High Density cooling systems

Transcription

1 OPERATION MANUAL Close Control Units Row-DENCO High Density cooling systems

2 Table of Contents Row-DENCO 1 Unit Identification Plate Unit Type Code Indoor type code Outdoor type code Overview of Units and Packaged Content Documents enclosed with the unit General characteristics Versions Type of system Safety and User Instructions Availability of the operation manual Scope of the operation manual Symbols used Labelling of safety instructions Used safety symbols Safety-conscious work procedures Proper use Safety devices Modifications and changes Spare parts Disposal Selection and qualification of personnel Technical Data Row-DENCO DX rack cooler Row-DENCO CW rack cooler Operating limits Receipt, Transport and Handling Transport Receiving the unit Storage Standard packaging and packaging with wooden crate (optional) Dimensional Drawings DRX (300 X 1000 X 42U RACK) DRX (300 X 1200 X 42U RACK) DRC (300 X 1000 X 42U RACK) DRC 036 (300 X 1000 X 42U RACK) DRC (300 X 1200 X 42U RACK) DRC 036 (300 X 1200 X 42U RACK) DROU 051 and DROU DROU PR GB Subject to modifications R2-01/2016

3 Row-DENCO Table of Contens 8 Installation Overview Diagram Install Row-DENCO Connection of the refrigeration circuit to the external evaporator (on-site) Refrigerant connections (DRX/DROU) Water connections (DRC) Electrical Connection Requirements DRX Connection Configuration DRC connection configuration Electrical specifications Commissioning and Testing Evacuation Charging Preparing for first start up Condensate drain Instruments and alarms Calibrating the control and safety devices Calibrating the dirty filter sensor Modulating water valve Way valve shut off Way ON/OFF valve (optional) Temperature and Hhumidity Pprobe (option DRZ-3HSENA.E04) Energy monitoring (optional) Dual power supply (optional) Humidifier Maintenance Maintenance Cleaning the air filter Checking and cleaning the condenser coils Checking and cleaning the drains General examination of operation Visual check of the condition of the pressurised containers Troubleshooting Dismantling and Disposal Dismantling Disposal Log Book for Chiller, Heat Pumps and Compressor/Condenser Units PROTECTION NOTICES The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design. PR GB Subject to modifications R2-01/2016 3

4 Unit Identification Plate Row-DENCO 1 Unit Identification Plate The unit identification plate is secured on the unit and is explained as follows. Enter the data from the unit identification plate in the operation manual. This record establishes the relationship between the unit and the operation manual. If this condition is met, the operation manual can then be used to enter test and inspection data for your unit. Company logo Unit type Company name Item number Serial Number Year of manufacture Operating weight Refrigerant Refrigerant charge volume Oil type Power supply Max. operating pressure high and low pressure side Max. power consumption Max. current consumption Max. operating pressure on water side Max. storage and shipping temperature Drawing number of wiring diagram Fig. 1-1 The Row-DENCO rating plate is positioned on a panel inside the unit, and provides the following information: model and serial number of the unit power supply (voltage, phases and frequency) power consumption of the unit current draw of the unit: FLI (Full Load Input), FLA (Full Load Current) and LRA (Locked Rotor Current) 4 PR GB Subject to modifications R2-01/2016

5 Row-DENCO Unit Identification Plate The DROU condensing units can be identified by the: Packaging label Showing the data identifying the product. Rating plate Showing the unit technical and performance data. If this is lost, ask After Sales Service for a replacement. NOTE! Tampering with or the removal or absence of rating plates or other means enabling the unit to be identified causes problems during installation and maintenance. PR GB Subject to modifications R2-01/2016 5

6 Unit Type Code Row-DENCO 2 Unit Type Code 2.1 Indoor type code Row-DENCO D R X 3 0 X X A 5 Product range Cooling system Dimension Unit size Series Power supply DR Row-DENCO C X Chilled water Split system 3 Width of unit x 100 mm 020 only DRC version 025 only DRC version 035 only DRC version 036 only DRC version 051 only DRX version 071 only DRX version 121 only DRX version A Series V/1Ph/50 Hz 6 PR GB Subject to modifications R2-01/2016

7 Row-DENCO Unit Type Code 2.2 Outdoor type code Row-DENCO D R O U D A 1.W Product range Key outdoor unit Outdoor system Refrigerant Unit size Series Power supply Version DR O U D Row-DENCO Outdoor units Condensing Unit R-410A A Series V/3Ph/+N/50 Hz - only Unit size V/1Ph/+N/50 Hz - only Unit size 051.N Standard version.w Winter-Kit down to -35 C ambient NOTE! For detailed planning please only use the order-related documentation. Detailed dimensional drawings can be obtained on request from your relevant DencoHappel sales office. Specifications and technical data are subject to regular updates. The manufacturer reserves the right to make necessary changes to information without prior written notice. PR GB Subject to modifications R2-01/2016 7

8 Overview of Units and Packaged Content Row-DENCO 3 Overview of Units and Packaged Content 3.1 Documents enclosed with the unit Each unit is delivered complete with the following documents: Row-DENCO installation, user and maintenance manual Wwiring diagram list of spare parts CE declaration with list of European directives and standards that the unit is compliant with warranty conditions 3.2 General characteristics Row-DENCO indoor unit Fig. 3-1 Description of the unit The Row-DENCO air-conditioning unit is an innovative and efficient system for managing hot spots in data centers, guaranteeing low energy consumption and possibility to be used with HIGH DENSITY racks that generate extremely high loads, up to and over 40 kw/m² per rack. The use of the latest generation EC fans with brushless motors ensures excellent performance in terms of low power consumption and low noise. N+1 dynamic management of the EC fans to optimise consumption and cooling system redundancy are available as standard. On the Row-DENCO versions, the units are positioned in rows of RACKS, with a layout so as to create cold aisles, where the cool air from the Rack Cooler is delivered, and hot aisles, where the air heated by the electronic equipment housed in the RACKS is discharged. These are individual units installed between the Racks in a row, so as to absorb the local heat load of the servers. On Row-DENCO versions, the air to be cooled is taken in at the rear of the unit directly from the data center hot aisle (35 C), giving considerable benefits in terms of both energy efficiency and cooling capacity, before being cooled and then delivered into the cold aisle (18-20 C), in other words, at the front of the same rack where the air is taken in. Structure Extremely compact structure that reduces overall dimensions, made from galvanised steel plate with RAL9002 epoxy powder coating. The panelling is coated with an innovative double layer of plastic, is lined on the inside with special soundproofing material. Fans The use of latest generation 225 mm diameter radial fans with EC brushless motors ensures excellent performance and low power consumption. N+1 dynamic management of EC fans is featured as standard, allowing operation at reduced flowrate to optimise power consumption. Moreover, in the event of a fault on one fan, the other fans are operated at maximum speed to ensure the same cooling performance. The fan section has been designed to allow rapid replacement in the event of faults, thus reducing system downtime. 8 PR GB Subject to modifications R2-01/2016

9 Row-DENCO Overview of Units and Packaged Content Filters Regenerable polyester fibre filtering media (G2 efficiency) treated with synthetic resins, supported by a frame with protective metal mesh. The filtering media is flame retardant. Air-Sources Heat Exchanger Finned coil with large frontal surface area, made from mechanically expanded tubes and aluminium fins with hydrophilic treatment and high heat transfer area. The coil is placed upstream of the fans for optimum air distribution. Electrical Ppanel Built and wired in compliance with IEC 204-1/EN standards, complete with fan contactor and overload protection. Microprocessor Control System The microprocessor, by managing the compressor for the direct expansion unit and the modulating 3-way valve for the water chiller, controls cooling capacity and operating alarms, with the possibility of connection to supervisory systems. Immersed Electrode Humidifier (optional) Modulating steam production and automatic control of salt concentration in the water tank to allow the use of untreated water Outdoor condensing unit Description of the DROU unit For direct expansion versions, the DROU outdoor condensing unit combined with the DRX indoor unit, is aircooled with axial-flow fans, fitted with INVERTER-DRIVEN HER- METIC SCROLL compressor for operation on R-410A refrigerant, mounted on rubber vibration dampers, complete with oil pre-charge, supplied with oil separator to ensure correct lubrication even at minimum speed, and fitted with thermal protector. Structure Powder coated metal plate base panelling and inside structure. Non-flammable closed cell polyethylene foam thermal insulation and soundproofing on the inside. Inverter-Driven compressors High efficiency hermetic scroll compressor with brushless DC motor, complete with thermal protector, with electronic capacity control managed by INVERTER. This ensures unit operating efficiency even at part loads, which represent more than 75 % of normal operating time, meaning effective overall average energy savings of up to 50 % compared to traditional ON/OFF technology. Mounted on rubber vibration dampers, complete with sump heater, oil charge and oil separator to prevent migration of the gas charge and ensure lubrication of the compressor sump during operation at minimum speed. Complete with thermal protector and sump heater installed as standard on all versions. Electrical panel Power and control electrical panel constructed in accordance with IEC 204-1/ EN , complete with control and terminal blocks for connection to the power supply and auxiliary controls. Protection grille The unit comes with a protection grill on the condenser coil. PR GB Subject to modifications R2-01/2016 9

10 Overview of Units and Packaged Content Row-DENCO Heat exchange coils Made using copper tubes mechanically expanded onto aluminium fins with a high heat exchange area. Condenser fan External impeller axial-flow fans, statically and dynamically balanced at low speed. Sixor four-pole electric motor with built-in thermal cut-out. Housed in aerodynamic tubes with accident prevention grill. Device for operation at low outside air temperatures: continuous fan speed control according using a pressure transducer. EC axial-flow fan available as an option Fig. 3-2: Explo Outdoor Condensing Unit 1: Grille Protection for finned coil 2: Electrical panel 3: Gas valve 4: Scroll compressor 5: Fan 10 PR GB Subject to modifications R2-01/2016

11 Row-DENCO Overview of Units and Packaged Content 3.3 Versions Air-Cooled direct expansions unit DRX The DRX series units, with single direct expansion cooling circuit, use air for cooling in the condensing stage, and are therefore combined with the DROU air-cooled outdoor condensing units. Refrigerant circuit DRX Unit featuring a refrigerant circuit complete with the following components: direct expansion coil low pressure switch electronic expansion valve pressure transducer and temperature probe for electronic valve shut-off valves for connection to outdoor unit connections available from top or bottom DROU Fig. 3-3 : Refrigerant piping Unit supplied pre-charged with refrigerant and factory tested. Unit featuring a refrigerant circuit complete with the following components: filter-drier liquid indicator safety pressure switch to control high discharge pressure (manual reset) liquid receiver external connections with valves Chilled water unit DRC The DRC units featuring a single chilled water cooling circuit supplied by a chiller installed on-site, while model DRC 036 has two independent circuits, one primary and one secondary as backup, both using chilled water (CW) supplied by two chillers installed on-site. The unit is supplied with a modulating valve complete with servo motor. The signal to open and/or close the valve is automatically managed by the electronic controller, so as to maintain the desired indoor conditions. The inside air is cooled when flowing through the cooling coil on the Row-DENCO. Water circuit Fig. 3-4 : Water piping Unit featuring a refrigerant circuit complete with the following components: chilled water coil 3-way modulating valve complete with three-position servomotor threaded water fittings connections available from top or bottom PR GB Subject to modifications R2-01/

12 Overview of Units and Packaged Content Row-DENCO 3.4 Type of system Rack cooling with cold/hot aisle configuration with front outlet hot aisle cold aisle hot aisle cold aisle hot aisle Fig. 3-5: Row-DENCO version with front outlet The units are installed in the rows of RACKS so as to form cold and hot aisles. The electronic equipment in the RACKS use their own fans to independently take in the cooling air delivered into the cold aisle. The hot exhaust from the RACK is discharged into the hot aisle, where it is taken in and cooled by the Row-DENCO unit. Air flow on Row-DENCO with front outlet (top view) hot aisle Row-DENCO version front Ooutlet/rear intake cooling-only configuration, without humidifier Row-DENCO version front outlet/rear intake configuration with humidifier cold aisle hot aisle dimensions L = 300 mm D = 1000/1200 mm H = 2085 mm dimensions L = 300 mm D = 1200 mm H = 2085 mm 12 PR GB Subject to modifications R2-01/2016

13 Row-DENCO Overview of Units and Packaged Content Rack cooling with cold/hot aisle configuration with side outlet hot aisle cold aisle hot aisle cold aisle hot aisle Fig. 3-6: Row-DENCO version with side outlet The units are installed in the rows of RACKS so as to form cold and hot aisles. The electronic equipment in the RACKS use their own fans to independently take in the cooling air delivered into the cold aisle. The hot exhaust from the RACK is discharged into the hot aisle, where it is taken in and cooled by the Row-DENCO unit. In the version with side outlet, the air is delivered directly to the front of the racks, reducing the risk of mixing between cold and hot air, and ensuring correct air distribution even when the rack cooler is installed at the start of the row. Air flow on Row-DENCO with side outlet (top view) hot aisle Row-DENCO version side outlet/rear intake right outlet right+left outlet cold aisle left outlet hot aisle dimensions L = 300 mm D = 1200 mm H = 2085 mm PR GB Subject to modifications R2-01/

