Westric IW Series Installation, Operation And Maintenance Manual Download Page 1

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Summary of Contents for IW Series

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Page 3: ...mbly 27 28 29 Electrical Wiring 30 Phase monitoring relay 31 Maximum distances and diameters of copper tubing 32 34 Maintenance 35 EC Fans Troubleshooting 36 System Operation 37 39 Danfoss Controller 40 Operation Panel Display and keys 41 42 PLC Screens 43 52 Operation Panel Display and keys configuration 52 TCP IP Link Web Server Optional 53 65 Controller Troubleshooting 65 Carel Humidifier Maint...

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Page 5: ...0V 60Hz 1ph G 380V 60Hz 3ph Stages Air Direction For Indoor Units For Outdoor Units 5 RT F Front and Back Return L Side and Back Return D Right Side an Back Return I Left Side an Back Return H Horizontal 6 to 15 RT A Upflow Controller For Indoor Units For Outdoor Units C Controller C Controller DX Units Only IW Series Indoor Unit Outdoor Unit C Scroll compressor inside M Variable Capacity compress...

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Page 7: ...arifies or simplifies a procedure DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided can result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided can result in minor or moderate injury NOTICE NO...

Page 8: ...VING PARTS Keep hands clothing and jewelry away from moving parts Check the equipment for foreign objects before closing the doors and starting the equipment Failure to follow these instructions will result in death or serious injury WARNING HAZARD OF EQUIPMENT FALLING OVER Use two or more persons at all times to move or turn this equipment Always push pull or turn while facing the front and rear ...

Page 9: ...tory programming Air Filters 30 30 medium efficiency filters ensuring the cleanliness of air circulating through the evaporator EC Fans High efficiency EC fans modulate their speed through the controller to obtain the necessary air flow for each moment of the refrigeration cycle in this way they increase the energy saving Clogged Air Filter Switch This device acts when the accumulated dirt on the ...

Page 10: ...eters etc The control panel is able to receive the signal from a power free contact from a fire control room this signal is used to switch off the units in case the fire alarm is triggered Main elements of unit panel Microprocessed controller Power Supply Transformer General circuit breaker Air inlet outlet temperatura sensors Relative Humidity Sensor Phase monitoring relay Terminal blocks Control...

Page 11: ...76 5276 05 Page 11 of 82 Different air flow configuration ...

Page 12: ...76 5276 05 Page 12 of 82 IW 005 006 Side Air Flow Rear Air Return Indoor Unit Dimensions ...

Page 13: ...76 5276 05 Page 13 of 82 IW 005 006 Front Air Flow Rear Air Return Indoor Unit Dimensions ...

Page 14: ...76 5276 05 Page 14 of 82 IW 005 Outdoor Unit Dimensions ...

Page 15: ...76 5276 05 Page 15 of 82 IW 006 Outdoor Unit Dimensions ...

Page 16: ...UTDOOR UNIT WIDTH mm 1160 771 OUTDOOR UNIT HEIGHT mm 757 945 OUTDOOR UNIT DEPTH mm 420 740 OUTDOOR UNIT WEIGHT Kg 75 110 85 120 WITHOUT COMPRESSOR WITH COMPRESSOR COMPRESSOR TYPE SCROLL VARIABLE CAPACITY SCROLL QUANTITY N 1 NOMINAL VOLTAGE 380 VAC 50 Hz 3 ph QUANTITY Kw 4 8 5 1 CURRENT DRAW Amp 8 4 8 9 OUTDOOR UNIT FAN TYPE AXIAL DIAMETER mm 508 550 QUANTITY N 1 DRIVE DIRECT OUTDOOR UNIT FAN MOTOR...

Page 17: ...RESISTORS OPTIONAL MODEL 3 x 800W QUANTITY Nº 1 NOMINAL VOLTAGE Volts 380 STAGES Nº 1 CURRENT DRAW AMP 3 6 A per PHASE POWER CONSUMPTION Kw 2 4 RECOMMENDED PIPE DIAMETERS FOR COMPRESSOR ON THE INDOOR UNIT SUCTION inch LIQUID inch 3 8 RECOMMENDED PIPE DIAMETERS FOR COMPRESSOR ON THE OUTDOOR UNIT SUCTION inch LIQUID inch 3 8 LOGIC CONTROLLER BRAND DANFOSS MODEL MCX ORIGIN Pais ROMANIA DRAIN PUMP OPT...

Page 18: ...ACITY Kw 18 2 19 2 21 5 Temperature and Humidity Working Range WARNING If the indoor humidity is too high the condensation effect around the coil can generate too much condensed water which could cause a water spill or trigger an alarm Nota If it is in a not operable condition use an auxiliary dehumidifier or an air conditioner to adjust the interior temperature and humidity until it falls within ...

Page 19: ...9 of 82 IW 005 006 External Components Item Description Item Description 1 PLC Display 6 Rear Door 2 Front Door 7 Top or bottom pipe access 3 Swiveling Casters 8 Top or bottom wire access 4 Wheels 5 Removable Side Panel ...

Page 20: ...n Item Description 1 EC Fans Qty 5 7 Evaporator Coil 2 Protection Grille 8 Service Valves 3 ON OFF Lever 9 Filter Drier 4 Operation Manual Holder 10 Humidity and Temperature Sensor 5 Drain Pump Optional 11 Power Factor Correction Capacitor 6 Compressor 12 Dirty Filter Pressure Switch ...

Page 21: ...76 5276 05 Page 21 of 82 IW 005 006 Internal Components rear view Item Description 13 Washable Air Filters 14 Electrical Panel slideable 15 High Temperature Limit Switch 16 Electrical Heater ...

