Swegon Cooler Series User manual

COOLING UNIT – COOLER
Installation and Maintenance Instructions
Sizes 14-60
Sizes 14-18
Sizes 24-60
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CONTENTS
1. Overview 3
1.1. General 3
1.2 Operating Principle 4
1.2.1 Cooler 14 and 18 4
1.2.2 Cooler 24, 34, 48 and 60 5
2 Safety Precautions 6
2.1 Safety switch/main switch 6
2.2 Hazards 6
2.3 Electrical equipment 6
2.4 User qualification 6
2.5 Decals 6
3 Installation 7
3.1 Unloading/site transport 7
3.1.1 Transport using a forklift truck 7
3.1.2 Lifting using a crane 7
3.2 Mounting 7
3.2.1 Fitting handles on Unit 7
3.3 Installation Principle 8
3.3.1 Installation – Cooler, size 14 9
3.3.2 Installation – Cooler, size 18 9
3.3.3 Installation – Cooler, size 24-60 9
4 Electrical Wiring 10
4.1 Wiring to mains power 10
4.1.1 Cooler – size 14 10
4.1.2 Cooler – size 18 10
4.1.3 Cooler – size 24 - 34 10
4.1.4 Cooler – size 48 - 60 10
4.2 Other electrical connections 10
4.2.1 GOLD, Verson B 10
4.2.2 Other types of air handling unit 11
5 Ferrit Block, 019 210 12
6 Communication Cable, 019 007 13
6 Cooling Connections 13
6.1 Location 13
6.2 Draining the cooling coil 13
6.3 Liquid connections 13
6.4 Venting nipples 13
6.5 Insulating the cooling agent circuits 13
6.6 Connection to the cooling unit 13
6.7 Safety drain 13
6.8 Filling with water/glycol mixture 13
6.8.1 Filling 14
6.8.2 Venting the system 14
7 Commissioning 15
7.1 Preparations 15
7.1.1 Before starting for first time 15
7.1.2 Starting up 15
7.1.3 To correct the phase sequence 15
8 Programming and Managing the Menus 16
8.1 Hand-held micro terminal 16
8.1.2 Display and buttons 16
8.2 Menu button captions and symbols 16
8.3 Menu groups and levels 16
9 Menus 17
9.1 Main menu 17
9.2 Information menus 17
9.3 Settings menus 18
9.4 Test menus 19
9.5 Alarm menus 20
10 Alarms 20
10.1 General 20
10.2 Resetting the alarms 20
10.3 Settings 21
10.4 Alarm conditions 21
10.5 Alarm priorities 22
11 Maintenance 23
11.1 Cleaning 23
11.2 Changing the water/glycol mixture 23
11.3 Handling the refrigerant 23
11.4 Charging with refrigerant 23
11.5 Annual inspection 24
11.6 Service 24
12 Cooling Coil and Cooling Agent Cooler 24
12.1 Instructions for BASIC 24
12.1.1 BCKO Cooling agent cooler, 006-014 24
12.1.2 BCKA Cooling coil, 004-014 25
12.2 Instructions for the GOLD, sizes 11-32 26
12.2.1 Installing the TBKA, TBKC cooling coil 26
13 Connection to Ducting 29
13.1 Type of end connection 29
14 Electrical Data 29
14.1 Cooling unit 29
14.2 Power supply 29
15 General Technical Data 30
16 Mechanical Design 31
16.1 Design 31
16.1.1 Dimensions and weights 31
17 Other Particulars 32
18 Enviromental Compatibility Declaration 32
18.1 Scrapping 32
19 Compliance Declaration 33
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Complete indirect system (sizes 24, 34, 48 and 60)
The size 24-60 Coolers have a complete indirect system.
Heat/cooling energy is transferred across a heat exchang-
er from the refrigerant to the circulating water mixed with
glycol. Both the brine circuit and the cooling agent circuit
must be filled with a mixture of water and 30% ethylene
glycol after the unit has been installed.
Fig. 2
Refrigerant
Cooler has double refrigerant circuits which are sepa-
rate from one another. The refrigerants used are of type
R407C and R134A in each circuit respectively, each with
its own compressor. On delivery, the refrigerant circuits
are charged. These refrigerants do not have any known
impact on the ozone layer and there are no known restric-
tions for their use at this present time.
Refrigerant volume
See section 14. General Technical Data.
Reporting obligation
The user is required to submit periodic reports to the local
inspectorate only if the total charge volume exceeds 10
kg.
Annual inspections
Annual inspections by an accredited inspectorate are
required if the volume of refrigerant in the one-piece unit
exceeds 3 kg. This is applicable to the size 24, 34, 48 and
60 Coolers only.
Quality Management System to ISO 9001 and
Environmental Management System to ISO 14001
Swegon maintains documented and certificated Quality
Management and Environmental Management Systems
that meet the provisions of ISO 9001 and ISO 14001
respectively.
1. OVERVIEW
1.1. General
Cooling Unit Cooler
The Cooler is a complete one-piece cooling unit for comfort
cooling in air handling systems. All the refrigeration and
electrical components are interconnected and housed in one
common casing. The units are test run prior to delivery.
The coils are designed for installation in the ducting. The
arrangement of piping between the cooling unit and the
coils and the electrical wiring of the cooling unit is carried
out at the building site.
The Cooler can be used together with an air handling unit.
The capacities of the six sizes are however matched to the
size 08-60 GOLD air handling system and the size 004-014
Basic air handling units.
Compressors
Sizes 14, 18, 24 and 34 each have two-piston compres-
sors. Sizes 48 and 60 each have two compressors as well,
but they are of Scroll-type.
Partially indirect system (sizes 14 and 18)
The size 14 and 18 Coolers have a partially indirect system.
On the warm side, a coil (condenser) is used for direct-
evaporating refrigerant, while on the cold side, there is a
heat exchanger, where energy is transferred to the water
mixed with glycol (brine) circulated to the cooling coil in
the supply air duct. The circuits must be filled with a mix-
ture of water and 30% ethylene glycol after the unit has
been installed.
