Operation Manual

Operation Manual
GEA Close Control

T-Range Aerial Values Always On The Level
Description
GEA Close Control T-Range
Description
Description ..................................................................................................................2 Introduction.................................................................................................................3 "HEALTH and SAFETY at WORK ACT" ....................................................................3 Safety Instructions .....................................................................................................5 Panelling......................................................................................................................6 Positioning and Levelling Air Handling Units .........................................................7 Noise Considerations.................................................................................................7 Service Connections ..................................................................................................8 Condensate and Humidifier Drains...........................................................................8 Chilled and Condenser Water Pipework ..................................................................9 Refrigeration Pipework ........................................................................................... 10 Leak Testing............................................................................................................. 11 Refrigerant Charges ................................................................................................ 12 Oil Charging ............................................................................................................. 12 Chilled Water Volumes............................................................................................ 13 Control of Refrigerant Discharge........................................................................... 13 Humidifier Information (if fitted)............................................................................. 13 Electrical................................................................................................................... 14 Cable Segregation and Electrostatic Discharge (ESD)........................................ 15 Pre-Operational Check List .................................................................................... 16 Operating Environment........................................................................................... 16 Commissioning........................................................................................................ 17 D 3-42 Drawing......................................................................................................... 19 U 3-42 Drawing......................................................................................................... 20 U/D 48-83 Drawing ................................................................................................... 21 U/D 3 - 5 Connection Detail Drawing ..................................................................... 22 U/D 8 - 12 Connection Detail Drawing ................................................................... 23 U/D 17 - 21 Connection Detail Drawing ................................................................. 24 U/D 23 - 28 Connection Detail Drawing ................................................................. 25 U/D 32 - 42 Connection Detail Drawing ................................................................. 26 U/D 48-53 Connection Detail Drawing ................................................................... 27 U/D 63-83 Connection Detail Drawing ................................................................... 28 C3-05 Controls - General Information.................................................................... 29 C3-05 Controls - Customer Access ....................................................................... 30 Note ........................................................................................................................... 31
PR-2007-0342-GB Subject to modifications Status 05/2007
Introduction
Introduction
GEA Denco thank you for purchasing their Air Conditioning Products. These products have been designed, for indoor use only, to cool, heat, humidify, dehumidify and filter air at atmospheric pressure using either (a) a Direct Expansion System ("X", "A", "W" or "F") utilising one of the following refrigerants: R407C or R134a or (b) a Chilled Water System ("C") using Chilled Water or an Ethylene Glycol solution. These products are not authorised for use in any other way. This manual has been compiled to help ensure the correct installation of the equipment. Please read it fully BEFORE COMMENCING THE WORK. All installation work, including the running and connecting of services, must be carried out only by COMPETENT PERSONS. The manual does not cover the detailed servicing, which is contained in a separate Operating and Maintenance Manual. The equipment has been designed and manufactured within a Quality Assurance System conforming to ISO 9001, and Quality Controlled to ensure that it reaches you in perfect condition. A full functional test was performed prior to despatch. In case of any doubt refer to the Contract wiring diagrams supplied by GEA Denco. For actual model type and number refer to the Serial Plate fitted to the Unit. Data in this booklet refers to equipment with STANDARD CATALOGUE SPECIFICATIONS. Variations may occur depending on contract requirements. It is important for you to appreciate that failure to follow the instructions in this manual may result in damage, incorrect operation or danger to health and safety, and may invalidate the warranty. Any works planned that are not covered in this Manual are subject to the approval of GEA Denco Limited.
"HEALTH and SAFETY at WORK ACT"

Due regard shall be given to observing safe procedures when working with or on the equipment. It is the responsibility of the Installer / Operator / Customer to ensure that the "Health and Safety at Work etc. Act (1974)" and Normal Safe Working Procedures are adhered to at all times. With reference to the "Control of Substances Hazardous to Health Regulations 1988 (COSHH)" the following paragraphs refer: " However, certain substances contained within materials used in the manufacture of our units could be hazardous when released, if the unit is misused, abused or maintained by unskilled labour. In this regard, we notify you that should the pipework or slab foam insulation (Armaflex or similar), electrical insulation or vinyl coatings were to be exposed to naked flame, toxic fumes will be given off. It will be seen, therefore, that no naked flame should be applied to any of the above-mentioned substances, nor to paint, rubber or plastic parts. Light oil is applied to some bare metal parts as a protective coating and this could cause dermatic reaction to sensitive skin. Refrigerant 22 contains hydrochlorofluorocarbons (HCFC's) and Refrigerants 134a and 407C contain hydrofluorocarbons (HFC's). Glycol/water mix is used during manufacture but drained before delivery. The quantities in use are minimal but care should be taken in disposal. We trust that this information is sufficient but should you require further information regarding our products or maintenance service, please contact our sales department.
"HEALTH and SAFETY at WORK ACT"
Installers' Responsibilities
The 1974 Act is aimed at securing your health, safety and welfare. The Act is also designed to protect people, other than those at work, against risks to health or safety arising out of or in connection with the activities of people at work. Do not attempt to carry out work of a dangerous nature. It is your legal duty to take reasonable care of your own health and safety and of other people who may be affected by your conduct. Employees must co-operate with their employer in order to comply with any duty or requirement specified in the Act. You must abide by the statutory safety rules of the Company in which you are working. Remember that, in law, you are liable for the same penalties as your employer or site agent if you do not comply with the relevant requirements of the Act.
Legionnaires' Disease
An Approved Code of Practice HS(G) 70 "The prevention or control of legionellosis, including legionnaires' disease" [ HMSO 1991 IBSN 0 11 885660 X (formally Guidance Note EH48) ] came into effect on 15 January 1992.
For further full guidance on minimising the risk of Legionnaires' Disease in Air Conditioning systems (i.e. installation and maintenance guidance) reference should be made to Technical Memorandum TM 13 "Minimising the Risk of Legionnaires' Disease" published by the Chartered Institute of Building Services Engineers (CIBSE). The sketches detail typical schematic arrangements.
Safety Instructions
Safety Instructions Electrical

