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Version 1.3, 2021-12-14

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About this manual

Scope of this manual

This manual describes the safety issues, preparation of the installation location
and installation of the IntrCooll®.

Caution
Before installing the IntrCooll®, read this manual closely to get familiar with the
functioning and strictly observe the given indications and instructions. If you do
not understand any part of the information in this manual, contact your local
service department.

The information contained in this manual is based on the latest information. It is
provided subject to alterations.

Audience

This manual includes information for:
-

Consultants,

-

Installation engineers,

-

Service / maintenance engineers.

Normal preparations and installation of the IntrCooll®, requires that these
persons:
-

have read this manual and understand the contents,

-

have been adequately trained,

-

are able to reproduce the procedures in this manual,

-

have enough technical knowledge and experience to carry out the assigned
tasks,

-

can recognize and prevent hazards.

Caution
Only qualified technicians are allowed to unpack and install the equipment.

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Summary of Contents for 3800OXYSTD

Page 1: ...IntrCooll Std Plus Direct Indirect evaporative cooler Manual Installation Version Version 1 3 Date 14 12 2021 ...

Page 2: ......

Page 3: ...for ducting 26 3 8 Roof transits for cabling plumbing 26 3 9 Supply air ducting 26 3 10 Exhaust air 27 3 11 Water requirements 29 3 12 Drain connection requirements 31 3 13 Overflow connection requirements 31 3 14 Water connections 32 3 15 Electrical requirements 36 3 16 Communication requirements 37 4 Install the IntrCooll 41 4 1 Preparations 41 4 2 Step 1 Positioning and leveling 42 4 3 Step 2 D...

Page 4: ...4 ...

Page 5: ...roval of Oxycom Spare parts other than those supplied by Oxycom are used The product is used for a purpose or in a way it was not designed for The product is treated in an improper careless incorrect and or negligent manner A defect or damage occurs to the product as result of an external cause and or situation for which Oxycom cannot be held responsible The warranty does not cover use in especial...

Page 6: ...2 Part 1 standard The most important The seals are made of Polyethylene PE and are of the closed cell type The seals are tested according to DIN EN ISO 846 and fulfill the requirements from the VDI 6022 Part 1 in terms of microbial inertness Parts of the housing that are exposed to water are covered with a powder coating The instructions in this document do not take into account different national...

Page 7: ...artment The information contained in this manual is based on the latest information It is provided subject to alterations Audience This manual includes information for Consultants Installation engineers Service maintenance engineers Normal preparations and installation of the IntrCooll requires that these persons have read this manual and understand the contents have been adequately trained are ab...

Page 8: ...er button Bullets and are used for lists of items or actions Single quotation marks and are used for quotations Bold text is used for sub titles and for information that needs special attention Read these instructions carefully Menu names in the user interface are always shown in italics for example the Main Menu Control elements like soft keys keyboard buttons hardware buttons and rotary knobs ar...

Page 9: ...ble near the IntrCooll Related documents This manual is part of the documentation set for the machine Installation manual The manual contains relevant items for the installation of the unit Also information for commissioning and unit settings are given Safety information sheet This document contains the safety related information for the unit As a hardcopy it is available inside the unit behind a ...

Page 10: ...10 ...

Page 11: ... recommendation applies regardless of other regulations that are issued by a higher authority or included in a safety standard The owner must ensure that personnel are qualified to perform the activities involved Caution Before operation or maintenance be sure to read and understand the safety information The safety information can be found behind the electrical panel on the IntrCooll ...

Page 12: ...Sticker manuals inside 12 ...

Page 13: ...for shortages or errors should be made immediately on receipt No responsibility will be assumed for delay damage or loss of material while in transit or as result of transit Broken damaged or loss of material should be refused or a full description of the damage or loss should be made to the carrier agent on the freight or express bill At the delivery do a check on the packaging to see if it is da...

Page 14: ...o unauthorized persons are in the vicinity Caution Always place the IntrCooll on a stable loading floor with sufficient load bearing capacity Caution Oxycom is not responsible for damage resulting from incorrect transport and storage Warranty rights will not be accepted in the event of incorrect transport and storage 2 3 Handling and storage When the IntrCooll is stored or moved before or between ...

Page 15: ...f crates see Transport IntrCooll Std Max 1 crate is allowed IntrCooll Plus Do not stack the crates Do not load other items on top of the crates Keep dry Handle with care Caution Never place the IntrCooll directly on the sump or the valves This will damage the IntrCooll ...

