USER MANUAL Intelecool 2
Contents
1. PROBLEM PROBABLE CAUSE REMEDY Unit will not start No power to unit Check voltage to input terminal block Control voltage circuit breaker open Locate short amp reset breaker Shut off by external Thermostat or stat is Defective Check operations of thermostat No cooling Low refrigerant charge Check with gauges Compressor contactor Check voltage at contactor not pulling in If not present then refer to Print amp determine voltage loss Check enthalpy sensor for full CCW No output from Thermostat Check operation of stat Should have voltage output to Y terminal during cooling Units cycles on High Loss or restriction of airflow Check condenser blower assembly Pressure Switch for proper operation Check for dirty filter or inlet grille restriction Defective fan cycling control Switch should make 240 PSIG 18 Intelecool 2 User Manual 31 07 2003 6 0 COMMISSIONING PREVENTIVE MAINTENANCE CHECKLIST INTELECOOL Customer Date Site address Controller Details Make Model Controller Sr Sl Commissioned by Please tick after each check is done Physical checks Installation of machines Sealing of gaps around the units Controller fitment Grilles fitment Electrical trunking fitment Cleanliness of air filter Cleanliness of evaporator coil Cleanliness of condenser coil Insulation fitment Fan rotation2. 50 Hz 10 50 Hz Motor full load current 0 65 Amps 0 65 Amps Motor speed RPM 910 910 Material of fins Aluminum Aluminum Thickness of fins 0 12 mm 0 12 mm Fin pitch 12 FPI 12 FPI Gauge of the tubes 30 Gauge 30 Gauge Tube OD 3 8 Inch 3 8 Inch Material of the tube Copper Copper FILTER Number of filters 1 1 Size in mm 415 x 800 x 40 415 x 800 x 40 Material Dry media Disposable Polyester Dry media Disposable Polyester Fabric Fabric Efficiency 80 down to 20 microns 80 down to 20 microns CABIENT INSULATION Minimum thickness mm 10 amp 12 10 amp 12 Material EPE Fibre glass EPE Fibre glass ELECTRICAL DATA Supply Three phase 415VAC Three phase 415VAC 10 50 Hz 10 50 Hz Full load current All components rated amps 8 7 Amps 5 8 Amps PHYSICAL SIZES Width x Height x Depth mm 984 x 1770 x 462 984 x 1770 x 462 Weight kg 170 140 UNIT CONSTRUCTION Mounting type Wall mounting Wall mounting Air delivery Horizontal discharge Horizontal discharge Cabinet Material 1 2 8 1 6 mm CRCA 1 2 amp 1 6 mm Surface finish Powder Coated Powder Coated Colour Siemens Grey Siemens Grey Paint thickness 50 microns 50 microns Intelecool 2 User Manual 31 07 2003 21
3. COMPRESSOR Number of Compressors 1 1 Type Compliant Scroll Compliant Scroll Compressor Operating Voltage Three phase 415VAC 10 50 Hz Three phase 415VAC 10 50 Hz Input Current per Phase 7 2 Amps 4 3 Amps Refrigerant R22 R22 Safety Controls LP 20 Psig 20 Psig HP 400 Psig 400 Psig Protections Built in thermal over load Built in thermal over load EVAPORATOR FAN SECTION Nominal air flow on filter 1600 CFM 1000 CFM Number of fans motors 2 Nos 1 No 2 Nos 1 Motor Opearating Voltage Three phase 415VAC Three phase 415VAC 10 50 Hz 10 50 Hz Motor full load current 0 85 Amps 0 85 Amps Motor Speed 910 rpm 910 rpm Type of fan Forward Curved DIDW Forward Curved DIDW EVAPORATOR COIL Face area 3 19 Sq Ft 3 19 Sq Ft Face Velocity 492 FPM 313 FPM Material of fins Aluminum Aluminum Thickness of fins 0 12 mm 0 12 mm Type of fin Super slit Super slit Fin pitch 12 FPI 12 FPI Gauge of the tubes 30 Gauge 30 Gauge Tube OD 3 8 Inch 3 8 Inch Material of the tube Copper Copper AIR COOLED CONDENSER Condenser coil Face area 5 50 Sg Ft 5 50 Sg Ft Nominal air flow 2750 CFM 2320 CFM 20 Intelecool 2 User Manual 31 07 2003 Face Velocity 467 FPM 422 FPM Motor Operating Voltage Three phase 415VAC Three phase 415VAC 10
4. 31 07 2003 11 2 4 CHECKLIST FOR COMPLETED INSTALLATION 12 PA HO O Proper clearance for service access has been maintained Equipment is leveled and mounting fasteners are tight Refrigerant piping is completed as per standard engineering practices Refrigerant leak test and charging is done if required Ducting completed if required Line voltage to power wiring matches equipment nameplate Power wiring connections completed to disconnect switches including earth Proper phase rotation has been observed so that scroll compressor will rotate in the correct direction Power line circuit breakers or fuses have proper ratings for equipment installed Control wiring connections completed to optional controls All wiring connections are tight Foreign materials have been removed from in and around all equipment installed shipping materials construction materials tools etc Fans and blowers rotate freely without unusual noise Complete Commissioning as per Commissioning Check List Intelecool 2 User Manual 31 07 2003 3 0 OPERATION 3 1 Compressorized Cooling Compressorized cooling is provided by a high efficiency system consisting of a scroll compressor thermostatic expansion valve evaporator 4 condenser coils A scroll compressor is used for reliable quiet amp smooth operation at a high EER value Energy Efficiency Ratio The Intelecool uses R 22 refrigerant in a conventional vapour
