Roca ASAI-25 User guide

1
GB
ASAO/ASAI
Ref.: N-21066 0499
Air-cooled unitary conditioners
InstructionsforInstallation,Operation,Maintenance
Autonomes Klimagerät mit Luftkühlung
Hinweise zu, Einbau, Bedienung,Wartung
EUROVENT
CERTIFIED PERFORMANCE
Clima Roca York S.L. is participating in the EUROVENT Certification Programme.
Products are as listed in the EUROVENT Directory of Certified Products, in the
program AC1.
Clima Roca York, S.L. ist am Zertifikationsprogramm EUROVENT beteiligt.
Die entsprechend gekennzeichneten Produkte sind im EUROVENT-Jahrbuch im
Programm AC1 enthalten.
CGM-97/013
ISO 14001
ER-028/1/91
ISO 9001

2GB
Index
Installation instructions 3
- General description 3
- Protection of the environment 3
- Warning signs 3
- Transport 3
- Location 4
- Clearances 4
- Air ducts 4
- Drain connections 4
- Orientation of the air intake and discharge 4
- On-site modifications 4
- Transforamtion process from horizontal to
vertical discharge 5 - 6
- Compact installation of the units 7
- Installation with separated units 7
Electrical installation 8
- Electrical characteristics 9
- Limits of use 9
- Before final approval of the installation 9
Operating instructions 10
- General information 10
- Important warning 10
- Recommendations for better functioning 10
- Ambient thermostat 10
- Start-up process 10
- Pressostats 11
Maintenance 11
- Indoor unit discharge ducts 11
- Cleaning the filters 11
- Cleaning the outdoor unit 11
- Filling the drain trap 11
- Checking belt tension 11
- Access to the units for maintenance servicing 11
General dimensions 12 - 15
Wiring diagram 16 - 32
Page
GB D
Inhalt
Hinweise zum Einbau 33
- Allgemeine Angaben 33
- Umweltschutz 33
- Hinweiszeichen 33
- Transport 33
- Austellung 34
- Freiraum 34
- Luftleitungen 34
- Anschluß der Abwasserleitung 34
- Ausrichtung von Ansaugung und Abgabe 34
- Vor Ort vorzunehmende Umbauten 34
- Umwandlung einer waagerechten in eine
senkrechte Abgabe 35
- Kompakte Aufstellung der Einheiten 37
- Aufstellung als separate Einheiten 37
Elektrischer Anschluß 38
- Elektrische Kenndaten 39
- Einsatzgrenzen 39
- Vor Abschluß des Einbaus 39
Hinweise zur Bedienung 40
- Allgemeine Angaben 40
- Wichtige Hinweise 40
- Ratschläge für einen optimalen Betrieb 40
- Raumthermostat 40
- Inbetriebnahme 40
- Druckwächter 41
Wartung 41
- Luftaustriff bei Raumeinheiten mit Verrohrung 41
- Reinigung der Filter 41
- Reinigung der Freilufteinheit 41
- Auffüllung des Siphons in der Abwasserleitung 41
- Überprüfung der Keilriemenspannung 41
- Zugang zu den Einheiten bei Wartungsarbeiten 41
Allgemeine Abmessungen 42 - 45
Schaltbilder 46 - 62
Seite

