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Klimaire Ecosaire CM Series, Installation, Operation & Maintenance Manual

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Klimaire Ecosaire CM Series Installation, Operation & Maintenance Manual Download Page 25

Owners Manual              Ecos

aire

®

CM Series Precision Air Conditioner

Refrigerant                                   Piping                                 Installation 

Ecos

aire

®

July 2007                                                                                                                                                                                               25

Data subject to change without notice.

Air-Cooled Direct Expansion and DualCool Units Only

When shipped, remote air-cooled units contain a refrigerant holding charge.  

The holding charge must be

reclaimed before removing the caps on  the remote-condenser tube stubs.  Failure to reclaim the hold-
ing charge can lead to property damage and/or personal injury.

Locate the refrigerant liquid-line solenoid valves.   Some units may

be equipped with manual-lift valves.  Where this is the case: 

1. Using two wrenches, remove the manual-stem covers.
2. Turn the manual stems clockwise to open the valves.

stem cover

manual stem 

Locate the compressor and attach reclaim hoses to the compressor rotalock-valve access ports.  

reclaim manifold
(by others)

This hose will be connected
in the next step.

Do not open rotalock
valves yet.

INST

ALLA

TION

SAMPLE

Number

, location, and

appearnce of component

s

may vary

.

SAMPLE

Number

, location, and

appearnce of component

s

may vary

.

Summary of Contents for Ecosaire CM Series

Page 1: ...klimaireINTL klimaireINTL com 1 647 477 3333 1 646 808 0240 KLIMAIRE International www klimaireINTL com Ceiling Mount Precision Cooling Systems Installation Operation Maintenance Manual...

Page 2: ...saire system Please read the entire manual carefully and if you have any questions con tact your local Ecosaire representative Your warranty is valid only if conditions explained in this manual are me...

Page 3: ...ty 75 Operation Contents 77 Maintenance Schedule 78 Maintenance Record 80 Maintenance Tasks 83 Logical Flow Charts 90 Supervisaire Controller 91 Password 92 Enable Disable 93 Clock 94 Set Point Adjust...

Page 4: ...network together with a supervisory panel complete with a backlit graph ics display for robust redundant environment control At the same time the network can be connected to a personal computer super...

Page 5: ...e units They may be easily replaced from the filter access door Refrigeration circuit is fitted with filter drier sight glass mois ture indicator liquid line solenoid valve adjustable externally equal...

Page 6: ...cooled condensers are available for the following conditions Design Standard Ambient Low Ambient Temp min max min max 95 F 35 C 0 105 F 17 41 C 40 105 F 40 41 C 100 F 38 C 0 110 F 17 43 C 40 110 F 40...

Page 7: ...control room conditions Heat is transferred via pumped glycol fluid flow to an outdoor heat exchanger The outdoor heat exchanger has multiple direct drive propeller fans and is built with aluminum bod...

Page 8: ...When the outdoor temperature is below 60 F 16 C the Ecosaire unit operates its refrigeration system to move heat into a flow of glycol Refrigeration condensing pressure is controlled by pressure con...

Page 9: ...r temperature of the chilled water becomes inade quate for proper operation the unit will automatically change to Air Cooled Direct Expansion Air cooled condensers are available for the following cond...

Page 10: ...gs The unit is rated for use with 45 F 7 2 C chilled water For flow rates and other details see Installation Piping If the flow rate or temperature of the chilled water becomes inadequate for proper o...

Page 11: ...s rated for use with 45 F 7 2 C chilled water For flow rates and other details see Installation Piping If the flow rate or temperature of the chilled water becomes inadequate for proper operation the...

Page 12: ...e July 2007 Data subject to change without notice Product Description Air Flow Options DESCRIPTION Horizontal Straight Horizontal Left Horizontal Down Horizontal Right S A M P L E N u m b e r l o c a...

