oxycom IntrCooll Std. User manual

IntrCooll Std. / Plus
Direct / Indirect evaporative cooler
Manual
Installation
Version: Version 1.3
Date: 14/12/2021

Table of contents
Preface 5
Warranty 5
Product liability 5
Compliance 6
Contact data 6
About this manual 7
Scope of this manual 7
Audience 7
Typographical conventions 8
Availability 9
Related documents 9
1 Safety 11
1.1 General (safety) 11
2 Handling and storage 13
2.1 Arrival of the package 13
2.2 Preparations 14
2.3 Handling and storage 14
2.4 Transport 16
3 Prepare the location 19
3.1 Location requirements 20
3.2 Support frame (Not provided) 22
3.3 Natural ventilator 23
3.4 Flashing kit IntrCooll® (Optional) 23
3.5 Roof beam supports 24
3.6 Opening and curb 24
3.7 Roof transit for ducting 26
3.8 Roof transits for cabling / plumbing 26
3.9 Supply air ducting 26
3.10 Exhaust air 27
3.11 Water requirements 29
3.12 Drain connection requirements 31
3.13 Overow connection requirements 31
3.14 Water connections 32
3.15 Electrical requirements 36
3.16 Communication requirements 37
4 Install the IntrCooll® 41
4.1 Preparations 41
4.2 Step 1. Positioning and leveling 42
4.3 Step 2. Duct connection to the IntrCooll 42
4.4 Step 3. Drain valve installation 43
4.5 Step 4. Flow regulator cap 45
4.6 Step 5. Making connections 46
4.7 Step 6. Check installation and settings 47
4.8 Step 7. Finish the installation 48
5 Operation procedures 53
5.1 How to operate the IntrCooll® 53
5.2 System status and settings 58
5.3 Update rmware 64
Appendices 67
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Preface
Warranty
For the warranty conditions, see our terms of delivery / warranty conditions
(already in your possession).
Except when otherwise described in the contract, Oxycom warrants that all
products supplied are of high quality and free from manufacturing defects in
workmanship and materials.
Warranty does not cover failure if it is damaged due to improper installation,
improper service procedures or if it is altered, tampered with or damaged by any
cause beyond Oxycom control.
The warranty will immediately cease to be valid if:
- The product is not installed, operated or maintained in strict accordance with
the instructions supplied.
- Operations are performed that are not described in this manual.
-Modications are made to the product without the prior written approval of
Oxycom.
- Spare parts other than those supplied by Oxycom are used.
- The product is used for a purpose or in a way it was not designed for.
- The product is treated in an improper, careless, incorrect and/or negligent
manner.
- A defect or damage occurs to the product as result of an external cause
and/or situation for which Oxycom cannot be held responsible.
The warranty does not cover use in especially corrosive or aggressive
environments e.g. in air with a high salt content such as saltwater coastal areas, or
sheet in contact with water or where corrosive chemicals, corrosive fumes,
condensation and ash, cement dust or animal droppings may aect the surface.
Product liability
Oxycom Fresh Air B.V. or subcontractor is not liable for any claims of third parties
caused by inexpert use of the machine and/or for any claims arising from use
other than as stated in this manual and in compliance with the terms of delivery.
For further details, see our terms of delivery (already in your possession).

Compliance
For the EU market the machine has been tested and complies with:
- the machinery directive 2006/42/EG
- the EMC directive 2014/30/EU
- the low voltage directive 2014/35/EU.
- the pressure equipment directive 97/23/EC
- the restriction of Hazardous Substances (ROHS) 2011/65/EU
- VDI 6022 Part 1 (January 2018)*
- VDI 3803 (May 2020)*
* When operated according to the required hygiene guidelines.
The product also complies with all applicable CE-directives and therefore has a CE
plate.
Additional safety features on the IntrCooll®
In addition to the usual general safety features, the IntrCooll® has several extra
safety features to comply with the VDI 6022 Part 1 standard.
The most important:
- The seals are made of Polyethylene (PE) and are of the closed cell type. The
seals are tested according to DIN EN ISO 846 and fulll the requirements from
the VDI 6022 Part 1 in terms of microbial inertness.
- Parts of the housing that are exposed to water are covered with a powder
coating.
The instructions in this document do not take into account dierent national
regulations and laws. When operating the machine, it is the sole responsibility of
the user to make sure that all applicable local laws and regulations are obeyed.
Contact data
If you have any questions or need further details on specic matters concerning
the equipment, do not hesitate to contact us:
Oxycom Fresh Air B.V.
P.O. Box 212
8100 AE Raalte
The Netherlands
Tel: [phone]
E-mail: [e-mail]
Website: www.oxy-com.com
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About this manual
Scope of this manual
This manual describes the safety issues, preparation of the installation location
and installation of the IntrCooll®.
Caution
Before installing the IntrCooll®, read this manual closely to get familiar with the
functioning and strictly observe the given indications and instructions. If you do
not understand any part of the information in this manual, contact your local
service department.
The information contained in this manual is based on the latest information. It is
provided subject to alterations.
Audience
This manual includes information for:
- Consultants,
- Installation engineers,
- Service / maintenance engineers.
Normal preparations and installation of the IntrCooll®, requires that these
persons:
- have read this manual and understand the contents,
- have been adequately trained,
- are able to reproduce the procedures in this manual,
- have enough technical knowledge and experience to carry out the assigned
tasks,
- can recognize and prevent hazards.
Caution
Only qualied technicians are allowed to unpack and install the equipment.

