Vertiv Liebert hpw series User manual

Liebert® HPW

Outdoor Package Cooling System for

Mobile Network Access Nodes

User Manual

English, cod. 265883, rev. 31.01.2019

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45 6

78 9

10 11

12 13

19 20

21 22

Caution

Recommendations:

S the manual is retained for the entire service life of the machine;

S the user reads the manual carefully before carrying out any operations on the machine;

S the machine is used exclusively for the purpose for which it is intended; incorrect use of the machine shall release

the

manufacturer from any liability.

This manual has been prepared to enable the end---user to carry out only the operations that can made with the

panels closed. Any operations that require the opening of doors or equipment panels must be carried out only by

qualified personnel.

Each machine is equipped with an electric isolating device which allows the operator to work in conditions of safety.

This device must always be used to eliminate risks during maintenance (electric shocks, scalds, automatic restarting,

moving parts and remote control).

The panel key supplied with the unit must be kept by the person responsible for maintenance.

For identification of the unit (model and serial no.) in case of the necessity for assistance or spare parts, read the

identification label placed on the outside and inside of the unit.

IMPORTANT:This manual may be subject to modification; for complete and up---to---date information the user should

always consult the manual supplied with the machine.

Attention: data relevant to the unit

supplied is indicated on the inboard label (see the blank

facsimi-le below).

Data in the manual is referred to standard

conditions and can be modified without any advance

notice.

POS. DESCRIPTION

1Compressor Full Load Ampere [A]

2Compressor Locked Rotor Ampere [A]

3Compressor quantity

4Evaporator fan Full Load Ampere [A]

5Evaporator fan Locked Rotor Ampere [A]

6Evaporator fan quantity

7Condenser fan Full Load Ampere [A]

8Condenser fan Locked Rotor Ampere [A]

9Condenser fan quantity

10 Electrical heating Ampere

11 Electrical heating steps

12 Humidifier Ampere

13 Steam production capacity

14 Max. unit AC Ampere

15 Max. unit DC Ampere

16 Rated peak withstand current

17 Rated short---time current

18 Refrigerant type

19 High pressure switch Stop

20 High pressure switch Restart

21 Low pressure switch Stop

22 Low pressure switch Restart

23 Min. room operation temperature

24 Max. room operation temperature

25 Min. room operation humidity

26 Max. room operation humidity

27 Max. refrigeration circuit pressure

Index

1 -- Preliminary operations ............................................................... pag. 1

pag. 11.1 --- Foreword ......................................................................................

pag. 11.2 --- Check operating limits ...........................................................................

pag. 11.3 --- Check sound pressure levels ......................................................................

pag. 11.4 --- Site preparation .................................................................................

pag. 11.5 --- Conditioner inspection ...........................................................................

pag. 11.6 --- General description ..............................................................................

pag. 11.7 --- Transport ......................................................................................

pag. 11.8 --- Positioning of air conditioner ......................................................................

pag. 11.9 --- Service area ....................................................................................

pag. 12 -- Mounting ............................................................................

pag. 23 -- Electrical connections ................................................................

pag. 23.1 --- Cautions .......................................................................................

pag. 23.2 --- Electrical supply ................................................................................

pag. 23.3 --- User interface ...................................................................................

pag. 23.4 --- Emergency cooling version (EFC 48 VDC and EFC 230 VAC) ..........................................

pag. 23.5 --- Electrical protection ..............................................................................

pag. 24 -- Starting and stopping ................................................................

pag. 24.1 --- First start---up (or after a long halt) .................................................................

pag. 24.2 --- Start---up with low outside temperature .............................................................

pag. 25-- Operation............................................................................

pag. 35.1 --- Adjustment of the condenser fan speed (optional) ....................................................

pag. 35.2 --- Emergency cooling (optional) .....................................................................

pag. 36-- Operatinglogics .....................................................................

pag. 36.1 --- Cooling only unit ................................................................................

pag. 36.2 --- Unit with electrical heating ........................................................................

pag. 36.3 --- Unit with freecooling .............................................................................

pag. 46.4 --- LAN local network management: Stand---by and Cascade modes ......................................

pag. 46.5 --- Alarm control ...................................................................................

pag. 46.6 --- Alarm board (optional) ...........................................................................

pag. 47-- Calibrations .........................................................................

pag. 47.1 --- Environment protection ..........................................................................

pag. 58 -- Maintenance / Spare parts ............................................................

pag. 58.1 --- Routine maintenance ............................................................................

pag. 58.2 --- Extraordinary maintenance .......................................................................

pag. 68.3 --- Dismantling the unit .............................................................................

pag. 68.4 --- Spare parts ....................................................................................

pag. 68.5 --- Regulation (EC) no. 517/2014 (F ---gas) .............................................................

Tables ............................................................... ..................... pag. 8

Drawings ................................................................................. pag. 16

Diagrams ................................................................................. pag. 26

pag. 1

1 --- Preliminary operations

1.1 --- Foreword

The following manual describes the installation, operation and

maintenance of Air Conditioners, series Liebert HPW.

Important:

Also consult the manual for the microprocessor control sup-

plied with the machine (if installed).

1.2 --- Check operating limits

The units are designed to operate within working ranges (see

from Tab. 1 to Tab. 6). These limits are referred to new

ma-chines or for those that have been correctly installed and

ser-viced. The warranty clauses are no longer valid for any

dam-age or malfunction that may occur during or due to

operation outside the application values.

1.3 --- Check sound pressure levels

From Tab. 1 to Tab. 6 shows, for the internal and the

external side, the sound pressure levels of the units in

standard config-uration, in continuous operation, at 2 m from

the front surface of the machine, at 1 m height in free field

conditions.

1.4 --- Site preparation

Liebert HPW shall be mounted on a flat vertical surface.

Prepare cut---outs on the wall for air supply and intake, electric-

al connections and unit fixing, according to the attached

tem-plate (see Fig. 7 and Fig. 8). Wall cut outs shall be

taped or sealed to prevent air or moisture entering the wall

cavity.

