FläktGroup Multi-DENCO Operation Manual Download Page 112

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Appendix

Multi

-DENCO

112

FläktGroup DC-2013-0101-GB • Subject to modifications • R4-05/2018

13.2 Pressure Test Certificate (DQA 653)

GEA Heat Exchangers Limited

Telephone: +44 (0) 1432 277277

Fax: +44 (0) 1432 268005

Customer

Site Address

Contract Number

Air Handling Unit Reference

Air Handling Unit Type

Condenser Unit Type

We certify that the following pressure tests have been completed with dry nitrogen

Remarks

DQA653 Rev DH1

Circuit

Date

Test Witnessed by :

Pressure

Duration of Test

Pressure Test Certificate

Dolphin House - Moreton Business Park

Moreton on Lugg - Hereford - HR4 8DS

Test Carried out by :

Company

Signature

Name

(Block Capitals)

Summary of Contents for Multi-DENCO

Page 1: ...Multi DENCO OPERATION MANUAL ...

Page 2: ...es 25 2 9 Spare parts 25 2 10 Disposal 26 2 11 Personnel selection and qualification 26 2 12 Noise 26 2 13 Environmental considerations 26 3 Technical Description 27 3 1 Unit description 27 3 2 Operating limits 28 3 3 Operating modes 28 3 4 Operating strategies 29 3 5 Components 31 3 6 Heat rejection systems 33 4 Shipping and Storage 35 4 1 Delivery 35 4 2 Handling 35 4 3 Storage 36 5 Installation...

Page 3: ...nance access 98 10 2 Servicing 98 10 3 Refrigerant leak testing 100 10 4 Compressor care 100 10 5 Humidifier maintenance if fitted 100 10 6 Closing down procedure 101 10 7 Logbook EU Regulation 102 11 Fault Finding and Troubleshooting 103 11 1 Common Issues 104 12 Dismantling and Disposal 106 12 1 Dismantling 106 12 2 Disposal 107 13 Appendix 108 13 1 Pre Commissioning Checklist DQA 880 109 13 2 P...

Page 4: ...r control Humidifier Filter Fan Heating Power supply D DENCO M Multi DENCO A Air cooled C Chilled Water X Split System 010 Size 010 018 Size 018 030 Size 030 045 Size 045 065 Size 065 092 Size 092 130 Size 130 D Downflow U Upflow P Front full height panel F Front air inlet grille panel L Front low level air discharge panel S Standard heat exchanger C CombiCool L Large heat exchanger I Inverter com...

Page 5: ...e refrigeration Refrigerant leakage detection Compressor soft start Service connections D DENCO M Multi DENCO RE Refrigeration D R410A 1 Single circuit N Small compressor C Standard compressor N Not fitted E Electronic expansion valve N Not fitted S Shut off valves compressor and liquid line L Shut off valve liquid line S Solder connections T Twin solder connections L Refrigerant leakage detection...

Page 6: ...nections BSPT G Flange pipework connections PN06 F Flange pipework connections PN16 S Solder connections N Not fitted T Temperature monitoring probes N Not fitted 2 2 way water valve P 2 way water valve pressure independent 3 3 way water valve with bypass B 3 way water valve with bypass regulating valve N Not fitted D DODC actuator 0 0 10 V actuator drive open spring return N Not fitted C kv 1 0 D...

Page 7: ...pipework connections G Flange pipework connections PN06 F Flange pipework connections PN16 S Solder connections N Not fitted T Temperature monitoring probes N Not fitted 2 2 way water valve P 2 way water valve pressure independent 3 3 way water valve B 3 way water valve with bypass regulating valve N Not fitted D DODC actuator 0 0 10 V actuator drive open spring return N Not fitted C kv 1 0 D kv 1...

Page 8: ... spot sensors and drain pan sensor 6 Water detection 6 spot sensors and drain pan sensor N Not fitted 1 Return Air T H sensor 2 Return Air T H sensor 10 m cable 7 Return Air T H Supply Air Temp sensors 8 Return Air T H Supply Air T H sensors 10 m cable 9 Return Air T H Supply Air Temp sensors 10 m cable A Return Air T H 10 m cable Supply Air Temp sensors B Return Air T H 10 m cable Supply Air T H ...

Page 9: ... L Lower display position N Not fitted R White O Other unit colour special G Filter differential pressure gauge N Not fitted 1 Top air discharge protection grille Eyelash 2 Top air inlet protection grille Eggcrate D Air damper P Prepared for loose air damper N Not fitted S Standard panels A Acoustic insulation panels N Not fitted S Standard packaging Domestic E Wooden crate packaging Export P Stan...

Page 10: ... 265 V N PE 60 Hz 5 1 230 V N PE 50 Hz 6 3 460 V N PE 60 Hz 7 3 400 V N PE 60 Hz W Winter kit 40 C ambient D Winter kit with double pressure relief valve 40 C ambient N Not fitted B Blygold heat exchanger coating E Epoxy heat exchanger coating N Not fitted N Not fitted R Aluzinc O Other unit colour special S Standard packaging Domestic E Wooden crate packaging Ex port H Horizontal airflow V Vertic...

Page 11: ...set FI7 F7 Spare filter set FI4C G4 Spare filter set FI7C F7 Spare filter set REM Remote monitoring touch screen display TOU Touch up paint kit D10 Ceiling connection duct 100 mm D15 Ceiling connection duct 150 mm D20 Ceiling connection duct 200 mm D25 Ceiling connection duct 250 mm D30 Ceiling connection duct 300 mm D35 Ceiling connection duct 350 mm D40 Ceiling connection duct 400 mm D45 Ceiling...

