MAN_serie VZ_ABB_eng

MAN_serie VZ_ABB_eng
USE, MAINTENANCE AND INSTALLATION MANUAL
AIR CONDITIONERS FOR ELECTRICAL ENCLOSURES
VZ1550
VZ1850
VZ1400
VZ2000
Manual Code VR-197-0-0002
ABB SACE S.p.A.
An ABB Group Company
Automation and Distribution Boards
23846 Garbagnate Monastero (LC)
Tel.: ++39 031 3570 1 - Telefax: ++39 031 3570 228
http://www.abb.com
Date: 05-may-06
ABB SACE S.p.A.
SERIE VZ
Page 1 of 21
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Rev.05
ABSTRACT
VZ SERIES
AIR CONDITIONING UNIT
1
REFERENCE NORMS AND SYMBOLS’ DESCRIPTION...............................................................................3
1.1
Reference norms...................................................................................................................3
1.2
Symbols’ description ..............................................................................................................3
2
DATA LABEL .................................................................................................................................4
3
CAUTION .....................................................................................................................................5
3.1
General Warnings..................................................................................................................5
3.2
Warnings on Handling ...........................................................................................................5
3.3
Warnings on positioning and installation..................................................................................6
3.4
Warnings on non-scheduled maintenance................................................................................6
4
DESCRIPTION OF THE UNIT ..........................................................................................................7
5
TECHNICAL DATA .........................................................................................................................8
6
5.1
Table ...................................................................................................................................8
HANDLING AND TRANSPORT .........................................................................................................9
7
INSTALLATION ...........................................................................................................................10
7.1
Installation of ACU ..............................................................................................................10
7.2
Installation of accessories ....................................................................................................14
8
USE ...........................................................................................................................................15
8.1
Use intended by the Manufacturer ........................................................................................15
8.2
Contraindications.................................................................................................................15
9
FIRST START..............................................................................................................................16
10
SCHEDULED MAINTENANCE.........................................................................................................17
11
10.1
What you must verify during scheduled maintenance .............................................................17
TROUBLESHOOTING ...................................................................................................................19
12
SAFETY AND PROTECTION DEVICES ............................................................................................20
12.1
Description .........................................................................................................................20
12.2
Check-up............................................................................................................................20
13 DISPOSAL OF THE ACU ...............................................................................................................20
13.1
Uninstallation......................................................................................................................20
13.2
Materials in the ACU ............................................................................................................20
13.3
Special materials: ................................................................................................................21
14 ATTACHMENTS ...........................................................................................................................21
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
Page 2 of 21
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Rev.05
Before proceeding with installation of the Air Conditioning Unit (from now on ACU or Unit),
it’s necessary to read this manual carefully. This manual is bundled with the ACU, and must
be stored with care.
1
REFERENCE NORMS AND SYMBOLS’ DESCRIPTION
1.1 Reference norms
MECHANICAL CONSTRUCTION
UNI - ISO Norms
ELECTRICAL CONSTRUCTION
IEC - CEI - EN - Norms
PIPING CONSTRUCTION
ISPESL – ISO - Norms
The ACU complies:
• With norms 89/392 CEE, 91/368 CEE, 89/336 CEE, 73/23 CEE, and subsequent
modifications.
• With norms CEI- EN 60204-1 (Safety of Machinery - Electrical Equipment of Machinery).
• With norm ISO R 1662 (Refrigerant Plants - Safety Requirements).
For the above ACU exists a technical documentation and working procedures
If other devices are bundled with the ACU, they will be supplied with their own
instruction manuals.
1.2 Symbols’ description
The symbols below are mentioned on this manual or on the Unit itself.
Warning
Useful suggestions
To be performed by a
trained technician
See also page or
chapter
Operation to be
performed by two
persons
Operation not allowed
Print or Copy this
Date: 05-may-06
See “Use, scheduled
maintenance and
installation manual”
Contact the
Manufacturer
Environmental care
ABB SACE S.p.A.
VZ SERIES
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Rev.05
2
DATA LABEL
Locate the label on the ACU to know technical data. If something is nonconforming, please contact
the retailer or the Manufacturer of the ACU.
Data on the label are necessary to correctly connect the machine, to start and to
service it.
On the label there are data concerning the ACU (model, serial number, weight, etc.) and data
concerning the cooling capacity at fixed ambient conditions - (see. norm UNI EN 814). The data
label is shown below.