Page 13: ...noid Valve D1 D2 D3 O 2 way Water Reg Valve D2 D3 F G W P 3 way Water Reg Valve D2 D3 F G W Q 2 way Water Modul Valve C D2 D3 F G W R 3 way Water Modul Valve C D2 D3 F G W S Water Flow Switch T Non fu...

Page 14: ...ONTROL AIR CONDITIONER Before calling for assistance be sure to have the model serial and tag numbers available for the service department Be sure the voltage and current ratings of the unit branch ci...

Page 15: ...m air to escape into the ceiling plenum Because of the small number of per sonnel in a typical computer site out door air should be reduced to less than 5 of the total circulated air If outdoor air is...

Page 16: ...ng plastering etc are underway it must be covered with the shipping carton or plastic film in order to keep the filters and internal components clean Do not allow water plaster con crete dusts or othe...

Page 17: ...Insulate hot gas tubes where they might be accidentally touched Lifting holes are provided at the top of the support legs The nuts and bolts securing the unit to the crate are used to mount the lower...

Page 18: ...Areas subject to heavy snow and ice accumulation should be avoided Areas subject to public access should be avoid ed Locate outdoor units in an area of clean air away from steam hot air or fume exhau...

Page 19: ...es result in higher power requirements and increased noise The maxi mum external static pressure is specified for each unit Static pressures higher than specified may reduce air flow below the mini mu...

Page 20: ...ECOSaire There should be no elbows transitions offsets duct heaters or other flow interruptions closer that 5 X the width of the blower On special order Dectron may be able to provide bottom top or s...

Page 21: ...of the window RIGHT Vanes and straight length allow air to flow evenly RIGHT Vanes and straight length allow air to flow evenly RIGHT Air can follow this transition RIGHT Sufficient straight length al...

Page 22: ...four feet of the Ecosaire unit Reduce to 1 4 O D and connect to the 1 4 compression fitting on the supply port as shown IMPORTANT Be sure the shut off valve is closed after the connections are comple...

Page 23: ...ut let side of the P trap may be neces sary Follow standard procedures Route drain pipe Route the drain pipe so that the only trap is the P trap In horizontal runs slope the pipe downward at least 1 4...

Page 24: ...subject to change without notice If pressure testing be sure to isolate the compressor from high pressure To System To System S a m p l e C o m p o n e n t s a n d t h e i r l o c a t i o n s m a y v...

Page 25: ...ocate the refrigerant liquid line solenoid valves Some units may be equipped with manual lift valves Where this is the case 1 Using two wrenches remove the manual stem covers 2 Turn the manual stems c...

Page 26: ...proceed immediately and rapidly since the filter drier will be exposed to atmosphere Close the rotalock valves and remove the reclaim equipment Remove the condenser tube stub caps with a tube cutter...

Page 27: ...8 7 8 1 1 8 1 1 8 1 1 8 1 1 8 1 1 8 1 3 8 1 3 8 5 8 5 8 5 8 5 8 5 8 3 4 3 4 3 4 5 8 5 8 5 8 5 8 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 7 8 7 8 Air Cooled Direct Expansion and Air Cooled DualCool Uni...

Page 28: ...e valves and other com ponents If the inside of the tubes is contami nated with dirt oil sludge rust or other materials then they must be thoroughly cleaned IMPORTANT Never allow liquid water to enter...

Page 29: ...M headmaster Ecosaire Unit with without HGBV HGBV Model lb lb CM010 1 5 1 0 ______ CM015 1 5 1 0 ______ CM020 3 0 2 0 ______ CM030 4 5 3 0 ______ CM050 6 5 4 5 ______ CM070 7 5 5 0 ______ CM080 15 0 1...

Page 30: ...service gauges an electronic micron level vacuum gauge and a vacuum pump as shown below Use core removal adapters to remove the cores from Schraeder type access valves To insure a correct vacuum read...

Page 31: ...tlet be routed outdoors In this case Locate the refrigerant receiver inside the air handler unit The relief valve is on top of the receiver Attach a suitably sized tube to the relief valve outlet taki...

