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Rev. : C
Page : 1/86
OPERATION AND MAINTENANCE MANUAL
COMPONENT LITERATURE
EQUIPMENT DEFINITION
GE DEVICE : N/A
SUPPLIER : EMICON
EMICON A.C. S.P.A. via A. Volta, 49 – 47014 Meldola (FC) – Italy
pag. 2 tel. (+39) 0543/495611 – fax. (+39) 0543/495612 – e-mail emicon@emiconac.it
ED - Power Line – Use and Maintenance Manual (rev. 2, 08/2013)
TABLE OF CONTENTS
1. INTRODUCTION ................................................................................... 7
1.1. Manual content ..................................................................................................... 8
1.5. Warranty.............................................................................................................. 10
2. DESCRIPTION .................................................................................... 13
2.1. ED Series description ........................................................................................ 13
2.3.1. Housing.......................................................................................................... 16
3. INSTALLATION .................................................................................. 35
3.1. Identification tag ................................................................................................ 35
3.10.4. Control of the correct sequence of the power supply phases .................... 54
3.11. Tightness test, vacuum and charge execution of the system (only for EDX
and EDE) ....................................................................................................................... 54
4. OPERATION ....................................................................................... 60
4.1. Documentation ................................................................................................... 60
5. MAINTENANCE .................................................................................. 65
5.1. Programmed maintenance ................................................................................ 67
6. DISMANTLING .................................................................................... 80
Emicon A.C. S.p.A. presents the following series belonging to ED Power Line :
• ED.X Series – air cooled precision conditioning unit with direct expansion coil;
• ED.H Series – water cooled precision conditioning unit with direct expansion coil;
• ED.E Series – precision conditioning unit with direct expansion coil and remote motor-condenser.
The units of ED Power Line are available in different configurations according to the air intake and
discharge:
The units of ED.E series need to be connected to the air motor-condensers of MCX Kc or Ka, designed for
external installation.
This diversification can satisfy the customers demands in terms of unit performance, airflow capacity and
energy saving.
The units of ED Power Line are produced using the best technologies and components currently available on
the market, among which the fans with AC (Autotransformer Controlled) motors. The single-inlet AC
centrifugal fans are equipped with an impeller with backward curved blades. They are equipped with an auto
transformer which can control the fan speed rotation.
ED Power Line is built using the panels coating technology. As a matter of fact, the galvanised steel panels
are coated with a protection film in PVC. This technology allows to obtain a high corrosion resistance and
prevents blisters from occurring in cases of high humidity conditions.
Before doing any operation on the unit, read the whole Manual and all its annexes which are an integral
part of it, and follow carefully all instructions described in it.
The non respect of the instructions described in the Manual during the installation, the operation, the
maintenance, the repair and the dismantling of the group, can cause serious damage to people, things and
environment.
In case of any doubts on the correct understanding of the instructions contained in the Manual, please
contact Emicon A.C. S.p.A. to get further explanations (hereinafter: The Manufacturer).
The unit must be installed, controlled, submitted to maintenance, repaired and dismantled in conformity with
the local laws into force.
In order to guarantee the unit compliance to the above mentioned directives, the unit is designed, manufactured
and tested according to the instructions established in the harmonised standards listed in the above mentioned
certificates of conformity.
4 Identification number 10 Year of production (when the production cycle has been
achieved)
5 Type of power supply 11 The text "Contains fluorinated greenhouse gases covered
by the Kyoto Protocol"
6 Type of refrigerant
The Manufacturer Warranty is void in case the guidance of this Manual has not been carefully
respected.
The Manufacturer refuses all responsiblity for any damage to people, animals, things or environment caused by
incorrect installation, maintenance or setting, that is to say caused by a misuse of the machine. It is considered
as “misuse” of the machine any use not explicitly allowed in this Manual.
On the first unit startup, duly fill in the relevant Report attached to this Manual and send
the Manufacturer a copy in order to make the warranty valid.
The Manual must be kept in a proper place by the owner or by the person in charge of the unit control
(hereinafter: The Owner). To this end, a plastic bag where to store the Manual has been placed inside the
electrical panel so that it can be always easily accessible for consultation and at the same time, it can be
preserved properly.
All people in charge of operating on the unit and in particular, the technicians who must work on the cooling
system, must read all the information and instructions contained in this Manual.
The non respect of the instructions contained in the Manual during any operations of
installation, operation, maintenance, repair and dismantling of the unit can cause serious
damage to people, animals, things or environment.
In case the Manual is lost or deteriorated, a new copy must be requested directly to the Manufacturer.
Do not touch the machine if with barefeet or with humid or wet parts of the body.
Do not perform any cleaning operation before the main switch is “OFF” and
power line disconnected.
Do not spread, leave unattended or to the reach of children any packaging material (carton
box, staples, plastic bags, etc) as they may be source of danger.
Any operation on the unit must be carried out in compliance with local technical standards.
Only qualified and trained personnel is allowed to remove the covering panels because inside
the unit there are parts with high risk of electric shock, areas with high temperature and
working mechanical components.
Inside the unit there are some parts which might be dangerous because of the following elements:
• Elements submitted to electrical tension,
• Working mechanical components,
When there is no protection equipment, the dangerous areas are clearly and properly marked.
All maintenance and repair operations which require the intervention of personnel having different specific
skills (like welders, electricians, programmers, etc.) must be carried out with the supervision of a personnel
expert in cooling systems.
The personnel working with refrigerant fluids must be properly trained to acquire the required skills related
to the security aspects for dealing with this kind of substances. Besides the topics indicated in the local
standards in force, training must also include the following topics:
• Knowledge of local legislation, norms and standards in force concerning the refrigerants;
• In-depth knowledge and suitable training concerning the use of refrigerants and of the necessary
individual protection equipment;
• Knowledge and training to prevent leaks, to use the cylinders for the charge, to detect leaks, to
recover and treat the refrigerants.
The personnel must be able to understand and put the applicable local standards into practice.
In order to maintain these skills, the personnel must be submitted regularly to a suitable training in
compliance with the local laws in force.
2. DESCRIPTION
- X - 10 - 1 - U - Kc
Kc = R 410° or Ka = R 134a
U = front air intake, upflow discharge
V = down air intake, upflow discharge
D = up air intake, downflow discharge
B = back air intake, upflow discharge
* Cooling Capacity in kW
X = air cooled
E = water cooled
H = with remote motor-condenser
ED = Direct Expansion Unit
* The cooling capacity is calculated with a temperature of 27°C with 50% of relative humidity.
The following pictures show the possible unit configurations according to the transfer path of the air inside the
unit before being discharged into the working room at the desired temperature.
The following paragraphs describe the characteristics of the main components of the unit. The figure 2.3 shows
as an example a scheme to detect the main components of the unit. It must be noted that in the ED.E series the
compressor/s is /are present only in the motor-condenser/s MCX.
2.3.1. Housing
The unit housing is made of press-formed sections in galvanised steel sheets, covered with RAL 9004 epoxy
paint.
The structural elements are assembled together in order to build a strong housing able to support both the
components of the unit and any eventual mechanical stress which might occur during the unit handling and
operation.