1.5 --- Conditioner inspection

On receiving the equipment immediately inspect its condition;

report any damage to the transport company at once.

1.6 --- General description

Liebert HPW canbeconfiguredinoverflow(Liebert HPW --- -

O) or down flow (Liebert HPW---D) version, resulting as

ex-tremely adaptive to different site layout; whatever is the

chosen delivery air version wall cuts are the same, the

condenser sec-tion is always positioned on the top part of

the unit reducing critical environment impact on condenser

efficiency and per-mitting easier and more effective

maintenance activities.

Liebert HPW, equipped withe the Emergency Cooling feature,

does not stop the operation even in case of mains failure:

fed by 48 V DC emergency supply from back up systems,

Liebert HPW autosets its parameters to ventilate and

maximise the freecooling to keep the indoor temperature

below the shut down limit, reliablity of the site means also

reliability of the unit. Downflow model allows to start the

Emergengy Freecooling at a higher external temperature,

reducing the site shut down risks.

No piping or refrigeration work is requested on site: just pre-

pare cut---outs in the wall, according to the template, andmake

power available. As soon the unit is fixed and sealed on

the wall, place the remote display in a suitable position and

feed the unit.

Installation can be further speeded up using the fast plug con-

nector option (available on request): no wiring is requested on

site and the connection can be performed even by non skilled

personnel. In case of unit replacement, the fast plugs allow

re-placement ina few minutes.

The unit is designed to be installed outdoor, coping with the

worst weather conditions.

The self ---supporting cabinet is made of heavy gauge galva-

nised steel panels, painted on both sides with RAL7035 poly-

ester powder, insulated with polyurethane foam, fire---proof

class 1. Fixed panels are secured by water---tight, aluminum

rivets. All external screws are anti---vandalism type, to be

opened with a special tool supplied with the unit. Metal safety

grids rated IP20 --- protect the machine and prevent contact

with sensitive/dangerous components.

The refrigeration compressor is a hermetic, scroll type, com-

plete with internal protection against over heating. A crankcase

heater maintains a minimum refrigerant temperature to

allow reliable start---up and operation even in very cold

climate. Thecircuitispre---

chargedwithrefrigerantandincludesather-mostatic expansion

valve, filter dryer and sight glass, low pres-sure and high

pressure switches and two access valves. The compressor is

housed in a compartment separated from the air flow and

protected by an insulated panel closed with anti---vandalism

screws, accessible from the front side for complete

maintenance.

The electrical board is housed in a compartment isolated from

the air stream and closed by a screwed on panel. It is built in

accordance with EN 60204---1 recommendations.

1.7 --- Transport

Always keep the unit vertically upright.

If possible transport the unit using a fork lift truck;

otherwise use a crane with belts or cables, avoiding the

exerting of pressure on the top edges of the packing.

Unpack the unit as close as possible to its installation posi-

tion. Once unpacked, avoid stress being transmitted to its

internal components.

For lifting the unit, the eyebolts available as accessory can

be used.

Attention:

--- use eyebolts with thread M10;

--- screw the eyebolt completely;

--- always use 4 eyebolts at the same time.

1.8 --- Positioning of air conditioner

S The air Conditioner shall be installed in any

environment

not affected by chemical agents (i.e. acid vapours).

Position the air conditioner so as to optimise the indoor air

distribution and avoid hot spots.

1.9 --- Service area

The unit must be provided with a suitable Service Area, as

fol-lows (see Fig. 5):

All ordinary maintenance can be performed from the

front.

Avoid possible obstacles hindering the air flows on the unit

outer side.

2 --- Mounting

For a correct installation proceed as follows:

Apply an insulating anti---vibration rubber between the unit

and the wall (see Fig. 9).

Before installing the unit open the integrated ducts for

the air distribution (fins) in the openings of the rear panel,

as in-dicated in the following points (1) and (2) and in

Fig. 10.

Secure the unit to the wall with 5+5 fasteners, flat---

head type with washer and nut on the indoor side (see

from Fig. 1 to Fig. 4). Hallow wall anchors or lag bolts

are suit-able as dictated by the wall constructions.

Seal the external boundary of the unit as preference

(see Fig. 9).

Caution: The units are designed to keep the room to be

conditioned as plenum, to prevent external dirt and

con-taminating agents from entering.

Plenum may reach high values in very sealed sites or if

the filters are not correctly serviced. In this way, doors and

win-dows are less functional and the unit efficiency is

de-

pag. 2

creased.

In these cases, Vertiv recommends a plenum damper

sized 600 x 400 mm (Vertiv code 134992) to be wall

or window mounted.

3 --- Electrical connections

3.1 --- Cautions

Before performing any operations on the electric parts, make

sure that:

all electrical components are undamaged;

allterminalscrewsare tight;

the supply voltage and frequency are as indicated on the

unit;

the automatic switch QF1 is in open position (OFF), for

units in “no emergency cooling version”.

the automatic switches QF1 and QF3 are in open position

(OFF), for units in “emergency cooling version”.

there are no components under voltage.

3.2 --- Electrical supply

Let the electrical power supply (not powered) pass through the

holes placed in the back panel of the air conditioner (see from

Fig. 1 to Fig. 4).

Caution: use screened cables for high voltage power supply,

with suitable section, and route them to the electrical panel.

Use copper conductors only.

Connect the power supply cable to the main switch QF1 inside

the electrical panel. Connect the earth cable to the yellow---

-green clamp. The alarm contacts available in the different

ver-sions are located inside the electrical panel. For the

alarms de-scription see chapter 6.5 and manual of the

installation control.

3.3 --- User interface

The control microprocessor board is inside the electric board

and is connected with the user interface (remote display) that

can be positioned inside the room as wished. The user

interface (remote display), on a painted metal box, connected

with the conditioner through a multi---pole screened cable,

standard supplied.

The user interface is graphic type (with graphic display and

keypad).

3.4 --- Emergency cooling version

(EFC 48 VDC and EFC 230 VAC)

When this option is available let pass the supply cable as

de-scribed in par. 3.2 and connect them to switch QF3

according to the diagram.

