off by Check the controller display to see if the unit has been disabled by; BMS, Time or Keyboard. If the unit is also part of a network, it could be on a Stand-by status. Outdoor fans not operating Outdoor unit isolated Check the isolator on the unit is set to the ON position Condensing pressures below the minimum requirements Outdoor unit not receiving control signal from indoor unit If the refrigerant circuit pressure is below the condenser s set-point the fans will not activate observe the pressure increasing in the unit controller and check fans start when pressure increases sufficiently Compare terminals at outdoor and indoor units to check cable integrity No image on the display No power to the unit Check the power supply at the mains power distribution board and at the local isolator. Unit not cooling/heating/ humidifying/dehumidifying Tab Display unit cable disconnected Airflow failure alarm Heater over-temperature alarm (heating only) Water detection alarm Sensor failure Low oil level (functions disabled by compressor alarms) Deactivate the unit and open the door with the display. Inspect the connection and cable at the display and the controller. Check fan operation and suitable clearances in and around the fan. Check output of the controller to the fan and each fan relay is energised. Check the heater thermostat for functionality, replace if necessary and check function of heaters. Standard configuration disables the humidifier only. Settings available in the controller allow for whole unit operation to be stopped. Inspect underneath the unit for presence of water and check coil condensate tray. Certain temperature and pressure sensors, upon failure, will disable functions of the unit. Refer to the controls manual to see what function is affected by each sensor. Check for possible leaks and the recent operations of the unit (to ensure suitable functionality). Add oil as necessary and re-commission the unit. PR GB Subject to modifications R3-11/

106 Dismantling and Disposal 12 Dismantling and Disposal 12.1 Dismantling To dismantle a unit, proceed as follows: Ensure all incoming electrical connections are isolated and cannot be inadvertently energised. Inverter technology and rotating fans required at least 5 minutes from electrically isolating the unit before any doors or panels can be removed. Use earth and short-circuit and cover or isolate any neighbouring live parts. Recover all refrigerant or cooling medium and use inert medium (e.g. Oxygen Free Nitrogen) to equalise the system pressure to meet ambient air pressure. Stop the unit as per chapter Disable electrical power to the unit as per chapter Ensure that the power supply cannot be 're-activated' by interlocking the supply/ supplies at the main power board and removing any fuses Humidifier Turn off the water feed to the humidifier (if fitted) Remove the humidifier connection to the condensate drain Ensure the humidifier bottle is suitably sealed or appropriately drained Water Circuits Close off/shut the valve on any water circuits, hot or cold (if fitted) Drain the water/water mixture from the circuit Disconnect the water connections and ensure no further fluid is leaking 106 PR GB Subject to modifications R3-11/2015

107 Dismantling and Disposal Refrigeration circuits A specialist refrigeration engineer should be employed to recover and safely dispose of the refrigerant gas and any associated oils and glycols prior to cutting and capping off the refrigerant pipework A qualified electrical contractor should be employed to remove/recover the main(s) and any interconnecting cabling Once mechanically and electrically separated from the system, attend to releasing the unit from any fixings to the floor or other sub-structures Prepare the unit for handling and transportation as per chapter Disposal NOTICE Dispose of all components and materials in accordance with local codes, practices and environmental regulations. An authorized appointed contractor specializing in waste processing shall dispose of the unit or its individual components. This appointed contractor shall ensure that: the components are separated according to material types the used operating materials are sorted and separated according to their respective properties fluorinated greenhouse gases are properly recycled or disposed of by a suitable qualified and certificated refrigerant handler they observe all local, national and international legislation and regulation regarding the disposal of materials. For example, within Europe, they may refer to (amongst others): Waste Electrical & Electronic Equipment (WEEE) 2012/19/EU Waste Framework Directive 2008/98/EC PR GB Subject to modifications R3-11/

108 Appendix 13 Appendix NOTE! Please note that these documents are samples from the time of publishing and may not be the latest revision. For copies of the latest versions, please contact your local sales office who will be able to provide them in either electronic or printed form Pre-Commissioning Checklist (DQA 880) This document is to be completed before the commissioning engineer arrives to ensure all requirements have been conducted and checked. The commissioning engineer will ask you to present this document before they can proceed Pressure Test Certificate (DQA 653) This is the template for recording the system pressure test conducted on the circuit, once the mechanical installation has been completed Commissioning Report (DQA 890) This is the template for the commissioning report of units. 108 PR GB Subject to modifications R3-11/2015

