Adsorption Chiller Aggregate ezea

Transcription

1 Adsorption Chiller Aggregate ezea Production year: [Prod-Baujahr] Serial number: [Prod-Ma-Nr] Number Version 1.0 AdKA2015OM-ENG Date of issue Language English Translation of the original German user manual, version 1.0 Target audience This operating manual was written for professionally trained and qualified personnel of the distributor / integrator. Copyright 2015 SorTech AG - The partial or total duplication as well as the passing on of this documentation on third parties is subject to the expressed permission to SorTech AG.

2 Change History Version Date Modification/description Release 1.0a Translation of the original German user manual F. Ruthenberg SorTech AG Zscherbener Landstraße Halle (Saale) Telephone Fax office@sortech.de Website

3 About this 3 / 150 About this This operating manual contains all information necessary to properly operate the Adsorption Chiller Aggregate ezea. The operating manual was written for professionally trained and qualified personnel of the distributor / integrator. The operating manual is a part of the Adsorption Chiller Aggregate ezea and must be stored for the entire product lifetime. It must be stored close to the installation site in a place which is easily accessible and identifiable for device operators. In case the Adsorption Chiller Aggregate ezea is passed on to a successive user, then the operating manual must be included as well. Only do service work on the Adsorption Chiller Aggregate ezea once you've completely read and understood the operating manual. The Adsorption Chiller Aggregate ezea is referred to short form as ezea. Product Identification The ezea can be clearly identified by the attached type plate (see Fig. 1). Fig. 1: Type Plate Make sure that this operating manual corresponds to your version of the ezea.

4 System Documentation: Overview System Documentation: Overview The following documents are available for the Adsorption Chiller Aggregate ezea. Tab. 1: System Documentation Document name (OM) Technical Manual (TM) Installation Manual for the Connecting Kits (IM-CK) Description This document is included in the delivery. A manual which helps specialist companies develop an integration and configuration concept for the AdCA This document is available separately. A manual for the installation and disassembly of the Connecting Kits (optional component) This document is available separately. All important system-related information (i.e. descriptions, instructions and notices) is laid out in these three manuals. The following table shows where specific information can be found in the system documentation: Tab. 2: Outline of System Documentation Information OM ezea TM AdCA IM-CK Product identification Warranty General Health and Safety Guidelines Intended Use Prohibition of Operation Hazard Potential Product description Short Description Technical Data Principles of System Configuration

5 System Documentation: Overview 5 / 150 Information OM ezea TM AdCA IM-CK Operating Limits / Installation Instructions Planning Hydraulics Planning Electrical Systems Installation Commissioning Operation Maintenance Repair Decommissioning Storage and Recommissioning Transport and Packaging Disassembly Disposal

6 Warranty Warranty The Adsorption Chiller Aggregate is treated as partly completed machinery according to the Machinery Directive 2006/42/EC. SorTech AG accepts no responsibility nor liability nor is subject to claims by the operator or third parties for any personal injuries or damage to property caused by an operator or a third party and resulting from one or more of the following reasons below: Unintended use of the Connecting Kits, Failure to comply with the instructions in this installation manual, Failure to comply with the stated operational limits and conditions, Improper installation, commissioning, operation or maintenance of the Connecting Kits, Unauthorised modifications to the connection kits, or Usage of unauthorised accessories or replacement parts. The Connecting Kits are customized to match the system in which they are integrated during initial device commissioning. As a result, the initial commissioning must be completed by an authorised service technician or a technician from SorTech AG. SorTech AG assumes no responsibility for any damages resulting from noncompliance with this requirement. Numerous tests and safeguarding procedures were conducted with the Connecting Kits. Nevertheless, the actual cooling capacity and efficiency of the machine may deviate from the stated specifications under certain circumstances.

7 Use of Symbols and Abbreviations 7 / 150 Use of Symbols and Abbreviations Pay close attention to the following symbols and abbreviations while reading this operating manual The following symbols are used in this operating manual: Tab. 3: Symbols Symbol Explanation Warning: risk of injury! Warnings related to risk of injury to personnel are depicted with one of these symbols depending on the level of danger. For more information, see chapter 1.3 on page 14. Warning: damage to property. Note instructions in the operating manual. General information and helpful tips related to the operation of the Adsorption Chiller Aggregate. The following specific abbreviations are used in this operating manual: Tab. 4: Specific Abbreviation Abbreviation A/R AdCA CCHP CHP COP DC Explanation As Required Adsorption Chiller Aggregates Combined Cooling, Heat and Power Combined Heat and Power Coefficient of performance (ratio of heating provided to electrical energy consumed) Direct Current

8 Use of Symbols and Abbreviations Abbreviation dqo EC ezea EPD HT Explanation Cooling capacity in kilowatt Electronically commutated (term for a synchronous motor powered by DC voltage, but which produces an AC electric signal; Example: EC-ventilators) Abbreviated name for the Adsorption Chiller Aggregate ezea Electric Power Distribution High Temperature (drive temperature) O. K. Okay KF LT MT Small Flange Low Temperature (cooling water temperature) Medium Temperature (recooling temperature) T A1 OUT Outlet Temperature of adsorber 1 T A2 OUT Outlet Temperature of adsorber 2 T Freeze T MT OUT T_FK T_Set_Ext T_Soll Frost protection limit parameter Outlet Temperature of the condenser Temperature limit for free cooling External Setpoint Temperature Setpoint Temperature

9 Table of Contents 9 / 150 Table of Contents Change History... 2 About this... 3 Product Identification... 3 System Documentation: Overview... 4 Warranty... 6 Use of Symbols and Abbreviations General Health and Safety Guidelines Required Qualifications Personal Protective Equipment Display of Warning Messages Intended Use Reasonably Foreseeable Misuse Prohibition of Operation Hazard Potential Hazardous Areas Risk of Death from Electric Shock Risk of Burns and Scalds Risk of Cuts Risk of Crushing Legal Provisions Product Description Overview of the ezea Standard Scope of Delivery Optional Scope of Delivery Configeration/Function Intended Use Structure Hydraulic Connections Interconnection of Multiple ezea s Power Supply Connection Regulatory Connections Funtionality Functional Construction Sequence of Events Operating Modes... 35

10 Table of Contents 2.9 Layout and Operation of the Control and Display Elements (Controller) Optional Components Recooler System Separation Water quality and filling of the system Technical Data Dimensions and Weight Performance Data Operating Limits of the Operating Modes Hydraulic connections Power Supply Connections Control System Connections Optional Components Recooler System Separation Project Planning Requirements for Project Planner Technical Manual Requirements for Interconnection Installation Safety Precautions Criteria for the Installation Site Install the ezea Connect the Hydraulics Connect the Electric Connections Installation of Optional Components Install a Recooler Install the System Separation Commissioning Safety Precautions Commission the ezea Operation General Information Power on the ezea Main Menu Menu "values"... 74

11 Table of Contents 11 / Menu "user inputs" Menu "messages" Menu "manual settings" Change Setpoint Temperature Maintenance Safety Precautions Maintenance Cycles Inspection Requirements Inspection Overview Requirement for System Maintenance System Maintenance Overview Check of the Vacuum Modules Explanation of "Activation" Establish Activation Test the Vacuum End Activation Do a Performance Test Repair Safety Precautions Troubleshooting Fault Messages and Solutions Problems from too little Cooling Load Decommissioning Safety Precautions Decommission the ezea Long-term Decommissioning Optional Components Storage and Recommissioning Storage Conditions Store the ezea Recommission the ezea Optional Components Transport and Packaging Safety Precautions during Transport Transport the ezea Delivery Packaging

12 Table of Contents 12.4 Repack after Disassembly Optionale Components Disassembly Safety Precautions Disconnect Electrical Connections Hydraulikanschlüsse trennen Disposal Prepare for Disposal Disposal Guidelines List of Figures List of Tables Glossary Appendix A: Configurations Appendix B: List of Spare Parts Appendix C: Drawings/Diagrams Appendix D: Diagrams/Characteristics Appendix E: Commissioning Checklist Appendix F: Maintenance Checklist

13 13 / General Health and Safety Guidelines Chapter Contents This chapter contains instructions related to general health and safety guidelines. Chapter Goals To alert the operator to possible dangers they may face when operating the ezea, increasing safety- conscious behavior and ensuring proper operation of the machine. Read all safety instructions before using the ezea. Failure to comply with these instructions can lead to personal injuries and/or damage to property. AdKA2014OM-ENG ::: 1.0 ::: English

14 General Health and Safety Guidelines ::: Required Qualifications 1.1 Required Qualifications Unless specifically stated, all tasks related to the ezea must be carried out by professionally trained and qualified personnel only. Personnel must possess the following proficiencies and / or meet the following requirements: Tab. 5: Qualification of personnal Tasks Person Proficiencies/Requirements Transport, storage Warehouse clerk / transporter No specific requirements Assembly, disassembly Installer Service training with certification Commissioning, decommissioning Service technican Service training with certification Operatio Operator No specific requirements Maintenance, repair Service technician Service training with certification Disposal Service technician Service training with certification 1.2 Personal Protective Equipment Wear protective gloves when servicing the ezea. The machine has hot surfaces and sharp edges which can cause injuries. No personal protective equipment is necessary when operating the ezea. 1.3 Display of Warning Messages Warning messages in this document are depicted in the following three ways: Designates a highly dangerous situation which can lead to serious injury or death.

15 General Health and Safety Guidelines ::: Intended Use 15 / 150 Designates a medium danger situation which can lead to serious injury or death. Designates a low danger situation which can lead to light or medium injuries. Personnel-related warning messages are structured in a clear and straight-forward way. Here is a general example which shows the structure and the contents of a warning message: 1. Signal word 2. Type and source of danger 3. Consequences of non-compliance 4. Measures to avoid danger / prevent harm Warnings related to property damage are depicted in the following way: Depicts possible property damage which may occur during use of the Adsorption Chiller Aggregate. 1.4 Intended Use The ezea was designed and tested for a specific use. Operate it according to this intended purpose only. The intended purpose includes use as a cooling machine to cool air or water. Additionally, the ezea may also be used as a thermal heat pump for heating purposes. Any other use of the ezea does not comply with the intended use and requires the express consent of SorTech AG. Obey all operating limits in Chapter 3 Technical Data on page 43 when operating the ezea. The operator is solely responsible for complying with these operating limits. The ezea is classified as incomplete machinery according to the Machinery Directive 2006/42/EC. SorTech AG accepts no responsibility for damage or malfunctions with the ezea which result from incorrect use of the machine and / or non-compliance with the instructions in this operating manual.

16 General Health and Safety Guidelines ::: Reasonably Foreseeable Misuse 1.5 Reasonably Foreseeable Misuse Information related to reasonably foreseeable misuse is not included in this operating manual due to the fact that only qualified personnel of the distributor / integrator may operate the ezea and the manufacturer offers comprehensive service information for the entire life cycle of the Adsorption Chiller Aggregate. This service offer provides important information regarding: Handling the machine, The intended use and Proper operation of the ezea. 1.6 Prohibition of Operation If the ezea can no longer be operated safely, decommission it immediately and store it in such a way that an inadvertent recommissioning is not possible. The ezea may not be operated when at least one of the following situations occurs: The casing of the ezea shows signs of heavy damage. Damage to the inner components of the machine may have occurred due to incorrect transport and assembly. Liquid is leaking from the inside of the ezea. The ezea was stored for an extended period of time in unfavorable conditions (e.g. exposure to solar radiation, high temperatures, frost, moisture or pressure).

17 General Health and Safety Guidelines ::: Hazard Potential 17 / Hazard Potential Hazardous Areas There is no hazard potential for an operator if the ezea is used according to the instructions and specifications contained in this operating manual. The ezea operates with a vacuum (no risk of explosion) and uses water as a coolant. Follow these safety instructions The following figure provides an overview of the hazardous areas of the ezea. Pay particularly close attention to these areas during servicing: D A Improperly made connections can expose live components! See chapter on page 18. E B Pressurised hydraulics, scalding water may escape! See chapter on page 18. C Non-insulated parts have hot surfaces! See chapter on page 18. D D Pipes and threads have sharp edges! See chapter on page 19. A B C E Casing has moveable and difficult to mount parts! See chapter on page 19. Fig. 2: Hazardous Areas on the ezea

18 General Health and Safety Guidelines ::: Hazard Potential Risk of Death from Electric Shock Follow these safety instructions Improperly made connections can expose live components. Touching these components can result in an electrical shock. Connect the power supply in the last step of the commissioning process. Do not service the machine while under voltage. Only qualified and professionally trained personnel may connect the ezea and other components to the power supply. Only do service work on the ezea once you've completely read and understood the operating manual. Follow the instructions in this operating manual Risk of Burns and Scalds Follow these safety instructions The hydraulic circuits of the ezea are pressurised. An improper connection can cause scalding water (up to 95 C) to escape. Avoid bodily contact. Only qualified and professionally trained personnel may connect the hydraulic circuits. Regularly check the hydraulic circuits for possible leakage. Drain the hydraulic circuits carefully during decommissioning. Wear appropriate protective gloves. Follow these safety instructions Non-insulated parts can have hot surfaces. Touching these surfaces can result in serious burn injuries. Avoid contact with potentially hot surfaces. Wear appropriate protective gloves. Avoid damaging insulating parts. Replace insulation when necessary.

19 General Health and Safety Guidelines ::: Legal Provisions 19 / Risk of Cuts Follow these safety instructions The pipes, threads and case of the ezea can have sharp edges which may cut hands and fingers. Wear appropriate protective gloves Risk of Crushing Follow these safety instructions The casing of the ezea contains movable parts. Due to the high accuracy of fit, some casing parts may be difficult to mount. Avoid crushed fingers. Mount the casing carefully. Follow the related instructions in this operating manual. Follow these safety instructions The ezea must operate on a flat, stable surface. Make sure the machine is properly secured during transport. An improperly secured machine can crush fingers and toes by shifting or falling over. Make sure the ezea is properly secured for transport. The fixing holes in the feet of the ezea can also be used to help secure the machine. Use the appropriate technical tools. Install the ezea on a flat, stable surface only. Before installing the ezea, adjust the feet to make sure the machine is level. 1.8 Legal Provisions In addition to all instructions contained within this operating manual, obey all universally valid legal and other contractual regulations regarding accident and environmental protection as well.