The label is on the internal frame of the ACU.
Manufacturer
identification data
ABB SACE S.p.A.
An ABB Group Company
Automation and Distribution Boards
23846 Garbagnate Monastero (LC)
Refrigerant
type
Serial Number ... ... ...
Model ... ... ...
Operating
conditions
Current
FLA
Current
LRA
Refrigerant
quantity
Supply Voltage ... ... ...
Frequency ... ... ...
Refrigerant ... ... ...
Quantity ... ... ...
A35/A35
Cool. Cap. ... ... ...
El. PWR ... ... ...
A50/A35
Cool. Cap. ... ... ...
El. PWR ... ... ...
FLA ... ... ... LRA ... ... ...
Net Weight ... ... ...
Indoor Protection ... ... ...
Manuf. Year ... ... ...
Made in Italy in compliance with
Input
Power
Cooling
capacity
norms
Data label sample
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
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Rev.05
3
CAUTION
3.1 General Warnings
This manual is addressed to:
Shipping clerks
Installers
Users
Maintenance operators
The knowledge and the application of safety norms are the base to correctly
perform the installation with no risks at all, and to maintain the Unit in it’s best
efficiency.
The installer must read carefully the content of chapter “INSTALLATION”.
The maintainer must read carefully the content of the chapter “SCHEDULED MAINTENANCE”.
Never make any operation if you are not sure of the consequences it could produce. In doubt,
please contact the Customers’ Care in your are, or directly the Manufacturer of the Unit.
The Manufacturer of the Unit declines every responsibility for any damage caused by an improper
use of the machines. Especially in the following cases:
misuse;
non-trained personnel use;
incorrect installation;
faulty material;
unauthorized service or modifications;
use of non-original spare parts;
carelessness of general prescription and specifically of those in the present manual;
exceptional events.
This manual explains the use of the Unit intended by the Manufacturer.
This manual must be stored carefully and must be available for reference. If necessary, make
copies of it, to be used on the field.
This manual must be kept with the Unit, until it is dismissed.
The Manufacturer reserves the right to modify manual contents without any prior notice.
3.2 Warnings on Handling
The transport must be performed by qualified personnel only
This manual points out the best and more appropriate way for the transport and the handling of the
Unit.
Always use suitable means of transport.
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
Page 5 of 21
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Rev.05
3.3 Warnings on positioning and installation
Positioning and installation must be performed by trained personnel only.
The installer must verify that every part of the Unit is in good working conditions, prior to install it. In
case of doubt, please contact the Manufacturer.
The use of Personal Protection Devices may be necessary, depending on working
conditions.
3.4 Warnings on non-scheduled maintenance
Every operation of non-scheduled maintenance must be performed by trained and
qualified technicians.
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
Page 6 of 21
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Rev.05
4
DESCRIPTION OF THE UNIT
VZ series ACU are packaged type, designed and manufactured to cool electrical enclosures and
similar items.
They are manufactured to be positioned on the external walls of the enclosure; their shape makes
them suitable for many applications.
The Unit operation is based on the principle of the reversed Rankine cycle, so heat is transferred
by a fluid (refrigerant) that acquires it in the evaporator coil and releases it from the condenser coil;
this happens in a sealed circuit. The fluid is driven by an electrically actuated compressor.
The evaporator coil is directly facing the electrical enclosure internal, while the condenser is facing
the external room.
All models are designed with forced-air-circulation evaporator and condenser, with radial fans, to
improve performances and to uniform the temperature’s distribution in the enclosure internal.
All models are basically equipped with temperature controller; they can also be equipped with
several optional accessories.
VZ series Units are manufactured with galvanized steel plates; they have self-sustaining structure,
and RAL 7032 standard color.
All Units are manufactured to grant maximum safety and reliability.
All the Units are designed, manufactured and verified in compliance with ISO 9001 Norms, which
ensures high quality standards.
Every Unit is tested extensively, to verify its compliance with design specifications.