3
GB
Transport
The outdoor units must always be transported in a vertical
position so that the oil cannot escape from the compressor.
Ifforsomereasonitisnecessaryfromtimetotimetovarythis
position,theunitshouldbeleftinthenewpositionforasshort
a time as possible.
Installation instructions
General description
The ASAO/I model conditioners are supplied in standard
form as separate units. They are designed for installation
with ducting, on terraces, roof-tops, in lofts and basements.
When necessary, and at the moment of installation, these
two units can easily be joined together, transforming them
into a compact set of equipment.
Control of stopping and starting and temperature regulation
are carried out through a special 24V thermostat which is
supplied with every ASAO outdoor unit.
Protection of the environment
Packing
Packingismadeofrecyclablematerial.Thedisposalofsame
should be carried out in accordance with the regulations on
selective residue disposal established by the local authori-
ties.
Disposal of the unit
When dismantling after a long service life, its components
should be ecologically salvaged. The cooling circuit is full of
HCFC-22 refrigerant which should be salvaged and, finally,
returned to the gas manufacturer for recycling.
Oilwillremainintheairtightcompressorso,itwillbereturned
along with the sealed circuit.
The air conditioning unit will be deposited wherever estab-
lished by the local authorities for its selective disposal.
Warning signs
The following signs indicate the presence of potentially
dangerous conditions for the users or service personnel.
Whenever found on the unit itself, keep in mind the warning
indicated by each one.
Attention: It is compulsory to read the
instructions prior to any handling.
Attention: Not to touch the hot surfaces.
This sign indicates an electrical risk or
danger.
Attention: The unit has a remote control
system and can start automatically. Two
minutes prior to having access to the inte-
rior, the power supply should be discon-
nected so as to avoid any contact with the
fan turbine in operation.
Attention: Wheel and belt transmission.
Attention: Possible escape of gas if incor-
rectly handled.

4GB
should be left for filing the trap with water at the beginning of
each season.
The drain line must have a minimum slope of 2 cm. for each
metre of length.
The connections on the apparatus are of steel tube with
3/4" G. interior thread.
Location
Thelocationmustbechosenprovidingpermanentaccessfor
maintenance service, both through the lateral and rear
panels.
The outdoor unit can be installed directly out doors. If it is
installed indoors, in basements, lofts, etc., ducting must be
fitted to bring in exterior air and for its extraction.
Clearances
In the installation of each apparatus, clearance must be left
for:
a) Intake and discharge of air to and from the outdoor unit.
b) Connection of drain and electrical tubing.
c) Air ducts.
d) Maintenance service.
e) Electrical wiring.
f) Cleaning the filters
On-site modifications
Iftheinstallationconditions require it, the discharge from the
indoor fan ASAI can easily be modified on site to provide
discharge vertically.
Air ducts
1- Connect the ducts, insulating them from the apparatus
with a flexible coupling, preferably of non-inflammable
material,toavoidtransmissionofvibrationfromtheappa-
ratus itself. If the ducts are made of flexible material they
will not transmit vibration.
2- Itisrecommendedthataregisterbefittedoneachsection
of the ducting to ensure correct balance of the system.
3- Leave easy access for cleaning and changing the air
filters.
4- With the ASAO-45 units, two separate ducts, one from
each fan, to the discharge, must be fitted to avoid
recirculation of air.
Drain connections
Run the drain tubes for each pan though a trap. Leave a
minimumleveldifferenceof75mm.betweentheheightofthe
connection to the apparatus and the line after the trap (see
drawing). This is to prevent the depression produced by the
fan from interfering with the emptying of the pan. Access
Orientation of the air intake and discharge
Thestandardorientationsforairintakeanddischargeareas
shown in the drawing.
ASAI
ASAO
600 800
600
AS SEEN FROM ABOVE
(measurements in mm)
SLOPE
2%
MINIMUM
75 mm
PLUG
INTAKE DISCAHRGE
DISCHARGE
(OPTIONAL)
DISCHARGE
INTAKE

5
GB
Transformationprocessfromhorizontaltover-
tical discharge
(ASAI-25, 30, 45)
1- Remove the attachment screws from the side panels 1
and 2 on the upper unit.
2- Remove side panels 1 and 2.
3- Loosenthescrewsattachingthefanmotortoitsbaseand
take off the drive belf.
4- Throughthelateralaccesses,unscrewpanels3and4,as
shown in the standard orientation drawing.
5- Unscrew the attachment of the fan to support 5.
6- Place panel 3 in the former position of panel 4, and panel
4 in the former position of panel 3.
7- Screw home the panels and the fan to support 5.
8- Replace the drive belt and attach the motor to its base.
9- Screw on the side panels 1 and 2.
Standard orientation Orientation as modified on site
1
4
3
2
45
3
LOCKSCREWS
3
5
4
20 mm
1
3
4
2

