Chiller BOX Vari User manual

EN
Installation, Operation, and
Maintenance Manual
GRAND
Vari & Vari Pro
N02119031 Rev. A

Chiller Oy will not assume responsibility for any errors or shortcomings that may appear in this document.
The end user is responsible for ensuring that the unit operates appropriately and safely. Working with
electric components is subject to permission. Always abide by the existing national legislation, regulations
and standards.
Chiller Oy is constantly developing its products and reserves the right to change its products.
GRAND Vari™ is a registered trademark of Chiller Oy.
All rights reserved © Chiller Oy 2020.
Chiller Oy
Address: Louhostie 2, FI-04300 Tuusula
Finland
Telephone: [phone]
E-mail: [e-mail]
Internet: www.chiller.eu
Approvals and version history
REVISION DATE DESCRIPTION
OF CHANGE
APPROVED BY
A 25.05.2020 First issue MH
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

Contents
1 General ............................................................................................................4
1.1 About this manual.....................................................................................4
1.2 Guarantee................................................................................................4
1.3 Inspection of the unit.................................................................................4
1.4 Related documentation .............................................................................5
2 Safety...............................................................................................................6
2.1 General safety instructions ........................................................................6
2.2 Safety-related signs ..................................................................................6
2.3 Safety symbols.........................................................................................6
3 Unit overview ...................................................................................................8
3.1 Introduction of the unit...............................................................................8
3.2 Unit dimensions........................................................................................9
3.3 Type plate ..............................................................................................10
3.4 Automation options and control connections ............................................. 11
3.4.1 Vari-option ................................................................................12
3.4.2 Vari Pro-option ..........................................................................13
4 Installation of the unit.....................................................................................14
4.1 General installation instructions ...............................................................14
4.2 Choosing the installation site ...................................................................14
4.3 Removing the air duct collar ....................................................................16
4.4 Mounting the unit ....................................................................................17
4.5 Attaching the water connections ..............................................................20
4.6 Installing sewerage for condensation water...............................................21
4.6.1 Sewerage without condensation water pump ...............................21
4.6.2 Sewerage with condensation water pump (option) .......................22
4.7 Attaching the electrical connections .........................................................25
4.8 Installing the external drain pan ...............................................................26
4.9 Installing the fresh air connection .............................................................27
4.10 Installing the grille...................................................................................27
4.11 Testing the condensation water pump.......................................................28
5 Operation of the unit ......................................................................................30
5.1 Controlling the unit..................................................................................30
6 Maintenance of the unit..................................................................................31
6.1 Maintenance schedule ............................................................................31
6.2 Cleaning the grille...................................................................................31
6.3 Removing the filter..................................................................................32
6.4 Cleaning and replacing the filter ...............................................................33
6.5 Opening the maintenance hatch ..............................................................34
6.6 Cleaning the condensation water basin ....................................................35
APPENDIX A: Vari-option control connections ...................................................38
APPENDIX B: Register listing for Vari Pro-option ...............................................40
APPENDIX C: Register listing for unit with Vari Pro room controller...................42
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

1 General
1.1 About this manual
This Installation, Operation, and Maintenance Manual has been prepared as
general instructions for appropriate installation, operation, and maintenance
procedures. When operating the unit, always follow the precautionary
instructions related to each component as well as the regulations and
recommendations given by the local authorities.
The unit must be installed, operated, and maintained by a professional and in
such a way that it does not cause danger to humans, the environment, or the
unit itself. The unit must not be used for other than its intended purposes without
a written consent from the manufacturer.
NOTICE
Before you start to install, operate, or maintain the system, read this manual
carefully and familiarize yourself with all of the instructions.
Keep the manual for later reference.
1.2 Guarantee
The guarantee for this unit is based on Chiller Oy’s terms of guarantee.
The guarantee becomes void, if:
•the product is modified or repaired without a written consent from Chiller Oy
•the unit parameters are modified without permission
•the configuration of the unit is changed
•the installation site, unit connections, installation ground, or installation
procedures do not follow these instructions
•the instructions in this Installation, Operation, and Maintenance Manual are
not followed.
The guarantee does not cover damages, if:
•the user does not follow the manufacturer’s instructions
•the unit is used in a way that it is not designed for and that causes damage to
the unit
•the unit is not maintained according to the schedule and instructions in this
manual.
Note! Warranty claims are processed only, if the complete type and serial numbers
of the unit (see Section 3.3 Type plate) are notified to the manufacturer in written
form.
1.3 Inspection of the unit
The units are shipped from the factory as assembled (apart from some
accessories), wired, and tested. In some unit models, part of the grille is shipped
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

