INSTALLATION AND USER INSTRUCTION MANUAL RENCOOL ECK4-48 1
ECK4 - DC VOLTAGE COOLING SYSTEM FEATURE LIST Complete self contained cooling system. External vertical flange mounting. 1.5mm zinc anneal heavy duty construction. RAL906 powder coating with textured finish. 304 stainless steel fasteners and structural rivets. Vermin proof enclosure. Direct drive DC motor and compressor system. High efficiency DC motor. Optimised rotary vane compressor. Low voltage cut-out. ATS and AMI fuse protection of devices. Simple 3 cable electrical connection. 42Vdc to 54Vdc operational range. brushless fans. Low and high evaporator fan speed selection. 2
HBNR o ring seal on all refrigerant connections. Copper tube & fin evaporator and condenser coils. Block style TX Valve. Removable and washable Dacron filter element. Low noise. Environmentally safe R134a refrigerant. technical support available. made to suit harsh conditions. ECK4 - DC VOLTAGE COOLING SYSTEM SPECIFICATION Dimension: 1415(H) x 750(W) x 220(D) Weight: 115kg Cooling Capacity: 13,340BTU/hr @ 35 C Ambient COP: approx 4.5 3
Nominal Voltage: 48Vdc Current Consumption: 22A max Refrigerant Charge: 900gm R134a Oil: PAG32 grade 160ml Low Voltage Cut-out: 42Vdc auto reset after input voltage above 50Vdc Brushless Fan: 172mm x 51mm 240cfm(x6) 22W 0.46A@48Vdc System Fuse: 50A bolt-in fuse or circuit breaker (Recommended) Note: The unit is designed to be installed as a negative earth system. Failure to connect in this manner will cause possible electrical component failure. Specifications are subject to change without further notice. Please contact distributor or the manufacturer for further information. ECK4 DC VOLTAGE COOLING SYSTEM PERFORMANCE 4
Cooling Capacity BTU/hr Fig 1. Cooling Capacity Ambient Temperature C / F Nominal Input Voltage Vdc Duty Cycle RH % Ambient Air Temperature C Total Current Draw A 48 100% 60 35 20 48 100% 60 45 22 Fig 2. Current Consumption Ambient air Temperature C Enclosure Volume m³ Air Flow CFM Evaporator Set Point Temperature C Evaporator Coil Heat Yield C Outlet Vent Temperature C 35 6 410 6.5 7.0 3 14 35 6 300 6.5 7.0 3 12 Fig 3. Outlet Temperature ECK4 DC VOLTAGE COOLING SYSTEM PRE INSTALLATION 5
Check the RENCOOL ECK4-48 for any damage during transportation. Take note of the information provided on id plate located on the front cover. If the unit has been in a horizontal position during transit or storage, place in a vertical position for a minimum of 1 hour prior to operation. The unit has 2 condensation drain outlets on the base of unit. Care must be taken to avoid damage when placing unit on the ground or another surface. Unit must be mounted vertical. Outlet air aperture must be orientated to be at the top. 100mm clearance to ground level from base of unit required. Apply mounting template to enclosure and ensure there is sufficient surface area to mount unit. Use Sikaflex marine grade adhesive sealant around all cut-out. A minimum of 6 mounting holes in the side flanges must be used. We recommend the use of 8 to ensure a positive weather proof seal. Use stainless steel fasteners (grade 304 or 316) for unit mounting. Use 6 B&S cable size (168x0.32 strands) for B negative and B positive cables. Use a minimum of 2.5mm² (26x0.32 strands) for the B positive sense cable. Ensure correct input voltage and polarity from the power source. A battery storage device must be installed between the charging device and the RENCOOL ECK4-48 unit. 6
The RENCOOL ECK4-48 contains R134a refrigerant under high pressure. Tampering with the refrigerant circuit may cause injury to personnel and the release of refrigerant into the atmosphere which could contravene local and national regulations. ECK4 DC VOLTAGE COOLING SYSTEM MOUNTING TEMPLATE 50 585 115 810 50 585 60 200 200 478 370 190 370 160 430 160 1415 130 160 350 50 All 8 mounting holes in flange are 10mm 200 75 750 30 30 780 Fig 4. Mounting Template 7
Template is viewed as the mounting face of the RENCOOL ECK4-48. Please ensure correct orientation. Check all dimensions and marking out prior to any cutting of enclosure. All dimensions are in mm and are nominal. Shaded areas indicate material removal from enclosure. Drawing not to scale. ECK4 DC VOLTAGE COOLING SYSTEM INSTALLATION Read through all installation procedures first and have a sound understanding of the desired final result. Remove the recirculate/return air filter assembly from the unit. As this is a push in clip fit, removal can be done by hand. Remove the thermostat control knob. Remove the 2 x Phillips head screws holding the thermostat in place. This will allow removal of the bezel and release the thermostat. Gently level the rocker switches from the housing (use a small flat blade screwdriver). 8
On/Off Switch Fan Speed Switch Fig 5. Switchgear Removal Thermostat Remove dial for screw access Disconnect the terminal connectors from the rear of the switches. The connector with the 1 x pink and 1 x purple cable is for the Fan Speed Switch (fan blade insert). The connector with the 1 x red/white, 1 x red/black and 2 x red cable is for the ON/OFF Switch (snowflake insert). Using a spanner or socket undo the 2 x 10mm head dome nuts and slowly remove the internal air diffuser panel. The thermostat will remain connected to the unit (take care not to damage the capillary tube). Using template make required cut-out in enclosure to be installed with the RENCOOL ECK4-48. Calculate the required length of the main mounting bolts. You will need to include the enclosure material thickness and 2 flat washers (1 internal & 1 external) the fastening nut (nyloc nut) plus 10mm. ECK4 - DC VOLTAGE COOLING SYSTEM Apply Sikaflex marine grade adhesive/sealant around all cut-outs. Do not forget the main mounting bolt holes. 9