20 General Health and Safety Guidelines ::: Legal Provisions

21 21 / Product Description Chapter Contents This chapter provides an overview of the ezea and its functions. Chapter Goals To introduce and describe the components and functions of the ezea, ensuring correct operation of the machine. AdKA2014OM-ENG ::: 1.0 ::: English

22 Product Description ::: Overview of the ezea 2.1 Overview of the ezea Standard Scope of Delivery Compare your delivered shipment with the components listed below. Make sure all components are in proper operating condition. Do not use damaged components! The scope of delivery of each shipment is carefully checked and confirmed by the manufacturer before delivery. Please direct all claims to your service partner. Operating manual Please follow all instructions on page 3 regarding the storage and passing on of the operating manual! Adsorptions Chiller Aggregate ezea (completely assembled, wired, with water as the refrigerant and zeolite as the adsorbent) consisting of the following components: Tab. 6: No. Scope of Delivery of the Adsorption Chiller Aggregate Components 1 Modul 1 (evacuated and leak-checked) 1 Modul 2 (evacuated and leak-checked) 3 Hydraulic and heat exchanger circuit (driving circuit (HT), recooling circuit (MT) and cold water circuit (LT)) 1 Switching unit (leak-checked) with integrated threeway-valves and 3 infinitely variable high efficiency pumps (depending on version) 1 Steel frame structure for attaching the modules with sheet metal casings 1 Integrated controller 1 Operating manual

23 Product Description ::: Overview of the ezea 23 / Optional Scope of Delivery Depending on the type of system integration and components necessary the scope of delivery may contain one or more of the following optional parts. Compare your delivered shipment with the components listed below. Make sure all components are in proper operational condition. Do not use damaged components! The scope of delivery of each shipment is carefully checked and confirmed by the manufacturer before delivery. Please direct all claims to your service partner. Recooler (dry Recooler with optional fresh water spray system, infinitely variable EC-ventilator and vibrations dampers). The Recooler is delivered in the variants horizontal installation and vertical installation for direct connection to the system separation (recooling circuit). System Separation (Connection unit used to operate the ezea with a Recooler or other heat sinks using a water-glycol mixture) consisting of the following components: Tab. 7: Scope of Delivery of the System Separation Usage Type No. Components [ST-G] 1 Plate heat exchanger, adapted to the ezea 1 Piping, copper 2 Safety groups 2 Expansion vessels, adapted to mains water 1 High efficiency pump (wet running pump), configured for the secondary circuit t [ST-O] (e.g. wet cooling tower or open recooling circuit) 1 Plate heat exchanger, adapted for the ezea A/R Piping, copper 1 Safety group 1 Expansion vessel, adapted to mains water 1 High efficiency pump (dry running pump), configured for the secondary circuit

24 Product Description ::: Overview of the ezea Usage Type No. Components [ST-B] 1 Plate heat exchanger, adapted to the ezea A/R Piping, copper 1 Safety group 1 Expansion vessel, adapted to mains water System separation is pre-assembled and delivered for direct connection to the recooling circuit of the ezea and the Recooler (optional). The following variants are possible: Variant 1 for 1x ezea, Variant 2 for 2x ezea, Variant 3 for 3x ezea or Variant 4 for 4x ezea. Through a parallel connection of two system separations (2x Variant 3 or 2x Variant 4) the system connection can be extended to 6x ezea or 8x ezea (see technical manual) Configeration/Function The ezea comes delivered in the following configuration: Optional: For use as a thermally driven heat pump in connection with an appropriate low temperature source, Integrated controller to manually or externally influence the performance of the ezea: Cold water temperature and cooling capacity or optionally heating temperature and heating performance when used as a heat pump, Continuous power modulation for an optimal operation mode of the adsorption cycles, with the option of including buffer temperatures (HT, LT), Monitoring of the cold water volume flow, Antifreeze protection and Direct switching of all system-relevant pumps and mechanical fans. Integrated pumps (infinitely variable), Free cooling, Heating (optional): Heating pump, direct heating, Interconnection of multiple Adsorption Chiller Aggregate, Integrated controls,

25 Product Description ::: Intended Use 25 / 150 External control (in slave operation) via a contact with ON/OFF switch, Outside temperature guided control, Indoor temperature guided control and Buffer temperature guided control. External setpoint temperature setting (0-5 VDC): Full or partial load control via the setpoint setting and Switch between modes via the 0-5 VDC signal (cooling mode: VDC / heat pump mode: VDC). Requirement external (peak load, backup) 2.2 Intended Use Wasre Heat into Cooling The ezea uses the waste heat of industrial machines and systems (e.g. CHP, solar, district or process heat) to produce cost-effective and environmentally friendly cooling energy. It can also be used in the low capacity range. The process modules contains no moveable parts because it uses zeolite as a working substance, eliminating the need for fluid circulation. This allows for operation with low drive temperatures. Low Drive Temperatures Heating (Heat Pump)) Combinable The ezea can produce cooling energy with low drive temperatures (from 75 C). This is especially important for solar cooling and process cooling. The ezea can also be operated as a heat pump. In this case the cold water circuit is hydraulically swapped with the recooling circuit. This allows the machine to be used for low temperature heating (as underfloor heating, for example). Depending on operating conditions, heat ratios of up to 150 % can be produced from energy drawn from the environment. The ezea can also be used in combination with small thermal power stations (TPS) (as combined cooling, heat and power, CCHP) to generate cooling energy from recuperated and insufficiently usable heat and with minimal use of electricity. Interconnection Multiple Adsorption Chiller Aggregate of ezea s can be interconnected to generate an even greater cooling or heating performance.

26 Product Description ::: Structure The ezea is not suitable for drive temperatures above 95 C, nor for ambient temperatures below 5 C without frostprotection measures. 2.3 Structure The ezea is made up of the components shown below (see Fig. 3 and Fig. 4) Fig. 3: Structure of the Adsorption Chiller Aggregate (1) 1 Controller 2 Front cover 3 Hydraulik connections 4 Module 1 5 Module 2 Controller The Controller is the control centre of the ezea. It monitors sensors, controls operating processes and enables the operator to control the Adsorption Chiller Aggregate directly via the integrated control and display elements (for the Layout and Operation of the Control and Display Elements see chapter 2.9 on page 36). The current operating condition as well as any occurring errors is shown on the display of the Controller (for error codes see chapter 9.3 on page 95). Front Cover The front cover protects the main switch and the hydraulic pumps. It can be removed for commissioning or other maintenance tasks. Do not remove the front cover while the ezea is in operation.

27 Product Description ::: Structure 27 / 150 Hydraulik Connections Module 1 und Module 2 The different circuits of the ezea are connected via the hydraulic connections (for more information see chapter 2.4 on page 28). The ezea is made up of two structurally identical modules (module 1 and module 2), both of which are contained within vacuum-sealed and insulated steel sheet housing. Both modules are divided into two processing chambers, in which the following processes alternately run: Evaporate and adsorb, Desorb and condense. These processes are explained in depth in chapter 2.8 on page Fig. 4: Structure of the ezea (2) 1 Main Switch 2 Switching Unit 3 Hydraulic pumps Main switch Switching unit The main switch separates the ezea from the power supply. The main switch is turned on when the machine is put into service. The switching unit connects modules 1 and 2 and is made up of three-way-valves and an internal piping system. Depending on the process phase module 1 or module 2, the adsorber is periodically loaded with driving heat or recooling water via the three-way-valves. Temperature sensors in each of the return lines of the heat exchanger circuit provide important data for the regulation and monitoring systems of the ezea Hydraulik Pumps Hydraulic pumps (high-efficiency pumps) are integrated into the lower switching unit (see Fig. 4. The hydraulic pumps provide the necessary volume flows for the three circuits.

28 Product Description ::: Hydraulic Connections 2.4 Hydraulic Connections Two connections for each of the three circuits are located on the rear portion of the upper side of the ezea. For the specifications of the individual connections, refer to the technical data in chapter 3 from page 43 onwards. For the dimensions of the hydraulic connections see the technical drawing in Appendix C from page 127 onwards. The hydraulic connections are labelled according to the related circuit, and inlets and outlets are marked with "IN" and "OUT", respectively (see Fig. 5) HT IN HT OUT MT IN MT OUT LT IN LT OUT Fig. 5: Hydraulic Connections (as seen from rear) 1 Input for hot water circuit 1 ¼ 2 Outlet for hot water circuit 1 ¼ 3 Input for recooling circuit 1 ½ 4 Outlet for recooling circuit 1 ½ 5 Input for cold water circuit 1 ¼ 6 Outlet for cold water circuit 1 ¼ The hydraulic connections for the ezea come delivered as as flattight threaded connection.

29 Product Description ::: Interconnection of Multiple ezea s 29 / Interconnection of Multiple ezea s Multiple Adsorption Chiller Aggregates can be interconnected in order to achieve a greater cooling capacity or, alternatively, heating performance in heat pump mode. The following interconnection setups are possible: Back-to-Back: The Adsorption Chiller Aggregates face backto-back (optional). Side-by-side: The Adsorption Chiller Aggregates are identically arranged next to one another (by request). On-Top: The Adsorption Chiller Aggregates are stacked one on top of the other (by request). Max. Interconnections Connections Installation Assistance It is possible to interconnect up to eight Adsorption Chiller Aggregates. The overall performance increases by the individual performance of an ezea for each additional machine. In all of the listed interconnection configurations, similar circuits are connected in parallel (e.g. HT IN with HT IN) via connection kits consisting of hoses and pipes. Each configuration comes with related installation assistance. 2.6 Power Supply Connection For the specifications of the individual connections, refer to the technical data in chapter 3 from page 43 onwards. The power supply can be directly connected to the ezea via labelled connection terminals located under the front cover and immediately behind the main switch (see Fig. 6).

30 Product Description ::: Regulatory Connections 2 1 Fig. 6: Power Supply Connection of the ezea 1 Cover 2 Electrical connection (only location show) 2.7 Regulatory Connections For the specifications of the individual connections, refer to the technical data in chapter 3 from page 43 onwards. Different signal lines are used for the regulation and system integration of the ezea. To that end the ezea comes equipped with the following regulatory connections: Control Signals External ON/OFF (potential-free): Switches the ezea on and off via a contact using an external control unit (in slave operation). Setpoint temperature setting (0-5 VDC): Regulates ezea based on ambient temperature, room temperature or the buffer temperature (for more information on signal voltage based functions, see chapter 3.6 on page 47). Control Signal (0-10 VDC): Controls the Recooler or external, infinitely variable pumps (when using external pumps instead of the integrated pumps in the ezea). Temperature Sensors Ambient Temperature Regulation: Switches between free and active cooling.

31 Product Description ::: Regulatory Connections 31 / 150 Sensor for Hot Water Tank (optional): The ezea can start / stop operating based on the buffer temperature of the hot water circuit. If the water temperature falls below a minimum buffer temperature set by the operator, then the ezea will no longer operate with hot water. When an operator-defined setpoint temperature is exceeded, the thermal cooling starts anew. Sensor for Cold Water Storage (optional): The ezea can start / stop operating based on the buffer temperature of the cold water circuit. If the water temperature falls below a minimum buffer temperature set by the operator, then the ezea will no longer produce cooling energy. Once an operator-set buffer temperature is exceeded, the thermal cooling starts anew. Sensor for Indoor Temperature (alternate use of the optional sensor for the cold water tank): The ezea can start / stop operating based on indoor temperature. If the indoor temperature falls below a minimum value set by the operator, then the ezea will no longer produce cooling energy. When an operator-defined setpoint temperature is exceeded, the thermal cooling starts anew. The installation of sensors for the hot water tank and cold water tank should not be in the pipes when they are carrying the medium. When the ezea is shut down, all pumps shut down and the flow in the circuits is no longer even. In this case it is no longer possible to start the machine in a proper functional manner. Return signal (230 VAC) for the operating condition of the ezea via the signal relay in slave operation (Operation, Off) Signal requesting additional cooling capacity with interconnected ezea (peak load cover, Backup), Switching signal for the external pump of the system separation (pump MT sec), Switching signal for the heat pump (cooling/heating) and Signal for fault messages from the ezea (e.g. anti-freeze). The control lines to the controller are clamped directly to the controller and lead out of the ezea on the top side.

32 Product Description ::: Funtionality 2.8 Funtionality Functional Construction In terms of functionality the ezea is divided into the following three circuits: Circuit 1: Hot water circuit (driving circuit), Circuit 2: Recooling circuit and Circuit 3: Cold water circuit (air-conditioning circuit). Optionally, a Recooler (see chapter on page 38 for a description) and/or a system separation (see chapter on page 40) can be integrated into the recooling circuit. The functional construction is depicted in Fig A 1 B 3 Recooling Circuit Hot Water Circuit Cold Water Circuit Fig. 7: Functional Construction A Condenser B Evaporator 1 Heat source / driving heat 2 Recooler (optional) 3 Object being cooled 4 System separation (optional) Hot Water Circuit Recooling Circuit Thermal energy is transferred via the hot water circuit (driving circuit), which then drives the ezea as well as the heat exchange occurring within. The heat from the object being cooled (also used to dry the working material) then moves from the ezea to the recooling circuit where it

33 Product Description ::: Funtionality 33 / 150 Cold Water Circuit is cooled to the mean ambient temperature and pumped back into the environment. The cold water circuit removes heat from the object being cooled Sequence of Events Adsorption via Zeolite The ezea operates according to the principle of solid matter sorption, also referred to as adsorption. The working material used here is zeolite, which periodically comes into contact with the evaporating refrigerant. As such, the production of cooling energy and the usage of driving heat do not occur continuously. By combining two adsorbers (one in each of the module) an effectively continuous mode of operation with periodic fluctuations in temperature can be achieved. In turn, these fluctuations can be evened out using the appropriate buffers. An adsorber in the desorption phase (phase 1) is referred to as a "desorber". Module 2 Module Fig. 8: Phase 1 Sequence of Events in the Processing Chambers of the Modules Module 2: Module 1: 1 Condenser 2 Evaporator 2 Desorber (Adsorber 2) 4 Adsorber 1(Desorber) A module of the Adsorption Chiller Aggregate operates according to the following four phases:

34 Product Description ::: Funtionality Desorbtion/Adsorbtion Phase 1 Hot water (circuit 1; see chapter on page 32) flows through the desorber (adsorber 1). This expels the refrigerant, which has accumulated on the inner surface of the zeolite, into the condenser where it is converted into a fluid state. The heat produced during this liquefaction is then expelled via the recooling circuit (circuit 2). Simultaneously, heat taken from the object being cooled is used to form water vapour in the evaporator, which is then fed through the cold water circuit and adsorbed by the adsorber (adsorber 2). The adsorption process generates heat, which is expelled together with the heat from the liquefaction process back into the environment via the recooling circuit (circuit 2). Phase 1 continues until a specific cold water setpoint temperature is reached. Heat Recovery Phase 2 Immediately following phase 1, the three-way-valves in the flow pipeline of the three circuits switch around such that recooling water flows into the previously desorbed adsorber 1. The energy initially stored in adsorber 1 is not pumped simultaneously to the MT OUT, rather it continues to be pumped through the driving circuit for a time. The return line of adsorber 2, which is desorbed immediately following the adsorption, is routed to the recooling circuit for a defined period of time. Phase 2 ends when the three-way-valves in the return line of the three circuits successfully produce a specific temperature difference between both adsorber return lines. Desorbtion/Adsorbtion Phase 3 Hot water (driving heat) begins to flow through adsorber 2 (which is now a desorber). Adsorber 1 adsorbs at the same time. The Adsorption/Desoption process continues as in phase 1.

