TechLine TECNAIR LV C Series User manual

www.tecnairlv.it
[email protected]
TECNAIR LV S.p.A
Via Caduti della Liberazione 53
21040 UBOLDO (VA)
Tel. [phone] / Fax [phone]
Manual code 75803707A.0708
INSTALLATION, USE AND MAINTENANCE
MANUAL
SCOPE OF THIS MANUAL:
DIRECT EXPANSION AND CHILLED WATER
AIR CONDITIONERS
SERIES C
Библиотека СОК 

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CONTENTS
1HOW TO USE THIS MANUAL 5
1.1 IMPORTANT WARNINGS 5
2WARRANTY 6
3DESCRIPTION OF THE UNIT 7
3.1 UNIT CODE 7
3.1.1 O / OVER (UPFLOW DISCHARGE) 8
3.1.2 U / UNDER (DOWNFLOW DISCHARGE) 8
3.2 OPERATING LIMITS 9
4INSTALLATION PROCEDURE 10
4.1 TRANSPORTATION 10
4.2 RECEIVING THE MACHINES ON SITE 11
4.3 POSITIONING THE UNIT AND INSTALLATION CLEARANCES 12
4.4 PLENUMS AND PLINTHS 13
4.4.1 INSTALLATION OF PLENUMS AND DUCT SECTIONS 14
4.4.2 INSTALLATION OF THE ADJUSTABLE PLINTHS 14
4.5 CEA AIR-COOLED CONDENSERS 15
4.6 WATER CONNECTIONS 17
4.6.1 CONDENSATE DRAIN AND SIPHONS 17
4.6.2 WATER-COOLED CONDENSERS 18
4.6.3 PRESSURE CONTROLLED VALVE 18
4.6.4 WATER COILS 19
4.6.5 INTERNAL IMMERSED ELECTRODE HUMIDIFIER 20
4.7 REFRIGERANT CIRCUIT CONNECTIONS 21
4.7.1 DISCHARGE OR HOT GAS LINE 21
4.7.2 LIQUID OR RETURN LINE 21
4.7.3 NON-RETURN VALVES ON DISCHARGE AND RETURN LINES 21
4.7.4 SOLENOID VALVE ON THE LIQUID LINE 22
4.7.5 VERY LOW EXTERNAL TEMPERATURE KIT 23
4.7.6 ROUTING OF THE REFRIGERANT CIRCUIT PIPES 24
4.7.7 DIAMETERS OF REFRIGERANT CIRCUIT CONNECTION PIPES 25
4.7.8 COMPLETION OF THE REFRIGERANT CHARGE 26
4.7.9 PRESSURE REGULATOR OF CEA CONDENSERS 28
4.8 ELECTRICAL CONNECTIONS 29
4.8.1 INSTALLATION OF THE REMOTE CONTROL INTERFACE 30
4.8.2 INSTALLATION OF THE REMOTE CONTROL TERMINAL AT A DISTANCE OF
OVER 50 M 31
5CHECKS AND FIRST STARTUP 32
6DEACTIVATION, DISASSEMBLY AND SCRAPPING 35
7USE OF THE AIR CONDITIONING UNIT 36
7.1 TEMPERATURE CONTROL 36
7.1.1 PROPORTIONAL CONTROL 36
7.1.2 PROPORTIONAL + INTEGRAL CONTROL 36
7.1.3 PROPORTIONAL + INTEGRAL + DERIVATIVE CONTROL 36
7.1.4 DIRECT EXPANSION AIR CONDITIONERS 37
7.1.5 CHILLED WATER AIR CONDITIONER 37
7.1.6 HEATING WATER COILS 37
7.1.7 COOLING CAPACITY CONTROL WITH HOT GAS INJECTION VALVE 38

