Uniflair CAL 0251 User manual

Versione: 1.0 - Data: 17.04.96
Pag. 23 - Cod.: 05MU050X1A
CAL
CONDENSATORE AD ARIA
AIRCOOLED CONDENSER
LUFTGEKÜHLTE KONDENSATOREN
CONDENSEUR REFROIDI PAR AIR
CONDENSADOR ENFRIADO POR AIRE
MANUALE DI ISTRUZIONI
ATTENZIONE: prima di installare o intervenire sul condensatore leggere attentamente le istruzioni e le
norme di sicurezza
INSTRUCTION MANUAL
WARNING: before installing or servicing the unit read the instructions and the safety notes carefully
BEDIENUNGSANLEITUNGEN
ACHTUNG: Bitte vor Installation oder jeglichem Eingriff an diesem Gerät die Bedienungs-anleitung und
Sicherheitsnormen sorgfältig durchlesen
MANUEL D’INSTRUCTIONS
ATTENTION: avant d’installer ou intervenir sur l’unité, lire attentivement les instructions et les normes
de sécurité
MANUAL DE ISTRUCCIONES
ATENCION: antes de proceder a la instalación o intervenir en la unidad, leer atentamente las
instrucciones y las normas de seguridad
UNIFLAIR

3
Fig. 1.
DISPOSIZIONE CON FLUSSO D’ARIA ORIZZONTALE
HORIZONTAL AIR DISCHARGE ARRANGEMENT
HORIZONTALER LUFTSTROM
ARRANGEMENT AVEC PULSION D’AIR HORIZONTAL
DISPOSICIÓN CON FLUJO DE AIRE HORIZONTAL
Fig. 1.
DISPOSIZIONE CON FLUSSO D’ARIA VERTICALE
VERTICAL AIR DISCHARGE ARRANGEMENT
SENKRECHTER LUFTSTROM
ARRANGEMENT AVEC PULSION D’AIR VERTICAL
DISPOSICIÓN CON FLUJO DE AIRE VERTICAL
1 Ventilatore Propeller Fan Axialventilator Ventilateur helicoïde Ventilador helicoidal
2 Staffe di supporto Holding Brackets Aufstellkonsolen Brides de support Bridas de soporte
3 Gambe di supporto Holding Legs Stützbeine Pieds de support Patas
4 Connessioni frigorifere Connections Anschlüsse Raccordements Conexiones
5 Sezionatore Mains Isolator Hauptschalter Sectionneur Interruptor
6 Regolatore di pressione Pressure Regulator Druckregler Régulateur de pression Regulador de presión
7 Targa di identificazione Identification Plate Typenschild Plaque d’identification Placa de identificación
N.B.: Il numero e la disposizione dei ventilatori varia con il modello di condensatore
Fan number and layout depend on condenser model
Anordnung und Anzahl der Ventilatoren ist abhängig vom Kondensatormodell
Le nombre et la disposition des ventilateurs varient selon le modèle de condenseur
El número y la disposición de los ventiladores varia según el modelo del condensador