35 Product Description ::: Funtionality 35 / 150 Heat Recovery Phase 4 Immediately following phase 3, the three-way-valves in the flow pipeline of the three circuits switch around such that recooling water flows into the previously desorbed adsorber 2. The Adsorption/Desoption process continues as in phase Operating Modes Cooling Mode (Standard) The cold water circuit is responsible for the cooling process when the Adsorption Chiller Aggregate is in cooling mode (circuit 3; see chapter on page 32). This circuit is hydraulically connected to the object being cooled (e.g. cooling ceiling or fan coil). Water flows through the cold water circuit in all phases of operation and transfers heat energy from the environment to the evaporator. The activated ezea automatically switches between the following types of cooling depending on the ambient temperature: Active Cooling: The ezea actively supplies the cooling energy. Free Cooling (optional): The cooling energy is provided by the ambient temperature level. The threshold temperature for Free Cooling (T_FK) can be set via the controller of the ezea. Heat Pump Mode In heat pump mode, the recooling circuit (circuit 2) is swapped with the cold water circuit (circuit 3). The process sequence itself does not change. The supplementary kit for the heat pump mode is available on request. When using this mode of operation, the hydraulic con- nections must be set up according to the connection diagram in Appendix C from page 127 onwards. When the ezea switches from cooling mode to heat pump mode, a 230 V switching signal is sent from the machine to the three-wayvalves. Obey all operating limits in chapter 3.3 on page 45.

36 Product Description ::: Layout and Operation of the Control and Display Elements 2.9 Layout and Operation of the Control and Display Elements (Controller) The operator can control the ezea directly via the control and display elements integrated into the controller. The control and display elements of the controller are shown below: A Fig. 9: Control and Display Elements of the Controller Position Element Purpose A Display Shows the operating parameters and menus. 1-5 LED Scroll Buttons (backlit) Steady green light: automatic control Flashing green light: manual control; note messages on the display. Stand-by (flashing quickly) Flashing red light: system malfunction (for error codes and related repair information, see chapter 9 on page 93) 1 Up Button In the operating menu: Move selection up Innerhalb eines Menüpunktes: Increase a numerical value 2 Down Button In the operating menu: Move selection down In a menu item: Reduce a numerical value 3 Left Button Reduce a numeric value along a given scale of values

37 Product Description ::: Layout and Operation of the Control and Display Elements 37 / 150 Position Element Purpose 4 Right Button Increase a numeric value along a given scale of values 5 Confirm Button Open the operating menu Select a selected menu item or confirm a user input. 6 Back Button Close a menu item without applying changes and return to the previous menu level. 7 - not assigned Hold for 2 seconds at any point to open the main menu. Close the operating menu. Operating Menu Main Menu The operating menu contains all necessary menu items for the stand-alone operation of the ezea (not in slave operation). The individual menu items are summarised in chapter 7 from page 71 onwards. When the operating menu is opened, the main menu comes into view. The most important parameters are shown and can be altered from this menu (see Fig. 10 for an example). Fig. 10: Main Menu (example) User Levels via Code The operating menu of the controller is divided into two user levels which can be accessed by entering the related code: User Level 0: Operator (no code necessary) User Level 1: Service technician (code is provided during service training) Information s shown as well as input options change depending on the active user level.

38 Product Description ::: Optional Components 2.10 Optional Components Recooler A recooling system integrated into the recooling circuit is necessary for the Adsorption Chiller Aggregate to operate. The default Recooler is described in this chapter. Layout and Operation The Recooler is an optional subcomponent which is installed separately from the ezea. In order to simplify the system design, system configuration and installation, the Recooler is precisely tailored to the ezea and comes delivered as a virtually complete subsystem (see Fig. 11). The Recooler uses EC-ventilators and an adapted variable speed control to ensure that the ezea only uses as much electricity as necessary to reach the desired cooling capacity. Fig. 11: Construction of the Recooler (vertical installation) The device configuration of the Recooler is designed to meet the specific requirements of the ezea exactly. The controller of the ezea continuously varies the rotational speed of the EC-ventilators based on the current operating point, ensuring minimal power consumption. Terminal Box The power supply and the control line for the Recooler are connected through the terminal box. The weather-proof cover protects the connections from water.

39 Product Description ::: Optional Components 39 / 150 Varianten Spray System The Recooler is available in different versions. The various versions differ in functional terms, mainly in the recooling performance. The Recooler comes equipped with a spray system. The spray system periodically sprays small amounts of water into the air flow, which then evaporate and produce a recooling temperature close to the ambient air temperature. This improves the cooling capacity of the ezea, particularly when operating in high ambient temperatures. Water is only sprayed for a short time, ensuring that no liquid film forms on the fins and reducing the danger of bacteria growth. This also ensures a continuous level of performance. Water consumption is also kept to a minimum thanks to the time-controlled activation of the spray system. Drain the spray system before the first frost to avoid damage. Protection against Legionella The water in the supply line of the spray system is flushed once a day to prevent the formation of legionella. With additional safety precautions, for example periodically draining the spray system or monitoring the internal water temperature, legionella bacteria cannot form in the remaining pipe installations and possible health risks can be avoided.

40 Product Description ::: Optional Components System Separation A system separation can be integrated into the recooling circuit to protect it from frost damage. The default system separation is described in this chapter. Layout and Operation Configurations The system separation is an optional subcomponent which can be used to operate the ezea with a Recooler or other heat sinks using a water-glycol mixture and is integrated into the recooling circuit. This protects the other internal circuits of the ezea from the glycol mixture. The system separation is available in configurations 10, 20, 30 and 40, which differ in recooling type (see Appendix A: Configurations on page 121 as well as Fig. 12). From a functional perspective, the configurations differ primarily in nominal volume flow rate and available delivery head Fig. 12: Configurations of the System Separation 1 3 System separation 10 System separation System separation 20 System separation 40

41 Product Description ::: Water quality and filling of the system 41 / Water quality and filling of the system Water quality and filling of the system Drinking water can be used for the filling of the system in the most cases. To avoid damage and the formation of stones measures in accordance with VDI 2035 Part 1 are required. A ph-level raising is usually not necessary. The cooling unit is to be used exclusively for the operation of the heat transfer water to a given specification. Material compatibility in the entire water cycle must be respected and the heat transfer water must be free from lime depositing and corrosive ingredients! After filling the system there must be a proper ventilation of the circuits carried out. In line with German drinking water ordinance are recommended as limiting values: Tab. 8: Water quality Water quality PH-level at 20 C 7,5-9,0 Electrical conductivity at 25 C µs/cm Water hardness 6-10 dh Hydrogen carbonate mg/l Sulphate < 70 mg/l Total count of bacteria at 22 C < 1000 KBE s/ml Appearance clear, without sediments Colour colourless Filling of the recooling system Water quality and fresh water spray Water quantity and fresh water spray In the operation of the system with a mixture (water/glxcol) the filling must be carried out in the mixed condition. When filling he system with the heat transfer medium the prescribed concentration values must be respected. After filling the system there must be a proper ventilation of the circuits carried out. The limits specified in the table below should be followd for the water quality of fresh water spray. Is very calcareous (calcium content > 4 dh) or otherwise polluted or contaminated water to fresh water spray used, an adequate water treatment is to be provided separately. By using the integrated cyclical spraying, controlled by the SorTech controller the operating time can be seen from the table below. The default value in the parameters of the ezea is parameterized 300 hours per year.

42 Product Description ::: Water quality and filling of the system Tab. 9: Water quality Water quality & spraying Spray with air flow direction Water hardness 0 to 2,2 dh Water hardness 2,2 to 4 dh Water hardness more than 4 dh Water hardness 0 to 2,2 dh Water hardness 2,2 to 4 dh Chloride Con- Centration < 10,0 ppm Chloride Con- Centration < 20,0 ppm Chloride Con- Centration > 20,0 ppm Chloride Con- Centration < 20,0 ppm Chloride Con- Centration < 20,0 ppm Electrical conductivity <1200 µs/cm ph-level between 6 to 8 Constant spraying controlled by external Controller Operating hours Recooling plant Cyclic spraying Controlled by SorTech Controller Operating hours ezea h/a h/a Without softening no Without softening no operation is possible operation is possible hrs./a hrs./a

43 43 / Technical Data Chapter Contents This chapter provides an overview of the technical data of the ezea. Chapter Goals To convey important technical parameters for correctly positioning, installing and operating the ezea. AdKA2014OM-ENG ::: 1.0 ::: English

44 Technical Data ::: Dimensions and Weight 3.1 Dimensions and Weight Tab. 10: Dimensions and Weight of the ezea Unit Value Width x depth x hight mm 670 x 560 x 1652 Installation surface m Total surface incl. space for maintenance and inspections m Empty weight kg approx Operating weight kg max Performance Data Tab. 11: Performance Data of the ezea 1 Unit Value Cooling capacity kw Max Hot Water Circuit (Driving Circuit) COP - Max Temperature range C Nominal volume flow rate l/h Available delivery head mbar 621 at a nominal flow rate of l/h Pressure loss mbar 579 at a nominal flow rate of l/h Recooling Circuit Temperature range C Max. 45 Nominal volume flow rate l/h Available delivery head mbar 540 at a nominal flow rate of 5100 l/h Pressure loss mbar 570 at a nominal flow rate of 5100 l/h 1 Performance- und COP-characteristic curve see Appendix D

45 Technical Data ::: Operating Limits of the Operating Modes 45 / 150 Einheit Wert Cold Water Circuit Temperature range C Min. 8 Nominal volume flow rate l/h Available delivery head mbar 585 at a nominal flow rate of l/h Pressure loss mbar 615 at a nominal flow rate of l/h Hot Water Circuit (Recooling Circuit) in Heat Pump Mode Temperature range C (up to 70 when free heating) Heating capacity kw Max. 40 Performance data is calculated based on the nominal operation point of one ezea. 3.3 Operating Limits of the Operating Modes The Adsorption Chiller Aggregate is not suitable for drive temperatures above 95 C, or for ambient temperatures below 0 C without frost-protection measures. Setpoint Temperatur (T_Soll) Tab. 12: Operating Limits of the Operating Modes Current Ambient Temperature Operating Mode 8 C - 21 C < T_FK Cooling mode: Free cooling 8 C - 21 C > T_FK Cooling mode: Active cooling 25 C - 40 C - Heat pump mode T_FK: Temperature limit for free cooling; controller parameter

46 Technical Data ::: Hydraulic connections 3.4 Hydraulic connections All three circuits must be equipped with pop off valves (for example 3.0 bar) as well as fill, rinse and drain valves. Tab. 13: Hydraulic Connections of the ezea Connection Labeling Spezification Hot Water Circuit (Driving Circuit) Inlet HT IN 1 ¼ Outlet HT OUT 1 ¼ Recooling Circuit Inlet MT IN 1 ½ Outlet MT OUT 1 ½ Cold Water Circuit Inlet LT IN 1 ¼ Outlet LT OUT 1 ¼ The hydraulic connections for the ezea must be set up according to the planned connection type.

47 Technical Data ::: Power Supply Connections 47 / Power Supply Connections Tab. 14: Power Supply of the ezea Unit Value Voltage VAC 230 Frequency Hz 50 Power consumption kw nominal 0,357 / maximal 0,648 Tab. 15: Connection Terminals of the ezea Klemme N L1 GRD Spezifikation Neutral lead Outer conductor Ground 3.6 Control System Connections Tab. 16: Technical control connection of the ezea Terminal Value Purpose 5 VDC-signal T_Set Cooling Heating Auto 0,77 V 8,0 C 25,3 C 6,0 C 3,05 V 25,3 C 25,3 C 25,3 C 3,25 V 25,3 C 26,8 C 26,8 C 5,00 V 25,3 C 40,0 C 40,0 C Control contact for slave operation (floating contact) Switch on/-off via an external control system Regulation via ambient temperature S2 0 ezea ON S11 1 ezea OFF PT 1000 characteristics Free Cooling / automatic operation change for heat pump mode Open Closed Active Cooling only / manual heat pump mode (e.g. with superordinated control) Free Cooling only / Heating (e.g. with superordinated control)

48 Technical Data ::: Control System Connections Terminal Value Purpose Regulation via indoor temperature Regulation via cold water tank / indoor temperature Internal control signal (0 10 VDC) S12 - in acc. with PT1000 characteristics S13 - in acc. with PT1000 characteristics 17 AC 0-10 VDC Regulation of the Recooler (rotational speed of the ventilators) N Fault R VAC Signal for fault messages of the ezea N ON/OFF return signal R VAC Return signal for the operating condition of the ezea via the signal relay in N slave operation Cooling/Heating R VAC Switch signal for the heat pump switchover N Pump MT sec R VAC Switching signal for the external pump of the system separation N Peak load cover R14M Potential-free Requests additional cooling output when multiple Adsorption Chiller Aggregates N are interconnected

49 Technical Data ::: Optional Components 49 / Optional Components Recooler Tab. 17: Dimensions and Weight of the Recooler Unit erec erec Width x depth x height mm 6130 x 1170 x x 2290 x 1510 Empty weight kg Tab. 18: Performance Data of the Recooler Unit erec erec Recooling output kw Ventilators - 3 EC-Ventilators 4 EC-Ventilators Air inlet temperature C 23,0 23,0 Standard signal for variable speed control V Sound pressure level at 10m db(a) Recooling Circuit Heat transfer fluid - Ethylenglycol 34% Ethylenglycol 34% Nominal volume flow rate m 3 /h 5,9 11,8 Pressure loss at nominal volume flow rate mbar max. operating pressure bar 4 4 Spray System max. water consumption m 3 /a 6 9 max. operating pressure bar at least 3-6 at least 3-6 Performance data is calculated based on the nominal operation point of one Recooler.

