Aircalo CASSETTE BALI Manual

INSTALLATION AND
MAINTENANCE
MANUAL
CASSETTE
BALI

1
1.GENERALITES .............................................................................................................................................. 1
2.PRESENTATION ........................................................................................................................................... 3
3.INSTALLATION ............................................................................................................................................. 3
Choice of the place ............................................................................................................................................ 3
Implantation ........................................................................................................................................................ 3
Reception – Storage .......................................................................................................................................... 3
Fixation .............................................................................................................................................................. 3
Condensate drain .............................................................................................................................................. 7
4.FRESH AIR CONNECTIONS ....................................................................................................................... 8
5.HYDRAULIC CONNECTIONS ...................................................................................................................... 9
Instructions ......................................................................................................................................................... 9
Control valves .................................................................................................................................................... 9
External Drain Pan ............................................................................................................................................ 11
6.ELECTRIC CONNECTIONS ........................................................................................................................ 12
Motor power ...................................................................................................................................................... 12
Electric power auxiliary heating resistor ........................................................................................................... 12
Electrical connections (4 Pipes) ........................................................................................................................ 13
Electrical connections (2 Pipes + Electrical heater) .......................................................................................... 14
7.BOX CONTROL ......................................................................................................................................... 195
Description ........................................................................................................................................................ 15
Control logic ...................................................................................................................................................... 16
8. LED INDICATION AND ERROR DESCRIPTION ....................................................................................... 17
9.SPEED CONTROL BOX .............................................................................................................................. 18
10.DIMENSIONS AND WEIGHT ...................................................................................................................... 19
11.START-UP ................................................................................................................................................... 21
12.MAINTENANCE ......................................................................................................................................... 262
Removing the internal components .................................................................................................................. 22
Fan motor replacement .................................................................................................................................... 23
Replacement control box .................................................................................................................................. 23
Condensate pump replacement ........................................................................................................................ 24
Replacing electrical resistance ......................................................................................................................... 25
Long shutdown periods ..................................................................................................................................... 25
User guide ........................................................................................................................................................ 25
13.SPARE PARTS .......................................................................................................................................... 266
To get all the air flow and acoustic performances, refer to the general catalogue and/or the BALI datasheet
(available on www.aircalo.fr)

2
1. GENERALITES
CAUTION: before any intervention on the system and before handling any intern component, cut the power of the
main circuit-breaker.
Read attentively this manual before starting the installation
The unit is in conformity with the Low Voltage Directive (CEE/73/23) and electromagnetic compatibility
(CEE/89/336).
Confide the installation to a qualified installer.
The maintenance must be made only by qualified personnel.
Respect safety requirements of national standards. In particular, check that you dispose of a connection
on the ground with an adequate size.
Check that the tension and the frequency of the power supply is like the ones necessary at the unit
which will be installed.
Eventually, take into account of others devices connected up at the same electric circuit.
Make sure that the safety requirements of national standards have been respected over the power
supply circuit
Use this unit only as a part of registered applications: they do not have to be used in a laundry room or
any other local with steam ironing.
It should be avoiding the use of Cassettes in an atmosphere that contains oil vapors or corrosive.
It is recommended to disinfect once by year, condensate drain pan to avoid the development and
spreading of legionella.
Keep the device away from frost.
Do not install or use damaged devices.
The manufacturer declines any responsibility for damage caused by the modification or mistake in
electric connections or hydraulic connections.
Failing to follow the electric security rules can cause a risk of fire in the case of an electric short.
In case of an unusual functioning, turn off the unit, remove the electricity supply and contact specialized
personnel.
Unless particular conditions, Aircalo gives one year parts warranty against defects in conception or
production. Are excluded defects of installation and use and also wearing parts and environment
condition which damage the smooth functioning of the device that would have not be specified in the
order.
Failing to follow the manufacturer instructions concerning the installation or the use of the unit in
conditions that exceed functioning limits indicated in this manual can lead to the loss of the unit warranty.

