CTXi operating and installation manual

Eaton Williams

OPERATING & MAINTENANCE MANUAL

FOR

CTXi 7 & 15 DF

AIR HANDLING UNIT

Eaton-Williams

Station Road

Edenbridge

Kent

TN8 6EG

England

Tel: +44 (0)1732 866 055

Fax: +44 (0)1732 866 653 www.eaton-williams.com

OPERATING & MAINTENANCE MANUAL FOR CTX7i DF AIR HANDLING UINTS

0410527-01 GB CTXi-7 & 15 Page 1 of 85

Eaton Williams

Copyright Notice and Disclaimer.

The confidential information contained in this document is provided solely for use by Eaton- Williams Group employees and system owners, and is not to be released to, or reproduced for, anyone else. Neither is it to be used for reproduction of this air handling unit or any of its components.

All specifications are nominal and subject to change without prior notice as design improvements occur.

Eaton-Williams Group shall not be liable for any damages resulting from mis-application or misuse of its products.

E & OE.

Eaton-Williams

Station Road

Edenbridge

Kent

TN8 6EG

England

Tel.: +44 (0)1732 866 055

Fax.: +44 (0)1732 866 653 www.eaton-williams.com


0410527-01 GB CTXi-7 & 15 Page 2 of 85

Eaton Williams

CONTENTS

Section 1

Section 2

Section 3

Section 4

Section 5

Section 6

Section 7

Section 8

Section 9

Section 10

Section 11

Safety Instructions

Introduction & Technical Data

Installation

Commissioning & Operation

Controller

Maintenance & Repair Procedure

Service Parts

Disposal Procedures

Reference Drawings

Unit Modification History

Maintenance Log

PAGE No

60

62

72

74

16

19

22

4

8

34

56


0410527-01 GB CTXi-7 & 15 Page 3 of 85

Eaton Williams

SECTION 1

SAFETY INSTRUCTIONS

1.1 GENERAL

1.2 INSTALLATION & HANDLING

1.3 APPLICATIONS

1.4 WARRANTY

1.5 ELECTRICAL CONNECTIONS

1.6 MAINTENANCE

1.7 SERVICE PARTS

1.8 CODES OF PRACTICE

1.9 WARNING AND SAFETY NOTICES

1.10 LIGHTING

1.11 PORTABLE TOOLS AND LAMPS

1.12 ESCAPE ROUTES

1.13 KEYS

1.14 DRIVE GUARDS AND HOUSINGS

1.15 WASTE DISPOSAL


0410527-01 GB CTXi-7 & 15 Page 4 of 85

Eaton Williams

* * * I M P O R T A N T N O T I C E * * *

S A F E T Y F I R S T

All personnel involved in the installation and maintenance of the air handling and ancillary equipment,

whether directly or indirectly, MUST read this notice and this complete document before the commencement of ANY work.

The following information MUST be read, fully understood and adhered to at ALL times:

1. The SAFETY of YOU and other persons MUST be your main concern.

2. NEVER carry out a task until you fully understand what you are being asked to do and how to do it safely.

3. NEVER carry out a task you feel could be dangerous to YOU or other persons.

4. DO NOT carry out any task that you are not qualified to undertake.

5. ALWAYS comply with ALL safety rules as laid down by the relevant authorities.

6. If you have any questions or concern over the safety of YOU or other persons, you MUST consult your supervisor within the Company before the commencement of any task.

7. NEVER start work on a unit or remove any casings, guards, doors or covers without first

SWITCHING-OFF POWER and isolating the unit and controllers from the electrical supply.

8. MAKE SURE all rotating parts are at rest before commencement of any work on the unit.

* * * A L W A Y S T H I N K S A F E T Y * * *


0410527-01 GB CTXi-7 & 15 Page 5 of 85

Eaton Williams

1.1 GENERAL.

Air conditioning equipment presents potential mechanical, electrical, noise or vibration hazards.

Observe all safety, installation, operation and maintenance instructions.

Installation, servicing and operation of the equipment only by fully trained and technically competent personnel.

Eaton-Williams air conditioning equipment is designed to minimise mechanical & electrical hazards by fully restricting access through unit casings, doors and covers whilst the equipment is operational.

Some installations may require additional protective features to prevent accidential contact with components.

Eaton Williams can provide advice and make recommendations for additional protection to suit the application.

All installation work must be completed in accordance with the safety, installation, operation and maintenance instructions, and the unit correctly earthed before it is operated. Prior to any maintenance work being carried out, ensure:

ü

Switch off equipment and “Lock-off”.

ü

Isolate equipment & controls from the electrical supply.

ü

All rotating parts have stopped.

Air Conditioning equipment may, in certain operating conditions, generate unacceptable noise and vibration levels. Eaton-Williamscan advise on relevant sound level data, appropriate action to be taken and supply suitable attenuators to reduce sound and vibration levels.

If in any doubt as to the correct interpretation of performing any of the safety, installation, operation and maintenance instructions, it is essential that Eaton-

Williams, their agent or distributor is consulted for advice and clearification.

1.2 INSTALLATION & HANDLING.

The installation and operation of the unit should be conducted in accordance with local regulations and accepted codes of good practice.

When moving and lifting the unit, caution must be observed at all times to ensure the safety of all personnel.

Only appropriate and approved lifting equipment must be used.


0410527-01 GB CTXi-7 & 15 Page 6 of 85

1.3 APPLICATIONS.

The unit is only to be used in the application for which it was designed.

The unit is not to be used in a hazardous environment unless it has been specially designed and approved for this application.

1.4 WARRANTY.

Failure to comply with the manufacturers installation instructions could affect the reliability and performance of the unit and invalidate the warranty.

Warranty is also subject to the implementation of a planned service/maintenance agreement as stipulated in the warranty booklet supplied with the unit and/or the sales contract.

1.5 ELECTRICAL CONNECTION.

The unit must be connected to an external isolator if one is not supplied fitted to the unit.

Electrical connections should be carried out in accordance with local regulations BS7671. Never make any connections in the unit circuits unless the electricity supply has been switched off at the isolator.

1.6 MAINTENANCE.

Before commencing any work on the unit, ensure the electricity supply has been switched off and can not be accidentially switched on, (e.g “ LOCK OFF ” or.

remove fuse).

CAUTION! As some units are dormant in stand-by mode and can restart without warning, do not assume that a non operational unit has been switched off.

CAUTION! Cable coloured orange may remain live even when the unit is isolated.

CAUTION! Before removing any access doors, panels or guards, ensure that all rotating parts have come to a standstill.

CAUTION! Pipework and some components within the unit remain very hot or cold for a period of time after stopping. DO NOT TOUCH.

Ensure all guards, covers and access doors are correctly fitted and secured before restoring power supply to the unit.

Eaton Williams

1.7 SERVICE PARTS.

Service parts must be to the same specification as those being replaced and obtained from Eaton-Williams.

Obsolete parts are replaced by suitable alternatives.

Service parts must only be used as replacement parts, and not for any other purpose.

1.8 CODES OF PRACTICE.

It is important that equipment and products which have been installed and commissioned by Eaton-Williams, is maintained by or under supervision of technical competent personnel and that all work is carried out in accordance with good engineering practice and strict adherence to:

I. IEE regulations

II. Codes of Practice

III. Supply authorities

IV. Statutory requirements

V. Manufacturers instructions and recommendations

VI. All other relevant information, regulation and legislation.

1.9 WARNING & SAFETY NOTICES.

Warning and safety notices must at all times be maintained , properly displayed and worded to give clear instructions. Proper fire precautions must be observed within the plant rooms and building.

1.10 LIGHTING.

In all plant rooms and service areas, lighting must be maintained at a high level to enable proper inspection to be carried out and prevent accidents due to poor lighting.

1.11 PORTABLE TOOLS and LAMPS.

Where power operated hand held tools or lamps are used, these items together with their power supply, must be in proper working order and conform to current regulations applying to their use.

1.12 ESCAPE ROUTES.

Periodic inspection of all escape routes and exits should be made to confirm that doors open freely and routes are clear of obstructions. Should oil be spilt on bases or floors, the area must be thoroughly cleaned and sanded.

1.13 KEYS

Access to all plant rooms and equipment contained therein, which requires a key to open for access, must be controlled and restricted to authorised personnel only.

1.14 DRIVE GUARDS.

It is important that after maintenance has been carried out on any piece of equipment on which drive guards or housings have been removed, that these are replaced immediately the work has been completed.