in a separate package for mounting onto the lower surface of the lowered ceiling
after installation.
When you receive the unit:
1. Inspect the delivery against the order.
2. Verify that the contents of the delivery meet the order.
3. Inspect all the delivered units carefully.
a. If the units have transport damages, notify the expeditor and the seller of
them.
b. Record the transport damages on the bill of freight.
c. Send a complaint about the damages to the transport company within 24
hours of delivery.
1.4 Related documentation
In addition to this manual, the unit is delivered with a unit-specific wiring
diagram.
In case you need a new wiring diagram, you can order it. You need the unit
serial number from the type plate for the order (see Section 3.3 Type plate).
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

2 Safety
2.1 General safety instructions
This unit is designed so that it does not expose people to hazard or risk,
provided that:
•The unit is installed, operated, and maintained according to the instructions
in this manual.
•No structural changes are made to the unit.
2.2 Safety-related signs
These are the safety-related signs used in this manual.
DANGER
DANGER indicates a hazard with a high level of risk which, if not avoided,
will result in death or serious injury.
WARNING
WARNING indicates a hazard with a medium level of risk which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a hazard with a low level of risk which, if not avoided,
could result in minor or moderate injury.
Note! Notes are used to indicate important information and useful tips.
2.3 Safety symbols
Hazard symbols
These symbols indicate a hazardous situation or action. Symbols are used to
warn of situations, which can cause environmental damage and personal injury.
General warning sign
Electrical hazard
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Prohibited action symbols
These symbols are used in warnings and notifications to indicate an action that
should not be taken. The prohibited action symbols are shown below.
Limited or restricted access
Do not touch
Mandatory action symbols
These symbols are used in warnings and notifications to indicate an action that
must be taken. The mandatory action symbols are shown below.
Read the manual or instructions
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

3 Unit overview
3.1 Introduction of the unit
The Grand fan coil unit is designed for room air conditioning, and it is equipped
with a fresh air connection. The unit is available in two sizes, Grand 70 and
Grand 100. The unit is also available with two automation options, Vari and Vari
Pro.
Figure 1: Overview of the unit
1. Coil and fan (inside unit)
2. Water connections
3. External drain pan
4. Free drain outlet (option, if the unit is without condensate pump)
5. Condensate pump outlet (option)
6. Electrical box
7. Fresh air connection, Ø 125 mm
8. Collar
9. Maintenance hatch
10. Grille
The unit directs air to the room from the upper side of the grille (blue arrow), and
returns the air back to the unit from the bottom side (red arrow). There is a
separator plate inside the unit that separates the air flow.
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

Figure 2: Air flow directions
CAUTION
Do not remove the separator plate at any time. If you remove the plate, the
unit does not function properly and the air does not flow correctly. For more
information, see Section 4.4 Mounting the unit.
3.2 Unit dimensions
The unit comes in two sizes, Grand 70 and Grand 100.
Note! The unit dimensions are given as reference. Chiller Oy reserves the right to
make changes to them. Check the actual dimensions from the order
documentation.
Figure 3: Main dimensions of Grand 70
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Figure 4: Main dimensions of Grand 100
3.3 Type plate
One type plate is located in the inlet opening and another one is located next to
the electrical box in the rear of the unit. The type plate in the inlet opening is
visible when you remove the intake grille and filter.
Note! Record the type plate information on the unit card and file it carefully. The
type and serial numbers of the unit are required for identifying the unit when, for
instance, purchasing spare parts.
When you order maintenance or order spare parts, you always need the serial
number. You cannot make an order without the serial number.
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