Ensure isolation of the mains isolator BEFORE any access panels are removed. Use ON/OFF SWITCH first to disable unit before using mains isolator. Mains isolator should be used to stop Air Handling Unit in emergency only. Note: If there is no Mains Isolator identify location of Local Isolator. Refer to the wiring diagrams and the units rating plate for the mains electrical supply for which the unit is suitable. The units MUST NOT be used on other electrical supplies without the prior approval of the Equipment Supplier.
Mechanical
Individual components of Aircooled systems ("X" and "A" versions) are delivered with holding charges of Nitrogen, which MUST be released before any work is carried out. Water cooled and Ambicool systems ("W" and "F" versions) are supplied fully charged with refrigerant. Therefore, any part of the refrigeration circuit that is being serviced should have the refrigerant gas fully removed BEFORE any work is attempted on any of the refrigeration components. See Control of Refrigerant Discharge. If any heat or flame is to be used on or near the unit and its associated installation care should be taken to avoid contact with any combustible surfaces. It should be noted that some insulation materials and refrigerants may give off toxic fumes when heated; therefore the working area should be thoroughly ventilated BEFORE and DURING the operation. Proper fire precautions should be observed and any necessary fire safety equipment should be on hand, typical for electrical, oil or foam fires.
General
Observe all electrical and mechanical safety labels fitted to various parts of the unit/system. Beware of the following danger areas within the unit when running: (a) Any rotating components (fans, pulleys, etc.). (b) Sharp edges (coil fins, sheet metal, etc.). (c) The top of scroll compressors, which become hot under normal running conditions. (d) Hot refrigeration or water pipework and electric heaters. (e) Hot humidifier bottle and humidifier sparge pipework (if fitted). (f) Condensate drain could contain hot humidifier discharge during the humidifier drain cycle. (g) Hot L.P.H.W. coil pipework (if L.P.H.W. coil fitted). (h) Possible live electrical components or terminals.
Panelling
Panelling
All front hinged access panels are held in place by turn latch / turn compression locks, which can only opened using the special keys provided. The panels may be removed from the unit by releasing each of the hinge retainers. If the hinged electrical door is being removed, care must be taken to first remove the cable to the controller display module. The rear and end panels, if to be removed for any reason, are held in place by six screws.
Weight of Panels
IMPORTANT: If any front hinged access panels are removed, please note that the standard panels for units can weigh up to 23 kgs (max.). However, if full acoustic treatment has been applied to these panels then these panels can weigh between 45 and 50 kgs (max.). If acoustic panels are fitted to a unit that is installed above floor height, then extra care must be taken when removing them. It is recommended that that this operation is carried out by at least two people. If the unit is installed at a height at which the removal of these panels is considered unsafe, then an access platform should be used.
Method Statement for Removal of GEA Denco Air Handling Unit Panels
IMPORTANT: It is recommended that this handling operation be carried out by at least TWO people. Place access platform adjacent to Air Handling Unit and stabilise (with outriggers if necessary). Shut down Air Handling Unit and isolate electrically. Support the panel (using Veribor or similar suction lifters if necessary) and test for firm grip. Release the turn latch / turn compression locks of the first panel for removal using the special key (supplied with the unit) and release the hinge pins. Remove panel to top of access platform and thence to floor level. Repeat above for all other panels required to be removed. The replacement of the panels is the reverse of the above procedure.
Positioning and Levelling Air Handling Units
Positioning and Levelling Air Handling Units

It is recommended that Units with a small footprint (especially T Range models 3 to 5) should be suitably stabilised by attachment to an adjacent wall etc using the brackets provided. This is especially necessary if the units are standing on a tall plinth or bottom section. Care should be taken when lifting the unit. Damage can occur, when positioning, to the panelling and exterior paintwork. It is therefore necessary to use an adequate number of personnel and the correct moving equipment, such as hydraulic lifting skoots. GEA Denco will take no responsibility for damage caused by mishandling during the positioning of the equipment.
Model U/D 3-5 Wall Bracket Fixing
IT IS ADVISABLE TO USE THE POLYTHENE COVER AS PROTECTION DURING THE INSTALLATION PERIOD AND IT MAY BE ADVISABLE TO INITIALLY USE THE CARDBOARD PACKING AS ADDITIONAL PROTECTION IF BUILDING OR OTHER CONSTRUCTIONAL WORK IS OCCURRING IN THE AREA WHERE THE UNIT IS TO BE SITED. The pallets have been designed with cut-outs at each end, such that hydraulic lifting skoots can be positioned under both side frames of the unit to lift the unit to enable the pallet to be withdrawn. Once the pallet has been removed, the unit may be lowered on the hydraulic lifting skoots and manoeuvred to its final position. Unit should be set in an upright position - level in both directions. Failure to carry out levelling correctly may cause operational problems, particularly to the drainage. The units are assembled on a level base and any misalignment of panels will indicate that the unit is not level. Pack as required to bring the panels into alignment. Always use a spirit level, and if packing pieces are used, put them at the corners of the unit. Plinths/Base Stands/Top Sections etc. may be part of the system supplied, ensure that adequate gasketing or sealing is provided between each section and that they are securely bolted together.
Noise Considerations
It is important that the problems of noise have been considered before the installation, i.e. The acoustic properties of the room - soft furnishings, curtains and carpets tend to deaden reflections. Bare walls, vertical cabinets etc. tend to produce reflections which result in higher noise levels. - Equipment placed hard against a wall can transmit noise through and along the wall into adjacent areas. - Floors with high deflections e.g. wooden floors, can amplify the noise produced by the unit. To reduce these problems, the following are suggested, dependent upon site conditions: Ensure that any vertical planes directly in front of the unit are acoustically dead. Where units are situated in equipment rooms, acoustic treatment of the walls of the equipment room should be considered. Acoustic pads may be placed behind equipment to reduce wall transmissions. In new buildings steel floor framing to match equipment supports may be used to transmit loads to the building columns. In existing buildings, supplementary steel framing may be necessary. Acoustic pads (cork, felt, good quality carpet) may be used beneath the equipment.
Service Connections
Abrupt bends in pipework should be avoided by fitting long turn elbows or forming long radius bends. Where pipes pass through walls or partitions, provide an oversize sleeve and pack with suitable insulation material. Insulate pipes and rigidly support to a solid structure, and box in with sound-deadening material. NOISE The airborne noise emission does not exceed 70 dBA at 3 metres under load conditions measured using a Precision Impulse Sound Level Meter (BS 5969 Type 1) in typical room conditions.
Service Connections Ductwork