The condenser coil is integrated into the cooling unit fitted
in the exhaust air duct.
Fig. 1
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1.2 Operating Principle
1.2.1 Size 14 and 18 Coolers
BT2 RP2:2 RP2:1
M2
SV EK
BT1 RP1:2 RP1:1
EV2
EV1
VVX2
VVX1
BT3
G1
E1
BT4
M1
Cooling coil
HT
SS
Condenser
coil
Fig. 3
BT1 Hot gas thermostat R134A
BT2 Hot gas thermostat R407C
BT3 Brine temperature sensor
BT4 Extract air temperature sensor
RP1:2 High pressure switch R134A
RP2:2 High pressure switch R407C
RP1:1 Low pressure switch R134A
RP2:1 Low pressure switch R407C
G1 Brine pump
M1 Compressor R134A
M2 Compressor R407C
VVX1 Evaporator
VVX2 Evaporator
SV Safety valve
EK Expansion vessel
E1 Electrical cubicle with safety switch, power sec-
tion, control card
SS Start and control signals
EV1 Expansion valve 1
EV2 Expansion valve 2
HT Hand terminal
Operation
There are two refrigerant circuits in the cooling unit The
circuits are separate from one another and each contains a
different type of refrigerant.
Each circuit is equipped with its own heat exchanger on
the cold side. On the warm side, both circuits are arranged
through a condenser coil.
The brine (water/ethylene glycol) passes the heat exchang-
er of both refrigerant circuits.
The refrigerant in gas form is compressed by each com-
pressor and then passes to the condenser coil, where it is
chilled by the air flowing through the coil, and condenses
to liquid form.
A reduction in pressure occurs in expansion valve EV. From
the expansion valve the refrigerant advances to evapora-
tor VVX where the refrigerant vaporises and absorbs heat
from the adjacent medium, i.e. the brine. This chills the
brine. Gas leaves the evaporator and flows back to the
compressor.
Water pump G1 pumps the brine (water/ethylene glycol)
in a circuit from evaporators VVX1 and VVX2, where it is
chilled by the refrigerant and advances to the cooling coil,
which in turn cools the supply air flowing to the air han-
dling unit. The refrigerants are never in physical contact
with the brine. Heat and cooling energy are transferred
across the heat exchangers in the evaporator and con-
denser.
Control
In a response to an ON/OFF control signal, the controller
switches in pump G1 and compressor M1. The cooling
capacity is controlled by switching in one or two compres-
sors. On increasing cooling load, the controller switches in
compressor M2 and at the same time switches out com-
pressor M1. If even more cooling is required, compressor
M1 is switched in to operate together with compressor
M2.
If the temperature of the outgoing brine becomes too
low, one of the compressors is switched out. When this
condition subsides, it is restarted automatically. Should the
pressure become too low, the low pressure switch will trip.
The equivalent will occur on the warm side. If the tem-
perature of the exhaust air becomes too high, one of the
compressors is switched out. If the pressure still rises, the
high pressure switch will trip.
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1.2.2 Size 24, 34, 48 and 60 Coolers
BT2 RP2:2
BT1 RP1:2
SV EK SV EK
M2
M1
RP2:1
RP1:1
G1
BT3
BT4
VVX1
VVX2 VVX3
VVX4
EV2
EV1
G2
HT
SS
Cooling coil
Cooling agent
cooler
E1
Fig. 4
BT1 Hot gas thermostat R134A
BT2 Hot gas thermostat R407C
BT3 Brine temperature
BT4 Cooling agent temperature
RP1:2 High pressure switch R134A
RP2:2 High pressure switch R407C
RP1:1 Low pressure switch R134A
RP2:1 Low pressure switch R407C
G1 Brine pump
G2 Heating medium pump
M1 Compressor R134A
M2 Compressor R407C
VVX1 Condenser
VVX2 Condenser
VVX3 Evaporator
VVX4 Evaporator
EK Expansion vessel
SV Safety valve
E1 Ellectrical cubicle with safety switch, power sec-
tion, control card
SS Start and control signal
EV1 Expansion valve 1
EV2 Expansion valve 2
HT Hand-held micro terminal
Operation
There are two refrigerant circuits in the cooling unit. The
circuits are separate from one another and each contains a
different type of refrigerant.
Each circuit is equipped with its own set of heat exchang-
ers on the warm and cold side respectively. The cooling
agent and the brine (water/ethylene glycol) both pass
through the heat exchanger of both refrigerant circuits.
The refrigerant in gas form is compressed by each com-
pressor and then advances to condenser VVX1 or VVX2,
where it is chilled by the cooling agent (water/ethylene
glycol) and condenses to liquid form.
A reduction in pressure occurs in expansion valve EV and
the pressure drops. From the expansion valve the refrig-
erant advances to evaporator VVX3 or VVX4 where the
refrigerant vaporises, boils, and absorbs heat from the
adjacent medium, i.e. the brine (water/ethylene glycol).
Gas leaves the evaporator and flows back to the cooling
compressor.
Water pump G1 pumps the brine (water/ethylene glycol)
in one circuit from condensers VVX3 and VVX4 where the
brine is chilled by the refrigerant and then proceeds to
the cooling coil, where it in turn cools the supply air dis-
charged from the air handling unit.
Water pump G pumps brine (water and ethylene glycol)
in the circuit from condensers VVX1 and VVX2, where the
brine cools the refrigerant and further to the brine cooler
(the coil in the exhaust air duct). The brine is cooled there
where it transfers heat to the exhaust air leaving the air
handling unit. After that the brine returns to the conden-
ser.
If the cooling agent isn’t chilled adequately, the COOLER
will temporarily lower its capacity to avoid a shutdown
(shuts off one refrigerant circuit and compressor). The
cooling unit will however revert to operating at full capa-
city again as soon as the operating conditions so permit.
