INSTALLATION AND OPERATING INSTRUCTIONS
CoolPacket
08/2010
CoolPacket
Contents
1. OVERVIEW...................................................................................................................................................................................3
1.1 Summary of guarantee regulations.........................................................................................................................................3
1.2 Receiving the unit.....................................................................................................................................................................3
1.3 Factory inspection....................................................................................................................................................................3
2. SAFETY REGULATIONS.............................................................................................................................................................3
2.1 Preamble....................................................................................................................................................................................3
2.2 Definitions..................................................................................................................................................................................3
2.3 Access to DANGEROUS AREAS..............................................................................................................................................4
2.4 General precautions..................................................................................................................................................................4
2.5 Precautions against risks due to the refrigerant....................................................................................................................4
2.6 Precautions against residual risks..........................................................................................................................................5
2.7 Prevention against residual mechanical risks.......................................................................................................................5
2.8 Prevention against residual electrical risks...........................................................................................................................5
2.9 Prevention against residual risks of a different nature.........................................................................................................5
2.10 Precautions to be observed during maintenance operations.............................................................................................5
2.11 Manual alarm reset..................................................................................................................................................................6
2.12 Operating range.......................................................................................................................................................................6
The operating ranges are indicated on the plate placed on the unit..........................................................................................6
3. INSTALLATION.............................................................................................................................................................................6
3.1 Moving and positioning the unit..............................................................................................................................................6
4. CONTROL OF COMPRESSOR FASTENING..............................................................................................................................6
5. ELECTRICAL CONNECTIONS....................................................................................................................................................6
5.1 Electrical power supply............................................................................................................................................................7
5.2 Power connections...................................................................................................................................................................7
5.3 Unbalance between the supply tension phases.....................................................................................................................7
6. water connections for air-water and water-water units................................................................................7
6.1 Evaporator.................................................................................................................................................................................7
6.2 Water circuit regulation equipment.........................................................................................................................................7
6.3 HYDRAULIC DIAGRAM.............................................................................................................................................................7
7.1 Ducts connection for AIR – AIR units......................................................................................................................................8
7.2 Ducts connection to the indoor unit for AIR – AIR units.......................................................................................................8
7.3 Condense drain connection for AIR – AIR units.....................................................................................................................8
8. START-UP PRELIMINARY PROCEDURES.................................................................................................................................9
8.1 Starting check............................................................................................................................................................................9
8.2 Refrigerant seals control..........................................................................................................................................................9
8.3 Refrigerant charge check.........................................................................................................................................................9
8.4 Refrigerant charge....................................................................................................................................................................9
9. START-UP...................................................................................................................................................................................10
9.1 Preliminary controls................................................................................................................................................................10
9.2 Starting up................................................................................................................................................................................10
9.3 Warm up of the plant for units air to water and water to water...........................................................................................10
9.4 Control of the oil charge.........................................................................................................................................................11
9.5 Power supply to the auxiliary circuit.....................................................................................................................................11
10 MAINTENANCE.........................................................................................................................................................................12
10 .1 SIGHT CHECK OF THE UNDER PRESSURE VESSELS STATE........................................................................................12
11. RECOMMENDED SPARE PARTS............................................................................................................................................13
12. IMPROPER USES....................................................................................................................................................................13
13. TROUBLESHOOTING..............................................................................................................................................................14
CoolPacket
Overview, Safety regulations
1. OVERVIEW
2. SAFETY REGULATIONS
1.1 GUARANTEE REGULATIONS
2.1 PREAMBULE
A. The guarantee for REMAK machines is 12 months from
the date the machine is operated for the first time but no
more than 18 months from the date of the invoice. The
warranty is reduced to 6 months from the start up date
for units running continuously, that is more than 12 hours
a day. The date the machine is operated for the first time
means the date reported in the “1st start up form” contained into the “machine log book”. This form should be filled
in and sent, within 8 days from the start up, to REMAK.
B. The guarantee is valid if all the installation regulations
have been adhered to (both those which may have come
from REMAK and those coming from current practice), if
the “1st start up form” has been filled in and sent to the
REMAK after sales department.
C. The guarantee is subject to any faults or defects being
reported within eight days from their discovery. The
guarantee will only be applied if and when the purchaser
suspends use of the equipment as soon as a defect has
been found.
C1. Replacement items are to be considered always ex
REMAK factory. Labour costs to replace failed items either
under warranty or not, will be not of REMAK care.
D. The guarantee is valid if the first running of the machine
is carried out by a REMAK authorised assistance centre.
E. The guarantee is subject to regular maintenance of the
unit which is appropriately indicated in the “machine log
book” located inside the electrical panel.
F. Warranty is automatically over in case of payments not
fulfilled, non-performance of the contract and even if the
units show tampering without REMAK writing approvals.
G. Non observance of the above mentioned rules and of
all the indications written on this manual, will cause the
immediate loss of warranty, getting free REMAK from any
responsibility for the unit and any damages to persons or
things.
All REMAK units are designed, built and inspected in
compliance with the European Community Directives n°
98/37/CE (three phase power supply), EN 60335 Part 1
and 2 , low voltage directive 73/23CEE, electromagnetic
compatibility directive EMC 89/336CEE, Pressure Equipment Directive 97/23/CEE. Before using the machine read
carefully the recommendations reported in the following
manual.
1.2 RECEIVING THE UNIT
On receiving the unit it is up to the customer to check that
there is no obvious damage or pieces missing. If this is
so, an immediate complaint must be made to the carrier
for damage or for not-delivery and the Receiving Card to
be found inside the unit electrical panel must be filled in.
Photographic evidence must be provided for macroscopic
damage. The card must be sent to REMAK within 8
days of receiving the goods: if it is not sent back or
delayed, the complaint will not be accepted.
1.3 FACTORY INSPECTION
REMAK units are inspected into the factory, in appropriate
areas, in accordance with internal procedures. Each performance test carried out on the unit is possible only if the
same conditions are reproduced and maintained (charge
consistency, constant temperature and evaporation - condensation and recovery capacity, quality and tolerance of
the measuring instruments etc.) in the test rooms.