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7.1.8 COOLING CAPACITY CONTROL WITH HOT GAS INJECTION VALVE AND
ELECTRONIC EXPANSION VALVE 38
7.2 SUPPLY AIR TEMPERATURE CONTROL (LIMIT) 39
7.2.1 µAC MICROPROCESSOR 39
7.2.2 pCO MICROPROCESSOR CONTROL 39
7.3 HUMIDITY CONTROL 40
7.3.1 DIRECT EXPANSION AIR CONDITIONERS 40
7.3.2 CHILLED WATER AIR CONDITIONER 41
7.3.3 SIMULTANEOUS HUMIDIFICATION AND COOLING 41
7.3.4 DEHUMIDIFICATION LOCK 41
8VENTILATION 42
8.1 FANS WITH 5-SPEED AUTO-TRANSFORMER 42
8.2 FANS WITH 0-10 V MODULATING CONTROL (pCO) 42
8.2.1 CONSTANT FLOW RATE CONTROL 42
8.2.2 CONTROL WITH CONSTANT PRESSURE IN THE UNDERFLOOR OR SUPPLY
DUCT 42
8.2.3 CONTROL OF AIR FLOW RATE ACCORDING TO COOLING CAPACITY 43
9FREE COOLING AND TWIN SOURCES (pCO) 44
9.1 WATER FREE COOLING 44
9.1.1 FREE COOLING CONTROL 44
9.2 DIRECT EXPANSION TWIN SOURCES 45
9.2.1 DIRECT EXPANSION - WATER TWIN SOURCES(OCA…?/TS - UCA…/TS) 45
9.2.2 WATER - DIRECT EXPANSION TWIN SOURCES(OCA…/TS - UCA…/TS) 45
9.3 WATER CHILLED TWIN SOURCES 46
9.3.1 WATER - WATER TWIN SOURCES(OCU…/TS - UCU…/TS) 46
10 LOCAL NETWORK 47
10.1 MASTER - SLAVE LOCAL NETWORK 47
10.2 CASCADE LOCAL NETWORK(pCO) 47
10.3 CRITICAL SITUATIONS 47
10.4 EMERGENCY OPERATION 47
11 ROUTINE AND MAJOR MAINTENANCE 48
11.1 PROGRAMMED MAINTENANCE CHART 48
11.2 MAINTENANCE OF THE FANS 50
11.3 REFRIGERATION CIRCUIT CHECKS 50
11.4 MAINTENANCE OF THE ELECTRICAL BATTERY 50
11.5 MAINTENANCE OF THE ELECTRICAL PANEL 50
11.6 MAINTENANCE OF THE AIR FILTERS 50
11.7 MAINTENANCE OF CEA AIR-COOLED CONDENSERS 51
12 FAULT DIAGNOSIS 52
12.1 DIRECT EXPANSION AIR CONDITIONERS - REFRIGERATION CIRCUIT PROBLEMS 53
12.2 CHILLED WATER AIR CONDITIONER - WATER CIRCUIT PROBLEMS 55
12.3 HEATING SECTION PROBLEMS 56
12.4 DEHUMIDIFICATION PROBLEMS 57
12.5 VENTILATION PROBLEMS 59
13 GLOSSARY 60
14 NOTES 61

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1 HOW TO USE THIS MANUAL
This manual describes the procedures for the installation, use and maintenance of series C air conditioning
units.
The following chapters contain information essential for obtaining the best performance from the unit you have
purchased; TECNAIR LV therefore recommends that you study this manual carefully.
Some of the topics covered in this manual refer to the functions of the microprocessor controls; TECNAIR LV
therefore advises your to read the MICROPROCESSOR CONTROL USER MANUAL, which is also supplied with the
unit, in order to gain a full understanding of the components and functions of your air conditioner.
If after reading this manual you are still experiencing difficulties or require any further clarification, please do not
hesitate to contact our after-sales service:
After-sales office
Tel. [phone] / Fax [phone]
@: [email protected]
1.1 IMPORTANT WARNINGS
The equipment described in this manual has been constructed to operate without risk for the intended
purposes, provided that:
•The installation, connection, operation and maintenance of the appliance are carried out by qualified
personnel in accordance with the instructions contained in this manual.
•All the conditions prescribed in the user manual for the unit’s microprocessor control are observed.
Any other use or modification of the equipment,
unless expressly authorised by the manufacturer, is deemed improper.
Any injuries or damage sustained as a result of improper use shall be the sole responsibility of the user.

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2 WARRANTY
TECNAIR LV air conditioners are subject to the following warranty conditions which are automatically deemed
to have been understood and accepted by the customer at the time of placing the order.
TECNAIR LV guarantees that the products supplied are well made and of good quality. It undertakes during the
period of warranty specified herein to repair or to replace with new at its own discretion, in the shortest time possible,
those parts found to present recognised defects in materials, construction or workmanship that render them unfit for the
intended use, provided that these faults are not the result of negligence on the part of the purchaser, neglect or
inexperience of the user, normal wear and tear, damage caused by third parties, acts of God or other causes not arising
out of manufacturing defects. TECNAIR LV however shall not be liable to for compensation for direct or indirect damage
of any nature incurred for any reason.
Defective components will be replaced at the Uboldo manufacturing plant, and all transportation and
replacement costs shall be borne by the Purchaser.
The duration of the warranty is 2 (two) years from the date of consignment.
The warranty shall be rendered void automatically if the equipment is repaired or modified or in any way
completed (such as, for example, in the case of non-supply of an electrical panel or similar) or in the case of the
installation of non-original parts (parts not supplied by TECNAIR LV).
The above warranty conditions apply provided that the Purchaser has fulfilled all contractual obligations and in
particular those regarding payment.