On units where ductwork is to be fitted, ductwork connections must be completed before any pipework and electrical connections are made in order that the final position of the unit can be fixed.
Pipe Connections
Pipework should be brought to and from the unit through the base only unless specifically designed for top entry pipework. When running the pipes care must be taken not to obstruct the airflow into the unit, particularly if the base is being used for return air or air discharge.
Mains Water Pipework

All mains water pipework to humidifiers must be installed to national and local standards. In particular, attention must be paid to Local Water Board requirements regarding Mains Water supplies to and overflows from the system.
Humidifier Supply (if fitted)

The unit is fitted with a flexible hose with 3/4" BSP connection to the Humidifier at one end and a 15 mm brass compression fitting complete with nut and olive at the other for connection to an external water supply. The water supply should have a stop cock adjacent to the unit and have a pressure of between 1 bar (14.5 psig) and 10.0 bar (145 psig). NOTE: Water not be via water softener.
Condensate and Humidifier Drains Downflow Units

All cooling coil drip trays have a 22 mm condensate drain that is fitted with a flexible transparent trap. The trap is fitted between the drain tray connection and the unit exit termination. The drain connection is a 22 mm compression fitting located in the bottom right-hand side of the unit. Access is through the hinged front access panel.
Upflow Units
These units are similar to downflow with the exception that they have a copper condensate trap located within the bottom of the unit.
Chilled and Condenser Water Pipework
All Units
The drains should run into a 35 mm or larger drain within 3 metres of the unit and discharge into a trapped air break as detailed in the "Legionnaires' Disease" section. The drain should be run in copper tubing or high temperature rigid plastic tubing. Drainpipe runs should be adequately supported at regular intervals and have a slope of at least 1 in 50 to ensure drainage. If the run is long and has a number of bends the tube should be adequately sized and suitable cleaning (rodding) eyes installed at bends. The pipework should be tested for any leakage upon completion of installation. IMPORTANT: The condensate/humidifier drain pipework should be earthed using the electrical bonding strap supplied with the unit. This connection should be as close to the unit as possible. NB: All drains should be trapped adjacent to the unit, the trap being at least 75 mm (3") in depth.
Chilled and Condenser Water Pipework

All chilled and condenser water pipework should be designed to good practice as detailed in GEA Denco Code of Practice CP 12. The following should be observed on chilled water units, drycooler (radiator) or cooling tower systems: Pipes should be sized in accordance with accepted practice. Care must be taken when sizing pipework and pumps to make sufficient allowance for the pressure drops. Lines should be adequately sloped to drain away, by gravity, water that is accumulated from condensing, defrosting or cleaning operations. All plumbing connections should be made in accordance with local Water Board recommendations. - Control devices such as solenoid valves, modulating valves or hand valves, which may cause hydraulic hammer, should be protected by a stand-pipe and air pocket to absorb shock. - A 40-mesh strainer should be provided at the inlet to each water cooled unit to protect the plate type heat exchangers from fouling. - Beware of any residual glycol solution that may be left in Air Handling Unit following testing. The following is submitted as a guide to the installation: All pipework should be installed to local and national standards. Whenever possible it is recommended that "reverse return" piping be used for multiple installations to ensure an easily balanced system. Regulating valves, preferably with pressure test points should be used at strategic points including all coils to enable balancing of water flow rates. Isolating valves should be provided at all items of equipment to enable servicing to be carried out without draining the system. Thermometers and pressure gauge test points should be located at coils, chillers and towers for commissioning and normal service checks. All high points and coils should be provided with vent cocks to enable system venting to prevent air locks. All coils and low points should be provided with drain cocks to enable draining. Pipe expansion and contraction should be allowed for by the installation of expansion bellows (where necessary). A closed type expansion tank should be provided for the system. A strainer with an adequate mesh should be installed prior to the pump inlet. On systems designed to operate on ethylene glycol, the solution strength must be adequate for the minimum ambient temperatures likely to be encountered. Systems not designed to operate on ethylene glycol should have any external pipework trace heated to give frost protection. Pipework must be properly cleaned and flushed. Refer to BSRIA Technical Memorandum TM 2 / 84.
Refrigeration Pipework
Condenser water, particularly if served by an open evaporative cooling tower, should be treated to prevent the deposit of hard water scale or biofilm on the condenser surfaces and filtered to prevent the circulation of other solid materials. All chilled water and condenser water pipework should be insulated. Chilled water pipework and valves should be vapour sealed to avoid condensation.
Freeze Prevention of Water Pipework