The inspection conditions are those indicated by the customer in the ordering phase: if not otherwise specified,
reference should be made to the nominal performance
indicated in the technical bulletin in force at the date of the
Confirmation of the Order.
2.2 DEFINITIONS
2.2.1 Owner:
The legal representative of the company, body or natural person who owns the plant in which the REMAK unit
is installed: he or she is responsible for the control and
respect of all the safety regulations indicated in this manual
as well as the national ones in force.
2.2.2 Installer:
The legal representative of the company appointed by the
owner to position and hydraulically, electrically etc. connect
the REMAK unit to the plant: he or she is responsible for
moving and the correct installation of the unit in accordance with the indications in this manual and with the national
regulations in force.
2.2.3 Operator:
A person authorised by the owner to carry out all the operations of regulation and control on the REMAK unit which
are specifically mentioned in this manual. He or she should
keep to actions described in the manual and limit his or her
action to what is explicitly allowed.
2.2.4 Technician:
A person who is directly authorised by REMAK or, secondarily, for all EU countries except for Italy, by the distributor
of the REMAK product, under their own responsibility, to
carry out all ordinary or extraordinary maintenance operations, as well as regulations, controls, repairs and parts
replacement which may be necessary during the lifetime of
the unit.
2.3 ACCESS TO DANGEROUS AREAS
The access to the unit dangerous areas is usually
obstructed through protection panels, which are removable, by using a tool. Axial fans are protected with
accident prevention grilles. Centrifugal fans are not protected on the discharge, as they have to be connected
to ducts. In case they have to run without ducts, it is the
installer duty to provide protection grilles.
Finned coil, for units not equipped with coil protection
grilles, is completely accessible with danger for cuts and
abrasions. In these cases technicians and operators must
be aware about this risk.
CoolPacket
Safety regulations
For all the units which allow access to the cooling piping or
to the packaged condensing coils with fins, without security
gratings (optional) or closing panelling, the following precautions must be taken:
-mark the areas with contact risks.
-apply warning signs.
The danger zone must be of a suitable size to avoid any
contact, even accidental contact.
In the presence of safety valves without relevant remote
controls, the operating area must be of a size which considers a range of action of the discharge flow of 3 metres.
REMAK declines any responsibility for damage to things
and unauthorised personnel in case of absence of clear
and static limiting systems of the risk areas and of the relevant warning and danger signs.
2.4 GENERAL PRECAUTIONS
The operator must only intervene on the unit commands;
he or she must not open any panels except for the one
which gives access to the command module.
The installer must only intervene on the connections
between the plant and the machine; he or she must not
open any machine panels nor carry out any commands.
The following precautions should be made when
approaching or working on the unit:
• do not wear jewellery, baggy clothes or any other accessory which can get caught up.
• Use appropriate protection (gloves, glasses etc.) when
using an open flame (welding) or compressed air.
• If the unit is located in a closed environment, wear hearing protection.
Safety data
Toxicity
• before disconnecting, removing tubes, filters, joints or
other line parts intercept the connection tubes, empty them
until the pressure reaches that of the atmosphere.
• do not use your hands to check for possible pressure
losses.
• always use tools which are in good condition; make sure
the instructions have been fully understood before using
them.
• make sure that any tools, electrical cables or other loose
objects have been removed before closing the unit and
starting it up again.
2.5 OPRECAUTIONS AGAINST RISKS DUE
TO THE REFRIGERANT
See table below.
2.6 PRECAUTIONS AGAINST RESIDUAL
RISKS
Prevention from risks due to the command system
• make sure the instructions for use have been understood
before carrying out any work on the control panel.
• always keep the instruction manual close at hand when
working on the control panel.
• start up the unit only after having certified that it is correctly connected to the plant.
• inform the technician promptly of any alarms which
appear on the unit.
• do not reset the alarms to manual restart without having
first identified the cause and removed it.
R407 - R134a - R410a
Not important
Splashes or sprinkles can cause chill burns. The risk of absorptions through the skin is not relevant.
Those refrigerants could take some lightly irritating effects and in lliquid stage they have a strong skinning
Risks for skin touching effect. In this case it is necessary to rinse with fresh water the contaminated parts of the skin
The refrigerant in liquid stage in contact with wet fabries cause freezing and adherence to the skin. In this
case it is necessary to put off the contaminated clothes to avoid freezing. Please contact a doctor in case of
irritation of the contaminated parts.
Vapors don’t take any effect. Splashes or sprinklers can cause chill burns. In those cases it is necessary to
Risks for contact with
rinse the eyes with water or with solution for ocular washings for 10 minutes. The intervention of a doctor is
the eyes
needed.
Should it happen, it causes chill burns. It does not cause vomiting. The person must be kept awake. It is
Risks for ingestion
needed to rinse the mouth with fresch water and to drink almosto 0,25 liters. The intervent of a doctor is
needed.
High concentration of vapours in air can lead to anaesthetic effects up to a loss of conscience. Long exposures
could give rise to cardiac arrhythmia and sometimes even to death.
Risks for inhalation
High concentrations can create a reduction of oxygen in air, with consequent possibility of suffocation. Should
it happen the person must be taken to the open air and let him to take a rest.
Administer oxigen if needed. In case the breathing has interrupted or become irregular, it is necessary to
apply the artificial breathing. In case of cardiac arrest a heart massage must be applied. Contact a doctor
immediately.
Conditions to avoid
Use in presence of exposed flames, and of elevates levels of humidity.
Dangerous reactions
Protection wearing Behavior in case of
losses or escapes
Dismantlement
Possibility of violent reactions with the sodio, the potassio, the barium and with other alkaline substances,
incompatible materials and all the alloys containing more than 2% of magnesium.
Wear protection apparel and self respirators. Insulate the source of the loss, if this operation can be done in
safety conditions. Small quantitative of refrigerant escaped at liquid state can be allowed to evaporate only if
the room is well ventilated. In case of great losses ventilate the room immediately. Plug the loss with sand,
soil or other absorbent material; avoid that the liquid refrigerant can enter in water-drainages or losing pools.