5
ENCLOSURE
SIDE
6
4
3
EXTERNAL
SIDE
1 COMPRESSOR
2 CONDENSER SECTION FAN
3 CONDENSING COIL
4 EXPANSION VALVE
5 TREATMENT SECTION FAN
6 EVAPORATING COIL
2
1
Basic cooling circuit diagram
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
Page 7 of 21
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Rev.05
5
TECHNICAL DATA
5.1 Table
Models
Measuring
units
VZ1550
VZ1850
VZ1400
VZ2000
Supply voltage (standard)
V
230
230
230
230
Frequency
Cooling capacity
Input power
Current
LRA
FLA
Fuse protection
Air flow rate (evaporator
side).
Air flow rate (condenser side)
Electrical protection degree
(enclosure side)
Refrigerant gas (standard)
Refrigerant quantity (weight)
Maximum external working
temperature
Noise level
Hz
W
W
A
A
A
Overall dimensions (WxDxH)
(mm)
Weight
Color
Reference to drilling template
Kg
RAL
Characteristics
50
60
50
60
605
330
670
360
810
400
900
450
12,5
8
2
4,9
50
60
60
1926 2200
800
920
22
4,5
5,9
1300 1480
650
720
21
4
8
mc/h
380
350
350
500
mc/h
400
400
600
950
IP
54
54
54
54
Type
g
R134a
490
R134a
490
R134a
550
R134a
550
°C
55
55
55
55
dB(A)
64
380 x 198 x
1025
33
7032
A
64
380 x 198 x
1025
33
7032
A
66
380 x 198 x
1025
36
7032
A
66
380 x 230 x
1100
42
7032
B
(1) Cooling capacity is referred at the following working conditions:
External temperature 35°C – Internal temperat ure 35°C - R. H. = 50%.
Date: 05-may-06
50
ABB SACE S.p.A.
VZ SERIES
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Rev.05
6
HANDLING AND TRANSPORT
The Unit must be transported by qualified personnel only.
The weight of VZ series Units is listed in chapter “TECHNICAL DATA”.
During handling keep the Unit upright, even if it is possible to incline it until 45°.
If during transport the Unit was stored horizontally. It’s necessary to wait at least 6 hours before
switching it on.
Lift the Unit only taking it for the body. During transport, the Units will be packaged alone or in
couple, over a wooden pallet.
In case it is necessary to move the electrical enclosure after the installation of the Unit, it’s
necessary to separate it from the enclosure, package it again and transport it packaged alone.
During transport hold the Unit absolutely upright, avoiding horizontal position.
While unpacking the Unit, be careful at spare parts bundled with it.
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
Page 9 of 21
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Rev.05
7
INSTALLATION
7.1 Installation of ACU
The ACU must be installed on the wall of the electrical enclosure, over a smooth surface, to avoid
vibrations. Leave a suitable distance between the ACU and its neighborhood, to easily service it, if
necessary, and to allow air circulation.
Verify that the part where the ACU will be mounted is capable of supporting the
weight of the ACU, especially if it is going to be mounted on the door of the
enclosure.
Make the openings for air inlet, air outlet, cables and mounting screws as follows.
3 80
1025
1100
38 0
19
A
8
23
0
Overall dimension
When the ACU must be installed on the door of the electrical enclosure, be sure that the hinges of
that door are strong enough, and verify that, when opening the door, the enclosure is stable and
does not tip over.
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
Page 10 of 21
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Rev.05
Make the openings as shown in the following schemes.
If the drilling template, 1:1 scale,(optional accessory) is bundled with the ACU, place it on the
external wall of the enclosure and cut out the openings and make the holes as shown on the
template.
The drawing reference number of the drilling template is DIMA0003078 (for model VZ2000) and
DIMA0003181 (for models VZ1550 – VZ1850 – VZ1400).
25
Ø9
160
50
WARM AIR
SUCTION
WARM AIR
SUCTION
269.5
269.5
60
125
0
Ø2
250
125
0
Ø2
Ø9
Ø9
Ø9
Ø9
Ø9
320
320
Type A
Type B
Drilling template
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
Page 11 of 21
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1000
1100
70
915
1015
250
Ø9
60
FRESH AIR
INLET
840
FRESH AIR
INLET
70
760
160
Ø9
Ø9
25
105
25
50
35.5
370
160
Ø9
160
25.5
370
105
25
Rev.05
Place the adhesive gasket (provided) along the unit’s border and in middle position between air
inlet and return air openings, as shown in picture below.
GASKET
How to place adhesive gasket
Thread the power supply cables in the appropriate hole, then fix the ACU on the wall with M6
screws (not provided) of suitable length.
Operation to be performed by two persons.