14 Safety and User Instructions Row-DENCO 4 Safety and User Instructions DencoHappel units are constructed using state-of-the-art technology and according to recognized safety regulations. Use the DencoHappel units in a technically sound condition for the intended purpose observing the current operation manual, taking safety aspects and potential hazards into account. It is important to appreciate that failure to follow the instructions in this manual may result in death or injury to the user, third persons, or damage to the Denco- Happel unit itself, connected units or other equipment! Have all faults repaired by an authorized specialist without delay! ATTENTION Damage to the unit! In case of alarms and faults, always make sure that the cause of the fault is identified. In particular, multiple resets of an alarms without first rectifying the cause can damage the unit and invalidate the warranty. 4.1 Availability of the operation manual This operation manual contains important information regarding safe and correct operation of the unit. This manual must always be available at the site where unit is operating. Every person working on the equipment must read this manual fully before commencing the work and take note of all relevant information while performing a task. The operation manual is intended to be used by fitting and installation companies, building services engineers, technical personnel or trained persons as well as electrical and refrigeration engineering specialists. 4.2 Scope of the operation manual This operation manual provides information about the following: Assembly/disassembly Installation Commissioning Use and operation Maintenance and Troubleshooting 4.3 Symbols used The following symbols are used to highlight particular text sections in this operation manual: This symbol is used to indicate normal lists. This symbol indicates handling instructions. This symbol indicates the result of an action. Notice! Additional details on using the unit are specified here. Recycling! This symbol is used to highlight instructions for the proper recycling of packaging material and assembly groups no longer in use (separated according to recyclable materials). Danger symbols are specified in section Labelling of safety instructions of page PR GB Subject to modifications R2-01/2016

15 Row-DENCO Safety and User Instructions 4.4 Labelling of safety instructions To designate the safety instructions the following symbols and notices are provided in appropriate places throughout this document: DANGER Death/serious irreversible injury Example: Indicates an extremely hazardous situation which will result in death or serious irreversible injury, if the safety instruction is not followed. Electrocution through hazardous voltage will lead to death or serious injury. Disconnect the unit from the power supply and ensure the power cannot be switched back on. Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components WARNING Death/serious injury Example: Indicates a hazardous situation which can result in death or serious irreversible injury, if the safety instruction is not followed. High concentration of refrigerants in the air can result in death or serious injury! High concentration of refrigerants in the air may have an anaesthetic effect and cause unconsciousness. Prolonged exposure may cause irregular heartbeat and sudden death. Very high concentration of refrigerant may cause suffocation by reduced oxygen content in the surrounding air. You should therefore only work in an adequately ventilated environment, and exercise due care and attention when carrying out the work. Wear protective clothing and, if necessary, an autonomous breathing apparatus CAUTION Minor or moderate injury Example: Indicates a hazardous situation which can result in minor or moderate injury, if the safety instruction is not followed. Sharp edges can cause injuries! Observe precaution when cleaning due to risk of cuts on thin and sharp edges. Wear protective gloves. PR GB Subject to modifications R2-01/

16 Safety and User Instructions Row-DENCO ATTENTION Environmental or material damage ATTENTION Examples: Indicates actions that can result in equipment or property-damage only accidents. ATTENTION Risk of environmental damage! Heavily contaminated filters can have a negative impact on production processes. Depending on the filtered-out materials, contaminated filters are therefore classified as hazardous waste and must be properly disposed of according to the prevailing guidelines and laws. ATTENTION Risk of damage to the unit! If dampers are abruptly shut during unit operation, the unit can be damaged beyond repair as a result of negative pressure or overpressure. 4.5 Used safety symbols Electrical hazard PERSONAL injury Overhead loads Risk of tipping Rotating components! Toxic substances Crushing of limbs Sharp cutting edges Inflammable materials Scalding Hot surfaces 16 PR GB Subject to modifications R2-01/2016

17 Row-DENCO Safety and User Instructions Cooling Environmental damage Damage to the unit 4.6 Safety-conscious work procedures Observe the following instructions when carrying out installation, adjustment or repair jobs: Wear suitable protective clothing during work, such as protective footwear, gloves, safety goggles, etc. Avoid flame sources, especially burning cigarettes. Open flame sources and smoking in the proximity to the unit are prohibited. Filters and especially used filters can easily catch fire. Leaking refrigerant can catch fire and emit noxious substances. When working within range of mains voltage: Electrocution through hazardous voltage will lead to death or serious injury. Disconnect the unit from the power supply and ensure the power cannot be switched back on. Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. When working with refrigerants: Please consider section "4.6.1 Handling refrigerants". Danger due to toxic substances! High concentrations of refrigerants in the air may have an anaesthetic effect and cause unconsciousness. Prolonged exposure may cause irregular heartbeat and sudden death. Very high concentrations of refrigerant may cause suffocation by reducing the oxygen content in the surrounding air. You should therefore only work in an adequately ventilated environment, and exercise due care and attention when carrying out the work. Glycols and other antifreeze agents are harmful for humans and animals, if swallowed. Consult a doctor immediately if swallowed by mistake. You should therefore only work in an adequately ventilated environment, and exercise due care and attention when carrying out the work. Caution due to low temperatures! Contact with a liquid refrigerant can result in skin burns or injury to other organs. Exercise due caution and attention when carrying out jobs and avoid contact with a refrigerant. Wear protective gloves. PR GB Subject to modifications R2-01/

18 Safety and User Instructions Row-DENCO For all kinds of work: High pressure hazard! When working on hydraulic or refrigeration circuits or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. Exercise due caution and attention when carrying out this work. Wear suitable protective clothing during work. ATTENTION Environmental damage! Do not pollute the environment with liquid products, refrigerants or oils. Dispose of the latter in accordance with local laws and regulations by avoiding harm to the environment.ethylene glycol and propylene glycol are categorised as Water Hazard Class 1 in accordance with the catalog of water pollutants (mild water pollutants). This also applies to mixtures with water. Please comply with the installation and transport instructions for DencoHappel units. Observe the pre-commissioning check points. Always make sure that the DencoHappel unit is accessible only to authorized and trained technical personnel. If necessary, use appropriate equipment to keep unauthorized persons away from the unit. Have all leaks eliminated by the DencoHappel Service or a specialist refrigeration company immediately (refer to section 4.10). The safety sheet stating the type of refrigerant charged on the given unit shall be firmly secured in the machine room of the unit in a well visible manner (refer to unit identification plate or operation manual for the unit). 18 PR GB Subject to modifications R2-01/2016

19 Row-DENCO Safety and User Instructions Handling refrigerants According to DIN EN 378 Part 1 the R-134a and R-410A refrigerants belong to A1 group. Refer to the unit identification plate for data and charge volume of a particular refrigerant. Observe the usage details in accordance with EC regulation 842/2006. First aid Inhalation Skin contact Eye contact Features of applicable refrigerant types: Non-combustible No direct toxic effect Colorless and odorless Heavier than air Contains fluorinated greenhouse gases as defined by the Kyoto protocol Ozone-depleting potential OPD: 0 Greenhouse potential GWP: R-134a: 1300, R-410A: 1980 Water hazard class WGK 1, with a slight risk to water Wear appropriate clothes when performing jobs with refrigerants and in the proximity to a refrigeration circuit, e.g. Sealing protective goggles PVA or leather gloves Protective clothes for entire body If necessary, an autonomous breathing apparatus First aid measures directly after or during contact with refrigerants: Ensure your own protection against leaking refrigerant. Under all circumstances - call a doctor or and/an ambulance. Remove clothes contaminated by the refrigerant. Additional measures after inhalation of refrigerants: Take the injured person to a well-ventilated location. Ensure that the injured person is in a stable lateral position. Consumption of food and beverages must be avoided. If the injured person collapses or loses consciousness perform mouth-to-mouth respiration. Additional measures after skin contact with refrigerants: Rinse the affected body parts using lukewarm water for at least 15 min. Additional measures after eye contact with refrigerants: Do not rub your eyes. Remove contact lenses if you have any. Rinse your eyes with lots of water. 4.7 Proper use The compressor-condenser units of the GL line are exclusively provided for connection to an on-site air handling unit with integrated evaporator for room climate control. Depending on the load consumption, the individual compressors are switched OFF and ON with a signal on-site in order to adapt the unit power to the load consumption. Improper use Proper use also includes observance of the operation manual and the inspection and maintenance conditions stipulated by DencoHappel. Any use other than that described above is considered improper. The manufacturer/ supplier is not liable for damage arising from improper use. The user alone bears the risk. PR GB Subject to modifications R2-01/

20 Safety and User Instructions Row-DENCO Personal Injury and Damage to the Unit! It is not allowed to operate DencoHappel units: in areas subject to explosion risk in environments with strong electromagnetic fields in environments with high levels of air contamination in environments with corrosive and/or aggressive air 4.8 Safety devices 4.9 Modifications and changes 4.10 Spare parts 4.11 Disposal 4.12 Selection and qualification of personnel Depending on the unit equipment, the following components are secured: Padlock in the door-stop device (TAS) on each door Locks of switch cabinet The panels and doors with lockable handles Fan chambers are secured by door protection grilles V-belt drives are secured by belt guards Ensure by others on site that the contact protection for intake and discharge fittings is provided. Changes, alterations or modifications of the unit are not allowed. Tampering with the unit or its misapplication will invalidate the CE conformity and void warranty. If delivered units are disassembled by others on-site, the factory warranty is rendered invalid. In this case professional services by DencoHappel should be arranged in advance. Only original DencoHappel spare parts are allowed, since DencoHappel is not liable if third-party spare parts are used. Equipment, operating supply materials, components and filters must be disposed of according to the material type in a safe and environmentally friendly manner. Ensure that every person working on the unit has read and understood entire operation manual. Please read this document fully before commencing any work, and not while performing a task. All jobs must only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the following areas: Occupational health and safety regulations Accident prevention regulations Directives and recognized codes of practice All jobs with the refrigeration circuit shall be performed only by certified and licensed staff in accordance with the valid EG Regulation 842/2006 Article 5, EG Regulation 303/2008 Article 4 and 5 as well as "Ordinance on climate protection against changes caused by release of certain fluorinated greenhouse gases" Article 5, passed by the German parliament. All skilled staff must be able to assess the entrusted work and must be able to recognize and avoid all associated dangers. 20 PR GB Subject to modifications R2-01/2016

21 Row-DENCO Technical Data 5 Technical Data 5.1 Row-DENCO DX rack cooler DRX Power supply V-Ph~Hz 230/1N/ /1N/ /1N/50-60 Refrigerant R410A R410A R410A No. of circuits No CAPACITY DELIVERED MAX MIN MAX MIN MAX MIN Total capacity (1) kw 10,63 4,72 16,59 6,78 28,62 11,76 Sensible capacity (1) kw 9,61 4,72 15,67 6,78 27,37 11,76 SHR 0,90 1,00 0,94 1,00 0,96 1 FANS Fan air flow-rate m²/h EC radial fan power consumption kw 0,16 0,04 0,304 0,064 0,86 0,09 No. of EC radial fans No Std. available static pressure Pa SOUND DATA Sound pressure (2) db(a) AIR FILTER Filtration grade G2 G2 G2 REFRIGERANT CONNECTIONS Refrigerant connections (ODS Ø) IN - LIQ OUT-GAS HUMIDIFIER (3) Capacity kg/h DIMENSIONS Length mm Depth mm 1000/ / /1200 Height mm DROU Power supply V-Ph~Hz 230/1N/50 400/3N/50 400/3N/50 COMPRESSORS MAX MIN MAX MIN MAX MIN No. of compressors No Compressor power consumption (1) kw 2,63 0,77 4,56 1,17 7,19 1,81 FANS Fan air flow-rate m3/h Fan power consumption kw 0,31 0,60 1,20 No. of fans No REFRIGERANT CONNECTIONS Refrigerant connections (ODS Ø) IN - GAS 3/4" SAE OUT-LIQ 3/8" SAE SOUND DATA Sound pressure (2) db(a) DIMENSIONS Length mm Depth mm Height mm Tab Inside conditions: air 35 C/27 % RH - Outside air temp.: 35 C 2 Measured at a height of 1.5 m and 2 m from the front of the unit in a free field mm DEEP RACK ONLY PR GB Subject to modifications R2-01/