3
2. PRESENTATION
Bali cassettes are equipped with EC fans. They are available in section:
- 600 x 600 mm
- 900 x 900 mm
3. INSTALLATION
Choice of the place
Avoid the following locations:
Exposure to sunbeam
Areas near sources of heat.
Humid locations and places where water may penetrate into the unit.
Places where curtains or furniture can disturb a good circulation of the air.
Location advised:
A place without obstacle that can cause an unequal distribution or return of the air.
Consider a location where the installation will be easier.
Allow required clearances.
Look for a place into the room that will guarantee a good distribution of the air.
It could be easier to connect condensate drain pipe through the appropriated pipework.
Implantation
It is recommended to position the unit in the center of the room to ensure a good air distribution.
Caution: the power capacity of installed units must be defined following the thermal balance and the
acoustic of the locals.
Check that the panels from the false ceiling can be dismounted in order to get enough space for
maintenance. All of the hydraulic and electric arrangements are put on a same lateral face.
Do not put the Cassettes on false ceilings which are not horizontals (because it caused water runoff).
Reception - Storage
Check the conformity of goods delivered according to the order. Read and control the instructions given
by the identification plate.
In the case of lack or damages, it must be done reserves on the delivery bill to the carrier. Then, confirm
this with a registered letter over 48 hours.
Storage the equipment in a clean, dry place, protected from shocks, vibration and temperature
fluctuation and at a relative humidity level of less than 90%. The period of storage should not exceed 1
year.
Proceed with the unpacking of the device using the protections of accident prevention which are
required. Recycle packaging in accordance with local laws regarding waste.
It is recommended to bring the unit as close as possible to its definitive location before to unpack it.

4
Fitting
Standard units
Use a lift truck to facilitate the installation of the ceiling unit.
To avoid damaging the slab, disassemble and store waiting for the end of the installation:
- Remove the intake grille.
- Remove the screws of the slab.
- Remove the panel of the unit.
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• Fit the 4 tie rods (recommended diameter M8) ceiling following the spacings of the cassette mounting ears to
rise. (The ears are formed with oblong holes to permit a final adjustment.)
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485× 863: Suspension Bolts
850× 850: Dimensions for opening
280 x 622: Suspension Bolts
600 x 600 : Dimensions for opening
BALI 60 BALI 90

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Counternut
Washer
NUT
Rod
Nut
50
Suspension Structure
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Mark the position of the suspension rods, water lines, condensate drain pipe, power supply cables and
remote control cable.
Supporting rods can be fixed, depending on the type of ceiling.
Fit suspension brackets supplied with the unit to the threaded rods.
Do not tighten nuts and counter nuts; this should only be done after the final leveling of the unit when all
the connections have been completed.
Ensure the ceiling is horizontally level, otherwise the condensate water cannot drain away.
The casing is fixed to the slab with 4 drop rods. The rods should have two nuts and washers to lock the
unit in position. The cassette brackets will then hook over the washers.
Take care when lifting the cassette into position. Don’t lift the unit by the drip tray.
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Fixingoncementceiling
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Exampleofwoodenframe
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Installation Procedure

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Ensure there is sufficient space around the unit to service it.
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Lift unit (without the air panel) with care by its four corners only. Do not lift unit by the condensate drain
discharge pipe or by the piping connections.
Incline the unit and insert it into the false ceiling. Insert the rods into the bracket slot. It might be
necessary to remove some T bars of the false ceiling temporarily to ensure there is enough clearance.
Using a level guide, line up the unit with a spirit level to ensure an even distance between the body of the
unit and the lower part of the false ceiling (see figure next).
Line up the unit to the supporting bars of the false ceiling, tightening the nuts and counter nuts of the
threaded rods.
After connecting of the condensate drain piping and piping connections, check again that the unit is
level.
The spaces between the unit and ceiling can now be adjusted. Use the drop rods to make the
adjustment.
Check to ensure the unit is level.
Tighten the nuts on the suspended rods.
Replace the profile "T" previously removed (false ceiling rails).
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Rod
T bar

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BA
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Condensate drain
The drain pipe has to be covered with an insulating material such as Polyurethane, Protylène or
Neoprene, with a thickness of 5 to 10 mm.
The unit is fitted with a condensate pump with a 500 mm. lift.
The unit is provided with 25.4mm drainage head made of ABS.
Before connecting polyvinyl tube with an inner diameter of 26 mm, check if the drainage head is in good
condition.
Fit drainage head into polyvinyl tube with a hose clip.
The drain must be installed with a downward slope.
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If multiple units, the figure indicates the discharge device to perform:
The condensate drain pipe must be installed with a minimum continuous slope of 2%. Connection to the
mains drainage must be sized with a siphon depending on the discharge pressure of the unit to allow for
sufficient water drainage and continuous.
After installation, put water into the auxiliary condensate tray to check leaks.
(mm)AB
Bali60/9029010ouplus