109 Appendix 13.1 Pre-Commissioning Checklist (DQA 880) Pre Commissioning Checklist As a pre-requisite to accepting a firm booking for commissioning we need clarification that all aspects of the installation are ready for us to proceed without delay when we arrive on site. Will you please therefore complete all relevant sections of this form and back to your contact. End Users Site Name: Installers Name: Full Site Address: Site Post Code: Contract No Contracts Engineer. Contracts Engineers Address. Checklist Item Is equipment in correct positions, mounted on floor stands (if required) and levelled up. Is work area clean, tidy, safe, and accessible? If area has raised floor is it complete and free from hazards. Are all grilles and ductwork complete and ready for use? Has refrigeration pipework been pressure tested and test certificates available for our inspection and retention? Is all refrigeration pipework installed, connected, evacuated, and left with a holding charge of refrigerant. Is mains cold water supply pipework connected and pressure available (equipment with humidifiers only) Is chilled water or condenser water pipework installed, fitted with auto air vents, strainers, and dosing pots, tested and systems filled and vented? Tick Boxes Yes No N/A Comments Failure to complete this form or failure to have all required items ready for commissioning may result in an abortive visit by our commissioning engineer, Your signature on page 2 authorises the acceptance of any abortive costs accordingly Page 1 of 3 DQA880 Rev DH1 PR GB Subject to modifications R3-11/

110 Appendix Checklist Item If chilled water or condenser water system is to be filled with a glycol mix has this been done and accurate concentration readings available for our retention. Is drainage pipework connected and tested. Are condensate pumps fitted and tested with electrical supply and pipework and has internal packing been removed. Has mains power supply been installed, connected, phase rotation checked, and power available at isolators. Has interconnecting electrical wiring been installed and connected as per wiring diagrams. Have fire shutdown connections been installed and verified as operating correctly. Have external stop start connections (if required) been installed and tested. Have interconnection cables (Denconet) been installed utilising correct Belden type cable and left for our connection. Do mains power supplies cables have source isolation that complies with the current electrical regulations. Is secure on-site parking available for our commissioning engineer s vehicle? Is an H & S induction required before our commissioning engineer can commence work? Spare Spare Spare Spare Tick Boxes Yes No N/A Comments Notes: 1. To comply with F-Gas regulations where the system has refrigerant charge (supply & commission projects) clients must have their own engineer on site for the duration of the works to add refrigerant to systems and create the relevant statutory records. 2. On chilled water or condenser cooling water systems (e.g. Ambicool) clients must have their own engineer on site for the duration of the works to measure and set up the flow rates. 3. If the equipment is to be connected to a BMS system then clients must have their own BMS engineer on site. Failure to complete this form or failure to have all required items ready for commissioning may result in an abortive visit by our commissioning engineer, Your signature on page 2 authorises the acceptance of any abortive costs accordingly Page 2 of 3 DQA880 Rev DH1 110 PR GB Subject to modifications R3-11/2015

111 Appendix Comments: Completed By: Signature: On Behalf Of: Date: Failure to complete this form or failure to have all required items ready for commissioning may result in an abortive visit by our commissioning engineer, Your signature on page 2 authorises the acceptance of any abortive costs accordingly Page 3 of 3 DQA880 Rev DH1 PR GB Subject to modifications R3-11/

112 Appendix 13.2 Pressure Test Certificate (DQA 653) Pressure Test Certificate Customer Site Address Contract Number Air Handling Unit Reference Air Handling Unit Type Condenser Unit Type We certify that the following pressure tests have been completed with dry nitrogen Circuit Pressure Duration of Test Date Test Carried out by : Test Witnessed by : Name (Block Capitals) Company Signature Remarks DQA653 Rev DH1 112 PR GB Subject to modifications R3-11/2015