In the 48---VDC units respect the polarity “+” and “---”.

In the EFC 230 Vac units the emergency electrical line has to

be always present.

3.5 --- Electrical protection

Caution: For the electrical protection of the conditioner an

adequate switch with current protection must be installed in

the power supply line. For the selection of the disconnect

switch please refer to the Tab. 7.

4 --- Starting and stopping

4.1 --- First start---up (or after a long halt)

Before starting the air conditioner do check if the power supply

voltage and frequency comply with those indicated on the

identification plate of the unit. After this, it is possible to power

the unit operating on the main switches QF1 and QF3

(only QF1 for units in “no emergency cooling version”), that

can be reached removing the front middle panel. For

the units equipped with microprocessor control, and after

having operated on the switches to ensure a suitable power

supply, it is possible to start and stop the unit following the

instructions here below.

On the user interface:

-check that the fans are working correctly;

-make sure that the temperature is guaranteed

and the compressor and the heaters (optional) work

when re-quired;

-make sure that the speed adjuster of the fan of the

con-densing section controls the fan operation (see chap.

7).

Note: turn the main switches QF1 and QF3 OFF (only QF1 for

units in “no emergency cooling version”) only if the unit is

stopped for a long time.

4.2 --- Start---up with low outside temperature

In case of low outside temperature (<0_C), the unit start---up is

helped by the delay time of the low pressure alarm

activation, within which the pressures in the refrigerating

circuit reach the standard operation values.

5 --- Operation

The unit operation is completely automatic. The below se-

quence explains (with the assistance of Fig. 11 and Fig. 12--- -

Operation diagram) how the unit operates (see also Fig. 13

--- Refrigerating diagram):

1) The temperature sensor, positioned inside the conditioned

room, informs the control about the condition of the air to

be conditioned.

2) The control compares the information received with the set

values of Set Point (= wished min. inner temperature)

and Proportional Band (and differential in the versions

with

Freecoolingoption),settingthe conditioner for theair

treatment in the following modes:

Cooling (Fig. 11 and Fig. 12)

After switching the unit on, the evaporating fan is

immediately started while the compressor is started when the

temperature of the room to be conditioned exceeds the set

value. The con-densing fan is automatically started when

the condensing pressure changes. The air taken in by the

centrifugal fan enters the unit through the suction inlet,

immediately passes through the filter and then the evaporator.

The cold refrigerant flows in-side the pipes of the evaporator,

thus cooling the air crossing it. The treated air is conveyed in

the conditioned room through the delivery inlet. The heat

taken from the room and the one generated by the

conditioner motor operation are disposed through the

condenser placed in the lower part of the unit and hit, thanks

to the fan, by the outside air. The fan operation is managed

with Variex, see par. 5.1 as a function of the con-design

pressure. For the operation logics of the control see chapter 6

Pressing the On/Off Key ( ) the Unit ON/OFF window will

appear. The unit is switched ON or OFF pressing the

Increase ( ) or Decrease ( ) Key for 3 seconds.;

Important! Itisextremelyimportanttoconsider the status of

the digital input of the microprocessor control managing the

unit ON ---OFF (see relevant handbook and wiring diagram).

Indeed, for the unit to start the digital input must be bridged

(see wiring diagram).

Check that there are no active alarms; wait until

the system reaches the standard operation and then make

the following checks:

pag. 3

Freecooling -- (Fig. 11 and Fig. 12)

When the outdoor temperature is lower than the indoor one,

the integrated modulating damper does open/close to cool the

room with external air: compressor is off. The exhaust warmer

air is automatically rejected outside through the unit, without

any additional louver (e.g. overpressure damper). The para-

meters can be adjusted. A dedicated temperature sensor is

present in the air delivery section to prevent the air from

enter-ing the room at too low temperatures (adjustable

parameter). The unit is further equipped with a washable

metal filter next to the outside air suction inlet. When the

expected conditions oc-cur, the servocontrol, managed by the

microprocessor control, opens the movable damper

separating the flows of the inside and outside air. In this way

the outside air, sucked by the fan, flows inside the room and

is discharged through the openings of the freecooling

compartment. The opening degree of the damper is

determined as a function of the set point value to be kept and

of the intake air temperature (see Chap. 6).

5.1 --- Adjustment of the condenser fan

speed (optional)

A sensor is positioned so as to detect constantly the

condens-ing pressure of the refrigeration gas. On the basis

of this in-formation, an electronic device (Variex) modulates

the fan ro-tation speed in order to keep the condensing

pressure within the allowed values. In this way, besides

optimizing the com-pressor operation, you can have a

remarkable reduction of the sound pressure level (mainly

during the night), an easier start---up of the compressor at

low temperatures and some en-ergy saving.

For the calibration of the speed adjuster refer to chap. 7.

5.2 --- Emergency cooling (optional)

5.2.1 -- Emergency cooling 48VDC

The 48 VDC emergency cooling provides for the evaporating

fans, the freecooling damper and the control to be always sup-

plied at 48 VDC, while the compressor, the condensing fan

and the heaters are connected with the AC mains. If the AC

main supply fails, the conditioner does not stop but

continues to ventilate, activating the integrated Freecooling

as soon as the relevant conditions are reached,

automatically optimized in emergency.

Important! For proper operation, the unit must be always

fed by 48VDC.

CAUTION: For safety reasons disconnect the QF1 and

QF3 switches (only QF1 for units in “no emergency cooling

ver-sion”) when you want to stop the unit.

5.2.2 -- Emergency cooling 230VAC-- 50Hz

In case of AC mains failure, the treating fans, the control

and the damper servomotor are supplied by the second

line at 230V/1Ph/50Hz arranged by the user (UPS/generator),

ensur-ing the operation as in the 48 VDC version.

6 --- Operating logics

The units, in the different versions, are featured by the auto-

matic operating logics specified here below.