22 Technical Data Row-DENCO 5.2 Row-DENCO CW rack cooler DRC Power supply V-Ph~Hz 230/1N/50-60 CAPACITY DELIVERED Total capacity (1) kw 16,14 20,52 24,6 20,95 Sensible capacity (1) kw 16,14 20,52 24,6 20,95 SHR 1,00 1,00 1,00 1,00 WATER SIDE No. of water circuits Water flow-rate (1) l/h Total unit pressure drop (1) kpa Water content l FANS Fan air flow-rate m³/h Power consumption with inverter-driven EC radial fans kw 0,516 0,688 0,86 0,86 No. of inverter-driven EC radial fans No Std. available static pressure Pa SOUND DATA Sound pressure (2) db(a) AIR FILTER Filtration grade G2 G2 G2 G2 CONNECTIONS Water connections IN 1"F GAS 1"F GAS 1"F GAS 1"F GAS OUT 1"F GAS 1"F GAS 1"F GAS 1"F GAS HUMIDIFIER Capacity kg/h DIMENSIONS Length mm Depth mm Height mm Tab Inside conditions: air 35 C/27 % RH - chilled water 10/15 C 2 Measured at a height of 1.5 m and 2 m from the front of the unit in a free field 5.3 Operating limits The units are designed for operation within the following operating ranges (the limits are considered for new units that have been correctly installed and maintained): Operating range DRX/DROU Room air temperature 23 C / 53 % RH - 40 C/20 % RH Outside air temperature: -20 C 45 C (with DROU.N Standard version) -35 C 45 C (with DROU.W Winter-Kit) Operating range DRC Room air temperature 16 C/82 % RH - 55 C/7 % RH Water inlet temperature 6 C - 16 C with a T from 3 C - 10 C Maximum operating pressure in the chilled water circuit: 16 bars 22 PR GB Subject to modifications R2-01/2016

23 Row-DENCO Receipt, Transport and Handling 6 Receipt, Transport and Handling 6.1 Transport Move the Row-DENCO as near as possible to the site of installation before removing the packaging and the pallet. Remove the unit from the pallet using the special slides supplied in the packaging. The units can be lifted: using a forklift, sliding the forks through the openings in the pallet using fabric slings through the pallet underneath the unit, using spacers to make sure that when the slings are in tension these do not apply pressure on the top edges REMOVE THE STRAPS AND THE PLASTIC WRAP- PING LOWER THE 2 METAL SLIDES REMOVE THE FIXING BRACKETS GRIP FIRMLY AND MOVE THE UNIT IN THE DIRECTION OF THE SLIDES WARNING: ALL HANDLING OPERATIONS MUST BE CARRIED OUT BY 2 PEO- PLE USING THE WHEELS PROVIDED, SLOWLY SLIDE THE UNIT ALONG THE SLIDES UNTIL VERTICAL AND COMPLETELY RESTING ON THE FLOOR WARNING: WHEN THE UNIT STARTS ROTATING THE WEIGHT NEEDS TO BE SUPPORTED AND MOVEMENT MANAGED FROM THE FRONT (SEE THE FIGURE) DO NOT REPEATEDLY BEND THE METAL SLIDES TO PREVENT THEM FROM BREAKING (MAX 5 TIMES) WARNING: Don t stand under the unit. Abb. 6-1 The DROU condensing units are supplied complete with: instruction manual warranty certificate CE declaration contained in a plastic bag (A) attached to the top of the unit. The unit must be handled by qualified and suitably equipped personnel only using equipment appropriate for the weight of the condensing unit. If a forklift truck is used, insert the forks under the base, spacing the forks as wide apart as possible. If a crane is used, pass the cables through the bottom of the base, making sure they do not exert pressure on the unit. Notice! The instruction manual is an integral part of the unit and should therefore be read and kept carefully. Personal injury! Do not dispose of packaging materials in the environment or leave them within reach of children as they may represent a hazard. ATTENTION Risk of damage to the unit! The weight of the condensing unit is biased towards the compressor side (side of the packaging with the bar code, see the figure at the bottom). During transport, the condensing unit should be kept in a vertical position. PR GB Subject to modifications R2-01/

24 Receipt, Transport and Handling Row-DENCO Size Dimension L Dimension P Dimension H Gross weight [kg] Net weight [kg] To lift and move the unit, use metal tubes (max dia. 1/2 "), inserting them in the feet provided, and same-length lifting cables. A BARCODE H L P Abb Receiving the unit The meanings of the symbols shown on the packaging are described in the table. FRAGILE: handle with care. TOP: indicates the correct position of the packaged unit. KEEP DRY: indicates that the packaged unit must be kept in a dry place. TEMPERATURE LIMITS: indicates the temperature limits for storing and handling the packaged unit. CENTRE OF GRAVITY: indicates the centre of gravity of the packaged unit. USE NO HOOKS: indicates that hooks cannot be used to handle or lift the packaged unit. KEEP AWAY FROM HEAT: indicates that the packaged unit must be kept away from sources of heat. DO NOT STACK the packages. Abb. 6-3 Check, upon delivery, that the Row-DENCO is intact and in perfect condition; immediately notify the carrier in writing of any damage that may be due to transport. In particular, check that the panel where the user terminal is fitted has not been damaged. 6.3 Storage The Row-DENCO must be stored indoors, preferably in its own packaging, and protected against excessive humidity (< 85 % RH) and temperature (< 50 C). 24 PR GB Subject to modifications R2-01/2016

25 Row-DENCO Receipt, Transport and Handling 6.4 Standard packaging and packaging with wooden crate (optional) H H P L P L Fig. 6-4: Standard packaging Fig. 6-5: packaging with wooden crate (optional) 300 X 1000 X 42U RACK 300 X 1000 X 42U RACK DRX DRX L mm L mm H mm H mm P mm P mm Gross Weight kg Gross Weight kg Net Weight kg Net Weight kg DRC DRC L mm L mm H mm H mm P mm P mm Gross Weight kg Gross Weight kg Net Weight kg Net Weight kg X 1200 X 42U RACK 300 X 1200 X 42U RACK DRX DRX L mm L mm H mm H mm P mm P mm Gross Weight kg Gross Weight kg Net Weight kg Net Weight kg DRC DRC L mm L mm H mm H mm P mm P mm Gross Weight kg Gross Weight kg Net Weight kg Net Weight kg PR GB Subject to modifications R2-01/

26 Dimensional Drawings Row-DENCO 7 Dimensional Drawings 7.1 DRX (300 X 1000 X 42U RACK) CONDENSATE DRAIN PIPE REFRIGERANT CONNECTIONS KNOCKOUT IN REFRIGERANT OUT REFRIGERANT AUXILIARY CONNECTIONS REFRIGERANT CONNECTIONS KNOCKOUT AIR OUT AIR IN PR GB Subject to modifications R2-01/2016

27 Row-DENCO Dimensional Drawings 7.2 DRX (300 X 1200 X 42U RACK) CONDENSATE DRAIN PIPE OUT HUMIDIFIER DRAIN CONNECTION (Ø32) IN HUMIDIFIER WATER FEED CONNECTION (G ¾"M) IN REFRIGERANT OUT REFRIGERANT GRILL ON Row-DENCO WITH SIDE OUTLET ONLY AUXILIARY CONNECTIONS REFRIGERANT CONNECTIONS KNOCKOUT 277 GRILL ON Row-DENCO WITH FRONT OUTLET ONLY AIR OUT (OPT) AIR OUT (OPT) AIR IN AIR OUT (OPT) PR GB Subject to modifications R2-01/

28 Dimensional Drawings Row-DENCO 7.3 DRC (300 X 1000 X 42U RACK) CONDENSATE DRAIN PIPE AIR OUT AIR IN WATER OUT G 1"F 97.5 WATER IN G 1"F AUXILIARY CONNECTIONS WATER IN G 1"F WATER OUT G 1"F PR GB Subject to modifications R2-01/2016

29 Row-DENCO Dimensional Drawings 7.4 DRC 036 (300 X 1000 X 42U RACK) CONDENSATE DRAIN PIPE AIR OUT AIR IN WATER OUT G 1"F WATER IN G 1"F AUXILIARY CONNECTIONS WATER OUT G 1"F WATER IN G 1"F PR GB Subject to modifications R2-01/

30 Dimensional Drawings Row-DENCO 7.5 DRC (300 X 1200 X 42U RACK) OUT HUMIDIFIER DRAIN CONNECTION (Ø32) CONDENSATE DRAIN PIPE IN HUMIDIFIER WATER FEED CONNECTION (G ¾"M) WATER OUT G 1"F 69 WATER IN G 1"F GRILL ON Row-DENCO WITH SIDE OUTLET ONLY AUXILIARY CONNECTIONS WATER OUT G 1"F WATER IN G 1"F AIR OUT (OPT) GRILL ON Row-DENCO WITH FRONT OUTLET ONLY AIR OUT (OPT) AIR IN AIR OUT (OPT) PR GB Subject to modifications R2-01/2016

31 Row-DENCO Dimensional Drawings 7.6 DRC 036 (300 X 1200 X 42U RACK) CONDENSATE DRAIN PIPE OUT HUMIDIFIER DRAIN CONNECTION (Ø32) WATER OUT G 1"F WATER IN G 1"F IN HUMIDIFIER WATER FEED CONNECTION (G ¾"M) GRILL ON Row-DENCO WITH SIDE OUTLET ONLY AUXILIARY CONNECTIONS WATER OUT G 1"F AIR OUT (OPT) GRILL ON Row-DENCO WITH FRONT OUTLET ONLY 74 AIR OUT (OPT) AIR IN AIR OUT (OPT) WATER IN G 1"F PR GB Subject to modifications R2-01/

32 Dimensional Drawings Row-DENCO 7.7 DROU 051 and DROU 071 DROU 051 1: POWER SUPPLIES 2: POWER TRANSDUCER (OPT.) 3: DOUBLE POWER SUPPLY (OPT.) 4: LIQUID LINE Ø 3/8" 5: GAS LINE Ø 18 6: GAS LINE Ø 22.2 ODS 7: LIQUID LINE Ø 16.2 ODS A R 6, A = = ,5 61,5 DROU R 7 A 497 R 7 22 B 25 A 1200 B , PR GB Subject to modifications R2-01/2016

33 Row-DENCO Dimensional Drawings 7.8 DROU 121 DROU 121 1: POWER SUPPLIES 2: GAS LINE Ø 22.2 ODS 3: LIQUID LINE Ø 16.2 ODS R 7 A R 7 22 B 25 A B CENTER OF GRAVITY PR GB Subject to modifications R2-01/

34 Installation Row-DENCO 8 Installation 8.1 Overview Diagram DROU DROUD 051A1N DROUD 071A1N DROUD 121A1N : 2-WAY MANUAL VALVE FOR REFRIGERANT CONNECTION (3/4" FLARE) 2: PRESSURE GATE 5/16 SAE 3: COMPRESSOR 4: CRANK CASE HEATHER 5: OIL SEPARATOR 6: STRAINER 7: CAPILLARY TUBE 8: HIGH PRESSURE SWITCH 9: CONDENSER 10: FAN 11: LIQUID RECEIVER 12: FILTER-DRIER 13: LIQUID INDICATOR 14: OUTDOOR AIR TEMPERATURE SENSOR 15: 2-WAY MANUAL VALVE FOR REFRIGERANT CONNECTION (1/2" FLARE) 16: CAPILLARY TUBE 17: LIQUID SEPARATOR 18: CHECK VALVE SUPPLIED 19: TEMPERATURE SENSOR Fig PR GB Subject to modifications R2-01/2016

35 Row-DENCO Installation DROUD 051A1W DROUD 071A1W DROUD 121A1W : 2-WAY MANUAL VALVE FOR REFRIGERANT CONNECTION (3/4" FLARE) 2: PRESSURE GATE 5/16 SAE 3: COMPRESSOR 4: CRANK CASE HEATHER 5: OIL SEPARATOR 6: STRAINER 7: CAPILLARY TUBE 8: HIGH PRESSURE SWITCH 9: CONDENSER 10: FAN 11: LIQUID RECEIVER 12: FILTER-DRIER 13: LIQUID INDICATOR 14: OUTDOOR AIR TEMPERATURE SENSOR 15: 2-WAY MANUAL VALVE FOR REFRIGERANT CONNECTION (1/2" FLARE) 16: CAPILLARY TUBE 17: LIQUID SEPARATOR 18: CHECK VALVE SUPPLIED 19: VALVE SOLENOID 20: SAFETY VALVE 21: TEMPERATURE SENSOR DRX DRX A : REFRIGERANT SOLDER CONNECTION: 0051 = Ø18 mm 0071 = Ø 22 mm 0121 = Ø 28 mm 2: HIGH PRESSURE TRANSDUCER 3: ELECTRONIC THERMOSTATIC VALVE 4: FANS 5: HEAT EXCHANGER (EVAPORATOR) 6: LOW PRESSURE SWITCH (AUTOMATIC RESET) 7: LOW PRESSURE TRANSDUCER 8: TEMPERATURE SENSOR 9: REFRIGERANT SOLDER CONNECTION: 0051 = Ø 12 mm 0071 = Ø 16 mm 0121 = Ø 18 mm 10: PRESSURE TEST FITTING 1/4 SAE 11: INLET AIR TEMPERATURE SENSOR 12: SUPPLY AIR TEMPERATURE SENSOR Fig PR GB Subject to modifications R2-01/

36 Installation Row-DENCO DRC DRC A5 DRC 3036 A5 BA x x x BA DIRECTION OF AIRFLOW V TO TO TW TI TI MV DIRECTION OF AIRFLOW V TO TO TW TW TI TI MV MV OV OV OV Fig MV 3-WAY MODULATING VALVE TI AIR INTAKE TEMPERATURE PROBE 1 Water In BA HEAT EXCHANGER TO AIR OUTLET TEMPERATURE PROBE 2 Water Out TW WATER TEMPERATURE PROBE V Fans OV 2-WAY ON/OFF VALVE (OPTION) 36 PR GB Subject to modifications R2-01/2016