113 Appendix 13.3 Commissioning Report (DQA 890) Multi Denco Commissioning Record Book Before working on this equipment, ensure that all incoming electrical connections are isolated and checked as voltage free by a competent person. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH Refer to appropriate electrical wiring schematic for all external wiring Section A: 1 copy for completion by contracts engineer in respect of each model or variant on site. All boxes in section A to be completed before handing - sending to commissioning engineer. Contract's Engs Name Date Required & Agreed End User's Name Induction Required If Yes State Time Of Start Client's Name Installer's Name Site Address Site Contact's name Contract Number Site Contact's Tel No Quantity of this model Air Balance Yes / No Supply Only Yes / No Water Balance Yes / No Supply & Install Yes / No Design RA Condition Temperature c Design RA Condition Humidity % RH Design Total Cooling Kilowatts Design Sensible Cooling Kilowatts AHU Model No Heat Rejection Model No PPE Requirements Parking on Site Do Site Specific RAM's apply Special Instructions Section B: For completion by commissioning engineer for each unit on site before starting commissioning. MANDATORY AHU Serial No. Heat Rejection Serial Nos AHU Location AHU Site Reference No. Heat Load Available During Commissioning Process Check piping installation complies with O&M manual & Approved Code of Practice-DX Installations Check & confirm interconnecting wiring and unit mains power supply matches contract wiring diagram Initial Box = Initial Box = Work may not proceed until the above checks have been completed and the initial box filled in and the contract technical data has been added. All instrumentation must be covered by a current calibration certificate including pressure gauges, vacuum gauges, thermometers, airflow meters, ammeter, multimeter, etc. Electrical Power Supply L1 Mains Supply Voltage L2 Mains Supply Voltage Fan Motor Currents Fan Motor 1 Current Min Fan Motor 1 Current Max Fan Motor 2 Current Min Fan Motor 2 Current Max Fan Motor 3 Current Min Fan Motor 3 Current Max Units V L3 Mains Supply Voltage V V Control Circuit Voltage V Amps Phase 1 Phase 2 Phase 3 A A A A A A Measurement of air volumes and the amperages of all fans in both minimum speed and maximum speed is mandatory - no exceptions are permitted. Page 1 of 4 SUPERSEDES ALL PREVIOUS VERSIONS WITHOUT EXCEPTION Form DQA890 DH1 NO MODIFICATIONS TO FORMAT ALLOWED Effective From August 2015 PR GB Subject to modifications R3-11/

114 Appendix Multi Denco Commissioning Record Book Air Volume Checks Measured Air Volume m 3 /s Air On Temperature C Max Fan Speed Setting % or V Air Off Temperature C Min Fan Speed Setting % or V Air Flow Fail Setting Check Yes/No Dehum Fan Speed Room Distribution Checked Glycol Circuit (if option fitted) % or V Yes/No Filter Change Option Fitted to Machine Mbar/Pa Yes/No Pump Make Pump Model Pump Suction Pressure Bar Pump Delivery Pressure Bar Design Flowrate Lps Actual Flowrate Lps Design Exp Vessel Pressure Bar Actual Exp Vessel Pressure Bar Drycooler Target Setting C Local Isolators Fitted Yes / No Fluid Inlet Temperature C Fluid Outlet Temperature C Auto Air Vents Fitted Yes / No Air Vents Checked Yes / No Glycol Concentration Glycol Type % Double Reg Valve Setting Volume Glycol Added No / kpa Litres Dry Cooler Motor Amps Glycol Pump Amps A A State average amps across all phases & motors if even State average amps across all phases & pumps if even Controls Temperature Set Point C Humidity Set Point %RH Dead Zone T C Dead Zone RH %RH Proportional Band T C Proportional Band RH %RH Oil Recovery Time (SIAM only) Seconds Controller Software Vers Number Sensor Calibration T C Sensor Calibration RH %RH Strategy Selected P or PI Type of control selected T or TH Software Settings Entered Yes / No Network Number of Unit Number Network Connected Yes / No Type of Comm's Card Comms Card Fitted Yes / No Hum and RH Control Enabled Yes / No Discharge Transducer Reading Bar Discharge Transducer Calibration Bar Suction Transducer Reading Bar Suction Transducer Calibration Bar Suction Sensor Reading C Suction Sensor Calibration C Refrigeration Circuit (if option fitted) Option Fitted to Machine Yes/No Pressure Test Level Bar Vacuum Achieved Torr Circuit Pipe Length M Total Pipework Rise M Compressor Model 1 Oil Added To Circuit Ltrs Compressor Model 2 Weight of Refrigerant R401A Kg Full Load Suction Pressure Bar Full Load Superheat Temp K Liquid Line Temperature C Part Load Superheat Temp K Stable Discharge Pressure Bar Sub Cooling Temperature K Full Load Discharge Temp C Full Load Discharge S / heat K Part Load Discharge Temp C Part Load Discharge S / heat K Compressor 1 Current A Design Compressor 1 Current A Compressor 2 Current A Design Compressor 2 Current A Condenser Motor Current A Software H.P Switch Setting Bar L.P. Envelope Threshold Bar Mech H.P Switch Setting Bar L.P. Alarm Threshold Bar EEV Sight Glass Condition Page 2 of 4 SUPERSEDES ALL PREVIOUS VERSIONS WITHOUT EXCEPTION Form DQA890 DH1 NO MODIFICATIONS TO FORMAT ALLOWED Effective From August PR GB Subject to modifications R3-11/2015