Page 16: ...ied on a wooden pallet with a cardboard cover Use a forklift to move the crate Please note the following The equipment is heavy Make sure the capacity of the forklift is sufficient to handle the equipment See Dimensions and weight Use forks with a correct length Obey the icons and instructions on the crate for correct forklift use Always obey local safety regulations for forklifts 16 ...

Page 17: ...ll has heavy parts Risk of crushing body parts or severe damage to the IntrCooll when handling lifting or moving Danger The safe working load of the lifting cables should be sufficiently high Cables which are not supplied as standard with the IntrCooll should have a safety factor of at least 5 Caution Never place the IntrCooll directly on the sump or the valve this will damage the IntrCooll Cautio...

Page 18: ...Lifting instructions A Rope length Rope length A IntrCooll Std 2 m minimum 4x IntrCooll Plus 3 6 m minimum 4x Maximum rope angle 30 18 ...

Page 19: ...ation can be found behind the electrical panel on the IntrCooll There are several methods accessories to support the equipment on the roof each having its own requirements Below a description on installation of IntrCooll on a standard support frame to be provided by contractor Optionally there are also plug and play solutions available not described in this manual Flashing kit and Natural Ventilat...

Page 20: ...it 3 1 1 Weight requirements For weight information of the unit refer to the specification sheets 3 1 2 Space requirements 3 1 2 1 Equipment dimensions For dimension information of the unit refer to the specification sheets IntrCooll Std IntrCooll Plus 3 1 2 2 Connection locations Bottom view with connections 20 ...

Page 21: ...oll Plus 11 4 male connection 5 Pump compartment 6 Drain valve 1 male connection 7 50 Hz 60 Hz by pass compartment Standard the 50 Hz cap is mounted 3 1 2 3 Free space around equipment The IntrCooll needs sufficient space around the unit to ensure that it functions correct and to make servicing possible The recommended minimum free space around the IntrCooll is 1000 mm for at least three sides of ...

Page 22: ...t frame can be ordered at Oxycom Article no 5301251 support frame for IntrCooll Std Article no 5301305 support frame for IntrCooll Plus Refer to the accessories brochure for more information on the optional support frame If the contractor provides a support frame Oxycom recommends the use of a support frame with the following specifications The profile for the welded frame is galvanized steel L pr...

Page 23: ...tilator As an option a natural ventilator can be ordered at Oxycom Refer to the accessories brochure for more information on the natural ventilator 3 4 Flashing kit IntrCooll Optional The IntrCooll can also be mounted on an optional Flashing kit This kit and associated installation instructions are available separately from Oxycom IntrCooll mounted on optional Flashing Kit ...

Page 24: ...cting Steel support beams examples Already present in the construction installed by the contractor 3 6 Opening and curb To install the IntrCooll properly prepare the building on the proposed installation location of the IntrCooll Prepare an opening in the roof of at least add additional space the construction around the ducting IntrCooll Std 600 mm x 600 mm IntrCooll Plus 900 mm x 900 mm The unit ...

Page 25: ...Prepare the location Version 1 3 2021 12 14 25 1 2 3 4 5 Example of a roof curb Wrong installation example poor accessibility of the drain valve ...

Page 26: ...ape Note For a IntrCooll Plus with a natural ventilator the use of a roof transit for cabling is not necessary With this setup the cabling goes through the natural ventilator to the unit To guarantee a waterproof transit of power cables control cables and water supply lines use commercially available products with the same functionalities as the examples below 3 9 Supply air ducting Duct specifica...

Page 27: ...the building at ceiling level as high as possible When natural vents are used overpressure these can be powered and controlled by the IntrCooll with a 0 V 10 V modulating control signal and 24 VDC maximum 5 watt power supply IntrCooll PCB connector to control and power the vent actuator J8 The contractor shall provide and install a 3 wire cable between the IntrCooll and the vent actuator Note Use ...

Page 28: ...n the IntrCooll and the exhaust fan and a separate power supply cable to a local mains power source IntrCooll PCB connector to control the exhaust fan J7 It is advised to install fans with capacity equal to the amount of air supplied by the IntrCooll The IntrCooll software has the ability to slightly reduce the airflow field setting to prevent negative pressure inside the building Note Make sure t...