8
SAFETY INSTRUCTIONS
•READ THE INSTRUCTION MANUAL CAREFULLY BEFORE CARRYING OUT ANY WORK ON THE EQUIPMENT.
•The condenser is factory precharged with dry nitrogen to prevent the ingress of any water vapour. Before removing the plugs from
the inlet and outlet connections for installation, discharge the nitrogen by means of the needle valve on the inlet manifold
•Work on the condenser should only be carried out by authorised and suitably qualified personnel
•The condenser contains live electrical parts and rotating devices: before carrying out any work on the electrics or on the fan, isolate
the unit (turn optional isolator to position ‘O’)
•The condenser contains gas above atmospheric pressure: tampering with connections or pipework can cause leakage of
compressed gas
•The temperature of the inlet pipe to the condenser can rise above 70°C and therefore presents the risk of burns
•INSTALL THE CONDENSER IN A POSITION WHICH IS INACCESSIBLE TO UNAUTHORISED PERSONNEL: the fins of the heat
exchanger are made from thin aluminium sheet and can cause cuts in the event of accidental contact.
NAMEPLATE
The nameplate of the condenser is located on one side (see
Fig. 1) and contains the following data:
•Unit model;
•Serial number;
•Year of manufacture;
•Current and power absorbed;
•Standard settings.
TRANSPORT - POSITIONING ON SITE
The condenser leaves the factory in perfect condition;
At the moment of delivery its condition should be carefully
checked and any damage which might have been caused in
transit should be notified in writing to the haulier.
During transit and positioning on site:
•Do not overturn or lean the condenser on its side.
•Before removing the packaging carry the condenser to the
nearest possible point to the actual installation location by
using a pallet truck or a forklift securing the unit to ensure
that it does not fall off.
•Carefully cut or remove the strapping and then remove the
packaging.
DIMENSIONS AND WEIGHT
See drawing DIUI ........... attached.
INSTALLATION
Position the condenser in the open air out of direct sunlight.
It can be installed:
•with horizontal air discharge (standard version) for best
protection (from snow or from objects falling from above)
and easier maintenance; in this configuration the
condenser must be protected from the wind which could
interfere with the operation of the fan;
•with vertical air discharge ; the optional leg kit is available
for this configuration (four legs up to model CAL 0661; six
legs for the larger models) and it is recommended for
installation in windy locations or wherever a horizontal air
flow would be obstructed. Assembly instructions are
included with the leg kit.
The limited weight of the CAL condensers means that they can
be installed on relatively lightweight bases.
Position the condenser on a solid, level surface.
Fix the condenser down using the appropriate bolt holes in the
base (horizontal air discharge) or in the bottoms of the legs
(vertical air discharge): See drawing No. DIUI........ attached for
dimensions.
Ensure that the necessary clearances for free circulation of the
air are left around the unit as shown in Fig.2.
Fig. 2a Horizontal Air Flow
Fig. 2b Vertical Air Flow
Use shims if necessary to ensure a level installation to within
one degree.
INSTALL THE CONDENSER IN A POSITION WHICH
IS INACCESSIBLE TO UNAUTHORISED
PERSONNEL:
The heat exchanger fins are made from aluminium sheet
which is only 0.1 mm thick and could cause cuts in the
event of forceful accidental contact.
N.B. the fan characteristic does not allow any ducting of the air flow.
> 0
,
7 m > 4 m
> 4 m
> 1 m
> 1 m

9
REFRIGERANT CONNECTIONS
The condenser has male rotalock connections.
The condenser is factory charged with dry nitrogen to
prevent the ingress of humidity and the connections are
sealed with plugs.
BEFORE REMOVING THE PLUGS FROM THE
CONNECTIONS, DISCHARGE THE NITROGEN BY
MEANS OF THE NEEDLE VALVE ON THE INLET
MANIFOLD.
Connection to the condenser can be achieved with one of the
following rotalock connectors:
3a) straight connectors: see fig. 3a;
3b) right angle connectors (supplied on request): see fig 3b;
3c) service valves (supplied on request): see fig. 3c:
to which the interconnecting pipework is connected.
A: ROTALOCK
CONNECTIONS
B: SEAL
Fig. 3
Take care that the connections are correctly made and in
particular do not invert the inlet and outlet connections (see fig.
4)
Fig. 4
Run the refrigeration lines taking care to ensure the following
(see also fig. 5);
•use straight line routes wherever possible;
A: discharge line
B: liquid line
C: trap
Fig. 5
•incline the discharge line with a gradient of 1/100 in the
direction of flow to facilitate oil entrainment;
•make a ‘U’ trap in the discharge line at the bottom of any
vertical risers;
•thermally insulate the refrigerant liquid line wherever it may
be exposed to sun;
•avoid any contact between the discharge line and the liquid
line.
Carry out the evacuation and charging of the complete
refrigerant circuit.
ELECTRICAL CONNECTIONS
CABLE SIZES - PROTECTION
(see wiring diagram SECA ......... attached)
The condenser can be operated automatically and
autonomously (as a function of the refrigerant pressure ) and
therefore its power supply does not necessarily have to come
from the indoor unit to which it is connected. It can come from
the nearest convenient distribution board.
Check that the voltage and frequency of the power supply
correspond to the data shown on the nameplate of the
condenser.
Connect the power supply cable to the isolator introducing the
cable into the switch box through an IP 55 rated cable gland
and screw the terminals down tightly.
The following table lists the principal electrical data needed for
the connection.
VOLTAGE No. kW FLA mm² FUS
CAL0231 230V/1ph/50 1 0,14 0,7 1,5 10 A
CAL0251 230V/1ph/50 1 0,14 0,7 1,5 10 A
CAL0331 230V/1ph/50 1 0,14 0,7 1,5 10 A
CAL0361 230V/1ph/50 2 0,28 1,4 1,5 10 A
CAL0511 230V/1ph/50 2 0,28 1,4 1,5 10 A
CAL0661 230V/1ph/50 2 0,28 1,4 1,5 10 A
CAL0801 230V/1ph/50 3 0,42 2,1 1,5 10 A
CAL1011 230V/1ph/50 3 0,42 2,1 1,5 10 A
CAL1301 230V/1ph/50 4 0,56 2,8 1,5 10 A
CAL1511 230V/1ph/50 5 0,70 3,5 1,5 10 A
CAL1801 230V/1ph/50 6 0,84 4,2 1,5 10 A
No. : Number of fans
kW kW : Nominal power
FLA A : Max. absorbed current
mm² mm² : Recommended cable size
FUS AT : Short circuit protection recommended
(for cable runs up to 30 m)
N.B. : The condenser is fitted with overload protection (bi-
metallic switch in each motor) but not against short circuit; so
feed the condenser via a suitable protection device (fuse or
circuit breaker of appropriate rating ).
OK
B
A
3a 3b
B
A
3c
B
A
B
1/100
A
max 5 m
max 30 m
1/100
A
Bmax 15 m
B
A
C
1/100