If water piping is installed where the temperature may drop below freezing, it must be arranged so that it can be completely drained. Condensers or water coils are difficult to drain completely and therefore; it is advisable to remove any remaining water by blowing through with compressed air. If systems are to remain out of operation for long periods, then it is recommended that they be refilled with an anti-freeze solution to prevent corrosion of the inner surfaces of the piping, condensers and coils. The anti-freeze solution should contain inhibitors to ensure it is not aggressive towards any of the materials of the coil or pipework, and the advice of the anti-freeze supplier should be sought. On re-commissioning the equipment, the anti-freeze solution must be drained and the system refilled with water.
Refrigeration Pipework
Refrigeration lines should always be as short and as direct as possible. The liquid and suction lines of condensing units should always be insulated when run outside a building. The suction line should be insulated within a building where its temperature is likely to be below that of the surrounding air, to prevent condensation. Similarly, the liquid line should be insulated wherever it is exposed to a heat source in order to prevent re-evaporation. Discharge lines exposed to outside conditions for more than 3 metres (10 ft.) should be insulated to minimise the risk of operating problems during cold weather. Vertical runs whether liquid, suction or discharge, should be insulated when over 1.8 metres (6 ft.) long to assist oil return. Every vertical suction riser greater than 1.0 metres (3 ft.) in height should have a "P" trap to facilitate oil return. To avoid the accumulation of large quantities of oil, the trap should be of minimum depth and the horizontal section should be as short as possible. Suction risers over 6 metres (20 ft.) height must be fitted with "S" traps or loops at maximum intervals of 6 metres (20 ft.) to assist oil return. All horizontal suction runs should have a slope of 1 in 200 minimum towards the compressor (direction of flow). When running liquid and discharge lines together they should be separated by at least 50mm (2") with the discharge line run above the liquid line. Do not leave compressors or filter driers open to the atmosphere any longer than is absolutely necessary and never for more than two minutes maximum.
Liquid Line Filter/Drier

The liquid line filter/drier serves to prevent scale or foreign matter entering the solenoid valve and the expansion valve. This strainer is placed in the liquid line so that any liquid, from the condenser or liquid charged in to the system, must first pass through it before entering the solenoid or thermostatic expansion valve.
Hangers
Tubing should be supported by suitable clips. Supports should be placed not more than 1.2 metres (4 ft.) apart. Hangers or brackets should be properly isolated where necessary to prevent noise or vibration transmission. The use of sponge rubber or Armaflex between the support and the tube usually satisfies this requirement. When
10 PR-2007-0342-GB Subject to modifications Status 05/2007
Leak Testing
lines are insulated the position of the hanger should be such as to bear on the outside of the insulation. Insulation Unless specifically mentioned all suction lines must be insulated. Insulation is only to be fitted after "all" pipework has been satisfactorily leak tested. All refrigeration pipework should be installed to national and local standards and as detailed in GEA Denco Code of Practice CP 12 also refer to the appropriate Aircooled Condenser and Condensing Unit Installation Manual. All soldering / brazing should be done in accordance with the requirements of the European Pressure Equipment Directive (P.E.D.), which includes soldering / brazing certification. Pipes must be properly sized to meet the design suction line loss, and the pipework system designed, to ensure oil return to compressors and avoidance of excessive pressure drops in discharge and/or liquid lines. Purpose made oil traps must be fitted to vertical suction lines every 6.1 metres (20 feet) when lifting. Aircooled Condensing Units or Condensers should not be sited more than 15 metres (50 feet) above or 4 metres (13 feet) below the base of the Air Handling Unit. Refrigerant pipe wall thickness must be suitable for the maximum system pressure applied. Systems using R410A refrigerant have a working pressure up to 38 bars. Extreme care should be taken to keep refrigeration tubing clean and dry prior to installation and the following procedures will help to adhere to good practice: Only refrigeration grade copper tubing correctly sealed against contamination should be used. - Do not carry out installation outside whilst it is raining. - Always cap the free end of tubing whilst carrying out installation. - Do not leave dehydrated compressors or filter/driers open to the atmosphere. - Use only copper eutectic or specialist soft solders containing at least 3.5% silver on suction and liquid lines and high temperature copper eutectic rods or silver solder on discharge lines. It is suggested that one of the following are used: (a) Copper to copper - Eutectic 1805 (2% silver) - no flux. (b) Copper to brass - Eutectic 1805 - flux 1802. (c) Copper to steel - Eutectic 1810 (2% silver) - flux 1820. NB: STANDARD SOFT SOLDER MUST NOT BE USED. With any high temperature rod where oxidisation is liable to take place use dry nitrogen to avoid scale formation inside the tubing. When using soldering paste or flux, use the minimum required to prevent contamination of the filter and joint. Flux only the male part of the connection never the female. After making the joint, remove the surplus flux with a damp cloth. Where vibration eliminators are used the ends should be wrapped with a damp cloth and rods with a melting temperature of no greater than 650oC (1200oF) should be used to avoid damage to the internal joints. -
Leak Testing
After all lines are connected, but before they are insulated, the system must be leak tested using an electronic leak detector. For satisfactory installation, the system MUST be leak tight. Leak testing should be carried out before initial charging and after any service work has been carried out, and prior to evacuation. Charging with refrigerant gas until system pressure is approximately 1.4 bar and then pressurising with dry nitrogen to a maximum of 22.8 bar. Note: please ensure that the LP switch is isolated during this test as this component has a maximum allowable pressure of 20 bar. Refer to Control of Refrigerant Discharge. For systems that contain R410A a leak test pressure of 42 bars should be applied.
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Refrigerant Charges
Refrigerant Charges
A.H.U. Model D3-5 D 8 - 12 D 17 - 28 D 32 - 42 D 48 53 D 63 83 U35 U 8 12 U 17 28 U 32 42 U 48 53 U 63 83 "A" and "X" Versions kgs 0.81 2.17 4.06 5.82 4.06 5.82 0.76 2.05 3.76 5.52 3.76 5.52 lbs 1.78 4.78 8.95 12.83 8.95 12.83 1.68 4.52 8.29 12.17 8.29 12.17 "W" Versions kgs 0.92 2.30 4.20 5.94 4.20 5.94 0.87 2.19 3.91 5.64 3.91 5.64 lbs 2.03 5.07 9.26 13.09 9.26 13.09 1.93 4.82 8.62 12.43 8.62 12.43 "F" Versions kgs 2.30 4.20 5.94 2.19 3.91 5.64 lbs 5.07 9.26 13.09 4.82 8.62 12.43 -
Note: Figures shown above are TOTAL per circuit for Units and do not include for any interconnecting pipework, liquid receivers, Aircooled Condensers or Aircooled Condensing Units. Refer to relevant Aircooled Condenser or Aircooled Condensing Unit Installation Manuals for relevant Condenser or Condensing Unit R407C refrigerant charge. When using R410A refrigerant multiply the above values by 0.95.
Oil Charging
Unit fitted with Copeland Compressors Refrigerant ALL In Compressor or Recharging Oil RL32-3MAF To Top Up Oil RL32-3MAF
As an alternative to ICI EMKARATE RL32-3MAF, MOBIL EAL ARCTIC 22CC can be used. If available then RL32CF and RL32S may still be used. The refrigerant compressor is filled with sufficient oil for standard installations where the liquid line run is under thirty (30) metres. Where runs are longer than this, additional oil as indicated above is required. As a guide, 5 g of oil should be added for each additional 1.0 kg of refrigerant charge. Additional oil should be added to ensure correct operation of oil traps (where fitted). Refrigerants R407C, R134a and R410A can ONLY be used with ester oils, however refrigerant R22 should be used with mineral oils. Mineral and ester oils MUST NEVER be mixed. Ester oils are very hygroscopic and therefore must not be exposed to the air for any length of time.
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Chilled Water Volumes
Chilled Water Volumes

