BHW INSTALLATION, OPERATION AND MAINTENANCE MANUAL MEDIUM STATIC PRESSURE DUCTABLE TYPE. Models:

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1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL BHW MEDIUM STATIC PRESSURE DUCTABLE TYPE Models: Cooling capacities from 3,1 to 25 KW Heating capacities from 4,5 to 55,5 KW

2 Thank you for trust in Hitecsa Product. From our company we are offering to the market, for more than 30 years, an extended range of specialized units for air conditioning and cooling installations. Our approach is based in efficiency, flexibility, manageability and practical solutions. It has built a hallmark of our product catalogue. The versatility of our factory allows us to contribute solutions almost customitzables in each project, searching a solution for every problem that arises in design and implementation of air conditioning installations. From Hiplus Aire Acondicionado s team, once more thank you very much.

3 BHW SAFETY PRECAUTIONS... 4 OPERATING LIMITS... 4 EQUIPMENT RECEPTION... 4 RIGGING... 4 INSTALLATION LOCATION... 4 SERVICE AREA... 5 APPROXIMATE WEIGHT DISTRIBUTION (KG)... 5 UNIT SETTLEMENT... 6 ELECTRICAL CONNECTIONS... 6 WATER DRAIN... 6 AIR DUCTWORK... 6 INDOOR FAN ADJUSTMENT... 7 ELECTRIC CONNECTION FOR UNITS BHW WITH 3 SPEED... 7 DIMENSIONS... 8 BHW 174, 205, 358, BHW BHW 720, TECHNICAL DATA OPTIONALS FANS WITH EC MOTOR 3 SPEEDS VERSION MAINTENANCE BEFORE START UP START UP OPERATING INSTRUCTION FOR EC FANS SAFETY INFORMATION, ALL UNITS OPERATING CONDITIONS ECM082 MOTOR GENTEQ MOTOR... 15

4 SAFETY PRECAUTIONS Installation and maintenance of air conditioning equipment can be dangerous because system is under pressure, has high temperature of some elements and includes electrical components. Only qualified and trained service personnel should install, start up and make maintenance of the air conditioning equipment. During every visit follow the recommendations from the Installation Operation Maintenance manual, what is shown on unit s stickers and take general legal safety precautions. Follow strictly all safety codes. Use safety glasses, work gloves and some other work safety accessory. ATTENTION! Before staring installation, service or maintenance turn off system main power switch to avoid electrical shock. When repairing the unit use only original spare parts and install them properly in the same place where have been located the old parts. Do not install the unit in explosive atmosphere. OPERATING LIMITS COOLING CYCLE TEMPERATURE Indoor air inlet 27ºC, TS 19ºC, TH Water inlet 7ºC Water outlet 12ºC EQUIPMENT RECEPTION 1. Inspect equipment received for damage or missing elements. If units are damaged or shipment is incomplete, file the claim with the transport company, immediately. Max. term 48h. 2. Check if unit nameplate voltage is correct and agrees with local power supply. RIGGING 1. Before moving the unit, be sure that all unit panels are well fixed. 2. Raise and set down the equipment carefully. 3. Always transport the unit to the installation place in its original packaging. INSTALLATION LOCATION 1. Check if construction is able to support the unit s weight. 2. Check if there is enough service space around the unit. 3. Choose a place free of dust and foreign matter. 4. If necessary, install vibration absorbers through the system to avoid noise transmission.

5 SERVICE AREA APPROXIMATE WEIGHT DISTRIBUTION (Kg). BHW WEIGTH

6 UNIT SETTLEMENT Be sure unit is correctly leveled. Be sure that after settlement of the unit indoor drain is working properly. ELECTRICAL CONNECTIONS ATTENTION! Before starting any type of operations put in position off main power switch. The electrical power supply to the unit should agree with data on the nameplate. Unit star-up at incorrect voltage and resulted from it damages are not covered by Hitecsa guarantee. When making electrical connections always use the unit wiring diagram. Unit current supply should be within +-5% of Volts and Amperes indicated on the unit nameplate. Do not operate at any different current from that is shown on the unit s nameplate. The installer has to install the line protection elements according to the local laws. The interconnecting wires have to be in the protection tube or inside the groove channel. WATER DRAIN The indoor drain (of condensate water) has connection 3/4 MPT. Condensate evacuation line diameter should be equal or larger than unit drain connection depending on the lie length and general building configuration. The condensate line should be pitched a minimum 2% for proper water evacuation. When drain line is exposed to air temperatures below 0 grades is necessary to provide thermal insulation or electrical heating wire to avoid water freezing and tube damage. It is convenient to install the trap with proper dimensions. AIR DUCTWORK - Air ducts dimensions are d in function of the air flow and the available external static pressure. - A qualified technician should make the air duct design. - Use air duct of nonflammable material, which in case of fire, will not emit toxic gases. It is advisable to use metal sheet ducts with insulation. - Use flexible elements between the air duct and the unit, to avoid vibrations and noise transmissions.