Page 12: ...ENCO O Chilled water OfficeCool H Split System OfficeCool 010 Size 010 018 Size 018 030 Size 030 045 Size 045 D Downflow U Upflow P Front full height panel S Standard heat exchanger H Heat pump heat exchanger N Not fitted S Steam humidifier standard conductivity L Steam humidifier low conductivity H Steam humidifier high conductivity N Not fitted 4 Filter G4 7 Filter F7 W Filter washable G4 P EC p...

Page 13: ...rnal casing This identification plate carries information that is important and unique to the unit Upon receipt of your equipment it is important to check the MODEL NUMBER a shor tened version called Model Type Code is shown on the serial plate prior to positioning and installation to ensure it matches your requirements Any discrepancies should be reported immediately to your representative Refer ...

Page 14: ... as standard fitted in indoor unit Electronic expansion valve as standard fitted in indoor unit Typically supplied with an outdoor condenser C Version Water based cooling Can operate with Glycol A method of heat rejection separate to Multi DENCO unit e g Chiller Can be provided with 3 way 2 way or 2 way PICV valves and a variety of actuators X Version Refrigeration based cooling R410A used as stan...

Page 15: ...o Indoor unit of Multi DENCO configuration with associated internal options pre installed unless requiring placement external to the unit or further installation in which case hardware is provided loose within the unit Outdoor unit Optional a condenser condensing unit or drycooler to act as a heat rejection unit for the system Unit documentation A copy of the current operation manual indoor and or...

Page 16: ...to standards and regulations are made within this manual These may be updated or revised by the relevant bodies after publication of this manual In all instances review the latest versions for any relevant updates EC No 842 2006 EN 378 DIN EN ISO 3745 2014 68 EU 2006 42 EC 2014 30 EU 2014 35 EU EN 12735 1 2010 EN 60204 1 2006 A1 2012 EU No 517 2014 2008 98 EC 2012 19 EU ...

Page 17: ...rson working on the equipment must read this manual fully before commencing the work and take note of all relevant information while performing a task The operation manual is intended to be used by fitting and installation companies buil ding services engineers technical personnel or trained persons as well as electrical and refrigeration engineering specialists 2 2 Scope of the operation manual T...

Page 18: ...is symbol is used to indicate normal lists This symbol indicates instructions to follow 9 The result of an action is indicated with this symbol NOTE Please refer to Controls Operation Manual for details about software and control operation of your Multi DENCO NOTE This manual is valid only for configurations built from our standard catalogue Any units designed or supplied under special configurati...

Page 19: ...4 1 Mandatory Signs 2 4 2 Prohibition Signs General Mandatory Sign Refer to manual or documentation Wear ear protection Wear eye protection Wear safety footwear Wear protective gloves Wear protective clothing Wear a protective mask Guards must be used during operation General prohibition sign No smoking No open flame fire open ignition source ...

Page 20: ...3 Warning Signs General warning sign Warning of low temperature Warning of electricity v Warning of suspended loads Warning of toxic substances Warning of hot surfaces Warning of automatic starting machinery Warning of sharp elements Warning of crushing to limbs Possible damage to machinery Environmental damage ...

Page 21: ...mple Electrocution through hazardous voltage will lead to death or serious injury Disconnect all electric power and ensure the power cannot be inadvertently energized Verify that all circuits are deenergized earth short circuit and block off all neighbouring live parts High concentration of refrigerants in the air can result in death or serious in jury High concentration of refrigerants in the air...

Page 22: ... equipment or property damage only accidents Examples Injury due to sharp cutting edges While cleaning care should be taken to prevent risk of injury due to thin fins Wear protective gloves NOTICE NOTICE Environmental Damage Dispose of all components and materials such as water glycol mix depending on material type in an environmentally friendly manner and in accordance with the local codes practi...

Page 23: ...es there are higher risks involved with the handling and operating around a Multi DENCO system Further information is provided in chapters 4 to 8 Always refer to the latest operation manual and support technical documents provided with the unit Do not make assumptions based on other products design or information If in doubt contact your local sales office Protect against unauthorised access Do no...

Page 24: ...ically isolated Ensure all guards and doors are closed Only remove guards or open doors When the unit has been electrically isolated Sufficient time has been allowed for the rotating fan momentum to cease Sufficient time has been allowed for inverter circuits to discharge NOTE Refer to Field Charge on the unit serial plate see chapter 1 2 in regards to system refrigerant volume NOTICE Always refer...

Page 25: ...r use It is not allowed to operate units in explosion risk areas in areas with strong electromagnetic fields electromagnetic immunity as of EMC Directive refer to the Declaration of Conformity in the unit documentation in environment with high levels of air contamination in environments with corrosive and or aggressive air 2 8 Modifications and changes Changes or modifications of any Multi DENCO u...

Page 26: ...lved with the system must understand and observe any local legislation regarding safe working practice 2 12 Noise The sound power level of the unit can rise up to 98 dB A according EN ISO 3745 accuracy class 1 2 13 Environmental considerations Some Multi DENCO versions can use refrigerants therefore careful and specific atten tion is required regarding the handling and storage Consideration must b...

Page 27: ...available in 7 sizes ranging from WxDxH 600x600x1940 mm to 3380x880x1968 mm These units come with a wide variety of accessories and opti ons meaning that each Multi DENCO unit can be tailored to your room s needs Once you have received your Multi DENCO unit typical onsite tasks include but are not limited to Installation and positioning of units Refrigeration pipework connections between indoor an...