37 Row-DENCO Installation 8.2 Install Row-DENCO The Row-DENCO indoor unit can rest directly on the floor, perfectly level, using the adjustable feet: incorrect levelling may cause condensate to overflow from the collection pan. ATTENTION Risk of damage to the unit! The Row-DENCO must be installed indoors and in non- aggressive environments. DencoHappel accepts no liability for incorrect installation when positioning the unit DROU Before installing the DROU unit, verify the following points: Check that the support surface is adequate to support the weight of the unit. Respect safety distances between the unit and other equipment or structures so that the fan air intake and outlet are not blocked in any way. The unit must be placed in an equipment compartment sized according to standards in force in the country concerned, and large enough to allow access for maintenance Positioning Before handling the unit, check the capacity of the lifting equipment used, respecting the instructions on the packaging. To move the unit horizontally, make appropriate use of a fork lift truck or similar, bearing in mind the weight distribution of the unit. To lift the unit, insert pipes long enough to allow positioning of the lifting slings and safety pins in the special holes in the base of the unit.to avoid the slings damaging the unit, place protection between the slings and the unit. Position the unit in the site indicated by the customer; place either a layer of rubber (min. thickness 10 mm) or vibration damper feet between the base and support surface. Fix the unit, making sure it is level and that there is easy access to refrigerant and electrical components. If the site is installed in a place exposed to strong winds, fix the unit adequately using tie rods if necessary. The following should be avoided: installing the unit in pits and/or air vents obstacles or barriers that could cause the exhaust air to be recirculated installation in sites with an aggressive atmosphere installation in confined spaces where the sound levels of the unit could be amplified by reverberation or resonance installation in corners where dust, leaves or other materials tend to collect. These could obstruct the passage of air, thus reducing the efficiency of the unit air discharged by the unit entering inhabited rooms through doors or windows causing unpleasant conditions for the inhabitants air discharged by the unit being obstructed by a wind blowing in the opposite direction direct exposure of the unit to sunlight PR GB Subject to modifications R2-01/

38 Installation Row-DENCO Clearances Fig Connection of the refrigeration circuit to the external evaporator (on-site) Notice! Medium connections may only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes (also refer to section 4.10 "Personnel selection and qualification"). High pressure hazard! When working on hydraulic or refrigeration circuits or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. Exercise due caution and attention when carrying out this work. Wear suitable protective clothing during work. Caution due to low temperatures! Contact with a liquid refrigerant can result in skin burns or injury to other organs. Exercise due caution and attention when carrying out jobs and avoid contact with a refrigerant. Wear protective gloves. Refrigerant lines Only copper refrigerant lines meeting DIN EN standards may be used. The relevant requirements especially apply to: quality of internal surfaces sealed pipe ends pipe labelling testing pressure resistance Line lengths and dimensions Short line lengths Keep the pipe length as short as possible. The greater the distance between chiller and the on-site evaporator, the greater are the pressure drops in connected pipes, resulting in reduced energy efficiency of the unit. The maximum distance as well as the maximum difference in height between the unit and the on-site evaporator are determined at following pages. 38 PR GB Subject to modifications R2-01/2016

39 Row-DENCO Installation Oil transportation must be ensured Keep pressure drop as low as possible When dimensioning the pipes, make sure that oil transportation is ensured under all operating conditions. Oil transportation must be ensured using the corresponding pipe dimensioning and pipe routing. It is also important that the pressure drop in the pipework is minimized to avoid unnecessary decreases in capacity.the greater the selected pipe diameter, the lower is the speed in the pipe, and the more difficult is the oil return.the smaller the selected pipe diameter, the higher the speed and the greater the pressure drop in the pipe. The units loses capacity and energy efficiency. 1% slope Always lay the suction line with a 1% slope (1 cm/m) in the flow direction Install oil traps as described at following pages. The dimensioning of the refrigerant lines is provided in this manual. PR GB Subject to modifications R2-01/

40 Installation Row-DENCO 1/100 thermal insulation Row-DENCO intake max 50 m 1/100 thermal insulation Row-DENCO DRX/DROU 051 max 15 m intake DRX/DROU max 30 m intake 1/100 max 15 m max 3 m thermal insulation Row-DENCO max 3 m N.B.: Install oil traps as shown in the figure, making sure to fill them with oil during commissioning the system. The liquid piping must be protected against sunlight. 40 PR GB Subject to modifications R2-01/2016

41 Row-DENCO Installation 8.4 Refrigerant connections (DRX/DROU) Diameters of the connections inside the unit The diameter of the refrigerant lines between the Row-DENCO and the condensing unit must be complied with, otherwise the warranty will be void. Avoid tight bends in the pipes (the radius of curvature should be at least equal to the diameter of the pipe). DRX Model DROU Model liquid line Ø (mm) liquid line Ø (mm) 12,7-1/2" 15,9-5/8" 18 gas suction Ø (mm) gas suction Ø (mm) 19,05-3/4" 22,7-7/8" 28 Tab. 8-1: Pipe diameter in mm Recommended outside diameters of the refrigerant lines to the equivalent length Unit model Equivalent total line length 0-10 m Suction Ø mm Liquid Ø mm Equivalent total line length m Suction Ø mm (*) 22 Liquid Ø mm (*) 12 Equivalent total line length m Suction Ø mm (*) Liquid Ø mm (*) Equivalent total line length m Suction Ø mm 18 (*) Liquid Ø mm 10 (*) Equivalent total line length m Suction Ø mm 18 (*) Liquid Ø mm 10 (*) (*) Allow for a 5 % drop in performance N.B.: Use only one pipe diameter for the Liquid line and one diameter for the Suction line. Do not mix different pipe diameters in one line. Minimum pipe thickness: Outside diameter Ø mm Minimum thickenss mm 1,0 1,0 1,0 1,0 1,0 1,0 1,2 Notice! The diameter of the refrigerant lines between the air-conditioner and the condensing unit must be sized according to the length, and therefore these will not always match the inside diameter of the weld fittings supplied by the manufacturer; the lines must be sized so as to always guarantee a minimum refrigerant speed of around 7 m/s. Special care must be taken when insulating the suction line pipes, to avoid formation of condensate. Check and make sure the indoor thermal heat load is never less than % of the air-conditioning capacity installed Equivalent lengths in metres of curved sections, on-off and non-return valves Nominal diameter (mm) ,50 0,25 0,75 2,10 1, ,53 0,26 0,80 2,20 2,00 PR GB Subject to modifications R2-01/

42 Installation Row-DENCO Nominal diameter (mm) ,55 0,27 0,85 2,40 2, ,60 0,30 0,95 2,70 2, ,70 0,35 1,10 3,20 2, ,80 0,45 1,30 4,00 3, ,10 0,55 1,75 5,00 4,50 Tab. 8-2: Equivalent lengths in metres of curved sections, on-off and non-return valves Model Refrigerant charge (kg) Oil charge (l) Model Refrigerant charge (kg) Oil charge (l) DROUD 051 A1.N 3 0,87 DROUD 051 A1.W 6 0,87 DROUD 071 A1.N 6 1,4 DROUD 071 A1.W 12 1,4 DROUD 121 A1.N 11 1,4 DROUD 121 A1.W 22 1,4 Tab. 8-3 N.B.: add lubricating oil equivalent to 10 % of the weight of the gas calculated only for the refrigerant connection lines between indoor and outdoor unit. The type of oil in use is FV50S. The DROUD outdoor unit is pre-charged with refrigerant to meet the needs of the indoor unit, the outdoor unit and up to 5 m of interconnecting pipe work. Longer pipe work separations may require additional refrigeration and oil. Pipe diameter R410A Tab. 8-4: Gas suction line gr/m ,9 5,1 8,0 13,6 21,6 30 Liquid line gr/m Refrigerant Content per linear metre Additional amount of oil per oil trap Pipe outside diameter mm Additional oil amount lenght of oil trap cl/cm 0,05 0,08 0,11 0,15 0,19 0,28 0,49 0, Connecting refrigerating circuit Connect the on-site pipe system to the liquid and suction line. The precise positions of the connections can be determined from the order-specific dimensional drawing of the unit. Notice! Dimensions of pipe connections on the unit are not decisive for the refrigerant lines to be routed. Routing refrigerant lines Notice! When routing the pipes, always make sure that the pipe ends are sealed. Even if the unit setup is incomplete, seal all pipe ends after the job is finished. Only this way can penetration of dirt and humidity be prevented. Pipes should always be routed with a slight slope to the flow direction. This favors a return transport of the refrigerant oil to the compressor. The refrigerant flows as a liquid through the liquid line (thinner tube) to the evaporator and then once again as a gas through the insulated suction line back to the compressor. Observe temperature-related changes in length! 42 PR GB Subject to modifications R2-01/2016

43 Row-DENCO Installation Cutting Deburring Use a pipe cutter to cut pipes, and cut slowly to avoid copper pipe deformation. Cut surfaces must be deburred. Ensure that copper chips do not penetrate into the pipe. Soldering and brazing Brazing is the prescribed connection technique and is performed as hard-soldering method defined according to DIN EN Possibly apply a flux material according to DIN EN Precaution measure for brazing Avoid oxidation during brazing Soldering and brazing requires extensive experience and must be performed by a qualified and licensed refrigeration technician. To avoid the formation of an oxide film on the pipe internal surfaces during brazing, this job must be exclusively performed using nitrogen (N 2 ). Brazing heat must be as high as necessary. During brazing it is not allowed to overheat material. Surfaces of brazed material can oxidize due to heat exposure. If the tube inner surface oxidizes due to overheating, tinder arises which remains as dust in the refrigeration circuit and disturbs the system. Brazing should therefore be performed at appropriately low brazing temperature and the smallest possible surface should be heated.to avoid thermal damage or interference with components near the brazing point, take precautionary measures, e.g. shielding using a metal panel or applying a moist cloth or other heat-absorbing material. Brazing points must be absolutely tight. Avoid shocks and vibrations during brazing to prevent build-up of cracks in the brazing joints. Refrigerant lines must not be clogged through scale or flux. A brazed joint may not obstruct refrigerant flow. Corrosion may not occur on brazed joints. Avoid oxidation. To improve the efficiency of brazing, different commercially available antioxidants can be purchased. These antioxydants can contain different aggressive components that attack pipe material and can adversely affect refrigerants or refrigerator oil, and should be used with extreme care. DencoHappel recommendation: use nitrogen! Connect a pressure-reducing valve at the nitrogen bottle. Mount a flow meter on the nitrogen bottle. Nitrogen should be directed in the refrigerant pipe to be brazed using a copper pipe. Seal the intermediate space between the nitrogen and refrigerant pipe to prevent nitrogen leakage. While nitrogen is flowing through refrigerant lines, the opposite pipe end must remain open. Use the pressure-reducing valve to set the value below 0.05 m³/h or 0.2 bar for the nitrogen flow. After brazing/soldering, maintain the nitrogen supply until the refrigerant pipe has cooled down sufficiently to be manually handled. After brazing/soldering, completely remove the remaining flux. Drying systems Notice! When replacing components within the refrigeration circuit, the drier must always be replaced too! The drier must always be replaced last. The new drier is vacuum-packed. After opening the vacuum packing, commence with brazing as soon as possible. Evacuation must be performed within 2 hours. The drier must also be replaced if the entire refrigerant has escaped because of a leak. PR GB Subject to modifications R2-01/

44 Installation Row-DENCO Insulation Insulation for the liquid line is not mandatory. A professional heat insulation should be provided for the suction line. Moreover, fire protection regulations must be observed. If the thermal insulation is subjected to direct sunlight, proper materials must be used in this case. Notice! Refer to DIN EN for further instructions on proper running of refrigerant lines. Suction lines Flare coupling Flanged pipe stub The fittings are flare couplings for all sizes. For the connections, proceed as follows: Prepare the end of the pipe by flaring it to the right shape. Connect the prepared line to the on-off valve on the suction line using two spanners, as illustrated in the figure below. Fig. 8-5 Gas line Liquid Lines Flare coupling Flanged pipe stub The fittings are flare couplings for all sizes. For the connections, proceed as follows: Prepare the end of the pipe by flaring it to the right shape. Connect the prepared line to the on-off valve on the liquid line using two spanners, as illustrated in the figure below. Fig. 8-6 Liquid line Notice! Flaring the pipes directly helps limit impurities inside the lines. All the pipes must be perfectly clean (clean using nitrogen or dry air before connecting to the two units) and free from moisture to allow efficient venting. 44 PR GB Subject to modifications R2-01/2016