Oxycom recommends the following training levels:
- User:
Lower vocational education level or intermediate vocational education level
and trained after the installation of the IntrCooll® by the installation
personnel.
- Installation engineer:
Intermediate vocational education level.
- Maintenance engineer:
Intermediate vocational education level.
Note
In case of doubt, always consult the Oxycom Service Department.
For more information on the IntrCooll® and other Oxycom products, please
contact Oxycom Fresh Air B.V..
Typographical conventions
The following kinds of formatting in the text identify special information:
Note
The illustrations in this manual are intended to clarify operations and
functionality. The illustrations might deviate from the actual situation.
- Actions that you should perform in a specic sequence are numbered, for
instance, "1. Press the power button."
- Bullets (- and •) are used for lists of items or actions.
- Single quotation marks (‘ and ’) are used for quotations.
- Bold text is used for (sub)titles and for information that needs special
attention: 'Read these instructions carefully'.
- Menu names in the user interface are always shown in italics, for example: the
'Main Menu'.
- Control elements like soft keys, keyboard buttons, hardware buttons and
rotary knobs are always shown between brackets, for example: [Start],
[Enter], [2].
- Messages displayed in the user interface are shown between quotation
marks, for example: "Emergency stop active".
- Cross-references to sections, tables, gures etc. are indicated as blue text or
written as (see "....." on page ...). The main purpose is easy recognition in the
paper and online (PDF) version of the manual. In the online version, the cross-
references function as hyperlinks that can be used to navigate through the
manual by clicking on them. Example: Scope on page 7.
For situations that may endanger users, cause damage to equipment or need
special attention the following text styles/symbols are used:
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Note
Provides additional information that is helpful to do a task or to avoid problems.
Caution
Warns for a situation that may cause material damage if one does not follow the
safety instructions.
Warning
Warns for a situation that may cause physical injury and/or material damage if
one does not obey the safety instructions.
Danger
Warns for a situation that will cause serious physical injury and/or heavy
material damage if one does not obey the safety instructions.
Availability
Oxycom expects this manual to be available to all installation technicians, users
and service engineers of the IntrCooll®. The original hardcopy (paper) version
should always be available near the IntrCooll®.
Related documents
This manual is part of the documentation set for the machine:
- Installation manual
The manual contains relevant items for the installation of the unit. Also
information for commissioning and unit settings are given.
- Safety information sheet
This document contains the safety related information for the unit. As a
hardcopy it is available inside the unit, behind a corner cover plate.
- Maintenance manual
This manual gives the maintenance intervals and the instructions for correct
maintenance.
-Specication sheet
The specication sheet contains all important specications for installation
and operation of the unit.
- Dimensional drawings
The dimensional drawings give an overview of the sizes of the unit
- Electrical drawings
These drawings give an overview of the electrical connections.
- Fan characteristics
The sheet gives information on the speeds and ow of the fans.

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1 Safety
1.1 General (safety)
Operating and maintenance personnel, as well as anyone who is around this unit
should be aware of the possible dangers. This recommendation applies regardless
of other regulations that are issued by a higher authority or included in a (safety)
standard. The owner must ensure that personnel are qualied to perform the
activities involved.
Caution
Before operation or maintenance be sure to read and understand the safety
information. The safety information can be found behind the electrical panel on
the IntrCooll®.

Sticker manuals inside
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2 Handling and storage
2.1 Arrival of the package
The IntrCooll® is always delivered on a wooden pallet.
Crate
Caution
Obey the instructions and icons on the crate.
At delivery of the IntrCooll®, make sure that all the components are present and
undamaged.
Claims for shortages or errors should be made immediately on receipt. No
responsibility will be assumed for delay, damage or loss of material while in transit
or as result of transit. Broken, damaged or loss of material should be refused, or a
full description of the damage or loss should be made to the carrier agent on the
freight or express bill.
- At the delivery do a check on the packaging to see if it is damaged.
- Take a note of the damage before you allow the Service Technician to unpack
the equipment.