At all times when drive guards or housings are removed, the electrical supply to the Unit must be isolated , locked off and the fuses removed and retained by the person carrying out the work.

Starting up of plant, replacing of guards and housings, any further disconnections and restoring of plant into full service is by authorised personnel only.

1.15 WASTE DISPOSAL.

All refrigerants, oils and other waste materials must be disposed off in a professional and responsible manner in strict adherence to environmental regulations. For details, consult your local environmental agencies.

CAUTION - Remotely Controlled Plant

DO NOT put hands or any other objects on any item of stationary rotating machinery as the equipment may start automatically and cause injury or damage


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Eaton Williams

SECTION 2

INTRODUCTION & TECHNICAL DATA

2.0

GENERAL

2.2

DESCRIPTION

2.3

FREE COOLING MODE

2.4

REFRIGERATION COOLING MODE

2.5

EMERGENCY COOLING

2.6

TECHNICAL DATA

2.7

UNIT COMPONENT DESCRIPTION

2.8

ELECTRICAL CHASSIS

OPERATION & MAINTENANCE MANUAL FOR CTXi 7 & 15 DF

0410527-01 GB CTXi-7 & 15 Page 8 of 85

2.0 GENERAL

Eaton Williams

CTXi-7 DF MASTER CTXi-7 DF SLAVE

CTXi-15 DF MASTER CTXi-15 DF SLAVE


0410527-01 GB CTXi-7 & 15 Page 9 of 85

Eaton Williams

2.1 GENERAL

This manual describes the installation, operation and maintenance of the CTXi air handling units. The units are designed for installation within standard, portable telecommunication switching rooms.

The CTXi units can be delivered in two versions:

• Master units, fitted with controller display.

• Slave units, no display.

Up to 15 Slave units can be connected to each Master unit, (total 16 units).

The unit is installed with the back mounted against a purpose made louvre with fresh air intake and condenser air discharge sections.

The unit is secured to the cabin wall with a soft gasket sealing between the back of the unit and the cabin wall around the louvre, eliminating air by-pass.

2.2 DESCRIPTION

CTXi units are designed as highly reliable air handling systems for telecommunications equipment rooms and other similar applications. They remove heat gains using available outside air and a close coupled, direct expansion refrigeration system.

The supply fan draw air from either inside the cabin,

(refrigeration cooling), or fresh air from outside the cabin, (free cooling). It passes through the filter and evaporator coil and is discharged from the bottom of the unit and into the room at floor level.

The unit is self-contained, comprising a supply air fan, damper, condenser fan, compressor, condenser coil, evaporator coil, filters, microprocessor controller and all refrigeration circuit components.

The control system is via a Mod Bus System or other proprietary protocol.

A drip tray is provided to collect any condensate forming on the evaporator coil. The drainpipes are trapped internally in the unit and are led to the bottom where it is discharged.

NOTE! DO NOT FIT EXTERNAL CONDENSATE

TRAPS.

Component layout is shown in the General

Arrangement Drawing.

A movable damper is hinged above the evaporator so the fan can draw air from either the room or the outside. The damper position is controlled by the microprocessor.

The microprocessor controller, contactors, MPCBs, alarm relays, incoming terminals for power supply and


0410527-01 GB CTXi-7 & 15 outgoing terminals are installed on the inside of the access door.

The cabinet is constructed from double skinned galvanised sheets enclosing thermal insulation that also acts as a sound insulator.

Access is from the front via double skinned hinged door, secured with triangular Eldon locks.

2.3 FREE COOLING MODE.

During free cooling mode, the outside air enters the unit through the louvre. From here, the air passes through a pre-filter, main filter, evaporator before being discharged from the bottom of the unit into the room at floor level of the cabin, from where it is distributed into the room space to be cooled. The air returns through the front of the unit and is discharged through the condenser coil into the outside.

Electric heaters are fitted in order to increase the air temperature during free cooling mode at low ambient temperatures.

2.4 REFRIGERATION COOLING MODE.

In refrigeration cooling mode, the damper is closed and re-circulates the cabin air through the main air filter and the evaporator where heat is removed from the air, before it is distributed into the room space to be cooled. Air from the outside is drawn through the louvre and condenser, where the heat gain is removed and discharged back into the outside.

2.5 EMERGENCY COOLING.

In the event of a mains, (230Vac) power failure, the

Unit will continue to operate in an emergency free cooling supply mode, using 48Vdc battery supply.

Page 10 of 85

Eaton Williams

2.6 TECHNICAL DATA:

Unit Designation

Nom Cooling Capacity

1)

Dimensions mm

1)

L x H

incl. Support plate H = 2224 mm x W

Weight

Supply Air Fans:

Double inlet, 48 Vdc

Motor 400 Watts

Supply: 48 Vdc 8 Amp

Main filter: Disposable panel

Pre-filter: . Washable synthetic fibre

Electric Heaters: 3kW 240/1/50

Refrigerant: R407c Kg

Compressor:

Hermetic scroll

Condenser Fan:

Axial fan, motor 200 Watts

Supply: 230/1/50, 0.94 Amps.

Evaporator Coil

Condenser Coil

Controller

CTXi-7

7.0kW

650 x 2100 x 620

270kg

1 pce

1 pce

1 pce

1 pce

2.5

7kW @ 24°C ambient

Motor 3.3kW 13.6 Amps

240/1/50

1 pce

1 pce

1 pce

Carel pCO

CTXi-15

15kW

1150 x 2100 x 620

480

2 pce

2 pce

1 pce

2 pce

4.7

15kW @ 24ºC ambient

Motor 4.3kW 10Amps

380/3/50

2 pce

1

1

Carel pCO

Warm room air discharge

Condenser air discharge

Warm return air

Warm return air

Cool ambient air

Cool ambient air

Cool supply air

Cool supply air

Free cooling mode Refrigeration cooling mode


0410527-01 GB CTXi-7 & 15 Page 11 of 85

Eaton Williams

2.7 UNIT DESCRIPTION.

1

3

2

1

2

4

4

CTXi-7 CTXi-15

5

5

6

7

7

1 Isolator switch

2 Controller display, (Master units only)

3 Return air grille

4 Supply air grille

5 Condenser air discharge

6 Inlet of outside air

7 Ambient air sensor


0410527-01 GB CTXi-7 & 15 Page 12 of 85

6

3

2

1

Eaton Williams

3

CTXi-7

4

5

2

7

6

1

8

9

10

11

8

12

12

13

13

CTXi-15

3

14

15 14

1 Scroll compressor - hermetic

2 Isolator switch

3 Condenser fan

4 Condenser

5 Sightglass

6 Terminal block for digital outputs

7 Filter/drier

8 Capacitor - condenser fan

15

9 Damper

10 Return air temperature sensor

11 Thermostatic expansion valve

12 Air filter panel

13 Electrical chassis

14 Condensate drain

15 Main supply air fan

4

6

5

7

9

10

11


0410527-01 GB CTXi-7 & 15 Page 13 of 85

CTXi-7

Eaton Williams

CTXi-15

1 2

Terminal block for digital out-puts, smoke extract and damper 24 Vdc supply. For more details, consult the unit wiring diagram.