Control
In response to an ON/OFF control signal, the controller
switches in pumps G1 and G2 and compressor M1. The
cooling capacity is controlled by switching in one or both
compressors. On increasing cooling load the controller
switches in compressor M2 and at the same time
switches out compressor M1. If still more cooling is re-
quired compressor M1 is switched in to operate together
with M2.
If the temperature of the outgoing brine becomes too
low, one of the compressors is switched out. When the
condition subsides, it is restarted automatically. Should the
pressure become too low, the low pressure switch will trip.
The equivalent will occur on the warm side. If the tem-
perature of the exhaust air becomes too high, one of the
compressors is switched out. If the pressure still rises, the
high pressure switch will trip.
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2 SAFETY PRECAUTIONS
2.1 Safety switch/main power switch
The safety switch is located inside the inspection door
(right-hand door on the size 24 - 60 units).
The safety switch must not be used for starting or stop-
ping the cooling unit. Make sure that the Cooler is
switched off by shutting down the air handling unit or by
temporarily switching out the cooling unit in the display.
Enter SET in the main menu, select SET again, then select
PROG and then SHUT OFF. After doing this, the safety
switch can be used to isolate the power.
Important!
Always switch off the safety switch when servicing un-
less otherwise specified in the relevant instruction.
2.2 Hazards
Caution!
Make sure that the power has been switched off before
carrying out any work inside the unit.
Caution!
Unauthorized personnel are not under any circumstanc-
es permitted to open the refrigerant circuit. The circuit
contains gas under high pressure.
Hazardous areas where there is refrigerant
The entire cooling unit is in principle a hazardous area due
to the presence of refrigerant. For particulars of how to
deal with leakage, see Section 10.3.
The circuits contain type R 407C and R134A refrigerant.
Caution!
Since the Cooler is located on the pressue side down-
stream of the air handling unit, the inspection lid must
not be opened while the fan is in operation. The door
may fly open and cause injury to personnel. (Applicable
to the size 14 and 18 units).
2.3 Electrical equipment
The electrical equipment of the unit is located behind the
inspection door in a separate electrical cubicle.
2.4 User Authorisation
Only a qualified electrician or trained service personnel is
permitted to carry out electrical wiring in the unit.
Only staff of an accredited refrigeration service company
is permitted to modify or repair the refrigerant circuit.
Modification or work on the cooling unit may only be car-
ried out by service personnel trained by Swegon.
Should the need arise to do any repair work, get in touch
with your nearest Swegon service representative, see the
last page of these instructions.
2.5 Decals
The model number label with type designation, serial
number, refrigerant volume, etc. is affixed to the inspec-
tion door of the unit.
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3 INSTALLATION
3.1 Unloading/transport within the
building site
Important!
The unit should always be horizontal while it is being
transported.
3.1.1 Transport using a forklift truck
Fig. 5
Caution!
Low centre of gravity! Lift the unit carefully.
3.1.2 Lifting using a crane
Place two sling spreaders on the upper side of the unit
and two on the underside of the pallet or under the unit.
Then lift in the pallet (or the unit if the pallet is not to be
attached).
See fig. 6.
Fig. 6
3.2 Mounting
The Cooler cooling unit should be located at a suitable
spot in the fan room.
The unit can be located with its backside against the
wall. Adequate open space must be provided outside the
inspection door to allow access to the safety isolating
switch/main circuit breaker located behind the inspection
door in compliance with local electrical safety regulations.
3.2.1 Fitting handles to the unit
Fit the handles on the inspection doors.
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3.3 Installation principle
The dimensions and capacity of the cooling coil and the
cooling agent cooler are specially suited for connection to
the size 08-60 GOLD and size 004-014 Basic air handling
units. For a survey of the sizes of cooling unit and their ca-
pacities that correspond to each size of air handling unit,
see Section 14, General Technical Data.
Cooler, sizes 14-18
Power supply Start and control signal Brine
Extract air
Outdoor air
Support legs
Condensate drain Cooling coil
Supply air
Venting nipple Venting nipple
Exhaust air
Fig. 7
Cooler 24-60
Start and control signal
Cooling agent
Venting nipples
Exhaust air
Outdoor air
Brine
Extract air
Supply air
Cooling coilCondensate drain
Cooling agent cooler
Power supply
Fig. 8
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General
The unique Wing fans in the GOLD and Basic air handling
units make it possible to connect coils directly against the
duct connection of the air handling unit without any pres-
sure losses or nonuniform air distribution.
Provision for inspecting and cleaning the GOLD unit must
be provided when the unit is installed, such as by fit-
ting inspection covers to the ducting or making the coils
withdrawable. The cooling coil can be incorporated into a
block or can be located separately at an appropriate spot
next to a Basic casing on the supply air side of the unit.
3.3.1 Installing size 14 Coolers
For GOLD: The cooling coil and the refrigerating machine
of the size 14 Cooler have an approved rubber seal for
circular connection to the supply air duct and exhaust air
duct respectively of the GOLD 08. A 400/500 mm conical
transition piece is required on the supply air side of the air
handling unit. The cooling unit has a rectangular outlet
connection to decrease pressure losses. The connections
of the GOLD 14-20 are rectangular and their dimensions
are matched to fit this unit. Slip-clamps are used for con-
nection.
For the Basic: The cooling unit is connected without any
end panel to the exhaust air side downstream of the fan in
the Basic. A cover plate must be fitted to the air handling
unit since the refrigerating machine is somewhat smaller,
see Fig. 9. The cooling coil can be incorporated into a
block or can be arranged separately at an optional spot in
a Basic casing on the supply air side of the unit .
See Section 5 for particulars of the cooling connection.
3.3.2 Installing size 18 Coolers
For the GOLD: The cooling coil and the size 18 cooling
unit have rectangular connections.Slip-clamps are used for
connection to the ducting.
For the Basic: The cooling unit is connected without any
end panel to the exhaust air side downstream of the fan
in the Basic. The cooling coil can be incorporated into a
block or located separately at an appropriate spot in a
Basic casing on the supply air side of the unit.
See Section 5 for particulars of the cooling connections.
