Большая библиотека технической документации каталоги, инструкции, сервисные мануалы, схемы.

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1 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E - BDE PRECISION AIR CONDITIONING UNITS MDT / MDD / MDE BDE INSTRUCTION MANUAL GB The contents of this document are subject to revision without notice due to continued progress in methodology, design and manufacturing. Read this manual before using the unit and keep it in a safe place for future reference. Rev EN 1 (50) Большая библиотека технической документации каталоги, инструкции, сервисные мануалы, схемы.

2 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E - BDE UNIFLAIR ITALIA S.r.l. Via dell industria, BRUGINE (Padova) Italy Tel. +39 (0) Fax +39 (0) Internet: INFO@uniflair.com Release: 4.2 Date: Checked by: 2 (50) Rev EN

3 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E - BDE INDEX Page Important warnings 5 GENERAL DESCRIPTION 6 Documentation enclosed with the unit 6 Description of the unit and intended use 6 MDT: aircooled twin-cool units 7 MDD: watercooled twin-cool units 7 MDE/BDE: energy-saving units 7 Access to main components 8 Data Plate 9 INSTALLATION GUIDE 10 Transport and movement 11 Dimensions and weights 11 Positioning the unit 12 Air distribution 13 Suction plenum 15 Fresh air filter 16 Refrigerant connections (MDT) 17 Water connections (MDD) 19 Water connections (MDD-MDE/BDE) 20 Humidifier connections 23 Connecting the condensate drain 24 Electrical connections 26 Recommended sizes of power supply cables and line fuses 28 START-UP AND TESTING 29 Evacuation of refrigerant circuit and refrigerant charging (MDT) 29 Thermostatic expansion valve regulation (MDT) 30 Remote control 31 Start-up procedure 31 FUNCTION & REGULATION 32 Water-cooled units (MDD) 32 Electrical connection and control of remote radiators (MDE/BDE) 33 Measurement and alarm devices 35 Regulation of condensation pressure (remote air-cooled condenser) 36 Setting the pressostatic valve (optional - water-cooled models only) 36 Setting the regulation and safety devices 37 Setting the airflow sensor 37 Setting the dirty filter sensor (optional) 37 Valve and servomotor 38 Rev EN 3 (50)

4 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E - BDE Page TECHNICAL DATA 39 General characteristics 39 Electrical data 41 MAINTENANCE 42 Regular checks 42 Changing the Low Pressure pressostat 42 Humidifier 43 PROBLEM SOLVING 46 Temperature control 46 Humidity control 46 Fans 47 Refrigerant circuit 47 Compressors 48 Electric heaters 48 IMPORTANT: the description of the Control System and the operating logic of the unit are given in the MP20 Control System Instruction Manual. 4 (50) Rev EN

5 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E - BDE This unit has been subjected to risk analysis under EC Directive 98/37/EEC (89/392/EEC). The technical solutions implemented during the design phase are described in the unit s technical documentation. This unit is built to perform the functions for which it was designed without risk as long as the installation, operation and maintenance of the unit are all carried out according to the instructions in this manual and on the labels on the unit. There are however some residual risks, particularly regarding maintenance. The risks which are particularly important for the safety of the user are marked with the danger symbol: IMPORTANT WARNINGS This unit contains refrigerant gas circuits under pressure, live electrical components, hot surfaces, sharp edges (such as the coil) and rotating devices such as the fans. Before accessing the inside of the unit, disconnect it from the electrical power supply. All service and maintenance operations must be performed when the unit is off and must be done by qualified and experienced personnel who are aware of the necessary precautions. In any case, all safety legislation of the installation location must be followed. In the event of fire, water and other conductive substances must not be used to put out the fire near live electrical components. This warning must be displayed on notices in the unit installation location. If the refrigerants used come into contact with fire they decompose, forming acids and other irritants. The smell of these substances, even at concentrations below danger levels, gives enough warning to allow evacuation of the area at risk. Make sure that the power supply voltage corresponds to the value shown on the data plate. Rev EN 5 (50)

6 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E - BDE GENERAL DESCRIPTION DOCUMENTATION ENCLOSED WITH THE UNIT Every MD*-BD* air conditioning unit is supplied complete with the following documents: Unit instruction manual; MP20 Microprocessor control instruction manual Electrical diagrams; Spare parts list CE declaration listing the directives and norms which the unit conforms Guarantee certificate. UNIT DESCRIPTION AND INTENDED USE MD*-BD* downflow air conditioning units are designed for high-technology applications such as computer rooms, telephone exchanges, control rooms, laboratories and clean rooms. Air-cooled direct-expansion units must be connected to UNIFLAIR CAL-series condensers. Water-cooled direct-expansion units must be connected to UNIFLAIR RAL-series radiators. All the units are fully assembled and tested in the factory and are built for applications where safety and reliability cannot be compromised. ACTIVE SAFETY control systems provide monitoring and prevention functions via: Function status indication Continuous reading and display of the temperature measured by the sensors. Indication of fault and alarm situations Automatic stopping of unit components in the event of risk; Compressor management to reduce the start-up frequency of each compressor and to avoid compressors being started at the same time. PASSIVE SAFETY The essential functions of air conditioning units are protected against faults and potentially dangerous conditions the control systems which includes: High and low-pressure pressostats to protect the refrigerant circuit (HP with manual re-set) Safety valve Low airflow differential pressostat Safety thermostat on units with electric heater Liquid shut-off valve to protect the compressor against migration of liquid refrigerant when the unit is off Compressor electric motor protection. PERSONAL SAFETY The design and wiring of air conditioning units conform to IEC electrical norms. The electrical panels, are equipped with an auxiliary 24V circuit and include individual short circuit protection using automatic circuit breakers. Fans are fitted with metals grilles conforming to IEC safety norms. 6 (50) Rev EN