Verify the correct and free movement of the fan facing the nozzle.
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
Page 12 of 21
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Rev.05
CONDENSER COIL
AIR OUTLET
WARM AIR
SUCTION
FRESH AIR INLET
CONDENSER COIL
AIR OUTLET
CONDENSER COIL
AIR INLET
VIEW FROM ENCLOSURE
INTERNAL
EXTERNAL VIEW
Working scheme
Be sure that air can circulate freely to refresh the condenser coil; avoid damaging the electrical
devices in the enclosure with metal chips produced when making openings and holes in the walls.
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
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Rev.05
7.2 Installation of accessories
Installation of optional accessories can be performed only by qualified technicians.
The electrical board is located immediately beyond the command switchboard. To reach it,
remove the external metal shell, as shown in chapter “FIRST START”.
To connect the door micro-switch, remove the jumper 6-9 in the terminal block J4, and connect the
micro-switch as shown below.
To connect the auxiliary isolating switch of the ACU, remove the jumpers L-3 and N-4 on the
terminal block J1 and connect the isolating switch as shown below.
Scheme of the electrical board of the ACU.
Drawing reference number of the label is ETIC0003079.
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
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Rev.05
8
USE
8.1 Use intended by the Manufacturer
The Unit is designed to cool electrical enclosures and similar items, and it is supplied to be
mounted on them with mechanical fixing devices (not provided); it can be positioned indoor and
also outdoor, but anyway sheltered from rain.
See chapter “TECHNICAL DATA” to use the Unit correctly.
8.2 Contraindications
The Unit is not intended to work in areas classified AD.PE EEx d (Risk of explosions).
It has no improved protections to sustain adverse atmospheric conditions.
It is not intended for other uses than what above.
To be authorized to use the Unit in other ways than what written above, you must
contact the Manufacturer or the dealer in your area.
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
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Rev.05
9
FIRST START
After you have installed the ACU, and you have connected it to the power supply line, press the
ON/OFF switch on the front panel to start it up; the yellow LED will show the Unit is working.
Verify that no strange noises (vibrations of metal plates, friction between the fan and the nozzle…)
are produced by the Unit when working.
ON/OFF Switch
To set the value of working temperature, proceed as follows:
• Remove the screw indicated by arrow 1
• Pull gently the lower part of the metal cover as shows arrow 2, enlarging slightly the sides
of the metal cover
• Lift the metal cover in direction of arrow 3.
While removing the metal cover, be careful not to damage the ON/OFF switch.
2
3
2
1
How to remove the metal cover
If the Unit is equipped with an electro-mechanical temperature controller, located immediately
beyond the command panel, rotate its knob to set the temperature.
When the Unit is equipped with an electronic controller, see the manual of the device (bundled with
the Unit).
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
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Rev.05
10 SCHEDULED MAINTENANCE
Before every maintenance operation, switch off the main power supply of the Unit.
Before switching off the power supply of the Unit and removing the metal cover, pay attention to
the noise produced by fans; in case of strange noises, please contact the customer care in your
area.
10.1 What you must verify during scheduled maintenance
Fans
Air Filter
(when present)
Condenser coil
Condensate
draining basin
Verify that fans rotate freely and without any strange noise.
In case, call the Customer’s Care in your area.
Verify the condition of the filter. If clogged, try cleaning it with a
vacuum cleaner or an air-blower gun or water; if it’s not possible
to clean it, replace it.
Periodically, clean the condenser coil using an air-blower gun.
Verify that the condensate draining works correctly and that no
dirt is in the basin.
Verify that the spiral pipe with hot refrigerant is located in the
basin.
To clean the air filter, it’s necessary to remove the metal cover; proceed as described below:
• Remove the screw indicated by arrow 1
• Pull gently the lower part of the metal cover as shows arrow 2, enlarging slightly the sides
of the metal cover
• Lift the metal cover in direction of arrow 3.
2
3
2
1
How to remove the metal cover
Remove the filter sliding it sideways in direction A; clean it using an air-blower gun or water;
replace it if clogged.
Clean the condenser coil (see arrow B) with an air-blower gun, blowing downwards, after you
removed the filter (if present).
During maintenance, be careful not to damage the fins of the condenser coil.
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
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Rev.05
B
A
A Slide the filter – B Condenser coil
Missing check-up may be a cause of malfunctions; periodical check-up, as explained in the table
above, are required.