50 Technical Data ::: Optional Components Tab. 19: Hydraulic connections of the Recooler Unit erec erec Recooling circuit mm 35.0 * 1, * 2,0 (inlet and oultlet) Spray System mm 21.3 * ,3 * 0.5 Tab. 20: Power Supply of the Recooler Unit erec erec Voltage VAC Frequency Hz 50/60 50/60 Power consumption kw 0,72 1,0 Tab. 21: Connection Terminals of the Recooler Main power supply (230 VAC) from EPD Terminal L PE N Specification Outer conductor (phase) Protective earth conductor (ground) Neutral conductor (neutral) Control signal from ezea, terminal 17AC V from ezea 8 GND The connection terminals are designed for a wire diameter no greater than 2.5 mm 3. Other Recoolers are presented in the technical data sheets.

51 Technical Data ::: Optional Components 51 / System Separation Tab. 22: Dimensions and Weight of the System Separation 10/20 Unit System Separation 10 System Separation 20 Width x depth x height mm 1133 x 678 x x 678 x 1014 Weight kg Tab. 23: Performance Data of the System Separation 10/20 Unit System Separation 10 System Separation 20 Fitting dimensions - DN 40 DN 50 Type of fitting - inner thread 1 ½ inner thread 1 ½ max. operating pressure bar 4 4 Towards the ezea Nominal volume flow rate m 3 /h 5, Pressure loss mbar Towards the Recooler Nominal volume flow rate m 3 /h [ST-O-10]: 5,1 [ST-G-10]: 5,9 (with Water-Glycol) Available delivery head mbar [ST-O-10]: 725 [ST-G-10]: 760 [ST-O-20]: 10,2 [ST-G-20]: 11,8 (with Water-Glycol) [ST-O-20]: 592 [ST-G-20]: 678 Maximum pressure loss mbar [ST-O-10]: 200 [ST-G-10]: 240 [ST-O-20]: 154 [ST-G-20]: 170 Tab. 24: Power Supply of the System Separation 10/20 Unit System Separation 10 System Separation 20 Voltage VAC Frequency Hz Max. power consumption W [ST-O-10]: 680 [ST-G-10]: 310 [ST-O-20]: 680 [ST-G-20]: 470

52 Technical Data ::: Optional Components Tab. 25: Connection Terminals of the System Separation 10/20 Main power supply (230 VAC) from EPD Terminal L PE N Specification Outer conductor (phase) Protective earth conductor (ground) Neutral conductor (neutral) Pump relay (control voltage 230 VAC) from ezea L Outer conductor (phase) N Neutral conductor (neutral) Tab. 26: Dimensions and Weight of the System Separation 30/40 Unit System Separation 30 System Separation 40 Width x depth x height mm 1206 x 967 x x 967 x 960 Weight kg Tab. 27: Performance Data of the System Separation 30/40 Unit System Separation 30 System Separation 40 Fitting dimensions - DN 65 DN 65 Type of fitting - Flange (PN6) Flange (PN6) max. operating pressure bar 4 4 Towards the ezea Nominal volume flow rate m 3 /h 15,3 20,4 Pressure loss mbar Towards the Recooler Nominal volume flow rate m 3 /h [ST-O-10]: 15,3 [ST-G-10]: 17,7 (with Water-Glycol) Available delivery head mbar [ST-O-10]: 1047 [ST-G-10]: 678 [ST-O-20]: 20,4 [ST-G-20]: 23,6 (with Water-Glycol) [ST-O-20]: 1233 [ST-G-20]: 967 Maximum pressure loss mbar [ST-O-10]: 173 [ST-G-10]: 186 [ST-O-20]: 206 [ST-G-20]: 232

53 Technical Data ::: Optional Components 53 / 150 Tab. 28: Power Supply of the System Separation 30/40 Unit System Separation 30 System Separation 40 Voltage VAC [ST-O-30]: 380 [ST-G-30]: 230 [ST-O-30]: 380 [ST-G-30]: 230 Frequency Hz Max. power consumption W [ST-O-30]: 2277 [ST-G-30]: 800 [ST-O-40]: 4347 [ST-G-40]: 1550 Tab. 29: Connection Terminals of the System Separation 30/40 (230V) Main power supply (230 VAC) from EPD Terminal L PE N Specification Outer conductor (phase) Protective earth conductor (ground) Neutral conductor (neutral) Pupm relay (control voltage 230 VAC) from ezea L Outer conductor (phase) N Neutral conductor (neutral) Tab. 30: Connection Terminals of the System Separation 30/40 (380V) Main power supply (380 VAC) from EPD Klemme L1 L2 L3 PE N Spezifikation Outer conductor (phase) Outer conductor (phase) Outer conductor (phase) Protective earth conductor (ground) Neutral conductor (neutral) Pupm relay (control voltage 230 VAC) from ezea L Outer conductor (phase) N Outer conductor (phase)

54 Technical Data ::: Optional Components

55 55 / Project Planning Chapter Contents This chapter contains general information regarding project planning with the ezea as well as the interconnection of multiple Adsorption Chiller Aggregates. Chapter Goals To prepare the operator for correct project planning with the ezea. AdKA2014OM-ENG ::: 1.0 ::: English

56 Project Planning ::: Requirements for Project Planner 4.1 Requirements for Project Planner Planning the integration of the ezea or the integration of multiple interconnected Adsorption Chiller Aggregates must be done by a specialist company. The company must specialize in air-conditioning and cooling technology. 4.2 Technical Manual The technical manual of the ezea is a manual which provides instructions for integrating and configuring the ezea to the specialist company. This document is available separately. 4.3 Requirements for Interconnection To interconnect multiple Adsorption Chiller Aggregates and achieve a greater cooling capacity or, alternatively, a greater heat- ing capacity, observe the following technical requirements: Necessary space: Depending on the different connection variations (see chapter 2.5 on page 29), different amounts of space are needed to set up the Adsorption Chiller Aggregate(s). Obey the technical data in chapter 5.2 on page 59 and in the installation help for the planned connection variation. Base: The Adsorption Chiller Aggregate(s) must be set up on a base which can support the total operating weight of all interconnected machines and their optional components (for weight values see chapter 3 from page 43 onwards The ezea does not produce any notable vibrations. Heat input: The hot water circuit (driving circuit) must transport a sufficient amount of heat to the Adsorption Chiller Aggregate (see chapter 3.2 on page 44) in order to efficiently produce the necessary cooling energy. Recooling system, cooling distribution, cooling load and pipeline dimensions: The recooling system, cooling distribution, cooling load and pipeline system must be able to handle the heat quantity and meet all flow-related requirements.

57 57 / Installation Chapter Contents This chapter describes the tasks necessary to assemble the ezea. Chapter Goals To convey how to correctly integrate the ezea in accordance with the general design of the system. Only properly trained and authorised personnel may assemble the ezea! AdKA2014OM-ENG ::: 1.0 ::: English

58 Installation ::: Safety Precautions 5.1 Safety Precautions Observe the following safety precautions during the assembly of the ezea: Improperly made connections can expose live components! Electric shock when touched. Only properly trained personnel may connect the machine. Follow the related instructions. Instability during parts alignment! Fingers and toes can be crushed by falling or shifting parts. Before installing the ezea, adjust the feet to make sure the machine is level. Set up the ezea on an even and stable base only (see chapter 5.2 on page 59). Casing consists of moveable and difficult to mount parts! Avoid crushed fingers. Mount the casing carefully. Follow the related instructions. Pipes and threads have sharp edges! Cuts to hands and fingers are possible. Wear appropriate safety gloves. Improperly performed electrical work can damage the components of the ezea. Only properly trained personnel may perform electrical work on the machine.

59 Installation ::: Criteria for the Installation Site 59 / Criteria for the Installation Site The Adsorption Chiller Aggregate is suitable for installation in indoor areas only. If you wish to install the machine outdoors, then consult the manufacturer and implement the recommended precautions to protect the installation from moisture. The ecoo 2.0 must be installed in an area accessible for both personnel as well as pallet jacks. The installation site must meet the following requirements (see Fig. 13): Tab. 31: Criteria for the Installation Site Criteria Ambient conditions Conditions for the base Minimum Size dry, free of frost and non-condensing atmosphere flat, level Load carrying capacity of the base at least 600 kg/m 2 ezea without interconnection ezea with multiple interconnection Side clearance between the ezea and walls / other machinery (single installation) Front and rear clearance for unrestricted maintenance access (single installation) Clearance height from the hydraulic connections Clearance height from the hydraulic connections 300 mm 500 mm Front side 100 mm Rear side 500 mm 1000 mm Total installation space required 1,47 m 2 Inclination in lateral and longitudinal directions Max. 2 Use additional underlays or height adjustment screws if necessary. Lowest allowable temperature 5 C Highest allowable temperature 45 C Power supply 230 V, 50 Hz

60 Installation ::: Criteria for the Installation Site These requirements must be met to ensure that the ezea operates at full performance. Fig. 13: Clearances in mm at Installation Site (single installation) For additional information, see the technical drawings in Appendix C from page 127 onwards. An integrated flow monitor in the cold water circuit protects the internal cooling components of the Adsorption Chiller Aggregate from freezing. Water freezing in the evaporator is harmless for the machine. Keep the display of the controller away from direct sunlight. In addition, the installation site must contain the following: A suitable driving heat source for a temperature range of 75 C to 95 C with corresponding output, A suitable heat dissipating machine (e.g. the Recooler) for a temperature range of 20 C (in case of active cooling with the Adsorption Chiller Aggregate only) to 45 C with corresponding output,

61 Installation ::: Install the ezea 61 / 150 A suitable low temperature source (e.g. a cooling distribution system) for a temperature range of 20 C to 10 C with corresponding output, Corresponding pipe installation for the system integration, A water connection for filling purposes and A water run-off for draining purposes. 5.3 Install the ezea Avoid instability during parts alignment! Fingers and toes can be crushed by falling or shifting parts. Before installing the ezea, adjust the feet to make sure the machine is level. Install the ezea on an even and stable base only (see chapter 5.2 on page 59). Pipes and threads have sharp edges! Cuts to hands and fingers are possible. Wear appropriate safety gloves. 1. Only install ezea in a site which meets all the criteria listed in chapter 5.2 on page Remove all packaging materials. Keep all packaging materials (plastic, screws, protective covers etc.) out of reach of children! Dispose of all packaging materials in the appropriate manner. The ezea comes pre-built. An individual ezea does not need to be secured to its base in all cases. Multiple Adsorption Chiller Aggregates may need to be secured together depending on the desired application.

62 Installation ::: Connect the Hydraulics 5.4 Connect the Hydraulics Casing consists of moveable and difficult to mount parts! Avoid crushed fingers. Mount the casing carefully. Follow the related instructions. Pipes and threads have sharp edges! Cuts to hands and fingers are possible. Wear appropriate safety gloves. HT IN HT OUT MT IN MT OUT LT IN LT OUT Fig. 14: Hydraulic Connections (as seen from rear) 1. Prepare the hydraulic connections for the intended connection type. Hydraulic connections are delivered as flat-tight threaded. 2. Note the markings on the ezea when connecting the hydraulic connections to the pipe and hose system (see Fig. 14). The manufacturer recommends using flat sealing, insulated, flexible metal hoses to link the hydraulic connections to existing installations. 3. Install a suitable ventilation system for each circuit.

63 Installation ::: Connect the Electric Connections 63 / 150 All three circuits must be equipped with pop off valves (for example 3.0 bar) and membrane expansion vessels with fill, rinse and drain valves. 4. Use expansion vessels which conform to the given temperature level and the pipeline volume. 5. Use the appropriate safety groups for the circuits. A line pressure of 1 bar (max. 4 bar, recommended 2 bar) must be maintained. With multiple interconnected Adsorption Chiller Aggregates (without integrated pumps with System separation [e.g. ST-B- 20]): 6. Install electronic stop valves controllable by 0-10 VDC in flow of the distribution line (from the ezea). This allows the stop valves to be controlled via the pump signal of the ezea 7. Check and secure all detachable connections on ezea. The ezea hydraulics are now connected. See chapter 6 on page 67 for additional steps before operating the machine. 5.5 Connect the Electric Connections See chapter 3 on page 43 for the appropriate connection terminals. 2 1 Fig. 15: Power Supply Connection of ezea 1 Case 2 Electrical connection (only location show)

64 Installation ::: Installation of Optional Components Follow the instructions below to connect the electrics of the ezea and, if necessary, of the optional components: 1. Remove the front cover. Live components! Electric shock when touched. Connect the power supply last. 2. Connect all application-specific and necessary control lines according to the electrical connection diagram. The electrical connection plan can be found in Appendix C from page 127 onwards. The electrics of the ezea and the optional components are now connected. 5.6 Installation of Optional Components Install a Recooler Criteria for the Installation Site The Recooler must be installed a short distance away from the ezea to ensure that the length of the connecting pipes is kept to a minimum. The connecting pipes should have as few bends and curves as possible. Use large bending radii. The installation site must meet the following requirements: Tab. 32: Criteria for the Installation Site of the Recooler Criteria Conditions for the base Inclination in lateral and longitudinal directions Minimum Size flat and horizontal Max. 2 If you wish to install the Recooler on a wall, suitable mounting panels are available separately. Power supply 230 V, 50 Hz Ensure that air can flow freely around the Recooler.

65 Installation ::: Installation of Optional Components 65 / 150 The project organiser must ensure that the installation is properly protected from static electricity. The manufacturer accepts no responsibility for damages caused by static! For fitting dimensions and clearance information, see the technical drawings in Appendix C from page 127 onwards. Install the Recooler In addition, the installation site must meet the following requirements: Shade: The Recooler must be installed in a spot with enough shade. This prevents loss of performance due to solar radiation. Sound Emission: The installation site should be somewhat secluded to avoid any potential noise disturbances. Spray System The spray system of the Recooler requires a suitable water source (for technical requirements see chapter from page 49 onwards). Water Drainage: An appropriate discharge point should be located near the Recooler in order to drain the carrier medium (fresh water). Follow these steps to install the Recooler: 1. Position the Recooler according to the planning documents. 2. Use appropriate screw retention to install the mounting screws of the Recooler to the ground. 3. Torque all mounting screws equally to ensure an even load distribution. 4. Let out the air from the Recooler. The Recooler comes filled with dried air. 5. Unilaterally widen the ends of the pipelines (for capillary brazing). 6. Connect the hydraulics. Connect the hydraulics without any mechanical stress! Make sure the connecting pipes are supported! 7. Braze the hydraulic connections to the pipes. Schwer montierbare, bewegliche Teile der Verkleidung! Use proper joint clearance Use an inert protective gas! Do not overheat the ends of the pipeline!