Page 32: ...whenever the Ecosaire unit is operational Do not allow a timer or other device to inhibit operation at any time the Ecosaire unit is operational IMPORTANT Cooling water must be protected from freezin...

Page 33: ...factory piping dia grams Install a fill port at the highest point of the sys tem To insure proper gly col water ratio never use automatic fillers Where copper tubing use Type L only is used joints sh...

Page 34: ...pen the fill valve and all air vents including the petcocks at the top of the FreeCool coils on the right hand side of the unit The pipe plugs on the pump impeller housing and at the top of the room u...

Page 35: ...same size as the chilled water valve for both the inlet and out let A shut off valve by others should be installed on the the inlet and outlet line Insulate the chilled water lines where they run thro...

Page 36: ...direction Use properly sized wire Refer to the unit nameplate for electrical ratings Size wires according to applicable codes with allowance for voltage drops Unit terminal voltage should be nominal...

Page 37: ...rily connect a jumper across the enable contacts as shown 2 Apply electric power to the branch circuit connected to terminals L1 L2 and L3 3 If the fans do not blow air in the proper direction see bel...

Page 38: ...0m 3 gang wall box by others At each end of the cable loop the modular telephone cable once as shown through clamp on split ferrite EMI cores by others The cores should have an impedance near 240 at 1...

Page 39: ...W BLUE WHITE BLACK RED GREEN YELLOW BLUE WHITE BLACK RED GREEN YELLOW BLUE WHITE BLACK RED GREEN YELLOW BLUE Assembling data reversed modular telephone cable Note that the lock tabs of the plugs are o...

Page 40: ...modular telephone plug by others is to be inserted into the display jack Insert 6P6C modular tele phone plug by others into the modular port Unit Controller Modular cable to round cable adapter by oth...

Page 41: ...See previous page for cable details Allow at least 10 inches of free cable for connection to the display The six pin modular telephone plug by others is to be inserted into the display jack Unit Cont...

Page 42: ...the end of the cable thorugh the hole in the sub base as shown Using care to maintain level screw the sub base to the wall box here Connect the cable to the modular telephone jack on the back of the d...

Page 43: ...an internal Ecosaire power source The condenser control wire size must be selected to allow for contactor coil inrush currents See the chart at right Alternatively a pilot relay by others may be inst...

Page 44: ...es provid ed by others In this case the remote on off switch must be wired to the Ecosaire controls see unit field wiring diagram in unit information package When dry contacts are open the unit will b...

Page 45: ...s Startup Page Supervisaire Controller Interface 46 Pre Startup Adjustments 49 Airflow 51 Remote Heat Exchanger 52 Humidifier 60 Add Refrigerant 61 Expansion Valve 62 Pre Startup Checklist 63 Enable O...

Page 46: ...ns and menus The button is used for scrolling upward to change set points enter passwords and to select display screens and menus The button is used to navi gate through menu selections and to accept...

Page 47: ...ight appears briefly followed by the unit default screen Optional remote displays may show the message NO LINK Where this is the case the address of the display must be set To set the display address...

Page 48: ...shown On initial application of power the panel will appear as shown Wait while the controller checks its internal functions self test please wait Dectron ECOS SuperVisaire Version x x mm dd yy Room S...

Page 49: ...rn to the default Room Status screen Alternatively press Esc as neces sary to return to the default screen To access the System ON OFF menu press Prg and enter the password as discussed in Startup Pre...

Page 50: ...d when prompted press to move the cursor to the password Press until the password reads 0008 If you overshoot press Press The password is entered and changes can be made Enter Password 0000 Enter Pass...

Page 51: ...ld be within 10 of the value stated on the submittal forms Some Ecosaire units may have voltage monitors that prevent operation in the event the branch circuit voltage is too high too low has lost a p...