Page 29: ...nctioning of the system Please consult Oxycom for a tailored advice specific for your situation The supplied tap water or reversed osmosis water must meet the requirements according to the table below Tap water 1 Reverse osmosis water Less than 1500 hours year Food medical industry Less maintenance Parameter Unit Supply Recirculation Supply Recirculation pH value 7 2 8 2 7 2 8 2 7 2 8 2 7 2 8 2 El...

Page 30: ...nsor that continuously measures the conductivity of the supply water When the upper limit factory setting is reached the entire water content in the tank is drained and replaced with clean supply water 3 11 1 3 Oxycom Water Quality Calculator Please contact Oxycom to be sure the supply water meets the supply water requirements on page 29 Use the Oxycom Water Quality Calculator to Check if the init...

Page 31: ...he distance between the connection and the rooftop i e to prevent dripping noise connect an extension tube to the drain It is possible to connect the drain valve to a local drain circuit 3 13 Overflow connection requirements The overflow connection on the IntrCooll can be set up in two different configurations The drain valve discharges directly onto the roof top To bridge the distance between the...

Page 32: ... to the mains water supply The water supply and drain piping must comply with the requirements as described in this manual Connection types Water supply hose and drain piping example Note Hoses and piping must be provided and installed by the contractor 32 ...

Page 33: ...iping and installation must be provided and executed by the contractor Oxycom recommends to Install a shut off valve with drain option for each unit for service maintenance reasons The drain can be used for emptying the tubing for the winter period in combination the optional freeze protection valve set ...

Page 34: ...ions close operation open winter drain 4 2 way valve for winter with positions open operation close winter 5 Accessory Freeze protection valve set art 5301085 6 Filter 0 1 mm not necessary in combination with R0 installation 7 Booster pump optional 8 Central water meter optional 9 Insulate pipework and place on slope 10 Maintenance valve with water tap 11 Shut off valve with positions open operati...

Page 35: ... to prevent excessive resistance To prevent accumulation of water on the rooftop make sure the water discharges from the roof via e g a gutter Note At removal of the transport plug residual water may flow out of the unit Note If the drain valve is connected to the sewer use unions to guarantee easy access to the drain valve when necessary 3 14 3 Overflow connections Requirements for overflow pipin...

Page 36: ...nce purposes 3 15 Electrical requirements 3 15 1 Unit specifications Refer to the specifications of the IntrCooll on page 67 for all specifications of the IntrCooll Std and Plus 3 15 2 Power supply fuse Oxycom demands the installation of an automated circuit breaker between the power source and the IntrCooll The external fuse must comply to the following specifications 3P N At least 16A Type C An ...

Page 37: ...er outlet near the IntrCooll This can be used by the service technician for maintenance equipment 3 16 Communication requirements There are several possibilities to control the IntrCooll The correct choice depends on the situation and specific requirements 3 16 1 Thermostat control IntrCooll can be controlled by a thermostat unless it is controlled by a BMS system The thermostat must be ordered se...

Page 38: ...erior wall close to a heat source or in a supply airflow of the IntrCooll Note It is advised to install an insulated plate on the back of the thermostat to minimize radiation from the wall 3 16 2 Oxyconnect gateway control Oxyconnect gateway control allows the control of multiple IntrCooll s by one or more thermostats It also provides for remote monitoring configuration and control ethernet connec...

Page 39: ...unit AHU There are two different control options Modbus RTU RS485 Analog control 6 wire cable 3 16 4 1 Modbus RTU RS485 Controller I 0 I 0 type I 0 function Protocol Connection type Connection J17 Isolated RS485 port Modbus control Modbus RTU 2 wire Pin 1 A Pin 3 B 3 16 4 2 Analog control 6 wire cable Controller I 0 I 0 type I 0 function Signal type Connection type Connection J6 Analog input Fan s...

Page 40: ... J12 0 no circuit Free Cooling 1 circuit Cooling J23 Alarm signal collective feedback to AHU 40 ...

Page 41: ...klift or pallet truck Caution Always secure the load tightly with specially designated securing chains Caution Always place the IntrCooll on a stable loading floor with sufficient load bearing capacity Note Oxycom is not responsible for damage resulting from incorrect transport and storage Warranty rights will not be accepted in the event of incorrect transport and storage During transport and ins...

Page 42: ...sitioning and leveling Caution Always place the unit level to prevent damage and to ensure correct functioning Make sure the local facilities match the required facilities for the IntrCooll Refer to Installation requirements Positioning and leveling 4 3 Step 2 Duct connection to the IntrCooll The design of the IntrCooll facilitates to connect the unit directly to the duct via the duct connection u...