The best procedure is the recovery and the recycle. If this is not possible the refrigerant must be conferred
to an accredited system for its destruction in order to neutralize acid and toxic by-products.
CoolPacket
Safety regulations
2.7 PREVENTION AGAINST RESIDUAL
MECHANICAL RISKS
• install the unit in accordance with the provisions of the
following manual.
• carry out all the maintenance operations provided for
by this manual regularly.
• wear a protective helmet before entering inside the
unit.
• before opening a machine panel make sure that it is
firmly connected by means of a hinge.
• do not touch the air condensation batteries without
having first put on protective gloves.
• do not remove the protections to the moving parts while the unit is running.
• before restarting the unit make sure that the moving
part protections are in the correct position
2.8 PREVENTION AGAINST RESIDUAL
ELECTRICAL RISKS
• connect the unit to the mains in accordance with the provisions of this manual.
• carry out all maintenance operations regularly.
• before opening the control panel disconnect the unit from
the mains by means of the external knife switch.
• check that the unit has been earthen correctly before
starting it up.
• control all the electrical connections, the connection
cables paying particular attention to the state of isolation;
replace the cables which are clearly worn or damaged.
• carry out periodic checks of the wiring inside the panel.
• do not use cables with an inappropriate section or flying
connections not even for a limited period or in an emergency.
2.9 PREVENTION AGAINST RESIDUAL
RISKS OF A DIFFERENT NATURE
• The residual risk due to pressure are mainly coming from
non funtioning of the safety devices. To prevent them it is
• necessary to follow the checks and replacements as following indicated (§12.1 and 13)
• To protect from safety devices exhausting it is not allowed
to remove the protections while the unit is in operation and
to approach the unit without wearing the right protections.
In case of accidental contact with refrigerant due to the
safety valves exhaust it is necessary to follow the above
indicated (§2.5)
• carry out the plant connections to the unit by following the
indications reported on the following manual and on the
panels of the unit itself.
• if a part is disassembled, make sure that it is correctly
reassembled before restarting the unit.
• do not touch the discharge line of the compressor, the
compressor itself or any other tube or component which is
inside the machine without putting on protective gloves.
• keep a fire extinguisher which is able to put out fires on
electrical equipment near the machine.
• on units installed inside, connect the refrigerant circuit
shut off valve to a network of tubes which are able to lead
the possible spillage of refrigerating fluid outside.
• eliminate any fluid loss inside or outside the unit.
• collect the discharge liquid and clean up any possible oil
leakage.
• periodically clean the compressor casing of the accumulated dirt deposits.
• do not keep inflammable liquids near the unit.
• do not dispose of the refrigerant fluid and the lubricating
oil in the environment.
• welding should only be carried out on empty tubes; do not
approach the tubes containing refrigerant fluid with flames
or other sources of heat.
• do not bend or strike tubes containing pressurised fluids.
2.10 10 PRECAUTIONS TO BE OBSERVED
DURING MAINTENANCE OPERATIONS
Authorised technicians may only carry out maintenance
operations.
Before carrying out any maintenance the following must be
performed:
• isolate the unit from the mains electricity by using the
external knife switch.
• place a notice on the external knife switch which says “do
not use - maintenance in progress”.
• make sure that any possible on-off commands are disabled.
• use appropriate safety equipment (helmet, isolating gloves, protective glasses, safety shoes etc.).
If measurements or controls must be carried out which
require the machine to be running the following observations must be followed:
• operate with the electrical panel open for as short a time
as is possible.
• close the electrical panel as soon as the individual measurement or control has been carried out.
• for units which are located outside, do not carry out interventions in dangerous atmospheric conditions such as rain,
snow, fog etc.
The following precautions should also be taken at all times:
• never dispose of fluids contained in the refrigerant circuit
into the environment.
• when replacing an EPROM or electronic card always use
appropriate equipment (extractor, anti static bracelet, etc.).
• if a compressor, the evaporator, the condensation batteries or any other heavy part is to be replaced, make sure
that the lifting equipment matches the weight to be lifted.
• in the air cooled units with an independent compressor
compartment, do not open the ventilator compartment
without having first isolated the machine using the knife
switch on the side of the panel and only after having placed
a sign which says “do not use - maintenance in progress”.
• if modifications must be carried out to the cooling, hydraulic or electrical circuit of the unit, as well as to its command
logic, contact REMAK.
• if particularly complicated assembly or disassembly operations are to be carried out contact REMAK.
• always use original spare parts bought directly from
REMAK or from official dealers of the companies reported
in the list of recommended spare parts.
• if the unit is to be moved after a year of being in the site
or if it has to be dismantled contact REMAK.
CoolPacket
Installation, water and electric connections
2.11 MANUAL ALARM RESET
If there is an alarm the unit must not be manually reset
before having located and eliminated the cause of the fault.
Repeated manual resets may cause the guarantee to be
annulled.
2.12 OPERATING RANGE
The compressors are fitted on shock absorbers. For fixing
through spring antivibration mounts, it is necessary to
remove blockages put to fasten the compressors, as indicated on the label on compressors body.
The operating ranges are indicated on the plate placed on
the unit.
5. ELECTRICAL CONNECTIONS
3. INSTALLATION
5.1 ELECTRICAL POWER SUPPLY
3.1 MOVING AND POSITIONING THE UNIT
The units have been designed to be lifted from above by
means of eyebolts and holes in the base members.
Use retractor bars to keep the lifting wires or chains away
from the unit.
Lifting procedures provided with the unit have to be
respected.
Attention: Do not use forklift trucks to lift the unit from
below.
If equipment for lifting from above is not available, using
rollers may move the unit.
The surface on which the unit is placed must be flat and
strong enough to withstand the weight of the unit while
running.