7 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E - BDE MDT: AIRCOOLED TWIN-COOL UNITS MDT TWIN-COOL units include two independent cooling systems: - direct expansion with air-cooled condensers; - chilled water. The unit is connected to the remote condensers with refrigerant tubes and to the chilled water piping system. The microprocessor automatically maintains room temperature by controlling: - switch over between the two cooling systems; - compressor operation during direct expansion function when the chilled water supply is unavailable; - the modulating motorised valve during chilled water function. For further details please refer to the microprocessor manual. MDD: WATERCOOLED TWIN-COOL UNITS MDD Twin-Cool units have 2 independent cooling systems: - direct expansion with water-cooled condensers; - chilled water. The unit is connected to the condenser cooling water supply as well as to the chilled water piping system. The microprocessor automatically maintains room temperature by controlling: - switch over between the two cooling systems; - compressor operation during direct expansion function, when chilled water supply is unavailable; - the modulating motorised valve during chilled water function. For further details please refer to the microprocessor manual. MDE/BDE: ENERGY-SAVING UNITS ENERGY SAVING units include two independent cooling systems: - direct expansion with water-cooled condensers supplied with water pumped in closed circuit and cooled by external radiators; - chilled water coil (economiser), connected in to the closed circuit glycol loop between the condensers and the external radiators. Whenever the outside temperature falls below the room temperature, the ENERGY SAVING unit starts to take advantage of the free cooling effect i.e.: cooling without the need to operate compressors. During warm weather the unit operates like a conventional glycol cooled system (diagram A) with the 3 way valve bypassing the economiser coil. In cooler weather or at night when the outside temperature drops and the water/glycol mixture leaving the radiator becomes colder than the room, the economiser coil is fed via the 3 way valve to provide a free cooling effect and reduce the amount of direct expansion cooling required (diagram B). When the outside temperature falls further there comes a point at which the free-cooling effect provided by the economiser is sufficient to meet the entire heat load and no direct expansion cooling is required at all. In this mode an ENERGY-SAVING unit operates like a chilled water unit with the 3 way valve controlling the flow through the economiser coil (diagram C). The microprocessor provides fully automatic control of the unit (for further details please refer to the mp20 microprocessor manual). Fig. 1.A Fig. 1.B Fig. 1.C Rev EN 7 (50)

8 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E - BDE ACCESS TO MAIN COMPONENTS The unit can be accessed from all sides by removing the covering panels. MODELS MD* MODELS BDE Fig. 2.a. Fig. 2.b. E 2 1 SIDE ACCESS E REQUIRED C D C A SIDE ACCESS REQUIRED 2 A D B B FRONT PANELS Front panel removal does not require the use of tools. The main panel A (see figs. 2.a. and 2.b.) is hinged and opens on release of handle B when pressed at the indicated point; this operation also frees the panel C. The remaining panels are engaged at the bottom and held to the front of the unit by spring-loaded catches; for removal, pull the top edge of the panel forward to release the catches (operation 1 ) and lift (operation 2 ). Do the opposite for assembly. SIDE PANELS These are fixed with five internal screws as follows: - three screws D distributed on the front side uprights, accessible after removal of the front panels; - two screws E on the rear uprights; the screws are marked with the symbol shown in fig. 3. and accessible at the bottom of the filter compartment (with the filters removed) and at the end of the fan compartment. REAR PANELS The rear panels are fixed with screws on each side. Fig (50) Rev EN

9 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E - BDE DATA PLATE The data plate is in the electrical panel housing and shows: - Unit model and serial number - Power supply (voltage, number of phases and frequency) - Power absorption of the unit and of the main components; - Current absorption of the unit and of the main components: OA (Operating current), FLA (Full load current) and LRA (Locked rotor current); - Setting values of the refrigerant circuit pressostats (high and low pressure) and of the other regulation and safety devices; - Refrigerant type and charging of refrigerant circuit. MODEL SERIAL No. POWER SUPPLY VOLTAGE ELECTRICAL CURRENT OA FLA LRA KW TOTALI SETTING OF SAFETY DEVICES REFRIGERANT Fig. 4. Rev EN 9 (50)

10 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E - BDE INSTALLATION GUIDE TRANSPORT AND MOVEMENT The unit should not be turned on its back or upside-down, or exposed to the weather and should be taken as near as possible to the installation location before removing the cardboard packing and the pallet. The unit can be lifted: - with a fork-lift, placing the forks in the appropriate slots of the pallet; - with straps passed under the unit, making sure that they do not put pressure on the upper rim of the unit. The unit must be stored, preferably in its packing, under cover and protected from excessive humidity (< 90% R.H.) and temperature (< 50 C). The dimensions and weight of the unit with packaging are given below: MD* mm M N O kg N BDE mm M N O O M Fig. 5. kg The symbols applied to the unit s packaging conform to ISO7000; they are explained in the table below. SYMBOL MEANING SYMBOL MEANING FRAGILE: handle with care. THIS SIDE UP shows the orientation of the unit. PROTECT AGAINST MOISTURE: the packaged unit must be stored in a dry place. CENTRE OF GRAVITY: shows the centre of gravity of the packaged unit. KEEP AWAY FROM HEAT: the unit must be kept away from heat sources. TEMPERATURE LIMITS: the unit must not be stored outside these limits. NO HOOKS: do not use hooks to lift the packed unit. DO NOT STACK RECEIVING THE UNIT When the unit arrives, check that it is complete and in perfect condition; notify the carrier immediately in writing of any damage that might have been caused in transit. 10 (50) Rev EN