2

1 2

CTXi-7

3

4

1 Pre-filter, washable

2 Heating rods

Electrical chassis - rear view

CTXi-7 CTXi-15

1 Converter 48Vdc to

24Vdc

2 Earth bar

1 pce

1 pce

2 pce

1 pce

3 Controller - main fan 1 pce 2 pce

1

CTXi-15

3

4 3

3 Thermostat - heating rods

4 Temperature sensor - ambient air

2


0410527-01 GB CTXi-7 & 15 Page 14 of 85

3

Eaton Williams

2.8 ELECTRICAL CHASSIS.

1 2

3 4

16

5

6

15

CTXi 7

14

1 MPCB-1: Main fan

2 MPCB-2: Compressor & Heater

3 MPCB-3: Condenser fan

4 MCB-4: Circuit breaker -48Vdc /

24Vdc converter

5 C-1: Contactor - main fan

13 12 11 10 9 8 7

6 C-3: Contactor - condenser fan 12 R-2: Relay - main fan fail

7 C-4: Contactor - heater

8 Contactor - compressor

9 Fuse

10 R-4: Relay - airflow fail

11 R-3: Relay - Filter dirty

13

14

15

16

R-1: 230Vac mains supply fail

PCB unit controller

Time clock

32-pin EPROM

21 22 19 1 2 3 4 5 6 7 8

CTXi 15 20

1 MPCB-1: Main fan 1

2 MPCB-2: Main fan 2

3 MPCB-3: Compressor

4 MPCB-4: Condenser fan

5 MCB-5: Circuit breaker - heater

6 MCB-6: Circuit breaker - heater

7 MCB-7: Circuit breaker 48Vdc

8 MCB-8: Circuit breaker 400Vdc

16 17 18 9 10 11 12 13 14 15

9 C-1: contactor - main fan 1

10 C-2: Contactor - main fan 2

16 R-2: Relay - main fan failure

17 R-3: Relay - filter dirty

11 C-3: Contactor - compressor 18 R-4: Relay - airflow fail

12 C-4: Contactor - condenser fan 19 Fuses



15 R-1: Relay - Mains supply failure

20

21

22

PCB unit controller

Time clock

32-pin EPROM


0410527-01 GB CTXi-7 & 15 Page 15 of 85

Eaton Williams

SECTION 3

INSTALLATION

3.1

GENERAL

3.2

ELECTRICAL CONNECTION


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Eaton Williams

3.1 GENERAL

The unit is despatched from the factory on a plinth, complete with protective packaging and covering.

Upon receipt, the packaging should be removed and the unit inspected for damage. Any damage should be reported to Eaton Williams Ltd immediately.

When handling, the unit is to be kept upright at all times. If the unit is to be lifted by crane or hoist, spreaders and packing must be used to avoid damage to the unit.

CORRECT LIFTING

• Secure the supplied angle piece to the wall and press unit back onto wall.

• Secure angle piece to top of unit, using setscrews and wood screws.

• Fit base angles to floor, fixing with screws, pressing unit back to seal on gasket.

• Ensure the mains supply isolator has been installed and is locked OFF .

• Check the isolator rating against the wiring diagram.

• Check the fuse rating.

• Check wire between the isolator and the unit on the appropriate terminals. Holes with rubber grommets are positioned on the topside of the unit.

3.2 ELECTRICAL CONNECTIONS.

M AINS SUPPLY CABLE ENTRY

IN-CORRECT LIFTING

CTXi-7

48Vdc

– 48Vdc

0V

230Vac

230V phase

230V Neutral

• Install louvre in the prepared opening (Client).

• Fix blanking plate.

• Fix the soft adhesive gasket around the openings corresponding to the rear of the unit.

• Place the unit up to the gasket and wall.


0410527-01 GB CTXi-7 & 15 Page 17 of 85

48Vdc

– 48Vdc

0V

CTXi-15

Eaton Williams

400Vac

400Vac 3-phase

230Vac Neutral

Protective earth

Isolator 1 Isolator 2

WARNING

!

DO NOT INVERT

230 / 400V

AC

& 48V

DC

As unit configuration and installed options will vary according to specific requirements

ALWAYS CONSULT THE DEDICATED WIRING

SCHEMATICS SUPPLIED WITH THE UNIT .


0410527-01 GB CTXi-7 & 15 Page 18 of 85

Eaton Williams

SECTION 4

COMMISSIONING & OPERATION

4.1

COMMISSIONING

4.2

RUNNING THE UNIT

4.3

OPERATIONAL CHECKS

4.4

OPERATION

4.5

“FIREMAN’s SWITCH” (optional)

4.6

“SMOKE ECTRACT” (optional)

4.7

“SMOKE DETECT” (optional)


0410527-01 GB CTXi-7 & 15 Page 19 of 85

Eaton Williams

4.1 COMMISSIONING

The unit is fully tested and commissioned at the factory. Therefore, minimal post commissioning is required at the site.

Before commencing to run the unit at site, the following checks should be carried out:

• Ensure all electrical connections at site are correctly made and mains supply is correct voltage.

• Ensure all sensors are correctly positioned.

• Ensure external controls, i.e. Fireman’s Switch and Smoke Extract Switch, if applicable, are in the RUN position. If these are not installed, ensure the appropriate terminals are linked out as per the wiring diagram.

• Ensure that all packaging has been removed.

• Ensure the fans are free to rotate.

• Check condensate drain and fill trap by pouring water into tray.

• Ensure all access panels are fitted and secure.

4.2 RUNNING THE UNIT

• Check that the MPCB’s are switched ON .

• Switch ON the Mains isolator.

• The supply fan should start according to the programmed delay.

• Force ON the condenser fan and check that it is rotating in the correct direction. This is a singlephase fan and the capacitor connections will control the fan direction of rotation.

• Force ON the compressor and check that the sight glass is “clear and dry”.

• Set controller.

4.3 OPERATIONAL CHECK

When carrying out the operational checks below, due allowance must be made for the built-in delays on various operations of the controller and for the speed of response of the controller to the changing conditions.

• Slowly raise the room temperature and check that the damper opens.

• Continue raising the room temperature until the damper closes and refrigeration cooling is switched ON .

• Slowly lower the room temperature until refrigeration cooling is switched OFF .

• Check that the damper opens.

• Insert cardboard over min. ¾ of the filter and check that the “ FILTER BLOCKED ” alarm is generated.

• Remove the cardboard.

• Trip the main fan MPCB and check that a “

MAIN

FAN ” alarm is generated.

• Restore the MPCB.

• With the Unit running in refrigeration mode, trip the condenser fan and check that the compressor switches OFF and a “ HIGH PRESSURE ” alarm is generated.


• Trip the compressor MPCB and check that a

“ COMPRESSOR FAILURE ” alarm is generated.


• Remove the access panel and check that the main fan switches OFF . Check that the refrigeration mode is also switched OFF .

• Replace access panel and ensure the unit restarts when the alarm has been cleared.

• Complete the commissioning documentation.

4.4 OPERATION

Whenever the electrical power supply is connected to the unit and the isolator switched ON , the supply air fan in the unit will run. The mode of operation, i.e. the position of the damper and the status of the refrigeration circuit components, will depend on the controller’s set point, the room air temperature and the outside air temperature.

The controller internally monitors the room temperature, and should the room temperature rise above set point, an alarm is given. The alarm can only be re-set when the temperature has fallen 2°C below setpoint.


0410527-01 GB CTXi-7 & 15 Page 20 of 85

Eaton Williams

With the controller in default settings and assuming the room air temperature to be greater than the outside air temperature, unit will operate in the following manner: i) If the room air temperature is greater than setpoint, the damper will begin to open from its fully closed position. If the room temperature does not fall, but rise to 1

°

C above setpoint then the damper will open fully. If the room temperature continues to rise until it is just over setpoint, the damper will close to its fully closed position, and the refrigeration circuit will be activated.

ii) The refrigeration circuit will remain active until the temperature has fallen to just below 1

°

C above setpoint. At that temperature, the refrigeration circuit will be switched OFF. The condenser fan will continue to run. After the overrun period, the damper will be opened to its fully open position.

Cooling by all fresh air will remain if the room temperature is at setpoint.

iii) However, if the room temperature is above setpoint but below 2

°

C above setpoint and the difference between the outside air temperature and the room temperature is 12

°

C or greater then refrigeration mode will be switched OFF and the damper will be opened to its fully open position.

iv) With the room temperature continuing to fall, the damper will be modulated until the room temperature has fallen to the setpoint. At this temperature, the damper will be fully closed.

If at any time the outside air temperature rises above the room air temperature, the damper will be closed.

4.5 FIREMAN’s SWITCH, (optional).

A “Fireman’s Switch” may be fitted at the site and wired into the unit’s terminals. If a fire were detected by the system, it would activate the switch and disconnect the 24-volt supply to the controller. With this supply disconnected the unit will be switched OFF .

Restoration of the 24-volt supply will return the unit to normal operation.

4.6 SMOKE EXTRACTOR, (optional).

A “Smoke Extract” switch may be fitted at the site and wired into the Unit’s terminals. If smoke is detected by the system, the operation of this switch will override all alarms, switch OFF the refrigeration circuit, moves the damper to the fully open position and switch ON the main fan. The main fan will NOT run in this mode if the MPCB has tripped. The unit will be returned to normal operation when the power supply is restored.