7 INDOOR FAN ADJUSTMENT Verify that the consumption of the fan doesn t exceed the maximum allowed. ELECTRIC CONNECTION FOR UNITS BHW WITH 3 SPEED N L Neutral Phase 0 Neutral 1 High 2 Medium 3 Low

8 DIMENSIONS BHW 174, 205, 358, 410 CONSTRUCTIVE DETAILS 1. Plenum tubular mouthpiece 2. Plenum impulsión 3. Coil 4. Turbine 5. Motor turbine 6. Power supply input 7. Water outlet (connection 3/4 ) 8. Water inlet (connection 3/4 ) 9. Drainage 3/4 male 10. Air filter MODEL A B C D E F G H I J K L 174 mm mm mm mm

9 BHW 515 CONSTRUCTIVE DETAILS 1. Plenum impulsión 2. Turbine 3. Motor turbine 4. Water outlet (connection 1 ) 5. Water coil 6. Water inlet (connection 1 ) 7. Electrical coil 8. Air filter 9. Drainage 3/4 male BHW 720, 724 CONSTRUCTIVE DETAILS 1. Plenum impulsión 2. Motors turbines 3. Turbines 4. Water outlet (connection 1 1/4 ) 5. Water coil 6. Water inlet (connection 1 1/4 ) 7. Electrical coil 8. Air filter 9. Drainage 3/4 male

10 TECHNICAL DATA BHW CAPACITIES Speed I KW 3,1 4,4 6,0 7,9 12,2 Cooling capacity (1) Speed II KW 4,1 5,0 5,9 9,1 13,9 20,2 25,0 Speed III KW 4,5 5,3 8,4 10,8 15,3 Heating capacity (2) Speed I KW 4,5 6,4 8,6 11,1 16,1 Speed II KW 5,8 7,1 9,7 12,6 18,2 26,5 32,7 Speed III KW 6,3 7,5 11,9 14,9 19,7 Heating capacity (3) Speed I KW 7,6 10,8 14,6 18,8 27,2 Speed II KW 9,8 12,1 16,5 21,4 30,8 44,8 55,5 Speed III KW 10,7 12,7 20,1 25,2 33,5 VENTILATION Fan model 146/ / / / /236 2 X 9/9DD 2 X 9/9DD Speed I m3/h Cold air flow Speed II m3/h Speed III m3/h Speed I m3/h Hot air flow Speed II m3/h Speed III m3/h Available static pressure Speed I Pa Speed II Pa Speed III Pa Motor fan power KW 0,18 0,18 0,25 0,25 0,55 0,25 0,36 HEAT EXCHANGER Water connections Ø ( ) 3/4 3/4 3/4 3/ /4 1 1/4 Cooling and heating water flow Speed I m3/h 0,53 0,76 1,03 1,36 2,09 Speed II m3/h 0,69 0,85 1,18 1,56 2,36 Speed m3/h 0,76 0,90 1,44 1,85 2,57 III ELECTRICAL SPECIFICATIONS 3,37 4,19 Voltage V / f / Hz 230 / III / 50 Nominal power input KW 0,20 0,26 0,36 0,56 0,60 0,81 1,6 Nominal current input A 1 0,5 1,75 2,5 2,75 3,9 7,4 DIMENSIONS Width mm Length mm Height mm Weight Kg (1) Cooling capacity for water temperature of 7ºC. (2) Cooling capacity for water temperature of 50ºC and indoor temperature of 20ºC. (3) Cooling capacity for water temperature of 70ºC and indoor temperature of 20ºC.