11 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E - BDE DIMENSIONS AND WEIGHTS B MD* mm A A B C C D*) E**) kg NOTE: Maximum tolerance on height B is ± 5 mm *) Free space for maintenance **) Free side access in the unlikely event of coil replacement E 60 C C 1 1 D A 1 A Fig. 6. Fig. 7. F2 F1 B E 60 BDE mm A A B C C D (1) E (2) F1 (3) F2 (4) C 1 C 1 D A 1 A kg NOTE: Maximum tolerance on height B is ± 5 mm (1) Free space for maintenance (2) Free space for access to the compressors (3) Free space for access to water connections (4) Free space for coil repalcement Rev EN 11 (50)

12 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E - BDE POSITIONING THE UNIT The unit can be placed directly on the floor. If possible it should be fixed to the floor with the brackets used to hold the unit to the transport pallet. The unit must be perfectly level with a maximum difference of 5 mm between sides: an inclination could cause the condensate tray to overflow. IMPORTANT: the unit must be installed in a closed environment and protected from adverse conditions. Fit an elastic gasket around the base of the unit to avoid the transmission of noise and vibrations. HEIGHT ADJUSTABLE MOUNTING FRAME (optional) A support frame is recommended: - to enable installation of the unit before the raised floor is installed; - to absorb mechanical vibrations; - to facilitate the connection of pipes and cables. The height of the optional mounting frame is variable between 200 and 600mm (shown as X in Fig. 8.); other heights are available on request. To avoid the transmission of vibrations, fit an elastic seal at least 5mm thick between the support frame and the floor panels; the frame must also be isolated from the floor structure. Fig. 8. A 1 C 1 MD* mm BDE A C X Down-flow Unit X = mm Raised floor Mounting frame The seal goes in this gap The seal goes in this gap 12 (50) Rev EN

13 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E - BDE WORKING SPACE MD* To facilitate maintenance, leave at least 700mm free space in front of the unit as shown in the diagram (fig point D). Side access may be necessary in the unlikely event of coil replacement. WORKING SPACE BDE To facilitate maintenance, leave at least 700mm free space in front of the unit as shown in the diagram (fig point D). With BDE units 1 metre free space must also be left clear to the right of the unit (fig E) in order to allow access to the compressors for refrigerant charging and other maintenance operations and 700 mm free space must also be left clear to the left of the unit (fig F1) in order to allow access to water connections. Side access from the left side may be also necessary in the unlikely event of coil replacement; leave around 2.5 metre free space for this purpose (fig F2). AIR DISTRIBUTION Treated air is delivered into the raised floor cavity and distributed through it into the room. Since the cooling capacity of the unit depends on the air flow, pay particular attention to: a) the hole in the raised floor under the unit; this must have the dimensions labelled G and H and the unit must be positioned exactly over the centre. The gap must not be even partially obstructed be sections of panels, stringers, pipes; fit an elastic gasket around the base of the unit to avoid the transmission of noise and vibrations. 30 H MD* mm G H G Fig. 9.a. Without optional Mounting Frame BDE mm G H b) free air flow in the raised floor cavity; the cavity under the raised floor must be at least mm high, not including the thickness of raised floor panels and stringers and free from obstructions, especially near the unit; c) grilles and holes for air distribution in the room; the air comes out of grilles or holes in the floor; the location and dimensions of these vents must correspond to the room heat load pattern. The air velocity out of the raised floor should be between 1 and 2.5 m/s The total free area (the sum of the sections of the air outlets) necessary for each model is calculated by dividing the total air flow rate (in m 3 /s) by the required airflow velocity (in m/s). The nominal airflow for each model is given in the technical data section of this manual. The location and dimensions of the outlets must correspond to the room heat load pattern and to the layout of the units. IMPORTANT: An insufficient outlet area reduces the airflow and the cooling capacity of the units: keep the air outlet completely clear. Rev EN 13 (50)

14 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E - BDE The exact dimensions of the air delivery section are shown in the diagrams below. A B Fig. 9.b. MD* Model A B Fig. 9.c. BDE Model (50) Rev EN

15 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E - BDE SUCTION PLENUM The air intake can be ducted with a connection via an optional plenum to the suspended ceiling or a return air duct. This plenum is available in a sound-absorbing version and with a removable front panel for removing the filter. 25 MD* mm A C 610 H1 600 BDE mm H1 C A 10.a. 10.b. A 2600 C 810 H FRONT OF UNIT 20 F Fig. 10. Fit optional plate F (see fig 10.) in front of the recirculation air filter housing to guarantee air tightness. Details of the top edge for fastening the return air extension hood are shown in figs. 10.a. and 10.b.. Rev EN 15 (50)

16 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E - BDE FRESH AIR FILTER (optional) The optional fresh air filter must be fitted to the left-hand side of the unit during installation, over the hole which allows air into the fan section (see fig. 11.). Connect the lower opening of the module to the nearest external air intake via a circular flexible tube with minimum diameter 80mm; secure the tube to the module with a band or tie. The flexible tube must be kept as short as possible; if the length is more than 6/7 metres, the optional forced ventilation module (external fan) should be fitted on the tube. To change the fresh air filter: 1) slide the cover of the module upwards; 2) take out the filter cartridge 3) put the new cartridge in and replace the cover. MODELS MD* MODELS BDE Ø 100 mm Models Ø 100 mm Model 0651only FIG. 11.a Fig. 11.b (50) Rev EN