Page 52: ...as to pro duce an upward air discharge as shown Single phase fans will inherently turn the proper direc tion If three phase fans turn the wrong way a qualified person should disconnect the branch cir...

Page 53: ...emote heat exchanger fans must rotate so as to pro duce an upward air discharge as shown Single phase fans will inherently turn the proper direc tion If three phase fans turn the wrong way a qualified...

Page 54: ...ntrol valve as shown at right Open the plug on the end of the valve by turning it counter clockwise Save the plug for future use Keep the O ring clean Locate the hex broached adjusting screw inside th...

Page 55: ...hangers with three phase fans confirm that the fans turn in the proper direction to blow air upward If they do not a qualified person should disconnect power from the remote heat exchanger swap any tw...

Page 56: ...32 9 36 67 0 141 159 6 5 5 0 8 7 9 5 17 7 37 2 42 0 24 6 18 9 32 9 36 67 0 141 159 Outdoor Temp 110 F 13 0 10 1 17 4 21 9 41 5 74 4 84 0 49 2 38 2 65 9 82 9 157 26 5 100 26 5 100 26 5 100 50 9 193 282...

Page 57: ...ly For all units be sure the compressor rotalock valves are open Locate the refrigerant receiver in the remote condenser Be sure the rotalock valves on the receiver are open by turning the stems count...

Page 58: ...ithout notice Locate the refrigerant receiver in the unit Be sure the rotalock valves on the receiver are open by turning the stems counter clockwise Replace the stem caps Glycol Cooled Direct Expansi...

Page 59: ...07 59 Data subject to change without notice For Glycol Cooled DualCool FreeCool or Chilled Water units be sure that any fluid valves by others are open For Water Cooled Direct Expansion units be sure...

Page 60: ...cylinder will continue to heat boil and refill in short cycles until the mineral concentration within the cylinder increases to normal As it does the water level will also drop to normal The water cy...

Page 61: ...e unit through the suction access valve while the compressor is running NEVER ADD LIQUID REFRIGERANT TO THE SUCTION ACCESS VALVE Units with two refrigeration circuits will have two sight glasses and t...

Page 62: ...r Tape the insulation to prevent air flow from changing the temperature reading Locate and identify the refrigerant sight glass Locate and identify the expansion valve Suction Tube Startup Prepare to...

Page 63: ...ate drain P trap has been filled with water and that the drain works For units with humidifiers con firm that the water supply tube is complete and tested For units requiring a conden sate pump confir...

Page 64: ...fusers are unobstructed Confirm that all construction dust and debris has been removed from ducts and plenums For glycol cooled and Free Cool units make sure all pipe air vents are closed tightly Rem...

Page 65: ...tedly until the cursor is at the desired value The example is to change the hour Press either or to change the selected value To store the setting press until the cursor is back in the upper left corn...

Page 66: ...lay 015 sec Humidity Alarms High XX X RH Low 20 0 RH Delay 015 sec Humidity Alarms High XX X RH Low 20 0 RH Delay 015 sec Startup Pre Startup Adjustments Humidity Set Points Press repeatedly to access...

Page 67: ...perature set pts Set point xx x F Temperature set pts Set point xx x F To access the temperature alarm set point screen press twice Temperature Alarms High 80 0 F Low 60 0 F Delay 015 sec Press Prg en...

Page 68: ...nums 1 Apply electric power Allow at least 10 hours of crankcase heater operation before enabling a compressor 2 Do not allow a compressor to run without adequate refrigerant Press to move the cursor...

Page 69: ...adjusting screw counter clockwise to lower the head pressure or clockwise to raise the head pressure as needed to make the head pressure at teh compressor be 250PSI 15 PSI Return the plug to the valve...

Page 70: ...pressure should be above 50 PSI If it is not above 50 PSI stop and determine the cause The discharge pressure should be 250 PSI 15 PSI If it is not then check that the coling fluid temperature and flo...