6.1 --- Cooling only unit

6.1.1 -- Control logic

The control algorithm is based on a one---step adjustment for

the mechanical cooling with compressor: the control manages

all the activation delays, so as to ensure the correct

operation and extend the operating life as much as possible.

Fig. a) Operation of the cooling only unit

Set Cooling °C

Cooling only unit

PBand

6.2 --- Unit with electrical heating

6.2.1 -- Control logic

For the hot and cold version the control algorithm is based on a

one---step adjustment for the compressor---aided electric

heating and mechanical cooling. The control manages all its

lags in the activation of the compressor, as previously de-

scribed, so as to guarantee its correct operation and to make it

function as long as possible.

6.2.2 -- Dead band

In this version the parameter “Dead band”, in the “optional

devices” menu of themicroprocessor control is very important,

and enables to transfer the heating semi---band inserting a

non---sensitive area (ventilation only) between the set point

temperature and the start of the heating semi---bands (see

Fig. b). In this way, without having to modify the proportional

band, the electric heating can be activated at lower temperat-

ures (according to the value set for the dead band) compared

to the standard setting, consequently reducing the power con-

sumption of the heaters and optimizing their operation accord-

ing to the site requirements.

Fig. b) Unit operation with electrical heating

Heating Cooling °C

PBand

Dead Band

Set point CoolingHeating °C

1/2 Band 1/2 Band

Set point

Cooling and

heating unit

Cooling and

heating unit

with Dead

band

6.3 --- Unit with freecooling

6.3.1 -- Control logic

The control algorithm is based on a single---stage adjustment

for the heating and cooling with the compressor and on an

ad-justmentof theproportional---

integrativetypeforthecoolingin the Freecooling mode, with

setting of the set point and propor-tional band (P) (Fig. c).

The control manages all activation delays of the compressor,

as we have seen in the 2 previous cases, in order to

guarantee the proper operation and to extend its life as much

as possible. The activation of the Freecooling mode occurs as

a function of thedifference(thatcan beset)between

theinsidetemperature and the outside temperature.

This means that if the difference between the two temperatures

increases beyond a certain value, the unit automatically

passes to the Freecooling function: the compressor is de---

ac-tivated and the analog output controls the 3---point

servomotor of the damper. The damper opening is

determined as a functionof thedifferencebetween

theoutsideand insidetemperat-ures and as a function of the

intake air temperature, which can-not be lower than a preset

safety value. If the inside temperat-ure exceeds the

proportional band by more than 20% for over 10 minutes, the

unit shifts to the compressor---aided cooling and the

Freecooling mode remains de---activated for 1/2 hour. If the

inside temperature exceeds the proportional band by

pag. 4

more than 50% for over 2 minutes, the Freecooling mode

is de---activated for 1 hour, and the unit shifts to cooling by

means of the refrigerating compressor.

Fig. c) Compressor, heater and damper opening

operation

Set CoolingHeating _C

Freecooling

mode

Compressor

cooling mode

PBand

6.4 --- LAN local network management:

Stand---by and Cascade modes

The control of the units in stand---by is completely automatic,

thanks to the possibility of connection with the microprocessor

control. A unit in stand---by is automatically activated in case of

alarm locking the main unit; this occurs even if the main unit is

switched off or disappears from the system due to a failure on the

control connecting network (bus). The hourly rotation of the

stand---by units occurs automatically every 24 hours, so as to en-

able an even wear of the system components.

If the system is connected with the graphic interface, it is possible

to set a different rotation control. Activating the Cascade function, if

several units are simultaneously on with the same Set Point, the

temperature used for the control is the average of the detected

ones: in cooling mode, the proportional band is divided in as

many parts as the double of units belonging to the system, so as

to shut the total available refrigerating capacity.

The activation of the Freecooling mode (if installed) is sequential

on the different units forming the system, and precedes the pos-

sible activation of the cooling with compressor.

TheFig. d),shownasanexample,representsthe operationof

a system formed by three units.

Fig. d) System with 3 units in cascade---microprocessor

control

Set _C

CoolingHeating

311

223

Freecooling mode

PBand

Set

Compressor cooling mode

PBand

CoolingHeating

6.5 --- Alarm control

The two alarm contacts available on the terminal board of the

electric board are:

1) General alarm (highest priority), including:

-compressor low pressure

-compressor high pressure (reset on the pressure switch)

-sensor fault

-memory fault

-fan fault

2) General warning (lowest priority), including:

Shigh temperature

Slow temperature

Note:

-An alarm causes the unit to stop and the unit in stand---

by (if available) to intervene.

-A warning does not stop the unit.

-Both the alarm and the warning activate sight and

sound signals.

-Both the alarm and the warning must be reset manually

on the microprocessor control.

In case the safety heater thermostat intervenes, the reset

must be carried out on the thermostat, following the same

instruc-tionsasbefore.

6.6 --- Alarm board (optional)

Besides the components described for the standard configur-

ation, an alarm card --- which can be supplied as optional

---there are relay contacts which have the following alarms:

1) compressor high and low pressure

2) High temperature

3) Low temperature

4) Indoorairclogged filteralarm

5) Fan fault

These alarms control unit in the same way as described in

the previous paragraph.

For the detailed description of the alarms, see the

micropro-cessor manual enclosed.

7 --- Calibrations

-The air conditioner has already been factory ---tested

and calibrated as described below (see Tab. 8).

-For the Microprocesso Control calibrations refer to the rel-

evant manual (to avoid wrong operations do not use

tem-perature and rel. humidity set points/proportional

bands which differ excessively from the standard

settings).

7.1 --- Environment protection

A misuse or an incorrect calibration of the unit leads to

in-creased energy consumption, resulting in an economic

and environmental damage. Use the freecooling function, if

avail-able.

pag. 5

8 --- Maintenance / Spare parts

F-or safety reasons, clear the unit opening the switch QS1 before performing any maintenance operatios

If installed:

AS THE MICROPROCESSOR CONTROL FEATURES

AUTOMATIC RESTART (AFTER A SUPPLY INTERRUPTION)

IT IS ADVISED TO DISABLE AUTORESTART AND OPEN THE

SWITCH QF1 FOR UNITS IN “NO EMERGENCY COOLING

VERSION, QF1+QF3 SWITCHES FOR UNITS IN

“EMERGENCY COOLING VERSION” WHEN PERFORMING

ANY MAINTENANCE.