17 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E, BDE REFRIGERANT CONNECTIONS (MDT) Each refrigeration circuit must be connected to its remote air-cooled condenser with one copper pipe for the gas output and one for the liquid return. Sealant is used on the threaded compressor intake and output connections: AREXONS 35A42 for diameters up to ¾ and AREXONS 35A72 for larger diameters. The figure below shows the base of the unit with the holes for the liquid line L and the gas output G.. G L G L W 1 *** 80 mm on model 0651 only 100*** W2 100 W3 Fig. 12. MDT W 1 70 W W W W W 6 70 L 3/4 G 3/4 G: Gas discharge line L: Liquid return line REFRIGERANT PIPING: SUGGESTED SIZES The table shows recommended diameters for output and liquid lines for distances up to 20 metres. MODEL: Number of lines 1 2 Gas discharge pipe 18 mm (Ø 3/4 ) 16 mm (Ø 5/8 ) 18 mm (Ø 3/4 ) Liquid return pipe 16 mm (Ø 5/8 ) The table shows recommended diameters for output and liquid lines for distances up to 30 metres. MODEL: Number of lines 1 2 Gas discharge pipe 22 mm (Ø 7/8 ) 18 mm (Ø 3/4 ) 22 mm (Ø 7/8 ) Liquid return pipe 18 mm (Ø 3/4 ) 16 mm (Ø 5/8 ) 22 mm (Ø 7/8 ) Pipes should have a total length of less than 30 metres and must be laid by an expert refrigeration technician in accordance with the instructions in fig. 13. Pay special attention to: - insulation of the gas piping in the raised floor; - protection of the liquid piping against the sun and other heat sources. D e 1 mm The values shown in the table refer to external diameter; pipe wall thickness is 1mm. Rev EN 17 (50)

18 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E, BDE THERMAL INSULATION 1/100 LIQUIDO OUTPUT Fig. 13.a MAX 30 METRES THERMAL INSULATION 1/100 MAX 5 METRES OUTPUT LIQUID Fig. 13.b OUTPUT 1/100 LIQUID MAX 5 METRES MAX 15 METRES THERMAL INSULATION MAX 5 METRES SYPHON Fig. 13.c N.B.: piping must be protected from sunlight 18 (50) Rev EN

19 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E, BDE WATER CONNECTIONS (MDT) Check chilled water pipe size and pump characteristics: insufficient water flow affects unit performance. Connect the unit to the piping system making sure that chilled water flows into the unit through the lower connection and comes out from side connection; seal the holes where the pipes pass through the base of the unit in order to avoid by pass of air. For all hydraulic connections (except the condensate drain) use: flexible pipes to avoid the transmission of vibrations and to enable the unit to be moved; 3 piece junctions, near the connections to enable the unit to be removed if necessary; shut-off valves to isolate the unit from the water circuit: if possible use full flow sphere valves to minimise pressure drop. Insulate all the chilled water pipes with closed cell insulating material (e.g. Armaflex or equivalent) to avoid condensation; insulation must allow access to valves and joints. Install a mechanical filter in the section of tubing near the intake of the unit to prevent the fouling of the heat exchanger with pieces of welding or flakes of oxidised metal from the water mains. MDT I I I U U U I 1 G.f 1.¼ G.f 1.½ G.f. U 1 G.f 1.¼ G.f 1.½ G.f. I: chilled water intake U: chilled water output SIDE U 3 I3 I U U I U 2 I 2 I 1 U 1 IU Fig. 14.a. Rev EN 19 (50)

20 INSTRUCTION MANUAL UNIFLAIRTM WATER CONNECTIONS (MDD-MDE/BDE) MD.T-D-E, BDE WATER CONNECTIONS - MDD Check chilled water pipe size and pump characteristics: insufficient water flow affects unit performance. Connect the unit to the piping system making sure that chilled water flows into the unit through the lower connection and comes out from side connection; seal the holes where the pipes pass through the base of the unit in order to avoid by pass of air. For all hydraulic connections (except the condensate drain) use: flexible pipes to avoid the transmission of vibrations and to enable the unit to be moved; 3 piece junctions, near the connections to enable the unit to be removed if necessary; shut-off valves to isolate the unit from the water circuit: if possible use full flow sphere valves to minimise pressure drop. Insulate all the chilled water pipes with closed cell insulating material (e.g. Armaflex or equivalent) to avoid condensation; insulation must allow access to valves and joints. Install a mechanical filter in the section of tubing near the intake of the unit to prevent the fouling of the heat exchanger with pieces of welding or flakes of oxidised metal from the water mains. MDD I I I U U U I 1 G.f 1.¼ G.f 1.½ G.f. U 1 G.f 1.¼ G.f 1.½ G.f. I: chilled water intake U: chilled water output SIDE U 3 I3 I U U I U 2 I 2 I 1 U 1 IU Fig. 14.b. 20 (50) Rev EN