5. Condenser fan rotation Compressor rotation Blower fan free rotation Unit vibration if any cede Please mention the values wherever necessary Electrical Incoming voltage volts Loose connection Earthing of units Earthing of controller Total unit current amp Blower fan current amp R Condenser fan current amp R Compressor current amp R relay settings amp Fan Condenser Compressor Mechanical readings Refrigerant pipes rubbing Compressor suction pressure psig Oil trace refrigerant leak if any Compressor discharge pressure psig Drain pipe clear for water movement Room temperature C Unit changeover Remarks Controller settings Mode of operation Unit selection O L trip settings amp Cycling hours hr Temp set points C Customer s signature Signature of CSE Intelecool 2 User Manual 31 07 2003 19 TECHNICAL SPECIFICATIONS INTELECOOL FOR TTSL THREE PHASE UNITS UNIT CAPACITY 3 5 TR with 910 rpm Blower Motor amp 2 TR with 910 rpm ZR47 Blower Motor 8 ZR 26 3 Phase Comp 3 Phase Comp Total Capacity TR 3 5 2 0 Sensible Capacity TR 3 0 1 9 Sensible Heat Ratio 0 86 0 95 Total Power Input kW 3 95 2 25 Specific Power Consumption kW Sensible Cooling 1 31 1 18 Capacity in TR DESIGN CONDITIONS Room Condition 24 C 24 C Standard Operating Ambient 35 C 35 C
6. compression refrigeration cycle Heat is removed from the air in the space by blowing it across the evaporator coil As heat is added to the refrigerant in the evaporator it boils and turns to a warm vapour The refrigerant vapour enters the compressor and is compressed resulting in high pressure 4 temperature After entering the condenser the hot vapour is condensed to a liquid by the air blown across the condenser coil Liquid refrigerant then passes through the thermal expansion valve and into the evaporator The expansion reduces the pressure and temperature to complete the cycle 3 2 High Pressure The high pressure switch is mounted in the compressor discharge line Electrically it is connected in the series with the compressor start circuit which will shut down the compressor and condenser fan if the discharge pressure exceeds 400 PSIG This protects the Intelecool in the event of condenser motor failure or the condenser coil breakage The pressure switch is an auto reset device When the system pressure drops below 320 PSIG the switch will reset controller is used the high pressure switch has to be reset manually 3 3 Low Pressure The low pressure switch is mounted in the compressor suction line Electrically it is connected in series with the compressor start circuit which will shut down the compressor and condenser fan if the suction pressure drops below 20 PSIG This protects the Intelecool in the event the evaporator fan fails
7. troubleshooting a compressor check all electrical components for proper operation 1 Cheek all fuses and circuit breakers 2 Check hi Low Pressure switch operation 3 Ifa compressor failure has occurred determine whether it is an electrical or mechanical failure Intelecool 2 User Manual 31 07 2003 15 Mechanical failure A mechanical compressor failure will be indicated by no burned odour The motor will attempt to run If you have determined that a mechanical failure has occurred the compressor must be replaced Electrical Failure An electrical failure will be indicated by a distinct pungent odor If a severe burnout has occurred the oil will be black and acidic In the event that there is an electrical failure and a complete burnout of the refrigeration compressor motor the proper procedures must be performed in order to clean the system to remove any acids that would cause a future failure CAUTION Damage to a replacement compressor caused by improper system cleaning constitutes abuse under the terms of the warranty and the WARRANTY WILL BE VOIDED CAUTION Avoid skin contact with the gas and oils Severe burns will result Use long rubber gloves when handling contaminated parts Compressor Replacement Replacement compressors are available from your nearest Emerson Network Power India Private Limited office They will be shipped in a crate to the job site by franchisee 1 Disconnect power 2 Attach suction a