11 OPTIONALS FANS WITH EC MOTOR 3 SPEEDS VERSION BHW CAPACITIES Speed I KW 3,1 7,9 12,2 Cooling capacity (1) Speed II KW 4,1 9,1 13,9 Speed III KW 4,5 10,8 15,3 Speed I KW 4,5 11,1 16,1 Heating capacity (2) Speed II KW 5,8 12,6 18,2 Speed III KW 6,3 14,9 19,7 Speed I KW 7,6 18,8 27,2 Heating capacity (3) Speed II KW 9,8 21,4 30,8 Speed III KW 10,7 25,2 33,5 VENTILATION Fan model EC082 EC 145 EC Speed I RPM Turning speed Speed II RPM Speed III RPM Speed I m3/h Air flow Speed II m3/h Speed III m3/h Available static pressure Speed I Pa Speed II Pa Speed III Pa Motor fan power KW 0,08 0,25 0,25 HEAT EXCHANGER Type Water coil with copper tubes and aluminium fins. Cooling and heating water flow Speed I m3/h 0,53 1,36 2,09 Speed II m3/h 0,69 1,56 2,36 Speed III m3/h 0,76 1,85 2,57 Water connections Ø( ) 3/4 3/4 1

12 BHW ELECTRICAL SPECIFICATIONS Voltage V / f / Hz 230 / I / 50 Speed I KW 0,06 0,13 0,14 Nominal power input Speed II KW 0,06 0,18 0,22 Speed III KW 0,06 0,21 0,32 Speed I A 0,44 0,80 0,98 Nominal current input Speed II A 0,44 0,94 1,49 Speed III A 0,45 1,19 2,13 SOUND LEVEL (4) Speed I db(a) 63 68,5 69,8 Sound power Speed II db(a) 64 69,8 71,8 Speed III db(a) 64, ,5 Speed I db(a) 43,98 48,48 49,78 Sound presure (a 2m) Speed II db(a) 43,98 49,78 51,78 Speed III db(a) 44,78 50,98 54,48 DIMENSIONS Width mm Length mm Height mm Weight Kg (1) Cooling capacity for water temperature of 7ºC. (2) Cooling capacity for water temperature of 50ºC and indoor temperature of 20ºC. (3) Cooling capacity for water temperature of 70ºC and indoor temperature of 20ºC. (4) Sound pressure level with supply and return jacks free discharge, measured 2 meters away, in free field. MAINTENANCE ATTENTION! Before performing service or maintenance operations, turn off the main power switch to avoid personal injury and put lock on power switch to avoid that any person not connected with the maintenance technical can switch on the electrical supply. It is advisable to make maintenance operation periodically according to the use and operation of the installation, as well as, on every change of the season. - Coils: At least once a year, clean condenser coils with water and detergent and dry later with air at a pressure of 600kPa. Never clean the coil with a wire brush. - Fans and motors: Verify the correct rotation of the fan to warn problems with the bearings. - Drainage system: Check if openings in the unit base for rain and defrost water evacuation is not blocked. - Water circuit: Check for leakage, noise and various system elements vibrations. Take temperature and pressure readings and record it on the maintenance form. - Electrical circuit: Make sure that all electrical cables and other elements are properly tightened. Take electricity consumption of each phase of every fan. Verify the starting current. Check the operations of all relays, contactor, etc. - Air filters: Clean air filters after 4 hours of system operation and then periodically according to the maintenance plan. Filters can be cleaned by immersion in warm water with soap, lates washed in clean water and dry.

13 BEFORE START UP - Check if all wires are well tightened. - Check if all panels are firmly secured with screws. - Verify if unit is installed on level. - Verify if there is enough space for service and maintenance. - Check if drain is not blocked. - Verify if air filters are clean and correctly mounted. - Check all grilles, air diffusers, air ducts and flexible connections. - Be sure that the electrical power source agrees with the unit nameplate rating. - Check that every fan rotates properly. START UP - Start up has to be performed by a qualified service person. - Make start-up check list and use similar check up for service and maintenance. Record chilled water inlet and outlet temperatures and pressures, outdoor air temperature, volts and amps of each fan. - Should remind that after 4 hours of system operation is necessary to clean air filters. - Observe at least, 3 cooling cycle operations. OPERATING INSTRUCTION FOR EC FANS SAFETY INFORMATION, ALL UNITS - This unit is solely intended as a built-in component as per EN and should not be operated otherwise. Sufficient protection against accidental contact according to machinery has to be safeguarded, especially for the rotating parts. Be careful in case fan-deck unit switch on. - The fans are only intended for moving air. - The fans are only to be operated within the ranges specified on the motor nameplate or in the technical specification released by Technical Dept. - The fans are supplied with external control board, in accordance to EMC guideline: EN ; EN ; EN ;EN ; EN ; EN ; EN ; EN ; EN The unit complies with the applicable standard and regulation and meet the requirements of the Low Voltage Directive 73/23/EEC and ECM guideline. - The unit meets the following standards: - EN 60529: Degree of Protection provided by enclosure ( IP code ) - EN /2+ EN /3: Electromagnetic Compatibility - EN : Safety of household and similar appliances ( see the Declaration of conformity ) - Do not open the control board if power supply is on. - Don t touch any parts if unit is running.