21 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E, BDE The water-cooled condenser must be connected to the cooling water piping system, making sure that water flows into the condenser through the lower connection I and leaves through the upper connection U. Use: - flexible hoses to avoid transmission of vibrations; - 3 piece unions, close to the connections, to permit possible removal of the unit; - shut-off valves to isolate the unit from the water circuit: if possible use full flow ball valves to minimise the water pressure drop. If the water temperature may drop below the dew point of the treated air, insulate the water pipes with closed cell insulating material (e.g. Armaflex or equivalent) to avoid condensation; insulation must allow access to valves and joints. Seal the holes where the pipes pass through the base of the unit in order to avoid by-pass of air. N.B.: cooling water pressure should not exceed 1000 kpa (10 bar). If the cooling water temperature is uncontrolled and may drop below 25 C, the use of a pressure operated water regulating valve (available as an optional extra) for each condenser is required; in this case the water pressure should not fall below 200 kpa (2 bar). IMPORTANT: the use of an evaporating cooling tower without efficient water treatment is not recommended since scale build-up could rapidly clog the condensers. MDD W 1 70 W W W W W 6 70 I w 1 G.f 1.¼ G.f 1.½ G.f. U w 1 G.f 1.¼ G.f 1.½ G.f. I: Condenser water intake U: Condenser water output SECTION. A-A MDD units only A U w I w W 5 W 4 W 6 A U w I w U w* I w* U w* I w* W 1 * MDD units only *** 80 mm on model 0651 only W 2 100*** 100 W 3 Fig. 15. Rev EN 21 (50)

22 U e E 4 Fig. 16.a. INSTRUCTION MANUAL UNIFLAIRTM WATER CONNECTIONS - MDE/BDE MDE BDE E E E E I e 1 G.f 1.¼ G.f 1.½ G.f. U e 1 G.f 1.¼ G.f 1.½ G.f. MD.T-D-E, BDE E 2 E 3 E 1 I e MDE E 1 I e 645 U e C-(D) F Fig. 16.b. E 2 E E 3 BDE IMPORTANT: the units should operate with a mixture of water and ethylene glycol (containing passivating inhibitors to prevent corrosion) in proportion to the external minimum design temperature. To prevent freezing during dehumidification, the circuit must always contain at least 10% glycol. Percentage in weight of ethylene glycol 10% 20% 30% 40% 50% Freezing temperature -4 C -10 C -17 C -25 C -37 C 22 (50) Rev EN

23 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E, BDE HUMIDIFIER CONNECTION Connect the humidifier intake (fig. 17. F ) to the building water supply using the 6 mm internal diameter flexible plastic tube included with the unit and a shut-off valve. D C 1 F C F 1 F 2 C F OPTIONAL Humidifier (versions D and H only) C 2 Fig. 17.a. SIDE (section) F C2 C 355 C-(D) F C 1 F 1 F 2 C 2 Fig. 17.b. MD* BD* C C F F C (D) F C(D): Condensate / Humidifier drain F: Humidifier feed Rev EN 23 (50)

24 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E, BDE The characteristics of the water supply must be within the following limits: MINIMUM MAXIMUM Mains pressure 1 bar 10 bar Electrical conductivity at 25 C 125 µs/cm 1250 µs/cm Dimensions of impurities - 0.1mm A mechanical filter with a mesh less than 50µm should be used. Do not use water from de-mineralising or water softening plants. The figure below represents connection of the condensate drain for unit versions D and H. At the condensate collection tray of the evaporating coil two corrugated siphoned tubes are connected (B1 e B2) and meet at the "T" form (B3) from which leaves the connection to the humidifier drain. During instalation, the water drain attachment (C-(D)) is connected to the building s waste water drain by means of a rubber or plastic tube with a resistance to temperatures reaching 100 C. A siphon must be provided on the piping on the outside of the unit, to avoid that water levels can rise and overflow the humidifier tray. At the end of the siphon the pipe should have an inclination that is sufficient to provide water discharge (at least equal to 1%). 1 Sez. 1-1 Sez. 2-2 B1 B1 B2 B3 B2 B3 C -(D) B3 1 C -(D) 24 (50) Rev EN

25 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E, BDE CONNECTING THE CONDENSATE DRAIN The figure represents connection of the condensate drain for unit versions C and T. At the condensate collection tray of the evaporating coil two corrugated siphoned tubes are connected (B1 and B2) and meet at the "T" form (B3) B1 B2 B3 C (-D) During installation, the water drain (C-(D)) is connected to the the building s waste water drain by means of a rubber or plastic tube with an internal diameter of 25 mm with a resistance to temperatures reaching 100 C. A siphon must be provided on the piping on the outside of the unit, to avoid that water levels can rise and overflow the condensate tray. At the end of the siphon the pipe should have an inclination that is sufficient to provide water discharge (at least equal to 1%). If used, the optional condensate pump should be placed at a lower level than the output connection; the pump head pressure must be sufficient to deliver the condensate to the drain. C-(D) Minimum inclination Syphone > 1 % Rev EN 25 (50)

26 INSTRUCTION MANUAL UNIFLAIRTM ELECTRICAL CONNECTIONS Correct and accurate electrical connections, carried out in compliance with local regulations, are extremely important for the prevention of accidents and for ensuring long, trouble-free operation. MD.T-D-E, BDE ACCESS TO THE ELECTRICAL PANEL Before working on the electrical parts of the unit, make sure that there is no power supply to the unit and that the switch on the electrical panel is off (in the O position); The power section of the electrical panel is protected by a plastic cover; to remove this cover, turn off the main switch to release the lock and then undo the four screws. CONNECTION TO THE MAINS - CABLE SECTIONS - FUSES Check that the mains voltage corresponds to the nominal data of the unit (voltage, phases, frequency) shown on the electrical panel. Power supply voltage must be within ±6% of the nominal value. In tri-phase units the difference between the phases must be less than 2%: unit operation with power supplies outside these limits may invalidate the guarantee. Pass the electrical supply cable through the hole in the bottom of the unit. The cable can also be passed through the sides or back of the base frame after opening the pre-cut holes. See also the table Recommended cable sections and line fuses. Take the cable up to terminal box A (fig.18.) containing the terminals of the 3 phase wires and of the yellow-green earth wire (detail B ). Fix the ends of the power supply cable to the top terminals of the general switch in the electrical panel and tighten the screws. N.B. in MD*0651 and BDE units the neutral wire must also be connected (detail C ). L1 L2 L3 B L1 L2 L3 N A 70 C 70 FIG. 18. MD* (50) Rev EN