In order to reduce the transmission of vibrations to the supporting structures, fit shock absorbers in every fastening
point. Rubber shock absorbers are recommended for units
installed on the ground, spring shock absorbers for units
installed on roofs. Open spaces around the unit must be
provided for in order to allow for the passage of necessary
airflow and in order to allow normal maintenance to be carried out (as shown on general catalogues).
Attention: in case two units have to be installed side
by side, the distance of respect must be doubled.
After the unit has reached the final position, fix the antivibration bolts.
3.2 PRECAUTIONS FOR DOMINANT WINDS
Avoid obstacles on suction and discharge sides of the
units. Respect the safety distances as shown on the units
dimensional drawings.
In case of presence of dominant winds in the installation
area it is strictly necessary to avoid (for units with horizontal flow fans) that such winds blow in front of the unit (fans
discharge side). In case of unit with vertical flow fans it is
strictly necessary to avoid installations where the dominant
winds could cause rejected hot air to come back to the
condensing coils.
4. CONTROL OF COMPRESSOR
FASTENING
The mains power supply characteristics have to match the
unit’s absorption. The mains power supply tension must
correspond to the nominal value ± 10%, with a maximum
difference between the phases of 3%.
5.2 POWER CONNECTIONS
Protect the unit electric box power supply circuit with protection devices (not included in the supplied equipment)
Connect the line terminals with a three-core cable of a
section, which is appropriate to the machine absorption.
The switch and the fuses like all the power connections
must comply with the regulations in force.
5.3 UNBALANCE BETWEEN THE SUPPLY
TENSION PHASES
Do not run the electrical motors when the voltage unbalance between the phases is more than 3%.
Use the following formula to check:
% Voltage unbalancement =
(Max.voltage deviation from deviation / voltage average)
*100
Important:
If the mains voltage has an unbalance of above 3%,
contact the company, which distributes the electrical
energy. If the unit functions with a unit voltage unbalance between the phases of above 3% the guarantee
is invalid.
CoolPacket
Installation, water and electric connections
6. water connections for airwater and water-water units
6.1 EVAPORATOR
The connection tubes have to be supported adequately in
order that their weight does not damage the plant. The following parts have to be installed on the water circuit of the
evaporator:
• Two pressure gauges of adequate scale (in and out of the
unit)
• Two shock-absorbing joints (in and out of the unit)
• One shut off valve (normal one in input)
• One setting valve (in output)
• Two thermometers (in and out)
• One circulation pump
• One safety valve on the water buffer
• One automatic air vent valve
• One expansion tank
• An inlet filter placed as near as possible to the evaporator
flange
• One flow switch
The above-mentioned installation indications represent
necessary conditions for the guarantee to be valid.
REMAK is at your disposal to examine any different
requirements, which have to be approved before starting
up the chiller.
It is necessary that the water flow rate to the unit is compatible with the evaporator one. It is also necessary that the
water flow rate is kept uniform while the unit is running: it is
suggested to use always a pump system dedicated to the
unit and independent from the remaining part of the plant.
Before stalling units with temperature around 0°C please
evacuate the exchanger with compressed air in order to
avoid breakings due to ice.
P = COOLING (HEATING) CAPACITY OF CHILLER
(HEAT PUMP) IN kW
DT = RDIFFERENTIAL SET ON MICROPROCESSOR
V = MINIMUM WATER CONTENT IN M3
The permitted tolerance for flow rates is equal to 10% of
the nominal.
6.2 WATER CIRCUIT REGULATION
EQUIPMENT
Centrifugal motor pump block
Assures the discharge and the prevalence necessary to
supply tube nest evaporator, the tank and the utility.
Automatic filling unit
Assures the water pressure in the plant is maintained at
least 1.5 bar, automatically resetting it when necessary.
Safety valve
Takes care of opening the plant in atmosphere if the pressure exceeds the value of 6 bar.
Expansion tank
Takes care of compensating small water hammering and
variations of volume for different temperatures.
Check valves
Take care of intercepting the pump for possible maintenance.
6.3 HYDRAULIC DIAGRAM
6.3.1 Hydraulic diagram for units without water tank
6.1A Heat recovery – Desuperheater
The heatexchanger piping must have the same installation
features suggested for the evaporator, both for items to fit
along the line and for information regarding the water flow
rate and the plant water content. (See 6.1c)
6.1B Condenser
Condenser piping must follow the same installation features for the evaporator.
Condensing temperature and water flow rate have to be
in accordance with nominal values, unless the acknowledgement order shows different indications. It is strictly
necessary that in the presence of condenser side dirty or
aggressive water, an intermediate heatexchanger must be
installed before the chiller condenser.
The above mentioned installation suggestions represent the necessary condition to keep warranty validity.
1) Pressure gauges - 2) Shock-absorbing joint - 3) Check
valve - 4) Calibration valve - 5) Thermometer - 6) Water
pump - 7) Safety valve - 8) Filling group - 9) Expansion
tank - 10) Filter – 11) Flow switch – 12) Fixed points
6.1C Calculation of minimum water content and flow
rates
To grant a perfect running, the machine needs a water content achievable using the following formula:
CHILLER
HEAT PUMP
OPTIMAL
MINIMAL
OPTIMAL
MINIMAL
V=P/14DT
V=P/35DT
V=P/7DT
V=P/20DT
CoolPacket
Aeraulic connections
6.3.2 Hydraulic diagram for units with water tank
(SE version)
dical clean up.
8) The inlet air grilles must be selected to give the lowest
possible resistance to the air flow and must be enough
strong to prevent the fins deformation and crushing from
air flow taking place: fins deformation could obstruct the
airflow.
9) In case the grille length exceeds 70-80 cm, a stiffening
comb must be provided.
10) Behind the grille must be installed nets to prevent
birds, rats or foreign body in general entrance.
To allow easy maintenance operations, it is suggested to
install the units keeping free the followings spaces:
1) Water drain - 2) Expansion tank - 3) Water pump - 4)
Check valve - 5) Shut off valve - 6) Evaporator 7) Filling group - 8) Safety valve - 9) Pressure gauges - 10)
Filter* - 11) Shock-absorbing joint - 12) Calibration valve 13) Thermometer - 14) Interception valve – 15) flow switch
– 16) Fixed points
*) Water strainer with meshes not over 2 mm for shell
and tube heatexchanger and not over 0.6mm for plated
heatexchanger. The water strainer is obligatory in order to
keep the warranty.