66 Installation ::: Installation of Optional Components 8. Removing any remaining installation materials in the pipelines. 9. Check the hydraulics for tightness with a pressure test. The Recooler is now installed Install the System Separation Criteria for the Installation Site The system separation must be installed a short distance away from the ezea to keep the length of the connecting pipes to a minimum and avoid any pressure loss. The installation site must meet the following requirements: Tab. 33: Criteria for the Installation Site of the System Separation Criteria Site Conditions Minimum Size Free of frost Maintenance clearance d sides 200 mm each front overhead rear 500 mm 500 mm 0 mm Type of Installation The system separation is suitable for stationary or wall installation. For wall installations it is important to first verify if the installation plans are cohesive with the overall project plan of the complete ezea system. For fitting dimensions and clearance information, see the technical drawings in Appendix C from page 127 onwards.

67 67 / Commissioning Chapter Contents This chapter describes the commissioning procedure for the ezea. Chapter Goals To show how to electrically connect the ezea and properly test the machine after commissioning. Only properly trained and authorised personnel may commission the ezea! Read and follow the instructions in this chapter before using the ezea for the first time. In accordance with the Machinery Directive 2006/42/EC, the Adsorption Chiller Aggregate may only be commissioned when the machine in which it is to be integrated also conforms to said directive. AdKA2014OM-ENG ::: 1.0 ::: English

68 Commissioning ::: Safety Precautions 6.1 Safety Precautions Observe the following safety precautions during the commissioning of the ezea: Improperly made connections can expose live components! Electric shock when touched. Connect the power supply last. Only properly trained personnel may connect the machine. Pressurised hydraulics, scalding water may escape! Improperly connected hydraulics can scald! Monitor hydraulic connections carefully when filling. Check for leakage. Wear appropriate safety gloves. Only properly trained personnel may commission the machine. Non-insulated parts have hot surfaces! Burn injuries are possible. Avoid contact with potentially hot parts. Wear appropriate safety gloves. I Avoid damaging insulation. Replace insulation when necessary.

69 Commissioning ::: Commission the ezea 69 / Commission the ezea The following electrical requirement must be met before commissioning the ezea: The available power supply is appropriate for the ezea. The ezea is connected to the protective earth via a suitably dimensioned protective contact. The interior or exterior protective earth conductor is continuously conducting. Only operate the ezea when there is an intact connection to the protective earth! Follow the instructions below to commission the ezea: 1. Fill the hydraulic circuits with approx bars of pressure and vent them. 2. Operate the main switch (see Fig. 16) to power on the electrics of the ezea. 1 Fig. 16: Main Switch of the ezea 1 Main switch 3. In the sub-menu "Commissioning" within the operating menu select the menu item "Valve run". 4. Turn on the hydraulic pumps of the cold water circuit, recooling circuit and hot water circuit and corresponding system air separator. In the main operating menu, change the parameter "system" to "on". 5. After venting go to menu point Commissioning and select Valve run disable.

70 Commissioning ::: Commission the ezea 6. Go through the commissioning checklist (see Appendix E on page 143) to continue the commissioning process. When delivered, the ezea is automatically configured for cooling mode. 7. Fill in all required information on the commissioning checklist and store it in an appropriate location. The commissioning process is not complete until the checklist is filled in completely. 8. Attach the front cover again. The commissioning of the ezea is now complete.

71 71 / Operation Chapter Content This chapter gives step-by-step operating instructions for the ezea. Chapter Goals To show how to correctly operate the ezea. AdKA2014OM-ENG ::: 1.0 ::: English

72 Operation ::: General Information 7.1 General Information The ezea is controlled directly via the controller (while not in slave operation). The operator uses the control elements shown in chapter 2.9 on page 36. The operating menu groups all important information (based on the active user code) into different sub-menus. 7.2 Power on the ezea Follow these steps to power on the ezea: 1. Remove the front cover. 2. Operate the main switch (see Fig. 17) to power on the electrics of the ezea. 1 Fig. 17: Main Switch of the ezea 1 Main switchr 3. Check the system pressure of the hydraulic circuits. 4. Attach the front cover again. 5. In the main operating menu, change the parameter "system" to "on". The ezea is now completely powered on. 6. With an internal setpoint setting: In the menu "User Inputs" enter the internal setpoint temperature for the cold water outlet or the hot water outlet if in heat pump mode (optional). The ezea is now successfully powered on.

73 Operation ::: Main Menu 73 / Main Menu Press the Confirm Button to open the operating menu in the main menu. Fig. 18: Main Menu (examples) Depending on the selected operator level, the following menu points are shown: Tab. 34: Items in the Main Menu Item System Mode State Parameter / Explanation ezea on/off cooling/heating cooling mode / heat pump mode on/standby/off operating state Line 1: Values Opens menu "values". Shows system information. See chapter 7.4 on page 74. Line 2: User inputs Opens menu "user inputs". User inputs for operating parameters. See chapter 7.5 on page 77. Line 3: Messages Opens menu "messages". Shows system messages from the ezea. See chapter 7.6 on page 79. Line 4: Code User inputs to change user level. User level 0: Operator (no code necessary) User level 1: Service technician (code is provided during service training) Line 5: Commisioning Opens the "commissioning" menu. Manual operation of the ezea and access to functions necessary for the commissioning of the ezea.

74 Operation ::: Menu "values" Item Parameter / Explanation Line 6: Manual settings Opens menu "manual settings". Manual operation of the ezea. See chapter 7.7 on page 79. Hold the Back Button for 2 seconds at any point to open the main menu. 7.4 Menu "values" The menu "values" provides the operator with information relating to operating mode, operating status, temperatures and current messages from the ezea. Fig. 19: Menu "values" (example view) The temperature values shown in the menu "values" relate to the ezea. The temperatures shown cannot be used for performance analysis purposes. To open the menu "values", select the main menu item "values" and press confirm. The following menu items are shown: Tab. 35: Menu Items in "values" Parameter Bedeutung Benutzerebene Beispiel temp cold Actual cold water output temperature 0 16,8 C stp cold Internal setpoint temperature for cold water output / hot water output in heat pump mode (optional) 0 15,0 C date Current date 0 und Time Current time of day (24 hour clock) 0 und 1 15:35

75 Operation ::: Menu "values" 75 / 150 Parameter Bedeutung Benutzerebene Beispiel w hours Total operating time 0 und 1 50 h sn ecoo Serial number of the ezea system ezea On/OFF 1 ON mode Operating mode cooling mode / heat pump mode 1 Cooling phase Active operating phase 1 3 cycles Cycle counter 1 54 time Counter hr Counter Duration of the heat recovery 1 25 s phase time Length of phases 1 and s volt ext stp ext Input signal voltage for external temperature specification for example. of a BMS External setpoint temperature for cold / hot water output 1 1,9 1 10,0 C If an external setpoint temperature (>0.5 V) is connected, the manual setpoint temperature is deactivated. stp man Internal setpoint temperature for cold water output / hot water output in heat pump mode (optional) 1 15,0 C T stp currently used temperature setpoint 1 10 C T LT OUT Actual cold water output temperature 1 16,8 C T LT IN Actual cold water input temperature 1 18,5 C T MT OUT Actual Recooler output temperature 1 28,8 C T A1 OUT Actual output temperature for adsorber ,9 C T A2 OUT Actual output temperature for adsorber ,2 C T E1 OUT Actual output temperature for evaporator ,8 C T E2 OUT Actual output temperature for condenser ,8 C T HT OUT Actual hot water output temperature 1 75,3 C T ambient Actual ambient temperature 1 26,8 C

76 Operation ::: Menu "values" Parameter Bedeutung Benutzerebene Beispiel T HT BU Actual temperature of the external hot water storage sensor T LT BU Actual temperature of the external cold water tank sensor 1 65,1 C 1 22,2 C T MT IN Actual reccooling input temperature 1 25,3 C dq LT Cycle Cooling capacity of the last cycle 1 7,5 kw To output a value for "dq LT" there must be a corresponding value stored under the menu item "df LT" in the menu "user inputs". This value is determined during the commissioning of the ezea. % rc Actual ventilator rotation speed 1 65 % % pump HT Actual pump rotation speed HT 1 80 % % pump MT Actual pump rotation speed MT 1 90 % % pump LT Actual pump rotation speed LT 1 75 % t spray Total length of time of previous spray processes s system ok. System message 1 0 dem. ecoo incoming request from the master 1 OFF Flow sw. Switching state of flow switch 1 ON dem slave-device Request on slave unit 1 ON dem ext. fcool External demand for free cooling 1 ON sec Pump HT Actual pump rotation speed MT extern 1 45 % The names of OA, OC, IA and IC always relate the measured temperature values on averaged values at the outlet (O) or inlet (I). These are depending on a cycle (C) or sliding averaged (A).

77 Operation ::: Menu "user inputs" 77 / Menu "user inputs" The operational performance of the ezea can be adjusted in the menu "user inputs". This menu allows the operator to turn the ezea on and off manu- ally as well as input user-defined setpoint temperatures (heating / cooling temperatures). Fig. 20: Menu "user inputs" (example view) To open the menu "user inputs", select the main menu item "user inputs" and press confirm. The following menu items are shown: Tab. 36: Menu Items in "user inputs" Parameter Function/Explanation User Level Standard Min. Max. System Turn the ezea on or off; activate automatic operation mode 0 and 1 off - If you wish to shut down the ezea via a higher- level control system, then the parameter "system" must be set to "Auto". Stp cold / Stp heat User inputs for internal setpoint temperatures 0 and 1 15 C / 35 C 6 C / 20 C 20 C / 50 C Language Change menu language 0 und 1 German German English Date Set the date 0 und 1 Time Set the time 0 und 1 Operating mode Switch between cooling mode and heat pump mode 1 off - If you wish to switch the operating mode of the ezea via a higherlevel control system, then the parameter "system" must be set to "Auto". RCS Mode CTRL-Mode Select the control strategy of the ezea (thermal or electrically optimised operation) Activates the external temperature sensors T HT ext and T LT ext 1 on 1 off

78 Operation ::: Menu "user inputs" Parameter Function/Explanation User Level Standard Min. Max. T Start HT BU LT BU mn LT BU mx HT BU Hys LT SP mn Hys LT SP mx Hys df LT Sets the start temperature of the ezea Sets the threshold temperature for the hot water tank Sets the minimum temperature for the cold water tank Sets the maximum temperature for the cold water tank Sets the hysteresis for the temperature threshold of the hot water tank Sets the hysteresis for the minimum temperature of the cold water tank Sets the hysteresis for the maximum temperature of the cold water tank Sets the volume flow used to calculate the cooling capacity dq LT 1 55 C C C C K K K l/h dq LT min Sets the minimum cooling capacity 1 0,5 kw 0 20 % min RCS Sets the minimum rotational speed of the Recooler % max RCS Sets the maximum rotational speed of the Recooler 1 35 % % T S BASE t S MV on t S year t S V LEG on time phase after Sets the temperature for the spray system Spray parameter; sets the duration for which the magnetic valve of the Recooler is opened maximum annual spraying duration Sets the duration for which the magnet valve is open to avoid legionella growth Sets the overrun duration for the ezea 1 34 C s h h 1 35 s s 0 600

79 Operation ::: Menu "messages" 79 / Menu "messages" The menu "messages" provides the operator with critical system information necessary to operate the ezea. Information which can be used for troubleshooting purposes is also shown here. Fig. 21: Menu "messages" (example view) To open the menu "messages", select the main menu item "messages" and press confirm. The following menu items are shown: Tab. 37: Menu Items in "messages" Message Back System ok. Function/Explanation Return to a higher menu level No faults reported For more information on fault messages, see chapter 9.3 on page Menu "manual settings" The Recooler, the spray valve, hydraulic valves and the signal relay can be manually actuated via the menu "manual settings". In addition, a simple performance test of these components is also possible in this menu. When the ezea is in manual operation mode, the LED Scroll Buttons on the controller blink green. Tab. 38: Menu Items in "messages" Parameter Function/Explanation User Level Values Valve run Cyclic switching of all three-way valves for venting the hydraulic 1 ON / OFF

80 Operation ::: Menu "manual settings" Parameter Function/Explanation User Level Values Active p M1 p M2 Activation of the modules by desorption of both modules to evacuate Ideal operating pressure within the right module during activation Ideal operating pressure within the left module during activation. 1 Activ / Operation 1 e.g. 25 mbar 1 e.g. 25 mbar To open the menu "manual settings", select the main menu item "manual settings" and press confirm. The following menu items are shown: Tab. 39: Menu Items in "manual settings" Parameter Function/Explanation User Level Values SPR Control the magnetic spray valve 1 Auto / on / off HV A1 IN Control the hydraulic inlet valve of adsorber 1 HV A2 IN Control the hydraulic inlet valve of adsorber 2 1 Auto / on / off 1 Auto / on / off HV A1 OUT HV A2 OUT HV E1 IN HV E2 IN HV E1 OUT HV E2 OUT dem slave-device Control of operations Operating mode Control the hydraulic outlet valve of adsorber 1 Control the hydraulic outlet valve of adsorber 2 Control the hydraulic inlet valve of evaporator / condenser 1 Control the hydraulic inlet valve of evaporator / condenser 2 Control the hydraulic outlet valve of evaporator / condenser 1 Control the hydraulic outlet valve of evaporator / condenser 2 Make a request for external cooling or to a slave system Turn the ezea on or off; activate automatic operation mode Switch between cooling mode and heat pump mode 1 Auto / on / off 1 Auto / on / off 1 Auto / on / off 1 Auto / on / off 1 Auto / on / off 1 Auto / on / off 1 Auto / on / off 1 Auto / on / off 1 Auto / on / off

81 Operation ::: Change Setpoint Temperature 81 / 150 Parameter Function/Explanation User Level Values sec. pump MT Request the secondary pump in the MT circuit 1 Auto / on / off error Fault in the ezea 1 Auto / on / off RCS % man Control the Recooler 1 Auto / on / off If value is set to on Enter rotational speed (in %) 1 0 % % Pump HT % man Control the pump in the hot water circuit (HT) 1 Auto / on / off If value is set to on Enter rotational speed (in %) 1 0 % % Pump MT % man Control the pump in the recooling circuit (MT) 1 Auto / on / off If value is set to on Enter rotational speed (in %) 1 0 % % Pump LT % man Control the pump in the cold water circuit (LT) 1 Auto / on / off If value is set to on Enter rotational speed (in %) 1 0 % % 7.8 Change Setpoint Temperature The setpoint temperature sets the temperature that the ezea should operate at. There are two possible ways to change the setpoint temperature: Input via Controller Option 1: Set the setpoint temperature via the controller on the ezea. 1. Select the menu item "user inputs" and press confirm. 2. In the menu "user inputs", change the value of the parameters "stp cold" for cooling mode or "stp heat" for heat pump mode. 3. Press confirm to save the new value. The setpoint temperature was successfully changed. If the external signal "stp ext" is present, then you cannot manually change the setpoint temperature. The external signal muss provide at least 0.5 V, otherwise the ezea will use the value defined via the controller.