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4. FRESH AIR CONNECTION
The fresh air system for cassette units allows up to 15% of unit airflow to be fresh air intake (per connection).
Maximum 2 fresh air connections per unit are allowed.
The corners of the cassette allow separate ductwork to be installed for outside air intake (Figure 10)
Cut and remove thermal insulating material.
Open the mounting plate (Figure 11 and Figure 12)
Install the flanges to casing and attach with 2 screws. The flange is a rectangular duct with the
dimensions of 110 x 55mm.
It is necessary to control the fresh air supply >70 Pa.
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Figure10
Figure11Figure12 Figure13
Figure14Figure15

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5. HYDRAULIC CONNECTIONS
Instructions
Operating limit:
Maximum allowable pressure 140 MCE
Min ambient air temperature 5 °C, max 32 °C
Minimum water temperature 2 °C, max 80 °C
Temperature blowing max 60 °C
Respect the inlet and outlet water coil as shown on the labels on
the unit.
For cassettes 4 pipes be sure to connect the chilled water circuit to
the coil specified "cooling" and the hot water circuit to the coil
mentioned "heating".
The tightening torque to be used for water connections is 25 Nm. It
is advisable to tighten with a wrench.
Fully drain the coil, using traps accessible by removing the filter
panel.
To make draining the unit if necessary, cut the electrical supply and
the water supply to the unit. Loosen the bleed screw to release pressure in the coil. Partially unscrew the
lower manifold piping or valve. The water flow can be exhausted via the auxiliary drain pan if it has been
installed correctly and its operation has been tested beforehand.
Note that the coil is partially drainable; for a complete discharge, it is necessary to blow air under
pressure into the coil.
It is recommended to do the connections to the coil with insulated flexible pipes. For connection with
steel pipes ensure they are alined and suspended to not make mechanical stress on the unit.
When the connections are completed, it is necessary to surround the valves and piping with insulating
materials such as polyethylene foam having a thickness of 5 to 10 mm.
Check all joints of the fittings when the system is filled with water.
The manufacturer can not guarantee the quality of the seals provided by the installer.
It assumes no responsibility for any dysfunction of the sets and damage that would result from leaks.
Size BALI 60 BALI 90
Principal coil 3/4" Female gas 3/4" Female gas
Auxiliary coil 1 row 3/4" Female gas 3/4" Female gas

10
Control valves
Standard valves are mounted by the installer. Mounting the motorized control valves can be part of our
optional supply. Actuated valves are intended to be supplied with 230 V, average consumption 5 VA.
The valves are of the type 2-way or 3-way with bypass.
The valves must close the water inlet when there is no power.
Before connecting, check the position of the electro valve: Normally closed on the coil side and Open on
bypass side.
When the ambient temperature does not satisfy the thermostat, electrical resistance causes the heating
of a thermostatic heating element which determines the descent of the piston; the valve gradually opens
to circulate the water in the coil.
When the room temperature reaches the level required by the thermostat or when the power is off, the
valve is gradually closed from the coil side and open on the bypass side.
Insulate carefully pipes, valve assembly, coil connections (cold side) to prevent condensation that may
form dripping onto the ceiling.
It is recommended to organize the regulation so that valves can not open if the fan motor is not working.
2‐Pipesystems:4‐Pipesystems:
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Once valves are fitted, make the electrical connection with the connectors. For 4-pipes wire marked
"valve heating" must be connected to the valve motor of the heating coil and the wire marked "cooling
valve" must be connected to the valve motor of the cold coil.