6.3.3 SUGGESTIONS FOR THE DESIGN OF THE
HYDRAULIC CIRCUIT FOR CONNECTIONS TO
UNITS TYPE „4PIPE“
In case of situations where units “Quattro” are foreseen to
work with low outdoor temperatures and it is not requested
the production of chilled water, should it be necessary the
defrost, it is right to arrange a solution to avoid that the chilled side water tank could reach very low temperatures.
Such a system could be obtained by means of an electric
heater or a water system to mix the water produced from
the hot side.
7. AERAULIC CONNECTIONS
7.1 DUCTS CONNECTION FOR AIR – AIR
UNITS
1) Heatexchanger suction and discharge air ducts must be
as shortest and straightest as possible.
2) The grilles installed on the external suction air must be
projected and constructed to offer the lowest resistance to
the airflow.
3) Right adjustments have to be applied to avoid mixing the
heatexchanger suction and discharging air. Discharge side
must always be upon any air suction. Possibly the discharge should be upside directed.
4) The air through the heat exchanger must not be taken
in proximity to heat sources (condensers, conditioners that
discharge hot air from kitchens etc.).
It is absolutely to avoid taking hot air from the kitchen cause the high percentage of fat, which would get the coils
dirty very quickly.
5) The inlet airside must not be directed towards dusty
areas.
6) The ducts must be leaning to outside to ensure the rain
water drainage.
7) The inlet air duct must be equipped with a removable
panel inside, in order to inspect the coil and to allow perio
a) on the left side of the unit (front sight- horizontal discharge), must be left one meter free to allow the following operations:
- filter replacement;
- Inspection of the direct expansion exchanger and expansion valve.
b) on the opposite side of point a), must be left 70 cm free
to allow the following operations:
- Maintenance, possible fan engine stripping down, belt
and air flow adjustments.
- Hydraulic connection to the drain pan.
- Motor power connections
7.2 DUCTS CONNECTION TO THE INDOOR
UNIT FOR AIR – AIR UNITS
The ducts sizing must take care of the unit nominal air flow.
The connection of the air-handling unit to the ducts network
must be always done through an antivibration joint. It is
suggested to avoid providing diffusion ducts at a distance
less than one meter from the discharge fan. In case of
ducts too short, in order to ensure the possible fan noise
absorption, a kind of baffle can be installed on the duct
bend. In these situation it is also suggested to internally
insulate the ducts with glass wool or other suited materials. The unit is provided with flange on the discharge side,
which allows, by using self-cutting screws, to connect the
antivibration joint.
Ducts and diffusion network will be to installer care.
7.3 CONDENSE DRAIN CONNECTION FOR
AIR – AIR UNITS
All outdoor and indoor units are equipped with drain pan
fitted beneath the exchange coil.
The drain connection on both fronts is 1” female gas.
The drain line to provide must have the same connection
diameter and around a 3% grade in the airflow direction.
On the joint proximity, it is necessary to put a siphon of
equal height of the fans head pressure, in order to avoid
the obstacle to the normal condensing drain and the suction of bad smell that could be easily passed on the ambient.
CoolPacket
Start-up procedures
8. START-UP PRELIMINARY
PROCEDURES
8.1 STARTING CHECK
Before starting the unit, even only momentarily, all the
machinery supplied by the chilled water, like the air handling units, pumps, etc. have to be checked. The pump
auxiliary contacts and the flow switch have to be connected
to the control panel as indicated in the electrical diagram.
Before carrying out interventions on the valve regulations,
loosen the relevant valve gland. Open the discharge valve
of the compressor. Open the liquid shutoff valve placed on
the liquid line. Measure the suction pressure. If it is lower
than 0.42 MPa jumper and strain the solenoid valve on the
liquid line. Bring the suction pressure to 0.45 MPa, then
remove the jumper. Charge all the water circuit progressively. Starts up the water pump of the evaporator with the
calibration valve shut and then slowly open it.
Discharge the air from the high points of the water circuit and check the direction of the water flow. Carry out
calibration of the flow by using a measurer (if present or
available) or by means of a combination of the readings
of the manometers and the thermometers. In the starting
phase calibrate the valve on the pressure difference read
on the manometers, carry out drainage of the tubes and
then carry out fine calibration on the temperature difference
between the water in and the water out. The regulation is
calibrated in the factory for water in to the evaporator at
12°C and water out at 7°C. With the general switch open,
check that the electrical connections are tightly clamped.
Check for any possible refrigerant leaks. Check that the
electrical data on the label correspond to those of the
mains supply. Check that the thermal charge available is
appropriate for starting.
8.2 REFRIGERANT SEALS CONTROL
REMAK units are sent with the complete charge of refrigerant and are at a sufficient pressure to check the seal after
installing. If the system were not under pressure, blow refrigerants (vapour) into it until pressure is reached and look
for leakage.
After having eliminated the leakage, the system has to be
dehydrated with a vacuum pump up to at least 1mm Hg absolute pressure (1 Torr o 133.3 Pa). This is the minimum
recommended value to dehydrate the plant.
Dangers do not use the compressor to vacuum the
system.
8.3 REFRIGERANT CHARGE CHECK
REMAK units are supplied with a complete charge of refrigerant. If bubbles can be seen through the peephole with
the compressor running with a full charge and steadily, it
means that the refrigerant charge is insufficient.
Danger: While refrigerant is being added do not exclude any control system and let the water circulate in the
evaporator to avoid the formation of ice.
Cooling circuit diagram with connection to vacuum pump
8.4 REFRIGERANT CHARGE
8.4.1 Charge with unit stopped and in vacuum
(refrigerant charge in the liquid phase)
Open the shut off valve as far as possible so that it closes
the service coupling. Connect the refrigerant cylinder to the
service coupling without tightening the coupling. Half close
the liquid shut off valve. If the circuit has been dehydrated
and is in vacuum, charge the liquid by turning the cylinder
upside down. Weigh and charge the appropriate quantity.