10
START-UP
Switch on the power supply to the condenser and close the
isolator (switch to position ‘1’).
The fan motor starts automatically when the refrigerant
condensing pressure reaches the preset value of the pressure
regulator (factory set). Therefore to check operation of the
condenser the compressor circuit to which it is linked must be
running.
CONTROL DEVICES - ADJUSTMENT
The condenser is fitted with a condensing pressure control
device which can be either:
1. On/off pressure switch (S version);
2 Stepless speed controller (version P);
3. VARICOND: multi step speed controller with
autotransformer supply (version V).
The control device is factory preset.
To check the setting connect a pressure gauge with scale
reading up to at least 30 bar to the pressure tapping located in
the inlet manifold of the condenser and watch operation of the
fan as the pressure changes. If the setting requires adjustment,
follow the instructions set out below and check the new setting
as explained above.
Before carrying out any work, ensure that the isolator is
switched off (switch in position ‘O’).
BEFORE CARRYING OUT ANY WORK, ENSURE
THAT THE ISOLATOR IS SWITCHED OFF
(switch in position “O”).
ON-OFF PRESSURE SWITCH
(version S)
The control device comprises a pressure switch with on/ off
contact which cycles operation of the fan as a function of the
pressure as shown in diagram Fig. 6; the contact:
•closes and feeds the fan motor when the pressure rises and
reaches the set value;
•opens when the pressure falls to a level equal to the set
point value SET minus the differential DIFF.
This control system is suitable for climates where external
temperatures seldom fall below 0°C.
In cold climates it could cause excessive hunting of the system.
Fig. 6
The values of SET and DIFF are adjusted by means of the
adjusting screws which are accessed by removing the external
casing of the pressure switch.
Recommended settings (factory preset);
SET = 18 bar DIFF = 4 bar
STEPLESS SPEED CONTROLLER
(version P)
The fan V is fed via a TRIAC voltage controller which senses
the condensing pressure (fig. 7).
Fig. 7
The output voltage from the controller (and therefore the fan
speed) varies between a maximum of 95% and a minimum of
40% of the mains voltage (i.e. from about 220 volts down to
about 90 volts on a 230 V mains supply) as the condensing
pressure varies within a band of 5 bar (proportional band
PROP): see fig. 8.
Fig. 8
This control system is suitable for external temperatures down
to -20°C.
The pressure set point SET, corresponding to the maximum
output voltage, can be adjusted by means of the adjusting
screw on the pressure sensor as shown in point 1, fig. 9.
Below the minimum working pressure MIN (lower limit of the
proportional band ) the fan must stop: to do this the
potentiometer indicated at 2 in fig. 9 must be turned fully anti-
clockwise (otherwise as the pressure reduced the fan would
continue to rotate, although at a lower speed, and control of the
condensing pressure at low external temperatures would be
lost). The amplitude of the proportional band PROP is not
adjustable.
Fig. 9
Set point recommended (factory preset):
SET = 21 bar
VARICOND: MULTI-STEP CONTROLLER WITH
AUTOTRANSFORMER
(version V)
Fan V is fed via autotransformer A increasing output voltage
switched by means of four pressure switches (P1, P2, P3, P4)
adjusted to increasing threshold pressure values (see fig. 10).
Fig. 10
P - bar
SET
DIFF
OFF
ON
~Vout
V
R
P - bar
VOLT
0
45 %
95%
Vout
SET
PROP
MIN
V
A
230 V
160 V
130 V
100 V
P4
P3
P2
P1
~
Vout
N
1
2