The components are placed inside the unit in such a way to be easily accessible from the front and to make
the startup and maintenance operations safe.
Thanks to the new motors, to the backwards curved blades and to the building materials,
the AC fans allow to have a low noise level, high airflow and above all a low energy
consumption.
For further details on the EC fan (to adjust the airflow and the static back pressure), refer to the
microprocessor manual.
The evaporating coil is composed of copper tubes mechanically expanded on hydrophilic treated aluminium
fins. By reducing the surface tension between water and metal surface, it allows a film condensation and
avoids condensate to drain outside the drip tray.
Coils are leak tested and cleaned before being installed by the Manufacturer.
The electric heaters are installed by the manufacturer on the discharge air side of the coil and are controlled
by the microprocessor on the unit.
Nominal
Absorbed
Steam Absorbed
EDX EDH EDE Humidifier Nominal
Frame Model Prodution Current
U-V-B U-V-B U-V-B model Capacity
Setting
kg/h kW A
71 x x x 1,5-3KGH
1 1,5 1,12 5
81 x x x 230V/1F
• A control electronic card with the terminal board for the transmission of the operating parameters
and the enabling of the control devices;
• A user terminal board with 6 backlit keys to modify the parameters. Semi-graphic and backlit
display LCD 64x120 pixel to visualise the operation status and the alarm messages.
Once the operation is finished, proceed backwards (with reference to figure 2.6) to shut the inspection
window and the outside panels.
EMICON A.C. S.P.A. via A. Volta, 49 – 47014 Meldola (FC) – Italy
tel. (+39) 0543/495611 – fax. (+39) 0543/495612 – e-mail emicon@emiconac.it pag. 23
(rev. 2, 08/2013) ED - Power Line – Use and Maintenance Manual
2.3.12. Opening of the electric board
On ED Power Line units, the panel of the electric board (if present) is provided with a lock key and another
one without lock key. Figure 2.7 shows the lock key.
It is advisable to close the electric board panel by means of the lock key. In particular, during the
maintenance operations, it is recommended to stop the unit by means of the main switch by
moving it in position OFF and shut the electric board by lock key.
To lock the internal or external main switch, follow the instructions shown in figures 2.8, 2.9 and 2.10.
a)
Figure 2.9: Lockable main switch outside the electric board (<100 A)
a)
Figure 2.10: Lockable main switch outside the electric board (>100 A)
2.5. Accessories
Here below you can find a list of the main accessories which can be installed on ED Power Line units.
OPTION ED.X ED.H ED.E Accessory description
Flooding detector: placed in the downflow units, it is already wired and detects water
AA Ɣ Ɣ Ɣ in the false floor. The positioning under the unit must be carried out by the personnel in
charge of the installation.
Electrical power supply different from standard: mainly, 230 V three-phase, 460
AE Ɣ Ɣ Ɣ
V three-phase. Frequency 50/60 Hz.
Smoke alarm: it consists of a sensor detecting smoke inside the unit and activating an
AL Ɣ Ɣ Ɣ
alarm signal which stops the fans.
Base-frame: it is adjustable from 170 mm to max 600 mm for installation on raised
B Ɣ Ɣ Ɣ
floors. It is provided with adjustable feet.
Hot water coil: 1-row or 2-row water coil, it is placed after the cooling coil for the re-
BC Ɣ Ɣ Ɣ heating and/or the heating of the treated air. Provided with modulating actuator and
with three-way valve, it is controlled by the microprocessor on board.
Hot gas coil: placed after the cooling coil, it makes the re-heating of the treated air and
is provided with a 3-way valve (ON/OFF) controlled by the microprocessor on board.
BG Ɣ Ɣ Ɣ
It is available only with the dehumidification control (DH option). (Alternative to BC
and not available with HG).
Base-frame with conveyor: it is provided with a suitable conveyor facilitating the
BN Ɣ Ɣ Ɣ airflow and remarkably reducing the pressure drop in case of horizontal airflow. It is
adjustable in height from min 400 mm to max 800 mm. (only for D version)
Base-frame with ON / OFF motorised damper: this device prevents the air return
from the unit when it is not working or in case some units are working close to it.
BS Ɣ Ɣ Ɣ
Available only for D version; for other versions, being a special execution, please
contact the Sales Dept.
Base-frame with conveyor and ON / OFF motorised damper: one base-frame with
BSN Ɣ Ɣ Ɣ
both options BN and BS to optimise the efficiency and the space.
Soundproofing jacket on compressors: made of soundproofing material,
CI Ɣ Ɣ Ɣ wrapped all around the compressors so to further reduce the overall sound level of
the unit.
Compressor inrush counter: electromechanical device positioned inside the
CS Ɣ Ɣ Ɣ
electrical board, recording the total inrush starts of compressors.
Dehumidification control system: managed by microprocessor, through the
electronic thermostatic valve, it operates on two parameters ensuring that the
DH Ɣ Ɣ Ɣ dehumidification process is carried out with a constant air flow, without
partializing the evaporating coil. This will optimise the air distribution throughout
the room.
Double panels: for shutting off the compartments affected by the air flow, they are
DP Ɣ Ɣ Ɣ made from pre-painted and galvanised steel plate, ensuring a reduction in the noise
transmitted through the panels and a better air tightness even without the external
F5,F6, Higher efficiency air filters: pleated filters with F5, F6, F7, F9 efficiency,
Ɣ Ɣ Ɣ
F7, F9 supplied as an alternative to standard G4 filters.
FR Ɣ Ɣ Ɣ Spare filter kit (G4) as a replacement to the ones on board of the unit.
Humidifier: of immersed-electrode type for the modulating production of steam. It
is composed of a steam cylinder, a steam distributor, water inlet and outlet valves
H Ɣ Ɣ Ɣ and a maximum level probe. The microprocessor on board indicates when the
steam cylinder must be replaced. The electrical protection is ensured by a
magnetothermic switch.
Hot gas by-pass: it is a mechanical device for modulating the cooling capacity, so
to reduce the ON/OFF of compressors and therefore to wait for the re-starting
HG Ɣ Ɣ Ɣ
timing, with influence on the condensing temperature. It is not available for sizes 1,
2, and 3 and with options BG or DH.
Fumigated wooden crate packing: available on request for critical transports, so
IE Ɣ Ɣ Ɣ
to assure a suitable protection to the unit.
RS485 serial interface: electronical card to be connected to the microprocessor to
allow communication between the units and a Carel supervision system. In this way, it
is possible to fully control the unit from remote. For connection to other supervision
IH Ɣ Ɣ Ɣ
systems, the protocol of the controlled parameters is available on demand. (the
supervision system and the management software are not included in the supply –
please contact the Manufacturer to check the available communication protocols).
Seawood packing: fumigated seawood case and protection bag with hygroscopic
IM Ɣ Ɣ Ɣ
salts, suitable for long sea transports.
Magnetothermic switches for auxiliary circuits: installed in replacement of the
IP Ɣ Ɣ Ɣ
fuses, as a protection of the auxiliary circuits.