45 Row-DENCO Installation Leak testing Connect the manometer to the service connections of the respective refrigeration circuit on the suction and pressure side. Before leak testing, examine the pressure values on the high and low-pressure manometer Indicated pressure must be within the overpressure range. In this case, open the liquid shut-off valve and the suction gas shut-off valve to test for leakage. If no overpressure is measured in the refrigeration circuit of the device, it should be assumed that the refrigeration circuit in the unit possibly has a leak. If this is the case, close the liquid shut-off valve and the suction gas shut-off valve to test for leakage. At first, test the refrigeration circuit in the unit on seal effectiveness and possibly remedy leaks Thereafter, open the shut-off valves in the liquid and suction line and examine the remaining refrigeration circuit on seal effectiveness. The system must be depressurized with dry nitrogen to test for leakage as long as the pipework is accessible and not yet insulated. For successful testing, test pressure must be as high as possible, but not exceeding the maximum allowed operating pressure.introduce nitrogen for depressurizing using a pressure-reducing valve on the cylinder valve of the unit. The control gauge on the pressure-reducing valve must be set to the maximum test pressure of the system. Increase pressure in the system in steps, first to 0.1 MPa (1 bar) overpressure and then to around 0.5 MPa (5 bar) overpressure. All pipe connections must be leak tested using foaming Leak Detection Spray. If no leaks are detected at 0.5 MPa (5 bar) overpressure, pressure is increased to the maximum allowed test pressure. Perform the pressure test using the maximum allowed test pressure for at least two hours. Subsequently, overpressure in the system can be reduced. 8.5 Water connections (DRC) The following are recommended for all water connections: flexible connections (available from the options in the price list) to avoid transmitting vibrations and allow small movements of the Row-DENCO Notice! Important: the flexible connections available as accessory are PN10. joints in three pieces, near the fittings, to simplify removal of the unit on-off valves to disconnect the unit from the water circuit: where possible use ball valves with full opening to minimise pressure drop PR GB Subject to modifications R2-01/

46 Installation Row-DENCO Fig. 8-7 The water pipes can be connected either from the top or the bottom. On the side uses, remove the cap from the inlet and outlet manifolds and connect the flexible piping. Make sure that the cross-section of the chilled waterlines and the characteristics of the circulating pump are suitable: an insufficient water flow-rate affects performance of the Row-DENCO. Check that the water inlet and outlet connections are correct. Insulate all the chilled water lines with closed cell material (e.g.: Armaflex or equivalent), to prevent condensation; the insulation must allow access to the valves and the three-piece joints. Make sure that the water circuit has been filled with an antifreeze mixture containing the right percentage of ethylene glycol. To select the pipes see the tables on "Continuous pressure drop for STEEL PIPES" N.B.: the unit uses PN16 connections Quality of water Make sure that the water contained in the water circuit meets the following requirements throughout the entire life of the system: ref. Description Symbol Values 1 hydrogen ion concentration ph calcium (Ca) and magnesium (Mg) content Hardness D 3 chloride ions Cl - < 150 ppm 4 iron ions Fe 3+ < 0.5 ppm 5 manganese ions Mn 2+ < 0.05 ppm 6 carbon dioxide CO 2 < 10 ppm 7 hydrogen sulphide H 2 S < 50 ppb 8 oxygen O 2 < 0.1 ppm 9 chlorine Cl 2 < 0.5 ppm 10 ammonia NH 3 < 0.5 ppm 11 carbonate-sulphate ratio HCO 3-/ SO 4 2- > 1 where: 1/1.78 D=1 Fr con 1 Fr= 10 gr CaCO 3 /m 3 ppm = parts per million; ppb = parts per billion ref. 1: ref. 2: ref. 3: ref : ref. 6-7: ref. 9: ref. 10: ref. 11: Explanations: A hydrogen ion concentration (ph) greater than 9 implies a high risk of fouling, while a ph less than 7 implies a high risk of corrosion Hardness refers to the quantity of Ca and Mg carbonate dissolved in the water at a temperature below 100 C (temporary hardness). High hardness implies a high risk of fouling. A chloride ion concentration higher than the value indicated will lead to corrosion The presence of iron, manganese and oxygen irons will give rise to corrosion Carbon dioxide and hydrogen sulphide are impurities that lead to corrosion occurring more readily The typical value in mains water is between 0.2 and 0.3 ppm. High values will cause corrosion The presence of ammonia boosts the oxidation capacity of oxygen At levels below the value shown in table, there is the risk of corrosion due to galvanic current running between the copper and the other less noble metals. In the presence of ethylene glycol (toxic), corrosive compounds will form over time, and therefore inhibitors need to be added. When the water is dirty and/or aggressive, an 46 PR GB Subject to modifications R2-01/2016

47 Row-DENCO Installation intermediate heat exchanger must be installed upstream of the heat exchangers on the chiller assembly Correction factors Ethylene glycol solutions Water and ethylene glycol solutions used as a heat carrier in the place of water reduce the performance of the unit. Multiply the performance figures by the values given in the following table. Freezing point Percentage of ethylene glycol by weight 0 12% 20% 28% 35% 40% Flow-rate correction factor cq 1 1,02 1,04 1,075 1,11 1,14 Pressure drop correction factor cdp 1 1,07 1,11 1,18 1,22 1,24 PR GB Subject to modifications R2-01/

48 Installation Row-DENCO Continuous pressure drop for steel pipes (inches) water temperature = 10 C Water flow l/h Linear Pressure Drops, (mm w.c./m) Selection Example: consider a limit speed inside the pipe of 1-1.2m/s cross-reference the required water flow-rate (in the example 5,000 l/h) determine the pressure drop according to the selected diameter (in the example 35 mmwc/m) 48 PR GB Subject to modifications R2-01/2016

49 Row-DENCO Electrical Connection 9 Electrical Connection Electrical connections may only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes. Ensure and observe protective measures! When installing and connecting the unit, observe all protective measures for lowvoltage systems according to the appropriate EU Directive as well as regulations and codes of the local utility provider. Potential equalization must be provided and equipment with all connected components must be earthed. Electrocution through hazardous voltage will lead to death or serious injury. Disconnect the unit from the power supply and ensure the power cannot be switched back on. Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. Notice! The cabling must be carried out according to the enclosed unit-specific wiring diagrams. Only separate mains power cable may be used. Never connect other units to this mains power cable. 9.1 Requirements Before you start setting up the unit s electrical connections, check the following: The properties of the mains power supply must comply with EN regulations and the power requirements of the unit. Voltage tolerance of mains power supply must not exceed tolerances ± 10% with a maximum phase difference of 3%. Do not operate the motors if the voltage difference between the phases exceeds 3%, as this will invalidate the warranty. To check, use the following formula (see example). Voltage imbalance [%] U max = max. voltage imbalance of average value average voltage U m Notice! When connecting the supply voltage, make sure you observe the clockwise rotation direction! If the rotation direction is wrong, change the phases at the main power supply of the unit. Change the phase sequence of the power supply line at the on-site source, never change the wiring in the unit switch box. PR GB Subject to modifications R2-01/

50 Electrical Connection Row-DENCO EXAMPLE Input data Result Requirements Calculate and determine specific input data and measurements beforehand. Rated voltage Voltage between phases 400 V/50 Hz/3 phases L1/L2 = 409 V; L2/L3 = 398 V; L1/L3 = 396 V Ermitteln Sie die Durchschnittsspannung U m 1st Step Average Hum. U m = U = 401 V 3 U m = 401 V Determine the maximum 2nd Step Voltage imbalance U max in %? voltage imbalance U max U max = max. voltage imbalance U m U max = 409 V V = 2 % U m = 401 V 401 V U max = 2 % Correct electrical connection, performed in a professional manner and in compliance with the standards in force, is important for the prevention of accidents and the good and long-lasting operation of the Row-DENCO. DRX/DROU Before performing any work on the electrical parts, make sure that there is no live voltage and that the disconnecting switch on the DROU is open (in position O ). The DROU condensing units leave the factory fully wired and simply require connection to the mains power supply and the remote switch (ON/OFF), operations that must be carried out by qualified personnel in compliance with current legislation. For all electrical work, refer to the electrical wiring diagrams in this manual. It is also recommended to check that: The characteristics of the mains electricity supply are adequate for the power ratings indicated in the electrical specifications below, also bearing in mind the possible use of other equipment at the same time. 50 PR GB Subject to modifications R2-01/2016

51 Row-DENCO Electrical Connection Power to the unit must be turned on only after installation work (refrigerant circuit and electrical) has been completed. All electrical connections must be carried out by qualified personnel in accordance with legislation in force in the country concerned Respect instructions for connecting phase, neutral and earth conductors. The power line should be fitted upstream with a suitable device to protect against short-circuits and leakage to earth, isolating the installation from other equipment. Voltage must be within a tolerance of ±10% of the rated power supply voltage for the unit (for three phase units, the unbalance between the phases must not exceed 3%). If these parameters are not respected, contact the electricity supply company. For electrical connections, use double insulation cable in conformity with legislation in force in the country concerned. If local and national standards require installation of a residual current circuit breaker upstream, use a type B device with threshold Id=300 ma. Choose a model that features: high frequency current filtering timer to help prevent disconnection due to the load of stray capacitance on start up Before starting the unit, check the tightness of all the electrical connections and cables on the unit, as these may have come loose during handling and transport. If these devices are not visible from the electrical panel of the unit, they should be lockable An effective earth connection is obligatory. The manufacturer cannot be held liable for any damage caused by the failure to correctly earth the unit. In the case of three phase units, ensure the phases are connected correctly. PERSONAL injury! Do not use water pipes to earth the unit Electrical panel The electrical panel is located inside the unit at the top of the technical compartment where the various components of the refrigerant circuit are also to be found. To access the electrical panel, remove the front panel of the unit by undoing the self-tapping screws. To access the components in the electrical panel and the terminal blocks, undo the four screws on the panel itself. Fig. 9-1 Before performing any work on the electrical parts, make sure that there is no live voltage. Check that the mains voltage corresponds to the rated values for the unit (voltage, no. of phases, frequency) shown on the electrical panel. The power supply voltage must be between ± 10% of the rated value: operation at voltages outside of these limits may void the warranty. PR GB Subject to modifications R2-01/

52 Electrical Connection Row-DENCO Connect the power cable to the IEC male plug supplied with the (see photo Abb. 9-3) and plug this into socket "P", shown in the figure, located on the top of the unit. Fig. 9-2: IEC male plug S Also connect the signal and auxiliary cable (as indicated on the wiring diagram supplied with the unit) to connector S on the top of the unit. P Fig. 9-3 The HUMIDIFIER has separate power supplies. Fig. 9-4 power supply (B) signal (A) auxiliary(d) signal (A) power supply (B) Fig PR GB Subject to modifications R2-01/2016

53 Row-DENCO Electrical Connection ATTENTION Risk of damage to the unit! Terminals that are not adequately tight may generate heat and sparks, causing fire Use suitably rated power supply cables. Cables that are too small and undersized may generate heat and cause fires. Do not run signal cables together with high voltage power cables (AC V or higher), as interference may cause operating problems. Do not lay low voltage cables together (30 VDC or lower), as the interference from these cables may cause malfunctions. Cable layout in conduit OK A D C B POWER CABLES SEPARATOR ELECTRICAL CABLE CONDUIT SIGNAL CABLES D A NO C B ELECTRICAL CABLE CONDUIT Use specific cables for wiring. Tightly secure the electrical connections and prevent any forces exerted on the cables being applied to the terminals Access to the Control Board To access the board, open the front panel and remove the electrical panel cover. Slide the panel out as illustrated in the figure. The electronic components are sensitive to discharges of static electricity from the human body. Touch an earthed object before handling any electronic component. Fig. 9-6 PR GB Subject to modifications R2-01/

54 Electrical Connection Row-DENCO 9.2 DRX Connection Configuration STANDARD HEATERS AND/OR HUMIDIFIER POWER TRANSDUCER KIT (#1) + DUAL POWER SUPPLY KIT (#2) POWER TRANSDUCER KIT (#1) + DUAL POWER SUPPLY KIT (#2) + HEATERS AND/OR HUMIDIFIER QS1 QS1 QS1 QS2 QS1 QS1 QS1 QS2 KIT #1 KIT #1 KIT #1 KIT #1 Id Id Id Id POWER TRANSDUCER KIT POWER TRANSDUCER KIT + HEATERS AND/OR HUMIDIFIER KIT #2 KIT #2 KIT #2 KIT # QS1 QS1 QS1 QS2 Id Id Id Id Id Id Id Id KIT KIT KIT KIT 1: DROU 2: DRX Id Id Id Id Fig. 9-7 DRX electrical connections ATTENTION KEEP SIGNAL CABLES AND POWER CABLES SEPARATE: use low-impedance twisted shielded cables for the signals for distances over 8 metres galvanically isolate the signal cables DROU QS TERMINALS * A SIGNAL CABLES * B * C * D POWER CABLES U N TERMINALS POWER PLUG DRX Id Id Fig PR GB Subject to modifications R2-01/2016