SEvery day check the microprocessor control readings for

temperature and, if shown, ambient relative humidity.

SThe Maintenance Programme described below should be

carried out by a skilled technician, preferably working un-

der a maintenance contract.

8.1 --- Routine maintenance

Maintenance program -- Monthly check

FANS

Check that the fan motor rotates freely without any abnormal noise, and ensure that the

bearings are not running hot.

Also check the current absorption.

AIR FILTERS

Check the filter conditions; if necessary clean or replace them.

How to replace:

Sopen the middle panel and remove filter cover

Svertically pull the metal pre ---filter out and blow carefully

Sextract the filter from its seat horizontally

Sintroduce the spare part

Sclose the panel

In very dusty environments perform this check more frequently.

CONTROL Verify the operation of the CONTROL’s LEDs, display and alarms.

ELECTRICAL CIRCUIT SCheck the power supply on all phases.

SEnsure that all electrical connections are tight.

REFRIGERATION CIRCUIT

SCheck the evaporating pressures (to be done by a refrigeration technician).

SCheck the compressor current absorption, its head temperature and the presence of

any unusual noise.

SEnsure that there is no ice formation on the evaporator.

ATTENTION: To move manually the damper (unit check, damper movement check), press the clutch (yellow button) on the ac-

tuator and then move the damper.

Do not press the clutch (yellow button) when the actuator is powered!

8.2 --- Extraordinary maintenance

8.2.1 -- Check of the system vacuum and leaks.

Note:

Before proceeding, recover all the refrigerant, according to the

local laws.

1) Switch the unit off (outer switch on OFF) and cut off open-

ing the switch QF1 for units in “no emergency cooling ver-

sion” and QF1+QF3 for units in “emergency cooling ver-

sion”.

2) Remove the panels necessary for inspecting the refrigerat-

ing circuit.

3) Connect a high efficiency vacuum pump to the needle

valves (Schräder) on the gas and liquid lines; also arrange

a connection with a nitrogen bottle.

4) Load the circuit with nitrogen (7 bar/700 kPa). Find pos-

sible leaks in the circuit by soapy water or other specific

product (foaming agents), and repair as necessary.

5) Drain the circuit by a vacuum of 0.3 mbar absolute .

6) After 3 hours check not to have exceeded 1.3 mbar abso-

lute; this condition ensures a humidity lower than 50 ppm

inside the system. If the vacuum is not kept there are still

leaks; repeat the operations from point 4.

8.2.2 -- Refrigerant charge operations.

After having eliminated the humidity from the refrigerating cir-

cuit (see 8.2.1), proceed as follows:

1) Make sure all the unit components are in operating order.

2) By a charge hose, connect the charge cylinder to the liquid

line of the circuit. Drain the substances that cannot be con-

densed from the hose.

Charge the circuit exclusively with the

refrigerant indicated on the identification

label.

Charge the quantity of refrigerant indicated in Tab. a.

3) Close the main switch QS1 for units in “no emergency

cooling version” and QF1+QF3 for units in “emergency

cooling version” and position the outer switch on ON.

4) Start the compressor.

5) The charge operation can be considered finished when,

keeping the condensation temperature at a steady level

(~ 50°C, if necessary partially clog the condensing coil),

no more bubbles appear for at least ten minutes. Check if

the overheating in these conditions is 7÷8 degrees.

Overheating calculation

a) With the unit operating in standard conditions,

measure the temperature of the suction line in the point

where the bulb of the thermal expansion valve is

fastened.

b) Detect the evaporation pressure gauge temperature

from a pressure gauge placed on the compressor

suction.

c) Subtract the just obtained temperature value from the

one measured in point a). The difference is the

overheating value.

8.2.3 -- R407C refrigerant units

8.2.3.1 --Features of the refrigerating fluid R407C

At standard temperature and pressure it is a colourless gas with

low toxicity, non---flammable, and it has an allowed exposure limit

value (AEL/TLV) corresponding to 1000 ppm (average value

measured on 8 hours/day). In the event of leakage, air the room

before use.

pag. 6

Tab. a --- R407C refrigerant charge

MODELS

HPW WM05S WM06S WM06M WM08M

Kg 2.35 2.35 3.0 3.0

HPW WM10M WM13M WM15M ---

Kg 3.0 3.55 3.55 ---

The oil to be used when topping up is EMKARATE RL

32---3MA or MOBIL EAL ARTIC 22CC, if it’s unavailable use

an oil with the same characteristics (see Tab. b and Tab. c).

NEVER MIX DIFFERENT OILS TOGETHER. CLEAN THE

PIPING COMPLETELY BEFORE CHANGING THE TYPE OF

OIL USED.

Ta b . b --- E M K A R A T E R L 3 2 --- 3 M A o i l

viscosity at 40_C

viscosity at 100_C

viscosity index (ISO Grade)

31.2 cST

5.6 cST

Tab. c --- MOBIL EAL ARTIC 22CC oil

approx. specific weight (at 15_C)

flash point (C.O.C.)

pour point

viscosity index

viscosity at 40_C

viscosity at 100_C

0.99 kg/l

245 _C

< --- 5 4 _C

116

23.6 cST

4.7 cST

8.3 --- Dismantling the unit

The machine has been designed and built to ensure continu-

ous operation. The working life of some of the main compon-

ents, such as the fan and the compressor, depends on their

maintenance.

The unit contains substances and components

hazardous for the environment (electronic com-

ponents, refrigerating gases and oils). At the end of

the useful life, when the unit is dismantled, the op-

eration must be carried out by specialized refriger-

ating technicians. The unit must be delivered to suitable cen-

ters specialized for the collection and disposal of equipment

containing hazardous substances. The refrigerating fluid and

the lubricating oil inside the circuit must be recovered accord-

ing to the laws in force in the relevant country.