The Chilled Water Air Handling Unit volumes shown below include coils, valves and unit pipework. A.H.U. Model WATER VOLUMES - litres D 5 12 28 42 53 83 3.5 7.0 13.8 20.4 27.6 40.8 U 3.1 5.8 12.0 17.8 24.0 35.6
Control of Refrigerant Discharge

By international agreement, the world-wide use of certain refrigerants will be reduced in stages. To this end listed below are suggestions on how refrigeration engineers can contribute by the discontinuing of releasing any refrigerant gas to the atmosphere. Release of refrigerant to the atmosphere is an offence under Section 33 of the Environmental Protection Act 1990. DO NOT ... (1) Blow off refrigerants to atmosphere. (2) Use refrigerants to clean coils etc. (3) Leak test using pure refrigerant. (4) Recharge before mending leaks. (5) Dispose refrigerant gas to waste. DO ... (1) Pump down into a receiver or empty cylinder using Reclaim Equipment. (2) Clean coils etc. using a hand brush, vacuum or compressed air. (3) Leak test using Nitrogen and just a trace of refrigerant gas. (4) Find and mend leaks before recharging system. (5) Send used refrigerant gas back for reprocessing.
Humidifier Information (if fitted) Water Connections

The humidifier unit may be connected to a standard piped cold water supply observing local regulations where applicable. DO NOT USE demineralised water. Pre-treatment of water fed to the humidifier is unnecessary. Where a salt exchange plant is in use at a site, the feed water to the unit should by-pass this. Water Quality Conductivity Feed Water Pressure Feed Water Connection Drain Water Connection Air Duct Pressure 125 - 1250 microSiemens/cm 1 - 10 bar 15 mm O/D Brass pipe 22 mm Compression or Copper 400 Pa
Beware of the following danger areas within the unit when running: Hot humidifier bottle and humidifier sparge pipework. Condensate drain could contain hot humidifier discharge during the humidifier drain cycle. Steam being emitted from humidifier sparge pipe.
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Electrical
Electrical
WARNING: DANGEROUS VOLTAGE LEVELS EXIST WITHIN THIS EQUIPMENT. USUAL ELECTRICAL SAFETY PRECAUTIONS MUST BE OBSERVED. THIS EQUIPMENT MUST BE EARTHED. All installation wiring associated with this equipment must be sized and comply with the latest edition of the IEE Regulations or to national/international codes of practice. A set of wiring diagrams is secured inside the unit.
Mains Supply
The Mains Supply for this unit is shown on the wiring diagrams. Voltage tolerance should not exceed tolerances of 10%. This equipment in its standard form is designed to operate with an electrical supply of 400V/3 Phase + Neutral/50Hz. This equipment is Class 1, as defined in the IEE Regulations and BS 2754 (1976). Appropriate holes are provided in the gland plate for cable termination. Use the correct size gland; do not remove any blanking plugs from unused holes. IMPORTANT: NEVER cut additional entry holes into the top of the electrical enclosure. Terminate all site earth cable conductors to gland plate earth bolt(s) provided. Ensure that the mains electrical supply is of the correct voltage, frequency, phase and rating. Ensure cable sizes are correct for the maximum load of the equipment under normal automatic running conditions. Recommended supply fuses should be to BS 88. The fuse size should be determined from the worst FLA shown on the wiring diagram. Before connection to the equipment, check each installed cable for continuity and short circuit. Check the tightness of all electrical connections prior to switching on supply. IMPORTANT: The condensate/humidifier drain pipework should be earthed using the electrical bonding strap supplied with the unit. This connection should be as close to the unit as possible.
Wiring Colour Codes