Attach unit to the enclosure using a minimum of 6 x bolt & nut with washers. The side mounting flanges have five available mounting holes on each side, to provide options to suit most likely applications. Ensure that the bolts & nuts are tensioned equally and no deformity is present between the unit and enclosure it is mounted to. Allow a suitable period for the sealant to cure prior to operating the RENCOOL ECK4-48 to provide a positive weather proof seal. The internal air diffuser and switchgear can now be re installed. As can be seen in Fig 6 there are 2 adjustment nuts (10mm head) on each side. These allow the stud to be extended to accept panel thickness of the enclosure up to 75mm. Please make sure the nut is securely locked once adjustment has been made. Fig 6. Air Diffuser Adjustment Nut Attach the thermostat and bezel first. The cables on the thermostat are 1 x red/black on terminal position P and 1 x pink (2 cables) on position 2. These are simple push on connectors. 10
Place the terminal connectors for the switches through the housing once air diffuser is in place..refer to previous section for correct connections. Connectors have a locking tab on one end only. Refit the recirculate/return air filter assembly (push in click fit). ECK4 DC VOLTAGE COOLING SYSTEM Remove the 24 x fasteners securing the outside perimeter of the cover plate and the 4 x lower fasteners on the grille. Refer to Fig 7. You will require a 5mm hex bit tool for removal (take care not to damage the underside gaskets). Remove 24 x cap head screws and washers from perimeter Only remove the lower 4 x cap head screws and washers from the grille Fig 7. Cover Plate Fastener Removal Locate the electrical connection studs (3 in total) in the drive unit compartment. There will be 1 x 8mm connection for B negative (black) and 1 x 8mm connection for B positive (red). Also present is 1 x 6mm connection for B positive sense. 11
Use crimped and soldered tube end eye lugs for termination. Do not over tension nuts on studs, they are brass and will shear if over stressed. Connect cables as per Fig 8. Taking care to observe polarity. B positive sense connection terminal 1 B negative connection terminal 3 Fig 8. Electrical Connection Stud B positive connection terminal 2 ECK4 DC VOLTAGE COOLING SYSTEM Pass 3 individual cables through the unit mounting face of the RENCOOL ECK4-48 via grommets to inside the enclosure. The B positive sense cable (from connection terminal 1) must be connected directly to the positive output of the power source. The B positive cable (from the connection terminal 2) must be connected via a circuit protection device of 50A rating, this can be either an AMI style bolt in fuse or circuit breaker. The B negative cable (from connection terminal 3) can now be connected to the negative output of the power source. It is recommended to use some form of cable conduit or protection suited to the application. 12
You may notice a slight current draw or flash when connecting the B negative terminal to the power source if the System On/Off switch is in the ON position. Simply turn the switch to the OFF position which is up. At this point all refrigerant and electrical connection procedures have been completed. A visual inspection of all rotating components and air intakes/outlets should be undertaken at this stage. Also check for any wiring disturbances during transit or installation procedure. Check that the 2 x drain valves are installed on the external underside of the unit. It is advised to leave the front cover off the unit until the unit has been verified as operational. Replace 28 x fasteners as removed with flat washers. A low torque tension is all that is required to maintain a positive seal of the gasket. ECK4 DC VOLTAGE COOLING SYSTEM OPERATION The unit is operated by an on/off two position rocker type switch. A fan speed two position rocker type switch. A thermostat 270 rotary style switch. There is also indirect control of the system via the B positive sense cable connected previously. 13
By depressing the [lower portion] on the on/off switch will cause the system to activate providing the applied voltage to the B positive connection terminal 1 is above 42Vdc. Once active the system will default to low evaporator fan speed. By rotating the thermostat dial in a [counter clockwise] direction sets a lower cut out temperature. By rotating the dial in a [clockwise] direction sets the thermostat at a higher cutout temperature. High evaporator fan speed can only be selected if the thermostat is in the run position. To select high evaporator fan speed, depress the [lower portion] of the fan speed switch. By depressing the [upper portion] low evaporator fan speed is selected, regardless of thermostat condition. The operation of the condenser fans are also in synchronisation with the thermostat operation. If the thermostat cycles out the condenser fans will shutdown. Once the thermostat returns to the run position the condenser fans will operate. The Drive system (DC motor and compressor) become