27 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D-E, BDE L1 L2 L3 N A B Fig. 19. BDE INSTALLATION AND CONNECTION OF CONTROL PANEL The control is not installed on the unit when it is shipped to prevent damage during transport. The package containing the control is in the fan housing on the right hand side of the unit. Fix the control panel(s) in accordance with the enclosed instructions and insert the cable connectors in the respective slots without forcing them (see control panel instruction manual). IMPORTANT: the connection of the control panel must always be carried out when the power is off (electrical panel switch in position O ). Rev EN 27 (50)

28 INSTRUCTION MANUAL UNIFLAIRTM MD.T-D-E, BDE RECOMMENDED POWER SUPPLY CABLE SECTIONS AND LINE FUSES UNIT - VERSION C UNIT - VERSION T UNIT - VERSION D UNIT - VERSION H MODEL LINE FUSES LINE FUSES LINE FUSES LINE FUSES MD x PE 40A 4x PE 40A 4x4 + 4PE 40A 4x6 + 6PE 50A MD x PE 40A 3x PE 40A 3x4 + 4PE 50A 3x4 + 4PE 50A MD x4 + 4PE 40A 3x4 + 4PE 40A 3x PE 50A 3x PE 50A MD x4 + 4PE 40A 3x4 + 4PE 40A 3x PE 50A 3x PE 50A MD x6 + 6PE 50A 3x6 + 6PE 50A 3x PE 63A 3x PE 63A BD x25+16PE 125A 4x25+16PE 125A 4x25+16PE 125A 4x25+16PE 125A BD x25+16PE 125A 4x25+16PE 125A 4x25+16PE 125A 4x25+16PE 125A 28 (50) Rev EN

29 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D.E, BDE START-UP AND TESTING EVACUATION OF REFRIGERANT LINES AND REFRIGERANT CHARGING (MDT) The unit is supplied pre-charged with refrigerant R22 or R407C. Check the type of refrigerant to use on the unit data plate and on the compressor. Create a vacuum in the refrigerant lines and the remote condenser; maintain pressure below 100 Pa absolute (0,7 mmhg) for several hours (preferably overnight) in order to evacuate air and any moisture traces. Start the compressor and then slowly charge the system with refrigerant through the special valve downstream of the thermostatic valve. Charge the system until the pressure in the lines is stable and the bubbles in the sight glass have disappeared. The charging must be done under normal room conditions and with an output pressure of around 18 bar (equivalent to a saturation temperature of 48 C in the case of R22); If the unit has on-off condensation control, make sure that the condenser fan does not keep switching on and off, if necessary by partially obstructing the intake area. Check that the subcooling of the liquid at the thermostatic valve intake is between 3 and 5 C less than the condensation temperature reading on the manometer scale and that the superheating of the vapour at the evaporator output is between 5 and 8 C. The dilution ratio of the system is around 5% by weight of oil to refrigerant. In the event that it is necessary to top up the oil use only these types: COPELAND COMPRESSORS Refrigerant Recommended Oil R22 (Mineral oil) Suniso 3 GS Texaco WF 32 Fuchs KM R407C (POE) Mobil EAL Arctic 22 CC ICI EMKARATE RL 32S Refrigerant R22 (Mineral oil) R407C (POE) MANEUROP COMPRESSORS Recommended Oil Maneurop 160P Maneurop 160SZ Rev EN 29 (50)

30 INSTRUCION MANUAL UNIFLAIRTM MD.T-D.E, BDE THERMOSTATIC EXPANSION VALVE REGULATION (MDT) The thermostatic expansion valve is set using the regulation screws shown in the diagram below (fig. 20.). On MDD and MDE/BDE models the regulation is pre-set in the factory. NOTICE: NOTICE: The instructions as below must be done when the unit is operating in Cooling function, under the following operating conditions: - Indoor temperature: 24 C. - Outdoor temperature: 32 C. Observe the glide with refrigerant R407C. Check that liquid subcooling at the condenser output is around 3-5 C (against bubble point for R407C); Check that thermostatic expansion valve superheating is around 5-10 C (against dew point for R407C); Check that the sensor bulb of the valve is correctly positioned, fixed and insulated. If superheating is higher than the correct level, increase the valve opening; if it is lower, reduce the opening. Bulb Expansion valve Equaliser tube Evaporator coil Fig. 20. Regulation screw The table below shows the approximate changes in superheating resulting from one full turn of the thermostatic expansion valve regulation screw. Model Valve Refrigerant Evaporation temperature Pressure change per turn (bar) -10 C C Change in superheating from one turn (Kelvin) 0702 TI(E) R R407C TCLE R R407C (50) Rev EN