Page 71: ...5 40 4 4 71 5 42 5 5 74 5 44 6 6 77 6 46 7 8 80 8 48 8 9 84 0 50 10 87 4 52 11 1 90 8 54 12 2 94 3 56 13 3 97 9 58 14 4 101 6 60 15 5 105 4 62 16 6 109 3 64 17 8 113 2 66 18 9 117 3 68 20 121 4 70 21...

Page 72: ...s Temperatures Coil 1 aa a F Coil 2 bb b F To access a customer temperature if any aa a press Temperatures Customer aa a F Valve Position bbb To access UNIT STATUS press aaa is the blower status bbb i...

Page 73: ...true Date and time set All alarms cleared ECOSaire Startup Report Warranty Registration Warranty void unless this form is completed and a copy returned to factory within 2 weeks after start up Instal...

Page 74: ...nty void unless this form is completed and a copy returned to factory within 2 weeks after start up Operational Data NOTE To obtain adequate readings a delay of ten 10 minutes is required after every...

Page 75: ...r 9 Seller warrants that the title conveyed under the terms of this Contract shall be good and marketable and that the goods shall be delivered free from any lien encumbrance or security interest what...

Page 76: ...a common carrier licensed public trucker or Buyer or its agent viii any loss or damage caused by failure to install or maintain equipment in accordance with Seller s instructions including without lim...

Page 77: ...nts Operation OPERATION Page Maintenance Schedule 78 Maintenance Record 80 Maintenance Tasks 83 Logical Flow Charts 90 Supervisaire Controller Interface 91 Password 92 Enable Disable 93 Clock 94 Set P...

Page 78: ...or so tight as to cause excessive shaft bearing wear See Operation Maintenance Blower Check that the condensate drain pan s is clean For units so equipped check that the remote heat exchanger is clean...

Page 79: ...tenance Record Maintenance Operation Ecosaire July 2007 79 Data subject to change without notice Photostat the next two pages as needed Tape the spine edges of the copies together Post the copies as a...

Page 80: ...rature Room humidity Air filters clean Humidifier strainer clean Humidifier high water sensor not lit Blower belt wear OK Blower belt tension OK Condensate drain pan clean Remote heat exchanger clean...

Page 81: ...Owners Manual Ecosaire CM Series Precision Air Conditioner Maintenance Record Maintenance Operation Ecosaire July 2007 81 Data subject to change without notice DATES...

Page 82: ...Ecosaire CM Series Precision Air Conditioner Owners Manual 82 Ecosaire July 2007 Data subject to change without notice Operation Maintenance This page intentionally left blank OPERATION...

Page 83: ...may vary Some units may have intakes for outdoor air CHECK THAT ALL FILTERS ARE CLEAN AND IN PLACE The size and number of filters may vary Air filters should be checked at least every month Dirty fil...

Page 84: ...down with warm water spray and a mild non foaming detergent To protect the heat exchangers from corrosion do not use alkaline or acidic cleaning solution The condenser should not be enclosed within a...

Page 85: ...es after five minutes of compressor operation If bubbles or droplets are noted contact a service technician or the factory Bubbles in the sight glass indicate problems such as a possible loss of refri...

Page 86: ...haft centers Multiply the number of inches by 1 64 This will be the deflection D in the diagram at right ex For S 32 inches D 32in x 1 64 1 2 in Measure the diameter of the smaller sheave Read the V b...

Page 87: ...20 0 21 2 24 8 8V 19 2 23 3 27 3 16 7 20 3 23 8 13 0 15 6 18 5 4 4 8 5 9 0 11 8 12 5 16 0 5VX 3 65 4 12 4 5 5 6 8 6 7 5 5 7 6 0 10 6 3V 5 5 6 4 7 5 4 8 5 7 6 6 3 9 4 4 5 0 2 2 3 35 3 65 4 12 4 5 5 6 8...

Page 88: ...of the unit CAUTION Cylinder and any undrained water might still be HOT MANDATORY CLEANING OF THE DRAIN VALVE Always clean the drain valve before installing a new cylinder since the valve port may be...