8.4 --- Spare parts

We recommend the use of original spare parts. When placing

an order please refer to “Component List” enclosed with the

machine and specify the unit model and serial no.

8.5 --- Regulation (EU) no. 517/2014 (F-gas)

Stationary air conditioners placed into the European Com-

munity market and operating

with fluorinated greenhouse gases (F- gas, such as R407C,

R134a, R410A), they have to comply

since Jan 1, 2015 with the F- gas Regulation (EU) No.

517/2014. It replaces the Re. (EU) no.

342/2006, applied since July 4, 2007.

By the way, the refrigerants as R22 are not F- gas

and their relevant regulation is Reg. (EU) no. 2037/2000.

Following notes have to be considered when

operating with the above mentioned equipments:

No 842/2006

•Fluorinated greenhouse gases are covered by the Kyoto

Protocol.

•The uorinated greenhouse gases in this equipment

should not be vented to the atmosphere.

•Referring to the value noted in Annex I and Annex IV of Regu-

lation (EU) No 517/2014 here below the global warming poten-

tial (GWP) of some major F- gases or mixtures:

R-R- GWP 1430

R-R- GWP 1774

R- GWP 2088

•Operators of the above mentioned applications, which contain

uorinated greenhouse gases, shall, using all measures which are

technically feasible and do not entail disproportionate cost:

a. Prevent leakage of these gases and as soon as possible

repair any detected leakage.

b. Ensure that they are checked for leakage by certied per-

sonnel.

c. Ensure for putting in place arrangements for the proper

recovery by certied personnel.

d. In case of applications containing 5 tons CO2equiva-

lent, i.e. 2.4 kg of R410A (10 tons in case of hermetically

sealed system) or more of F- gases: certied personnel

and Companies (according to Reg. 303/2008) provides

regular leak testing (according to Reg. 1516/2007 and

Reg. 1497/2007) and maintain records of maintenance

activities in a dedicated log book.

e. Recovery for the purpose of recycling, reclamation

or destruction of the uorinated greenhouse gases,

pursuant to Art. 8 of the Regulation shall take place

before the nal disposal of that equipment and, when

appropriate, during its servicing and maintenance.

•Operator, according to Regulation Article 2, point 8, means

the natural or legal person exercising actual power over the

technical functioning of products and equipment covered by

this Regulation. The State may, in dened, specic situations,

designate the owner as being responsible for the operator’s

obligations. Where large installations are involved, service

companies are contracted to carry out maintenance or servic-

ing. In these cases the determination of the operator depends

on the contractual and practical arrangements between the

parties.

•Direct methods of leakage checking approved by the

manufacturer (Reg. 1516/2007 and Reg. 1497/2007)

a. Gas detection device adapted to the refrigerant in the

system;the sensitive of portable gas detection devices (as a

direct test method) shall be at least ve grams par year.

b. Proprietary bubble solutions / soapsuds.

•Additional information located into a dedicated label of

unit (Reg. 1494/2007)

a. Where uorinated greenhouse gas is foreseen to be add-

ed to the equipment outside of the manufacturing site at the

point of installation, a dedicated label accommodates notation

of both the quantity (kg) pre-charged in the manufacturing

plant and of the quantity charged at the installation site as well

as the resulting total quantity of f-gas as a combination of the

above mentioned quantities, in a manner which conforms to

the legibility and indelibility.

Our split units are usually not pre-charged on factory, in this

case the total quantity of refrigerant charged in the unit has

to be written in the relevant label, during the commissioning

operation at the installation site.

b. Our packaged units (not split) operating with f - gas are

usually full charged on factory and the total amount of refrig-

erant charge is already reported on the label. In this case, the

label has no need of further written information.

c. In generally, the above mentioned information has been

located in the main nameplate of relevant unit.

pag. 7

d. For equipment with double refrigeration circuits, in re-

gards to differentiates requirements on the basis of the quan-

tity of f-gas contained, the required information about refrig-

erant charge quantities has to be listed separately for each

individual circuit.

e. For equipments with separate indoor and outdoor sec-

tions connected by refrigerant piping, the label information

will be on that part of the equipment which is initially charged

with the refrigerant. In case of a split system (separate indoor

and outdoor sections) without a factory pre-charge of refriger-

ant, the mandatory label information will be on that part of the

product or equipment which contains the most suitable service

points for charging or recovering the uorinated greenhouse

gas(es).

•Safety data sheets of f-gases used in the products are avail-

able on demand.

pag. 8

Tab. 1 -- 50Hz Technical data for “48Vdc EMERGENCY FREECOOLING” unit versions (EFC-- DC)

Model: HPW WM05SD WM05SO WM06SD WM06SO

Operating limits

Main power supply voltage 230V ±10% / 1Ph / 50Hz

Emergency power supply voltage 48Vdc ±17%

(with emergency cooling) (*)

Outdoor conditions

from 10°C(**)

from --- 3 0 °C(***)

to 49°C(****) 49.5°C(****) 47°C(****) 47.5°C(****)

Indoor conditions with compressor running (*****) from 20°C , 3 0 ---

80% R.H. 21°C, 30---80% R.H. 22°C , 3 0 ---

80% R.H.

to 35°C, 40% R.H.

Storage conditions from --- 4 0 °C, 5% R.H.

to 55°C, 90% R.H.