31 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D.E, BDE REMOTE CONTROL MP20 control systems feature as standard the automatic management of two units, one operating and one in stand-by, without the need for additional devices. To enable this, connect terminals NC10-C10 on the 2 nd level alarm relay on the first unit to remote control terminals on the second unit, and vice versa. The electrical diagram included with the unit shows the terminals for the interconnection of the units Remote control 50 0 ID1 IDCM1 NO10 C10 NC10 2 nd level alarm Fig. 21. START-UP PROCEDURE Check that the auxiliary transformer is supplied through the terminal (220/240/380/415) corresponding to the effective mains voltage. Connect the power supply to the electrical panel, set the auxiliary automatic circuit breakers, turn on the current and check that the yellow LINE LED on the control board is on. Arm all the automatic switches on the electrical panel. Do not start the unit for at least 12 hours to allow the preheating element to evaporate any liquid refrigerant which may have accumulated in the compressor. Open all chilled water shut-off valves (chilled water models: MDT-MDD-MDE/BDE). Open all condensation water shut-off valves (water-cooled models: MDD-MDE/BDE). Open all shut-off valves on the refrigerant circuits (air-cooled models: MDT) Check that power is on to the remote air-cooled condensers (MDT units) Check that power is on to the remote radiators (MDD-MDE/BDE units) Check that the cooling water circulating pump is working and power is on to the external radiators (watercooled models). AT LEAST 12 HOURS AFTER TURNING ON THE POWER SUPPLY: Start the unit by pressing the button on the control terminal; after a short delay the fan will start and the green LED on the control panel will come on. If there is an alarm shown by the red ALARM LED and the buzzer, consult the microprocessor control manual. Rev EN 31 (50)

32 INSTRUCION MANUAL UNIFLAIRTM FUNCTION AND REGULATION WATER-COOLED UNITS (MDD) MD.T-D.E, BDE OPEN WATER CIRCUIT If the cooling water temperature is not controlled and may go below 28 C, a pressostatic valve must be fitted for each condenser; in this case the supply pressure must not go above 200 kpa (2 bar). IMPORTANT: do not use water cooled by an evaporating tower since the condensers would quickly become blocked with scale. CLOSED WATER CIRCUIT The condensers are supplied with water in a closed circuit cooled by external radiators; check that the section of the piping and the performance of the pump are sufficient. An inadequate water flow reduces the performance of the air conditioning unit. The cooling water temperature must be controlled so that it does not go below 28 C (fig. 22). The microprocessor control system performs this function; it measures the water temperature with optional sensor A, adjusting the fans C of the external radiators (see mp20 instruction manual - analogue output "Y1"). If the temperature of the cooling water is not controlled, a constant water flow condensation pressure regulation system must be used (available as an option) on each cooling circuit. IMPORTANT: the cooling water must contain a percentage of ethylene glycol (of the passive, noncorrosive type) in proportion to the likely minimum outdoor temperature. Percentage of glycol by weight 10% 20% 30% 40% 50% Freezing temperature -4 C -10 C -17 C -25 C -37 C Limit of equipment supplied by UNIFLAIR 28 C T A C Fig (50) Rev EN

33 TM UNIFLAIR INSTRUCTION MANUAL MD.T-D.E, BDE ELECTRICAL CONNECTION AND CONTROL OF REMOTE RADIATORS (MDE/BDE) The room units need to be wired to the radiators only for transmitting the signal required to control the radiator operation, as described hereafter. The remote radiators - electrically supplied from the nearest power point, independently from the room unit - must be provided with a fan contactor whose coil shall be energised with a 24 V AC signal to start the fans. In MDE units the microprocessor measures and compares the return air temperature and the outdoor temperature and, when feasible, switches from the mechanical cooling mode to the energy-saving mode. The microprocessor measures also the coolant temperature and, when this is lower than the return air temperature, opens the 3-way valve to feed the free cooling coil (analogue output Y0). The water/glycol coolant temperature is kept at two different levels: - at approx C, to be set according to the design conditions, during the warm weather mode (operation with mechanical cooling only); - between 8 and 10 C during the energy-saving mode (free-cooling operation). The microprocessor has the capability of controlling the coolant temperature (with the NO contact 13 placed in the interface card: refer to the mp10/mp20 microprocessor manual) according to one of the following systems. WATER CIRCUIT WITH ONLY ONE ROOM UNIT (see fig. 23.a.) The ENERGY-SAVING unit measures with its own sensor the coolant temperature and controls it by energising the contactor of the radiator (max 2 pieces) through the contact 13 of the interface card. The radiator can be alternatively of the type: - without thermostatic control. The microprocessor of the room unit controls at any time the coolant temperature providing an on-off signal to start the radiator fan(s) - with thermostatic fan speed control by regulating fan speed. During the mechanical cooling mode the radiator controls the coolant temperature with its built-in thermostatic fan speed control. During the Energy-Saving cycle the microprocessor controls the coolant temperature providing an on-off signal to start the radiator fan(s). WATER CIRCUIT WITH MULTIPLE ROOM UNITS AND RADIATORS IN PARALLEL (see fig. 23.b.) In multiple installations, with several room units (each one capable of fully independent operation) and several radiators connected in parallel in the same water circuit, the control system is more flexible. The coolant temperature is controlled by the «RADIATOR MANAGER» (RM in fig. 23.b.), a separate electrical panel with an independent multi-step solid state temperature controller with two different and individually programmable set points («Summer» & «Energy-Saving»). The «RADIATOR MANAGER» (available in 4-step and 8-step version) is connected with a double wire: - to each MDE room unit which, by closing the contact 13 of its interface card, has the capability to switch the operation from the mechanical cooling mode to the energy-saving mode; - to the contactor coil of each radiator to start and stop its fans. In this case too, the radiators can be either: - without thermostatic control: The «RADIATOR MANAGER» keeps the coolant temperature at the set value by controlling the number of operating radiators; - with thermostatic fan speed control: During mechanical cooling, each radiator controls coolant temperature with its own fan speed control. During the Energy-Saving cycle The «RADIATOR MANAGER» keeps the coolant temperature at the set value with the step control of the number of operating radiators N.B.: The mp10/mp20 microprocessor provides a 0-10V DC modulating signal to control radiator fans via specific fan speed control (analogue output Y1); further information is available on request. Rev EN 33 (50)