115 Appendix Multi Denco Commissioning Record Book Chilled Water (if option fitted) Option Fitted to Machine Yes/No CW Flowrate Lps Double Reg Valve Setting No / kpa CW Water Inlet Temp. C CW Water Outlet Temp C Electric Heating (if option fitted) Option Fitted to Machine Yes/No Thyristor Control Fitted Yes/No Heater 2 Current A Heater 1 Current Humidifier (if option fitted) A Heater 3 Current Option Fitted to Machine A Yes/No L1 Humidifier Current A Water Supply Conductivity Ms L2 Humidifier Current A Bottle Type kg L3 Humidifier Current A % Output Set % Bottle Conductivity Range Ms Bottle Part Number Number Condensate Pump Drain (if option fitted) Gravity or Pumped N/A Pump Model System Lift Function Test Pass / Fail Please initial box below to certify and confirm that the listed functional tests have been carried out on the equipment Low pressure transducer set correctly & functions Head pressure control function & setting correct High pressure transducer set correctly & function High temperature alarm set and function operating High pressure switch set correctly & functions Low temperature alarm set and function operating Airflow failure transducer set correctly & functions Filter blocked transducer set correctly & functions Water detection operates ( if fitted & laid out) Alarm output relays set up and operating correctly Layout of the suction lines has been checked Superheat stable and correctly set as TI & OEM Discharge line temperature sensor fixing checked System correctly evacuated before charging Discharge line traps fitted if required Any additional oil added taken from new can Requirement for crankcase heating checked System fully leak tested after commissioning Fans free from vibration at all speeds Condensers correctly installed Discharge pressure is at least 1.8 times suction pressure Pressure transducer readings checked DQA892 Multi Denco Charging procedure followed Spare You are verifying that key issues - functions have been checked and conform to the requirements- settings in the O & M manual Please Detail Any Checks - Measurements Not Completed And Reasons Why Please detail all site related issues (not equipment) found during commissioning that might affect performance and reliability Please detail any issues or site related problems (not equipment) with air distribution in the conditioned space Additionally Complete And Sign Page 4 for DX Units Charged In The Field Page 3 of 4 SUPERSEDES ALL PREVIOUS VERSIONS WITHOUT EXCEPTION Form DQA890 DH1 NO MODIFICATIONS TO FORMAT ALLOWED Effective From August 2015 PR GB Subject to modifications R3-11/

116 Appendix Multi Denco Commissioning Record Book F-Gas regulation No 842/2006 Record Log Sheet Information For Owners Use - Answer All Questions Plant Name Reference Number Location of Plant Serial Number Plant Operator Plant Operator Operator Contact Cooling Loads Served Refrigerant Type Quantity Installed Plant Manufacturer Year of Installation Refrigerant Additions (If none state none) Date Engineer Amount Added in KG Reason for Addition Refrigerant Removals (If none state none) Date Engineer Amount Removed in KG Reason For Removal & What Was Done With Recovered Refrigerant Leak Tests (State Method Used - Mandatory) Date Engineer Test Result Follow Up Actions Required Leak Detector Details Model Number Serial Number Follow Up Action (If none state none) Date Engineer Related To Test On Actions Taken Testing Of Automatic Leak Detector (State none if not fitted) Date Engineer Test Result Comments Notes: Notes: Engineers Full Name Engineers Signature Date Page 4 of 4 SUPERSEDES ALL PREVIOUS VERSIONS WITHOUT EXCEPTION Form DQA890 DH1 NO MODIFICATIONS TO FORMAT ALLOWED Effective From August PR GB Subject to modifications R3-11/2015

117 PR GB Subject to modifications R3-11/

118 118 PR GB Subject to modifications R3-11/2015

119 PR GB Subject to modifications R3-11/

120 DencoHappel is a globally operating company with great expertise in air treatment, air conditioning and filtration technology. Our nearest consulting and service teams will be glad to discuss ideas and develop creative and effective solutions with you.