11
The adjustment of the pressure switches is co-ordinated in
order to obtain ‘quasi proportionality’ of the fan speed as the
pressure varies.
The VARICOND system is contained in a metal enclosure fixed
to the side of the condenser and it is suitable for outside
temperatures down to -20°C.
The adjustment of each single pressure switch is carried out as
described in the preceding paragraph ‘ON/ OFF PRESSURE
SWITCH’.
Recommended set point values (factory preset):
SET DIFF
P1 0V ↔100V 16,6 bar 3,1 bar
P2 100V ↔130V 20,3 bar 5,7 bar
P3 130V ↔160V 21,8 bar 3,0 bar
P4 160V ↔230V 23,5 bar 2,7 bar
BEFORE CARRYING OUT ANY WORK ENSURE THE
ISOLATOR IS SWITCHED OFF
(switch in position “O”).
MAINTENANCE
•Regularly check the state of the condenser fins; remove
from them all foreign objects (leaves, feathers, seeds, dust,
etc.) using a jet of water or compressed air.
The heat exchanger fins are made of thin
aluminium sheet and can cause cuts in the event
of the accidental contact.
•Check that the operation and current absorbed by each fan
is normal and without any unusual noises;
•Check that the control device is operating normally (see
section CONTROL DEVICES - ADJUSTMENT).
FAULT FINDING
WARNING: BEFORE WORKING ON THE CONDENSER READ CAREFULLY THE SAFETY NOTES AT
THE BEGINNING OF THIS MANUAL.
Operation of the condenser is strictly linked to the working
conditions of the unit to which it is connected and therefore
possible faults which may apparently be attributed do the
condenser could actually be caused by external factors. The
following table lists the most likely faults.
FAULT POSSIBLE CAUSE CHECK/ CORRECTIVE ACTION
HIGH DISCHARGE PRESSURE: A) The heat exchanger fins are dirty
or blocked by foreign objects
Clean the condenser fins following the instructions in the
section ‘MAINTENANCE’
REFRIGERANT CIRCUIT B) Cooling air temperature to
condenser too high
1) Check for potential short circuiting of condenser
cooling air
HIGH PRESSURE SWITCH
TRIPS
2) Check the value of the actual cooling air temperature
against the design value for the project
(not dependent on causes external
to the condenser such as:
C) Lack of condenser air flow Check that the condenser is installed with the minimum
clearances specified (see section ‘INSTALLATION’)
•non condensing gases in the
circuit
•valves partially closed in the
section of pipe between the
compressor and the
condenser
D) One or more fans out of service Check for motor internal protection tripped and if
necessary replace the fan motor
•suction pressure too high
•circuit overcharged with
refrigerant with excessive sub-
cooling at the condenser )
E) Control device out of adjustment
or faulty
Check and adjust if necessary the control device (see
section ‘ CONTROL DEVICES - SETTING ‘); replace if
necessary
LOW DISCHARGE PRESSURE A) Control device out of adjustment
or faulty
Check and adjust if necessary the control device (see
section ‘ CONTROL DEVICES - SETTING ‘); replace if
necessary
B) Refrigerant leak Locate and rectify the leak and recharge with refrigerant

CAL
COLLEGAMENTI FRIGORIFERI
REFRIGERANT CONNECTIONS
E
B
A
B
A
C
1 2 3 4
A
D
E
A
1. Svitare il tappo giallo (E) avvitato sull’attacco rotalock (A);
2. Rimuovere la guarnizione nera in gomma (D): questa guarnizione è utilizzata solamente per garantire la tenuta del
circuito precaricato con azoto;
3. Verificare che sia presente la guarnizione bianca in teflon (B) sull’attacco rotalock (A);
4. Avvitare il giunto (C) sull’attacco (A).
GB 1. Unscrew the yellow cap (E) on the rotalock connection (A);
2. Remove the black rubber seal (D): this is only used to seal the circuit charged with nitrogen;
3. Check that the white teflon seal (B) is on the rotalock connection (A);
4. Screw the joint (C) on to the connection (A).
Version 1.1 - 14.09.99 File: cal_multilingue.doc
Allegato al manuale CAL (vers. 1.0 del 17.04.96)