The wiring colour code for cables within this equipment is as follows: Green/Yellow L1, L2, L3 Blue Brown Pink Orange Protective Earth conductors AC Three Phase Power Circuits AC Power Neutral AC Single Phase Power Circuits M.E.L.V. and DC power circuits ( M.E.L.V. Machine Extra Low Voltage not > 25 AC RMS or 60V DC with 10% maximum ripple ) External interlocks which may remain live when isolator is off
NOTE: This colour code DOES NOT apply to electronics wiring.
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Cable Segregation and Electrostatic Discharge (ESD)
Cable Segregation and Electrostatic Discharge (ESD) Cable Segregation

IMPORTANT: Ensure that segregation is maintained between control wiring ( 24V AC or DC) and mains potential wiring (400V/230V) throughout the entire installation. The ramifications are: Control signals to condensing units must run in a separate cable to the mains power cable. - Where power and signal/control cables have to run in close proximity, then a minimum gap of 30 mm between each category to be maintained. - Power and signal/control cables should never cross, but if unavoidable, ensure that they cross at 90o. IMPORTANT: Any additional equipment installed in the unit, or supplied from it, will render the warranty invalid, unless it complies with current EMC Standards in force and any equipment fitted is approved by GEA Denco. The alarm relays can be connected to 240V AC maximum 5A (res.). When interrogating the volt free contacts of the alarm relay ensure that the cable is installed in the appropriate trunking (low voltage or high voltage). -
Electrostatic Discharge (ESD)

When working inside the electrical enclosure, that person MUST ensure that they have taken sufficient precautions for electrostatic discharge protection. Inside the electrical enclosure, there is an electrostatic discharge connection point to fit a suitable ESD protection strap.
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Pre-Operational Check List
Pre-Operational Check List

AFTER ALL NECESSARY INSTALLATION WORK HAS BEEN COMPLETED AND BEFORE THE MAINS SUPPLY IS APPLIED TO THE UNIT, ENSURE YOU HAVE READ ALL THE PREVIOUS SECTIONS OF THIS MANUAL, AND THAT THE RELEVANT PARTS HAVE BEEN FULLY COMPLIED WITH. If unit has been stored in a colder environment than its final site, allow a period for acclimatisation and evaporation of any condensation that may have occurred before the mains power supply is connected. - Keep ALL access panels closed to prevent the unnecessary ingress of dust or other particles. - Ensure all exterior access panels have been replaced and secured in position to ensure the correct airflow. - When the unit is running, if switched off do not switch back on for at least 20 seconds. IMPORTANT: Danger exists from fans running on following the unit being switched off. It is recommended that no panels be removed for at least 2 minutes to allow the fans rotational momentum to cease. ALWAYS REPLACE THIS MANUAL IN THE SERVICES SECTION OF THE UNIT.
WARNING: DANGEROUS VOLTAGE LEVELS EXIST WITHIN THIS EQUIPMENT. USUAL ELECTRICAL SAFETY PRECAUTIONS MUST BE OBSERVED.
Operating Environment
1. Room conditions for the switchgear / controls of Air Handling Units are as follows: Maximum Standing Ambient Minimum Standing Ambient Maximum Humidity Maximum Working Pressure - Refrigerant Maximum Working Pressure - Water 35oC 5oC 90% non condensing 25 bar 7 bar
2. The exterior of an Air Handling Unit is generally dust and damp-proof to IP 41. Do not install unit in areas where the environment contains large concentrations of dust, as this will tend to deposit on the electronic circuit boards (PCB's) and can cause malfunctions. 3. The humidity sensor can be damaged by aggressive vapours (chlorine, acetone) and must not be used in rooms where the environment contains these vapours. 4. The return air temperature and humidity sensor is dust and damp-proof to IP 20 and therefore the airflow side of the unit is designed to IP 20.
16
Commissioning
Commissioning Commissioning: General

IMPORTANT NOTES: On T Range Models 3 - 5, due to the starting characteristics of the fan, a mechanical noise will be evident for a few seconds until the fan reaches full speed. The T Range "X", "A", "W" and "F" versions incorporate scroll compressors that will only compress in one rotational direction. The rotational direction is dependent upon the phasing of the power to motor terminal connections (L1, L2 and L3). Verification of correct rotational direction is made by observing that the suction pressure drops and discharge pressure rises when the compressor is energised. Reverse rotation results in a sound level above that with correct rotation, as well as substantially reduced current drawn compared to tabulated values. There is no negative impact on durability caused by operating the scroll compressors in the reverse direction, however, after several minutes the compressor internal protection will trip. THIS PROTECTIVE DEVICE SHOULD NEVER BE BY-PASSED FOR ANY REASON.
1. All commissioning work must only be entrusted to COMPETENT personnel in refrigeration, water pipework and electrical engineering. 2. The following equipment will be required to fully commission a unit: 1 - Amprobe 1 - Multimeter (preferably digital) 1 - Anemometer 1 - Inclined manometer 0-10" wg 1 - Portable test manometer (0-20 feet 0-50 feet) 1 - Complete set of unit schematic wiring diagrams 1 - Vacuum pump 1 - Oil pump
Direct Expansion Systems ONLY
- 1 - System analyser gauge manifold (Ensure pressure rating is suitable when using R410A) - 1 - Refrigerant Reclaim Equipment - 1 Water Conductivity Meter 3. Check the mechanical installation for: (a) It is necessary before starting the fans to ensure that the mechanical adjustment of the fan drive arrangement is correct. - (b) External refrigeration and any water pipework and drains are connected correctly. Pay particular attention to the refrigeration pipework for remote Condensing Units or Condensers. 4. Check the electrical installation for: (a) Segregation of signal and main potential (240V/415V) cabling. (b) Correct termination and integrity of signal and mains cabling connections. Pay particular attention to the controls cabling for remote Condensing Units or Condensers, which should be run separately to Mains supply. (c) Understand function and operation of remote interlocks. (d) Function of auxiliary alarm (if utilised). -
IMPORTANT: Aircooled Condensing Units / Condensers need to be separately commissioned PRIOR to the commissioning of the refrigeration components in the Air Handling Unit. See the relevant Installation Manual for this action.
PR-2007-0342-GB Subject to modifications Status 05/2007 17
Commissioning
Commissioning: Chilled Water System