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3 DESCRIPTION OF THE UNIT
The machine in question is an air conditioner with direct expansion or chilled water coil designed for use in
computer centres.
The cabinet consists of hot-galvanised sheet panels in a frame constructed of painted aluminium section; the
panels are made from hot-galvanised sheet steel covered in a PVC film, secured by quick-thread screws that can be
unscrewed using a special safety wrench. The structure incorporates a thermal and acoustic insulation system using self-
extinguishing materials (polyurethane foam) protected by plastic film.
The machine comprises the following sections:
•Ventilation section: consisting of one or more plug fans.
•Filter section: self-extinguishing non-regenerable filters; the machine includes provision for the use of
a differential pressure switch to allow display of clogged filter warning signal;
•Refrigeration circuit: comprising an expansion coil with copper pipes and aluminium cooling fins, a
scroll compressor fixed to the machine frame on rubber mountings, thermostatic expansion valve,
receiver-drier, plate-type condenser (accessory), low pressure switch (automatic reset) and high
pressure switch (manual reset), pressurisation nitrogen charge, antifreeze lubrication oil charge;
•Water circuit (Series U): with cooling expansion coil with copper pipes in aluminium cooling fins, 3-way
motorised valve with manual emergency control, water circuit with anti-condensation thermal
insulation;
•Electrical power and control panel.
3.1 UNIT CODE
The code contains the following information:
O C A 5 1 a H FC R407C
1 2 3 4 5 6 7 8 - 9 10
O Upflow air discharge
1 O
Air discharge type: U Downflow air discharge
2 C
Series for technology rooms
A Direct expansion coil with remote condenser
3 A
Cooling type: U Chilled water coil with remote cooling
4 5
Nominal size (nominal cooling capacity in TONS)
5 1
Number of cooling circuits or number of rows on chilled water coil
6 a
Series modification index
H High air flow rate
7 H
Air flow rate/cooling capacity ratio L Low air flow rate
8 FC
FREE COOLING unit type
9 TS
TWIN SOURCES unit type
10 R407C
Refrigerant type

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3.1.1 O / OVER (UPFLOW DISCHARGE)
3.1.2 U / UNDER (DOWNFLOW DISCHARGE)

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3.2 OPERATING LIMITS
SERIES C AIR CONDITIONING UNIT
UNIT TYPE DIRECT EXPANSION CHILLED WATER
CHARACTERISTICS L H -
MAXIMUM
TEMPERATURE 30°C 30°C 30°C
MINIMUM
TEMPERATURE 21°C 19°C 20°C
MAXIMUM
HUMIDITY 50% 50% 50%
MINIMUM HUMIDITY 20% 20% 20%
STORAGE
CONDITIONS Temperatures from-20°C to + 50°C
CONDENSERS AND DRY COOLER
UNIT TYPE AIR WATER
CHARACTERISTICS WITH VARIATOR
AND ELECT. PANEL
WITHOUT
VARIATOR
AND ELECT. PANEL
WITH PRESSURE
CONTROLLED
VALVE
WITHOUT
PRESSURE
CONTROLLED
VALVE
Up to 30°C: ∆T = 17°C
Up to 35°C: ∆T = 15°C
Up to 40°C: ∆T = 13°C
MAXIMUM
TEMPERATURE
Up to 46°C: ∆T = 10°C
45°C
MINIMUM
TEMPERATURE
IN air
T°
- 25°C -40°C
IN
water
T°
7°C 25°C
WATER CIRCUITS
TYPE CHILLED WATER HOT WATER INTERNAL
HUMIDIFIER
WATER-COOLED
CONDENSER
MAXIMUM
PRESSURE 16 bar (1.6 Mbar) 16 bar (1.6 Mbar) 8 bar (0.8 Mbar) 16 bar (1.6 Mbar)
MINIMUM
PRESSURE - - 1 bar (0.1 Mbar) 1 bar (0.1 Mbar)
MAXIMUM ∆P AT
VALVE 1 bar (100 Kpa) 1 bar (100 Kpa) - -
MAXIMUM
TEMPERATURE - 85°C 40°C -
MINIMUM
TEMPERATURE 5°C - 1°C -