Sound pressure level

Outdoor sound pressure level (1) dB(A) 52.5 52.5 54.0 54.0

Indoor sound pressure level (1) dB(A) 57.0 57.0 57.0 57.0

Standard electrical features

Compressor --- AC power input (2) kW 1.26 1.25 1.63 1.63

Compressor --- AC operative current (OA) (2) A5.8 5.7 7.6 7.6

Compressor --- AC max. current (FLA) A10.0 10.0 11.4 11.4

Compressor --- AC starting current (LRA) A35.0 35.0 47.0 47.0

Condenser fan --- AC power input (2) kW 0.24 0.24 0.24 0.24

Condenser fan --- AC max. power input kW 0.24 0.24 0.24 0.24

Condenser fan --- AC operative current (OA) (2) A1.1 1.1 1.1 1.1

Condenser fan --- AC max. current (FLA) A1.4 1.4 1.4 1.4

Condenser fan --- AC starting current (LRA) A1.6 1.6 1.6 1.6

Evaporator fan --- DC power input (2) kW 0.10 0.10 0.10 0.10

Evaporator fan --- DC operative current (OA) (2) A2.6 2.6 2.6 2.6

Evaporator fan --- DC max. current (FLA) (3) A2.6 2.6 2.6 2.6

Evaporator fan --- DC starting current (LRA) A0.1 0.1 0.1 0.1

Electric heating (optional)

Heating capacity kW 1.5

H e a t i n g --- m a x . c u rr e n t A6.5

Weight kg 170 175

OA: Standard Operating Ampère

FLA: Full Load Ampère

LRA: Locked Rotor Ampère

Notes:

(*) The emergency cooling option (EFC) is required.

(**) If ON/OFF condensing fan control option has been chosen.

(***) If modulating condensing fan control (Variex) option has been chosen.

(****) Maximum outdoor temperature referred to:

--- 30°C / 39.5% R.H. at the evaporating suction side, for WM05---06SD models;

--- 27°C / 47% R.H. at the evaporating suction side, for WM05---06SO models.

(*****) Conditions referred to the evaporating suction side; the min. indoor temperature is referred to 30% of indoor relative humidity and to the min. outdoor

temperature; for higher relative humidity and/or outdoor temperatures, the min. indoor temperature is lower than the table data.

(1) Measured with 35° C outdoor temperature at 2m far from the unit; free field conditions.

(2) Electrical features are referred to 35°C outdoor temperature, to nominal power supply and to the following Indoor conditions:

--- 30°C / 39.5% R.H. at the evaporating suction side, for WM05---06SD models;

--- 27°C / 47% R.H. at the evaporating suction side, for WM05---06SO models.

(3) It refers to nominal speed (Factory setting).

pag. 9

Tab. 2 -- 50Hz Technical data for “48Vdc EMERGENCY FREECOOLING” unit versions (EFC-- DC)

Model: HPW WM06MD WM06MO WM08MD WM08MO WM10MD WM10MO

Operating limits

Main power supply voltage 230V ±10% / 1Ph / 50Hz 400V ±10% / 3Ph+N+PE / 50Hz

Emergency power supply voltage 48Vdc ±17%

(with emergency cooling) (*)

Outdoor conditions

from 10°C(**)

from --- 3 0 °C(***)

to 52°C(****) 50.5°C(****) 50°C(****)

Indoor conditions with compressor running (*****)

from 21°C , 3 0 ---

80% R.H.

22°C , 3 0 ---

80% R.H. 20°C, 30---80% R.H. 21°C, 30---80% R.H.

to 35°C, 40% R.H. 34°C,

40% R.H.

33°C,

40% R.H.

35°C,

40% R.H.

33°C,

40% R.H.

Storage conditions from --- 4 0 °C, 5% R.H.

to 55°C, 90% R.H.

Sound pressure level

Outdoor sound pressure level (1) dB(A) 50.0 49.5 52.0 52.0 55.0 55.0

Indoor sound pressure level (1) dB(A) 57.0 57.0 60.0 64.0 64.0 64.0

Standard electrical features

Compressor --- AC power input (2) kW 1.46 1.49 1.90 1.93 2.66 2.68

Compressor --- AC operative current (OA) (2) A6.8 7.0 3.5 3.5 4.8 4.9

Compressor --- AC max. current (FLA) A11.4 11.4 5.1 5.1 7.0 7.0

Compressor --- AC starting current (LRA) A47.0 47.0 32.0 32.0 46.0 46.0

Condenser fan --- AC power input (2) kW 0.20 0.20 0.22 0.22 0.72 0.72

Condenser fan --- AC max. power input kW 0.23 0.23 0.23 0.23 0.78 0.78

Condenser fan --- AC operative current (OA) (2) A1.1 1.1 1.1 1.1 3.5 3.5

Condenser fan --- AC max. current (FLA) A1.4 1.4 1.4 1.4 3.5 3.5

Condenser fan --- AC starting current (LRA) A1.6 1.6 1.6 1.6 7.4 7.4

Evaporator fan --- DC power input (2) kW 0.10 0.10 0.28 0.45 0.45 0.45

Evaporator fan --- DC operative current (OA) (2) A2.6 2.6 5.8 9.4 9.5 9.5

Evaporator fan --- DC max. current (FLA) (3) A2.6 2.6 9.6 9.6 9.6 9.6

Evaporator fan --- DC starting current (LRA) A0.1 0.1 0.1 0.1 0.1 0.1

Electric heating (optional)

Heating capacity kW 1.5 3.0

H e a t i n g --- m a x . c u rr e n t A6.5 6.5

Weight kg 195 205 220

OA: Standard Operating Ampère

FLA: Full Load Ampère

LRA: Locked Rotor Ampère

Notes:

(*) The emergency cooling option (EFC) is required.

(**) If ON/OFF condensing fan control option has been chosen.

(***) If modulating condensing fan control (Variex) option has been chosen.

(****) Maximum outdoor temperature referred to:

--- 30°C / 39.5% R.H. at the evaporating suction side, for WM06 --- 08 --- 10MD models;

--- 27°C / 47% R.H. at the evaporating suction side, for WM06 --- 08 --- 10MO models.

(*****) Conditions referred to the evaporating suction side; the min. indoor temperature is referred to 30% of indoor relative humidity and to the min. outdoor

temperature; for higher relative humidity and/or outdoor temperatures, the min. indoor temperature is lower than the table data.

(1) Measured with 35° C outdoor temperature at 2m far from the unit; free field conditions.