By manually opening the 3-way control valve, balance the chilled water pipework to achieve the design flow rate through the cooling coils and by-pass arrangement. The best method of measuring water flow is by incorporating orifice and double regulating valves at each unit, so enabling readings to be taken on the orifice valve and regulating flow on the double regulating valve. Alternatively, a double regulating valve with pressure tappings can be used. If these valves have not been installed, pressure drop readings should be taken across the coil and across the 3-way valve. The double regulating valve in the by-pass line should be set to correspond to the coil pressure drop, thus ensuring correct control by the 3-way valve and constant flow through the system. Commission the chiller and associated equipment in accordance with manufacturers recommendations.
Commissioning: Direct Expansion System

IMPORTANT: When working with solenoid valves, the solenoid coil should not be removed from the valve body / stem until the coil has been electrically disconnected. Ensure that the compressor / remote condensing unit MCB's are in the "OFF" position. Ensure that the crankcase heater (fitted to "X" version only) and condenser supply MCB's are in the "OFF" position ("A" version). Select a low value temperature setpoint compared to the return air temperature. Check that the 24V AC signal is present at the solenoid valves. Reset the temperature setpoint. Set Combined HP/LP switches to values given below: R407C Low Pressure Cut Out Low Pressure Differential Low Pressure Cut In High Pressure Cut Out 2.2 bar (32 psig) 1.8 bar (26 psig) 4.0 bar (58 psig) 24 bar (348 psig) R134a 0.55 bar (8 psig) 1.45 bar (21 psig) 2.0 bar (29 psig) 20 bar (290 psig) R410A 4.2 bar (61 psig) 2.6 bar (38 psig) 6.8 bar (99 psig) 38 bar (551 psig)
Ensure that all compressor and pipework shut-off valves are open. Ensure that the system is thoroughly leak tested and refrigerant systems evacuated before proceeding to add the refrigerant and oil type as labelled in the service section of the Unit. Refer to Control of Refrigerant Discharge. Check the operation of the pressure switches. Revert all cooling MCB's to "ON". After re-energising the Air Handling Unit, make the necessary adjustments to achieve the design condensing temperature, depending on: (a) Water cooled condenser. Adjust water flow rate to condenser. - (b) Aircooled condenser. Adjust fan speed controller or fan pressure switch (depending which fitted) and check fan operation. Check and adjust, (if necessary), the expansion valve superheat (4oC). Important: "W" and "F" versions are fitted as standard with hot gas by-pass valves (hot gas by-pass is an option on "A" versions). On low load room conditions, this valve can be adjusted to suit the actual room load. Minimum suction pressure suggested is 4.8 bar (70 psig R407C) and 7.5 bar (109 psig R410A). Adjust setpoint to required design room condition and check for automatic operation within room design limits.
18 PR-2007-0342-GB Subject to modifications Status 05/2007
D 3-42 Drawing
D 3-42 Drawing
19
U 3-42 Drawing
U 3-42 Drawing
20
U/D 48-83 Drawing
U/D 48-83 Drawing
21
U/D 3 - 5 Connection Detail Drawing
22
23
24
25
26
U/D 48-53 Connection Detail Drawing
27
28
C3-05 Controls - General Information
C3-05 Controls - General Information
ALARM Key
Graphical LCD
Four Programming Keys ( )
ON/OFF Key
Graphical Display comprises: - Unit ON/OFF key, providing "master" control of the local unit. - Graphical liquid crystal display, providing icon status of the unit functions, parameter menus, historic data logging, alarm buffer and access to other controllers via the network system. - Four programming keys, providing access to display features. - Alarm key to view active alarms.
Unit Functions are indicated via icons. These are:
UNIT RUN - shown when Unit fan(s) are running
COOL - shown when cooling demand is greater than 0 %.
HEAT - shown when heating demand is greater than 0 %.
HUMIDIFY - shown when humidification demand is greater than 0 %.
DEHUMIDIFY - shown when dehumidification demand is greater than 0 %. The 8 row LCD indicates Unit Function via the icons on rows 1 and 2. The remaining rows show the selected data, updated in real time. The programming keys ( ) have to be pressed in a coded sequence in order to enter or change the function currently being accessed. Current Alarm status can be reviewed by using the Display Groups and Time-Out Display The information shown on the bottom of the display can be one of five (5) Groups. Every Group displays a different list of information. key to access the Alarm Buffer from the time-out display.
29
C3-05 Controls - Customer Access
C3-05 Controls - Customer Access

IMPORTANT NOTE: Apart from accessing the controller for the following purposes, users should have no need to change any of the settings, which have been set at the factory and maybe adjusted by the Commissioning Engineer. To do so could disable the unit or severely affect its operation and safety.
Customer Access Summary

Setting / checking Temperature and Humidity Setpoints. Setting / checking Unit ON/OFF Days and Times. Setting Unit System Clock.
Entry into Level 1

(1) From Time Out Display press key to access the Main Menu. (2) Position arrow against Level 1 and press key to access the level. (3) Enter the Code or Password for Level 1 as follows:
Level 1 Flow Chart