82 Operation ::: Change Setpoint Temperature External Adjustment Option 2: External adjustment of the setpoint temperature The setpoint temperature is set by a higher-level control system via the external signal "stp ext". For the voltage characteristics necessary to determine the external setpoint temperature, see Appendix D from page 137 onwards. An internal setpoint temperature is used in the area not covered by the voltage characteristics (<0.5 V, 3.05 V <> 3.25 V, >5 V) An external "stp ext" signal with 0 V will not shut down the ezea.

83 83 / Maintenance Chapter Contents This chapter contains instructions for regular maintenance of the ezea and those subsystems. Chapter Goals To show how to properly maintain the functionality of the ezea and those subsystems. Only properly trained and authorised personnel may perform maintenance on the ezea and those subsystems! AdKA2014OM-ENG ::: 1.0 ::: English

84 Maintenance ::: Safety Precautions 8.1 Safety Precautions Observe the following safety precautions when performing maintenance on the ezea : Improperly made connections can expose live components! Electric shock when touched. Only properly trained personnel may connect the machine. Pressurised hydraulics, scalding water may escape! Improperly connected hydraulics can scald! Carefully inspect hydraulic connections. Check for leakage. Wear appropriate safety gloves. Only properly trained personnel may perform maintenance activities. Non-insulated parts have hot surfaces! Burn injuries are possible. Avoid contact with potentially hot parts. Wear appropriate safety gloves. Avoid damaging insulation. Replace insulation when necessary. Casing consists of moveable and difficult to mount parts! Avoid crushed fingers. Mount the casing carefully. Follow the installation instructions. Improper electric connections can damage the components of the ezea. Only properly trained personnel may connect the machine. Improper evacuation can damage the ezea. Only properly trained personnel may perform maintenance activities.

85 Maintenance ::: Maintenance Cycles 85 / Maintenance Cycles The maintenance of the entire system should be performed once a year. The review of vacuum modules must be done every two years. When using in industrial application an inspection (visual inspection) at regular intervals is recommended. Inspection visual inspection industrial use semi-annually System - Testing/Maintenance annually Vacuum module - Testing every 2 years 8.3 Inspection Requirements Before carrying out maintenance work, the following conditions must be guaranteed: The ezea and subsystems are properly-connected and ready for use. 8.4 Inspection Overview The ezea has many robust, non-moving parts. As a result, the scope of maintenance tasks for the machine is limited. The necessary inspection tasks can be summarised as follows: 1. Visual inspection of the hydraulic system 2. Check the levels of all hydraulic circuits and if necessary carry out a filling of circuits. 3. Check the recooler of pollution and clean if necessary. 4. Verify the parameters of the controller as well as any fault messages. 8.5 Requirement for System Maintenance Make sure the following requirements are met before performing any maintenance work: The ezea is correctly connected and ready for operation. Sufficient heat input (>60 C) is available.

86 Maintenance ::: System Maintenance Overview 8.6 System Maintenance Overview The ezea has many robust, non-moving parts. As a result, the scope of maintenance tasks for the machine is limited. The maintenance tasks can be summarised as follows: 1. Test the leak tightness of the hydraulic system and the electric connections of the ezea. 2. Test the leak tightness and functionality of the valves and pumps 3. Verify the parameters of the controller as well as any fault messages. 4. Test the performance of the ezea with a short performance test. 5. Test the leak tightness of the hydraulic system and the electric connections of the recooler. 6. Check the recooler for any contaminants and remove them, if necessary. 7. Verify that the mounting screws of the recooler sit securely. 8. Test the leak tightness and operation of the System Separation (pumps). The maintenance checklist in Appendix F on page 147 can be used for any inspection or maintenance tasks. 8.7 Check of the Vacuum Modules A service kit is necessary to check the vacuum of the modules. It includes a vacuum pump, a manometer, connection components and an evacuation adapter which is needed to safely open the ezea. The service kit can be purchased directly from the manufacturer of the ezea. Follow these instructions to check the vacuum of the modules: 1. Establish activation (see chapter on page 87). 2. Check the vacuum (see chapter on page If necessary: Evacuate the vacuum of the modules (see chapter on page 88). 4. End activation (see chapter on page 91). 5. Do a performance test (see chapter on page 92).

87 Maintenance ::: Check of the Vacuum Modules 87 / 150 When using external pump, make sure that during the activation of the (external) cold water circulation pump should be turned off because the ezea locked this cycle internally Explanation of "Activation" In order to check the vacuum in the ezea, the machine must be put into a fixed operating state. This state is referred to as "activation". It is only possible to obtain exact pressure measurements and evacuate the system (if necessary) in this operating state. In activation, hot water flows through both adsorbers of the ezea and recooling water only flows through the condenser. This flushes the refrigerant from both adsorbers. The refrigerant vapour condenses at the chilled condensers. Simultaneously, the refrigerant is separated from any inert gases (rare gases) inside the the modules. The inert gases collect in the condensers and can then be drawn from the modules by a vacuum flange. The higher the temperature differences between the Hot water circuit (T A1 OUT, T A2 OUT) and the recooling circuit (T MT OUT), the more effective this separation process is. A temperature difference of at least 50 K is required for activation Establish Activation Improperly establishing activation can damage the ezea. Only properly trained and authorised personnel may perform maintenance on the ezea. Make sure that there is enough hot water at a high temperature is available (min. 60 C) before establishing activation in the ezea. When activation is established, the ezea is put into a fixed operating state. Follow the instructions below to establish activation in the ezea: 1. In the main operating menu, change the parameter "system" to "on". The ezea is now completely powered on. 2. Hold the Confirm Button to open the operating menu. 3. Select the menu item "code" and press confirm. 4. Enter the proper code and confirm. The controller is now operating on the service level. 5. Open the menu "commissioning".

88 Maintenance ::: Check of the Vacuum Modules 6. Change the parameter "active" from "w hours" to "active". 7. Open the menu "manual settings". 8. Change the parameter RCS % man to "manual". 9. Set the parameter "rcs" to 100%. Activation has been successfully established in the ezea. Note the following instructions. When operating in high ambient temperatures, the spray system of the recooler can be used to create an additional drop in temperature. To do so, change the parameter "spr" to "manual". Monitor the following temperatures in the ezea via the controller to determine the correct point in time to test the vacuum: T A1 OUT T A2 OUT T MT OUT The temperatures T A1 OUT and T A2 OUT should be at a similar level to each other ( T, approx. 1 K) as well as to the driving source (e.g. hot water tank). The recooling temperature T MT OUT should be at the same level as the ambient temperature. If the three temperatures show little fluctuation, then the ezea is in activation and the vacuum is ready to be tested. It can take up to 30 minutes to establish activation Test the Vacuum Only test the vacuum with the service kit. Incorrectly opening the ezea can lead to irreparable damages to the machine. The manufacturer accepts no responsibility for damages caused by improperly opening the ezea. A service kit is needed to test the vacuum. See Fig. 22 for a depiction of its components.

89 Maintenance ::: Check of the Vacuum Modules 89 / 150 Fig. 22: Service Kit for Vacuum Test 1 Rotary vane pump 2 Centering ring & Clamping ring 3 2-way ball valve DN16KF 4 Centering ring & Clamping ring 5 T-piece DN 16KF 6 Capsule pressure gauge 7 Centering ring & Clamping ring 8 Reducing piece 9 Centering ring & Clamping ring 10 PVC hose 11 Centering ring 12 Reducing piece 13 Centering ring & Clamping ring 14 Rotary and linear motion feedthrough 15 Centering ring & Clamping ring 16 Operating fluid 2.5l The service kit can be purchased directly from the manufacturer of the ezea. The list of spare parts is located in Appendix B on page 123 Follow the steps below to test the vacuum in the first module of the ezea: 1. Confirm that the ezea is in activation. 2. Check the oil in the sight glass of the vacuum pump. It must be visibly clear. The fill level must also be adequate. 3. Check all small flange connections. They must be tightly connected together.

90 Maintenance ::: Check of the Vacuum Modules Instructions for the connection and usage of the service kit can be found in the operator manual included with the kit. 4. Connect the evacuation adapter to the vacuum flange of the ezea via a 40 KF clamping and centring ring (see Fig. 22 on page 89). 5. Hand-tighten the clamping ring. 6. Close the pump valve. 7. Connect the service kit to the power supply. 8. Start the vacuum pump via the operating switch. 9. Allow the vacuum pump to warm up for approx. 15 minutes. The gas ballast valve of the vacuum pump must remain open the entire time. 10. Slowly open the pump valve to evacuate the vacuum hose up to the evacuation adapter. 11. Monitor the pressure in the vacuum pump. The pressure must sink below 5 mbar. If the vacuum pump cannot reach 5 mbar or less, then immediately stop the test. The vacuum pump must be repaired first. The returning flow of oil in the vacuum pumps can irreparably damage the ezea. 12. Close the pump valve. 13. Monitor the manometer to test the leak tightness of the evacuated area between the pump valve and the vacuum flange of the ezea. 14. If pressure increases, check the centring rings and gaskets for correct seating. If necessary, tighten the centring rings. 15. Unscrew the rotary/linear feedthrough on the evacuation adapter to open the vacuum flange of the ezea. 16. Read off the pressure value of the ezea and record it. 17. Read off the setpoint value on the controller. ( commissioning, p M1 or p M2 ) 18. If there is at least a 2 mbar difference between the two values, then evacuate the module according to the following steps from 19 to evacuate, otherwise continues at step 23 Evacuate the vacuum modules of the ezea using the following steps listed:

91 Maintenance ::: Check of the Vacuum Modules 91 / Open the pump valve and evacuate the ezea. 20. Constantly monitor the actual pressure and the setpoint pressure. 21. When the setpoint pressure is reach, end the evacuation process. 22. Screw the rotary/linear feedthrough into the evacuation adapter to close the vacuum flange of the ezea. Carefully screw in the rotary/linear feedthrough. Too much force can damage the rotary/linear feedthrough and clog up the vacuum flange. 23. Close the pump valve 24. Please keep the pump running for at least 5 minutes to release condensable gases from the oil. 25. Stop the vacuum pump via the operating switch 26. Remove the evacuation adapter and, if necessary, the vacuum hose 27. Repeat steps 1 to 26 for module Screw the rotary/linear feedthrough into the evacuation adapter to close the vacuum flange of the ezea. 29. Close the pump valve 30. Please keep the pump running for at least 5 minutes to release condensable gases from the oil. 31. Stop the vacuum pump via the operating switch 32. Remove the evacuation adapter and, if necessary, the vacuum hose The vacuum in the ezea has been successfully tested. Follow the instructions in chapter on page 91 to end activation End Activation The activation procedure must be reversed once the vacuum has been tested: 1. Open the menu "commissioning". 2. Open the menu "manual settings". 3. Change the parameter "RCS % man" to "AUTO" (If necessary, change the parameter "spr" to "AUTO"). 4. Open the menu "commissioning".

92 Maintenance ::: Check of the Vacuum Modules 5. Change the parameter "active" from "active" to "operation". The activation of ezea is successfully reset, if the menu has not changed to the value 30 "measured values" of the "Phase" parameter Do a Performance Test 1. Operate the ezea with the desired parameters. 2. Read off the cycle counter and record the results. 3. Allow the machine to run through two complete operating cycles. The cycle counter must increase. The ezea is again ready for operation.

93 93 / Repair Chapter Contents This chapter contains troubleshooting and repair instructions for the ezea. Chapter Goals To show how to restore proper functionality to the ezea. Only properly trained and authorised personnel may perform repairs to the ezea! AdKA2014OM-ENG ::: 1.0 ::: English

94 Repair ::: Safety Precautions 9.1 Safety Precautions Observe the following safety precautions when performing repairs to the ezea: Improperly made connections can expose live components! Electric shock when touched. Only properly trained personnel may connect the machine. Follow the related instructions. Pressurised hydraulics, scalding water may escape! Improperly connected hydraulics can scald! Carefully inspect hydraulic connections. Check for leakage. Wear appropriate safety gloves. Only properly trained personnel may perform repairs. Non-insulated parts have hot surfaces! Burn injuries are possible. Avoid contact with potentially hot parts. Wear appropriate safety gloves. Avoid damaging insulation. Replace insulation when necessary. Casing consists of moveable and difficult to mount parts! Avoid crushed fingers. Mount the casing carefully. Follow the installation instructions. Improper electric connections can damage the components of the ezea. Only properly trained personnel may connect the machine. Improper evacuation can damage the ezea. Only properly trained personnel may perform repairs.

95 Repair ::: Troubleshooting 95 / Troubleshooting If the ezea does not function correctly, then follow the steps below to locate the problem responsible: 1. Check the LED Scroll Buttons on the controller (for possible indications see chapter 2.9 on page 36). 2. Check for fault messages in the menu "messages" in the operating menu. Fig. 23: Fault Message (example) 3. Follow the instructions in chapter 9.3on page 95 to correct the fault. 4. Acknowledge the fault. 5. If the fault cannot be corrected, contact your service partner or the manufacturer of the ezea. 9.3 Fault Messages and Solutions Fault messages are shown on the display of the controller. To see and confirm them, select the menu item "message" in the main menu. The following messages can appear: Tab. 40: Fault Messages in Menu "messages" Code Message Cause Solution 0 System ok. No faults reported - 1 Condensation The temperature of the cold water circuit (LT) is higher than the temperature of the recooling circuit (MT). Possible condensation of the process water in the adsorber The ezea will correct this fault unaided Check temperature levels if necessary

96 Repair ::: Fault Messages and Solutions Code Message Cause Solution 2 freeze prot (dv) No Signal Check pump settings of the cold water circuit Flow monitor of the cold water circuit reports an inadequate volume flow Clean dirt traps Open the hand valve Notify service technician if necessary 3 freeze prot (T) LT OUT Defective pump Defective flow monitor Refrigerant temperature fell, below minimum limit. Cold water circuit absorbs no cooling energy Replace pump Check the frost protection monitor Ensure proper cooling distribution (e.g. switch on fan coils) 4 faulty pump Fault with the pump(s) Check pump functionality Notify service technician if necessary Defective pump, replace if necessary Vent the circuits Disconnect pump from supply voltage for a short time Replace pump 6 Freeze-prot-fc-T Free Cooling: See error code 3 7 Freeze-prot-fc-df Free Cooling: See error code 2 See error code 3 See error code 2 8 Freeze-prot LT IN See error code 3 See error code 3 9 Freeze-prot MT IN See error code 3 See error code 3 10 Freeze-prot TE IN See error code 3 See error code 3 13/14 Limit MT IN Inlet temperature of recooling ist o low ezea automatically reduced pump and fan speed of the recooler

97 Repair ::: Problems from too little Cooling Load 97 / 150 Code Message Cause Solution 15 Limit LT OUT Outlet temperature of the cold water circle near the frostprotection limit 16 dq LT min Poor evaporator performance inefficient operating mode 17 dq LT min Heat pump mode: Poor evaporator performance inefficient operation ezea automatically reduced pump and fan speed of the recooler and minimize it. Power down the ezea if necessary Power down the ezea if necessary short/break T E1 Short circuit/sensor break Notify service technician short/break T E2 Short circuit/sensor break Notify service technician short/break T A1 Short circuit/sensor break Notify service technician short/break T A2 Short circuit/sensor break Notify service technician short/break T MT OUT short/break T LT OUT Short circuit/sensor break Short circuit/sensor break Notify service technician Notify service technician short/break T LT IN Short circuit/sensor break Notify service technician short/break T LT OUT Short circuit/sensor break Notify service technician short/break T E1 Short circuit/sensor break Notify service technician short/break T E2 Short circuit/sensor break Notify service technician The ezea can correct some faults through automatic procedures (e.g.: freeze protection dv). 9.4 Problems from too little Cooling Load Which problems can be expected when the actual cooling load is less than the minimum displayable cooling capacity of the ezea? If the requested cooling performance falls below the minimum partial-load operational range of the ezea (usually 60 % of the maximum cooling capacity), energy is drawn bit by bit from the refriger-

98 Repair ::: Problems from too little Cooling Load ant until it cools down to the predefined frost limit temperature (default setting: 2 C). The ezea then shuts down. To avoid this kind of a deep drop in temperature, install the temperature sensor "T_LT_ext" and set a minimum buffer temperature (under the parameter "T_LT_mn" in the operating menu). This is especially important to note when using cooling via cooling ceilings, in which case the temperature of the refrigerant can fall below the dew point when temperatures are too low.