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4 INSTALLATION PROCEDURE
4.1 TRANSPORTATION
Unless otherwise agreed with the Customer, TECNAIR LV shall supply their machines ex works with standard
packaging consisting of: wooden pallet (1), protective polystyrene packing (2,3) and polythene sheet (4).
During transportation the machines must not be laid on their sides or overturned but must remain in the vertical
position at all times otherwise their internal components could be damaged.
As the Carrier is always responsible for damage sustained by the goods during transport, before signing the
delivery note to accept the supply, check the integrity of the packaging and that there are no visible signs of damage to
the conditioner or the leakage of oil or refrigerant.
In the case of evident damage to the unit or if there is slightest doubt as to whether the conditioner has been
damaged during transport, it is necessary to express your reservations in writing to the Carrier, whilst also informing the
TECNASIR LV Sales Department.

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4.2 RECEIVING THE MACHINES ON SITE
For unloading of the units, please observe the procedures indicated in the illustrations reproduced below, which
are also affixed to the original packaging of the unit.
If the unit is not to be installed immediately after its arrival on site, it should remain in its original packaging and
stored in a dry, enclosed area, preferably heated to a temperature of 15°C during the winter months.

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4.3 POSITIONING THE UNIT AND INSTALLATION CLEARANCES
To avoid any problems and damage to the air conditioners during transportation, we recommend that the units
should only be removed from their packaging when they have reached their final destination.
It also essential to make sure that the floor on which the air conditioner is to be installed is capable of supporting
its weight. The weight of the unit can be found in the commercial documentation or read directly from the data plate
located inside the unit.
During installation, respect the clearances required for routine and major servicing indicated in the drawing
enclosed with the order confirmation. The figure below shows the dimensions to be taken into account during installation.
For the exact values of the dimensions indicated in the figure, refer to the drawings supplied with the order confirmation.
Installation dimensions Hole for installation with raised floor
In all cases it is essential leave free space of approximately 800 mm over the entire
width of the machine (C) and clearance of 50 mm at the rear of the unit (E).

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4.4 PLENUMS AND PLINTHS
Various type of air distribution plenum and plinth are available as accessories for both the Under (U) and Over
(O) versions of the unit. The various options are listed in the table below:
Front view Right - Left side view
Plenum with front grille only or both front
and side grilles
Front view Top view
Soundproofed duct section
Front - Rear view
Duct section with F7 filter
Front view Overview
Adjustable plinth with baffle

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4.4.1 INSTALLATION OF PLENUMS AND DUCT SECTIONS
The plenums and duct sections at the top of the unit are to be installed using the four brackets supplied, which
are to be fitted to the upper frame members of the unit.
Fixing bracket
To install the brackets proceed as follows:
1) Fix the brackets to the aluminium frame of the unit using self-tapping screws.
2) The brackets are to be positioned centrally on each side of the unit and fixed with two self-tapping
screws.
3) Position the plenum/duct section making sure that the aluminium sections are properly aligned.
4.4.2 INSTALLATION OF THE ADJUSTABLE PLINTHS
The plinths are to installed as follows:
1) Position the plinth on the subfloor.
2) Adjust the vibration damping feet to ensure that the plinth is flush with the finished floor surface and
perfectly level.
3) Position the unit on the plinth, making sure that the aluminium sections are properly aligned with each
other.

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4.5 CEA AIR-COOLED CONDENSERS
CEA air-cooled condensers must be installed in accordance with the following instructions:
HORIZONTAL INSTALLATION
SINGLE ROW
1) Remove the condenser from the
packaging.
2) Fit the fixing brackets (2) to the
condenser (1).
3) Position the condenser horizontally
(4)on a support (3).
4) Fix the feet (5)using the screws
provided(6).
DOUBLE ROW
1) Remove the fixing screws (2) from the
packaging (1) and remove the
condenser (3).
2) Position the condenser horizontally
on a support(4).
3) Remove the fixing brackets by
undoing the relative screws (5).
4) Fix the feet (6) using the screws
provided (5).
VERTICAL INSTALLATION
SINGLE ROW
1) Remove the condenser from the
packaging.
2) Position the condenser (1).
3) Fix the brackets using the screws
provided (2).
DOUBLE ROW
1) Remove the fixing screws (2) from the
packaging (1) and remove the
condenser (3).
2) Position the condenser (4).
3) Fix using the screws provided (5).