The type plate specifies the following information about the unit:
TYPE Unit type Including accessories
(18 characters consisting of
letters and numbers)
SER.NR. Unit serial number Seven (7) number
combination
POWER Power type 230 VAC, 50 Hz
INPUT Electrical information Input power W and current
A, max. values*:
GRAND 70 / 73 W, 0.76 A
GRAND 100 / 78 W, 0.76 A
MANUF.DATE Date of manufacture
*The actual input power of the unit is usually below the max. value. For
specific information, please contact your nearest reseller.
Figure 5: Example of the type plate
3.4 Automation options and control
connections
The unit is available with two automation options referred to as Vari and Vari
Pro. The automation option is selected during the unit order. Once the unit is
delivered, you can see the automation type on the type plate (“Type”, unit type is
either Vari or Vari Pro). The automation option of the unit affects the way the fan
coil is controlled and what external equipment can be connected to the unit.
Note! Perform all electrical connections always according to the wiring diagrams
supplied with the unit delivery.
Note! When connecting the alarm signal to the BMS, add a 30 s filter time to alarm
management.
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

3.4.1 Vari-option
The automation option Vari has the following properties:
•Analogue control (0-10 V and 24 V AC/DC for on/off on all inputs)
•Suitable for analogue control from building automation or traditional room
controller
•Potential free alarm contact, open in alarm or when unit not powered
•No additional sensor inputs or control outputs.
See Appendix A Vari-option control connections for further details.
Figure 6: Vari control card
Figure 7: Vari wiring instructions on the electrical box cover
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

3.4.2 Vari Pro-option
The automation option Vari Pro has the following properties:
•Control with the Vari Pro graphical room controller or directly by Modbus RTU
from building management system
•1 analogue sensor input (defined during unit order process)
•1 digital control output (defined during unit order process)
•No analogue control options.
Note! Vari Pro has advanced timed functions, such as valve exercise every 24
hours. The unit will resume normal operation after the timed function has ended.
See Appendix B Register listing for Vari Pro-option for further details.
Figure 8: Vari Pro control card
Figure 9: Vari Pro wiring instructions on the electrical box cover
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

4 Installation of the unit
4.1 General installation instructions
CAUTION
Only professionally skilled and qualified personnel can install the unit.
Note! Always follow local safety regulations when you install, operate, and maintain
the unit.
Read these instructions carefully before installing the unit.
When you install the unit, make sure that
•the unit is mounted to the ceiling firmly and that it does not cause danger or
harm to any person, object, structure, or equipment.
•all instructions given by the manufacturer and seller are followed.
•installation, lifting, and moving the unit is performed carefully.
•fire safety and the availability of fire equipment is ensured when performing
welding or soldering operations.
Note! The manufacturer is not accountable for installations that have not been
performed according to the installation instructions, or for using the unit in
conditions that differ from those specified in Section 4.2 Choosing the installation site.
The installation concept "Install, Use, Maintain" is applied with this unit.
The installation order of this concept is:
•installation on the ceiling
•pipe connections
•electrical connections
•external drain pan
•grille
•testing and commissioning of the unit.
Note! Do not remove any of the coverings that protect the unit openings before the
installation is complete and all dust has been cleared.
4.2 Choosing the installation site
When you choose the installation site for the unit, make sure that you leave
enough space around the unit for maintenance work. You can see the
dimensional requirements for the service area in Figure 10: Service area
requirements. Make also sure that there is a maintenance hatch in the
underside of the false ceiling. The recommended minimum size is 600 mm x
width of the unit (700/1000 mm).
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