6GB
ASAI-60 unit
TheASAI-60needsatransformationkitwhichincludes:rear
and upper panel, belts, motor pulleys and fan.
1- Dismantle the standard upper, rear and side panels and
the fans, and orientate them as shown in the drawing,
attaching them to the upper panel together with the
transformation kit.
2- Oncethefanshavebeeninstalled,attachtheupperpanel
ref. 1 to the unit.
3- Attachtheleft-handsideanglesupportandright-handfan
support ref. 3 to the unit.
4- Change the motor pulleys, fan and belts ref. 2 for those
included in the kit.
5- Fit the upper panel ref. 4.
6- Finally, fit the standard side panels.
4
3
2
1

7
GB
Compact installation of the units
The units are supplied prepared for connection of their
cooling circuits and electrically.
To install the units as a compact system, the outdoor ASAO
unit and the indoor ASAI one have to be joined through the
holesprovidedinthembythescrewsprovided.Thesewillbe
found in a bag inside the electrical box in the ASAO-60 and
in the indoor unit in the ASAI-25, 30 & 45.
The indoor and outdoor units are supplied with the cooling
circuit connections ready for soldering and to be intercon-
nected on the outside of the casing.
The ASAO/I-25 and ASAO/I-30 units have one sole circuit.
The ASAO/I-45 and ASAO/I-60 units has two circuits.
And the refrigerant load should be applied onsite.
Charge process
1 - Depressurise the units.
2 - Drain the refrigerant.
3 - Clean out with dry nitrogen.
4 - Solder the tubing under dry nitrogen inside the tubes.
5 - Forsolderinguselowmelting-pointrodswithaminimum
silver content of 5%.
6 - Fill with 2 kg. R-22 refrigerant to detect leaks.
7 - Drain off the refrigerant.
8 - Clean out with dry nitrogen.
9 - Create a vacuum down to 200 microns.
10- Put in the refrigerant, using scales or a calibrated
cylinder. Charge accuracy should be within 30 grams.
Theoutdoor unitisfittedwithplug-in pointsattheconnection
outlets for verification of pressure and temperature, Super-
heat and Sub-cooling. Check that these values are in the
order of 5°C.
Installation with separated units
Separation between the units
The length of connecting tubing should be kept down to the
minimum possible.
Maximumadmissibledistanceswiththecircuitandstandard
diameter tubes are:
Total length
of tubes
m
Maximum level
difference between units
m
1020
For greater lengths the installation must be made after a
previous project approved by our technical service.
This project may require modification of any of the following
elements:
- Tube dimensions.
- Refrigerant charge.
- Suction traps.
- Suction accumulator.
- Liquid solenoid valve.
In such cases the maximum lengths which can be recom-
mended are:
Cooling interconnections
When forming the tubing to join the two units special care
shouldbe takentokeepthetubes cleananddryevenbefore
installation. The following recommendations should be ob-
served:
1 - Use only copper tubing of refrigerant quality.
2 - Do not carry out outdoor work if it is raining.
3 - The ends of the tubes should be kept closed during the
installation.
4 -The dryer filters and compressor should not be left
exposed to the elements for more than one or two
minutes.
5 - For soldering use low melting-point rods with a minimum
silver content of 5%.
6 -During soldering and for as long as the tube stays hot, a
current of dry nitrogen should be kept up to avoid the
formationofoxideswhichcouldcausecontaminationand
blockage.
7 - For copper-copper unions stripper should not be used.
Units at same level, maximum length
Installation type
50m
Outdoor unit higher than indoor. Maximum
length and level difference. 50
m
Outdoor unit lower than indoor. Maximum
length and level difference. 15
m
PANEL
LOCKSCREW UPPER AND LOWER
UNITS LOCKSCREWS
(TWO ON EACH SIDE)
UPPER UNIT
(INDOOR)
LOWER UNIT
(OUTDOOR)