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Clearances for horizontal installation
Clearances for vertical installation

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4.6 WATER CONNECTIONS
WARNING!
TECNAIR LV tests water components with dried compressed air at 24 Bar. This
ensures that no water is present in the water circuits thereby preventing the
possibility of freezing during storage prior to installation.
However, during the positioning and installation operations, it is essential to
take special care not to fill the water circuits, even accidentally, before all the
necessary antifreeze measures stipulated in the design specifications have
been taken (e.g. insulation, addition of glycol, etc.).
4.6.1 CONDENSATE DRAIN AND SIPHONS
All air conditioners, whether direct expansion or water chilled coils, require a condensate drain connection
between the machine and the building waste drains system and the humidifier drain.
The siphon, essential for draining condensate as the bowl is located in a point of negative pressure, is supplied
already installed on the unit and is to be connected when the unit is placed in position by the installer. The humidifier
drain, which does not require a siphon, is supplied ready connected to the termination of the condensate drain. The drain
pipe used is 19x25 Retiflex with 1/2’ fittings.

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4.6.2 WATER-COOLED CONDENSERS
On machines with integral water-cooled condensers, it will be necessary to install the supply and discharge lines
to the condenser. The diameters of the pipes and the inlet and the outlet unions are indicated in the order confirmation.
To ensure that circuit pipes are installed correctly, we recommend that the following indications are
observed:
•Use pipes made of copper or steel
•Support pipes with suitable brackets (1)
•Insulate both pipes with Armaflex type insulation (2)
•Install shut-off valves to facilitate maintenance (3)
•Install a Thermometer (4) and Pressure gauge (5) on the inlet and outlet
•Install a drain outlet in the lowest part of the circuit (6)
•Use a water/glycol solution where necessary
4.6.3 PRESSURE CONTROLLED VALVE
The pressure controlled valve (accessory) is essential when the water is supplied from a well, river or aqueduct;
however it is not necessary when the water is supplied from a water tower. In practical terms, the valve is necessary if
there is the possibility that the water temperature can fall so low during winter (e.g. below 15 degrees) that the machine’s
condensation temperature is consequently reduced too much). The valve is factory-installed on the condenser water
inlet.
If the water supply is obtained from a well or river, two filters of suitable characteristics for the type of water must
be installed in parallel, (one as backup for the other) to prevent the condenser from becoming clogged by impurities in
the water.

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4.6.4 WATER COILS
It will be necessary to install inlet and outlet pipes on both machines with chilled water coils and those with hot
water coils. The diameters of the pipes and the inlet and the outlet unions are indicated in the order confirmation.
The water inlet and outlet unions are indicated in the figure below. The unions can also be identified by their
adhesive labels.
The maximum pressure of the water supply to the coils is 16 bar (1.6 Mpa). The maximum pressure difference
between the water inlet pipe and the outlet pipe is 1 bar (100 kPa), as at pressure differences greater than this value the
return spring would not be able to shut off the water flow. In the event of greater pressure differences, it will be necessary
to install a pressure reducing valve upstream of the 3-way valve.
To ensure that circuit pipes are installed correctly, we recommend that the following indications are
observed:
•Use pipes made of copper or steel
•Support pipes with suitable brackets (1)
•Insulate both pipes with Armaflex type insulation (2)
•Install shut-off valves to facilitate maintenance (3)
•Install a Thermometer (4) and Pressure gauge (5) on the inlet and outlet
•Install a drain outlet in the lowest part of the circuit (6)
•Use a water/glycol solution where necessary

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4.6.5 INTERNAL IMMERSED ELECTRODE HUMIDIFIER
During installation of the unit it is necessary to connect a supply pipe (as shown in the figure) with the system
characteristics indicated below. The discharge pipe is supplied ready-installed by Tecnair LB.
The water connection should satisfy the following conditions:
•A shut-off cock must be installed in the water supply pipe
•There must be a mechanical filter installed on the supply line
•The water temperature and pressure must be within the permitted value range 9)
For more information of the characteristics of the humidifier water circuit, please refer to theUser manual for
the internal humidifier.
WARNING!
DRAIN WATER AT 100 °C