Lack of neutral for power supply 400/3/50: general unit power supply without
neutral conductor.
MN Ɣ Ɣ Ɣ
In case of IT electrical supplies, Emicon AC s.p.a. must give,
prior assessment, the authorisation to the wiring connection.
Electrical heaters: made in aluminium and installed after the cooling coil, for the
re-heating and/or heating of the treated air. The heating capacity is split on 3 steps
RE Ɣ Ɣ Ɣ max, so to reduce the energy absorption. They are controlled by the microprocessor
on board of the unit. The electrical protection is ensured by a magnetothermic
switch.
Gravity overpressure damper for ducted units, to prevent the air return when the
units are not operating, where the several units are installed in the same room.
SV Ɣ Ɣ Ɣ
Available for U, V, B versions; for D version, being a special execution, please
contact the Sales Dept.
Figure 2.12: Refrigerant scheme with n°1 circuit and n°2 compressors
Figure 2.14: Refrigerant scheme with n°2 circuits and n°4 compressors
2.9. Dimensions
The following table show the dimensions and weight of the ED Power Line units related to figure 2.15.
For installations inside the European Community, it must be taken into account that the unit can be
considered as a Direct System according to the EN 378-1 standard (par. 4.1.2, 4.4.1.1 and fig. 1 a). The kind
of refrigerant and the charge present in the cooling circuit are shown in the unit Identification Tag.
The correct unit identification by means of the serial number is essential for the execution of
any operation to carry out on the unit. The serial number must be always advised whenever
submitting a request of technical service support to the Manufacturer.
Any claim regarding the delivered material must be sent to the Manufacturer within 8 days from
the goods reception, by e-mail, fax or registered letter.
3.3. Handling
The handling of the unit must be carried out by expert personnel, equipped with appropriate equipment in
relation to the weight and dimensions of the unit. During the handling, the unit must be always kept upright, that
is to say, with the base-frame parallel to the floor.
It is advisable to remove the packaging only when the unit is finally installed, and possibly, only after the unit is
positioned on the place of its final installation.
Even if packed, it is forbidden to put the units one on another. If the unit is stocked after
reception, even if packed, it must be sheltered against bad weather.
The weight of some models might be unbalanced, therefore check the unit stability before
starting to handle it.
Lift the unit vertically, without jerks and at a suitable speed to the charge so as to not
jeopardize the structure integrity.
In case the fork lift is employed, the forks must be spaced out to the maximum allowed by the pallet size.
The lifting devices, such as cables and belts, used to handle the unit must be compliant
to the local regulations into force.
Before starting to handle the unit to place it, it is advisable to identify first the best way to arrive to its
final position, taking into consideration the dimensions and weight of the unit and its options, and the
available equipment.
The unit installation must be carried out in compiance with the local regulations into force.
• The floor where the unit is positioned must bear the total weight of the unit under normal operation;
• Enough room must be left around the unit to allow the routine and special maintenance (such as the
replacement of compressors and exchangers) as shown in Figure 3.2;
• Connections for cooling, electrical, hydraulic and condensate/humidifier drainage circuits must be
done.
The unit has been designed for internal installation and operation (like for example a technological data centre).
During the operation, the unit base-frame must be horizontal: the maximum acceptable
slope is 5° in length and width directions.
The unit does not need any special foundation as it can be simply laid down on the surface.
In case of units provided with downflow air discharge, it is necessary to take into account that the floating
floor height might greatly influence the unit performance.
In order to avoid high noise level and/or inacceptable reductions of air flow, the floating floor height should
never be inferior than the unit width.
Make sure that the value of the pressure drop of the air distribution system is not higher than the unit available
pressure in its standard configuration. If this is the case, then adjust by auto-transformer (AC fan) or by 0-10V
signal (EC fan).
Make sure that the number and the characteristics of the air suction and distribution grids are suitable for the
unit air flow capacity.
For the installation of any spare accessory, strictly follow the attached instructions to each of them.
* It is necessary to respect the distances shown in the picture also in case of lateral hydraulic connections or
in case option PR is installed.
Before proceeding with the installation, make sure that the unit characteristics described in
the documentation attached to this Manual are compatible with the characteristics of the
project.
Designed to work with air cooling system, copper pipes must be employed for the connections to their ventilated
condenser units which are installed outdoor.
The piping scheme is shown in Figure 3.4 (ED.X) and Figure 3.5 (ED.E).
Even if refrigerant is not classified as a toxic substance, pay the maximum attention during
the refrigerant charge operation and strictly follow the security requirements in compliance
with D.Lgs 81/08 ; in particular, the appropriate and necessary equipment must be worn to
avoid contact, inhalation and ingestion.
If any of the above mentioned cases occurs, it is advisable to consult the security
specifications for the operations of first aid and emergencies concerning the employed
refrigerant.
In case it is necessary to go to the doctor, it is advisable to bring these refrigerant
specifications with you.
If the discharge pipes go through rooms where people normally live, it is advisable to install rubber vibration
dampers and a sound attenuator as nearest as possible to the compressor.
The piping insulation, except for special requirements, can be applied on the following parts only:
• Discharge pipes (ED.X), where pipes are lapped by the unit air discharge (in the
suspended floor); where pipes can be accessible to unauthorised people so that any
damage or skin burn can be avoided.
During the piping installation, the refrigerant tubes must be sealed to prevent humidity and dirt from going inside.
The piping arrangement must consider easy access for operations like bracket insertion, tube welding and inspection.
It is here reminded that the total piping length is the result of its geometrical calculation plus the length of valves,
bents and fittings present on the line itself. If failing to have more accurate information, you can obtain the total
length by multiplying the geometrical length of the line by 1,5 or 2.
Lines must be realised with pickled and clean copper pipes specific for cooling circuits, and must have the
diameters indicated in Table 1 ( ED.X 1-circuit ), Table 2 (ED.X 2-circuits), Table 3 (ED.E 1-circuit) and
Table 4 (ED.E 2-circuits).