34 INSTRUCION MANUAL UNIFLAIRTM MD.T-D.E, BDE T A FIG. 23.a A T T RM S A FIG. 23.b. 34 (50) Rev EN

35 TM UNIFLAIR DIRECTION FOR USE MD.T-D.E, BDE MEASUREMENT AND ALARM DEVICES The unit is equipped with the following devices (see fig 24.): - STU: room temperature and humidity sensor; - FS: air flow sensor (differential pressostat) - PFS: dirty filter sensor (differential pressostat); - AP: high pressure p-stat with manual reset - BP: low pressure p-stat witch with automatic re-set - TSR: electric heater safety thermostat; the re-set button is in the coil housing - Chilled water temperature sensor (for reading and controlling CW operation in MDT and MDD models) installed on the chilled water supply pipe to the unit - SE: external air temperature sensor (in MDE/BDE models) to be installed outdoors in the shade - SCW: closed circuit water temperature sensor (in MDE/BDE models for reading and control of glycoled water supply temperature): installed on the water supply pipe to the unit The following optional devices can be connected to the microprocessor control: - Underfloor flooding detector consisting of: a) SAS device inserted in the appropriate socket of the electrical panel; b) RAS sensor (or sensors, connected in parallel) installed at the points to be monitored; - ATA and BTA: high/low room temperature sensors: to be installed close to the unit; - AUA and BUA: high/low room humidity sensors: to be installed close to the room unit; - SFF: fire and smoke sensors: to be installed in the room or under the raised floor, in a low air-speed zone. SI mp20 PFS FS STU MP20 SAS SAS TSR AP BP TSR AP BP FS PFS RAS RAS Fig. 24.a. Fig. 24.b. MDT / MDD / MDE BDE Rev EN 35 (50)

36 DIRECTION FOR USE UNIFLAIRTM MD.T-D.E, BDE REGULATION OF CONDENSATION PRESSURE (Remote air-cooled condenser) Unit condensation temperature must be between: - minimum 40 C (for correct thermostatic expansion valve function and to avoid freezing of the coil in partial operation) - maximum 63 C. For this purpose there are condensation pressure regulation devices which should be set as follows. Condensation pressure is controlled by regulation of the condenser fan by one of these options which must be chosen when the REMOTE CONDENSER is ordered (see CAL Instruction Manual): 1) pressostat PV which measures condensation pressure and activates the fan of the air-cooled condenser; 2) regulator RV which modulates the speed of the fan as a function of condensation pressure. The table below shows the settings of the two systems. Description Intervention Differential Re-set PV standard Fan Pressostat 18 bar (closing) 4 bar 14 bar RV optional Speed regulator 20 bar (maximum speed) 4 bar 16 bar (minimum speed) When setting the pressostat or the regulator, check the condensation pressure with a manometer connected to the pressure connector of the gas output valve. SETTING THE PRESSOSTATIC VALVE (Optional - water cooled models only) The pressostatic valve controls the water flow to prevent condensation pressure from falling too low and to reduce water consumption. Set the pressostatic valve with the regulation knob (clockwise to increase the pressure) until the pressure is stable at the recommended value of 17 bar (equivalent to a saturation temperature of around 45 C in the case of R22). Check the pressure with a manometer on the pressure connector of the output valve. 36 (50) Rev EN

37 TM UNIFLAIR DIRECTION FOR USE MD.T-D.E, BDE SETTING THE REGULATION AND SAFETY DEVICES After starting the unit, make the following settings: - Room temperature: see control manual; - Room relative humidity (D and H versions): see control manual; - Fan speed: see section on Fan Speed Regulation; - Dirty filter differential pressostat: see section on setting the dirty filter sensor. Check that safety devices are set at the values shown in the table below. The regulation and safety devices are set in the factory as shown in the table below and must not be changed without good reason. SETTING VALUES Description Intervention Differential Re-set ALL MODELS AP HP Pressostat 27.5 bar (opening) - Manual reset BP LP Pressostat 2.0 bar (opening) 1.5 bar 3.5 bar TSR Safety Thermostat (optional) 320 C (opening) - Manual reset VS Safety valve 29 bar - - WATER-COOLED MODELS VP Pressostatic valve 15 bar - - SETTING THE AIRFLOW SENSOR The FS differential pressostat should intervene if the fan is not working (if the unit has one fan only) or if one of the fans is not working (in the case of multiple fans). The setting of the airflow differential pressostat is 1.0 mbar (100 Pa). Since the difference in pressure between the fan intake and delivery depends on the airflow, it is necessary to set the pressostat after installation, making sure that the contact closes when the fan is in normal operation. To set the pressostat: set the fan speed regulator at the required value (see Fan Speed Regulation); simulate a fan fault (stop the fan, or one of the fans if multiple); check that the pressostat intervenes if the pressostat does not intervene, gradually lower the setting until it does The FS differential pressostat can be set on a scale from 0.5 to 5.0 mbar (from 50 to 500 Pa). SETTING THE DIRTY FILTER SENSOR (Optional) The PFS pressostat must be set as a function of the pressure drop; this depends not only on how dirty the filter is but also on the airflow and therefore on the setting of the fan speed regulator. The setting must be done when the filter is clean: - set the fan speed regulator at the desired value (see Fan Speed Regulation); - set the pressostat intervention at 1.5 mbar; - gradually cover the surface of the air filter and check that the pressostat intervenes when the filter is about 50-60% covered; - if the pressostat does not intervene, gradually lower its setting; if it cuts in too soon, increase the setting. Rev EN 37 (50)