Page 28: ...m C 10 10 10 10 Indoor Temperature Maximum C 40 40 32 40 Indoor Humidity Absolute Minimum g kg 2 2 2 2 Indoor Humidity Absolute Maximum g kg 18 18 18 18 Outdoor Ambient Air Temperature Minimum Standard C 20 N A 15 N A Outdoor Ambient Air Temperature Minimum with low ambient kit C 40 N A N A N A Outdoor Ambient Air Temperature Maximum C 55 N A 46 N A Condensing Temperature Minimum C 35 N A 35 N A C...

Page 29: ...l circuit is unable to meet the cooling requirements of the room then the unit changes to use the secondary circuit When possible the unit will try to switch back to the primary CombiCool circuit This feature is ideal to provide internal redundancy to each unit CombiCool FreeCool if fitted The unit is fitted with the same CombiCool Coil as above but can be configured with a FreeCool strategy When ...

Page 30: ...culated on temperature humidity or both when Multi DENCO units are connected in a network Each unit sends their sensor readings to every unit in the network Each unit then takes all the values and calculates the aver age independent of the network units This gives the advantage of balancing the cooling requirements across all of the units within a room rather than on individual airflows The softwa...

Page 31: ...and alarms are displayed in plain text The display has a screen saver function which changes to signify when there is an alarm present 3 Microprocessor control The microprocessor can control all the functions for cooling heating humidifying and dehumidifying It can monitor all digital and analogue inputs and outputs and can be linked in a network between units The C5 12 controller can output to th...

Page 32: ...cal heating are equipped with sturdy sheathed elements with stainless steel finning and rated to operate at black heat in order to prevent annealing conditions and sparking Overheat protection is provided through a thermostat Klixon The available heating duty is sufficient to prevent low supply temperatures in the dehumi dification mode Electric heating can also have an integrated thyristor contro...

Page 33: ...ect the heat that the Multi DENCO unit has absorbed from the room They consist of a large coil and a fan to condense the R410A gas into a liquid form Condensers can be supplied with AC or EC fans and can be installed with vertical or horizontal airflow Nominal duties for condensers range from 5kW to 100kW when using a 15 C tempe rature differential The refrigerant gas inlet and liquid outlet pipes...

Page 34: ... Typically used in CombiCool configurations our drycoolers are designed exactly the same as our condensers dimension and build design but are used to cool water or glycol based fluids These units can be used for FreeCool strategies also 3 6 5 Plate heat exchangers Where installation of A Version units requires a large distance between the indoor unit and any heat rejection location a plate heat ex...

Page 35: ... 15 With the packing pallet and slinging the unit use spreader bars to prevent damage NOTE Missing parts or claims of shipping damage shall only be reported to the transport insurance if the damage has been confirmed by the delivering carrier NOTE We recommend to keep the equipment in the original packaging for protection ease of handling shipping and storage Remove the original packaging only bef...

Page 36: ...it down gently without a large impact Take steps to avoid twisting the cabinet during positioning If necessary use a specialist company to transport the unit Fig 4 1 Handling of unit in export packing and wooden crate Placement at the installation site is covered by chapter 5 3 4 3 Storage Storage conditions for uninstalled units Air temperature 20 C to 50 C Air humidity up to 90 relative humidity...

Page 37: ... Sufficient clearance in front of the unit must be ensured for maintenance and service jobs If applicable to local regulation Check installation site fulfill requirements as defined in EN 378 3 2008 A1 2012 It is recommended that once the the Multi DENCO unit is located then it is fixed in placed e g bolted bracketed etc to prevent unwanted movement or vibrations Note on unit assembly and installa...

Page 38: ...e following are suggestions dependent upon site condi tions Ensure that any vertical planes directly in front of the unit are acoustically insulated Where units are situated in equipment rooms acoustic treatment of the walls of the equipment room should be considered Acoustic pads may be placed behind equipment to reduce wall transmissions Panels and cables in the air flow direction can cause vibr...

Page 39: ...ween the base stand and the unit should be lined with a 3 mm semi hard gas ket For more details or specification please contact your local sales representative Fig 5 2 5 2 3 Support plinth For units installed without a raised floor a plinth should be used to allow for service connections to the unit The standard plinth is 200 mm tall and uses the same frame and materials as the unit for a consiste...

Page 40: ...2 6 Horizontal air discharge For upflow units that do not have ceiling voids a horizontal air discharge section can be used to change the airflow direction The design can have a grille on the front panel only 1 way blow or grilles on the front and sides 3 way blow The assembly is bolted onto the top of the unit through the frame This can be acces sed via the service panels on either side of the un...

Page 41: ...y install the equipment may result in death or serious injury Secure the unit against tipping before removing the unit from the pallet Do not lean against or lean objects against the unit Do not expose any part of your body limbs or hands to the space between the unit and any substructures see chapter 5 2 or between the unit and the ground NOTICE During installation and placement weight loads may ...

Page 42: ...ping 5 4 Clearance and Access 5 4 1 Clearance Fig 5 8 Columns A B and D are recommended minimum values to ensure satisfactory operation by your Multi DENCO unit Column C is the mandatory minimum values to ensure serviceability for your Multi DENCO unit NOTE We strongly recommend using a third party specialist lifting company to offload and position all Multi DENCO equipment Size Unit Width mm Nomi...