3.3.3 Installing size 24-60 Coolers
For the GOLD: Cooling coil and cooling agent cooler for
the size 24, 34, 48 and 60 cooling units have rectangular
connections. Slip-clamps are used for connection.
For the Basic: The cooling coil and cooling agent cooler
can be incorporated into a block or can be installed sepa-
rately in the Basic casing at an appropriate spot on the
supply air or exhaust air side of the unit.
See Section 5 for particulars of the cooling connections.
Fig. 9
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4 ELECTRICAL WIRING
Important!
The installation work shall be carried out by an authorized
electrician.
4.1 Wiring to the mains power
The power cable must be arranged through the front
panel of the unit. A permanent cable gland has been fac-
tory-fitted to the side of the inspection door.
The location of the gland varies slightly depending on the
size of cooling unit.
The incoming cable for 400 V power (5-wire system) must be
connected directly to the safety switch, which has four nor-
mally-closed contact functions. The safety switch is installed
in the built-in electrical cubicle. The terminal block for incom-
ing earth is situated adjacent to the safety switch.
If a 4-wire system is used, a jumper should be fitted be-
tween the earth and zero terminal blocks in the Cooler.
For access to the connections of the safety switch, the
safety guard above the electrical cubicle components has
to be dismantled.
4.1.1 Size 14 Coolers
The cable gland is located to the right at the top of the
front panel.
The fuse for the cable shall be rated for 20 A(T).
When sizing the cable, take into account the ambient tem-
perature and how the cable will be arranged.
See Fig. 10.
4.1.2 Size 18 Coolers
The cable gland is located at the bottom edge of the front
panel.
Fuse for the cable should be rated for 25 A(T). When sizing
the cable, take into account the ambient temperature and
how the cable will be arranged.
See Fig. 10.
4.1.3 Size 24 and 34 Coolers
The cable gland is located uppermost and to the right on
the front panel.
The fuse for the cable shall be rated for 32/35 A (T) for the
size 24 Coolers and 35 A(T) for the size 34 Coolers. When
sizing the cable, take into account the ambient temperature
and how the cable will be arranged.
See Fig. 10.
4.1.4 Cooler sizes 48 - 60
The cable gland is located uppermost and to the right on
the front panel.
The fuse for the cable shall be rated for 63 A(T). When siz-
ing the cable, take into account the ambient temperature
and how the cable will be arranged.
Fig. 10
4.2 Other electrical connections
4.2.1 GOLD, Version B
General
The Cooler is supplied with two alternative accessories for
controlling the cooling load.
Extra interference protection is required for the Cooler
variants operating where the cooling load is controlled by
an external 0 –10 V DC signal.
To meet the provisions stipulated in the EMC Directive,
concerning insensitivity to interference, the analogue
inputs must be protected by a Ferrit block, 019 210.
Communication cable 019 007 is the accessory, that must
be used when the Cooler operates together with the
Version B GOLD ventilation unit. See the individual instruc-
tions.
Design
The ferrit block, 019 210, is designed for snapping
around wires.
The block consists of two ferrit-halves, enclosed in a
plastic casing that can be opened.
The plastic casing has ”hinges” and a simple lock that make
it easy to open and close around relevant wires.
Dimensions: H = 15 mm, W = 15 mm, L = 29 mm and
diameter of the openings = 6.6 mm.
Communication cable 019 007 is a 5 m long flat cable,
with a type RJ 1 modular connection fitted at both ends.
The cable transfers normal communication signals bet-
ween the control unit and the GOLD unit (Version B), but
not 4 V DC. Both types of control have their own 4 V DC
supply.
Important: Do not use an ordinary bus cable! If the 4 V DC
connections are interconnected, this will cause malfunc-
tions.
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Connection of the control and regulation cable to
the air handling unit.
Only one communication cable is required for transmitting
information between the Cooler and the GOLD control
systems. All the operating conditions and alarms are
transmitted across this cable.
Communication: Communication between the Cooler
and the GOLD unit takes place by means of a special
communication cable (PM part number 019 007).
Installation in the GOLD:
Connect communication cable 019 007 to any of the
ABC Bus outlets on the control unit. For the Gold (Ver-
sion B) see Fig.11!
Use one of the holes in the oval rubber-covered cable
glands on the backside of the electrical cubicle’s junction
hood, for running the cable in to the control unit. See
Fig. 12! Move a part of the cable gland to the side to
insert the Modular connection through it. Connect the
cable to a bus connection on the control unit. Adjust
the cable length inside the electrical cubicle and adjust
the cable in the cable gland. Refit the cable gland in its
correct position.
Lay the communication cable in a safe manner from the
plastic hood on the top panel of the GOLD unit (Version
B) to the Cooler unit.
Installation in the Cooler: Connect communication ca-
ble 019 007 to any of the ABC Bus outlets on the control
unit. For the Cooler, see Fig. 11b!
Remove the safety guard over the electric cubicle of the
Cooler. Loosen the oval cable gland on the front side of
the electrical cubicle just so much to enable you to push
the quick connector on the communication cable th-
rough the opening. See Fig. 12!
Fasten the connector in any of the connections for ABC
Bus/communication on the control circuit card
ABC Bus
ABC-Bus
Fig. 11
Fig 11b.
Hand-held Micro Terminal Connect the quick connector
of the hand-held micro terminal to one of the connections
on the control circuit card, i.e. to the centre outlet up to
the left or any of the 6 right-hand modular connections at
the lower edge of the control circuit card. Lead the cable
through the cable gland in the same manner as the com-
munication cable, described above.
hand-held micro terminal of the Cooler can also be con-
nected to any vacant ABC Bus connection on the circuit
card or hand-held terminal of the GOLD unit.
Commissioning
At the lower edge of the control unit in the Cooler there
is a red block with four DIP switches that have to be set to
appropriate settings. For communication with the GOLD
unit, set all 4 switches to the ON position (up).
Use the hand-held terminal to set the cooling unit func-
tion to the auto operation mode. Do this under SETTINGS.