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External Drain Pan
Instructions:
Align the two screw holes in the fixing plate to the two holes in the external drain pan. (Figure 8)
Make sure the drain pan is horizontal.
Tighten the two screws while making sure the external drain pan is installed evenly against the fixing
plate. (Figure 9)
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Figure8
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Figure9
Auxiliary condensate tank
Auxiliary condensate tank
Auxiliary condensate tank

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6. ELECTRIC CONNECTIONS
The electrical installation of a device must comply with the installation rules in force and carried out by
qualified personnel according to the diagrams attached end of document.
The supply voltage is 230 V single-phase + earth (operation mini 198 V ; Max: 264 V).
Make the connection of earth before any other connection.
Check that the power supply is done through a switch that disconnects all poles, keeping a distance of at
least 3 mm between the contacts.
Caution : Electrical regulation requires that any installation of rotating equipment should have an effective
protection from all points of view. In this context, the guarantees issued by the Union of Electrical Construction
does not apply to motors whose winding is "burnt".
The warranty is void in case of changes in wiring and factory settings.
All electrical connections should be made on the terminal block on the same side as easements of the
unit.
An electrical box must control each device. In the case of multiple devices controlled by a single
thermostat, it is necessary to provide an electrical relay system.
We recommend the use of electric supply cable from the unit HO7 RN-F type. The section of the wire
connections must be defined in terms of power absorbed (below) and cable lengths to put depending of
the geometry of the premises.
Motor power
Electric power auxiliary heating resistors
Power BALI 60 BALI 90
2000 W 4.40 (A) -
4000 W - 8.80 (A)
Note : A reset safety thermostat is integrated into the control box.
Caution :
Post-ventilation: It is necessary to provide a delay of forced operation of the fan motor after stopping the
electric coil to ensure dissipation of residual energy on resistance. Post-ventilation time 45 seconds.
Non-observance of this control can result in damage to the unit or the environment.
During operation of the electric coil, a power cut can cause tripping of the safety thermostat.
The operation of electrical heaters is prohibited when the main battery is supplied with hot water.
If the airflow is not sufficient, the electrical coil will not start. The minimum speed for continuous
operation of the electrical resistances is 300 RPM.
BALI 60 BALI 90
Input power (W) 80 362
Intensity (A) 0.35 1.57

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Electrical connection – type 3 fan speeds – 4 Pipes
(for auto-speed 0 – 10V – refer to regulator technical leaflet).

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Electrical connection – type 3 fan speeds – 2 Pipes + Electrical Heater
(for auto-speed 0 – 10V – refer to regulator technical leaflet).

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7. BOX CONTROL
Description
Condensate management with valve protection and NC alarm contact.
Integrated fan relays for zone control applications.
ON/OFF thermostat input and low-voltage modulating fan speed input flexibility.
Simple error diagnostic and LED error display.
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I/O Port Definitions
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I/OCode2‐Pipe4‐Pipe
AnalogueinputCoiltemperaturesensor AI1Cooling/heatingcoilsensor
(Ti1)Analogueinput
Voltageinput
HighfanspeedH
230VACinputsignalsfromwiredthermostat
MediumfanspeedM
LowfanspeedL
PhaseL
External230VACpowersupplyconnectiontothePCB.
Maxlength:5m.
NeutralN
EarthGND
AutoON/OFFAUTO230VACinputsignalfromwiredthermostat,activates
modulatingcontrolmode
SignalInputModulatingsignal+/‐ Lowvoltagemodulatingsignalinput(standard0~10VDC;
optional0~5VDC)
Digitalinput
ProgramminginterfaceTTLLowvoltagedigitalsignalinputforboardprogramming
FloatswitchFloatVoltage‐free(NC)
Voltageoutput
WaterpumpWPVoltageoutput(L)
ECmotorCN45‐wireconnectionwith230VACpowersupplytoEC
motorand0~10VDCmodulatingsignaloutput
SteppingmotorCN1‐2Low‐voltageoutput
DigitaloutputLEDdisplayX‐DISLow‐voltageoutput
Voltage‐freeoutputAlarm
Voltage‐freealarmcontact:
(a)Standardconfigurationis(NC).
Onboard Configuration
The PCB can be configured for different modulating signal inputs. Refer to jumper configuration table below.
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CodeStateDescription
S1OpenPCBconfiguredfor0~5VDCmodulatingsignalinput.
S1ClosedPCBconfiguredfor0~10VDCmodulatingsignalinput (standard)
S3N/AReserved
S4N/AReserved