If necessary, do not hesitate to call the Customer’s Care to have an efficient technical
assistance to perform the check-up above.
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
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Rev.05
11 TROUBLESHOOTING
TROUBLE
ACU does not start up
CAUSE
Missing power supply.
The fuses are gone.
The ACU does not cool; the fan
does not work.
The ACU does not cool; the internal
fan does not work.
Missing power supply.
The ACU is off
The temperature controller set point
is higher than room temperature.
The temperature controller does not
work
High-pressure side pressure-switch
has worked
The ACU does not cool enough
Room temperature is higher than
maximum working temperature.
Too small refrigerant charge
The condenser coil is clogged
Internal fan does not work
External fan does not work.
RIMEDY
Verify the electrical connections to
the supply line
Verify the position of the switch (if
present).
Call the Technical Assistance.
Verify the electrical connections to
the supply line
Push the ON/OFF switch to start
the ACU up.
Verify the temperature controller
set-point
Call the Technical Assistance.
Verify if the condenser coil is clean
and if the external fan works.
Call the Technical Assistance.
Verify room temperature and the
power to sink.
Call the Technical Assistance.
Verify if the condenser coil is clean
Call the Technical Assistance.
Verify the air ducts of the openings
of the enclosure; make sure the air
can pass freely through the
openings.
Verify the temperature controller
Wrong temperature controller set
set point.
point.
Call the Technical Assistance.
Set the temperature controller at a
Too low temperature of treated air
higher temperature
The electrical enclosure is not sealed Seal the enclosure in some way.
Clean the condensate draining
Condensate draining basin is dirty.
basin
Clogged draining pipe.
Clean the condensate draining pipe
The ACU produces too much
Condensate draining basin is full.
condensate; probably the
enclosure is not sealed.
Too small air flow rate in the
enclosure internal.
The ACU works intermittently.
Condensate in the enclosure
internal.
Water leaks from the ACU
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
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Rev.05
12 SAFETY AND PROTECTION DEVICES
12.1 Description
Name
High pressure-switch.
Safety thermostat
Description
It stops the Unit when pressure in the discharge line is higher than a fixed
value; it resets when pressure goes down again to an allowed value. For
multiple actions, verify if the condenser coil and the filter are clean, the fan is
working and the room temperature is in the allowed range. In case of frequent
actions of this pressure switch, then control if the condenser fan works
properly, the filter and condenser coil are clean and the room temperature is
higher than the allowed value.
When the unit is equipped with diagnostic module, it indicates High
temperature condition in the enclosure. The LED “Max Temperature” will light
on. When the Unit is in Heating Mode, the thermostat will also disconnect the
electrical heater. In case of frequent actions of this thermostat when the Unit
is in Cooling Mode, then control if the evaporator fan works properly and the
thermal load is higher than cooling capacity.
12.2 Check-up
The refrigerant circuit is sealed so, if no accident occurs, no refrigerant leaks are possible; every two years
the ACU must be checked up by a qualified technician, to verify the heat exchangers, the fans, the auxiliary
circuits and mechanics and safety devices.
13 DISPOSAL OF THE ACU
13.1 Uninstallation
Every operation concerning the uninstallation of the ACU must be performed by qualified and
authorized technicians.
All the operations concerning the uninstallation are listed in the service manual, in chapter
concerning installation.
13.2 Materials in the ACU
The ACU is formed of materials that can be treated as secondary raw material (recyclable); the
materials are listed below:
Structure:
Heat exchangers
Electrical parts
Compressor
Painting
Date: 05-may-06
Iron and steel plates.
Aluminium and copper.
Copper, PVC e Various materials.
Iron, copper and Various materials.
Epoxy material.
ABB SACE S.p.A.
VZ SERIES
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Rev.05
13.3 Special materials:
The dismissing of the ACU must be performed by authorized Companies.
•
•
•
The disposal of lubricant oil in the compressor must be performed authorized Companies
The refrigerant must be evacuated by special devices, then stored in vessels and sent to
qualified Companies for disposal.
Electrical components and the dehydrator filter must be considered special materials, and they
must be sent to an authorized Company for disposal.
14 ATTACHMENTS
•
User Manual of electronic temperature controller (if present)
Date: 05-may-06
ABB SACE S.p.A.
VZ SERIES
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