See the Operation and Maintenance Instructions for the
GOLD.
4.2.2 Other types of air handling unit
Instructions for the Cooler with 0-10 V controller
Connection of the control and regulation cable to air
handling units other than the GOLD version B.
DIP-switch settings: At the bottom of the control unit in
the Cooler there is a red block with 4 DIP switches, which
have to be set. If 0-10V control is used, set the switch no.
1 to the OFF position (down) and switch nos. 2 – 4 to the
ON position (up). See Fig. 11b!
Hand-held micro terminal: The hand-held micro termi-
nal is connected to one of the ABC-Bus-connections on
the control circuit card,The centre outlet up to the left (Fig.
13) or one of the 6 right-hand modular connections at the
lower edge of the control circuit card (Fig. 11).
Dip switch
SW1
ABC Bus
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Mounting: Dismantle the safety guard over the electri-
cal cubicle of the Cooler. Loosen the oblong cable gasket
on the front of the electrical cubicle, just so much that the
quick connector of the communication cable can be inserted
through the opening. See Fig. 12.
A common cable can be used for both the signals. The ex-
isting cable glands can be used if the diameter of the cable
does not exceed 6.5 mm. If a thicker cable is used, wire it th-
rough any of the lead-throughs to the side of the cable gland.
Fig. 12
Start signal free normally-open contacts for cooling,
on/off
Connect to terminal blocks 45 and 46.
0-10 V control signal for regulating the cooling capacity
The control signal must not exceed 10 V +10 %.
Connect to terminal blocks 47 (−) and 48 (+).
Important!
Both signal inputs must be connected.
Type A and B Group alarms
Priority A group alarms are indicated on a closure of the potential-
free relay contacts between terminals 9 and 10.
Priority A group alarms are indicated on a closure of the potential-
free relay contacts between terminals 11 and 12.
In-operation indication
Indication that the pumps are in operation can be
obtained by an alternating potential free relay contact. Terminal
block 15(NC), 16(Com) and 17(NO).
A common cable may be used for all signals. The existing cable
gasket may be used if the cable diameter does not exceed 6.5
mm. If a thicker cable is used, it will have to be run through one
of the cable glands to the side of the cable gasket.
Installation in the GOLD, Version C.
Run the cable(es) into the electrical cubicle via the cable gland, or
via lead-throughs on the backside of the top panel hood.
Start signal
Connect to terminal numbers 7 and 8.
0-10 V control signal
Connect to terminal numbers 42 (-) and 43 (+).
Group alarm A and possibly group alarm B
Connect alarms from the Cooler to the External Alarm 1 or the
External Alarm 2 terminals. The alarm in the Cooler is factory-
preset with priority A, which means that only group alarm A
normally needs to be connected. Connect the conductors from
terminals 9 and 10 in the Cooler controller to terminal numbers
50 and 51, or 52 and 53, in the GOLD control unit.
In-operation Indications
There is no external operation input in the GOLD unit.
5 FERRITE BLOCK 019 210
Instructions for the Cooler with 0-10 V Controller
General
The Cooler is supplied with two optional accessories for
controlling the cooling load. Extra interference protection
is required for the Cooler variants for which the cooling
load is controlled by an external 0 –10 V DC signal.
To comply with the provisions of the EMC Directive that
deals with insensitivity to interference, analogue inputs
must be protected by a Ferrite block, 019 10.
Communication cable 019 007 is the accessory that must
be used if the Cooler operates together with the GOLD
ventilation unit, Version B. See individual instructions on
this topic.
Design
Ferrite block, 019 10 is designed to snap on around ca-
bles. The block consists of two ferrite halves that rest in a
plastic casing that can be opened. The plastic casing has
”hinges” and a simple lock that simplifies opening and
closing it around relevant conductors.
Dimensions: H= 15 mm, W= 15 mm, L= 9 mm and diame-
ter of openings = 6.6 mm
Installation
After installing the relevant cables for operating and con-
trolling the Cooler, fit the ferrite block.
Fit the ferrite block around the conductors connected to
terminals 47 – 48 (0-10 V control signal) and the conduc-
tors on terminals 43 – 44 (steady 10V output signal), if
used.
Position the ferrite block as near as possible to terminals
47 – 48.
43
44
47
48
- + - +
P N L
Ferritblock
019 210
45
46
Fig.26
1 2 3 4 5 6 7 8 101112
914 151617 1819 20 212223232413
25262728 29
30 31 32 34 35 36
33 40 41
42 43 44 4546 4748 4950 5152
39
38
37
- + - + - + - + - + - + - +
P N L
Fig. 13
Ferrite block
019 210
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6 Communication Cable 019 007
Instructions for the Cooler
General
The Cooler is supplied with two optional accessories for control-
ling the cooling load.
Communication cable 019 007 is the accessory that must be
used if the Cooler operates together with the GOLD ventilation
unit, Version B. See individual instructions on this topic.
Extra interference protection is required for the Cooler variants
for which the cooling load is controlled by an external 0 –10 V
DC signal. In these cases, the ”Ferrite block” accessory should be
used. See individual instructions.
Design
Communication cable 019 007 is a 5 m long flat cable, with a
type RJ 1 modular connection fitted at both ends.
The cable transfers normal communication signals between the
control unit and the GOLD unit (Version B), but not 4 V DC. Both
types of control have their own 4 V DC supply.
If an ordinary bus cable is used, the 4 V DC connections will be
interconnected and this will cause malfunctions.
Installation
Connect communication cable 019 007 to any of the ABC Bus
outlets on the control unit.
Use one of the holes in the oval rubber-covered cable glands on
the backside of the electrical cubicle’s junction hood, for running
the cable in to the control unit.
Move a part of the cable gland to the side to insert the Modular
connection through it. Connect the cable to a bus connection
on the control unit. Adjust the cable length inside the electrical
cubicle and adjust the cable in the cable gland. Refit the cable
gland in its correct position.
Lay the communication cable in a safe manner from the plastic
hood on the top panel of the GOLD unit.