Page 43: ... roof The overflow connection may be combined with the drain If the wastewater is discharged onto the roof local discoloration can occur due to minerals calcium Duct connection face do not screw in the red zone Example flexible duct connector 4 4 Step 3 Drain valve installation The drain valve must be installed to the IntrCooll It is delivered together with the IntrCooll but not installed on the u...

Page 44: ...anel back in its original position afterwards 3 Mount the drain valve to the 11 2 BSP Female fitting which is located at the bottom side of the IntrCooll Use tread sealant or sealing tape between the threads 4 Place cover panel on the valve Make sure the valve is positioned correct The valve must drain onto the roof or into the drain piping 44 ...

Page 45: ...ifference between the amount of water the pump delivers at 50 Hz or 60 Hz Because of this it is necessary to mount the correct flow regulator cap Standard the 50 Hz version is mounted The 60 Hz version is strapped near the mounting position Exchange the regulator cap if necessary Caution On the IntrCooll Plus 60 Hz version the flow regulator cap must be completely removed not mounted Flow regulato...

Page 46: ...ns water supply 1 Install the approved stop valve between the mains water supply and the supply solenoid of the IntrCooll 2 Install the approved pressure reducing valve to prevent that the pressure in the cold water supply pipe exceeds the maximum working pressure of 6 bar 87 psi 3 Use a flexible hose to connect the IntrCooll to the mains water supply to prevent from water hammer Drain connection ...

Page 47: ...a short 2m power supply cable to connect to the main switch or terminal box which is provided and installed by the contractor If this power supply cable is too short a new cable must be installed at the same connections Connect the new cable to the internal switch and to earth screwed terminal connector Oxycom recommends the use of a cable according to the following specifications Type H07RN F or ...

Page 48: ...hermostat is J17 2 wires used for RS485 communication 2 wires for 24 VDC power supply 4 8 Step 7 Finish the installation To finish the installation 1 Check the following No tools and peripherals remain in the interior of the IntrCooll All components are in place All tubes and hoses are re connected All electrical components are re connected 2 Place all covers on the unit 4 8 1 Step 7b Fill out ins...

Page 49: ...ocation requirements on page 20 D If the unit is placed elevated more than 1 5 m above roof floor a service platform with minimum free space see 2 A and 2 B is provided o o Remarks 3 Equipment installation YES NO A Support frame s for IntrCooll not applicable for optional Flashing Kit or Natural Ventilator module o o Support frame Not provided B Equipment will be placed level to prevent water leak...

Page 50: ...cal connections on page 47 E Power supply cable connected correctly o o Electrical connections on page 47 F Power supply cable of equipment maximum 1 5m will be connected to an external terminal box so that equipment can easily be disconnected when necessary o o G Equipment will be earthed o o Electrical connections on page 47 H Main power outlet for service maintenance available on the roof in cl...

Page 51: ...o o Control by an air handling unit on page 39 Remarks 6 Water Supply requirements YES NO A Local water quality according to specification o o Supply water quality requirements B Measured and noted the conductivity of the water on the site o o Supply water quality requirements C Water Supply according to specifications o o Supply connections D Shut off valve provided and installed by contractor o ...

Page 52: ...52 ...

Page 53: ...the IntrCooll is connected The correct filters are installed The correct flow regulator cap 50 Hz 60 Hz is installed The drain is connected to a local drain circuit The IntrCooll is connected to the mains power supply The maintenance switch is in ON position The padlock switch is in ON postion The thermostat is switched on and connected to the IntrCooll For correct settings refer to the enclosed d...

Page 54: ...by turning the main switch 1 on The OxyLogic display will light up and the unit will start up It can take up to several minutes until the unit will start depending on the settings 4 Remove the cover of the pump section 5 Check if the pump rotates in the right direction The arrow on top shows the direction counterclockwise If this is not correct it must be corrected refer to the wiring diagram for ...

Page 55: ...a maximum of 60 minutes after which it is automatically emptied Note If the IntrCooll did not receive a cooling request for an hour the drying cycle automatically starts When the IntrCooll cools the whole day the drying cycle starts at night time set Note The Oxyvap pads need to dry to minimize bacterial growth The silver ions in the coating on the slats can kill the bacteria present Note Only whe...