Page 43: ...ith an integrated display remove the cable between the C5 12 controller and the display module Release the upper hinge retainer and remove panel To reinstall the doors first lift the panel and clip into the bottom retainer Release the top retainer shift the panel upwards to the unit and clip into the top retainer The rear and side panels can be removed by unscrewing six screws per panel It is reco...

Page 44: ...thin the unit But the two hoses must be connected to the sensor during installation to enable the sensor to read the air pressures Two hose ports are available high pressure which needs the hose to be positioned within the floor void The other hose low pressure which needs to be installed within the room space Air hose opening in the raised floor must be positioned at the right angle to air flow i...

Page 45: ...sin or silicone sealant is an effective way to keep the water sensor in its correct location Fig 5 14 Water detection spot sensors Spot sensors are also available for water detection These should also be installed in the under unit drip tray if included Distribute the sensors evenly to help ensure all areas under the unit can detect a water build up Important Note The water detection tape should b...

Page 46: ...r hour for 1 metre discharge height 28 litres per hour for 9 metre discharge height For hot water condensate pumps units with a humidifier Pump Capacity 5 litres Max Discharge Height 6 metres Max Flow Rate 480 litres per hour for 1 metre discharge height 120 litres per hour for 6 metre discharge height 5 5 6 Remote monitoring touch screen display The display can be mounted up to 50 m away from the...

Page 47: ...g pipework requirements No more than 35 m above the height of the indoor unit No more than 10 m below the height of the indoor unit The interconnecting pipework between the indoor and the condenser must be less than 100 m For more details about interconnecting pipes please see chapter 6 Note It is mandatory to connect the Multi DENCO indoor unit to a heat rejection unit This is achieved typically ...

Page 48: ...g underneath the unit can cause a reduction in airflow as well as an increase in noise as air passes around the obstruction All outdoor units should be fixed to a rigid structure using the holes provided wherever possible If the units are in an exposed situation and normal bolting is not practical then alternative brackets fixings or adhesive should be used Condensers are delivered with the mounti...

Page 49: ... must be greater than 2X Requirements if more than one unit is installed by a solid wall Solid obstructions along any two walls When multiple units are located with solid obstructions along any three sides the open side must give free air to each of the units When multiple units are located alongside two solid obstructions and two louvered sec tions C D L The total free area of the louvres should ...

Page 50: ...3 way air discharge 5 8 EC Declaration of Conformity For any installation of Multi DENCO equipment that requires interconnecting pipework it is the responsibility of the installer to produce an EC Declaration of Conformity if installed within the European Economic Area EEA Outside of the EEA there may be similar separate requirements by different nations To assist with these requirements we have p...

Page 51: ...hnical principle 9 EMC emissions for residential commercial and light industrial environments 10 EMC immunity for industrial environments 11 Refrigerating Systems 12 Pressure equipment for refrigerating systems and heat pumps General piping 13 Applied National Standards Technical Specifications This assessment will need to include creating a technical file including 1 Description of the equipment ...

Page 52: ...e greater the distance between the air handling unit and the outdoor heat rejection unit the greater the pressure drops in connected pipes resulting in reduced energy efficiency of the unit Liquid receivers Installing a refrigerant receiver is not mandatory With long pipe runs and low ambient temperature operation of the unit it is however recommended to install a refrigerant receiver If a receive...

Page 53: ...ity but will be more susceptible to high pressure drops A Version Discharge Line Recommended pressure drop 1 0K Max pressure drop 2 5K Liquid Line Max pressure drop 1 5K NOTE Prior to installation it is particularly important to check the correct size refrigeration pipework is being installed Contact your local representative if you are unsure NOTE Only the pipe sizes listed below are ALLOWABLE fo...

Page 54: ...ation with 2 condenser in tandem configuration Both must be placed on the same level If this is not possible an external liquid receiver must be installed Pipes 2 and 4 pipework after the T Joint should be 1 pipe diameter size smaller than pipes 1 and 3 respectively see tab 6 1 and 6 2 Ensure that A A and B B For Horizontal Airflow A B 5 metres For Vertical Airflow A 5 metres and B 5 metres Metric...

Page 55: ...Multi DENCO Medium Connections FläktGroup DC 2013 0101 GB Subject to modifications R4 05 2018 55 Horizontal airflow Fig 6 1 Vertical airflow Fig 6 2 Isometric View Top View Isometric View Side View ...

Page 56: ...Offsets Anacondas see manufacturer s datasheets for details If using expansion loops or offsets the following minimum dimensions must be obser ved Fig 6 3 Pipe Pipe Operating Temperature C Expansion in 0 C Temperature mm m Expansion in 21 C Temperature mm m Hot Gas Line 80 1 35 1 00 Liquid Line 45 0 76 0 41 Suction Line 12 0 20 0 15 Tab 6 3 Expansion Loops Offset Tube Outer Diameter Size of expans...

Page 57: ... ding walls or roof structures When cutting copper tubing or pipe care must be exercised to prevent the filings or cuttings from entering the pipe Some effective means should be used to clean out the small particles of copper when they do enter the tube or pipe When cutting copper tubing with a wheel cutter it is extremely important to use sharp wheels The copper wears the edge of the wheels more ...

Page 58: ...d or brazed joints it is essential that the surfaces to be joined are clean Unclean metals do not take the flux properly which results in bare spots over the brazing alloy and will not flow Thin films of soldering alloy make the strongest joints Clearances of between 0 02 mm to 0 07 mm are all that are required Too much clearance prevents the proper capillary action wastes alloy promotes a weak jo...