Insert and connect the cable correspondingly in the Gold control
unit.
Commissioning
Set the Dip switches on the control unit in the Cooler for com-
munication with the GOLD.
Set Dip switches SW1, 1– 4 = On (up). The Cooler controller will
then operate as a ”slave”.
On delivery, Dip switch SW1, 1 = Off and 2 – 4 = On. The Cooler
controller is then a “master”.
Use the hand-held terminal to set the cooling unit function to
the auto operation mode.
Do this under SETTINGS. See the Operation and Maintenance
Instructions for the GOLD.
Fig. 14
‘
6 COOLING CONNECTIONS
Connection of the cooling coil and the cooling agent
cooler to cooling unit
6.1 Location
The cooling coil shall be located in the supply air ductwork.
Sizes 14 and 18: Install the refrigerating machine in the
exhaust air ductwork down-stream of the fan. Sizes 24,
34, 48 and 60: install the cooling agent cooler in the
exhaust air ductwork. The cooling unit is designed to
stand alone in the fan room.
6.2 Condensate from cooling coil
The cooling coil is equipped with a drip tray with drain
connection (to collect condensate from the coil). A drain
pipe should be arranged from the condensate drain con-
nection to a floor gulley. Size 14 units with the size 08
Gold unit: use the connection on the outlet air side and
plug the connection by the inlet air.
6.3 Liquid connections
Liquid is conveyed by means of pipework. The coils have
female-threaded connections and the Cooler has smooth
connections for brazing or compression ring fittings. The
liquid circuits should be connected in a counter-flow mode
to enable maximal cooling capacity. Shut-off valves should
be installed in the pipework leading to and from the cool-
ing coil to avoid having to drain the whole system of fluid
if work is necessary (such as having to replace a circulation
pump).
6.4 Venting nipples
Fit venting nipples at the highest point of the connect-
ing pipework at both the outlet and inlet of the cooling
coil and the cooling agent cooler respectively. Locate the
nipples where the water is on its way downstream.
See illustrations in Section 3.3.
6.5 Insulating the brine circuit
Insulate the brine circuit of the cooling coil in compliance
with local standards.
6.6 Connection to cooling unit
Connect the cooling coil and the cooling agent cooler to
cooling unit as illustrated in Section 3.3.
6.7 Safety drain
Safety valves for relieving the water circuits are fitted to
the expansion vessels. The safety valves open if the pres-
sure in the system is too high, i.e. they open if the pressure
reaches 1.5 bar.
The drain pipe from the safety valve should be extended to
a receptacle; not directly to a floor gulley since the liquid
circuit contains glycol.
One (sizes 14-18) or two hoses (sizes 4-60),13 mm i.d., is/
are run from the safety valves and out through the casing
to be fitted with an extension to a collecting tank, see Fig.
7 and 8.
Dip switch
SW1
ABC Bus
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6.8 Filling with water/glycol mixture
Caution!
The ethylene glycol used is toxic and must never be
consumed!
Accessories used
• Mixing vessel.
• Filling pump for pipes and coils.
5.8.1 Filling
For particulars of the volume to be filled, see information
for the relevant size in the charts in Section 11.
• Blend water/glycol (with 30% admixture of glycol)
into an appropriate mixing vessel and stir.
• Connect the filling hose to the tap in the unit.
Return from coil
Pump
Strainer
Fig. 15.1
• Open the tap.
• Use an appropriate filling pump with hose.
• Fill up the water/glycol mixture until the plastic vessel
is filled halfway (cold side). On the hot side the expan-
sion vessel can be filled until the safety valve opens.
See Fig. 15.1.
• Shut-off the tap.
Important!
The system must be vented, see Section 6.8.2.
It is essential to evacuate all the air out of the system. It is
advisable to run the pumps with connection to an open
vessel and to alternately vent the unit and hoses, and fill
up. See fig. 15.2.
6.8.2 Venting the system
Vent the system as follows:
• Set the safety switch of the cooling unit in the ON
position.
• Start the pumps.
Important!
If you are starting the unit for the first time, first follow
the directions in Section 6, Commissioning.
Return from coil
Pump
Strainer
Fig. 15.2
• Press button 3 TEST in the main menu for 5 seconds.
• Press the arrow button to advance down to Brine pump
press button 4 PROG, press button + so that the value
will be 1, do the same for the cooling agent pump.
• Open venting plugs by cooling coil and cooling agent
cooler. Cooling coil only on sizes 14 - 18.
• Open the venting nipples on the water connections
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• The venting holes shouldn’t be completely open, but
only slightly to allow the air to be forced out.
• To remove all the air from the cooling unit, start the
pumps to transport any air remaining in the circuit to
the venting nipple. Always check that there is
positive pressure in the system (check the
manometer), otherwise the air cannot be forced out.
If the pressure isn’t positive, fill up with more of the
water/glycol mixture.
• The system should maintain a positive pressure of
about 0.5 bar while you are venting it.
• If there is still air in the system, repeat the venting
procedure as many times as necessary until there is
no air left in the system.
• When the system reaches the correct pressure,
close the tap and take away the filling pump.
7 COMMISSIONING
7.1 Preparations
7.1.1 Before starting up for the first time
• The water circuits shall be filled and vented.
• The power supply must be connected.
• The external control signal or communication cable of
the GOLD unit must be connected.
• Check the Dip-switch settings on the control
card. For communication via bus with the GOLD
unit, all switches (1 - 4) should be in the ON position.
For control via external 0 - 10 V DC signals, switch 1
should be OFF and switches 2 - 4 should be ON.
• The hand-held micro terminal must be connected.
• Check that all fuses and motor protection circuit
breakers are switched in.
The control system of the unit has a preprogrammed fac-
tory setting, which makes the unit ready to use when basic
settings have been entered.
7.1.2 Starting up
• Set the Cooler safety isolating switch to the ON position.
• Take the hand-held terminal and enter the TEST mode
by pressing the TEST pressure button and holding it
pressed in for about 5 seconds.