Page 89: ...be taken so that the cylinder leads of the same color are always directly opposite each other as indicated by the dot formation on the top of the cylinder 6 The white cylinder plug on all units is fo...

Page 90: ...eater 1 OFF Heater 2 ON Response 99 Heater 1 ON Heater 2 ON Output proportional heating signal Run blower YES YES YES Humidity set point Room air humidity Humidity set point YES YES NO Enable humidifi...

Page 91: ...to change set points enter passwords and to select display screens and menus The button is used to navi gate through menu selections and to accept changes The Prg button is used to access the set poin...

Page 92: ...mpted press to move the cursor to the password Press until the password reads 0008 If you overshoot press Press The password is entered and changes can be made Enter Password 0000 Enter Password 0008...

Page 93: ...o the default Room Status screen Alternatively press Esc as neces sary to return to the default screen To access the System ON OFF menu press Prg and enter the password as discussed in Startup Pre sta...

Page 94: ...dly until the cursor is at the desired value The example is to change the hour Press either or to change the selected value To store the setting press until the cursor is back in the upper left corner...

Page 95: ...ec Humidity Alarms High 80 0 RH Low 20 0 RH Delay 015 sec Humidity Alarms High XX X RH Low 20 0 RH Delay 015 sec Humidity Alarms High XX X RH Low 20 0 RH Delay 015 sec Press repeatedly to access Humid...

Page 96: ...re set pts Set point xx x F Temperature set pts Set point xx x F To access the temperature alarm set point screen press twice Temperature Alarms High 80 0 F Low 60 0 F Delay 015 sec Press Prg enter th...

Page 97: ...urrent alarms press repeatedly noting each alarm Eventually the screen will show No more alarms NO MORE ALARMS Press ENTER to clear Press ALARM to view To clear the current alarms press The alarms are...

Page 98: ...STATUS after a short delay Select Configuration Menu 1 by pressing Prg and Esc at the same time Config Menu 1 System Run Hours Alarm History Control setup To select Alarm History press twice To view p...

Page 99: ...view the run times for the BLOWER and the HEATERS press EQUIPMENT RUN HOURS Blower xxxxxhrs Heat 1 xxxxxhrs Heat 2 xxxxxhrs To view the run times for the HUMIDIFIER and the FreeCool VALVES if any pre...

Page 100: ...flow of air and that the air is less than 105 F 4 For water cooled units check that water is flowing and of proper temperature 5 Check that all refrigerant isolation valves are open CORRECTIONS Consul...

Page 101: ...ller Diagnostics Operation ALARM 00 00 00 00 Fire detected CHECKS 1 Check for fire or smoke 2 Check for fire alarm input voltage CORRECTIONS If fire or smoke is found follow proper emergency procedure...

Page 102: ...after the compressor has been running for two minutes 6 Check the operation of the refrig erant low pressure switch It should open as the pressure falls below 20 PSI and close as the pressure rises ab...

Page 103: ...dows new electrical equipment more people than usual etc CORRECTIONS If controller does not agree with known good thermometer contact factory for corrective measures If room temperature is too high or...

Page 104: ...measures If the cable continuity is correct but the sensor resistance does not correspond to that shown in the chart for the known temperature the sensor must be replaced If controller does not agree...

Page 105: ...ling band 1 Heating Band may too small 2 Integral term may be too small CORRECTIONS Correct as necessary If the heating capacity is not sufficient contact factory for solutions Close any doors or wind...

Page 106: ...the load 2 Check for changes in humidity load since design stage CORRECTIONS If the humidifier capacity is not sufficient contact the factory for solutions Close any doors or windows that have been l...

Page 107: ...ear with relative humidity This signal cannot be calibrated in the field Contact the factory for software solutions Volts DC Relative humidity Air and fluid tem peratures are measured by NTC thermisto...

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