Page 59: ...support clamping It is recommended All tubing should be independently clamped in position using a cushion based vibration absorption clamps Supports should be spaced at no more than 1 5m separation A thermal break should be provided between suction pipes and any support brackets 6 2 11 Fan removal to aid installation On certain downflow units access to the refrigeration pipework connections can be...

Page 60: ...th safe methods of working and good refrigeration practice Certification On all new installations once the system is found to be leak free a label stating date and time and final pressure reading is to be attached to the pipework inside the unit A pressure test certificate must be signed witnessed and passed to the commissioning engineer Each fan assembly is heavy and can weight up to 36 kg specia...

Page 61: ... that the adjacent area is clear of non essential staff complete a risk assessment and establish an exclusion zone for safety purposes 2 Low side strength test Complete a strength test on the whole system by pressurising with dry nitrogen to a maximum of 33 0 bar and leave on test for a minimum of 30 minutes 3 High side strength test On completion of step 2 CLOSE THE SUCTION LINE SHUT OFF VALVE an...

Page 62: ...r supply should have a stop cock adjacent to the unit The earth bonding supplied must be connected to the incoming water supply and also to the drain line if electrically conducting tubing is used for instance copper pipe Supply water quality In general the water supply feed to the humidifier must be normal quality drinking water but must comply with the following parameters Water feed pressure be...

Page 63: ...Normal tap water Water with low salt content Min Max Min Max Activity of hydrogen ions pH 7 8 5 7 8 5 Specific conductivity 20 C σR 20 C μS cm 350 1250 75 350 Dissolved solid materials cR mg l 1 1 1 1 Solid residue at 180 C R180 mg l 1 1 1 1 Total hardness TH mg l CaCO3 100 2 400 50 2 160 Temporary hardness mg l CaCO3 60 3 300 30 3 100 Iron manganese mg l Fe Mn 0 2 0 2 Chlorides mg l Cl 30 20 Sili...

Page 64: ...in pipework should be leak tested Depending on unit type condensate traps may be in built into the unit or the pipe work may be provided loose review unit design before completing installation Condensate trap must be filled with water prior to commissioning and after long inac tive periods Electrically conductive drain pipework should be earthed at a point adjacent to the unit Fig 6 6 Condensate d...

Page 65: ... preferably with pressure test points for measurement of volume flow should be used before each unit to enable balancing of water flow rates This regulating valve should be installed before each unit Separate isolating valves should be provided at all equipment to enable servicing to be carried out without draining the water circuit system Thermometers and pressure gauge test points should be loca...

Page 66: ...G EXPANSION TANK WATER FILL CHILLED WATER RETURN TO CHILLED WATER MAIN CHILLER CHILLED WATER SUPPLY FROM CHILLED WATER MAIN CHILLER UNIT ON SITE RECOMMENDED RECOMMENDED M CONDENSATE TRAY DRAIN HUMIDIFIER WATER SUPPLY IF FITTED CONDENSATE HUMIDIFIER DRAIN LINE TYPES CHILLED WATER SUPPLY CHILLED WATER RETURN CONDENSATE HUMIDIFIER DRAIN P W TO EXPANSION VESSEL ...

Page 67: ... Increased power and current consumption of a pump Lower cooling capacity Larger thermal expansion when compared with water only Parameter Unit Value pH value at 20 C 7 5 9 Conductivity at 20 C μS cm 700 Dissolved solid materials cR O2 mg l 0 1 Total hardness TH dH 1 15 Dissolved sulphur S not detectable Sodium Na mg l 100 Iron Fe2 Fe3 mg l 0 1 Manganese Mn2 mg l 0 05 Ammonium content NH4 mg l 0 1...

Page 68: ...nnecting chilled water pipework Access to water pipe connections can sometimes be difficult if there is no side access The procedure to remove indoor fans to allow easier access to the connections is in chapter 6 2 11 Connect the piping system to the chilled water inlet outlet in accordance with best practice and conforming to and local and national regulations NOTICE Excessive volumes of glycol w...

Page 69: ...port valve which is wired and fitted within the unit casing It is important to consider the fitting of commissioning sets in the supply return pipe work to allow accurate water measurements and flow adjustments These should be supplied and fitted in accordance with the manufacturer s recommendations The installation of the hot water pipework is similar to that of the chilled water pipework chapter...

Page 70: ... Equipped and any connected component must be wired with an earth connection Unmade or partly made electrical connections have a high hazard of creating an electrical potential on other materials This can lead to death or serious injury When installing electrical connections Ensure all power supplies are disconnected including existing connections and power to new connections to be made Ensure any...

Page 71: ...tion to the isolator 7 2 4 Cable routing inside unit Multi DENCO units are designed for cable entry from the BOTTOM of the unit Secure any interconnecting cables within the unit and ensure that the cables cannot make contact with the fan or any hot components Do not remove any unused rubber glands or blanking plugs Do NOT drill any holes in the top panels of ANY electrical cabinets Cable routing m...

Page 72: ...ed for each condenser and connected to the indoor unit separately We recommend any 2 core screened data cable for control wiring for example Beldon 8761 Alpha 2401C BICCH8082 NOTE We STRONGLY recommend that the outdoor unit should be connected to the indoor unit for its power supply 1 Condenser 2 Condenser Control Power Control Power AC Fans Not Required 2 Core Earth Not Required 2 Core Earth Sepa...