• Start the pump/pumps to run for a few minutes to
check that the liquid control systems are free from air.
Start the pumps by pressing the PROG button to
advance to the control position. Use the ”arrow
right” and ”arrow left” buttons to move the marker
and press the ”+” button to highlight ”1” (operation)
or the ”--” button to highlight ”0” (stop).
• Repeat the same procedure to start the compressors
in the next menu image.
(The pumps must be in operation).
• Size 48 and 60 Coolers: the direction of rotation of
the compressors is important.
• Start one compressor at a time and advance 2 menus,
to the temperature reading image. Check that BRINE
TEMP drops and that COOLING AGENT TEMP rises
after just a few minutes of operation. If this does not
occur, the direction of rotation may be wrong. If this
is the case, change the sequence of the power supply
phase wires, see Section 7.1.3.
• Repeat this check to make sure that the direction of
rotation is correct.
• Set the compressors and pumps to 0 (stop).
• Press the RET button to return to the main menu.
From there, press the SET button to advance to the
settings mode. Press button 2 for Auto operation and
confirm by pressing the SET button.
• The Cooler is now ready for operation and will oper-
ate whenever the connected control signal calls for
cooling.
• Remove any impurities that may have collected in the
strainer(s)!
7.1.3 Correcting the phase sequence
Caution!
To be carried out by an authorized electrician or trained
service personnel only.
• Stop the Cooler by selecting SWITCHED OFF under
the settings mode.
• Then switch off the safety isolating switch on the
Cooler.
Important!
Isolate the power supply to the unit.
• Transpose the two phase power supply conductors to
obtain the correct direction of rotation.
• Switch on the power supply to the unit.
• Turn the safety isolating switch to the ON position.
• Start the Cooler as described under Starting up, see
Section 7.1.2.
Commissioning Report
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8 PROGRAMMING AND MANAG-
ING THE MENUS
8.1 The hand-held micro terminal
The GOLD Cooler has a hand-held micro terminal with
menus viewing settings, readings and possible alarms.
The hand-held terminal consists of a sealed control box
with a bus cable connection. The bus cable supplied is 3
m long and its one end is designed for connection to the
control circuit card in the electrical cubicle of the Cooler.
If a communication cable is used for connecting the Cool-
er to a GOLD unit, the hand-held terminal of the Cooler
can also be connected to a free bus connection on the
control circuit card or hand terminal of the GOLD.
The hand-held terminal has a four line display screen and
4 push-buttons The right-hand button contains an alarm
LED.
8.1.2 Display and Buttons
All settings can be read in clear text in the display.
All information is presented in various menus.
The main menu normally appears in the display, if no other
menu has been selected.
If no return to the main menu is manually keyed, the
display will automatically return to the main menu after
about 30 minutes.
The functions of the four buttons change depending
on which menu is shown. The function of the buttons is
explained by the caption or symbol shown in the display
right above each button. For explanation, see Section 8.2.
8.2 Menu button captions and symbols
The most common button functions are described below.
In some of the separate menus, the buttons have other
functions. These different functions are explained in the
relevant menu section.
↓Advance 1 step to the next menu in the group.
↑Go back 1 step to the previous menu in the group.
RET Return to preceding menu level (main or start
menu).
PROG Changes to the submenu of the menu shown
(alter settings level).
+ Increases the value of the highlighted figures.
− Decreases the value of the highlighted figures.
→Advance to highlight new figures/line.
After the last figure/line, the image changes back
to the readings level in the menu.
←Go back to highlight previous figures/line.
After the last figure/line, the image changes back
to the readings level in the menu.
1 - 4 Used to select a function if numbered options
appear in the image displayed.
SET Confirms your choice and changes the image
back to the readings level in the menu.
8.3 Menu groups and levels
The menus of the hand-held micro terminal are broken
down into various menu groups. The four menu groups
can be selected in the main menu by pressing the buttons
identified by their captions: INFO, SET, TEST and ALARM.
Menus and functions are explained under each group as
specified in Section 9.
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9 MENUS
9.1 Main Menu
INFO : INST : : TEST : LARM
*COOLER* TUES 12:49
. . : 100%
AUTO OPER
▼
Fig. 16
The COOLER image indicates type of unit, the present day
of the week and the time.
The second and third lines indicate the in-operation status
of the cooling unit.
SWITCHED OFF is shown when the control circuit card has
not received an operation command. STOP is shown when
operation command has been given, but the cooling load
signal is 0. A percentage figure that may vary between
0–100% together with the text AUTO OPER indicates the
cooling capacity at which the unit is operating.
The text DELAYED START and the percentage figure are
alternately displayed when any of the cooling compressors
are unable to start, because the restart delay time has not
run out.
9.2 Information Menus
INFO : INST : : TEST : LARM
▼
*COOLER* TUES 12:49
. . : 100%
AUTO OPER
Main menu.
: : : RET :
▼
OPER LEVEL 100%
BRINE PUMP 1
COOLING AGENT PUMP 1
OPER LEVEL indicates the present cooling load, as in the
main menu.
BRINE PUMP shows the pump status.
1 = On and 0 = Off.
COOLING AGENT PUMP shows the status of the pump.
1 = On and 0 = Off. (Size 14 and 18 Coolers: this line is
empty).
: : : RET :
▼
COMPRESSOR.1 1
COMPRESSOR.2 1
COMPRESSOR.1 shows the status of compressor 1.
1 = On and 0 = Off.
COMPRESSOR.2 shows status of the compressor 2.
1 = On and 0 = Off.
: : : RET :
▼
BRINE TEMP -7,9˚C
COOLING AGENT TEMP 34,6˚C
PROGRAM VERSION : 1.14
BRINE TEMP shows the present temperature of the brine
medium.
COOLING AGENT TEMP shows the present temperature of
the heat carrying medium. (Size 14 and 18 Coolers: CON-
DENSER TEMP is displayed).
PROGRAM VERSION shows the current program version of
the control equipment.