4.7 SMOKE DETECT SWITCH, (optional).

An external “Smoke Detect Switch” may be fitted at the site and wired into the unit’s terminals. If smoke were detected by the system, it would activate the switch and disconnect the 24-VDC supply to the damper motor. The damper will close due to the spring-return and the unit will continue to work in refrigeration mode.


0410527-01 GB CTXi-7 & 15 Page 21 of 85

Eaton Williams

SECTION 5

CONTROLLER

5.1

GENERAL

5.2

SET ADDRESS OF CONTROLLER

5.3

SET ADDRESS OF DISPLAY

5.4

POSITION OF E-PROM

5.5

DESCRIPTION OF CONTROLLER DISPLAY

5.6

UNIT PROGRAMMING

5.7

FRONT SCREEN DISPLAY

5.8

ALARM MANAGEMENT

5.9

GATEWAY-CAREL INTERFACE ModBus-JBus,

(optional).


0410527-01 GB CTXi-7 & 15 Page 22 of 85

Eaton Williams

5.1 General

A Carel controller is fitted to the CTXi range of units.

The software programme within the controller has been specifically written for the CTXi units. The software programme is downloaded into the controller during manufacture.

No adjustment or alteration of the programme within the controller is possible. However, the

SETPOINT

,

HIGH

ROOM TEMPERATURE ALARM POINT

,

HIGH ROOM

TEMPERATURE ALARM RESET , LOW PRESSURE ALARM DELAY and START DELAY are adjustable via a plug-in access unit.

The wiring diagram shows the connections from the sensors and switches to the inputs and the connections from the outputs to the contactors, actuators and relays.

Digital Outputs

• Supply fail alarm.

• Main fan off alarm.

• Filter dirty alarm.

• Airflow failure alarm.

• General alarm.

• Maintenance alarm.

• Low temperature alarm.

• High temperature alarm.

• Compressor HP / LP alarm.

• Main fan ON / OFF.

• Condenser fan ON / OFF.

• Heater ON / OFF.

• Compressor ON / OFF.

Digital Inputs

• Compressor O/L.

• Filter dirty.

• 230 Volt failure.

• Heater/compressor ON check.

• Condenser fan O/L.

• High-pressure (HP).

• Low pressure (LP).

• Airflow.

• Heater stat.

• Main fan O/L.

• Smoke extract.

• Damper supply (break).

Analogue Outputs

• Damper modulating control.


0410527-01 GB CTXi-7 & 15 Page 23 of 85

Eaton Williams

5.2 SET ADDRESS OF CONTROLLER.

NOTE! Observe precautions for the handling of electrostatic discharge sensitive devices -

EARTH STRAPS MUST BE USED to prevent electrostatic discharge.

Controller PC Board

Clock Memory and Address Board

Address switches

"ON" side

SW-1

SW-2

SW-3

SW-4

SW-5

SW-6

"OFF" side

UNIT

1

9

10

11

12

13

6

7

8

2

3

4

5

14

15

16

ADD

1

9

10

11

12

13

6

7

8

2

3

4

5

14

15

16

SW-1

ON

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

OFF

ON

OFF

SW-2

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

ON

ON

OFF

SW-3

OFF

OFF

OFF

OFF

ON

ON

OFF

OFF

ON

ON

ON

ON

OFF

ON

ON

OFF

SW-4

OFF

ON

ON

ON

ON

ON

OFF

OFF

OFF

OFF

OFF

OFF

ON

ON

ON

OFF

NOTE! Power supply must be switched OFF before setting address switches

SW-5

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

ON

SW-6

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

ON


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5.3 SET ADDRESS OF DISPLAY.



Back of CAREL display with cover removed

Address switches

SW

1

SW

2

SW

3

SW

4

SW

5

SW

6

SW

7

SW

8

"ON" side

"OFF" side

@ Set address to Binary Code "17" by positioning switches as shown in table below.

SW-1

ON

SW-2

OFF

SW-3

OFF

SW-4

OFF

SW-5

ON

SW-6

OFF

SW-7

OFF

NOTE! Power supply must be switched OFF before setting address switches

5.4 POSITION OF E-PROM.

SW-8

OFF



Controller PC Board 32-Pin E-Prom

Ensure that all pins are located properly in the sockets

Ensure that notch is pointing towards PC Board centre

For detailed instructions on replacing the E-Prom, see section 6.4.1

NOTE! Power supply must be switched OFF before replacing the E-Prom


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5.5 DESCRIPTION OF CONTROLLER DISPLAY.

1

2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17

1 DISPLAY SCREEN

2 MENU KEY

3 SPANNER KEY

4 PRINTER KEY

5 INPUT / OUTPUT

6 HOUR KEY

7 SET KEY

8 PROG . KEY

9 INFO . KEY

10 ( NOT USED )

11 ( NOT USED )

12 ON / OFF KEY

13 ALARM KEY

14 UP ARROW KEY

15 DOWN ARROW KEY

16 ENTER KEY

17 LED' S


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5.5 DESCRIPTION OF CONTROLLER DISPLAY.

1. CONTROLLER DISPLAY:

2. MENU KEY:

3. SPANNER KEY:

4. PRINTER KEY:

5. INPUT / OUTPUT KEY:

6. HOUR KEY:

7. SET KEY:

8. PROG. KEY:

9. ? INFO KEY:

10.

11.

12. ON / OFF KEY:

13. ALARM KEY:

14. UP ARROW KEY:

15. DOWN ARROW KEY:

16. ENTER KEY:

17. LED:

This provides information on Unit(s) operating parameters.

Pressing this key to return to standard <FRONT> screen or scroll between standard <FRONT> screen and <OPERATING MODE> screen.

Press this key to access show settings of Unit main. Use UP ARROW key to scroll between components. Entering the correct password at <MAINTENANCE

SCREEN> will access section where values can be altered using the UP and

DOWN ARROW keys and the ENTER key.

Press this key to access alarm history. Use UP ARROW key to show earlier alarm events.

Press this key to access information on Unit analogue and digital inputs and outputs. Subsequent pressing the DOWN ARROW key will scroll between 6 screens. Return to <FRONT> screen by pressing MENU key.

Pressing this key will show date and time. To change values, press ENTER key, adjust values using UP and DOWN ARROW keys. Save changes by pressing

ENTER key. Press MENU key to exit to <FRONT> screen.

Press this key to display actual setpoint temperature. Press DOWN ARROW key to bring cursor down to <TEMP> . Press ENTER key. Press UP and DOWN

ARROW keys to change Unit setpoint. Press ENTER key to save changes. Press

MENU key to return to <FRONT> screen.

Pressing this key will access Unit programming set-up and operating parameters.

See section 5.6 UNIT PROGRAMMING.

Pressing this key will scroll between the Units connected in the pLAN.

This key is not used in this application.

This key is not used in this application.

Press this key to switch Unit ON or OFF at keypad.

An LED in the key will light up and indicate that an alarm condition was registered. Screen will show relevant alarm. Press UP and DOWN ARROW keys to check for multiple alarms. Press ALARM key to clear alarms. MPCB trips will have to be manually reset before they can be cleared. Heater alarms are cleared by switching OFF the Unit. Any faults must be rectified or the alarm conditions could re-occur.

Is used to scroll through menus or change values.

Is used to scroll through menus or change values.

Press this key to verify changes in Unit set-up.

LED's placed in the keys indicate that the key is active.

For further and more detailed information on the CAREL controller, please consult this manufacturer's manuals.


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5.6 UNIT PROGRAMMING.

"PROG."

Enter the Service

Password.........

"ENTER"


Password 1234

"ENTER"


Password 1234 right password

Screen 1

Temperature setpoint limit

Minimum 10.0ºC

Maximum 30.0ºC

To change the settings of any of the following screens, proceed as follow:

Press ENTER to move cursor to relevant setting.

Press to adjust value setting.

Press ENTER to confirm new value setting.

Continue to press ENTER until no item is flashing.

Use to scroll through screens.

Screen 2

Temperature

Band cool

Band heat

Neutral zone

03.0ºC

02.0ºC

00.0ºC

Screen 3

External temp. limit for free cooling

Limit low 05.0ºC

Limit high 40.0ºC*

Screen 4

Compressor together

Free cooling N

Screen 5

Minimum range for enable free cooling 02.0ºC

Minimum opening free cooling 00.0%*

Screen 6

Threshold free cooling

Alarm 00.0%*

Screen7

Supply air temp limit

Limit max 40.0ºC*

Limit min -50.0ºC

Screen 8

Automatic start after power failure Y

Screen 9

Room temp. threshold low alarm

Setpoint -05.0ºC*

Offset -04.0ºC*

Screen 10

Room temp. threshold high alarm

Setpoint 30.0ºC

Offset 02.0ºC

Screen 11

Supply air limit

Enable

Setpoint

Offset

N

15.0ºC

01.0ºC

NOTE! * Indicate parameters that have been changed from factory defaults.