Page 73: ...control of condensing units If 2 outdoor units are required 2 boards will be provided Designated terminal blocks are available within the controls cabinet for connecting of the outdoor condensing unit for power supply For further details please see the unit specific electrical contract drawing Power Control 24 VDC 1 Phase Power Supply 2 Core Earth 3 Core Earth 3 Phase Power Supply 4 Core Earth 3 C...

Page 74: ... side of the cabinet through the rubber grommets provided 7 4 2 Remote display For a remote dual display provided with a Multi DENCO unit the electrical require ments are 2 core screen cable for data signal to the unit s C5 12 controller A 24V AC power source this can be from the Multi DENCO unit The remote display can be installed up to 50m away from the Multi DENCO unit In all installations cons...

Page 75: ... and also within the Controls Manual 7 4 4 Network wiring Fig 7 3 A recommended cable specification to use for the network wiring is 22 AWG 0 326 mm stranded conductors polyethylene insulation twisted pair with 22 AWG 0 326 mm drain wire and aluminium foil outer shield covered in a PVC jacket Examples of this style of cable are Beldon 8761 Alpha 2401C BICC H8082 NOTE If networking multiple Multi D...

Page 76: ...w High Temperature 12 13 The unit s maintenance alarm indication e g Dirty Filter humidifier 17 5 Alarm contact of condensate pump optional accessory 100 101 Indication of unit s operation i e fans enabled VDC GND U1 U2 Air intake sensor VDC GND U3 U8 Air discharge sensor optional only if the item is fitted Serial Card Interface cards for building management optional Rx Tx Rx Tx GND Unit s network...

Page 77: ...re different commissioning procedures e g winter kit This chapter applies to initial commissioning as well as re commissioning due to extended shut down periods or relocation Only R410A can be used in Multi DENCO systems Refrigerants poses hazardous risks Refrigerant cylinders can be heavy Refrigerant cylinders can have unstable centres of gravity Refrigerants are stored or used at high pressures ...

Page 78: ...ital refrigerant cylinder weighing scales 8 2 Pre commissioning procedure For all checks we recommend following EN 378 3 2008 A1 2012 Ensure all protective clothing and equipment is worn In particular Suitable eye protection Suitable hand finger protection Protective cloths for entire body including safety footwear 8 2 1 Pre commissioning checklist We recommend that the Pre Commissioning Checklist...

Page 79: ...ck the unit is mounted suitably within the room e g if on a base frame Check that the entire heat exchanger is protected by the air filter s If fitted check the humidifier is supplied with water and that the earth bonding device is secured to the incoming pipework Check that the condensate drain is connected correctly and water can drain freely for both coil condensate and humidifier if fitted Roo...

Page 80: ...he earth terminals are secured tightly Check any signal and mains power cables are segregated Check inside of the control cabinet for loose connections or damaged components Tighten all supply terminals in the motor terminal clamps Ensure temperature and humidity sensors are adequately protected by their enclosures ONLY when all the above checks been completed can the unit s circuit breakers MCBs ...

Page 81: ...ystem under vacuum via the discharge line NOTE It is recommended a triple evacuation is thoroughly conducted If the system cannot be evacuated to the levels defined below you must NOT add any refrigerant and the system installation must be checked and corrected Once completed re con duct the procedure and ensure requirements are achieved Incorrect or inadequate evacuation resulting in moisture or ...

Page 82: ...r the gauge lines should be carefully purged of any air NOTE Multi DENCO units can contain two different types of compressors each with their own oil type Please follow the below recommendations A Version Size 010 065 FV50S Emkarate RL68H Mobil Arctic EAL68 A Version Size 092 130 POE 160SZ Emkarate RL32H Alternative oils are compatible with the original oil type used therefore these can be mixed a...

Page 83: ...to commission a Multi DENCO A Version unit in a room with no heat source is difficult as you would not be able to give a consistent operation to observe refrigerant charge Alternatively commissioning a unit on a cold day could result in lower condensing temperatures which may cause over charging of a unit Wherever possible attempt to recreate the required conditions needed by the end user so that ...

Page 84: ...r Enable any isolator or circuit breakers in the main power distribution board both boards for units with dual power supply Ensure the outdoor unit s isolator is set to ON if applicable Enable any in line isolation for the Multi DENCO unit Set the door interlock isolator if fitted to the ON position Wait 1 2 minutes for the unit to start up When display is active press the Enable button in the bot...

Page 85: ...ure to calibrate these sensors may lead to inefficient operation or possibly alarms and non operation 8 3 5 Commissioning refrigerant circuits Consideration and Targets Below are the commissioning targets for an optimum system charge Superheat 7 9 K Default set point 8 K Sub cooling 5 8 K Discharge superheat Compressor s at Low Speeds 50 RPS 15 25K Compressor s at High Speeds 50 RPS 25 35K All 3 o...

Page 86: ...s listed earlier in this chapter If fitted required adjust the fan speed controller settings to modify the sub cooling settings If overcharge remove refrigerant from system If refrigerant circuit charge is to your satisfaction re perform the Calibration of refrigeration devices chapter 8 3 2 to ensure proper operation of control devices If good operation is observed record the total charge of the ...

Page 87: ...o requires additional top up of oil ensure this is conducted whilst the unit is off and deactivated Function Test of Safety Device s Multi DENCO units are fitted with High Pressure HP switch s to mechanically protect the refrigeration circuit After charging these MUST BE TESTED For details of the procedure please refer to the controls manual Unit stopped Both compressors operating Size 092 to full...