Page 56: ...e IntrCooll service documentation for the maintenance instructions According to the maintenance instructions the IntrCooll requires mid season cleaning each season Therefore the IntrCooll must be put in cleaning mode To activate cleaning mode Press and hold buttons 1 and 2 on the OxyLogic LCD and hold for 5 seconds 5 1 5 3 Bring the IntrCooll back into service Before using the IntrCooll after it i...

Page 57: ...into Advanced mode g Click Read settings h Read the Differential Pressure value from the Readings tab This value must match the ISP value which you can find in the supplied Datasheet If a setting is not correct change it 7 To change a setting a Select a parameter tab that needs correction Heating parameters Free Cooling parameters Cooling parameters b Adjust the Supply air fan speed Maximum fan sp...

Page 58: ...ain is activated Water disinfection is deactivated The pump is deactivated The drain valve will open and all water will be drained When the tank is empty the water supply solenoid will open for 10 seconds to flush the tank When the tank is empty the drain valve will be closed and the supply solenoid opened to refill the tank until level high is reached When one of the 2 conditions for cooling ceas...

Page 59: ...y active in the IntrCooll Display menu The actual state of various components inside the unit These values have the prefix W Settings menu Setpoints that can be changed These items have the prefix S Error messages These items have the prefix Error To view select edit or reset the values on the OxyLogic LCD there are 3 buttons near the OxyLogic LCD on the PCB OxyLogic LCD 1 Navigation button 1 2 Na...

Page 60: ...easured actual power consumption if optional energy meter is selected W13 Amperage Measured value Amps Measured actual amperage if optional energy meter is selected W14 Voltage Measured value Volt Voltage if optional energy meter is selected W15 PressureLoss Measured value Pa Differential pressure over Oxyvap Filter Coil filter fouling can be derived from this value W16 Water flow Measured value l...

Page 61: ...s Local time derived from thermostat W33 Software version Shows the current software version on the Oxylogic 5 2 4 Operating modes Operating modes Operating mode Description Heat reclaim Unit is in heating mode only when Heat Reclaim is activated Free cooling Unit is in free cooling mode cooling with outdoor air without water Standby Stand by Tank fill Unit is filling the water tank Pre wet Unit i...

Page 62: ... increased rates S07 OverflowProt Setting 15 15 Seconds Overflow protection timer opening itme of drain valve when level high is reached S08 Rinse Setting 10 10 Seconds Flsuh duration after draining opening time of supply solenoid S09 Heat Reclaim Setting Off Off Enable of disable HeatReclaim heating mode enable when Heat Reclaim or 4S module is used for this unit S10 Operation Method Setting Auto...

Page 63: ...us baudrate S23 Modbus Parity Setting 8N1 8N1 Unit modbus parity S24 Drain Valve Setting 2 wire N O 2 wire N O Configure drain valve type older units have 3 wire valves new units have 2 wire valve S25 Water Desinfection Setting None None UV C Lamp on off Optional S26 Digital Input J12 Setting Not used Not used Select function of digital input J12 Not used AHU pre cooling Fire contact S27 Winter Mo...

Page 64: ...07 A Outdoor temperature sensor shows deviating value check or replace sensor Port 1 Error 08 08 B Supply temperature sensor shows deviating value check or replace sensor Port 3 Error 09 09 B No connection with thermostat or network Modbus check cables and parameters Port 16 Error 10 10 A Error supply fan check cables and fan Port 13 Error 11 11 A Error exhaust fan check cables and fan Port 14 Err...

Page 65: ...irmware file in the folder Software Update firmware on the IntrCooll using USB 1 On the OxyLogic LCD press and hold the navigation button 1 and the reset button 3 simultaneously 2 Release the reset button 3 3 When the OxyLogic LCD shows USB ready release the navigation button 1 The OxyLogic LCD is now ready for updating 4 Plug in the USB to Micro USB data cable to connect OxyLogic with your laptop...

Page 66: ...procedure Ethernet Update firmware on the IntrCooll using Ethernet 1 Connect Ethernet cable to the OxyLogic module 2 Connect the Ethernet cable to the laptop 3 Configure the LAN settings on the laptop IP adres 192 168 0 30 Subnet 255 255 255 0 Gateway 192 168 0 1 4 Right mouse click on UpdateTool file and click Run as administrator important 5 The UpdateTool opens 6 Click on Select port Ethernet A...

Page 67: ...Version 1 3 2021 12 14 67 Appendices ...

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