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SELECT: <UNIT CONFIGURATION>

Screen 1

Clock board Y

Supervisor board Y

Screen 2

Supply air temp.

Probe enabled

Humid probe enable

Y

N

Screen 12

Speed communication for supervisory 1200 (RS422/RS485)

Gateway access 001

"MENU"

FRONT

SCREEN

Enter manufacturer password 1234

Right password

"MENU"

+ "PROG."

Enter manufacturer password .........>

"ENTER"

Enter manufacturer password 1234

Right password


Unit configuration

General parameters

Timing

Unit initializat

"ENTER"

Screen 3

External air temp.

Probe enabled Y

Screen 4

Compressor No

Enable heater

Free cooling

Enable freec. al:

1

Y

Y

N

Screen 1

Clock board Y

Supervisor board Y

"MENU"



Timing


"ENTER"


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SELECT: <GENERAL PARAMETERS>

Screen 1

Temp. and regulation

Proportional internal time

(only P+N) 0600 SET

Screen 2

Step compressor 1

Position 65.0%

Hysteresis 35.0%

Screen 3

Identific address for supervisor system network................


Screen 1

Temp regulation

Proportional integral time

(only P+N) 0600 SET

"MENU"



Timing


"ENTER"

SELECT: <TIMING>

Screen 1

Time delay switching main fan ON 005 sec

Time delay switching main fan OFF 010 sec

Screen 5

Free cooling alarm delay time 0180 sec

Screen 9

Time off free cooling for exceeding humiditi limits 2hrs

(Not applicable as Unit has no humidity control)

Screen 2

Delay off cond. fan from.

shut-down 0120 sec

Screen 3

Low pressure alarm delay time 0180 sec

Temp. and humid alarm delay time 0300 sec

Screen 4

Airflow alarm or overload main fan delay time 0030 sec*

Screen 6

Minimum compressor OFF time 0180 sec

Minimum compressor ON time 9959 sec

Screen 7

Delay on compressor from main fan start 0120 sec

Screen 8

Delay between starts same compressor 0360 sec

Screen 1

Time delay switching main fan ON 005 sec

Time delay switching main fan OFF 010 sec

"MENU"



Timing


DO NOT HIGHLIGHT

<Unit initializat> as this will reset back to factory default settings

"MENU"

FRONT SCREEN


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5.7 FRONT SCREEN DISPLAY

1 TIME

2 ROOM TEMPERATURE IN

°

C

3 ON / OFF AT KEYBOARD

4 DATE & YEAR

5 UNIT NUMBER IN P LAN

¶

·

¸

¹

º

5.8 ALARM MANAGEMENT

Alarm conditions are indicated in two ways:

• Audible by the buzzer, (integrated into the pCO relay card).

• Visually by the LED in the ALARM key.

Alarms are cleared by pressing the ALARM key until no further alarm conditions are displayed on the screen. Tripped

MPCB's must be reset before the alarm can be cleared, and heater alarms are cleared by switching OFF Unit.

ALARM RESET

Ambient high temperature

Ambient low temperature

Ambient high humidity

Ambient low humidity

Automatic

Automatic

Automatic

Automatic

Compressor high pressure Manual

Compressor high pressure (internal) Automatic

Dirty filters

Airflow

Manual

Manual

Damaged ambient temp probe

Damaged humidity temp probe

Damaged external temp probe

Damaged delivery air temp probe

Automatic

Automatic

Automatic

Automatic

Resistance thermal

Compressor thermal

Main fan thermal

Condens. fan thermal

Smoke extract

Manual

Manual

Manual

Manual

Automatic

Power failure

Clock card damaged

Compressor operation time

Filter operation time

Main fan operation time

Resistance operating time

Condens. fan operating time

Free cooling operation time

Resistance operation

Compressor operation

Epromnook

Freecooling anomalies

Unit malfunction

Malfunction

Automatic

Manual

Manual

Manual

Manual

Manual

Manual

Manual

Manual

Manual

Automatic

Automatic

Automatic

Automatic

No

No

No

No

No

No

No

No

No

No

No

No

No

UNIT

STOP

No

No

No

No

No

No

No

Yes

No

No

No

No

No

No

No

No

Yes

No

UNIT FUNTION

Unchanged

Unchanged

Unchanged

Unchanged compressor OFF compressor OFF

Unchanged

Unit OFF

Only fan ON

Unchanged

Free cooling OFF

Free cooling OFF

Resistance OFF

Cooling OFF

Unit OFF

Cooling OFF

Cooling, heating stop

ON fan and 100% free cooling

Comp./resist. OFF

Unchanged

Unchanged

Unchanged

Unchanged

Unchanged

Unchanged

Unchanged

Resistance OFF

Compressor OFF

Unchanged

Free cooling OFF

Unchanged

Unchanged

NOTES

Delay from fan ON

Delay from fan ON

Delay from fan ON

Delay from fan ON

Immediate

Delay from compressor ON

Only signalling

Immediate

1 min. delay

1 min. delay

1 min. delay

1 min. delay

Immediate

Immediate

Immediate

Immediate

Immediate

Immediate

Immediate

Only signalling

Only signalling

Only signalling

Only signalling

Only signalling

Only signalling

3.5 min. delay

6 min. delay

Immediate

Delayed from ON vent.

Delayed 30 sec from Unit

ON and 5 sec at full operation

Delayed 30 sec from Unit

ON and 5 sec at full operation.


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5.9 GATEWAY-CAREL INTERFACE to MODBUS-JBUS PROTOCOL, (optional)

GENERAL DESCRIPTION

The GATEWAY allows interfacing the CAREL systems with systems that communicate by means of the standard ModBus-JBus protocol. The GATEWAY automatically translates the Carel transmission protocol into the ModBus-JBus communication protocol. The product includes a diskette with a program, which configures the GATEWAY according to the particular requirements of the application, and of the peripheral network to supervise. The program must be installed on a PC. Instructions on the use of the program are contained in the file <readme.doc> , which is included with the program. The protocol translator has been produced to ensure the connection of all the CAREL instruments to ModBus-JBus systems by means of a standard GATEWAY , thereby avoiding successive and expensive adaptations of the software. The standard ModBus-JBus protocol referred to here, is the version published in the official document:

Modicon Modbus Protocol

Reference Guide

March 1992, PI-MBUS-300 Rev.D

The protocol utilised here, is the time-based RTU.

CONTROLLER PCB

J7

Fig. 1

PCOSER4850 card

Fig. 2 Fig. 3

The GATEWAY can connect up to 16 pce pCO controllers. Each pCO controller will require a PCOSER4850 PCB card, (Fig. 1). With unit switched OFF , insert PCB card to connect on pins in position J7 on controller main PCB, (Fig.

2 & 3). The PCOSER4850 cards are then connected to the GATEWAY as shown on wiring diagram ZZ0052-06A, (see section 9).


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Fig. 4

MCB

Fig. 5 Fig. 6

Fig. 4 shows the position of the GATEWAY control box and MCB, (Fig 6), and the communication link, (Fig. 5) in the electrical chassis.

Fig.'s 4, 5 & 6 shows the GATEWAY as it is positioned in CTXi-15 units. As of yet, the position of GATEWAY components in CTXi-7 units has not been finalised.

For detailed information, please consult the GATEWAY MODBUS official manual.


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SECTION 6

MAINTENANCE & REPAIR PROCEDURES

6.1

MAINTENANCE GENERAL

6.2

3-MONTHLY OR LESS

6.3

12-MONTHLY OR LESS

6.4

REPAIR PROCEDURES

6.4.1 REPLACE CONTROLLER PCB E-PROM

6.4.2 REPLACE CONTROLLER PCB

6.4.3 DAMPER ACTUATOR

6.4.4 MAIN FAN

6.4.5 CONDENSER FAN

6.4.6 COMPRESSOR

6.4.