55 Row-DENCO Electrical Connection 9.3 DRC connection configuration ATTENTION KEEP SIGNAL CABLES AND POWER CABLES SEPARATE: use low-impedance twisted shielded cables for the signals for distances over 8 metres galvanically isolate the signal cables STANDARD DOUBLE POWER SUPPLY KIT HEATERS AND/OR HUMIDIFIER DUAL POWER SUPPLY KIT + HEATERS AND/OR HUMIDIFIER POWER TRANSDUCER KIT POWER TRANSDUCER KIT (#1) + DUAL POWER SUPPLY KIT (#2) + HEATERS AND/OR HUMIDIFIER 1: DRC Fig. 9-9 DRC electrical connections TERMINALS DRC CRCC POWER SUPPLY 5 6 U N A* SIGNAL CABLES C* POWER CABLES TERMINALS Set point variation 5: 0-10 VDC 6: G0 PE U N 230V- ~ -50/60Hz Fig PR GB Subject to modifications R2-01/

56 Electrical Connection Row-DENCO 9.4 Electrical specifications The cross-section of the power cable must be chosen according to the length of the cable and the type of installation, based on the maximum current draw of the Row- DENCO and so as to prevent excessive voltage drops (the power supply voltage must be between ± 10 % of the rated value) Total power consumption (230 V/1/50 Hz - 400/3N/50 Hz) Indoor units Evaporator fans Humidifier Model V/Ph/Hz V/Ph/Hz qty. FLI* (kw) FLA* (A) V/Ph/Hz qty. FLI (kw) FLA (A) kg/h DRC 3020 A5 230/1/50 230/1/50 3 0,51 4,35 230/1/50 1 2,25 9,80 3 DRC 3025 A5 230/1/50 230/1/50 4 0,68 5,80 230/1/50 1 2,25 9,80 3 DRC 3035 A5 230/1/50 230/1/50 5 0,85 7,25 230/1/50 1 2,25 9,80 3 DRC 3036 A5 230/1/50 230/1/50 5 0,85 7,25 230/1/50 1 2,25 9,80 3 Evaporator fans Humidifier Model V/Ph/Hz V/Ph/Hz qty. FLI* (kw) FLA* (A) V/Ph/Hz qty. FLI (kw) FLA (A) kg/h DRX 3051 A5 230/1/50 230/1/50 2 0,34 2,90 230/1/50 1 2,25 9,80 3 DRX 3071 A5 230/1/50 230/1/50 4 0,68 5,80 230/1/50 1 2,25 9,80 3 DRX 3121 A5 230/1/50 230/1/50 5 0,85 7,25 230/1/50 1 2,25 9,80 3 Outdoor units Model V/Ph/Hz V/Ph/Hz (1) see the paragraph on CONNECTION CONFIGURATIONS FLI = Power consumption in kilowatts FLA = Maximum current LRA = Compressor peak current SA = Unit peak current * = Total value for all fans The data refer to maximum power consumption. STD cond. fans EC cond. fans Compressor qty. FLI* (kw) FLA* (A) V/Ph/Hz qty. FLI* (kw) FLA* (A) V/Ph/Hz DROUD 051 A5 230/1/50 230/1/50 2 0,32 1,40 230/1/50 2 0,10 0,80 230/1/50 1 5,60 17,20 3 DROUD 071 A1 400/3N/50 230/1/50 1 0,60 2,62 230/1/50 1 0,72 3,20 400/3/ ,08 15,39 5 DROUD 121 A1 400/3N/50 230/1/50 2 1,20 5,24 230/1/50 2 1,44 6,40 400/3/ ,70 25,56 17 qty. FLI (kw) FLA (A) LRA (A) 56 PR GB Subject to modifications R2-01/2016

57 Row-DENCO Commissioning and Testing 10 Commissioning and Testing 10.1 Evacuation Reasons for evacuation Before charging the system with a refrigerant, the refrigeration circuit must be evacuated using a vacuum pump in order to remove air and humidity. Air in the refrigeration circuit has the following effects: increase in energy consumption of compressors reduction in cooling capacity increase of discharge temperature poor heat transfer in the condenser High-pressure failures can be the consequence already at relatively low ambient temperatures. Humidity in the refrigeration circuit has the following effects: internal ice formation in the expansion valve and capillary ducts origination of acid in connection with refrigeration oil copper cladding chemical disintegration of refrigerant Procedure for evacuation Reducing pressure in the unit components to values below the water vapour pressure leads to evaporation of water. The higher the ambient temperature, the faster and more efficiently humidity can be removed thanks to a higher vapor pressure. Because of this reason, it is not always possible to sufficiently dry the refrigeration circuit at low ambient temperature. Connect the service manometer assembly to the service ports. Compare the orderrelated refrigeration circuit diagrams. For evacuation, use the vacuum pump ( bar) fitted with a high-grade pressure gauge a with 0 to 150 mbar abs scale range, to reach a pressure below water vapor pressure at the current ambient temperature. Vapour pressure for water (Ps) T [ C] Ps [MPa] abs. Ps [bar] abs Tab. 10-1: At ambient temperature of 15 C water begins to evaporate at a pressure of MPa (0.017 bar). The required dryness of the system is ensured if an absolute vacuum of around MPa or bar is reached and this condition can be maintained for more than 6 hours with a deactivated vacuum pump. If this value can not be reached, break the vacuum by introducing dry nitrogen and repeat the evacuation procedure. PR GB Subject to modifications R2-01/

58 Commissioning and Testing Row-DENCO Absolute pressure [bar] 0,018 0,016 0,014 0,012 0,01 0,008 0,006 0,004 0,002 Pressure rise after evacuation Time [h] Humid and leaking Humid and leak-free at Ta = +10 C Dry and leak-free Fig. 10-1: Pressure rise after evacuation 10.2 Charging Danger of low temperature and high pressure! When charging a refrigeration system with a refrigerant, there is a risk of injury from contacting liquid refrigerant or fluids/gases escaping at high pressure. Contact with a liquid refrigerant can result in skin burns or injury to other organs.exercise due caution and attention when carrying out jobs on the unit and avoid contact with the refrigerant. Wear suitable protective clothing during work. R-410A The plant is only approved for operation with the refrigerant R-410A. The R-410A is a zeotropic mixture consisting of three different refrigerants. Since this mixture shows a defined composition only in the fluid-state, it may only be filled with liquid R-410A. Use the service port of the liquid line to charge liquid refrigerant in each refrigeration circuit of the unit. The refrigerant volume for charging or its approximate calculation is provided in the Data&Facts catalog of the relevant unit series. To avoid overcharging, first charge around 80 % of the calculated volume. Use the liquid refrigerant to fill each liquid line of the unit refrigeration circuit. After breaking the vacuum with a liquid refrigerant, all shut-off valves of the unit must be opened. During the function test and for topping up the refrigerant, observe the liquid flow through the liquid line sight glass to receive an overall picture. Check for bubble-free flow in the sight glass! 10.3 Preparing for first start up Before starting up the condensing unit, make sure that: all safety conditions have been respected the condensing unit is adequately fixed to the surface it rests on clearances have been respected refrigerant connections have been carried out as indicated in the instruction manual the circuit has been emptied the refrigerant circuit valves are open electrical connections have been carried out correctly voltage is within a tolerance of 10% of the rated voltage for the unit 58 PR GB Subject to modifications R2-01/2016

59 Row-DENCO Commissioning and Testing the unit is correctly earthed all electrical and refrigerant connections are tight Before starting up, power up the unit for at least two hours by switching QF and QS to ON, so as to allow the oil in the compressor sump to heat up Commissioning (after the 2 hours) ON Before starting the condensing unit: Make sure the mains remote switch QF is in the OFF position OFF Fig Remove the inspection panel Fig Remove the door from the electrical panel by moving QS to OFF Fig Switch the compressor circuit breaker QM1 ON Fig If an alarm is activated, refer to the control panel instruction manual. Close the electrical panel again and tighten the fastening screws Move the main unit switch QS to the ON position Fig PR GB Subject to modifications R2-01/

60 Commissioning and Testing Row-DENCO Replace the inspection panel Move the mains switch QF (outside the unit) to the ON position Fig Starting and stopping the unit ON Move remote switch SA1 (if featured) to the ON position. The operations for STARTING and STOPPING the unit are controlled by the combined HED indoor unit. OFF Fig Commissioning procedure Arm the circuit breaker in the auxiliary circuits; Arm all the circuit breakers on the electrical panel; Power up the Row-DENCO electrical panel and close the main disconnect switch on the unit (position 'I'); Check that the control board is powered. After having powered up the Row-DENCO, wait at least 12 hours before starting so as to suitably heat the oil in the compressors. During extended shutdown there may be spontaneous migration of refrigerant to the compressor sump, which at the start may cause the oil to foam and consequent damage due to insufficient lubrication. As a result, do not disconnect power when shutting down during the week; Open the on-off valves in the refrigerant circuits and check that the air-cooled remote condensers are powered (air-cooled models); At least 12 hours after power up Start the Row-DENCO using the buttons on the user terminal (ENTER +USER PASSWORD) and the fans will start automatically. If an alarm is activated refer to the controller instruction manual DRC When power is supplied to the unit, wait around 35 seconds (time taken for the program to load) and then start the unit from the keypad (ENTER + USER PASSWORD) and the fans will start automatically. Make sure that the chilled water valve is working correctly; Check that the sections of corrugated pipe for draining condensate have been filled with water during installation. 60 PR GB Subject to modifications R2-01/2016

61 Row-DENCO Commissioning and Testing 10.4 Condensate drain Condensate is removed from the pan located underneath the unit; the end of the drain pipe should be connected to the sewerage system in the building via a rubber or plastic hose with an inside diameter of 16 mm. During installation, pour water into the condensate collection pan so as to fill the drain trap with water Instruments and alarms The Row-DENCO is fitted with the following instruments: DROU Unit high pressure switch with manual reset; DRX/DRC Unit low pressure switch with automatic reset dirty filter sensor (optional) (differential pressure switches) temperature sensor or room temperature and humidity sensor BH1 (on units with humidity control) The following optional instruments may also be fitted: Flood sensor made up of: device to be inserted in the special socket on the electrical panel sensor (or sensors, connected in parallel) to be positioned at the points monitored Smoke sensor 10.6 Calibrating the control and safety devices After starting the Row-DENCO, make the following adjustments (see the microprocessor controller manual): room temperature (cooling set point) dirty filter differential pressure switch: see the paragraph on "CALIBRATING THE DIRTY FILTER SENSOR" The calibration values of the control and safety devices must not be altered. Symbol Description Activation Differential Reset F1 High pressure switch 37,4 bar (opening) - Manual Reset F2 Low pressure switch 3 bar (opening) 0,9 bar 3,9 bar (automatic) 10.7 Calibrating the dirty filter sensor + - A B D 1 E 3 mbar mbar 2 B C D Fig Pressure switch must be calibrated according to the pressure drop, which depends not only on how dirty the filter is, but also the air flow-rate. Calibration must be performed with a clean filter, as follows: switch the unit on progressively cover the surface of the air filter and make sure that the pressure switch is activated when around 50-60% covered; if the device is not activated, progressively reduce the calibration of the pressure switch; if the device is activated too early, increase the calibration Operation and adjustment Electronic Valve The DRX units feature electronic expansion valves as standard. PR GB Subject to modifications R2-01/

62 Commissioning and Testing Row-DENCO These valves have a much wider modulation capacity than traditional mechanical thermostatic valves; this feature is essential in applications with operation at part load. The electronic expansion valve does not require calibration in the field, as all the parameters are set directly in the factory. Fig Modulating water valve The DRC units with chilled water circuit are fitted with a 2- or 3-way modulating valve complete with 3-position or 0-10 V servomotor. Electrocution through hazardous voltage will lead to death or serious injury. Disconnect power before working on the servomotor. Fig The servomotor position is proportional to the control voltage applied, between 0 and 10 VDC. The servomotor stops: automatically at the end of its travel in the position corresponding to the control voltage in the current position if power is cut off Type supply Travel time at 50 Hz Control signal SSC619 AC/DC 24 V 30 s DC 0-10 V Description This servomotor with 0-10 V control is used to drive 2- or 3-way valves with 5.5 mm travel. Functions When the actuator is powered at 0-10 VDC or with a 3 position signal, it transmits motion to the valve. Controllers with 0-10 V signal, SSC619: the valve is open or closed in proportion to the power supply signal Y 0 volts: the valve is completely closed and the servomotor remains in the current position. If no power is supplied the actuator maintains its current position Auto-calibration - SSC When 24V AC/DC is supplied, the servomotor automatically and independently performs auto-calibration, regardless of the signal. This process takes around 60 seconds. 3 Fig PR GB Subject to modifications R2-01/2016

63 0 1 Row-DENCO Commissioning and Testing Manual override The knob on the servomotor can be used to move the actuator to all positions between 0 and 1. If the control signal is applied, this has priority in determining the valve position. A B A B 1 0 (Y, Y1) A B (Y2) Fig : Manual override Maintenance in position 1: valve open in position 0: valve closed The servomotors are maintenance-free. If maintenance is required on the system, remember to: disconnect power (unplugging the connector) the servomotor must only be tested when the valve has been installed correctly. PR GB Subject to modifications R2-01/