99 99 / Decommissioning Chapter Contents This chapter provides instructions for decommissioning the ezea in preparation for a long shutdown period (for transport or storage, for example). Chapter Goals To show how to correctly decommission the ezea. Only properly trained and authorised personnel may decommission the ezea! AdKA2014OM-ENG ::: 1.0 ::: English

100 Decommissioning ::: Safety Precautions 10.1 Safety Precautions Observe the following safety precautions when decommissioning the ezea: Improperly disconnecting the machine can expose live components! Electric shock when touched. Only properly trained personnel may connect the machine. Follow the related instructions. Pressurised hydraulics, scalding water may escape! Improperly connected hydraulics can scald! Monitor hydraulic connections carefully when draining. Check for leakage. Wear appropriate safety gloves. Only properly trained personnel may decommission the machine. Casing consists of moveable and difficult to mount parts! Avoid crushed fingers. Mount the casing carefully. Follow the related instructions. Pipes and threads have sharp edges! Cuts to hands and fingers are possible. Wear appropriate safety gloves. Improperly performed electrical work can damage the components of the ezea. Only properly trained personnel may perform electrical work on the machine.

101 Decommissioning ::: Decommission the ezea 101 / Decommission the ezea Always power down the ezea via the controller and the main switch. Only then disconnect the power supply! Disconnecting the power supply during operation can cause a hydraulic short circuit, which would result in an unnecessary waste of heating energy. Follow the instructions below to decommission the ezea: 1. In the main operating menu, change the parameter "system" to "off" to shut down the ezea. 2. Wait until the parameter "system" shows "off". This process can take up to 60 seconds. 3. Remove the front cover. 4. Operate the main switch (see Fig. 24) to completely power down the ezea. 1 Fig. 24: Main Switch of the ezea 1 Main switch 5. Attach the front cover again. 6. If the ezea is to be shut down for a long period of time, consult the information in chapter 10.3 on page 102. The decommissioning of the ezea is now complete.

102 Decommissioning ::: Long-term Decommissioning 10.3 Long-term Decommissioning If the ezea will not be used for a long period of time, then it should be decommissioned completely. This protects the ezea from possible damage due to frost. To put the ezea out of service, discharge the hydraulic circuits and clean them out with a wet vacuum. Despite emptied hydraulics, make an anti-freeze installation, as process water in the two modules and the other residual water in the heat exchangers can freeze and may cause damage. The manufacturer accepts no responsibility for damages caused by improperly decommissioning the machine or not decommissioning it at all Optional Components Recooler Follow the instructions below to decommission the Recooler: 1. Disconnect the Recooler from the power supply 2. Drain the Recooler and clean it out with a suitable wet vacuum. 3. Drain the spray system. 4. Protect open connections from contamination. The decommissioning of the Recooler is now complete. System Separation Follow the instructions below to decommission the system separation: 1. Disconnect the system separation from the power supply. 2. Drain the system separation. 3. Protect open connections from contamination. The decommissioning of the system separation is now complete.

103 103 / Storage and Recommissioning Chapter Contents This chapter provides instructions for storing the ezea in long shutdown periods and recommissioning it after storage.. Chapter Goals To show how to correctly store and recommission the ezea. AdKA2014OM-ENG ::: 1.0 ::: English

104 Storage and Recommissioning ::: Storage Conditions 11.1 Storage Conditions The Adsorption Chiller Aggregate must be stored at a site which meets the requirements listed in Tab. 41. Tab. 41: Storage Conditions for the ezea Unit Value Storage temperature C 0-60 Relative humidity % Store the ezea Before storing the ezea, follow the decommissioning procedure described in chapter 10 on page 99. Follow the instructions below to store the ezea: 1. If the storage site is different than the installation site, then disassemble the Adsorption Chiller Aggregate as described in chapter 13 on page Close all hydraulic connections to protect them from contamination. 3. If the storage site is different than the installation site, then transport the ezea to the storage site in compliance with the information in chapter 12 on page Make sure the storage site meets the requirements shown in Tab. 41 on page 104. The ezea has been successfully put into storage.

105 Storage and Recommissioning ::: Recommission the ezea 105 / Recommission the ezea The recommissioning process contains all necessary steps immediately after storage. Once these steps are complete, follow the remaining commissioning steps described in chapter 6 on page 67. Follow the instructions below to recommission the ezea: 1. If the storage site is different than the installation site, then transport the ezea to the installation site in compliance with the information in chapter 12 on page Open all hydraulic connections. 3. If the storage site is different than the installation site, then install the ezea as described in chapter 5 on page Use the commissioning process described in chapter 6 on page 67 to operate the ezea again. The recommissioning of the ezea is now complete Optional Components Recooller Protect the Recooler from contamination, moisture, frost and damage during storage. Follow the instructions below to recommission the Recooler: 1. Reconnect connections and control lines. 2. Check control lines. 3. Fill the Recooler and vent it. 4. Fill the spray system. 5. Reconnect the Recooler to the power supply 6. Check fans for proper operation. The recommissioning of the Recooler is now complete. System Separation Protect the system separation from contamination, moisture, frost and damage during storage. Follow the instructions below to recommission the system separation:

106 Storage and Recommissioning ::: Optional Components 1. Reconnect connections and control lines. 2. Check control lines. 3. Check the pump for free movement. 4. Fill the system separation and vent it. 5. Reconnect the system separation to the power supply. The decommissioning of the system separation is now complete.

107 107 / Transport and Packaging Chapter Contents Dieses Kapitel enthält Hinweise zum Transport der ezea und zur dafür notwendigen Verpackung. Chapter Goals To show how to avoid damage during transport. AdKA2014OM-ENG ::: 1.0 ::: English

108 Transport and Packaging ::: Safety Precautions during Transport 12.1 Safety Precautions during Transport Observe the following safety precautions when transporting the ezea: Instability when loading and unloading! Avoid crushing injuries caused by falling or shifting. Make sure the ezea is properly secured for transport. Use appropriate technical aids and tools. Avoid vibrations, hard impacts and shocks. Secure the ezea to prevent it from toppling over. The ezea is a complex and sensitive vacuum system. Handle with utmost care when loading, unloading, transporting or positioning the machine Transport the ezea The ezea can be transported with standard commercial pallet jacks and forklift trucks. Securely load the ezea before transport to avoid load shifting Delivery Packaging The ezea comes delivered in a cardboard box secured to a pallet. The delivery unit is wrapped in a protective plastic foil. Remove all packaging materials before installing the ezea. Keep all packaging materials (plastic, screws, protective covers etc.) out of reach of children! Dispose of all packaging materials in the appropriate manner.

109 Transport and Packaging ::: Repack after Disassembly 109 / Repack after Disassembly 1. Drain the hydraulic valves. 2. Protect the hydraulic connections from contamination. Use the appropriate end caps for the existing connection types. 3. Securely position the ezea on an appropriate pallet. 4. Protect the casing of the ezea from damage. Use protective foil and edge protectors. 5. Ensure that the packaging used also protects the machine from frost damage Optionale Components Reooler and System Separation Follow the instructions below to properly prepare the Recooler and the system separation for transport: 1. Drain the hydraulic systems. 2. Die Steuer- und Versorgungsleitungen trennen. 3. Protect open connections from contamination. 4. Protect protruding edges from damage. Use appropriate edge protection. 5. Protect painted surfaces from damage. Use appropriate protective covering (foil, cardboard, etc.)

110 Transport and Packaging ::: Optionale Components

111 111 / Disassembly Chapter Contents This chapter describes the tasks necessary to disassemble the ezea. Chapter Goals To show how to correctly disassemble the ezea. Only properly trained and authorised personnel may disassemble the ezea! AdKA2014OM-ENG ::: 1.0 ::: English

112 Disassembly ::: Safety Precautions 13.1 Safety Precautions Observe the following safety precautions when disassembling the ezea: Improperly made connections can expose live components! Electric shock when touched. Disconnect the power supply. Only properly trained personnel may connect the machine. Follow the related instructions. Pipes and threads have sharp edges! Cuts to hands and fingers are possible. Wear appropriate safety gloves Disconnect Electrical Connections Before disconnecting the electrical connections of the ezea, follow the decommissioning procedure described in chapter 10 on page 99. Follow the instructions below to disconnect the electrical connections of the ezea and the optional components (if necessary): Live components! Electric shock when touched. Disconnect the power supply first. 1. Disconnect the power supply. 2. If necessary, store the power supply line in a suitable place. 3. Disconnect the control lines. The electric connections of the ezea and the optional components have been successfully disconnected.

113 Disassembly ::: Hydraulikanschlüsse trennen 113 / Hydraulikanschlüsse trennen Casing consists of moveable and difficult to mount parts! Avoid crushed fingers. Mount the casing carefully. Follow the related instructions. Pipes and threads have sharp edges! Cuts to hands and fingers are possible. Wear appropriate safety gloves. Follow the instructions below to disconnect the hydraulic connections of the ezea and the optional components (if necessary): 1. Properly disconnect the hydraulic connections from the pipe and hose system in accordance with the type of connection used. 2. Drain the hydraulic valves. 3. Close all hydraulic connections to protect them from contamination. The hydraulic connections of the ezea and the optional components have been successfully disconnected.

114 Disassembly ::: Hydraulikanschlüsse trennen

115 115 / Disposal Chapter Contents This chapter provides information on general requirements and special guidelines related to the disposal of the ezea. Chapter Goals To show how to properly dispose of the ezea in accordance with mandatory legal requirements. AdKA2014OM-ENG ::: 1.0 ::: English

116 Disposal ::: Prepare for Disposal 14.1 Prepare for Disposal Before disposing of the Adsorption Chiller Aggregate, follow the decommissioning procedure described in chapter 13 on page 111. Evacuate both modules of the Adsorption Chiller Aggregate before disposing of the machine. For assistance see chapter on page 88 as well as the instructions in chapter 8.7 on page Disposal Guidelines Die nachfolgend aufgeführten Vorgaben für die Entsorgung der ezea, der optionalen Komponenten und der Verpackungselemente sind zu beachten. Tab. 42: Disposal Guidelines Material Disposal Options Pipes, casing Copper, steel Scrap Electronics Mix Electronic scrap Module 1 / Module 2 Copper Return to manufacturer Aluminium Steel Zeolite Component adhesives Packaging Paper, cardboard Foil Paper waste receptacles Composite materials Dispose of all materials in accordance with local guidelines. Consult your local municipal administration for suitable recycling centres and collection points.

117 List of Figures 117 / 150 List of Figures Fig. 1: Type Plate... 3 Fig. 2: Hazardous Areas on the ezea...17 Fig. 3: Structure of the Adsorption Chiller Aggregate (1)...26 Fig. 4: Structure of the ezea (2)...27 Fig. 5: Hydraulic Connections (as seen from rear)...28 Fig. 6: Power Supply Connection of the ezea...30 Fig. 7: Functional Construction...32 Fig. 8: Phase 1 Sequence of Events in the Processing Chambers of the Modules...33 Fig. 9: Control and Display Elements of the Controller...36 Fig. 10: Main Menu (example)...37 Fig. 11: Construction of the Recooler (vertical installation)...38 Fig. 12: Configurations of the System Separation...40 Fig. 13: Clearances in mm at Installation Site (single installation)...60 Fig. 14: Hydraulic Connections (as seen from rear)...62 Fig. 15: Power Supply Connection of ezea...63 Fig. 16: Main Switch of the ezea...69 Fig. 17: Main Switch of the ezea...72 Fig. 18: Main Menu (examples)...73 Fig. 19: Menu "values" (example view)...74 Fig. 20: Menu "user inputs" (example view)...77 Fig. 21: Menu "messages" (example view)...79 Fig. 22: Service Kit for Vacuum Test...89 Fig. 23: Fault Message (example)...95 Fig. 24: Main Switch of the ezea List of Tables Tab. 1: System Documentation... 4 Tab. 2: Outline of System Documentation... 4 Tab. 3: Symbols... 7 Tab. 4: Specific Abbreviation... 7 Tab. 5: Qualification of personnal...14 Tab. 6: Scope of Delivery of the Adsorption Chiller Aggregate...22 Tab. 7: Scope of Delivery of the System Separation...23 Tab. 8: Water quality...41 Tab. 9: Water quality & spraying...42 Tab. 10: Dimensions and Weight of the ezea...44 Tab. 11: Performance Data of the ezea Tab. 12: Operating Limits of the Operating Modes...45 AdKA2014OM-ENG ::: 1.0 ::: English