operational once the system is active and the thermostat is in the run position. There is also a safety circuit to cut the power supply to the drive system if any one of the following conditions are observed: The DC motor overheats. The air conditioning compressor overheats The refrigerant pressure is either to high or to low. All these devices are automatic reset once they return to their operational state. When the system is active and the thermostat is in the run position and the high evaporator fan speed is selected. Once the thermostat cycles out the evaporator fan will return to the default low speed. When the thermostat cycles back in the evaporator fan will return to the selected high speed. The low voltage cut-out device obtains its signal from the B positive connection terminal 1. If this voltage falls below 42Vdc for duration of more than 20secs the entire system will shutdown, regardless of the switch position. The low voltage cut-out device will only re supply power to the system once the voltage at B positive connection terminal 1 rises above 50Vdc. 14
ECK4 DC VOLTAGE COOLING SYSTEM ELECTRICAL RS2 RS3 RS4 VC1 RS1 F 2 F 3 F 4 F 5 Fig 8. Control Enclosure Component Layout F1 30A AMI BOLT IN FUSE DC MOTOR LOCATED ON DRIVE BASE RS1 DC MOTOR OUTPUT RELAY 48Vdc F2 5A ATS BLADE STYLE CONTROL CIRCUIT SWITCHING RELAY COILS RS2 LO EVAPORATOR FAN SPEED 48Vdc F3 5A ATS BLADE STYLE CONDENSER FANS RS3 HI EVAPORATOR FAN SPEED 48Vdc F4 3A ATS BLADE STYLE EVAPORATOR FANS LO & HI SPEED RS4 CONDENSER FANS 48Vdc F5 1A ATS BLADE STYLE DRIVE UNIT AUX COOLING FAN VC1 LOW VOLTAGE CONTROL DEVICE 48Vdc Incorrect or substitution of fuse type and rating will cause possible electrical component failure and void warranty. 15
ECK4 DC VOLTAGE COOLING SYSTEM WARRANTY SCOPE OF WARRANTY RENCOOL will issue a limited warranty on the RENCOOL ECK4-48 for a period of 12 months from the date of purchase. Warranty covers all components and material/workmanship subject to the terms and exclusions herein described. Replacement and/or repair of components under a valid warranty claim does not result in an extension of the warranty period. Execution of warranty is to be made between the user and RENCOOL. TERMS AND EXCLUSIONS Any attempt to remove or modify the id plate will void warranty. The model and serial number is required prior to all warranty request numbers being issued. Warranty excludes components subject to the following: Normal operational wear. Modified or non genuine replacement parts. Adverse environmental exposure. Improper handling or storage. Incorrect installation and operation. Un-authorised repair. Removal of refrigerant service port anti tamper seals. 18
Contact the distributor for further information or specification. ECK4 DC VOLTAGE COOLING SYSTEM 16
User agrees to terms and exclusions of warranty upon receipt of unit. Refrigerant will not be offered as a replacement component. REPAIRS AND REPLACEMENT Any repairs or modification and replacement of components undertaken without a warranty request number as issued will void warranty. All replacement components must be original equipment or otherwise instructed in written form and stating manufacturer, model and part number. All transportation or shipping costs including storage and duties/taxes for replacement components are the responsibility of the user. All repairs and replacement of components must be undertaken by a suitably qualified technician. ECK4 DC VOLTAGE COOLING SYSTEM WARRANTY CLAIMS All claims made under the warranty must be accompanied by either a warranty request number or job number issued. All components replaced under warranty must be returned to validate said claim or photographic documentation of failure and component. *2 Labour charge rates will be subject to the schedule as defined 19
. *3 The refrigerant component replacement cost will be issued under a valid warranty claim with the exclusion of the following: Transportation or shipping cost including storage Any duties of fees imposed by local or national authority in the or disposal of R134a refrigerant. handling/storage and The issue of a warranty request number or job number does not indicate a valid warranty claim. *1 The user is defined as the person or company that is issued the bill of sale or invoice for the purchase of the RENCOOL ECK4-48 *2 We will not be held responsible for any incorrect consignment or non-arrival of components for warranty claim or for any cost involved with return *3 The schedule for labour charge rates is defined by the current rate of charge. Calculations will incorporate appropriate time periods for work procedures. DISCLAIMER It is the responsibility of the installer to ensure all safety function and protective measures of the equipment to which the RENCOOL ECK4-48 is being installed are not compromised and allowed to operate in accordance with the manufacturer s specification. It is the responsibility of the installer to ensure that the warranty of the equipment to which the RENCOOL ECK4-48 is installed will not be void or negated. We accept no liability for damage to equipment in which unit is installed. The unit is not designed as life supporting system and should never be used in this manner. We accept no liability in any injury or death to human or animal in the event of unit failure or during the course of normal operation. 20
ECK4 DC VOLTAGE COOLING SYSTEM 17