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Control Logic
Unit Power ON/OFF
The unit is turned ON when:
-One of the fan speed inputs (H/M/L) is ON
- ON/OFF signal input is ON.
The unit is turned OFF only if all of the fan speed inputs (H/M/L) are OFF AND Auto ON/OFF signal input
is OFF.
Alarm Protection and Error Display
If the float switch is open for 5 minutes, then the (NC) voltage-free alarm contact shall be open and the
(NO) voltage free alarm contact shall be closed.
If the float switch is open for 10 minutes, the LED display reports a condensate management failure (see
table on the next page).
Drain-Pump Run Management
When the unit turns ON:
-If Ti1 < 15 ºC, the drain pump turns ON.
-If Ti1 ≥ 15 ºC, the drain pump turns OFF.
When the unit turns OFF and the drain pump is ON: the drain pump will remain ON for 5 minutes, before the drain
pump turns OFF.
At any time:
-If the float switch is OPEN, the drain pump will turn ON.
-If the float switch is OPEN and then CLOSES, the drain pump will remain ON for 5 minutes, and then
turn OFF.
Swing and Louver Control
When the unit is OFF, the louvers are closed (angle at 100º against vertical).
When the unit turns ON, the louvers open (angle at 87º against the horizontal).
When the unit turns OFF, the louvers returns to a closed position (100º against the vertical).
Modulating Signal Input
When the “Auto ON/OFF” 230VAC input is ON, the fan motor rpm speed shall be modulated by the “+/-”
low voltage modulating signal input.
The standard configuration is for 0~10VDC modulating signal input.
The optional configuration is for 0~5VDC modulating signal. To set the PCB to the optional configuration,
the S1 jumper must be closed.

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8. LED INDICATION AND ERROR DESCRIPTION
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SK‐NCGH‐002/003‐ECM
FanspeedsettingLEDindicationCondition
HighspeedREDLEDONNormal
MediumspeedYELLOWLEDONNormal
LowspeedGREENLEDONNormal
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Forallunits‐GreenLEDblinks
ItemItemItemItem
Indoorcoilsensor1failureGreenLEDblinks4times,
stopsfor3s
Ti1sensorunpluggedor
damaged.
1. CheckifTi1plugis
connectedornot.
2. Checkifsensor’sresistance
iscorrectornot.
WaterpumpfailureGreenLEDblinks7times,
stopsfor3sFloatswitchisopened.
1. Checkifthecondensate
waterpipeisconnectedor
not.
2. Checkifthepumpis
functioningornot.
ECmotorfailureGreenLEDblinks9times,
stopsfor3sNoECmotorfeedback
1. CheckDIPB‐SW5andSW6
setting.
2. ChecktheECmotor.

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9. SPEED CONTROL BOX
Bali cassettes come with 3 fan speeds (Low / Medium / High) factory set. With the speed control box (accessory
optional) it is possible to change the fan speed ventilation, especially if the sound level is estimated excessive by
the user. Procedure:
1) Turn OFF the unit.
2) Open speed control box’s back cover, where two DIP switches can be seen.
3) Turn the DIP switch 1 to “ON” position.
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4) Wired speed control box LCD will display the following;
5) The box shows :
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Table for RPM setting for EC fans:
ModelHighMedium Low
BALI60800560 250
BALI90930650 400
Air flow/Voltage for EC fans
BALI 60 BALI 90
Air flow
(m3/h)
Voltage
(V)
Power
abs. (W)
Speed
RPM Air flow (m3/h)
Voltage
(V)
Power
abs. (W)
Speed
RPM
160 2.97 6.6 180 1.55 7.6
210 3.96 10.0 240 2.08 10.7
255 4.81 14.4 440 3.81 23.0
340 6.31 28.4 580 5.0 39.2
375 6.91 36.9 705 6.07 63.7
ThisisthemotorRPMsetting.
PressTEMP.+/‐buttontoincreasetheRPMsettingby
10RPMstep.
Thisisthespeedlevelsetting.
d0meanslowspeed
d1meansmediumspeed
d2meanshighspeed
PressPARAMETER+/‐buttontoselect.

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10. DIMENSIONS AND WEIGHT
BALI 60
BALI 60 = 32 kg net