Swegon COOL DX 008 User manual

GB.COOLDX.SI.G.190603
Chiller COOL DX version G
Installation and Maintenance Instructions
SILVER C, size 008-080
The document was originally written in Swedish.
COOL DX

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CONTENTS
1. Overview 3
1.1. General 3
1.2 Basic function diagram 4
2 Safety Instructions 5
2.1 Safety Isolating Switch/Main Switch 5
2.2 Risks 5
2.3 Electrical equipment 5
2.4 Authorisation 5
2.5 Decals 5
3 Installation 6
3.1 Unloading/site transport 6
3.1.1 Handling with truck 6
3.1.2 Handling with crane 6
3.2 Arrangement 6
3.3 Basic Installation Diagram COOL DX 7
3.3.1 Height adaptation to SILVER C/water trap 8
3.3.2 Connection to SILVER C air handling unit,
COOL DX, sizes 008-012 9
3.3.3 Connection to SILVER C air handling unit,
COOL DX, sizes 020-040 10
3.3.4 Connection to SILVER C air handling unit,
COOL DX, sizes 060-080 11
3.3.5 Stand-alone COOL DX 11
3.3.6 Supply air filter 11
4 Power connection 12
4.1 Supply connection 12
4.2 Connection of signal, 0 – 10 V 12
5 Commissioning 13
5.1 Preparations 13
5.1.1 Before initial start up 13
5.1.2 Control functions 13
5.1.3 Pressure sensor 13
5.1.4 Phase sequence monitor 14
5.1.5 Measure whether the phase-sequence is wrong 14
6 Alarms 14
7 Maintenance 15
7.1 Cleaning 15
7.2 Handling of refrigerant 15
7.3 Leakage tracing interval/Obligation to report 15
7.4 Service 15
8 Trouble shooting and leakage tracing 16
8.1 Troubleshooting Schedule 16
8.2 Leakage Tracing 16
9 Dimensions 17
10 General technical data 18
11 Internal wiring diagram 19
12 Commissioning Record 23

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Refrigerant
The COOL DX has double refrigerant circuits, which are
separate from each other. Type R410A refrigerant is used.
The refrigerant circuits are charged with refrigerant on
delivery. At present, this refrigerant has no known influ-
ence on the ozone layer and no known future restrictions
are anticipated.
Refrigerant volume
See section 10. General technical data.
Installation check/Obligation to report/
Leakage tracing interval
Must be carried out according to the F-Gas Regulation
EU/517/2014 and associated local legislation.
Quality System to ISO 9001
and Environmental Management System to ISO
14001
Swegon AB works to a certified quality system that con-
forms to ISO 9001 standard and a certified Environmental
Management System that conforms to ISO 14001.
1. OVERVIEW
1.1. General
COOL DX Chiller
Chiller COOL DX is a complete chiller for comfort cooling
in the air handling system. All the components refrigera-
tion engineering-wise and electrically pre-wired and col-
lected inside a common casing. The outer skin is made
of galvanized sheet steel, pre-painted in Swegon’s grey
metallic colour (closest comparable: RAL, 9007). The inner
skin material is aluminium-zinc coated sheet steel. Envi-
ronmental class C4. Panel thickness of 52 mm with inter-
vening insulation consisting of mineral wool.
The cooling coil and condenser are fabricated of copper
tubing and profiled aluminium fins; the casing is made of
galvanized sheet steel.
The chillers are test run prior to delivery.
The COOL DX is available in 19 capacity variants spread
on nine physical sizes, designed for use with the size 008 -
080 SILVER C air handling units.
Compressors
The compressor in the COOL DXchiller is of scroll compres-
sor type and/or rotary compressors.
Completely direct-acting system
The COOL DX has a completely direct-acting system. It has
an evaporation coil for direct-evaporating refrigerant on
the cold side and a condenser coil on the hot side.