Equivalent length
Ɏ Discharge connection (mm)
71 1 1 10 10 12 10 12 10 12 10
81 1 1 12 10 12 10 12 10 12 10
101 1 1 12 10 12 10 12 10 16 10
131 1 1 16 12 16 12 16 12 16 12
161 1 1 16 12 16 12 16 12 18 12
211 1 1 16 12 16 12 18 12 18 16
231 1 1 16 12 16 12 18 12 18 16
261 1 2 16 12 16 12 18 12 18 16
271 1 1 22 16 18 12 18 12 22 16
281 1 1 22 16 18 12 18 16 22 16
331 1 1 22 16 22 16 22 16 22 16
371 1 1 22 16 22 16 22 16 22 16
421 1 1 22 16 22 16 22 16 28 18
461 1 1 22 16 22 16 22 16 28 18
501 1 1 22 16 22 16 22 16 28 18
551 1 1 22 16 22 16 22 16 28 18
591 1 1 22 16 22 16 28 18 28 18
771 1 1 28 22 28 18 28 22 35 22
921 1 2 28 22 28 22 28 22 28 22
991 1 2 28 22 28 22 28 22 28 22
Equivalent length
Number of compressors
Number of circuits
Number of circuits
10 metres 20 metres 40 metres
Ɏ Suction pipe
Ɏ Suction pipe
Ɏ Suction pipe
Ɏ Liquid pipe
Ɏ Liquid pipe
Ɏ Liquid pipe
ED.E
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
71 1 16 10 16 10 16 10 16 10
81 1 16 10 18 10 18 10 18 10
101 1 16 10 18 10 18 10 22 10
131 1 22 12 22 12 22 12 22 12
161 1 22 12 22 12 28 12 28 12
211 1 22 12 22 12 28 12 28 16
271 1 28 16 28 12 28 16 35 16
331 1 28 16 28 16 28 16 35 16
421 1 35 16 35 16 35 16 35 18
501 1 35 16 35 16 35 16 42 18
591 1 35 16 35 16 42 18 42 18
771 1 42 22 42 18 42 22 54 22
921 1 42 22 42 22 42 22 54 22
991 1 42 22 42 22 54 22 54 22
Equivalent length
Ɏ Suction connection
Number of circuits
Ɏ Suction pipe
Ɏ Suction pipe
Ɏ Liquid pipe
Ɏ Liquid pipe
Ɏ Liquid pipe
(mm)
ED.E
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
Dry air also enables the circuit to dry up. If the circuit pressure drops, this means that the circuit is not sealed off.
It is then necessary to let in a small quantity of refrigerant so that it is possible to locate the leak by means of
appropriate detectors. If a leak is detected, after the repair, a new test leak, the vacuum and the charge of the
system must be carried out again following the instructions as described in par. 3.11
It is also possible to use water from water city systems adequately treated.
In these cases, the water condenser is equipped with a pressostatic valve as optional (VP or VPC): when
calculating the circulation pump size, the pressure drop of this component must be also kept into account. On
demand, the condensers can be sized to be able to employ a water and ethylene glycol mixture in a closed
circuit cooled by a forced ventilation coil exchanger (dry-cooler) which dispels the heat into the atmosphere.
The use of glycoled water allows the cooling circuit to also work at low outdoor temperatures. The
percentage of ethylene glycol to be used is indicated in Table 5.
When employing this mixture, the condenser must be equipped with a temperature control device of the anti-
freeze mixture.
If the anti-freeze mixture contains a lower ethylene glycol percentage than above recommended, there could
be risks of freezing, while a higher percentage can reduce the unit performance. At the beginning of every
EMICON A.C. S.P.A. via A. Volta, 49 – 47014 Meldola (FC) – Italy
tel. (+39) 0543/495611 – fax. (+39) 0543/495612 – e-mail emicon@emiconac.it pag. 47
(rev. 2, 08/2013) ED - Power Line – Use and Maintenance Manual
winter, it is recommended to check the correct concentration of glycol in the system; please only use inhibited
ethylene glycol in order to avoid rusting of the hydraulic circuit.
Do not use anti-freeze liquids unsuited to copper, stainless steel and to all other materials present in the
system.
It is recommended to install a filter with grid not larger than 1mm on the condenser water inlet.
It is also advisable to install a ball check valve on the condenser inlet and outlet so that it is possible to shut
off the conditioning unit in case of special maintenance operations: the installation of a three-piece joint
between the valves and the conditioning unit will ease these operations.
The water system pressure must range between 1,5 and 3,5 bar.
The new air intake duct is connected to the nearest external intake through a coupling of Ø 100 mm mounted on
the side panel of the unit.
The fresh air intake optional is equipped with a pleated air filter easily removable for cleaning or replacement
purpose by removing the cap by means of screws as shown in figure 3.5.
Even if the humidifier is provided with a filter, it is advisable that the supply water does not have any
impurity bigger than 100 micron.
Do not use demineralised water (suggested hardness 15-40° F, with conductivity 300-1250
ȝS/cm). The supply water pressure must range between 0,8 and 7 bar.
On demand, it is available a device which can work with specific conductivity between 125 and 500 ȝS/cm.
For further details on chemical characteristics of the supply water following the specific conductivity,
please read the Humidifier Use and Maintenance Manual.
The supply water must not be treated with softeners because they can cause electrodes
corrosion and can generate foam, thus compromising the correct operation of the unit.
It is not advisable to use well water, process water coming from the cooling circuits or, in
general, that may contain polluted chemicals or bacteria that could be spread in the
environment together with the produced steam.
Once the installation is completed, wash the supply water piping making the water running for
few minutes directly in the drainage line (without entering into the humidifier); this will help to
eliminate any waste or installation remains which could cause a bad operation of the unit.
The power cable of the unit must be protected by means of an automatic switch having appropriate
size and characteristics and in compliance with the local regulations into force.
The system must be realised in such a way so as to be able to shut off the unit without interrupting all the other
services, like lightening, ventilation, alarms and security systems.
In case of IT electrical supplies, Emicon AC s.p.a. must give, prior assessment, the
authorisation to the electrical connection.
Only authorised and trained personnel can carry out any operation on the electrical wiring
in compliance with the existing local regulations.
Before working on the unit wiring circuit, it is necessary to check the wiring diagram
attached to this Manual.
Make sure that the power tension and the frequency are the same as stated on the unit
indentification tag and on the wiring diagram attached to this Manual.
It is necessary to use a power cable of appropriate size and of moderate length in order to avoid voltage drops.
Please refer to the data indicated in the wiring diagram attached to this Manual to calculate the
cross section of the power cable, the size and the intervention value of the automatic switch.
Make sure there is no humidity trace inside the electrical panel and on all electric and
electronic components. In case humidity is found, detect and eliminate the cause of the
infiltration.
Make sure the circuit and the electric components have not been damaged during the
transportation, handling and positioning. If any damage is detected, proceed with the
repair;
Make sure the electrical wires are properly tightened; if necessary, tighten adequately any
loose wire.
Inside the electrical board, connect the phases and the neutral to the terminals of the main switch and the
earth wire to the corresponding terminal. Use a power supply cable of adequate cross section and of
moderate length to avoid voltage drops.
The input position for the power supply cable is indicated in the dimensional drawing of the unit attached to this
Manual. The power cable input must be adequately protected in
compliance with the existing local regulations.
If the power cable comes from the top wiring box, perform a bend
on the cable as shown in the picture on the right.
Check the wiring diagram for the exact correspondence of the terminal numbers.
Inside the electrical board there is a terminal board where digital and analogical inputs are made available with
reference to the unit operation. Since the terminal configuration can vary according to the unit, please refer to the
configuration shown in the wiring diagram attached to this Manual.
Figure 3.10 shows, as an example, the available terminals for the free contacts described here below.
Once the unit has been connected to the power supply, it is necessary to check that the phases have been
connected in the correct sequence. On this purpose, check that all electrical motors rotate in the foreseen
direction.
In case of three-phase units, if the rotation direction of some components is not correct, this means that all
motors rotate in the wrong direction and, therefore, two out of three phases must be inverted in the terminals
of the main switch.
In order to avoid any connection mistakes, do not disconnect other conductors than those
concerned in the operation.