Open the valve completely. Start up the unit and leave it
running at full charge for some minutes. Check that the
indicator is clear with no bubbles. Make sure that the transparency condition without bubbles is due to the liquid and
not to the vapour. Correct functioning of the unit allows for
overheating of 4 - 7° C and subcooling of 4 - 8°C. Values of
overheating which are too high may be caused by a lack of
refrigerant, whereas high subcooling values may mean an
excess of charge.
After intervention on the charge, it is appropriate to check
that the unit runs within the declared values: with unit
steadily running on a full charge, measure the temperature
of the suction line downstream of the thermostatic valve
bulb; read the balance pressure to the evaporator on the
low pressure manometer and the corresponding saturation
temperature.
Overheating is equal to the difference between the temperatures measured in this way. Then measure the temperature of the liquid line coming out of the condenser and read
the balance pressure to the condenser on the high-pressure manometer and the corresponding saturation temperature. The subcooling is the difference between these
temperatures.
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Start-up
9. START-UP
9.1 PRELIMINARY CONTROLS
Charge in the liquid phase
8.4.2 Refrigerant charge addition with the unit
running (refrigerant charge in the vapour phase)
Warning: charge vapour only. Do not charge liquid because it may damage the compressor.
Connect the refrigerant cylinder to the service valve without
tightening the coupling. Drain the connection piping and
tighten the coupling. Charge each circuit until the indicator indicates liquid without bubbles. Now the unit has the
required charge. Make sure not to over charge the circuit.
Charging more than necessary leads to a higher delivery pressure, greater power consumption and possible
damage to the compressor.
Before starting up the equipment it is very important to
check that all the operations described in the paragraph
“SETTING FOR START UP” have been carried out correctly.
Moreover check that all the mechanical and electric
equipment has been tightened perfectly. Particular
attention should be paid to the main components
(compressor, exchangers, ventilators, electrical
motors, and pump) if loose fastenings are found tighten them well before starting up the machine.
The oil heaters have to be inserted at least 8 hours before
starting up. Ensure that the compressors’ carter is hot.
Open the compressor valve and the cooling circuit one,
which may have been shut for charging. Control all the
machinery connected to the unit.
9.2 STARTING UP
Start up the unit by pressing the ON/OFF button. About
20 seconds pass from the moment in which the start up
request of the unit is given to the moment in which the
(first) compressor starts. Three hundred and sixty seconds
will pass from the last shut down to the next start up of the
same compressor.
Check the rotation direction of the fans and rotative compressors. If it is not the right one, invert two supply phases.
Ensure that all the safety and control equipment is functioning correctly. Control the temperature of the water coming
out of the evaporator and regulate the control setting if
necessary. Control the oil level.
9.3 WARM UP OF THE PLANT FOR UNITS
AIR TO WATER AND WATER TO WATER
Charge in vapour phase
In order to keep all the machine components in good condition and to optimise their use, during the warm up it is
necessary to bring the circuit to the right temperature before releasing cooling energy to the utilities.
The following steps must be followed for this to be carried
out.
* start up the machine
* wait for the water in temperature to reach the running
temperature
* start up the consumers
Follow the above mentioned procedure every time the
plant is stopped long enough for the water temperature
contained in it to rise.
9.3a Warm up for air to air units
Once the units have been installed, ducts connection,
electrical connections (with the relevant electric panel)
carried out, the following steps must be followed to start up
the unit:
1) After making sure that the general switch has been
connected (as suggested on the label put on the electric
panel), switch on the unit through the thermostat in the
requested mode, switching on the electric panel fan.
2) Check the fan rotation direction and in case reverse the
phases on terminals inside the electric panel.
3) Set the thermostat to the required temperature, which
has to be lower than the ambient one in summer mode.
10
CoolPacket
Start-up
In this position, the compressor and the outdoor unit fan
motor start running; check the fan rotation direction and if
it is necessary all the operations concerning the inversion of the phases have to be repeated. Starting from this
moment, while the air handling unit fan will be continuously
running, the outdoor unit will run or will stop according to
the thermostat needs.
4) Once the unit has been started, it is suggested to check
that current absorption values are within the limits shown
into electrical data.
9.4 CONTROL OF THE OIL CHARGE
All the compressors mounted on REMAK units are factory
charged with oil whose chemical characteristic of stability
are very good, so it is not necessary to change frequently
the lubricant oil.
In case of burns for the electrical motor or fault of the compressor, it is necessary to make a test to check the acidity
of the lubricant oil and, eventually, clean the circuit to
reduce the acidity to correct values, mounting for instance
an antiacid filter and changing the oil in the circuit.
Screw compressors
WARNING: the oil into the carter has discharge pressure!
The oil circulation is due to differential pressure; The
minimum oil flow, because the oil still has his lubricant
function and screw seal, is ensured when the compressor
is working into the right limits.
During the start up it is admitted, for few seconds, that the
compressor run without oil but, after 20 seconds from the
start up the differential pressure must be at least 6 bar,
otherwise the compressor is stopped from the microprocessor.
The units equipped with Refcomp compressors, are equipped with a further safety. In fact it is mounted a differential
pressure switch on the oil filter whose set is 3,5 bar. If the
pressure drop through is higher than this value it means
that the filter is dirty and must be changed.