8GB
Diameter of the interconnection tubing
Loosecablescancauseoverheatingoftheconnectorsoraninadequate
operation of the unit. Fire risk could also exist. For this reason, make
sure that all cables are properly connected.
Afterthetubehasbeeninsulated,donottrytobenditinexcessbecause
it could become cracked or broken.
Do not supply power to the unit and do not start up operations until the
tubing and electrical connections with the outdoor unit have been
completed.
Make sure that electrical supply is correctly connectec to the units, as
shown in the electrical diagrams.
Refrigerant charge
The nominal charge show in the table below is calculated for
functioning as a compact unit.
Whenasplitsystemisinstalled,therefrigerantchargehasto
be increased as a function of the length of liquid tubing.
Charge process
1 - Depressurise the units.
2 - Drain the refrigerant.
3 - Clean out with dry nitrogen.
4 - Solder the tubing under dry nitrogen inside the tubes.
5 - Forsolderinguselowmelting-pointrodswithaminimum
silver content of 5%.
6 - Fill with 2 kg. R-22 refrigerant to detect leaks.
7 - Drain off the refrigerant.
8 - Clean out with dry nitrogen.
9 - Create a vacuum down to 200 microns.
10- Put in the refrigerant, using scales or a calibrated
cylinder. Charge accuracy should be within 30 grams.
Theoutdoor unitisfittedwithplug-in pointsattheconnection
outlets for verification of pressure and temperature, Super-
heat and Sub-cooling. Check that these values are in the
order of 5°C.
Insulation of tubing
The interconnecting cooling tubing must be insulated.
The insulation requires certain characteristics: it must be
easy to install; be hard-wearing; be water and fire resistant;
and have a minimum thickness of 12 mm.
To avoid deterioration through exposure to sunlight it is
recommended that it be painted with water-enamel.
Electrical installation
Each conditioner is delivered with a control box for connec-
tion to the mains through a main switch with fuses or an
automatic cut-out.
The electric heater, if there is one, must be installed with
power line and switches independent of those of the condi-
tioner.
In all cases established national regulations must be
observed.
ASAO/I-25 en 45
11/8" (28.5 mm)
Model Gas line
diameter
(wide tube)
ASAO/I-30 en 60
Liquid
line diameter
(narrow tube)
ASAO/I-25 11 1 1/2"(12.7mm) 104 grs.
ASAO/I-30 15 1 5/8"(15.87mm) 170 grs.
ASAO/I-45 11.6 x 2 2 1/2"(12.7mm) 104 grs.
ASAO/I-60 7 x 2 2 5/8"(15.87mm) 170 grs.
Model Aantal
circuits Diameter vloeistofleiding
Nominale
vulling
R-22 kg
Extra
vulling in gr
(per meter)
1/2" (12.7 mm)
5/8" (15.87 mm)
CAUTION