After inverting the phases, if some components still rotate in the wrong direction, it is necessary to check and
eventually to correct the sequence of the power supply conductors of each component, as described above.
3.11. Tightness test, vacuum and charge execution of the system (only for EDX
and EDE)
The units ED.H are supplied with the refrigerant and antifreeze oil charge, therefore they must
be submitted to the operations described here below only after having carried out an operation
on the cooling circuit.
For a correct and reliable operation of the system, once the connection lines between the indoor and the
outdoor units are carried out, it is extremely important to clear the circuit of any air, humidity, non-
condensable gas and, in general, of any polluting substance before executing the refrigerant charge.
The presence of solid particles, such as metal dust, welding debris and dirt of small dimensions that cannot
be detected by the mechanical filters, can cause serious damages to the surfaces in motion and involve a
reduction in efficiency and of compressor life.
Do not perform any holes in the cooling circuit, the complete removal of metal
particles produced would be then prevented.
If excessive humidity persists inside the cooling circuit, negative consequences can arise. Humidity can
freeze inside the thermostatic valve and can even clog it up, causing the unit stop because of the low pressure
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ED - Power Line – Use and Maintenance Manual (rev. 2, 08/2013)
alarm. A significant amount of humidity can saturate the filter drier in a very short time and it will be
necessary to replace it (with consequent operating interruption of the system).
Humidity interacts chemically with the refrigerants and especially with polyester lubricant oils (normally employed
with refrigerant type R407C, R134a, R404A, etc.). This interaction creates acid substances that, if present in fair
amount, can damage the compressor electric motor insulation causing motor burns and rusted copper pipes that can
generate solid impurity.
Reduce as least as possible the exposure of the circuit and its parts to the
atmosphere, especially if compressors are charged with polyester oil.
If non-condensable gases are not eliminated accurately from the circuit, they can gather inside the condenser
and the liquid receiver. If gases are in the condenser, they can cause a reduction of the useful thermal
exchange surface, meaning a condensing temperature increase and, consequently, a reduction of the energy
efficiency and of the system reliability. In worst cases, the unit can be stopped by the activation of the high
pressure switch.
Big amounts of non-condensable gases gathered in the liquid receiver can cause the malfunctioning of the
thermostatic valve, since it might be fed not only by the liquid refrigerant, as it should be, but also by a
mixture of refrigerant and non-condensable vapours. If this occurs, there will be a strong reduction of the
evaporating temperature up to the activation of the low pressure switch in worst cases, thus involving a
reduction of the unit cooling capacity and a reduction of the system efficiency and life.
a) Tightness test
c) Refrigerant charge
c) Locate the eventual leaks by means of a leak detector having a realiable calibration (5 gr/year or
better) with reference to the employed refrigerant. In particular, check the joints concerned by the
repair.
d) In case a leak is detected, discharge the cooling circuit, carry out the repair and repeat again the leak
test.
Do not use oxygen, hydrogen or any other types of reactive and inflammable gases to
pressurise the cooling circuit: only use dry nitrogen.
It is forbidden to charge the circuit and, in particular, the low pressure side, at a pressure
higher than 16 bar.
Do not use the compressor for carrying out the vacuum inside the cooling circuit.
Make sure that all valves are open in order to avoid that some circuit parts result cut off.
To obtain a sufficient vacuum, it is necessary to use a two-stage pump with adequate features.
Normally, vacuum is considered to be adequate if when starting the unit the humidity presence in the
refrigerant is below 100 ppm; as a matter of fact, under this value, during the operation, the drier filter can
keep this value below 20 ppm.
Once the cooling lines are completed and checked that no leaks are present, the vacuum must be carried out
as described here below:
a) Connect a vacuum pump of a suitable water flow capacity (a two-stage pump able to keep a pressure
of 0,02 mbar) to the circuit by using the charge connections present on discharge and liquid receiver
(if the latter one is not present, the charge connection is placed on the suction pipe). The positions of
charge / discharge are properly marked by means of adhesive labels, see following figure.
b) Let the vacuum pump work until the pressure shown on the appropriate vacuum meter does not go
below 0,04 mbar.
Vacuum must be checked by placing the vacuum meter on the circuit and not on the pump.
c) Isolate the pump from the circuit by means of the appropriate cut-off valves and wait for 30 min.
d) If pressure goes on increasing during the pump stop period or if it is impossible to reach the desired
pressure value, it means there is a leak in the circuit. It is necessary to detect and repair the leak, and
after that, repeat again the procedure starting from step b).
e) If pressure goes up until it reaches a climax value, it means the circuit contains a big amount of
humidity. In this case, it is necessary to let in nitrogen in the circuit (up to about 2 bar) and repeat
steps b), c) and e) for at least twice; then proceed with step f).
f) If pressure stabilises after a short increase, it means the circuit is leak proof and reasonably dried. Start
up again the pump after the shut-off valves are open and let it operate for 2-4 hours according to the
circuit size after pressure has returned below 10 mbar.
While the circuit is vacuum, do not let the compressor operate nor carry out any kind
of test.
If the appropriate equipment is not available or if the circuit was open for long time, it might be necessary to
repeat steps b) and c), by using the refrigerant instead of the nitrogen to break the vacuum.
Do not use a different refrigerant than the one indicated in the Identification Tag.
Avoid any refrigerant gas release in the environment during the charge operations.
If the refrigerant is a mixture of several components, such as R410A or R134a, make sure to
introduce it in the circuit in a liquid state to avoid the components separation. On this
purpose, bottles are provided with two distinct valves: one for vapour and one for liquid.
Once vacuum is completed, the circuit must be charged with the correct quantity of refrigerant and, if necessary,
of antifreeze oil.
a) Connect the refrigerant cylinder to a 1/4” SAE male (7/16” – 20 UNF) charge connection placed
on the liquid refrigerant line.
b) Let a small quantity of liquid go out in order to eliminate the air from the connection pipe.
c) Open the cylinder valve and let the refrigerant enter the cooling circuit for pressure difference;
replace the refrigerant bottle when it is empty.
d) If pressure reaches a climax value at room temperature, the refrigerant cannot flow naturally from
the cylinder. Therefore, it is necessary to connect the bottle to a charge connection placed on the
suction line.
f) Start up the compressor, open the bottle valve and complete the charge. Replace the bottle when
necessary.
g) Charge small quantities of refrigerant at a time, by checking each time the pressure and the
operating temperatures to avoid an overload of the system.
h) Complete the charge by comparing the quantity of refrigerant introduced with the value indicated in
the Identification Tag (only on EDH).
i) Check that the quantity of refrigerant introduced in the circuit is correct by checking the sight glass
and by measuring the liquid subcooling and the suction superheat.
The connection pipes must be as shortest as possible and must be provided with valves so as to reduce the
possibility of refrigerant leaks.
To facilitate the charge operation, the following tables show, as an indication, the necessary amount of
refrigerant to charge the different types of indoor units and the corresponding connecting pipes. For a correct
calculation of the refrigerant quantity, it must be also taken into account the volume of the outdoor unit cooling
circuit and of any other component installed (such as additional liquid receivers, oil separators, etc.).