Semi-hermetic reciprocating compressors
When the oil differential pressure cut off switch intervenes,
connect a pressure gauge to the Schrader valve available
on the compressor in correspondence to the pressure cut
off switch connection on the oil pump discharge. With compressor running, read the pressure on this pressure gauge
and the one on the refrigerant low pressure gauge. If the
difference between the two readings is lower than 0.07
MPa and if the oil is not visible on the indicator, lubricant
must be added, after having checked that it did not end up
in the refrigerant circuit due to a functioning anomaly. In
order to carry out an addition of oil, close the liquid shut off
valve and wait for the pressure in the compressor to fall to
0.015 MPa relative, by short-circuiting the low pressure cut
off switch. Wait for a few minutes and repeat the operation
as many times as is necessary to bring the pressure down
to 0.015 MPa. The normal water flow to the evaporator
must be assured during the operation. Close the compressor discharge valve. Connect the Schrader valve placed in
correspondence to the carter near the oil indicator using
a flexible tube to a hand pump immersed in the oil container. Add the necessary quantity of oil, being careful not to
allow foreign bodies or air into the compressor. Disconnect
the flexible tube. Perform a vacuum on the compressor.
Open the shut off valves. Remove the short circuit form the
low pressure cut off switch. Start up the compressor once
again. Let it run for 20 minutes on a full charge and check
the oil level. Using this procedure at 0.015 MPa, a small
quantity of refrigerant gets into the oil. During the addition
of the oil the refrigerant escapes into the atmosphere, blocking the entry of air into the compressor. If the carter shows
no pressure ( 0,015 MPa), once oil charging has finished,
it will be necessary to vacuum the compressor once again
by means of a service connection. When oil charging has
to be completed or repeated, we recommend using only
approved quality oil.
9.5 POWER SUPPLY TO THE AUXILIARY
CIRCUIT
The power supply to the auxiliary circuit is 220V for all the
units. Connection to the power circuit is inside the panel
and is carried out in the factory. The compressor oil heaters, the protections against compressor over temperature
and the cooling water safety indicator are connected so as
to always be operative, as long as the electrical panel is
power supplied.
11
CoolPacket
Maintenance
10 MAINTENANCE
Maintenance operations are fundamental in order to keep
the units running properly, both purely functional and energetically points of view.
Every REMAK unit comes with a logbook, in which the user
or the person delegated to machine maintenance can keep
all the required notes, in order to keep a historical log of
the REMAK unit.
A lack of notes in the logbook could be considered proof of
careless maintenance.
10.1 SIGHT CHECK OF THE UNDER
PRESSURE VESSELS STATE
The risks due to the pressure inside the circuit have benne
eliminated or (when it is not possible) reduced by means
of safety devices. It is important to check periodically the
status of these devices and to carry out the components
inspections and replacement as follows.
Check at least once per year the under pressure vessels
state.
It is important to check that the surface does not get rusty
and that neither corrosion nor deformations are visible.
In case the superficial oxidisation and the corrosion are not
properly controlled and stopped in time, cause a thickness reduction with a consequent reduction of the vessel
mechanical resistance.
Use antioxidant paint or products to protect.
Description of the operations
Control of compressor oil level
Control of the suction temperature (superheating)
Control of the hydraulic circuit water filling
Control of electric absorption fan motors and compressor
Control of power supply and auxiliary power
Control of refrigerant charge through liquid sight glass
Control of the state of the carter electric heaters
Carrying out tightening of all the electrical connections
Coil cleaning
Control of the functioning of the compressor solenoid valves and liquid line
Control of the setting of the regulation and safety thermostat
Control of the state of the fan and compressor contactors
Functional test of the evaporator heater
Noise control of the engine and fan bearings
Pressure tank state checking
Cleanness control for coils and air-filters
Recommended
frequency
monthly
monthly
monthly
monthly
monthly
monthly
monthly
monthly
seasonal
seasonal
seasonal
seasonal
seasonal
weekly
yearly
weekly
Further operations for units with centrifugal fans
Control of the cleanliness of the discharge and circulation ducts
Control of the correct functioning of possible dampers or inlets
Control of the lubrication of the shaft bearings
Control of the pulley - engine and pulley - fan alignment
Control of the tension of the transmission belts; if they are excessively worn they should be replaced
Check that the rotor is centred on the shaft and that it does not touch the Archimedean screw
Control of cleaning if necessary of the fan rotor and Archimedean screw
Control and if necessary tightening of the blocking screws of the engine pulley
Control of the presence of excessive or unusual vibrations
Control of the fan joint seal - outlet
Control of the current absorption of the three engine phases
12
yearly
seasonal
seasonal
seasonal
seasonal
seasonal
seasonal
seasonal
seasonal
seasonal
seasonal
CoolPacket
Recommended spare parts
11. RECOMMENDED SPARE PARTS
There follows a list of the recommended parts for several
years’ running. REMAK is at your disposal to recommend a
personalised list of accessories according to the commissioned order, including the part number of the equipment.
1 year
Components
fuses
filter dryers
solenoid valves
thermostatic valves
pressostats
pressure gauges
contactors and relays
thermal protectors
carter electric heaters
4-way valve
check valve
safety valve
sight glass
fans and engines
Quantity
(all)
(all)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
2 year
Components
fuses
filter dryers
solenoid valves
thermostatic valves
pressostats
pressure gauges
Quantity
(all)
(all)
(all)
(all)
(all)
(all)
contactors and relays
thermal protectors
carter electric heaters
4-way valve
check valve
safety valve
sight glass
fans and engines
electrical components
compressors
(all)
(all)
(all)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
(1 per type)
(all)
(1 per type)
5 year
Components
fuses
filter dryers
solenoid valves
thermostatic valves
pressostats
pressure gauges
contactors and relays
thermal protectors
carter electric heaters
4-way valve
check valve
safety valve
sight glass
fans and engines
electrical components
compressors
heatexchanger
Quantity
(all)
(all)
(all)
(all)
(all)
(all)
(all)
(all)
(all)
(all)
(all)
(all)
(all)
(all)
(all)
(all)
(1 per type)
13
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Safety
12. IMPROPER USES
The unit is projected and built up to grant the maximum
safety in its proximity, as well as to resist to the aggressive
environmental conditions. The fans are protected by grilles.
Residual risks are indicated with warning labels.
SAFETY SYMBOLS
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Troubleshooting
13. TROUBLESHOOTING
Given below is a list of the most common problems and
their causes. These causes are due to cooling system issues, electrical panel issues or safety device failure, in addition to any electronic faults affecting unit operation.