Page 88: ...ion inhibitors see chapter 6 6 2 Glycols on page 67 Pumps must never have a negative pressure or vacuum on their inlet Automotive inhibitors and anti freeze MUST NOT BE USED as nearly all automotive anti freeze contains silicate based inhibitors which gel and foul coating heat exchan ger surfaces and reducing energy efficiency These silicates have also been shown to significantly reduce the lifesp...

Page 89: ... operational in win ter it may be sufficient to choose a lower fluid concentration one that merely protects against bursting since some crystal formation in the fluid will not be harmful 8 3 7 Water balancing 3 2 port Drive Open Drive Close Valves DODC Ensure the valve is 100 open during water balancing failure to follow this may result limited capacity of the unit To force the valve to be 100 ope...

Page 90: ... conditions adjust the setting PIC Valve Max Value to achieve the design maximum flow rate see the C5 12 controller manual for instructions on how to do this Record the maximum flow rate and PIC Valve Max Value 8 3 8 Variances for winter kit Units operating in low ambient temperatures may be fitted with a winter kit The system operates as a liquid backup At high ambient temperatures the system reg...

Page 91: ...ropriate service gauges After each addition allow the system to stabilise and check conditions before adding any more Monitor the sight glass throughout the process when flashes of liquid are ob served stop adding refrigerant NOTICE Overfilling of liquid receivers can result in poor system performance or failure The liquid receiver should never exceed 80 full Condenser Size Liquid Receiver 100 Cap...

Page 92: ...iver should match Tab 8 5 For example if the temperature is above 20 C the liquid receiver should only be 80 full no liquid refrigerant in the condenser coil Otherwise if ambient temperature is 0 C on the day of commissioning then the liquid receiver should be about 30 full lots of liquid refrigerant in the condenser coil Using a touch probe on the receiver shell under the insulation measure every...

Page 93: ... settings After commissioning we recommend that your service technician saves the unit confi gurations to the controller This can allow for the system settings to be restored back to the configuration made during commissioning More details of this feature are availa ble in the controller manual 8 4 3 Commissioning report As mentioned previously it is very important that you submit a copy of the Mu...

Page 94: ...ociated outdoor unit if applicable Location of power distribution board isolator Location of the mains isolator Either fitted within the door of the Multi DENCO unit or within 1m of the unit Location of circuit breakers MCBs inside the Multi DENCO unit Shut off isolation valves for the Multi DENCO unit including if applicable Refrigerant circuit Chilled Water Circuit Hot Water Circuit Humidifier C...

Page 95: ...Unit ON OFF by keyboard 9 Unit Number for networking 2 Unit Status 10 Model Reference 3 Alarms Page 11 Icon if any alarms are active 4 Unit Graphs 12 Date 5 Login 13 Unit function Icons 6 Status Information 14 Network Status 7 Current Temperature depending on control sensor 15 Time 8 Current Humidity depending on control sensor 16 Help additional information NOTICE During operation Do not open any...

Page 96: ... operational risks death or serious injury Inverters also store energy for a period of time after isolation Disable the unit Electrically isolate the unit Wait AT LEAST 5 minutes 9 Once fan momentum has ceased and the inverter energy discharged you can open the doors and conduct work Multi DENCO units use fans which are regulated independently by the main control board Removing guards whilst unit ...

Page 97: ...ountry specific qualifications in refrigerant handling and a sound knowledge of the operation and the dangers involved with inverter techno logy and other electrical services Ensure all incoming electrical connections are isolated and cannot be inadvertently energised Inverter technology and rotating fans required at least 5 minutes from electrically isolating the unit before any doors or panels c...

Page 98: ...ter every inspection any relevant information must be recorded into the logbook Certain countries have specific legislation regarding record keeping e g Fluorinated Greenhouse Gases Regulation EU No 517 2014 Please refer to chapter 10 7 Log book EU Regulation for more details During maintenance and servicing Do not allow the system pressures to rise above the Maximum Operating Pressure MOP stated ...

Page 99: ...loss since last inspection rectify as necessary 10 Inspect fan touch protection devices for compliance and functionality 11 Check operation of on board electrode steam boiler humidifier if fitted Check drain down and fill function disposal pumps and bottle current Replace any expired bottles Every Six Months 1 Check contactors for damage or eroding 2 Check that the electrical contactor overloads f...

Page 100: ...r some time weak acids may appear from the oil and refrigerant by system heat and electrical arcing This acid will remain INERT until moisture is added to the system for example via air ingress into the system during service work 10 5 Humidifier maintenance if fitted As the humidifier usually operates in automatic mode and the relevant wear of the device is displayed a standard maintenance interva...

Page 101: ... When the equipment is to be taken out of service for an indefinite period we recom mend a qualified air conditioning engineer An engineer will also be required for the restarting of the equipment For units fitted with chilled water cooling and or hot water heating the mains power should remain ON for at least the stroke time of the valve actuator to ensure that the valve closes fully 10 6 1 Freez...

Page 102: ...should be kept in the logbook also The refrigerant source should also be recorded Changes and replacements of any components of the refrigeration system Results of all periodic routine tests The periods of any significant non use Members of the EU must also comply with the Fluorinated Greenhouse Gases Regu lation EU No 517 2014 alongside any further country specific legislation This regu lation pl...

Page 103: ...e some simple areas that you can check to gather valuable information Have conditions within the room changed Has the equipment been recently moved Has the airtightness of the room been compromised e g door window open Is there new equipment with higher lower heat load Is the air path temporarily blocked Has additional cooling equipment been added to the room Have the grille tiles been moved Obser...