Figure 10: Service area requirements
Note! Always take local safety regulations and installation requirements into
account when choosing the installation site and before starting the installation.
Take also the following matters into consideration, when choosing the
installation site:
•the requirements for the service room and the safety requirements for the
unit and its accessories must be complied with.
•the installed unit must stand in a level position.
•the unit must not be installed above any other units or equipment.
•the unit must not be installed in a room that has flammable or explosive
substances or has airborne substances that corrode PVC plastics, EPS
plastics, ABS plastics, copper, or aluminium.
•the unit must be installed in the room so that it allows free air circulation in
the unit.
•the unit must not be installed in a room where recirculation air can bring such
substances to the inlet opening of the unit that block air circulation (for
instance greases from the kitchen).
•the installation and maintenance room required for electrical installations,
pipe-laying, and installation of sewerage for condensation water.
Table 1: Limitations for the GRAND installation site
Temperatures Min. Max.
Indoor air 5 °C (A) 26.5 °C / 50% Rh
Water 4 °C (B) 80 °C (C)
Ethyl alcohol (35%) 4 °C 80 °C
Ethylene glycol (35%) 4 °C 80 °C
Propylene glycol (35%) 4 °C 80 °C
Notes.
AIf the room temperature is below 0 °C, the unit must be drained of water and the
condensation water must be removed.
BFor lower temperatures, using anti-freeze agent is imperative.
CThe maximum water pressure is 1000 kPa/10 bar.
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

Figure 11: Dimensions for installation, front view
Figure 12: Dimensions for installation, side view
See the accurate dimensions for the openings from Figure 13: Dimensions for
the installation openings.
Figure 13: Dimensions for the installation openings
A B C D E
Grand
Vari 70
665 ± 5 mm 180 ± 5 mm 720 mm 600 mm 433-483 mm
Grand
Vari 100
990 ± 5 mm 180 ± 5 mm 1020 mm 600 mm 433-483 mm
4.3 Removing the air duct collar
If the unit is delivered with the air duct installed, the air duct collar must be removed
before mounting the unit to the ceiling.
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

1. Open the screws of the air duct collar.
2. Remove the collar.
4.4 Mounting the unit
The unit is mounted on the ceiling from four (4) mounting points. The mounting points
are integrated in the unit frame.
DANGER
Risk of severe injury. Make sure you attach the unit firmly to the ceiling. If the
unit is not properly attached, it can fall and cause severe injury.
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

1. Install the unit to the ceiling from the four (4) mounting points.
2. Use supports to mount the unit to the ceiling. Make sure that you use
supports that are suitable for the installation site and the ceiling material.
Note! The supports must be strong enough for the max. weight (56 kg) of the unit.
Note! Do not hoist the unit from pipe joints, valves, or the condensation water basin.
You can hoist the unit on the ceiling by using a drywall panel lift, or similar.
WARNING
Use a hoist that is rated to handle the weight of the unit.
a. If you use threaded bars for supporting the unit, you must secure the joint
between the threaded bar and the support with locknuts and washers.
b. Make sure that the bars are attached tightly to the ceiling and they do not
come off.
3. Make sure that the distance between the unit and the ceiling is at least 30
mm.
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

4. After you have mounted the unit to the ceiling, use a spirit level to make sure
that the unit is horizontally leveled.
CAUTION
The unit must be leveled. If the unit is not leveled properly, the condensation
water will run in a wrong way and this can damage the unit or surroundings.
5. Make also sure that the separator plate is horizontally levelled.
CAUTION
The separator plate must be horizontally leveled. If the plate is not leveled,
the air does not circulate properly in the unit and the unit does not function
as intended.
6. Install the accessories (control valves, shut-off valves, external drain pan
etc.), if they are delivered as separate items.
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual

4.5 Attaching the water connections
The unit is intended to be connected to a cooling and/or heating water circulation that
cannot damage the heat exchanger. More detailed information on water connections
are specified separately for each order, depending on the accessories selected.
Note! Connecting the unit to the water circuit causes pressure losses. For
information on unit type-specific pressure losses in the water circuit, please contact
the manufacturer.
1. Before you connect the unit to a cooling and/or heating water circulation,
make sure that the water in the water circuit has
a. a maximum operation pressure of 10 bar
b. a minimum temperature of +4 °C (inlet water)
Note! Water must never be allowed to freeze inside the coil, condensate basin, or
piping of the unit.
c. a maximum temperature of +80 °C (inlet water).
2. Attach the water connections as shown below.
1Heating water inlet 5Heating water outlet
2Cooling water inlet 6Cooling water outlet
3Air-vent
4Condensate outlet (with optional condensate water pump only)
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N02119031 Rev. A GRAND Vari & Vari Pro – Installation, Operation, and Maintenance Manual