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Function
There are two refrigerant circuits in the chiller. The circuits
are separated from one another.
Each circuit is equipped with its own finned condenser,
finned evaporator and compressor.
The two compressors are of different capacity, which
makes it possible to regulate the capacity in 3 steps.
COND
VSH2
M1 M2
EVAP
VET1VET2
IPL1IPL2
FD1FD2
COND Condenser
VSH1 Overpressure protection
VSH2 Overpressure protection
B1-1 High pressure sensor
B2-1 Low pressure switch
B1-2 High pressure sensor
B2-2 Low pressure switch
BP1-2 High pressure switch, alarming
BP2-2 High pressure switch, alarming
M1 Compressor
M2 Compressor
M3 Compressor (size 80, cap. var. 3)
EVAP Evaporator
VET1 Expansion valve with thermostat
VET2 Expansion valve with thermostat
IPL1 Sight glass, cooling medium circuit 1
IPL2 Sight glass, cooling medium circuit 2
FD1 Filter dryer
FD2 Filter dryer
B2-2
HP
The gaseous refrigerant is compressed by cooling com-
pressors M1 and M2 and from there flows to condenser
COND, where it is cooled by the extract air and is con-
densed to liquid form.
The gaseous refrigerant flows through expansion valve
VET1 and VET2, where the pressure and the temperature
decrease.
From the expansion valves, the refrigerant advances to
evaporator EVAP, where the refrigerant evaporates and
cools down the outdoor air.
The evaporated refrigerant flows from evaporator EVAP
further to the suction side by the compressors to once
again be compressed.
Regulation
The cooling capacity is regulated in three binary steps by
having one or two compressors in operation.
COOL DX is controlled via a signal, 0 – 10 V.
Step 1: When cooling is needed, Compressor M1 is start-
ed.
Step 2: If more cooling is needed, Compressor M2 starts
and at the same time Compressor M1 stops. An adjust-
able time delay (a step duration of 250 seconds) ensures
that Compressor M2 will not start until Compressor M1 is
operating at full capacity.
Step 3: If even more cooling is needed, Compressor M1 is
restarted and is run at the same time as Compressor M2.
This third cooling step is also delayed by a preset time de-
lay setting. In addition, the restarting time (300 seconds)
for Compressor M1 shall have expired.
If less cooling is needed and the compressors are subse-
quently switched out step-by-step, there will be no delay
between compressors. The restarting time (300 seconds)
for Compressor M1 shall have expired to enable it to start
again in Step 1 after it has been operated in Step 3.
If any compressor is stopped, the restarting time must
expire before a restart can take place. The restart time is
calculated from one start to the next start.
If the pressure in the cooling circuit becomes too low, or
if the pressure in the condenser circuit becomes too high,
the compressor is stopped.
When the restart time has expired, the compressors will try
to restart.
If the pressure increases more, high pressure switches BP1-
2 and BP2-2 will trip and stop the chiller.
Alarms are shown on the hand-held terminal, see separate
instructions for IC208CX control.
Pressure switches BP1-2 and BP2-2 can be manually reset
by pressing a button under each protective sock on the
upper side of the pressure switch. This can be done with-
out removing the protective sock.
1.2 Basic function diagram
B1-2
LP
HP
B2-1
HP
B1-1
LP
HP
BP2-2BP1-2
VSH1
M3

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2 SAFETY INSTRUCTIONS
2.1 Safety Isolating Switch/Main Switch
The safety isolating switch is positioned on the inspection
side of the chiller.
The safety switch should not be used for start or stop of
the chiller.
Ensure that COOL DX is shut-off by turning off the chiller
via the display.
When this has been carried out, the current can be iso-
lated with the safety switch. The safety switch must be
switched off in order to make it possible to open the
inspection door.
Important:
Always switch off the safety isolating switch before ser-
vicing the unit if not otherwise specified in the pertinent
instructions.
2.2 Risks
Warning
Before carrying out any work, make sure that the power
supply to the air handling unit has been switched off.
Warning
Under no circumstances may the refrigerant circuit be
opened by unauthorised personnel, since it contains gas
under high pressure.
Risk areas with refrigerant
Risk area for refrigerant is in principal inside the entire
chiller.
For handling when leakage, see section 7.2.
Refrigerant used is R 410A.
Warning
The unit’s inspection door must not be opened when
the SILVER C air handling unit is operational. The door
can open and injure personnel. (The safety switch on the
COOL DX must be switched off in order to make it pos-
sible to open the inspection door of the chiller.)
2.3 Electrical equipment
The machine’s electrical equipment is housed in a separate
cabinet inside one of the inspection doors.
2.4 Authorisation
Only authorized electricians shall be permitted to install
electrical wiring in the unit.
Only an accredited refrigeration company shall be permit-
ted to modify or repair the refrigeration circuit.
Other service work in the unit should only be performed
by service personnel trained by Swegon.
2.5 Decals
The type number mark with type designation, serial num-
ber, refrigerant volume and more is affixed on the chiller’s
door.
Type designation: COOLDX-aa-F-c-d-e-f-g
SILVER C size
Capacity variant

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3 INSTALLATION
3.1 Unloading/site transport
Important:
All transport should take place with the chiller in hori-
zontal position.
3.1.1 Handling with truck
Warning
High centre of gravity! Lift the chiller carefully.
3.1.2 Handling with crane
Place two line spreaders on top of the chiller and two on
the underside of the pallet or below the chiller and lift in
the pallet (or the chiller if the pallet is not to be included).
See the illustration.
3.2 Arrangement
Place the COOL DX at a suitable location.
Safety isolating switch/main switch must have the requi-
site space to serve according to applicable electrical regu-
lations.
The unit can stand with the back against the wall, but to
facilitate any service of the rear compressor, a distance of
about 1 metre is recommended.