MAIN MENU Level 1 Level 2 Level 3 Historic Data Software Version Time Control Password ? Setpoints Temp Setpoint Hum Setpoint Version Enabled Enable On/Off Times On / Off Times >Disabled ON/OFF TIMES On F1-1 00:00 F1-2 00:00 F2 00:00 F3 - On On / Off Days Monday Tuesday Wednesday Thursday Friday Saturday Sunday Temp Setpoint Reschedule F4 F4 F4 F4 F4 F4 F4 Yes >No Hum Setpoint Reschedule Enable Time Zones Yes >No Set Clock Hour Minutes Day Month Year Set Hour Set Minutes Set Day Set Month Set Year Z1: Z2: Z3: Z4: Z1: Z2: Enable Time Zones Z3: Z4: ON 0:00 0:00 0:00 0:00 ON 00:00 00:00 00:00 00:00 SET 000.0C 000.0C 000.0C 000.0C SET 000% 000% 000% 000% Off 00:00 00:00 00:00 F4 - Off Set Temp Setpoint Set Hum Setpoint
5.0 deg C 21.0 35.0 deg C 0 %RH 50.0 100 %RH
30
Note
Note
31
Our Market in Europe
E B
GEA Happel Belgium N.V. B-1130 Brussels Tel. +32 / 2 / 2406161 EVISS Ltd. BG-7000 Rousse Tel. +359 / 82 / 81000 GEA Klimatehnika RS-11070 Novi Beograd Tel. +381 / 11 / 3193955 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Klimatec Schweiz AG CH-3065 Bolligen-Station Tel. +41 / 31 / 9171919 GEA LVZ, a.s. CZ-46312 Liberec Tel. +420 / 48 / 5225-111 GEA Klimatizace spol. s r.o. CZ-46312 Liberec Tel. +420 / 48 / 5225-303 GEA Happel Klimatechnik GmbH D-44625 Herne Tel. +49 / 2325 / 468-00
EST
GEA Air Treatment Marketing Services Int. GmbH - oficina Espaa E-28036 Madrid Tel. +34 / 91 / 3837701 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Happel France sarl F-59436 Roncq Cedex Tel. +33 / 3 / 20689020 OY TEKNOCALOR AB FIN-01300 Vantaa Tel. + 358 / 9 / 82546020 Denco Ltd. UK-HR4 8DS Hereford Tel. +44 / 1432 / 277 277 GEA Klimatechnika Kft H-1037 Budapest Tel. +36 / 1 / 4393200 GEA Klima-rashladna tehnika d.o.o. HR-10000 Zagreb Tel. +385 / 1 / 6064900
GEA Happel Luxembourg L-4940 Bascharage Tel. +352 / 26 / 502970 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Klimatehnika RS-11070 Novi Beograd Tel. +381 / 11 / 3193955 GEA Klimaprodukter AS N-0484 Oslo Tel. +47 / 220 / 27990 GEA Happel Nederland B.V. NL-2909 LL Capelle a/d Ijssel Tel. +31 / 10 / 2350606 Nnio, Lda. P-1269-090 Lisboa Tel. +351 / 21 / 3826160 GEA Klimatyzacja Sp. z o.o. PL-54610 Wroclaw Tel. +48 / 71 / 3737952
RUS
GEA Kondicioner Moskva RU-105094 Moskva Tel. +7 / 495 / 9566674 GEA EXOS Ventilation AB S -74528 Enkping Tel. +46 / 171 / 85530 GEA Klimatizcia s.r.o. SK-83104 Bratislava Tel. +421 / 7 / 44457917 GEA Klimatizacijska Tehnika d.o.o. SI-1000 Ljubljana Tel. +386 / 1 / 2573850 GEA Klimatehnika RS-11070 Novi Beograd Tel. +381 / 11 / 3193955 ISISAN TR-80700 Balmumcu Istanbul Tel. +90 / 212 / 2757171 GEA Ukraina t.o.v. UA-01135 Kyiv Tel. +38 / 044 / 4619356
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Air Treatment Division
For detailed information on all corporate areas, go to www.gea-airtreatment.com or contact
A company of GEA Group
us by email info@gea-airtreatment.com
PR-2007-0342-GB Subject to modifications Status 05/2007 Copyright GEA Air Treatment
GEA Klimatechnik GmbH A-4673 Gaspoltshofen Tel. +43 / 7735 / 8000-0
DK
GEA Klimateknik ApS DK-2610 Rdovre Tel. +45 / 38 / 887070
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Operation Manual - 2007 - GB GEA DENCO Close Control T-Range

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Operation Manual - 2007 - GB GEA DENCO Close Control T-Range

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GEA Close Control T-Range

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

"HEALTH and SAFETY at WORK ACT"

PR-2007-0342-GB Subject to modifications Status 05/2007

"HEALTH and SAFETY at WORK ACT"

GEA Close Control T-Range

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

Safety Instructions Electrical

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

Positioning and Levelling Air Handling Units

Positioning and Levelling Air Handling Units

Model U/D 3-5 Wall Bracket Fixing

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

Service Connections Ductwork

Mains Water Pipework

Humidifier Supply (if fitted)

Condensate and Humidifier Drains Downflow Units

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

Chilled and Condenser Water Pipework

Chilled and Condenser Water Pipework

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

Freeze Prevention of Water Pipework

Liquid Line Filter/Drier

GEA Close Control T-Range

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

Chilled Water Volumes

Chilled Water Volumes

Control of Refrigerant Discharge

Humidifier Information (if fitted) Water Connections

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

Wiring Colour Codes

NOTE: This colour code DOES NOT apply to electronics wiring.

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

Cable Segregation and Electrostatic Discharge (ESD)

Cable Segregation and Electrostatic Discharge (ESD) Cable Segregation

Electrostatic Discharge (ESD)

PR-2007-0342-GB Subject to modifications Status 05/2007

Pre-Operational Check List

GEA Close Control T-Range

Pre-Operational Check List

PR-2007-0342-GB Subject to modifications Status 05/2007

GEA Close Control T-Range

Commissioning Commissioning: General

Direct Expansion Systems ONLY

GEA Close Control T-Range

Commissioning: Chilled Water System

Commissioning: Direct Expansion System