8. USER MANUAL Intelecool 2 4 EMERSON Network Power Plot No C 20 Road no 19 Wagle Industrial Estate Thane West 400604 Maharashtra India Phone 91 22 25828405 25802388 25807000 Fax 91 22 25828358 25800829 QS SP PRD 3 05 00 iebert ool L ntelec 0 Intelecool 2 User Manual 31 07 2003 CONTENTS Introduction Installation Operation Maintenance Troubleshooting guide Commissioning preventive maintenance checklist Intelecool 2 User Manual 31 07 2003 1 INTRODUCTION 1 1 GENERAL The Emerson Network Power India Private Limited Intelecool environmental control system 15 designed for convenience and dependability in unmanned and remote locations typical of the telecommunications industry Ease of installation operation and service coupled with the use of high quality high reliability components make Intelecool ideally suited for maintaining an environment for sensitive electronic equipment Self Contained The Intelecool product is completely self contained All components are enclosed in the weatherproof cabinet Space Savings The Intelecool does not use any of the valuable floor space inside the secure space Instead it is mounted on the outside wall No additional space is required outside or on a roof Easy to Install The Intelecool is assembled wired pipes charged with refrigerant and fully factory tested as a system to ensure trouble free installation and star
9. ch bolts and nuts not supplied through holes provided in unit base WARNING Use caution and adequate equipment to safely handle the unit Weight of each unit ranges from 145 to 215 kg depending on the model CAUTION Do not over tighten mounting bolts Over tightening may result in damage to gasket or unit cabninet Caulk and flash top and sides as required to form a watertight seal Top flashing not factory supplied is recommended to ensure water does not run behind the unit Intelecool 2 User Manual 31 07 2003 9 2 3 2 Piping connections The Intelecool is a self contained packaged unit All refrigerant piping connections are made at the factory so no external condenser 15 required The evaporator coil condensate is factory supplied and drains outdoors through the unit base pan Oil to be provided depending upon locations of the indoor amp outdoor units Note during commissioning the system pressures must be maintained as follows Suction 70 to 80 psig Discharge 280 to 300 psig 10 Intelecool 2 User Manual 31 07 2003 2 3 3 Electrical connections Each unit is shipped from the factory with all internal wiring completed Refer to electrical schematic when making connections Electrical connections to be made at the installation site are i Line power supply to the power input ii Controller wiring in case of optional two unit controller customer supplied or Liebert option WARNING Use v
10. d with customary HVAC wiring designations R G W Y inside low voltage partition of the unit electric box The control interface can be provided by source ranging from a wall mounted thermostat or a controller 1 3 OPTIONAL FEATURES Micro control A micro control can be supplied which will ensure control up to a maximum of two units Indoor Supply Return Grilles In Intelecool the supply grille is an aluminium louvered double deflection type grille allowing user adjustment of direction of air distribution The return grille is an aluminium louvered adjustable single deflection style grille Intelecool 2 User Manual 31 07 2003 5 1 4 DIMENSIONAL DATA 450mm 1770mm 200000000 099999999 000000000 000000000 200000000 000000000 000000000 200000000 6 Intelecool 2 User Manual 31 07 2003 2 HOLE O 12 5 CUTOUT TO BE MADE WALL F i 133 4 717 ore 3 1 DIO Cm GOR CUTOUT TO BE il MADE IN WALL COR 00 4 O 45 O Q 144 65 691 8 147 35 10 66 962 49 10 66 983 8 Intelecool 2 User Manual 31 07 2003 2 INSTALLATION 2 1 INSTALLATION CONSIDERATIONS Room Preparation The room should be well insulated and should be sealed to reduce airborne contaminants from penetrating the site Uncontrolled outside air should be kept to a minimum Outside air adds to the coo
11. iency of the unit 8 can result in high compressor head pressure amp loss of cooling Clean the condenser coil each time the evaporator filters are replaced Cheek for bent or damaged coil fins and repair as needed Check all refrigerant lines for leaks Clean the condenser coil of all debris that will inhibit airflow This can be done with compressed air or commercial coil cleaner For access to the coil first remove the top panel by rotating two fasteners Remove the condenser grille by pulling it up and forward Remove the middle panel by removing screws and then pull panel down and forward Removing the top condenser coil blocker will enable inspection and cleaning of the backside of the coil Replace all panels in reverse order 4 5 Compressor Replacement Infrequently a fault in the motor insulation may result in a motor burn but in a properly installed system burnouts rarely occur Of those that do most are the effects of mechanical or lubrication failures resulting in the burnout as a secondary consequence If problems that can cause compressor failures are detected and corrected early a large percentage can be prevented Periodic maintenance inspections by alert service personnel on the lookout for abnormal operation can be a major factor in reducing maintenance costs It is easier and far less costly to take the steps necessary to ensure proper system operation than it is to allow a compressor to fail and require replacement When