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3.3 Basic Installation Diagram COOL DX
Locate the COOL DX chiller against the outdoor air and
exhaust air side of the SILVER C air handling unit. COOL
DX can also be installed as a stand-alone unit, if you order
a stand-alone COOL DX, select the variant with end con-
nection panels.
The dimensions and capacity of the chiller COOL DX is
matched for connection to the SILVER C air handling unit
in sizes 008-080.
For a list of the capacity sizes of chillers matched to re-
spective unit size, see section 10. General technical data.
COOL DX 008
COOL DX 012-080
Right-hand version Left-hand version
Cooling coil in lower level/SILVER C fan arrangement 1 Cooling coil in upper level/SILVER C fan arrangement 2
Cooling coil in upper level/SILVER C fan arrangement 1 Cooling coil in lower level/SILVER C fan arrangement 2
Right-hand version
Left-hand version
Outdoor air Supply air Extract air Exhaust air

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3.3.1 Height adjustment to the height of the SIL-
VER C/water trap
COOL DX, size 008
In combination with the SILVER C RX 08
The SILVER C air handling unit can be mounted on base
beams, a stand or some other form of foundation. Base
beams and stands are available as accessories.
Appropriate base beams and stands are also available as
accessories for the COOL DX. The base beams/stands are
matched to one another in terms of height. The stands
also provide space for accommodating a possible water
trap in the lower level (right-hand unit version).
In combination with the SILVER C PX 008
The air handling unit is supplied with base beams. A set of
legs (accesssory) can be mounted in the base beams.
Appropriate base beams and set of legs are also available
as accessories for the COOL DX. The base beams/sets of
legs are matched to one another in terms of height. The
sets of legs also provide space for accommodating a pos-
sible water trap in the lower level (right-hand unit version).
COOL DX, sizes 012-080
The SILVER C air handling unit and the COOL DX cooling
unit are supplied with a 100 mm high base beam.
Applicable to a cooling coil in the lower level:
If a water trap (accessory) is fitted, the SILVER C air han-
dling unit and the cooling unit must be raised at least 50
mm to provide space for the water trap. Adjustable sup-
port feet (accessories) can be appropriately fitted to the
base beams for this purpose.

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3.3.2 Connection to SILVER C air handling unit,
COOL DX, sizes 008-012
The sealing strips are factory-fitted to the unit.
The chiller is connected directly to the air handling unit by
means of the supplied bolts + pre-fitted rivets nut and 2
expansion locking devices, see the figure.
Secure the chiller to the air handling unit from inside the
unit via the inspection door. It may be necessary to remove
the fan assembly or filter cassettes in order to reach the
expansion-type locking device.
Expansion-type locking device
In this case, fastening is done with the bolts and
pre-fitted rivet nuts.
COOL DX Chiller

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3.3.3 Connection to SILVER C air handling unit,
COOL DX, sizes 020-040
The sealing strips are factory-fitted to the unit.
Dock the chiller directly to the SILVER C air handling unit
by means of the supplied bolts (4 bolts) + pre-fitted rivet
nuts.
In this case, fastening is done with the bolts supplied and pre-fitted rivet nuts in
predrilled holes.
Option 1
If there is sufficient space for working from the rear of the
air handling unit, the simplest way to secure the chiller at
the rear edge of the SILVER C air handling unit is by exter-
nally jointing it, see Illustration 1.
Secure the chiller to the front edge of the SILVER C air
handling unit within the unit via the inspection cover, see
Illustration 3.
Option 2
The chiller is secured to the back edge of the SILVER C
air handling unit within the casing, see Illustration 2. This
requires removal of the fan assembly and filter cassettes.
Secure the chiller to the front edge of the SILVER C air
handling unit within the unit via the inspection cover, see
Illustration 3.
To secure accessories to the front edge
In this case, fastening is done with the bolts supplied and pre-fitted rivet nuts in
predrilled holes.
To secure accessories to the rear edge
Alternative 1, External installation
Alternative 2, Internal installation
Illustration 2
Illustration 3
COOL DX Chiller
COOL DX Chiller
Remove the cover and insulation. Secure the chiller to the SILVER C air handling unit
with the bolts supplied and pre-fitted rivet nuts. Refit the blanking plate and the
insulation.
The SILVER C air handling unit, rear
Illustration 1
COOL DX chiller, rear