SENSORS, FUSES, RELAYS, CONTACTORS etc

6.5

TROUBLE-SHOOTING


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6.1 MAINTENANCE

As well as the specific guidance given at the beginning of this document, all safety regulations and codes must be observed. Specific care should be taken to prevent any release of refrigerant to the atmosphere.

The CTXi ranges of units have been designed for minimum routine maintenance. An alarm indication is shown when maintenance/repair attention is required.

Routine Maintenance is limited to:

• Checking and Changing Filter panels

• Checking the Refrigeration Sight Glass

• Cleaning the Evaporator Coil

• Cleaning the Condenser Coil

The periodicity of these checks should be set by local conditions and experience to just precede an Alarm

Indication. However, the intervals between checks should not exceed 3 months for the first check above and 12 months for the remainder of the checks.

Release filter by twisting the four clips. Carefully lift out filter and dispose into container/plastic bag.

Clean evaporator as described

Only qualified and experienced technicians should work on this unit.

ALWAYS ISOLATE THE UNIT

ELECTRICALLY BEFORE WORKING ON IT.

6.2 EVERY 3-MONTHS OR LESS

Filter change:

• Open front access door.

• Remove pre-filters.

• Remove filter panels where fitted and place in plastic bag for subsequent disposal.

• Vacuum out the filter mounting and evaporator coil.

• Insert NEW filter panels. Make sure the airflow markings show the correct airflow through the unit. (See illustration).

• Vacuum the washable filters. Wash these in a warm soapy solution if excessively soiled. Allow drying thoroughly before refitting to the unit.

• Close access door.

• Switch on at isolator.

When inserting new filter element, ensure the correct flow direction as indicated on filter frame.

(Arrow pointing towards evaporator).

• Ensure that the unit restarts.

• Enter the work carried out in the Maintenance

Log, date it and sign it.

6.3 EVERY 12-MONTHS OR LESS

• Carry out 3-monthly check.

• Before replacing the filters, clean the evaporator coil by spraying a biocide solution through the coil from the top, ensuring that the dirty water runs away through the condensate drains.

• Check that the traps remain filled with water.

Replenish water.

• Replace the Filters but DO NOT replace the access panel

• Remove the grille from the right hand side of the unit.

• Vacuum the condenser coil. If it is excessively dirty, wash it with the same type of solution as used for the evaporator coil.

• Re-install the right hand grille and front access panel.


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• Switch ON power at isolator.

• Force the unit into refrigeration mode of operation.

• Check that the refrigerant in the sight glass is clear and dry.


Log, date and sign it.


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6.4.1 REPLACE E-PROM IN CONTROLLER PCB.

1. Isolate ALL Units from Mains electrical supply.

2. Remove smoke extract wiring link between terminals 32 and 33 if this option is fitted.

Terminal 33

Terminal 32


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6.4.1 REPLACE E-PROM IN CONTROLLER PCB.



3. Remove the original E-Proms from the position shown, using a suitable extractor tool.

4. Insert the new 32-Pin E-Prom ensuring that the notch is positioned towards the bottom as showed below.

32-Pin E-Prom

Notch pointing downwards


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5. Connect a touch screen to the Unit as shown above. The touch screen can then be situated remote from the Master

Unit during the following configuration procedure.

6. Re-connect the Mains supply


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7. Screen will show the following display: Current date, time and room temperature. Simultaniously press keys

MENU and PROG.

to show……

8. The above screen. Press ENTER key to move cursor to (0000).


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9. Using the UP ARROW and DOWN ARROW keys, enter the pass number “1234” , then press the ENTER key.

Note cursor position before pressing ENTER

4 x

10. Press DOWN ARROW key four times to move the cursor to the “Unit Initializat.” line. Then press ENTER key.


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11. When this screen is displayed, press the ENTER key…………

12. To show this display. The Controller is now down-loading the manufacturers parameters - Please wait………..


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2 x

13. Until the down-load is complete and this screen is displayed, the alarm light will flash once and the alarm will sound once. Press MENU key twice…………..

14. To return to the FRONT screen as displayed above.

15. Turn the Unit OFF .

16. Repeat this procedure for all the Air Handling Units in the room.

17. Re-connect the display in the Master Unit - Return all Air Handling Units to normal operation.


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6.4.2 REPLACE CONTROLLER PCB

1. Switch off and isolate all Air Handling Units from the electrical supplies.

2. Open front door.



3. Unplug sockets containing wires, from the controller PCB

4. Remove the 6 pce screws holding the PCB and remove from electrical chassis.

32-Pin E-Prom

Í

Screws

FIG. 1

Clock PCB

Í

Screw


Í

Screw

Í

Screw

Ì

Sockets with wiring


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5. Remove the orginal E-Proms from the PCB, using a suitable extractor.

6. Remove the clock-PCB.

7. Fit E-Prom and Clock-PCB to new controller PCB.

32-Pin E-Prom

FIG. 2

Top of controller PCB showing E-Prom position


8. Check the address settings of clock-PCB. The address switches to be set to Unit number. See table 1 :

FIG. 3

OFF side ON side Clock Memory Board & Address

SW-1

SW-2

SW-3

SW-4

SW-5

SW-6

Address Switches

• Address is set by Binary code.

Table 1:

Unit

3

4

1

2

Type

Master

Slave

Slave

Slave

ADD

3

4

1

2

SW-1

ON

OFF

ON

OFF

SW-2

OFF

ON

ON

OFF

SW-3

OFF

OFF

OFF

ON

SW-4

OFF

OFF

OFF

OFF

9. Fit new controller PCB, using the original 6 pce screws. Re-connect sockets with wiring.

SW-5

OFF

OFF

OFF

OFF

SW-6

OFF

OFF

OFF

OFF


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Back of controller display

SW-1 - 2 - 3 - 4 - 5 - 6 - 7 - 8

ON side

OFF side

FIG. 4

10. Set SW 1 and 5 to ON . All others to OFF . This is Binary No. 17.

Connect touch screen

FIG. 5

11. Connect a touch screen to the Unit as shown above. The touch screen can then be situated remote from the Master

Unit during the following configuration procedure.

12. Re-connect the Mains power supply to the Units.


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• The touch screen will “Bleep” twice and remain blank. Light in ENTER key will show.

FIG. 6

13. Simultaneously press UP ARROW, DOWN ARROW and ENTER buttons for approx. 5 seconds……

FIG. 7

• Until the above screen appears. Remove fingers.

• The Terminal Adress 17 = Touch screen number.

• Set the I/O board address using DOWN ARROW key to set clock PCB Number according to address list in Table 1.


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FIG. 8

14. When the correct address has been selected, press ENTER key to show the above screen.

15. Press the ENTER key again to show…………

FIG. 9

• This screen.


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FIG. 10

16. Pressing the UP ARROW key several times, change 58 to 17 .

17. Press ENTER .

18. Leave S H unchanged after 17 .

19. Press Enter .

20. Using the UP ARROW key, change 60 to NONE .



23. Using UP ARROW key, change 62 to NONE .


25. Press ENTER until curser reaches the worh NO .

26. Change this to YES using the UP ARROW key.

• The screen should now look like this…………


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FIG. 11

27. If screen look like this - press ENTER .

FIG. 12

• The Unit will now be ON and the display showing TIME, DATE, ROOM TEMPERATURE , etc.


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FIG. 13

28. Simultaniously hold down UP ARROW, DOWN ARROW and ENTER keys for about 10 seconds. Display will show screen in FIG. 11 - keep the three keys pressed until the following screen is displayed.

No of Units attached and turned "ON". One

for each Unit.

FIG. 14

• This screen is confirmation that information set-up is correct. - Press ENTER to return to normal screen.


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FIG. 15

29. Disconnect the Mains power supply for 10 seconds - then reconnect Mains power. Screen should show the above display prior to returning to normal operational screen.

IF A NEW E-PROM WAS FITTED, PLEASE FOLLOW THE PROCEDURE

FROM THE “REPLACEMENT OF E-PROM” SECTION.


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6.4.3 DAMPER ACTUATOR

The damper actuator is changed using following procedure:

• Ensure that the power to the unit is switched at the isolator and the isolator is locked

• Open front door.

OFF .

OFF

• Remove the screws in the damper blade on the link plate.

• Remove the two hinge bolts and remove damper plate.

• Disconnect the wires to damper motor.


Log, date and sign it.

6.4.5 CONDENSER FAN REPLACEMENT

The Condenser Fan is changed using following procedure:

• Ensure that the power to the unit is switched OFF at the Isolator and the Isolator is locked OFF .