118 List of Tables Tab. 13: Hydraulic Connections of the ezea Tab. 14: Power Supply of the ezea Tab. 15: Connection Terminals of the ezea Tab. 16: Technical control connection of the ezea Tab. 17: Dimensions and Weight of the Recooler Tab. 18: Performance Data of the Recooler Tab. 19: Hydraulic connections of the Recooler Tab. 20: Power Supply of the Recooler Tab. 21: Connection Terminals of the Recooler Tab. 22: Dimensions and Weight of the System Separation 10/ Tab. 23: Performance Data of the System Separation 10/ Tab. 24: Power Supply of the System Separation 10/ Tab. 25: Connection Terminals of the System Separation 10/ Tab. 26: Dimensions and Weight of the System Separation 30/ Tab. 27: Performance Data of the System Separation 30/ Tab. 28: Power Supply of the System Separation 30/ Tab. 29: Connection Terminals of the System Separation 30/40 (230V) Tab. 30: Connection Terminals of the System Separation 30/40 (380V) Tab. 31: Criteria for the Installation Site Tab. 32: Criteria for the Installation Site of the Recooler Tab. 33: Criteria for the Installation Site of the System Separation Tab. 34: Items in the Main Menu Tab. 35: Menu Items in "values" Tab. 36: Menu Items in "user inputs" Tab. 37: Menu Items in "messages" Tab. 38: Menu Items in "messages" Tab. 39: Menu Items in "manual settings" Tab. 40: Fault Messages in Menu "messages" Tab. 41: Storage Conditions for the ezea Tab. 42: Disposal Guidelines

119 Adsorptionskälteaggregat Declaration of Incorporation 119 / 150 Declaration of Incorporation

120 Glossary Glossary Parameter Designation Explanation dv LT Flow monitor Monitors the volume flow in the cold water circuit HV A1 IN Hydraulic valve A1_IN Regulates fluid flow into adsorber 1 HV A1 OUT Hydraulic valve A1_OUT Regulates fluid flow out of adsorber 1 HV A2 IN Hydraulic valve A2_IN Regulates fluid flow into adsorber 2 HV A2 OUT Hydraulic valve A2_OUT Regulates fluid flow out of adsorber 2 T HT IN T HT OUT Temperature in hydraulic flow HT Temperature in hydraulic return HT Fluid flow into the ezea, coming from buffer Fluid flow into the ezea, going into the buffer T LT IN T LT OUT Temperature in hydraulic flow LT Temperature in hydraulic return LT Fluid flow into the ezea Fluid flow out of the ezea T MT IN T MT OUT T SET Temperature in hydraulic flow MT Temperature in hydraulic return MT Fluid flow into the ezea, coming from Recooler Fluid flow out of the ezea, going into the Recooler Setpoint of the cold water Target temperature for the cold water output temperature output - Annual performance factor Yearly average of cooling capacity to absorbed electrical performance of the ezea and Recooler (optional) Hydraulic pump in driving and recooling circuit

121 Appendix A: Configurations 121 / 150 Appendix A: Configurations Designation/Explanation Recooler erec erec Recooling capacity of 40 kw with 3 EC-ventilators Recooler erec erec Recooling capacity of 80 kw with 4 EC- ventilators Recooler erec erec Recooling capacity of 120 kw with 6 EC- ventilators Recooler erec erec Recooling capacity of 160 kw with 8 EC- ventilators Recooler erec erec Recooling capacity of 200 kw with 10 EC- ventilators Recooler erec erec Recooling capacity of 240 kw with 12 EC- ventilators Recooler erec erec Recooling capacity of 280 kw with 14 EC- ventilators Recooler erec erec Recooling capacity of 320 kw with 16 EC- ventilators System Seaparation 10 System Separation 10 [ST-G-10] for an individual ezea in connection with solutions for a hydraulically closed recooling system System Separation 10 [ST-O-10] for an individual ezea in connection with solutions for a hydraulically open recooling system System Separation 10 [ST-B-10] for an individual ezea in connection with solutions for a freely configurable recooling system AdKA2014OM-ENG ::: 1.0 ::: English

122 Appendix A: Configurations Designation/Explanation System Separation 20 System Separation 20 [ST-G-20] for 2 interconnected ezea s in connection with solutions for a hydraulically closed recooling system System Separation 20 [ST-O-20] for 2 interconnected ezea s in connection with solutions for a hydraulically open recooling system System Separation 20 [ST-B-20] System Separation 30 System Separation 30 [ST-G-30] for 2 interconnected ezea s in connection with solutions for a freely configurable recooling system for 3 interconnected ezea s in connection with solutions for a hydraulically closed recooling system System Separation 30 [ST-O-30] for 3 interconnected ezea s in connection with solutions for a hydraulically open recooling system System Separation 30 [ST-B-30] System Separation 40 System Separation 40 [ST-G-40] for 3 interconnected ezea s in connection with solutions for a hydraulically open recooling system for 4 interconnected ezea s in connection with solutions for a hydraulically closed recooling system System Separation 40 [ST-O-40] for 4 interconnected ezea s in connection with solutions for a hydraulically open recooling system System Separation 40 [ST-B-40] for 4 interconnected ezea s in connection with solutions for a hydraulically open recooling system

123 Adsorptionskälteaggregat Declaration of Incorporation 123 / 150 Appendix B: List of Spare Parts ezea No. Assembly Article No. Designation Manufacture 1 MSR Interface adapter VBus /LAN Resol 2 MSR Datalogger [DL-1] Resol Note: Web interface with data logger function for individually installed ezea 3 MSR Datalogger [DL-6] Resol Note: Web interface with data logger function for up to 6 interconnected ezea 4 MSR Sensor for detecting the temperature of heat transfer fluid Resol Note:: PT 1000B according to DIN EN 60751; C 5 MSR Immersion sleeve Resol Note: For incorporating temperature sensors, uses standard screw connection thread ½" 6 MSR Indoor temperature sensor Resol Note: Temperature sensor for acquiring indoor temperatures; installed on even surfaces; with PT 1000 characteristics 7 MSR Outdoor temperature sensor Resol Note: Temperature sensor for acquiring outdoor ambient temperatures; installed on even surfaces; with PT 1000 characteristics 8 MSR Flow monitor Resol 9 MSR Strömungswächter Sika Note: For monitoring the flow in the cold water line 10 Hydraulics Three-way-valve DePala 11 Hydraulics Drive unit DePala 12 Hydraulics Wilo Stratos Wilo Note: High efficiency pump 13 Hydraulics Hydraulic unit (feed) SorTech AG Note: Hydraulic swing including valve body (flow)

124 Appendix B: List of Spare Parts No. Assembly Article No. Designation Manufacture 14 Electronics Note: Terminal block Connection unit for power supply 15 Electronics Main switch Siemens 16 Casing Controller plate, frame Metalsid,Metallika 17 Casing Casing top Metalsid,Metallika 18 Casing Front, bottom Metalsid,Metallika 19 Casing Front top, plate Metalsid,Metallika System separation No. Assembly Article No. Designation Manufacturer 20 System separation 21 System separation 22 System separation 23 System separation Para Wilo Note: only for SYSTEM SEPARATION 10 [ST-G 10] TP 25-90/2 Grundfoss Note: Only for SYSTEM SEPARATION 10 [ST-O 10] Stratos Wilo Note: Only for SYSTEM SEPARATION 20 [ST-G 20] TP /2 Grundfoss Note: Only for SYSTEM SEPARATION 20 [ST-O 20]

125 Adsorptionskälteaggregat Declaration of Incorporation 125 / 150 No. Assembly Article No. Designation Manufacturer 24 System separation 25 System separation Plate heat exchanger GPLK Note: for all SYSTEM SEPARATIONS Plate heat exchanger GPLK Note: for all SYSTEM SEPARATIONS 20 Funke Funke 26 System separation 27 System separation Main Switch Siemens Note: for all SYSTEM SEPARATIONS Boiler safety group Haustechnik Note: DN 25, for all SYSTEM SEPARATIONS Service-Kit No. Assembly Article No. Designation MAnufacturer 28 Service-Kit Vacuum pump WLS Tec 29 Service-Kit Vacuum pump oil, 500ml WLS Tec 30 Service-Kit ISO KF Reducing piece DN 40/25 ISO KF Reducing piece DN 25/16 ISO KF Centring ring with o-ring gasket, DN 25 ISO KF Centring ring with o-ring gasket, DN 40 WLS Tec WLS Tec WLS Tec WLS Tec Note: used to connect the individual components of the service kit 31 Service-Kit ISO KF Centring ring with o-ring gasket, DN 16 WLS Tec Note: used to connect the individual components of the service kit 32 Service-Kit ISO KF Clamp, DN 16 WLS Tec Note: used to connect the individual components of the service kit 33 Service-Kit ISO KF Clamp, DN 25 WLS Tec

126 Appendix B: List of Spare Parts No. Assembly Article No. Designation MAnufacturer ISO KF Clamp, DN 40 WLS Tec Note: used to connect the individual components of the service kit 34 Service-Kit Vacuum hose with ISO KF connections WLS Tec 35 Service-Kit ISO KF Tee, DN 25 WLS Tec 36 Service-Kit Ball valve WLS Tec 37 Service-Kit ISO KF Filter-sinter ring DN 16 WLS Tec 38 Service-Kit Manometer, operating pressure range 0 to 100 mbar Oerlinkon 39 Service-Kit Evacuation Adapter Trinos/Pfeiffer Vakuum Note: used to connect the service kit to the vacuum flange of the ezea

127 Appendix C: Drawings/Diagrams 127 / 150 Appendix C: Drawings/Diagrams Fitting Dimensions of the Adsorption Chiller Aggregate Connection Diagram Fitting Dimensions of the Recooler erec Fitting Dimensions of the Recooler erec Fitting Dimensions of the System Separation Fitting Dimensions of the System Separation Hydraulic Connection Plan for Heat Pump Mode Circuit Diagram without system separation Circuit Diagram with system separation 230V Circuit Diagram with system separation 400V 136 AdKA2014OM-ENG ::: 1.0 ::: English

128 Appendix C: Drawings/Diagrams Fitting Dimensions of the Adsorption Chiller Aggregate

129 Appendix C: Drawings/Diagrams 129 / 150 Connection Diagram

130 Appendix C: Drawings/Diagrams Fitting Dimensions of the Recooler erec L B H 6130 mm 1170 mm 1510 mm Fitting Dimensions of the Recooler erec L B H 5030 mm 2290 mm 1510 mm

131 Appendix C: Drawings/Diagrams 131 / 150 Fitting Dimensions of the System Separation 10

132 Appendix C: Drawings/Diagrams Fitting Dimensions of the System Separation 20

133 Appendix C: Drawings/Diagrams 133 / 150 Hydraulic Connection Plan for Heat Pump Mode

134 Appendix C: Drawings/Diagrams Circuit Diagram without system separation

135 Appendix C: Drawings/Diagrams 135 / 150 Circuit Diagram with system separation 230V

136 Appendix C: Drawings/Diagrams Circuit Diagram with system separation 400V

137 Appendix D: Diagrams/Characteristics 137 / 150 Appendix D: Diagrams/Characteristics Power Charts Cooling capacity (dq NT) 16 kw 14 kw 12 kw 10 kw 8 kw 6 kw 4 kw 2 kw Performance for cold water inlet temperatures(t NT IN) of 19 C 90 C 85 C 75 C 0 kw 22 C 24 C 26 C 28 C 30 C 32 C 34 C 36 C 38 C 40 C 42 C 44 C Recooling temperature (T MT IN) Cooling capacity (dq NT) 16 kw 14 kw 12 kw 10 kw 8 kw 6 kw 4 kw 2 kw Performance for cold water inlet temperatures (T NT IN) of 16 C 90 C 85 C 75 C 0 kw 22 C 24 C 26 C 28 C 30 C 32 C 34 C 36 C 38 C 40 C 42 C 44 C Recooling temperature (T MT IN)

138 Appendix D: Diagrams/Characteristics Performance for cold water inlet temperatures (T LT IN) of 13 C Cooling capacity (dq NT) 10 kw 8 kw 6 kw 4 kw 2 kw 90 C 85 C 75 C 0 kw 22 C 24 C 26 C 28 C 30 C 32 C 34 C 36 C 38 C 40 C 42 C 44 C Recooling temperature (T MT IN) Cooling capacity (dq NT) 8 kw 7 kw 6 kw 5 kw 4 kw 3 kw 2 kw 1 kw Performance for cold water inlet temperatures (T LT IN) of 10 C 90 C 85 C 75 C 0 kw 22 C 24 C 26 C 28 C 30 C 32 C 34 C 36 C 38 C 40 C 42 C 44 C Recooling temperature (T MT IN)

139 Appendix D: Diagrams/Characteristics 139 / 150 COP Charts COP for cold water inlet temperatures (T LT IN) of 19 C 0,6 0,5 0,4 90 C 85 C 75 C COP 0,3 0,2 0,1 0,0 22 C 24 C 26 C 28 C 30 C 32 C 34 C 36 C 38 C 40 C 42 C 44 C Recooling temperature (T MT IN) 0,6 0,5 0,4 COP for cold water inlet temperatures (T LT IN) of 16 C 90 C 85 C 75 C COP 0,3 0,2 0,1 0,0 22 C 24 C 26 C 28 C 30 C 32 C 34 C 36 C 38 C 40 C 42 C 44 C Recooling temperature (T MT IN)

140 Appendix D: Diagrams/Characteristics COP COP for cold water inlet temperatures (T LT IN) of 13 C 0,6 0,6 90 C 0,5 85 C 0,5 75 C 0,4 0,4 0,3 0,3 0,2 22 C 24 C 26 C 28 C 30 C 32 C 34 C 36 C 38 C 40 C 42 C 44 C Recooling temperature (T MT IN) COP for cold water inlet temperatures (T LT IN) of 10 C COP 0,7 0,6 0,5 0,4 0,3 90 C 85 C 75 C 0,2 0,1 0,0 22 C 24 C 26 C 28 C 30 C 32 C 34 C 36 C 38 C 40 C 42 C 44 C Recooling temperature (T MT IN)

141 Appendix D: Diagrams/Characteristics 141 / 150 Voltage Characteristics of the Setpoint Temperature

142 Appendix D: Diagrams/Characteristics

143 Appendix E: Commissioning Checklist 143 / 150 Appendix E: Commissioning Checklist Fill in the following checklist during the commissioning process. The commissioning process is not complete until the checklist is filled in completely.

144 Adsorption Chiller Aggregate Appendix E: Commissioning Checklist

145 Appendix E: Commissioning Checklist 145 / 150

146 Appendix E: Commissioning Checklist

147 Appendix F: Maintenance Checklist 147 / 150 Appendix F: Maintenance Checklist The following checklist can be used in conjunction with inspection and maintenance tasks.

148 Appendix F: Maintenance Checklist

149 Adsorption Chiller Aggregate Appendix F: Maintenance Checklist 149 / 150

150 Appendix F: Maintenance Checklist