9
GB
Electrical characteristics
Limits of use
Before final approval of the installation
- Condensation drainage is car-
riedoutperfectlyandthere are
no leaks in the water circuit.
- Operatinginstructionshavebeen
give to the user.
Verify:
- Voltage is always belween 198 -
254 V or 342 - 436 V.
- The section of the supply cable is
at least that recommended in the
corresponding wiring diagrams.
- The need to clean the air filter
has been notified.
- The guarantee card bas has been
filled out.
- Maintenanceinstructionshavebeen
given, or a regular servicing con-
tract has been signed.
Vermogen A
Power supply V.ph.Hz.
CompressorFan Outdoor
fan
Indoor
fan
Power
sup. cable
cross
section
Int.Ext. Nominal A
mm2
Nominal
NominalMaximum
Compressor
230.3.50
400.3.50
230.3.50
400.3.50
400.3.50
400.3.50
183 22.8 34.5 14 5.2 23 5.2 10 50
90 13.2 20 7 2 10 3 6 32
170 28.5 33 23 4.7 31 6.6 16 80
100 16.5 19 10 2.7 25 3.8 10 50
2 x 91 2 x 12.5 2 x 14.5 10 3.5 2 x 13 2 x 3 16 63
2 x 100 2 x 16.5 2 x 19 25 7.1 80 13 25 100
230.3.50
400.3.50
230.3.50
400.3.50
400.3.50
400.3.50
Model
ASAO/I-25
ASAO/I-30
ASAO/I-45
ASAO/I-60
-Start Start Start
Automatic
circuit
breaker
Important: The automatic switch sizing and the power line section are orientative, and should be corrected in accordance with site conditions and
legislation.
Maximum
436
Maximum
46
Air intake temperature
condensing unit °C
Air intake temperature
evaporating unit °C
Voltage limits
Nom. 230 V Nom. 400 V Temperature WB Temperature DB Temperature DB
Maximum
32
Minimum
342
Minimum
14
Maximum
23
Minimum
19
Minimum
19
Minimum
198
Maximum
254
Notes: WB-Wet bulb. DB- Dry bulb.

10 GB
Operating instructions
General information
Start-up and automatic temperature regulation are carried
out through the ambient thermostat.
Place the thermostat about 1.5 metres above floor level,
where no obstacle can prevent it from measuring the real
temperature of the room.
Important warning
The thermostat should be located on a wall that is not
exposed to direct sunlight. Should this not be the case, the
temperatures would not be real, and operation would be
inadequate.
Before starting up, turn on the main switch to activate the
electric heater in the compressor crankcase.
The compressor must not be started up until at least
eight hours have elapsed.
Thisistoallowforevaporationofanyrefrigerantinliquidform
which may have mixed with the compressor oil.
Thermostat for ASAO/I-25 & 30
Connection:
Toheatthesystem,theelectricalsupply
must be switched on at least 8 hours
before the conditioner is put into
operation.
Leavethesupplyconnectedunlessyou
are going to leave the conditioner idle
for a long period of time.
Start-up process
Connectthemainandearthwirestotheboardprovidedinthe
control box.
Connect the ambient thermostat cable to 24 V on the board
provided in the control box.
Once the equipment has been installed in accordance with
theinstructionsgivenpreviously,andtheappropriatechecks
have been made, the start-up process can be initiated. This
is done through the thermostat.
a) For ventilation only:
Lever A in ON position.
Lever B in OFF position.
Dial in any position.
b) Summer conditioning:
Lever A in ON or AUTO position.
Lever B in COOL position.
Dial indicating the temperature desired.
c) Winter conditioning:
(With heating coils)
Lever A in ON or AUTO position.
Lever B in HEAT position.
Dial indicating the temperature desired.
Thermostat for ASAO/I-45 & 60
Recommendations for better functioning
- Turn the console on before the room gets hot. The heat
accumulated on furniture, walls, etc. makes the console
take longer to achieve the desired temperature.
- Itis advisabletoinspect andserviceyour unitinthe spring;
this avoids damage and insures a long sevice of your
console.
Ambient thermostat
Characteristics:
a) Operating voltage 24V.
b) Admissible strength 2 A.
c) WithaswitchforthefuncioningofCOOL-OFF-HEAT,and
another for the fan, with positions AUTO-ON (Automatic-
-Continuous).
d) With heat and cold anticipators adjustable between 0.1
and 1.2 A.
e) With a bi-metal thermometer.
ON
ELECTRICAL
SUPPLY
CAUTION
FAN
AUTO
ON
HEAT
OFF
COOL
10 15 20 25 30
LEVER
"A" LEVER
"B"
FAN
AUTO ON HEAT COOL
10 15 20 25
HEAT COOL
C
LEVER "B"LEVER "A"
OFF