12. ling heating and filtration loads of the site Doors should be properly sealed to minimize leaks and should not contain grilles Location considerations The Intelecool is field mounted on an outside wall and additional framing in the wall may be required to ensure adequate structural support The outdoor area near the condenser supply and discharge must also be considered To ensure adequate air supply the unit should be mounted in a clean area away from loose dirt and foreign matter that may clog the condenser unit Unit should not be located near steam hot air or fume exhausts Also the unit should not be mounted closer than 12 feet from an opposing wall obstruction or unit For service clearance provide 36 inches in front of the unit and 30 inches on each side When mounting multiple units side by side provide a minimum of 36 inches between adjacent units 2 2 EQUIPMENT INSPECTION Upon arrival of the unit inspect all items for visible damage Concealed damage may be discovered later during installation Report damage to the shipper immediately and file a damage claim Also inform your Liebert supplier 8 Intelecool 2 User Manual 31 07 2003 2 3 UNIT INSTALLATION 2 3 1 Unit mounting The Intelecool unit is installed against and through outside wall Two openings in the wall are required for the evaporator supply and return Install unit in a level position to assure proper refrigerant flow oil return and condensate drain T
13. most cases evidence of malfunction is present prior to component failure periodic inspections can be a major factor in the prevention of most system failures Refrigerant Lines Check all refrigerant lines and capillaries for vibration isolation amp support as necessary Visually inspect all refrigerant lines for leaks Thermostatic Expansion Valve The thermostatic expansion valve TEV keeps the evaporator supplied with enough refrigerants to satisfy load conditions It does not turn the compressor on or off but correct valve adjustment is necessary for proper system operation Determine TEV operation by measuring superheat see Superheat If too little refrigerant is being fed to the evaporator the superheat will be high if too much refrigerant is being supplied the superheat will be low The correct superheat setting is between 10 and 13 F 5 5 and 7 2 C Superheat To determine superheat Measure the temperature of the suction line at the point where the TEV bulb is clamped Obtain the gauge pressure at the compressor suction valve Add the estimated pressure drop between bulb location and the suction valve Convert the sum of the two pressures to the saturated temperature Subtract this temperature from the actual suction line temperature The difference is superheat 14 Intelecool 2 User Manual 31 07 2003 4 4 Air Cooled Condenser Restricted airflow through the condenser coil will reduce the operating effic
14. nd discharge gauges to access fittings 3 Recover refrigerant using standard recovery procedures and equipment Use a filter drier when charging the system with recovered refrigerant 4 Remove pressure switch capillaries and disconnect all electrical connections 5 Remove failed compressor CAUTION A scroll compressor must rotate in the proper direction Record compressor motor connections when removing failed compressor Wire the replacement compressor motor the same way to maintain proper rotation direction Install replacement compressor and make all connections Pressurize and leak test the system at approximately 350 PSIG pressure Follow manufacturer s instructions for cleanout kits oN Connect vacuum pump to both the high and low sides of the system through properly sized connections Evacuate the system twice Break the vacuum each time with R 22 Refrigerant gas 16 Intelecool 2 User Manual 31 07 2003 10 Charge the system with refrigerant 12 Apply power amp operate system Check for proper operation Refer to design pressures in the following table OUTDOOR AMBIENT OF C Design pressures PSIG kPa 95 35 105 40 6 115 46 1 Discharge 290 2000 330 2275 370 2550 Suction 73 505 75 520 77 530 Note Based on indoor conditions of 80 SF 26 7 C 50 RH and clean coils Intelecool 2 User Manual 31 07 2003 17 5 0 TROUBLE SHOOTING GUIDE
15. o install the Intelecool unit follow the instructions below a b C h Verify that an adequate structural support is provided for the unit Using a chalkline mark the outside wall with a level horizontal line where the bottom of the unit is to rest Prepare supply and return openings in an outside wall Refer to the drawing for your unit to determine opening dimension and location Prepare two upper mounting holes either at the top or midsection of the unit The mounting holes may be pilot holes for lag screws or clearance holes for bolts that will extend completely through the wall 5 8 for 1 2 bolts Note that the outside of the top holes will be accessible only through the supply opening from inside the room once the unit is placed against wall The middle holes can be accessed from outdoors when the top front panel is removed Screw Bolt unit mounting base angle to the outside wall with six 5 16 bolts just below chalkline and centered below the holes made in steps 2 and 3 Apply gasket tape around perimeter of the unit back and the evaporator supply and return openings With the unit front panel removed rotate two fasteners lift the unit onto the base angle making certain that the rear unit foot falls behind the turned up front edge of the mounting angle Insert top or mid unit fasteners in holes and tighten drawing the unit into place If desired the unit can be secured to the mounting angle with two 5 16 in