Use only new refrigerant or recycled refrigerant whose composition is known and having suitable
characteristics to be used in cooling circuits.
Before charging the refrigerant from a cylinder, it is necessary to check the quality and the quantity of fluid it
contains.
The amount of refrigerant charged in the cooling circuit must be measured by weight or by volume. It is
good practice to charge the refrigerant in liquid state.
In case the cooling lines are very long or in case the oil separators are installed on the compressors discharge, a fair
quantity of antifreeze oil must be added.
Make sure the employed oil is compatible with the one charged in the compressor
(check the compressor identification tag).
In case oil separators are employed, add the lubricant quantity suggested by the Manufacturer.
An overload oil charge can lead to a system efficiency drop and to compressor breaking.
4. OPERATION
Before starting the unit, the personnel must be informed and trained through the Manual
about the unit construction, management, operation and maintenance, about the security
measures and the regulations to comply to, about the eventual individual protection
garments to wear.
4.1. Documentation
The Owner of the unit must require the authorisations and prepare the documentation for the unit installation
and operation as foreseen by the applicable local regulations. In particular, he must acquire and put the
necessary documentation available to confirm that the installation has been carried out following the project
specifications, according to what required by the local regulations.
The necessary information to keep a reliable and safe system must be visible, close to the unit and in a protected
position, in compliance to the existing local regulations.
The first start-up of the unit must be carried out by an expert technician authorised by the
Manufacturer.
a) Check if any damage has occurred during the transportation, the stock or the handling of the unit;
b) Compare the circuit with the hydraulic and wiring diagrams;
c) Check the foreseen security devices and its corresponding documentation;
d) Check the certificates, the identification tags and, in general, all foreseen documentation;
e) Check that the accessible pipes cannot cause any accidental damage to people;
f) Check that the power supply is adequate to the system’s requirements in terms of characteristics and
capacity;
g) Check the placement and the condition of valves and shut-off valves;
h) Check that brackets and fixing devices are adequate;
i) Check the quality of weldings, brazings and joints;
j) Check that the protections against mechanical damages, heat and devices in motion are adequate;
k) Check the unit is accessible for inspection, maintenance and repair of main components;
l) Check if the sound insulation is present and in good condition;
The technician who has carried out these controls must report them in compliance with the existing local
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ED - Power Line – Use and Maintenance Manual (rev. 2, 08/2013)
regualtions.
Before starting the unit, on its first start-up or after a long unit stop, check the wirings and
the connections to the protection conductors. In case defects are detected, do not start the
unit.
Before starting the unit, check that the following conditions are respected:
• The ground wiring has been carried out correctly and has been connected to an efficient system;
• The electrical power supply is protected by an automatic switch of adequate size and features;
• The parameters related to temperature and antifreeze alarm are set correctly on the microprocessor.
For EDH units, the following conditions must be also checked:
• The hydraulic system has been duly cleared of any dry air by means of the appropriate air discharge
valves;
• The condensing water flow and temperature are correct;
During the unit operation, it is advisable to keep the pressure in the hydraulic circuit between
1,5 and 3,5 bar.
• The hydraulic connections have been carried out correctly and do not present any leak;
• If necessary, the hydraulic circuit must contain the antifreeze mixture in the required concentration;
Once the operations are completed as described above and in paragraphs 3.10 and 3.11, the unit is ready for the
start-up. Make sure the valves are open according to the following instructions:
c) Turn the stylus clockwise for one turn, if the manometer plug 1 is employed
4.2.2. Startup
Before starting the unit, for the first time or after a long unit stop, check if the parameters set on the
microprocessor correspond to the foreseen operating conditions.
Wait at least 3 hours before starting the unit to allow the oil sump heater to pre-heat the oil.
Once the unit is started, after a short period needed to the microprocessor for an auto-test, push the ON/OFF
button on the microprocessor keyboard, switching it to ON. At this point, all system components will start
working automatically according to the selected and detected thermal and humidity parameters.
In case of 3-phase motors, check the rotation direction of fans and compressors; if
rotation is reversed, two out of the three phases must be inverted in the terminals of the
main switch (see par. 3.10.4)
Once the unit has reached steady operation conditions, the technician performing the first start up must
check the operational parameters and report them in the appropriate First Startup Form, attached to the
Manual.
Send the Manufacturer a copy of the First Startup Form, duly filled in in all its parts in order to
make the unit warranty valid.
During the first startup operations, the technician must check that the safety and control
devices are working correctly.
If the unit does not work for more than 24 hours, turn the main switch to OFF position to cut off the power
supply.
If any technical faults are found during the unit operation, they must be set up as soon as
possible, so to avoid they show again on the next startup.
4.3. Setup
The setup must be performed when the unit is operating in conditions as close as possible to the nominal
ones.
Make sure:
The thermostatic valve heating setting is already adjusted in the factory at 5°C. If different values are detected,
then check the correct value on the microprocessor. Then, check the suction gas heating as described here below
and, if necessary, adjust the thermostatic valve setting. When the unit is working at the nominal conditions,
connect a manometer on the low pressure side. Check the temperature on the compressor intake (Fig.4.4) by
means of a contact thermometer (Fig. 4.3).
If superheating is over 10°C, the thermostatic valve must be opened, while if it is below 5 °C, the valve must be shut
off (Fig. 4.5 cap removal and Fig. 4.6 opening adjustment).
Valve adjusting operations must be always carried out with caution, turning the adjusting screw only half
turn each time; wait for few minutes before every new adjustment in order to allow the unit to reach steady
conditions.
The electronic thermostatic valve adjustment is a very delicate operation, therefore it must
be carried out by a skilled technician.
Only skilled technicians authorised by the Manufacturer can change the parameters set on the
microprocessor. As a matter of fact, if wrong parameters are set up, the unit could work in
different operation conditions than foreseen, thus involving possible damages to the unit and
the circuit.
To set and modify the operating parameters, check the humidifier manual (here attached).
NB: After 3 resets, the low pressure alarm makes the unit stop working.
5. MAINTENANCE
The Owner must make sure that the unit is submitted to an adequate maintenance as described in the Manual
and in compliance with the existing local regulations.
The unit maintenance must be carried out only by qualified and trained personnel, equipped
with individual protection devices as established by the existing local regulations.
In general, any person involved in the refrigerant handling must be equipped at least with protection
gauntlets and glasses.
When performing the unit maintenance, make sure about the following:
The maintenance operations not involving specific refrigeration skills can be carried out by personnel having
adequate competence, charged by the Owner.
During the maintenance operations, only the authorised and concerned personnel can stand close to the unit.
During the maintenance operations, all labels and warnings on the system and on its components must be
checked. All deteriorated and unreadable texts must be replaced.
Do not make modifications to the unit or replace its components without the prior Manufacturer’s
authorisation.
Before performing any operation on the unit, switch off the electrical board by turning the main
switch to OFF position and put a padlock to the main switch as described at par.2.3.14
Inside the unit there might be high voltage areas: all operations demanding the access to these
areas can be carried out only by a qualified and trained personnel in compliance with the
existing local regulations.