- Provide a detailed description or take a photograph of the damage.
- Report any damage to the crate to the transport company.
2.2 Preparations
Wear the safety devices according to the local rules.
At least wear the following protective clothing:
- safety shoes,
- hard helmet,
- gloves.
Caution
The IntrCooll® should be transported by suitable means of transport. First and
foremost, consider the permitted load capacity.
Caution
Always use the supplied pallet and the included supports when moving the
IntrCooll® horizontally with a forklift or pallet truck.
Caution
Always secure the load tightly with specially designated securing chains.
Caution
Ensure that no unauthorized persons are in the vicinity.
Caution
Always place the IntrCooll® on a stable loading oor with sucient load-bearing
capacity.
Caution
Oxycom is not responsible for damage resulting from incorrect transport and
storage. Warranty rights will not be accepted in the event of incorrect transport
and storage.
2.3 Handling and storage
When the IntrCooll® is stored or moved before or between installation(s):
- Always obey the instructions and warning signs that are printed on the box.
- Do not unpack the IntrCooll®, leave all packing materials in the original state.
- Store the IntrCooll® in a safe and dry place indoors.
- When there is no original packing material, cover the IntrCooll® with a tarp to
prevent contamination.
- Always make sure to carefully support the base of the IntrCooll® and maintain
free space between the oor and the valves.
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- Stacking of crates: (see Transport)
• IntrCooll Std.: Max. 1 crate is allowed.
• IntrCooll Plus: Do not stack the crates.
- Do not load other items on top of the crates.
- Keep dry.
- Handle with care.
Caution
Never place the IntrCooll® directly on the sump or the valves. This will damage
the IntrCooll®.

2.4 Transport
2.4.1 Package dimensions and weight
For dimensions and weight information of the unit, refer to the specication
sheets.
2.4.2 Forklift instructions
The equipment is supplied on a wooden pallet with a cardboard cover. Use a
forklift to move the crate. Please note the following:
- The equipment is heavy. Make sure the capacity of the forklift is sucient to
handle the equipment. See Dimensions and weight.
- Use forks with a correct length.
- Obey the icons and instructions on the crate for correct forklift use.
- Always obey local safety regulations for forklifts.
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Forklift positions
2.4.3 Hoist instructions
Danger
Always use certied hoisting equipment to hoist the IntrCooll®.
Danger
To lift, always use all 4 lifting terminals on top of the IntrCooll®. Failure to use all
lifting terminals may cause serious injury and/or damage the machine.
Danger
Always respect the correct length and angle of the ropes when lifting the unit.
Danger
The IntrCooll® has heavy parts. Risk of crushing body parts or severe damage to
the IntrCooll® when handling, lifting or moving.
Danger
The safe working load of the lifting cables should be suciently high. Cables
which are not supplied as standard with the IntrCooll® should have a safety
factor of at least 5.
Caution
Never place the IntrCooll directly on the sump or the valve, this will damage the
IntrCooll.
Caution
Prevent shock loading, avoid sudden stops or starts. Shock loading can occur
when a suspended load is accelerated or de-accelerated, and can overload the
IntrCooll®. When completing an upward or downward motion, ease the load
slowly to a stop.

Lifting instructions
A Rope length
Rope length (A):
- IntrCooll Std.: 2 m. minimum (4x)
- IntrCooll Plus: 3.6 m. minimum (4x)
Maximum rope angle:
- 30°
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3 Prepare the location
Caution
Before operation or maintenance be sure to read and understand the safety
information and warranty conditions. The safety and warranty information can
be found behind the electrical panel on the IntrCooll®.
There are several methods/accessories to support the equipment on the roof,
each having its own requirements. Below a description on installation of
IntrCooll® on a standard support frame (to be provided by contractor).
Optionally there are also plug-and-play solutions available (not described in this
manual): Flashing kit and Natural Ventilator module.

3.1 Location requirements
The location must be able to provide space for the unit and carry the weight of
the unit.
3.1.1 Weight requirements
For weight information of the unit, refer to the specication sheets.
3.1.2 Space requirements
3.1.2.1 Equipment dimensions
For dimension information of the unit, refer to the specication sheets.
IntrCooll® Std. IntrCooll® Plus
3.1.2.2 Connection locations
Bottom view with connections
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