16. oltmeter to make sure power is turned off before making any electrical connections CAUTION Refer to electrical schematic when making connections 2 3 4 Power connections All power wiring control wiring and ground connections must be in accordance with the National Electric Code and local codes Use copper wiring only Make sure that all the connections are tight Make sure that the voltage supplied agrees with the voltage specified on the unit nameplate A power disconnect switch field supplied is required for maintenance For access to the electrical enclosure first remove the top panel by rotating two locks Remove the condenser grille by pulling it up and forward Remove electrical box cover on right side by removing Screws Route the supply power to the customer supplied disconnect switch and then to the unit circuit breaker or terminal block inside the unit Route the conduit to the hole provided in the cabinet Connect earth ground to lug provided near circuit breaker or terminal block Refer to the unit wiring diagram supplied along with the unit CAUTION The scroll compressor must be rotating in the correct direction for proper operation This is determined by the way three phase power supply is supplied to the unit at installation 2 3 5 Control connections In case of an optional unit controller the Control wiring needs to be done The controller may be a factory field supplied Intelecool 2 User Manual
17. t up 1 2 STANDARD FEATURES Compressor The heart of the refrigeration system is a quiet efficient Scroll compressor The compressor operates at 2900 RPM 50 Hz and features suction gas cooled motor internal centrifugal oil pump Vibration isolating mountings internal thermal overloads high 8 low pressure switches Refrigeration System The refrigeration circuit includes a liquid line filter drier an adjustable externally equalized expansion valve and high and low pressure switches Evaporator Coil The evaporator coil is constructed of mechanically expanded copper tubes in enhanced surface aluminium fins 4 Intelecool 2 User Manual 31 07 2003 Condenser Coil The air cooled condenser coil is constructed of mechanically expanded copper tubes in enhanced surface aluminium fin Condenser Coil Evaporator Blower AN Evaporator Blower Evaporator air is supplied by a dual direct drive blower package The fans are centrifugal double width double inlet Filter The filter is 2 inches deep pleated with a minimum efficiency rating of 80 85 down to 20 microns based on ASHRAE standard 52 76 located within the cabinet Cabinet The Exterior cabinet is constructed of CRCA and power coated for weather resistance Internal structural parts are hot dipped galvanized steel The evaporator compartment is insulated with 72 thick EPE Expanded poly ethylene Control Interface The unit is supplie
18. the filter becomes clogged or there is a loss of refrigerant The pressure switch is an auto reset device When the system pressure rises above 60 the switch will reset If controller is used the low pressure switch and compressor are connected separately and the signal is given by the controller for compressor Start Stop depending on the signal from the switch If controller is used the low pressure switch has to be reset manually Intelecool 2 User Manual 31 07 2003 13 4 0 MAINTENANCE 4 1 Filters In Intelecool a replaceable evaporator air filter is supplied with the unit The filter is easily serviceable from the outside through the top front access panel Filters are usually the most neglected item in an environmental control system To maintain efficient operation they should be checked monthly and changed as required Units supplied with economizers may require replacement filters more frequently because of airborne dust and organic materials 4 2 Blower Package Periodic checks of the blower package include Blower wheels housings motor and motor mounting bracket With the power off inspect and remove any debris removed from the wheels and housings Also check to see that they are tightly mounted on the motor shaft and rotate freely without rubbing against the housing 4 3 Refrigeration System Each month the components of the refrigeration system should be inspected for proper function and signs of wear Since in
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