The surface of components on the compressor discharge line and on the liquid line can
reach high temperatures and they can cause burns in case of contact.
On the unit there are some sharp or cutting parts which can hurt and cut if accidentally hit.
In case of any doubt on the trouble detected or on the actions to be taken to solve it, please
contact the Manufacturer.
The maintenance operations during the unit life operation and, in particular, the periodical leak detections,
the controls of the safety devices, must be carried out in compliance with the existing local regulations.
If any device for the leak detection is installed on the circuit, it must be controlled at least
once per year to make sure it is working correctly.
The result of the tests and the measures taken must be written on the Register.
The personnel performing the leak test are not allowed to use naked flame or any other potential source of
fire ignition.
Any eventual refrigerant leak must be detected and repaired as soon as possible by a certified personnel in
conformity with the existing local regulations.
1
( ) For the units installed on the territory of the European Community, the leak test must be carried out
following the instructions described in the Commission Regulation (EC) 1516/2007.
All operations having a daily and monthly frequency can be carried out directly by the Owner of
the circuit. All the other operations can be carried out only by a trained and qualified personnel.
Do not touch the unit if barefooted or with humid or wet parts of the body.
Do not perform any cleaning operation before disconnecting the power line by rotating the main
switch in OFF position and put the padlock as described at par.2.3.14.
Only trained and qualified technicians in compliance with the existing local regulations can
carry out any operations on the cooling circuit.
When working on the unit, it is necessary to be equipped with the required individual protection
devices. In particular, it is necessary to wear at least the protection glasses, the gauntlets, the
helmet and the safety shoes.
FREQUENCY
OPERATION TO BE PERFORMED Every Every Every 2 Every 6 Every Every 5 When
day month months months year years necessar
ELECTRIC CIRCUIT AND CONTROL DEVICES
Check that the unit is working regularly and that there is no
X
alarm signals
• The control of the cleaning condition of the air filters and of the humidifier cylinder depends on the kind of
installation.
If a fault compromising the reliability of the unit operation is detected, it must be eliminated
before starting the unit.
During its operation life, the unit must be submitted to inspections and controls according to the existing
local laws and regulations. In particular, in absence of more severe requirements, follow the instructions
described in the Table 5.2 (see EN 378-4, annexe D), with reference to the described situations.
A X X X
B X X X
C X X
D X X
Inspection following an operation which might have possible effects on the mechanical resistance, or
A.
following a change of use, or following a unit stop of more than two years; all components which are
no more appropriate must be replaced. Do not perform a test at a higher pressure than that one of the
project.
Inspection following a repair or a substantial change to the system or to its components. It is possible to
B. test only the components involved in the operation, but if a refrigerant leak is detected, a leak test must
be carried out on the entire system.
C. Inspection following the unit installation in a different position than the original one. If possible effects
on the mechanical resistance are likely, please refer to point A.
D. Leak test following a founded suspicion of refrigerant leak. The system must be inspected to detect the
leak through either direct measures (use of leak detectors) or indirect measures (deduction of the leak
presence following the analysis of the operating parameters), concentrating on the most subject parts
(i.e. the joints).
1) Following the colour of the sensible material present in the sight glass, it is possible to deduct if the
humidity in the refrigerant is within acceptable limits: usually the light glass is bright green if the
humidity amount is sufficiently low; while it migrates towards yellow as the refrigerant becomes
more humid (in any case, please refer to the indications on the sight glass).
If the unit was stopped for long time, check the colour of the humidity probe at least after
one hour of operation to allow the dehydrating filter to eliminate part of the humidity
present in the refrigerant.
2) By observing the sight glass, it is also possible to understand if the refrigerant charge in the circuit is
adequate: usually, the refrigerant charge is considered sufficient if after 10 minutes of operation at
the nominal conditions there are no vapour bubbles through the sight glass.
• The evaporating pressure by means of a manometer connected to one of the appropriate connections
placed on the suction line;
• The suction temperature by means of a contact thermometer placed on the low pressure side at about
20 cm of distance from the evaporator.
If necessary, to measure the temperature, partially remove the insulation material covering
the suction pipe. The detector must be preferably placed on a horizontal tract, at 10 o’clock
poisition compared to the pipe axis. The contact between the probe and the surface can be
improved by using the appropriate conductive paste.
The refrigerant overheating is the difference between the suction temperature, estimated by means of a
contact thermometer, and the saturation temperature (dew value in case of zeotropic blends, that is to say
characterised by a temperature glide) corresponding to the evaporating pressure shown on the manometer.
All units are direct expansion with finned coil. The superheating values are set on the
microprocessor at the factory (5 ÷ 7 °C)
If the superheating value is below 5 K or over 7 K, it is necessary to change the parameters of the
thermostatic valve (see the Microprocessor Manual here attached) to let it stabilise around 5 ÷ 7 K.
• The condensing pressure by means of a manometer connected to one of the appropriate connections
placed on the liquid line;
The contact between the probe and the surface can be improved by using the appropriate
conductive paste.
The refrigerant subcooling is the difference between the saturation temperature (the bubble value in case of
zeotropic blends, that it to say characterised by a temperature glide), corresponding to the condensing
pressure measured by a manometer, and the refrigerant temperature, measured by a contact thermometer.
If the subcooling value is below 3 K or over 10 K, it could be necessary to change the refrigerant quantity
charged in the circuit to let it stabilise around 5 ÷ 7 K.
Fuses can be replaced only after disconnecting the unit from the power supply, rotating the
main switch on OFF position and put a padlock on the main switch as explained at
par.2.3.14.
It is forbidden to by-pass the fuses used on the unit or to replace them with other fuses having
a bigger size.
Fuses can reach very high temperatures and they can cause burns if not handled with the due
precautions.
In case of adjustable devices (thermal relays or motor overload protections), make sure the
absorption value set is not higher than the value indicated in the identification tag of the
component to be protected.
Check also that the electrical cables are fixed correctly and firmly in the appropriate terminals.
When necessary, remove any eventual dust and debris which might cause a noisy and unreliable functioning
of the device.
Table 5.3 describes the most commun faults which might occur on the unit and for each of them the most possible
causes and solutions are stated.