64 Commissioning and Testing Row-DENCO Repair The servomotor cannot be repaired and if necessary must be replaced completely A AB A B AB AB B A B A B AB 0 100% AB 100 0% H1 H2 1 2 L3 H G L2 L1 Fig DN G ["] H [mm] H1 [mm] H2 [mm] VXP G2B > ~ ,5 52,5 62,5 1,95 1,70 L1 [mm] L2 [mm] L3 [mm] L4 [mm] VVP... [kg] VXP... [kg] Way valve shut off For applications where a 2-way valve is required, check that the Close Off values shown in the table below are compatible with the system. Other values available only on specific request. 2 Way Valve Close-Off DRC MODEL Actuator Valve model KVS close off* (kpa) 0020 SSC VXP SSC VXP SSC VXP SSC VXP *close off = Maximum pressure differential allowed for the motorised valve to close against system pressure 64 PR GB Subject to modifications R2-01/2016

65 Row-DENCO Commissioning and Testing Way ON/OFF valve (optional) The on-off valve shuts off water flow into the DRC unit (see OVERVIEW DIAGRAM) in the event of a flood alarm. The 2-way ON/OFF valve kit comprises: valve body 24 VAC electric servo control with limit switch 2 x 3-piece joints Fig Connect the servomotor power cable to the special terminals in the DRC electrical panel (see wiring diagram). Assembly For correct assembly of the valve any position is allowed, except where the servo control is facing downward Temperature and Hhumidity Pprobe (option DRZ-3HSENA.E04) The temperature/humidity probe is required in order to use the IDM (Integrated Dynamic Management) function. This measures the dew point of the intake air to the DRC and activates a special alarm signal if the water temperature is below dew point and consequently there is the risk of dehumidification and condensate forming. The figure shows the optional temperature and humidity probe. In the event of replacement, release the white plastic cover by pressing point (A) with a screwdriver or other pointed object; lift the cover (B) to access the fastening screws (C) and terminals (D). For the probe electrical connections use shielded cable; the connections to the terminals on the board are shown in the wiring diagram. B A 80 D C H O U T M T OU T + Fig : Wiring diagram 126 mm PR GB Subject to modifications R2-01/

66 Commissioning and Testing Row-DENCO Energy monitoring (optional) This device provides continuous measurement of power consumption, monitoring current, voltage and power. These values can be sent to BMS systems via a serial connection, fitting the unit with a communication board to manage the specific protocol. Connect the device to the Row-DENCO indoor unit via RS485 serial cable, as shown on the unit wiring diagram. Fig Overview diagram GND 6 TX+ 2 RX+ TX- 4 1 RX- 3 T 5 A10 POWER TRANSDUCER KIT RS485 CONNECTION Fig : Overview Diagram Dual power supply (optional) The dual power supply kit allows the unit to keep operating when there is a power failure on the main power line. In the event of a power failure on the main power line, the system automatically switches to the secondary or backup power supply. This ensures complete redundancy of the power supply and consequently total unit cooling capacity even in emergency situations. The kit is supplied already on the DROU outdoor units, while for the Row-DENCO indoor units, the kit is supplied separately. 66 PR GB Subject to modifications R2-01/2016

67 Row-DENCO Commissioning and Testing Humidifier System components Upon request, the air-conditioning unit can be fitted with an immersed electrode humidifier. 3 4 KM TA1 1. A B YV1 8.YV2 10. BH1 8 Fig : Components 1: Humidifier interface board: A3; (inside the electrical panel). 2: Current transformer TA1 (inside the electrical panel) for measuring the current input of the steam cylinder. 3: Water fill tank. 4: High water level electrodes in the steam cylinder. 5: Overflow pipe (BEHIND THE CYLINDER). 6: Boiler cylinder (or steam cylinder). 7: Water fill solenoid valve: YV1. 8: Cylinder drain solenoid valve:yv2. 9: Microprocessor control board:a1. 10: Temperature and humidity probe: BH Humidifier operating principle In the immersed electrode humidifier, the current that runs between the electrodes, through the water contained in the boiler cylinder, generates the heat required to boil the water. By controlling the level of the water and the concentration of salts inside the steam cylinder (6) using the fill (7) and drain (8) solenoid valves, the amount of current delivered can be regulated, and measured using a current transformer (2). When steam production is required, the humidifier contactor CU closes (see the wiring diagram) so as to supply power to the immersed electrodes. When the current falls below the set value due to the lowering of the water level, the fill valve (7) is opened. The drain valve (8) is activated cyclically, depending on the characteristics of the supply water, so as to maintain the optimum salt concentration inside the cylinder (6). PR GB Subject to modifications R2-01/

68 Commissioning and Testing Row-DENCO The only periodical maintenance operations required are the inspection and cleaning of the parts in the steam production unit. The operations indicated below should be performed annually, preferably before shutting down the unit in summer Fill and drain assemblies To ensure the correct operation of the humidifier, the supply/fill and drain assemblies need to be inspected periodically. Proceed as follows: completely drain the water from the boiler using the manual controls on the controller A1 disconnect the power supply by opening the main switch on the electrical panel remove the fill pipe from the 3/4 GAS fitting on the fill solenoid valve remove and clean the filter located inside the solenoid valve fitting dismantle the drain assembly (shown in Figure 13), clean the pipes and remove any flakes of scale from the cup-drain trap Steam cylinder Fig The steam cylinder requires periodical cleaning to remove the scale deposits that form on the surface of the electrodes and the flakes that deposit on the filter at the base of the cylinder. To remove the cylinder, proceed as follows: completely drain the water from the boiler; to do this, see the paragraph manual controls in the controller manual disconnect the power supply by opening the main switch on the electrical panel remove, from the top of the cylinder, the hose that carries the steam to the distributor disconnect the power connections by unscrewing the knobs on the cable ends and remove the plugs from the level electrodes release the strap that secures the cylinder to the unit slide the cylinder out upwards The steam cylinder can be reused a number of times after cleaning the electrodes: if, however, the wear on the grills of electrodes is such that these cannot be regenerated, they must be replaced. The only spare part is the complete cylinder body (with filter included) Humidifier power supply OUT Ø 32mm position: V-F Underneath the fill solenoid valve on the steam production unit is the threaded male fitting (V) for the humidifier water supply. This is already fitted with a plastic hose, diameter 6 mm, for connection to the building's water supply (see figure, point F). V: Steam production unit - inlet connection (threaded male fitting 3/4 G); F: Rubber hose, diameter: Ø 6mm. IN 3/4 G Ø 6mm Fig PR GB Subject to modifications R2-01/2016

69 Row-DENCO Commissioning and Testing To supply the humidifier, use drinking water without any chemical treatment or demineralisation. The characteristics of the water that supplies the humidifier must be within the following values: LIMIT VALUES FOR IMMERSED ELECTRODE HUMIDIFIER FEED WATER LIMITS WITH MEDIUM-HIGH CONDUCTIVITY Min Max Mains pressure bar 1 8 Hydrogen ions ph - 7 8,5 Specific conductivity at 20 C σr, 20 C - μs/cm Total dissolved solids TDS - mg/l ( ) 1 () 1 Dry residue at 180 C R180 - mg/l ( ) 1 () 1 Total hardness TH - mg/l CaCO3 100( 2 ) 400 Temporary hardness - mg/l CaCO3 60( 3 ) 300 Iron + Manganese - mg/l Fe + Mn 0 0,2 Chlorides - ppm Cl 0 30 Silica - mg/l SiO Residual chlorine - mg/l Cl - 0 0,2 Calcium sulphateo - mg/l CaSO Metallic impurities - mg/l 0 0 Solvents, diluents, soaps, lubricants - mg/l 0 0 Tab (1) Values depending on specific conductivity; in general: TDS 0,93 * σr, 20 C ; R180 0,65 * σr, 20 C (2) not lower than 200% of the chloride content in mg/l of Cl- (3) not lower than 300% of the chloride content in mg/l ofcl- The cylinder supplied as indicated in the price list refers to the model for medium conductivity ( μs/cm). Models are available upon request for low conductivity ( μs/cm) or high conductivity ( μs/cm). Contact the office to a specific quotation Humidifier and condensate drain Underneath the drain solenoid valve on the steam production unit is an attachment for draining the water. This is already fitted with a hose coupling for connecting the hose running to the sewerage system in the building. A rubber or plastic hose should be used, resistant to 100 C, with an inside diameter of 32 mm. Fit a trap in the section of the hose outside of the unit to avoid bad odours and to prevent water from overflowing from the humidifier pan. Fig During installation, pour water into the condensate collection pan and the humidifier pan, so as to fill the drain traps outside and inside the unit with water. Downstream of the drain trap ensure a minimum slope of 1%. Hot surfaces can cause injuries! The water exiting the steam cylinder is very hot. The humidifier drain hose must not be fastened to electrical cables and must run down vertically so as to avoid any contact with these cables. Wear protective gloves. PR GB Subject to modifications R2-01/

70 Commissioning and Testing Row-DENCO Condensate drain pump and humidifier drain pump Std condenssate drain pump (low water temperature) Depending on the version, a condensate drain pump or a humidifier drain pump with mechanical features such as to be able to resist the high temperatures of the water exiting the steam cylinder. The condensate drain pump for low water temperature is installed on the unit, while the high temperature model is supplied unassembled and needs to be installed outside of the unit. The pump must be installed below the height of the drain connection, in accordance with the instructions supplied in the packaging. Check that the head is sufficient to lift the condensate to the point of drainage. Technical specifications: Maximum flow-rate: 30 l/h Maximum suction height: 4 m Maximum discharge height: 13 m (flow-rate = 8 l/h) Maximum pressure: 18 m (flow-rate = 0l/h) TABLE OF EFFECTIVE FLOW-RATES (l/h) Total pipe length with 6 mm ID pipe (C) Suction (A) Discharge (B) 5 m 10 m 20 m 30m 0 m m m m 6 m m m m m m m m 6 m m m m m m 4 m m m m m 2 m m m PR GB Subject to modifications R2-01/2016

71 Row-DENCO Commissioning and Testing Condensate drain pump for high water temp. (humidifier) These pumps are designed to collect the hot water produced by the humidifier drain cycles, as well as the condensate produced. The pump body is made from Cycoloy, a heat-resistant material, the pre-wired safety float is a low voltage switch used to stop the drain cycle in the unlikely event where the pump malfunctions. The pump is started by internal float switches. Fig Technical specifications: Tank capacity: 4 litres Recommended maximum head: 6 m Maximum water flow-rate: 900 l/h with zero head Rated power: 0.6 A, 230 VAC Power cable (2 m long) Safety switch: max 4 A Power supply voltage 220/240 VAC Current draw: 0.7 A Power consumption: 175 W Dimensions Height: 205 mm Width: 300 mm Depth: 150 mm Weight: 3.6 kg Electrical connections Brown: Line Blue: Neutral Green/yellow: Earth 2 x black: Safety switch Installation notes: This pump is designed to be installed only horizontally, resting the base on a perfectly flat, horizontal surface or fastening it horizontally to the wall through the holes provided on the frame. The pump requires a drain hose with an inside diameter of 9 mm. Make sure the hoses are not choked or twisted along the path between the pump and the point of drainage. Securely fasten the hoses with a clamp to the pump outlet fitting, to prevent them from coming loose and consequently causing water to be released at high pressure. IMPORTANT: The pre-wired safety switch must always be used. SAFETY SWITCH PUMP MOTOR PUMP START SWITCH BLACK BLACK LINE NEUTRAL (N) EARTH (PE) PUMP FRAME Fig PR GB Subject to modifications R2-01/

72 Commissioning and Testing Row-DENCO Maintenance guide At least once every 6 months, pour a bactericidal solution into the tank, to prevent accumulation of residues and sludge at the bottom that may cause the pump to malfunction. NB: Users must check that any chemicals contained in the condensate are compatible with operation of the pump. IMPORTANT: Test pump operation by filling it with water until the motor starts, to check for any leaks and verify correct drainage of the water FLOW-RATE IN LITRES/HOUR Fig HEAD IN METRES Maintenance This section is extremely important for correct operation of the appliance. Just a few operations completed scrupulously and regularly will avoid serious damage to the components. Access to the unit is only allowed to authorised and specifically trained personnel. The maintenance operations can be summarised as follows: cleaning the air filter checking and cleaning the drains general examination of overall appliance operation Vvisual check of the condition of pressurised vessels General examination of operation This is a general examination aimed at comparing the operation of the appliance with the last check performed. Consequently, any differences in the operating characteristics over time can be highlighted. A detailed and periodical visual check of the appliance and general cleaning are always important to ensure correct operation. The above-mentioned operations can in general be performed once a month. Naturally, in special situations and specific installations the frequency may change. A well maintained system is unlikely to cause disruptions and stoppages to the production cycles. After 10 years of operation a complete inspection should be performed to check, and if necessary replace any damaged/worn components. Replacing the fans Caution due to rotating components! Before removing the fan from the frame, make sure it has completely stopped. Wear protective gloves. 72 PR GB Subject to modifications R2-01/2016

73 Row-DENCO Commissioning and Testing B If maintenance or replacement of the fans is required, these can be removed without having to power down the entire unit. Open the front door and remove the quick-connect power to the fault fan that has to be replaced (see Fig pos. A). When the fan is stopped, unscrew the screws securing the fan support (see Fig pos. B) and remove it from the unit. A The remaining fans will operate at maximum speed to compensate for the missing fan during maintenance. Fig PR GB Subject to modifications R2-01/