14 OPERATING CONDITIONS UNITS Motor model ECM082 GENTEQ Voltage supply 230V±10% 230V±15% Frequency Duty cycle Max. operating ambient temperature Input signal Output signal 50/60Hz S1, continuous operation. Intermittent duty cycle is permitted 1-10 Vdc, 0,9 Vdc motor stops 50ºC 10 Vdc 1-10 Vdc Speed rpm rpm Life expectancy hours hours Overload protection. Temperature sensor and internal fuse Locked rotor protection, via software. ECM082 MOTOR LOCKED ROTOR PROTECTION 40mm STACK ECM motor Vdc= 10V, 230V, 50Hz Test in free-air on fan deck unit type 2x146x226mm, ABS material - 15 cycles of 7 each for a total time of 100 after that motor stop, electronic control board in stand-by at minimum consumption I=45mA. re-start the motor switch off and switch on power supply. - Cycles counter reset after 30 of operation at nominal rpm, after this time in case of locked rotor control board return to count 15 cycles, before this time control board maintains in memory the cycles till now got. - In all conditions, after the motor stopped definitely due to rotor locked, to re-start occurs switch off, wait for some second, about 7, and switch on again. OVERLOAD PROTECTION Temperature sensor: via hardware through NTC In case the power stage temperature exceeds its upper limit due to overload (higher current), NTC modifies its resistance leading the motor control which it reduces the speed and power in order to return within its limit. If this does not happen then the control board stops the motor and fault signal appears. FAULTS - Motor Gate kill fault: in case of Mosfet s short circuit, they get open to avoid damage on dc bus due to critical overvoltage fault. Motor stops definitively - Dc bus overvoltage. If the voltage is greater than 270V the motor is stopped. It is restarted if the voltage goes under 270V. - Dc bus under voltage fault. If the voltage goes under 70V the board stops the motor and restarts it only when the voltage goes over 144V. - Motor over speed fault. If the speed goes over 2000 rpm the motor is stopped and restarted.

15 - Motor zero speed fault. If the motor is stopped but it should be running it will be restarted. - Start fail fault. The start procedure is repeated. - Temperature sensor fault: In case of long terms overload, the control board stops the motor. - Communication fault: If a problem is detected in the communication between the Master processor and the motor processor, the motor processor will be reseted and restarted. GENTEQ MOTOR OPERATING SPEED LIMIT Operating speed limits: due to the large centrifugal forces present in the motor during high-speed operation, speed limits on present production are as follows: -1/3 hp may operate at speeds up to 1900 rpm. - All others may operate at speed up to 1500 rpm. Operation above these limits may result in permanent damage to the motor. LOCKED ROTOR PROTECTION Protection of ECM Motors: ECM motors are referred to as Impedance Protected simply because there are no thermal protectors mounted on the windings to protect motors but the protection is done by the electronic control. There is no separate class in Safety agency standards for protection using electronic control. Given the two classes namely Thermally Protected and Impedance Protected, impedance protected comes closer to electronic protection employed in ECM, therefore ECMs are referred as Impedance Protected. by safety agencies. How does the Electronic Protection work: At operating condition there are two means of limiting current into the motor. The first one called peak current regulate actually regulates the current supplied to motor by means of a resistor in the electronic control which limits current to a value that is sufficient to deliver full output. The motor thermal characteristics are such that at this full output the temperature of the windings does not exceed insulation rating for the motor (for example 130 Deg C for class B insulation system) or thermal rating of the electronic components. The second means of protection is done by current trip. This is also set by another resistor in the electronic control. When the current exceeds a pred value the electronic control automatically trips or stops energizing motor with current. At Locked rotor condition, the electronic control senses no rotation condition and shuts down. It continues to try starting motor with small amount of current but fails to do so when rotor is truly locked. It can continue trying to start the motor indefinitely but amount of current is so small that it does not result in any heating of motor windings or electronic components.

16 HIPLUS AIRE ACONDICIONADO S.L. Masia rrents, 2 Tel Fax Vilanova i la Geltrú Barcelona, España We reserve the right to make modifications without prior notice. This document is a translation from the original document.