: : : RET :
*OPER TIME DAY AND NIGHT*
COMPRESSOR 1 2999
COMPRESSOR 2 1998
OPER TIME DAY AND NIGHT shows current operation time
for each compressor. The time is measured in minutes
but specified in day and night, due to limited space in the
display.
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9.3 Settings Menus
INFO : INST : : TEST : LARM
* COOLER * TUES 12:49
STOP
AUTO OPER
▼
Main menu.
: : :RET : PROG
** OPER MODE **
AUTO OPER
▼
The preset operating mode is shown on the second line.
Pressing PROG changes the image to the settings menu.
1 = SWITCHED OFF and 2 = AUTO OPER.
Select appropriate number and confirm by pressing SET.
: : :RET : PROG
* REGULATION SPEED*
STAGE TIME 600S
▼
Preset value for the STAGE TIME, delayed switching in
from compressor stage 1 to stage 2 and vice-versa. Same
delay also applies to switching between stage 2 and stage
3.
Pressing PROG changes the image to the settings menu.
The step time can be set between 0 and 600 s.
: : :RET : PROG
*** COOLER ***
SIZE 24
▼
The preset COOLER SIZE is shown on the second line. The
preset size must agree with current unit size and should
only be changed if the control circuit card is replaced.
Pressing PROG changes the image to the settings menu.
The sizes 14, 18, 24 , 34, 48 and 60 can be set.
: : :RET : PROG
* ACTTUAL TIME *
WED TIME 07:30
DATE 17/03 - 2003
▼
Shows preset ACTUAL TIME. The second line shows the
current day of the week and time. The third line shows
current date. (dd/mm – year)
Pressing PROG changes the image to the settings menu.
: : :RET : PROG
* SPRåK/LANGUAGE *
ENGLISH
▼
Shows preset LANGUAGE. The second line shows current
language selected.
Pressing PROG changes the image to the settings menu.
Press the arrow up or down to advance to the desired lan-
guage from the current list and confirm by pressing SET.
If the Cooler is connected to the GOLD unit by means of
a communication cable, same language appears in both
displays.
: : :RET : PROG
FACTORY SETTING 0
Activating the FACTORY SETTING. The factory setting
function resets all the parameters back to their original
settings. This function should only be used when problems
with settings have arisen.
Pressing PROG changes the image to the settings menu.
Set the value to 1, confirm by pressing SET. The param-
eters will be reset when the display image returns to the
Main Menu.
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9.4 Test menus
Whenever any of the menus under TEST is selected, the
control system will leave the normal in-operation status
and go over to manual test run status.
Warning!
The various ouputs are now controlled by the operator
in fully manual mode. The safety functions are switched
off and the operator assumes all responsibility.
The only provision is that the pumps must be in operation
before any compressor can be started.
INFO : INST : : TEST : LARM
*COOLER* TUES 12:49
SHUT OFF
▼
Main menu
The TEST button must be held in for 5 s. before the
image will change.
: : :RET : PROG
OPER LEVEL 00%
BRINE PUMP 1
COOLING AGENT PUMP 1
▼
OPER LEVEL indicates the current percentage, the same as
in the main menu.
BRINE PUMP and COOLING AGENT PUMP shows the sta-
tus for each pump in the manual mode.
Pressing PROG alters the image to the settings menu.
(Cooler 14 and 18: Line 3 is empty.
: : :RET : PROG
COMPRESSOR.1 1
COMPRESSOR.2 1
▼
COMPRESSOR 1 and COMPRESSOR 2 show the status of
each compressor in the manual mode.
Pressing PROG alters the image to the settings menu.
Important!
The pumps must be in operation before the compressors
can be started.
: : :RET : PROG
GROUP ALARM A 1 B 0
OPER INDICATION 1
OPER INDICATION 10V
▼
GROUP ALARM A, B and OPER INDICATION show the
status of each relay output in the manual mode.
Pressing PROG alters the image to the settings menu.
: : : RET :
BRINE TEMP -2,6˚C
COOLING AGENT TEMP 34,6˚C
BRINE TEMP and COOLING AGENT TEMP show present
temperatures. (For the size 14 and 18 Coolers: BRINE
TEMP and CONDENSER TEMP is shown).
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9.5 Alarm menus
INFO : INST : : TEST : LARM
▼
* COOLER * TUES 12:49
SWITCHED OFF
Main menu
: : : RET :
* ALARM HISTORY *
L1 NR 55 17/02 12:15
L2 NR 54 14/02 12:11
▼
: : : RET :
* ALARM HISTORY *
L3 NR 52 12/01 22:47
L4 NR 52 11/02 02:30
▼
ALARM HISTORY shows the 4 most recent alarms initiated
in the system. L1 shows the most recent one.
The alarms are shown with the number of the alarm and
the date and time when it was initiated.
: : :RET : PROG
* PRESET ALARM * NR 50
PRIORITY 1
ALARM IND 1 STOP 1
PRESET ALARM is the reading and settings menu for the
12 different alarms that have been present in the system.
By pressing PROG the image changes to the menu for set-
ting the alarm numbers. From here you can advance to the
desired alarm number.
By pressing SET the image changes over to the level for
setting of the current priority and condition of the alarm.
PRIORITY can be selected for 1 or 2.
ALARM INDICATION can be selected to 0 (no indication on
the hand terminal) or 1.
STOP can be selected by marking 0 (when alarm the unit
continues) or 1 (when alarm the unit is switched off).
10 ALARMS
10.1 General
The alarm number and cause is displayed in clear text on
the screen. A red lamp incorporated into button number
four also flashes on the hand-held micro terminal.
Typical alarm text in the display.
: : : : RES
* * * ALARM 50 * * *
HIGH PRESSURE SWITCH
COMPRESSOR. 1 TRIPPED
Fig. 17
10.2 To reset alarms
Manual reset means, unless otherwise indicated, that the
RES button on the hand-held terminal is pressed.
Automatic reset means that the control unit resets the
alarm after the fault has been remedied.
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