(2) Electrical features are referred to 35°C outdoor temperature, to nominal power supply and to the following Indoor conditions:

--- 30°C / 39.5% R.H. at the evaporating suction side, for WM06 --- 08 --- 10MD models;

--- 27°C / 47% R.H. at the evaporating suction side, for WM06 --- 08 --- 10MO models.

(3) It refers to nominal speed (Factory setting).

pag. 10

Tab. 3 -- 50Hz Technical data for “48Vdc EMERGENCY FREECOOLING” unit versions (EFC-- DC)

Model: HPW WM13MD WM13MO WM15MD WM15MO

Operating limits

Main power supply voltage 400V ±10% / 3Ph+N+PE / 50Hz

Emergency power supply voltage 48Vdc ±17%

(with emergency cooling) (*)

Outdoor conditions

from 10°C(**)

from --- 3 0 °C(***)

to 51°C(****) 48.5°C(****)

Indoor conditions with compressor running (*****) from 22°C, 30--- 80% R.H. 24°C, 30---80% R.H.

to 32°C, 40% R.H.

Storage conditions from --- 4 0 °C, 5% R.H.

to 55°C, 90% R.H.

Sound pressure level

Outdoor sound pressure level (1) dB(A) 55 55 58 58

Indoor sound pressure level (1) dB(A) 59 64 63 67

Standard electrical features

Compressor --- AC power input (2) kW 2.56 2.60 3.29 3.30

Compressor --- AC operative current (OA) (2) A4.8 4.9 6.1 6.1

Compressor --- AC max. current (FLA) A 7 7 10 10

Compressor --- AC starting current (LRA) A46 46 50 50

Condenser fan --- AC power input (2) kW 0.68 0.68 0.69 0.72

Condenser fan --- AC max. power input kW 0.78 0.78 0.78 0.78

Condenser fan --- AC operative current (OA) (2) A3.4 3.5 3.3 3.5

Condenser fan --- AC max. current (FLA) A3.5 3.5 3.5 3.5

Condenser fan --- AC starting current (LRA) A7.4 7.4 7.4 7.4

Evaporator fan --- DC power input (2) kW 0.45 0.45 0.82 0.78

Evaporator fan --- DC operative current (OA) (2) A9.5 9.5 17.2 16.3

Evaporator fan --- DC max. current (FLA) (3) A9.6 9.6 19.2 19.2

Evaporator fan --- DC starting current (LRA) A0.1 0.1 0.1 0.1

Electric heating (optional)

Heating capacity kW 3.0 6.0

H e a t i n g --- m a x . c u rr e n t A6.5 13.0

Weight kg 250 260

OA: Standard Operating Ampère

FLA: Full Load Ampère

LRA: Locked Rotor Ampère

Notes:

(*) The emergency cooling option (EFC) is required.

(**) If ON/OFF condensing fan control option has been chosen.

(***) If modulating condensing fan control (Variex) option has been chosen.

(****) Maximum outdoor temperature referred to:

--- 30°C / 39.5% R.H. at the evaporating suction side, for WM13---15MD models;

--- 27°C / 47% R.H. at the evaporating suction side, for WM13---15MO models.

(*****) Conditions referred to the evaporating suction side; the min. indoor temperature is referred to 30% of indoor relative humidity and to the min. outdoor

temperature; for higher relative humidity and/or outdoor temperatures, the min. indoor temperature is lower than the table data.

(1) Measured with 35° C outdoor temperature at 2m far from the unit; free field conditions.

(2) Electrical features are referred to 35°C outdoor temperature, to nominal power supply and to the following Indoor conditions:

--- 30°C / 39.5% R.H. at the evaporating suction side, for WM13---15MD models;

--- 27°C / 47% R.H. at the evaporating suction side, for WM13---15MO models.

(3) It refers to nominal speed (Factory setting).

pag. 11

Tab. 4 -- 50 Hz Technical data for “NO FREECOOLING”, “FREECOOLING” and “230V/1Ph/50Hz

EMERGENCY FREECOOLING” unit versions (NO FC, FC and EFC-- AC)

Model: HPW WM05SD WM05SO WM06SD WM06SO

Operating limits

Main power supply voltage 230V ±10% / 1Ph / 50Hz

Emergency power supply voltage 230V ±10% / 1Ph+PE / 50Hz

(with emergency cooling) (*)

Outdoor conditions (**)

from 10°C(**)

from --- 3 0 °C(***)

to 49°C(****) 49.5°C(****) 47°C(****) 47.5°C(****)

Indoor conditions with compressor running (*****) from 20°C , 3 0 ---

80% R.H. 21°C, 30---80% R.H. 22°C , 3 0 ---

80% R.H.

to 35°C, 40% R.H.

Storage conditions from --- 4 0 °C, 5% R.H.

to 55°C, 90% R.H.

Sound pressure level

Outdoor sound pressure level (1) dB(A) 52.5 52.5 54.0 54.0

Indoor sound pressure level (1) dB(A) 56.0 56.0 56.0 56.0

Standard electrical features

Compressor --- AC power input (2) kW 1.26 1.25 1.63 1.63

Compressor --- AC operative current (OA) (2) A5.8 5.7 7.6 7.6

Compressor --- AC max. current (FLA) A10.0 10.0 11.4 11.4

Compressor --- AC starting current (LRA) A35.0 35.0 47.0 47.0

Condenser fan --- AC power input (2) kW 0.24 0.24 0.24 0.24

Condenser fan --- AC max. power input kW 0.24 0.24 0.24 0.24

Condenser fan --- AC operative current (OA) (2) A1.1 1.1 1.1 1.1

Condenser fan --- AC max. current (FLA) A1.4 1.4 1.4 1.4

Condenser fan --- AC starting current (LRA) A1.6 1.6 1.6 1.6

Evaporator fan --- AC power input (2) kW 0.14 0.14 0.14 0.14

Evaporator fan --- AC operative current (OA) (2) A0.7 0.7 0.7 0.7

Evaporator fan --- AC max. current (FLA) (3) A0.7 0.7 0.7 0.7

Evaporator fan --- AC starting current (LRA) A1.2 1.2 1.2 1.2