• Open access panel.

• Disconnect the condenser fan wire and remove from the wiring loom.

• Whilst supporting the condenser fan, remove the four bolts holding it on the panel.

• Remove the fan complete with the guard and discard.

• Feed the cable through the grommet hole and clip to the wiring loom as appropriate.

• Locate the new fan and insert the bolts.

• Whilst supporting the damper actuator, undo the bolts holding it to the frame of the unit and remove the damper actuator complete with the connecting mechanism and cable.

• Discard the damper actuator.

• Fit the connecting mechanism to the new damper actuator making sure that it is fitted to the correct side as noted previously.

• Replace motor in reverse order of removal.


Log, date it and sign it.

6.4.4 MAIN FAN REPLACEMENT

The Supply Fan is changed using following procedure:

• Ensure that the power to the unit is switched OFF at the isolator and the isolator is locked OFF .

• Ensuring that the fan blades will not catch on the panel, tighten the four holding bolts.

• Reconnect the wires to the condenser fan terminals.

• Replace the access panel.

• Open access panel.

• Remove the wiring gland at the top of the fan.

• Undo the bolts that hold the fan to the frame.

• Withdraw the fan.

• Discard the fan.

• Restore power to the unit and force ON the condenser fan.

• Check that the fan rotation is correct. This is a single-phase fan and the capacitor connections will control the fan direction of rotation.

• Restore power to the unit.


Log, date and sign it

6.4.4 COMPRESSOR

• Position the new fan and insert the bolts.

• Identify and reconnect the wires as previously noted.

• Close access panel.

• Restore power to the unit.

NOTE! BEFORE PROCEEDING WITH ANY

WORK, CAREFULLY READ AND FOLLOW

INSTRUCTIONS SUPPLIED WITH

REFRIGERANT RECLAIMING

EQUIPMENT.

• Check the rotation of the fan is correct.


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NOTE! GREATEST POSSIBLE CARE

SHOULD BE TAKEN AT ALL TIMES TO

AVOID THE RELEASE OF REFRIGERANTS

INTO THE ATMOSPHERE.

NOTE! DUE TO THE NATURE OF THE

DESIGN AND OPERATION OF SCROLL

COMPRESSORS, EVACUATION AND

CHARGING OF THE REFRIGERANT

SYSTEM MUST TAKE PLACE FROM BOTH

THE HIGH- AND LOW-PRESSURE SIDE

SIMULTANEOUSLY.

NOTE! ALL REFRIGERANTS, OILS AND

OTHER WASTE MATERIALS MUST BE

DISPOSED OFF IN A PROFESSIONAL

AND RESPONSIBLE MANNER IN STRICT

ADHERENSE TO ENVIRONMENTAL

REGULATIONS.

In case of a compressor failure, an “Acid Test” must be carried out to determine if the system has been contaminated. If no acids are detected, then the compressor changed as follow:

• Ensure that the power to the unit is switched OFF at the isolator and the isolator is locked OFF .

• Open front access panel.

• Reclaim the refrigerant in an approved manner ensuring that no refrigerant leaks to the atmosphere.

• Disconnect the wiring to the compressor.

• Unsolder or cut the pipe connections to the compressor.

• Undo the four bolts securing the compressor to the floor of the unit.

• Withdraw the compressor.

• If the unit is to be left without a compressor for any length of time, the pipes should be sealed and the system charged with dry nitrogen to prevent the ingress of moisture and other contaminants.

• Position the new compressor.

• Insert and fully tighten the securing bolts, using new anti-vibration mounts.

• Connect the pipes to the compressor either by soldering direct or by inserting new lengths of refrigeration grade copper pipe as required.

• Re-connect the wires to the compressor terminals.

• Ensure that the Earth wire is connected.

• Evacuate the system to not less than 30mbar and allow standing for at least 15 minutes.

• If there is any loss of vacuum, the system should be checked for leaks. These should be rectified and the system re-evacuated and allowed standing for a further 15 minutes.

• If there are no leaks, the system should be charged with the correct type and weight of refrigerant. See the Serial Plate for type and weight.

• Restore the power to the unit.

• Force the unit into refrigeration mode of operation and check the sight glass.

• Check for leaks.

• Return the unit to normal operation.

If acids are detected in the system, the system will require flushing.

• Cut out the filter/drier.

• Temporarily bridge the ends of the pipes where the filter/drier and compressor should be installed, using flexible connections and clips.

• Remove the expansion valve and wash thoroughly in solvent.

• Reassemble the expansion valve, top only.

• Flush the complete system with solvent using a pump and solvent tank.

• Reclaim the solvent.

• Install a new filter/drier.

• Replace the expansion valve.

• Install the new compressor as previously described.


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• After 48 hours of operation, carry out new acid test and fit a new filter drier.

6.4.7 SENSORS, FUSES, RELAYS,

CONTACTORS ETC

However, it must be ensured that the Unit is isolated from the mains supply before any work is carried out, and any wiring connections must be carefully identified and noted before they are disconnected.

• All these components are changed by simply disconnecting, replacing and reconnecting them.

6.5 TROUBLE-SHOOTING

The following chart shows the likely causes of fault indication and the corrective action required. The legend in brackets in the first column shows the indication that occurs on the remote display unit, where this is fitted.

ALARM INDICATION

MAINS FAILURE

MAIN FAN OFF

FILTER DIRTY ALARM

AIRFLOW ALARM

HP TRIP

(High pressure)

LP TRIP

(Low pressure)

HT ALARM

(High room temperature)

POSSIBLE CAUSE

1) Fuse F-1.

2) Mains not ON.

3) Relay not operating

1) Contactor not working.

2) 48Vdc supply fault.

3) Fuse F-3.

4) MCB tripped.

5) Relays R-1 & R-2 inoperative.

6) Fire shut down link.

1) DP switch.

2) Clogged filter.

1) AF switch.

2) Relay R-4.

1) Condenser fan not operating.

2) Dirty coil.

3) Blocked louvre.

4) System overcharged.

1) Loss of charge.

2) Low airflow on main fan.

1) Mechanical cooling failure.

LT ALARM

(Low room temperature)

HEATER ALARM

ANOMALIE

COMPRESSOR

COMPRESSOR

OVERLOAD

1) Room temperature fallen below pre-set limit.

2) Very low ambient temperature.


2) MCB tripped.

3) Poor wiring connection.


2) MPCB tripped.

3) Poor wiring connection.

1) High current load.

2) Faulty compressor.

3) MPCB tripped.

MAINTENANCE ALARM Service interval has been exceeded.

CORRECTIVE ACTION

1) Check / change fuse.

2) Switch ON power.

3) Check / replace relay.

1) Check / replace if faulty.

2) Check and restore.

3) Check / change fuse.

4) Check cause and reset.

5) Check and replace if faulty.

6) Check and rectify.

1) Change filter, check DP switch.

2) Replace / check tubing.

1) Check AF switch and replace if faulty.

2) Check / replace relay.

1) Check cause and rectify.

2) Check cause and clean.

3) Check cause and clean.

4) Evacuate and re-charge correctly.

1) Leak test and repair, evacuate & re-charge.



1) Check heaters are working.

2) No remedy



3) Check wiring circuit.



3) Check wiring circuit.


2) Replace compressor.


Carry out service and set new interval.

GENERAL ALARM Indicate an alarm condition occurred.

Investigate cause of alarm and rectify.


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SECTION 7

SERVICE PARTS LIST

7.1

CONTACT NUMBERS

7.2

SERVICE PARTS HELD AT SITE

7.3

SERVICE PARTS LIST


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7.1 CONTACT NUMBERS.

Maintenance / Service Contracts:

Contact Tel No 1

Contact Tel No 2

Fax No

01732 869 600

01732 869 601

01732 869 630

General Service and Repair:

Contact Tel No 1

Contact Tel No 2

Fax

Emergency Service:

Contact Tel No

01732 869 605

01732 869 615

01732 869 630

International: +44 1732 869 600

+44 1732 869 601

+44 1732 869 630

+44 1732 869 605

+44 1732 869 615

+44 1732 869 630

Only issued to clients with Service & Maintenance Contracts.