Page 104: ...adjustments must be conducted by qualified individuals with full knowledge of the system design and requirements The following table contains a sample list of mechanical issues and possible remedies to fix them A list of common control issues can be found in the separate controller manual NOTE The advice in the following section assumes the unit has been operating consi stently for a significant a...

Page 105: ...ve the pressure in creasing in the unit controller and check fans start when pressure increases sufficiently Outdoor unit not receiving con trol signal from indoor unit Compare terminals at outdoor and indoor units to check ca ble integrity No image on the display No power to the unit Check the power supply at the mains power distribution board and at the local isolator Display unit cable disconne...

Page 106: ...rain Ensure the humidifier bottle is suitably sealed or appropriately drained Water Circuits Close off shut the valve on any water circuits hot or cold if fitted Drain the water water mixture from the circuit Disconnect the water connections and ensure no further fluid is leaking Ensure all incoming electrical connections are isolated and cannot be inadvertently energised Inverter technology and r...

Page 107: ...er chapter 4 12 2 Disposal An authorized appointed contractor specializing in waste processing shall dispose of the unit or its individual components This appointed contractor shall ensure that the components are separated according to material types the used operating materials are sorted and separated according to their respective properties fluorinated greenhouse gases are properly recycled or ...

Page 108: ...ed 13 2 Pressure Test Certificate DQA 653 This is the template for recording the system pressure test conducted on the Multi DENCO circuit once the mechanical installation has been completed 13 3 Multi DENCO Commissioning Report DQA 890 This is the template for the commissioning report of Multi DENCO units NOTE Please note that these documents are samples from the time of publishing and may not be...

Page 109: ... rk installed strainers an stems filled plete this form tive visit by ou a e Co to acceptin tallation are erefore com roup contac Name act No acts acts rrect positio stands if re tidy safe a has raised from hazar ductwork co pipework be rtificates ava retention pipework in ated and le refrigerant er supply pip essure avail umidifiers o condenser fitted with nd dosing p and vented or failure to ha ...

Page 110: ...otation che isolators ng electrical ected as pe n connectio ed as opera p start con talled and te ion cables sing correct t for our con upplies ca at complies egulations parking avai gineer s veh ion required gineer can c with F Gas n projects o add refrig water or c own engine tes pment is to engineer on or failure to ha ur commissioni acceptance of a water ycol mix ha ble for our ed and and test...

Page 111: ...eh Date Failure to comp in an abort of 3 ents eted By ure half Of plete this form tive visit by ou a or failure to ha ur commissioni acceptance of a ave all require ing engineer Y any abortive co d items ready f Your signature osts according for commissio on page 2 aut gly DQ oning may resu thorises the QA880 Re ult ev DH1 ...

Page 112: ...ite Address Contract Number Air Handling Unit Reference Air Handling Unit Type Condenser Unit Type We certify that the following pressure tests have been completed with dry nitrogen Remarks DQA653 Rev DH1 Circuit Date Test Witnessed by Pressure Duration of Test Pressure Test Certificate Dolphin House Moreton Business Park Moreton on Lugg Hereford HR4 8DS Test Carried out by Company Signature Name ...

Page 113: ...otor 3 Current Min Yes No Design RA Condition Air Balance Water Balance All boxes in section A to be completed before handing sending to commissioning engineer PPE Requirements AHU Serial No L1 Mains Supply Voltage L3 Mains Supply Voltage Section B For completion by commissioning engineer for each unit on site before starting commissioning MANDATORY Heat Rejection Serial Nos Site Address Design To...

Page 114: ...cuit if option fitted Oil Recovery Time SIAM only Sensor Calibration RH Network Connected Dehum Fan Speed Air Flow Fail Setting Check Drycooler Target Setting Pump Suction Pressure Pump Delivery Pressure Design Flowrate Actual Exp Vessel Pressure Pump Make Pump Model Design Exp Vessel Pressure State average amps across all phases pumps if even Double Reg Valve Setting Glycol Circuit if option fitt...

Page 115: ...ion Fitted to Machine Condensate Pump Drain if option fitted Bottle Conductivity Range Water Supply Conductivity Output Set System Lift Function Test Pass Fail Pump Model L3 Humidifier Current Heater 3 Current Option Fitted to Machine Thyristor Control Fitted Heater 2 Current L2 Humidifier Current Bottle Type Bottle Part Number N A Head pressure control function setting correct High pressure trans...

Page 116: ...on Refrigerant Type Plant Manufacturer Cooling Loads Served Leak Tests State Method Used Mandatory Refrigerant Removals If none state none Quantity Installed Year of Installation Engineer Refrigerant Additions If none state none Date Amount Added in KG Plant Operator Operator Contact Reference Number Test Result Comments Engineer Related To Test On Actions Taken Follow Up Action If none state none...

Page 117: ...Multi DENCO FläktGroup DC 2013 0101 GB Subject to modifications R4 05 2018 117 ...

Page 118: ...Multi DENCO 118 FläktGroup DC 2013 0101 GB Subject to modifications R4 05 2018 ...

Page 119: ...Multi DENCO FläktGroup DC 2013 0101 GB Subject to modifications R4 05 2018 119 ...

Page 120: ...mulated industry experience The widest product range in the market and strong market presence in 65 countries worldwide guarantee that we are always by your side ready to deliver Excellence in Solutions PRODUCT FUNCTIONS BY FLÄKTGROUP Air Treatment Air Movement Air Diffusion Air Distribution Air Filtration Air Management Air Conditioning Heating Controls Service Learn more on www flaktgroup com or...

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