In case of an alarm signal, before proceeding with any repair, it is advisable to check the following:
• The operational conditions must correspond to the foreseen ones and, in any way, they must be
compatible with the unit operational limits;
• All electric cables of the concerned components must be fixed in the corresponding terminals (see the
Wiring Diagram here attached);
• The set values for the concerned parameters must be coherent with the operational conditions (refer to
the Microprocessor Manual here attached).
starting of the unit Enable the external impulse from the user terminal
(display) when the unit starts
See point 15
g. The control system does not work Consult the Microprocessor Manual here attached
h. Thermal load higher than estimated Check the room thermal load
signal) c. The control system does not work Consult the Microprocessor Manual here attached
d. Thermal load higher than estimated Check the thermal loss value
4. Room humidity too b. Latent load higher than estimated Check the room latent load
high (high room
c. The compressor does not work when in
humidity alarm) See point 10
dehumidification phase
a. Check if the humidifier is present If the humidifier is absent, proceed with its installation
5. Room humidity too
b. The humidity set-point is set at a too Increase the humidity set-point value
low (low room humidity
low value
alarm)
c. The humidifier does not work Consult the Humidifier Manual here attached
7. The 3-way valve does a. The c ontrol system does not work Consult the Microprocessor Manual here attached
not work (present in Check the electrical connections and eventually replace
b. The valve servomotor does not work
case of options BC or the servomotor, if defective
BG) c. The valve is blocked mechanically Try to unblock manually the valve or replace it
b. One or more condensing fans are out of Check the internal heat protection of the out of order
order (ED.X and ED.E) fans: replace the defective fans
e. The condensation water flow capacity Make sure all valves are positioned correctly
f. Water to the plate condenser too hot Check the capacity of the cooling system of the
(ED.H) condensation water
a. The automatic switch is activated Reset the automatic switch, check the short circuit pause
c. The contactor does not work Check the contacts and the contactor coil
a. Thermal load higher than estimated Check the room thermal load value
12. Compressor suction Make sure the overheating of the thermostatic valve is
b. Air to the condenser too hot Check the presence of any condensation air re-cycle
c. Insufficient condensation air flow Make sure there is no obstruction to the air flow in the
capacity finned exchanger coil
14.Compressor high f. Circuit charged with too much High refrigerant subcooling: remove some refrigerant
refrigerant: condenser partially flooded from the circuit
pressure output
The flow sight glass presents gas bubbles. The
g. Non condensable air or gas in the compressor discharge temperature is high: the cooling
circuit circuit must be discharged and charged again after the
vacuum execution
i. Insufficient condensation water flow Check the circuit pressure drop and compare it with the
capacity (EDH) pump available pressure
j. Encrusted plate condenser (EDH) Clean the exchanger with specific products
a. The control system of the condensation Check the setting and functioning of the condensation
15. Compressor low pressure is not working properly control system
pressure output
b. Suction pressure too low See point 13
a. The set-point temperature is too low Increase the set point temperature
16. The electric heater
Make sure there is no short circuit.
does not work (if b. Magnetothermic switch disconnected
present) Reset the disconnected switch.
d. The contactor does not work Check the contacts and the contactor coil
a. Hot water flow capacity is insufficient Check the duct and make sure there is no leak or
c. The set point temperature is too low Increase the set point temperature
a. The probe corresponding to the alarm Check if the defective probe is connected and working.
18. Probe alarm
code is defective or disconnected If necessary, replace the probe.
a. Current black out Check the main switch and the power cable
c. Transformer protection activated Check eventual short circuits on the auxiliary circuit
f. The fan thermal protection blocks its Check if the rotor is blocked, or if the power supply is
operation not sufficient or if there is a phase loss
If brazings and weldings must be performed in presence of the refrigerant, besides the individual protection
devices necessary for the fluid handling, the concerned personnel must also wear a respirator with a specific
protection filter for possible decomposition compounds.
The cooling circuit contains high pressure refrigerant. Before performing any operation on
the cooling circuit, discharge the pressure completely and with precaution.
Do not modify the unit or replace its components without the explicit Manufacturer
authorisation.
The operations carried out by a personnel having different qualifications (like welders, electricians,
programmers, etc) must be carried out under the supervision of a personnel having the necessary competence
on air conditioning.
Welding and brazing operations must be performed only by adequately trained personnel, in conformity with
the qualified procedures, only after the concerned section of circuit has been discharged of refrigerant and
flushed with nitrogen.
During the welding and brazing operations, remove all those parts which might be damaged by
heat or protect them by wrapping the components with wet cloths.
In absence of more restrictive requirements, the repair of the cooling circuit components must be carried out
according to the following phases, when applicable:
a) Analysis and assessment of the risk for the operation,
g) Repair execution,
h) Check and test of the repaired parts (pressure test, tightness test, operational test),
b) Make sure that in the working area there are no flammable materials or fire ignition sources;
c) Make sure that suitable fire and protection devices are available;
d) Before starting to work on the cooling circuit and before performing any welding or brazing, make
sure the working area is properly ventilated;
e) Make sure all the personnel in charge of the operation is adequately trained.
When an operation involving the cooling circuit discharge is carried out, it is necessary to collect the refrigerant
gas in an appropriate recuperator for the environment safety.
During the operations requiring the refrigerant handling, make sure the ventilation is adequate and in the
proximity there is no naked flame or other fire ignition sources.
The equipment for the refrigerant recovery must be compliant to the existing local regulations and must be in
good maintenance condition; it is advisable they can operate up to a pressure of 0,3 bar.
Once the repair on the cooling circuit is achieved, the following procedures must be carried out:
The operations involving the refrigerant use must be carried out so as to reduce as much as possible any
release in the atmosphere.
Charge the refrigerant in the cooling circuit only after that the cooling circuit has succeeded a tightness test.
Do not connect the refrigerant cylinder to a higher pressure system, when a reflux situation
is likely.
The refrigerant cylinders must be disconnected from the system as soon as the fluid transfert operation is
terminated.
The refrigerant cylinders must not be beaten, hit, let fall or exposed to heat sources during the operation.
They must be visual inspected to check their condition.
Do not charge in the cylinders a bigger quantity of refrigerant than the maximum foreseen
which must be clearly stated on the cylinder.
Do not introduce refrigerant in cylinders intended for a different substance; the compound
present in the cylinders must be clearly indicated on them.
To avoid to mix different refrigerant qualities (new, re-cycled, re-used), the refrigerant quality must be
clearly indicated on the cylinders.
The refrigerant cylinders must be conserved in an appropriate area, far from any fire source, protected from
heat sources or from direct sun exposure.
The cylinders must be handled with precaution to avoid mechanical damages; if necessary, they must be
secured to avoid they can fall.
The cylinders valve must be closed and protected. Gaskets must be replaced when necessary.
a) Check all safety, control and measurement devices and make sure they work properly;
After each repair operation, check and record the functioning of eventual security systems, such as for
example the refrigerant detector and the systems of mechanical ventilation.
All lost or unreadable labels on the components of the cooling circuit must be replaced.
After the repair is finished, an operational test must be carried out; if a refrigerant leak is detected, the entire
system must be submitted to a tightness test.
The unit tightness must be checked again within one month from the repair to check if the operation was
effective.
6. DISMANTLING
When the unit has to be dismantled, it is necessary to separate all its components and to ship them to a separate
waste collection area. This activity must be carried out by a specialised company in compliance with the existing
local regulations.
The operations of refrigerant recovery, re-usage, re-cycle, regeneration and diposal must be
carried out only by a trained, qualified and equipped personnel, in compliance with the
existing local regulations.
The refrigerant pressure present in the cooling circuit can be elevated, therefore discharge
it with caution.
The refrigerant fluid released in a sudden way can cause burns in case of contact, due to the
low temperature.
The refrigerant filters used can contain residual quantities of fluid which must be eliminated
before their disposal.
If the unit has worked with an antifreeze mixture, it is necessary to collect all the fluid
contained in the unit and deliver it to a specialised centre for waste disposal.
Do not release in the atmosphere the antifreeze mixture present in the unit.