74 Maintenance Row-DENCO 11 Maintenance ATTENTION Risk of damage to the unit! Every components replacement (compressor, safety pressostat, liquid receiver, ecc.) have to consider the main component list enclosed in the unit. This section, aimed above all for the end user, is extremely important for the correct operation of the appliance. Just a few operations completed scrupulously and regularly will avoid serious damage to the components. Only authorized and specialist personnel can operate into the units. The maintenance operations can be summarised as follows: clean the air filter check and clean the condenser coils check the water-cooled condensers for fouling check and clean the drains check the humidification system general examination of the overall operation of the appliance visual check of the condition of the pressurised containers 11.1 Cleaning the air filter The gradual fouling of the filters reduces the flow-rate of the conditioned air, with a consequent reduction in cooling capacity. In the direct expansion units, a reduction in the air flow-rate may cause the activation of the low pressure switch and/or cause serious damage to the compressor. This can be avoided by the periodical cleaning of the filters. The frequency at which the filters must be checked exclusively depends on the amount of dust in the environment. In any case, the following are recommended: every week check that the filters are clean every two weeks clean the filters with a vacuum cleaner every month wash the filters with soapy water every six months replace the filters It is clear that the recommended times are purely indicative, and in some cases it may be necessary to increase the frequency of the checks and maintenance operations. These operations must be carried out with the unit off and after having made sure that the appliance is disconnected from the power supply Checking and cleaning the condenser coils In the hotter period, when the unit operates at maximum capacity, the condensing coils must be able to offer the maximum heat exchange. Normally installed outside or communicating with the outside, these may pick up dirt such as paper, dry leaves and dust, thus reducing the heat exchange. Make sure that this situation does not arise. Failure to perform maintenance will cause the activation of the high pressure switch and the unit to shutdown. Frequently check the condition of the heat exchanger during the poplar pollination period or the autumn (falling leaves). Remove any objects accumulated on the coil and wash with a jet of water. These operations must be carried out with the unit off and after having made sure that the appliance is disconnected from the power supply. 74 PR GB Subject to modifications R2-01/2016

75 Row-DENCO Maintenance 11.3 Checking and cleaning the drains All the water drains (humidifier and condensate) must ensure perfect drainage, to avoid flooding in the room. When the humidifiers drain the water, they discharge a quantity of lime scale that depends on the hardness of the supply water. This lime scale may accumulate in the bottom of the drain hose and block the flow of water. If cleaning is required, add ordinary descaler to the section of circuit involved. This operation must be carried out with the unit off and after having made sure that the appliance is disconnected from the power supply General examination of operation This is a general examination aimed at comparing the operation of the appliance with the last check performed. Consequently, any differences in the operating characteristics over time can be highlighted. A detailed and periodical visual check of the appliance and general cleaning are always important to ensure correct operation. The above-mentioned operations can in general be performed once a month. Naturally, in special situations and specific installations the frequency may change. A well maintained system is unlikely to cause disruptions and stoppages to the production cycles. After 10 years working a complete checking is recommended Visual check of the condition of the pressurised containers Check the condition of the pressurised containers at least once a year (if these are fitted). It is very important to check that rust does not form on the surface, that there is no corrosion and that there are no visible deformations. If not controlled and stopped, surface oxidation and corrosion will over time cause a decrease in the thickness of the container and a consequent reduction in its mechanical strength. Protect with paint and/or corrosion proofing products. In the event of visible deformations, stop the unit and contact the nearest service centre. PR GB Subject to modifications R2-01/

76 Troubleshooting Row-DENCO 12 Troubleshooting Troubleshooting is simplified by the information provided by the microprocessor controller: if an alarm is signalled, refer to the controller manual. If required, contact the nearest service centre, indicating the probable causes of the fault. FAULT CAUSE FAULT THE AIR-CONDITIONER DOESN'T START The electrical panel is not powered Check for voltage; close the main switch. The auxiliary circuits are not powered Check that the cutout IM in the auxiliary circuits is armed. Check the fuse on the main board. The control panel does not start the Row-DENCO. Check for DC power ROOM TEMPERATURE TOO HIGH The parameter settings on the microprocessor controller are not correct. See the controller manual. The air flow-rate is too low or null. See LOW OR NO AIR FLOW. The probe isn't working. Check the electrical connections and the configuration of the controller Thermal load higher than expected. Check the thermal load in the room being air-conditioned. The compressor/compressors don't start, despite being activated by the controller See THE COMPRESSOR/COMPRESSORS DON'T START. ROOM TEMPERATURE TOO LOW The parameter settings on the microprocessor controller are not correct. See the controller manual. The power of the heaters is not sufficient or the heaters aren't working. Check that the heater thermal cutout is armed. Check the power supply to the electric heaters. If the heater safety thermostat is activated, resolve the causes and reset the alarm. The hot water coil isn't working correctly. Check the flow-rate and the temperature of the water hot. Check the operation of the control valve and the servomotor. The hot gas post-heating system isn't working during the dehumidification plus post-heating phase Check the operation of the hot gas three-way valve; Check the operation of the compressor used for postheating: in this case, see THE COMPRESSOR/COM- PRESSORS DON'T START. 76 PR GB Subject to modifications R2-01/2016

77 Row-DENCO Troubleshooting FAULT CAUSE FAULT AMBIENT HUMIDITY TOO HIGH The parameter settings on the microprocessor controller are not correct. See the controller manual. Latent load higher than expected Check and calculate the latent load; check the flow-rate and the conditions of the outside air; check the inflow of outside air. The compressor isn't working during the dehumidification phase. See THE COMPRESSOR/COMPRESSORS DON'T START. The dehumidification valve doesn't close. Check the operation of the solenoid valve that controls the dehumidification circuit. The control system isn't working. See the controller manual; check the operation of the panel and/or the probe. AMBIENT HUMIDITY TOO LOW The parameter settings on the microprocessor controller are not correct. Check the room temperature setting (see the control panel manual). Latent load lower than expected. Check the consistency of the latent load. The humidifier isn't working. Check the pressure of the supply water; Check the operation of the manual control system and the steam production unit (see the control panel manual) The control system isn't working. See the control panel manual; check the operation of the panel and/or the probe. LOW OR NO AIR FLOW The fans are not powered. Check the power supply to the fans. The filters are blocked (possible activation of the dirty filter alarm). Clean the filter using a vacuum cleaner after having shaken off the larger particles of dust. Replace the filter if excessively clogged. Check the correct calibration of the dirty filter differential pressure switch F4. Obstructions to the air flow. See the paragraph on AIR DISTRIBUTION The fan thermal cutout has tripped. Check the resistance of the fan windings; after resetting, measure the voltage and power input. EC radial fan speed set too low Excessive pressure drop in the air distribution system. Check the sizing of the air distribution system (ducting, false-ceiling, underfloor plenum, grills) PR GB Subject to modifications R2-01/

78 Troubleshooting Row-DENCO FAULT CAUSE FAULT HEATER SAFETY THER- MOSTAT ACTIVATED Insufficient air flow-rate See LOW OR NO AIR FLOW. Thermostat connection wire cut or broken Check the continuity of the connection from the safety thermostat to the control system. Faulty thermostat Replace the heater safety thermostat. HIGH COMPRESSOR DISCHARGE PRESSURE A) Air or incondensable gas in the refrigerant Empty and recharge the circuit. circuit, seen by the presence of bubbles, despite measuring a high subcooling. Empty and recharge the circuit. B) Insufficient air flow-rate to the remote heat exchanger or air too hot Check the operation and the correct direction of rotation of the fans on the outdoor heat exchanger. Check that the exchanger is not dirty and remove any material that may be blocking it (leaves, paper, seeds, dust, etc.) with a jet of compressed air or with a brush; Check the outdoor unit for any obstacles to the flow of air and any recirculation of the cooling air; Check that the temperature of the cooling air does not exceed the design value. Insufficient water flow-rate to the condenser or water too hot. Check the flow-rate, the pressure and the temperature of the cooling water in the closed circuit; Check the calibration and the operation of the pressure control valve. Excessive refrigerant charge; condenser partially flooded. Excessive subcooling of the liquid at the condenser outlet. Remove refrigerant from the circuit. Valves on the high pressure side of the circuit partially closed. Check the opening of the valves. HIGH PRESSURE SWITCH ACTIVATED (high compressor discharge pressure) The condensing pressure control system isn't working. Check the operation of the condenser fans and the corresponding protection device; repair or replace the faulty fans; Check the calibration and the operation of the remote condenser fan pressure switch or the speed controller. (See CONTROLLING THE CONDENSING PRES- SURE) The system is affected by an excessive discharge pressure See HIGH COMPRESSOR DISCHARGE PRESSURE. 78 PR GB Subject to modifications R2-01/2016

79 Row-DENCO Troubleshooting FAULT CAUSE FAULT LOW COMPRESSOR DISCHARGE PRESSURE The condensing pressure control system isn't working (see the control panel manual). Check the calibration and the operation of the condenser fan pressure switch or the speed controller; Excessive water flow-rate to the condenser or water too cold. Check the temperature of the cooling water. Check the calibration and the operation of the pressure control valve (if fitted). Install a pressure control valve to manage the flow-rate of water according to the condensing pressure. Suction pressure too low See LOW COMPRESSOR SUCTION PRESSURE. HIGH COMPRESSOR SUCTION PRESSURE Thermal load higher than expected Check the ambient thermal load; check, above all for intense dehumidification, the flow-rate and the conditions of the outside air; check the inflow of outside air. The system is affected by an excessive discharge pressure See HIGH COMPRESSOR DISCHARGE PRES- SURE. Too much refrigerant in the circuit. Remove refrigerant from the circuit Return of liquid refrigerant to the compressor intake Check that the thermostatic valve superheating value is correct; check that the valve sensor bulb is not discharged and that it is correctly positioned, secured and insulated. LOW COMPRESSOR SUCTION PRESSURE (and possible defrosting of the coil) Room temperature too low The air flow-rate is too low or null See ROOM TEMPERATURE TOO LOW. See LOW OR NO AIR FLOW. Liquid receiver outlet valve not completely open Check the opening of the valve. Refrigerant filter blocked Check that the thermostatic valve superheating value is correct; check that the valve sensor bulb is not discharged and that it is correctly positioned, secured and insulated. Insufficient refrigerant charge Check the liquid subcooling at the condenser outlet; if necessary, restore the charge. LOW PRESSURE SWITCH ACTIVATED (low compressor suction pressure) Thermostatic valve not correctly calibrated or faulty Dewatering filter cartridge dirty Check that the thermostatic valve superheating value is correct (around 5 C). Check and if necessary replace the dewatering filter cartridge; the temperature difference measured upstream and downstream of the filter must be less than 2 C. The system is affected by an excessively low discharge pressure See LOW COMPRESSOR DISCHARGE PRES- SURE. PR GB Subject to modifications R2-01/

80 Dismantling and Disposal Row-DENCO 13 Dismantling and Disposal ATTENTION Risk of environmental damage! Have qualified licensed staff dismantle and dispose of the unit! 13.1 Dismantling To dismantle the units proceed as follows: Electrocution through hazardous voltage will lead to death or serious injury. When carrying out decommissioning and dismantling work on the unit: Disconnect the unit from the power supply and ensure the power cannot be switched back on. Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. High pressure hazard! When carrying out decommissioning and dismantling jobs on the unit, shut off and empty all connected pipework until the system pressure has equalized with the ambient air pressure. Failure to follow safety precautions can result in serious injury. Wear suitable protective clothing during work. Close all hydraulic shut-off valves. Isolate all connections and ensure there are no leaking materials such as oil, refrigerant or water-glycol mix. Release the fixing to the floor. ATTENTION Risk of damage to the unit! The weight of the condensing unit is biased towards the compressor side (side of the packaging with the bar code, see the figure at the bottom). During transport, the condensing unit should be kept in a vertical position. The unit is ready for transport. Consider all instructions on shipping (refer to chapter 6). 80 PR GB Subject to modifications R2-01/2016

81 Row-DENCO Dismantling and Disposal 13.2 Disposal Notice! The operator of the refrigeration unit is responsible for taking all necessary precautionary measures and ensures that only certified and licensed staff properly recovers, recycles, processes and disposes of fluorinated refrigerants containing greenhouse gases (F-Gases in accordance with Fluorinated Greenhouse Gases Regulation (EU) No 517/2014). An authorized appointed contractor specializing in waste processing must dispose of the unit or its individual components. This appointed contractor must ensure that: the components are separated according to material types the used operating materials are sorted and separated according to their respective properties fluorinated greenhouse gases are properly recycled or disposed ATTENTION Risk of environmental damage! Dispose of all components and materials (such as oil, refrigerants and water-glycol mixture) in an environmentally friendly manner in accordance with the local codes, practices and environmental regulations. PR GB Subject to modifications R2-01/

82 Appendix I 14.1 Log Book for Chiller, Heat Pumps and Compressor/Condenser Units 82

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