Service Parts:

Contact Tel No 1

Contact Tel No 2

Fax

01732 869 615

01732 869 614

01732 865 709

+44 1732 869 615

+44 1732 869 614

+44 1732 865 709

SERVICE PARTS - SITE STOCK LIST

The Table below shows the recommended site holding of consumable service parts for each CTXi Unit:

COMPONENT

Main filters

Pre-filter

Pre-filter

PART NUMBER

3020467

3020507

3020511

CTXi-7

2 pce

2 pce

CTXi-15

4

2

This list does not cover major spares such as main fan, condenser fan, compressor and damper actuator.

7.2 SERVICE PARTS LIST

Service parts must be to the same specification as those being replaced and obtained from Eaton-Williams. Obsolete parts are replaced by suitable alternatives.

COMPONENT

MAIN FILTER

PRE-FILTER

PRE-FILTER

CONDENSER FAN

MAIN FAN 48Vdc

COMPRESSOR - SCROLL

PART NO

3020467

3020507

3020511

MG1141A-GO2

3300011

MG1143A-R01

CTXi-7

1

1

CTXi-15

2

1

1

1

1

2

2


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COMPONENT

COMPRESSOR - SCROLL

DAMPER MOTOR

DAMPER BALL JOINT + 10mm ROD

DAMPER CRANK ARM

DRIER

SIGHTGLASS

EXPANSION VALVE

ADAPTOR ¼"

ORIFICE 03

ORIFICE 05

VALVE - HAND SHUT OFF

SWITCH - DIFFERENTAL PRESSURE

PRESSURE SWITCH - LP

PRESSURE SWITCH - HP

SENSOR 1.5MT

CONDENSER COIL

CONDENSER COIL

EVAPORATOR COIL

EVAPORATOR COIL

HEATER ELEMENTS 3kW @ 240V

ISOLATOR 38A OT63E3

ISOLATOR 38AOT63E4

SHAFT 180mm

HANDLE, PADLOCKABLE

CONTACTOR 8A 24Vdc

CONTACTOR 8A 24Vdc

CONTACTOR 12A 24Vdc

PART NO

HAK547-02

HAK531-01

HAK546-02

MG1143A-G08

1100158

1100159

1100167

1100168

1060355

1060375

1060356

2120363

2120364

2120042

3050180

2100162

2100151

1220250

HAK530-01

2050455

3040183

3040185

3040186

2080115

2080249

2120310

2120340


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1

1

1

2

3

1

1

1

1

1

1

1

1

2

CTXi-7 CTXi-15

1

1

1

1

2

1

1

1

3

1

1

1

1

3

1

1

1

1

1

1

2

1

1

1

2

2

2

2

3

3

Eaton Williams

COMPONENT

MPCB 2.5A

MPCB 4A

MPCB 10A

MPCB 16A

MCB 1A

MCB 4A

MCB 13A

AUX CONT BLOCK

FUSE 1A 20x5 Anti-surge

FUSE 3.15A 20x5 Anti-surge

CONTROLLER 48Vdc to 48Vdc

CONVERTER 48Vdc to 24Vdc

RELAY DPDT 24Vdc

RELAY DPDT 230Vac

BASE - RELAY 8-pin

RESISTOR 0.6W 1PC 150k OHM

CAREL CONTROLLER

CAREL PCB BOARD - CLOCK MEMO

PCB BOARD - PCOSER4850

EPROM 32-pin M27C1001-12F1

CAREL DISPLAY

PART NO

1081307

1080096

1151111

1151410

1170036

1170062

1170102

1160145

1151400

1081308

1081310

1081311

1081107

1081111

1081113

1081314

1080091

1151403

1151402

1151350

1151401

1

4

1

3

1

1

3

1

1

1

1

CTXi-7

1

CTXi-15

1

1

1

1

1

2

1

1

4

2

3

3

2

1

1

1

1

4

2

1

2

2

1

1

1


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SECTION 8

DISPOSAL PROCEDURES


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DISPOSAL PROCEDURE.

NOTE!

All refrigerants, oils and other waste materials must be disposed off in a professional and responsible manner in strict adherence to environmental regulations.

NOTE!

Greatest possible care should be taken at all times to avoid the release of refrigerants into the atmosphere.

The de-commissioning, dismantling and disposal of air handling units should be undertaken only by experienced personnel and by full adherence to all safety rules, in particular protection of lungs, eyes and skin from refrigerants, dust etc. Only approved lifting gear and power tools should be used and access to the work area restricted to authorised personnel.

1. Disconnect unit from the electrical supply.

2. Reclaim ALL refrigerant from the unit, using approved reclaiming equipment according to the manufacturer’s instruction. Only operatives registered for refrigerant safe handling must carry out recovery of refrigerant.

3. Dispose of the reclaimed refrigerant through an approved recycling facility.

4. Separate the unit sections and remove to an approved recycling facility.


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DRAWING No

ZZ0052-02 I

LAD622G

LAD641

ZZ0052-05

ZZ0052-06A

NAD 321

NAD 325A

QAK 284

QAK 292

SECTION 9

REFERENCE DRAWINGS

TITLE

WIRING DIAGRAM CTXi-7

WIRING DIAGRAM CTXi-15

MASTER

WIRING DIAGRAM CTXi-15 SLAVE

COMMUNICATION COMMON GROUND

RS 485 WIRING pCO SERIAL CONN.

REFRIGERATION SCHEMATIC CTXi-7

REFRIGERATION SCHEMATIC CTXi-15

GENERAL ARRANGEMENT CTXi-7

GENERAL ARRANGEMENT CTXi-15


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REFERENCE DRAWING: ZZ0052-02 I WIRING DIAGRAM CTXi-7


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REFERENCE DRAWING: LAD622G WIRING DIAGRAM CTXi-15 MASTER


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REFERENCE DRAWING: LAD641 WIRING DIAGRAM CTXi-15 SLAVE


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REFERENCE DRAWING: ZZ0052-05 COMMUNICATION COMMON GROUND


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REFERENCE DRAWING: ZZ0052-06A WIRING pCO SERIAL CONNECTIONS.


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REFERENCE DRAWING: NAD 321 REFRIGERATION SCHEMATIC CTXi-7


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REFERENCE DRAWING: NAD 325A REFRIGERATION SCHEMATIC CTXi-15


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REFERENCE DRAWING: QAK 284 GENERAL ARRANGEMENT CTXi-7


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REFERENCE DRAWING: QAK 292 GENERAL ARRANGEMENT CTXi-15


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SECTION 10

UNIT MODIFICATION HISTORY


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HISTORY OF UNIT MODIFICATION

MODIFICATION DATE SIGNATURE

Make extra copies of this page as required


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SECTION 11

MAINTENANCE LOG


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DATE

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MAINTENANCE LOG

DESCRIPTION OF WORK SIGNATURE


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CTXi operating and installation manual

Eaton-Williams

Eaton-Williams

CONTENTS

Section 1

Section 2

Section 3

Section 4

Section 5

Section 6

Section 7

Section 8

Section 9

Section 10

Section 11

Safety Instructions

Introduction & Technical Data

Installation

Commissioning & Operation

Controller

Maintenance & Repair Procedure

Service Parts

Disposal Procedures

Reference Drawings

Unit Modification History

Maintenance Log

PAGE No

60

62

72

74

16

19

22

4

8

34

56

SECTION 1

SAFETY INSTRUCTIONS

1.1 GENERAL

1.2 INSTALLATION & HANDLING

1.3 APPLICATIONS

1.4 WARRANTY

1.5 ELECTRICAL CONNECTIONS

1.6 MAINTENANCE

1.7 SERVICE PARTS

1.8 CODES OF PRACTICE

1.9 WARNING AND SAFETY NOTICES

1.10 LIGHTING

1.11 PORTABLE TOOLS AND LAMPS

1.12 ESCAPE ROUTES

1.13 KEYS

1.14 DRIVE GUARDS AND HOUSINGS

1.15 WASTE DISPOSAL

whether directly or indirectly, MUST read this notice and this complete document before the commencement of ANY work.

The following information MUST be read, fully understood and adhered to at ALL times:

ü

ü

ü

SECTION 2

INTRODUCTION & TECHNICAL DATA

2.0

GENERAL

2.2

DESCRIPTION

2.3

FREE COOLING MODE

2.4

REFRIGERATION COOLING MODE

2.5

EMERGENCY COOLING

2.6

TECHNICAL DATA

2.7

UNIT COMPONENT DESCRIPTION

2.8

ELECTRICAL CHASSIS

SECTION 3

INSTALLATION