In the event of malfunction, the power supply must be disconnected before carrying out any diagnostics tests.
EFFECT/
PROBLEM
1.
The unit will not
start
2.
Compressor will
not start
3.
Compressor
starts and stops
repeatedly
4.
Compressor
stops due to low
pressure switch
activation
PROBABLE CAUSE
Faulty connection or switches open Incorrect voltage
External signal failure
Faulty service sensor
Faulty anti-freeze sensor
Service thermostat signal failure
Anti-freeze thermostat signal failure
SOLUTION
Check the voltage and close all contacts
Check water circulation pump operation, air out the system
Check component and replace if necessary
Check component and replace if necessary
System at temperature, request failure, check calibration
Check water temperature, check calibration
Check for any short-circuits in wiring or windings of pump motor, comGeneral thermal magnetic breaker override
pressor, fan and transformer
Power grid phases inverted
Invert phases
Power supply line open
Reactivate thermal magnetic breaker
Safety thermostat intervention
Restart thermostat
Contactor blocked
Replace contactor
Terminal blocks loose
Secure terminal blocks
Control connection error
Check connections and rectify if necessary
Check power line voltage, identify and eliminate the cause of low
Low power voltage
voltage
Check voltage supplied to compressor remote switch coil and coil
Compressor remote switch off
continuity
Check to see if motor connections are open or short-circuited.
Compressor motor failure
Replace compressor if necessary
Compressor seized or burnt
Replace compressor
Check cooled water pump and flow meter and check flow meter
Cooled water flow meter open
controller settings
Mechanical damage due to lack of lubricant Consider installing oil separators Top¬up oil
Lack of fluid circulation
Check fluid status
Check for any short¬circuits in wiring or windings of pump motor,
Power circuit open
compressor, fan and transformer
Compressor has been run in critical conditions or there is insufficient
Motor thermal protection open
load in the circuit: check to see if running conditions fall within operating limits
Check cooling circuit using leak detector (electronic if available) once
Lack of cooling gas
the circuit is set to a pressure of around 4 bar; repair, empty system
and reload
Minimum pressure switch active
See point 5
Faulty compressor remote switch
Check and replace if necessary
Change values according to manufacturer indications or to within the
Incorrect set point calibration values
established operating limits
Check cooling circuit using leak detector (electronic if available) once
Lack of cooling gas
the circuit is set to a pressure of around 4 bar; repair, empty system
and reload
Increase differential setting, check to see if wiring is cut or replace
Low pressure switch malfunction
instrument
Pressure switch visibly out of service
Check and replace if necessary
Compressor suction valve partially closed Open compressor suction valve
Cooling filter blocked
Check and replace if necessary
Compressor suction filter blocked
Clean filter
Ice build¬up inside evaporator circuit
Check anti¬freeze solution or for damage
Check cooling circuit using leak detector (electronic if available) once
Little or no cooling gas present
the circuit is set to a pressure of around 4 bar; repair, empty system
and reload
Finned battery obstructed, capacity too low Remove dirt from battery
Water circulation pump blocked
Unblock rotor
Water circulation pump not working
Check and replace if necessary
Expansion device not working correctly
Check, recalibrate and replace if necessary
Presence of humidity in cooling circuit
Replace filter and dry/reload if necessary
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CoolPacket
Troubleshooting
Check to see if wiring is cut or replace instrument, recalibrated
instrument
Pressure switch visibly out of service
Check and replace if necessary
5.
Compressor supply valve partially closed
Open compressor supply valve
Compressor
Cooling filter blocked
Check and replace if necessary
stops due to high
Excess cooling gas
Discharge excess gas
pressure switch
Finned battery obstructed, capacity too low Remove dirt from battery
activation
Water circulation pump blocked
Unblock rotor
Water circulation pump not working
Check and replace if necessary
Presence of condensable gas in cooling
Reload circuit once discharged and placed under vacuum
circuit
6.
Frosted liquid
Liquid filter blocked
Replace filter
pipe downstream
from a filter
Check cooling circuit using leak detector (electronic if available) once
Lack of cooling gas
the circuit is set to a pressure of around 4 bar; repair, empty system
and reload
7.
Operating thermostat incorrectly calibrated Check calibration
Unit runs without
Excessive thermal load
Reduce thermal load
switching off
Compressor does not provide established
Check, replace or repair
output
Liquid filter blocked
Replace filter
Check cooling circuit using leak detector (electronic if available) once
8.
Insufficient coolant load
the circuit is set to a pressure of around 4 bar; repair, empty system
Unit runs regularand reload
ly but at insufficiCheck power supply and valve coil, check valve and replace if
Defective 4-way inversion valve
ent capacity
necessary
Expansion device not working correctly
Check, recalibrate and replace if necessary
Water circulation pump not working
Check and replace if necessary
9.
Check cooling circuit using leak detector (electronic if available) once
Compressor
Insufficient coolant load
the circuit is set to a pressure of around 4 bar; repair, empty system
suction tube
and reload
frosted
Liquid filter blocked
Replace filter
Water circulation pump blocked
Unblock rotor
10.
Check power supply and valve coil, check valve and replace if
Defective 4¬way inversion valve
Unit never runs
necessary
Check and reset parameters
defrosting cycle Incorrect calibration values
11.
Unusual noises
Compressor noisy
Check and replace if necessary
in system
High pressure switch malfunction
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CoolPacket
Notes
Printing and language mistakes are reserved.
These Installation and Operating Instructions (as a whole or a part) must not be printed or copied without prior
written permission from REMAK a. s., Zuberská 2601, Rožnov pod Radhoštěm, Czech Republic.
These „Installation and Operating Instructions“ are the sole property of REMAK a. s.
The up to date version of this document is available at our website: www.remak.eu
Changes reserved.
Issued: 9th August, 2010
17
REMAK a.s.
Zuberská 2601, 756 61 Rožnov pod Radhoštěm,
tel.: +420 571 877 778, fax: +420 571 877 777,
email: remak@remak.eu, internet: www.remak.eu
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