Page 22: ...on Item Description 1 EC Fans Qty 5 8 Evaporator Coil 2 Protection Grille 9 Service Valves 3 ON OFF Lever 10 Power Factor Correction Capacitor 4 Operation Manual Holder 11 Humidity and Temperature Sensor 5 Drain Pump Optional 12 Dirty Filter Pressure Switch 6 Compressor 13 Humidifier 7 Filter Drier ...

Page 23: ...age 23 of 82 IW 005 006 Internal Components rear view with humidifier Item Description 14 Washable Air Filters 15 Electrical Panel slideable 16 High Temperature Limit Switch 17 Electrical Heater 18 Humidifier flute ...

Page 24: ...76 5276 05 Page 24 of 82 Slideable Electrical Panel View ...

Page 25: ...own the ramps Checking of unit upon receipt Upon receiving the units carefully inspect them to verify that they were not damaged during transportation and also that there are not missing parts Notify the company in writing of any damage that might have been caused during transportation Check that all items supplied with the units are included in the packaging as well as the items needed for instal...

Page 26: ...76 5276 05 Page 26 of 82 Once the unit is in its intended location use a wrench to adjust each leveling foot until it makes contact with the floor Adjust each foot until the unit is level and plumb ...

Page 27: ...76 5276 05 Page 27 of 82 Installation and Assembly ...

Page 28: ...th confined aisles Cold aisle Front Air Flow Only illustrative figure does not indicate the disposition nor the quantity of necessary equipment Hot aisle Side Air Flow Only illustrative figure does not indicate the disposition nor the quantity of necessary equipment ...

Page 29: ...76 5276 05 Page 29 of 82 Hot aisle Two Side Aire Flow Only illustrative figure does not indicate the disposition nor the quantity of necessary equipment ...

Page 30: ...h neutral identify reliaby the neutral wire and check that between phase and phase are the required 380V measuring between phases STANDARD COLOR CABLES Name COLOR R Phase Brown S Phase Black T Phase Red Neutral Light Blue Ground Yellow Green It s required BY SAFETY STANDARDS to connect the ground cable provided on the electrical panel with a terminal for this purpose Make sure that the voltage to ...

Page 31: ...there is more voltage than necessary wait for it to normalize LED U on Indicates that there is less voltage than necessary wait for it to normalize LED P on Indicates that there is a lack of one or more phases check the power supplier ABB CM MPS If the R T YELLOW LED is on it indicates that the operation is correct If the R T YELLOW LED flashes it indicates a timer working In case of a fault it wi...

Page 32: ... a trap should be made every 4 m approx between each the total sum should not exceed 9 m in height When you have greater heights than 9 m an oil separator must be placed between the compressor and the condensing coil to avoid the expulsion of the oil to the circuit and that can not return to the compressor due to the great height difference Important When get the pipes through the walls cover the ...

Page 33: ...llation is completed and after a period of operation check that the unit pressures are adequate high 480 psi and low 120 130 psi Verifying also that the power consumption of the compressor is at the nominal value of the manual Take care to cover a little the condenser coil if it is a cold or warm day to simulate approximately the pressures on a hot day ...

Page 34: ...of operation check that the unit pressures are adequate high 480 psi and low 120 130 psi Verifying also that the power consumption of the compressor is at the nominal value of the manual Take care to cover a little the condenser coil if it is a cold or warm day to simulate approximately the pressures on a hot day NOTICE TAKE THESE VALUES AS ESTIMATED AND ALWAYS VERIFY THEM WITH A UNIT TEST ...

Page 35: ...m When the coil is dry remove the thickest parts at sight with a brush then with a vacuum cleaner remove the dust If the coil still remains dirty or with signs of grease wash it with some light detergent Electrical Panel For the maintenance of the electrical panel of disconnect the General breaker Check the electrical panel by adjusting the contact screws and or breakers verify manually that the c...

Page 36: ... states and its corresponding indication LED STATE INDICATION Off No power Continuously Blinking Standby The board is waiting for the PLC to turn on the fans On The board is monitoring each fan state 1 Blink and a large pause Failure on Fan 1 2 Blinks and a large pause Failure on Fan 2 3 Blinks and a large pause Failure on Fan 3 4 Blinks and a large pause Failure on Fan 4 5 Blinks and a large paus...

Page 37: ...t condition of that air inlet It also has a relative humidity sensor Outlet air sensors Like the return sensors the unit has two output temperature sensors one placed one third the height from the floor and the second two thirds the height from the floor Cooling temperature control The controller modulates the speed of the fans that is governed by an algorithm in the program of the controller whic...

Page 38: ...ms the manual restore of the alarms is recorded and the power up of the controller Timers Dirty filter if the system detects a dirty filter it turns on an alarm but it does not turn off the unit in the adjustment values the number of hours that the unit can work in this state is determined after this period the unit stops All entries are filtered with a delay of 3 seconds to avoid false alarms by ...

Page 39: ...a reliable communication to connect all the units of the network with a ground cable Use a twisted pair to connect the differential signals and use another conductor for example a second twisted pair to connect the ground Standard topology The nodes must be connected according to the topology of the network This means that the communication cable is connected from one device to the next without de...

Page 40: ... modifications Reference A Power Source 24VAC B Expansion Valve C CAN communication with others master or slaves Westric s units D Analog inputs 1 to 7 E Digital outputs 1 to 5 F Digital output 6 G Analog outputs 1 to 3 H Not used I Communication RS 485 Modbus slave J Digital inputs 1 to 8 ...

Page 41: ...n without pressing any key the system returns to the main screen it is the screen that shows the unit function temperature humidity time and date Cleaning the screen Use a soft cloth lightly moistened with water PLC LEDs GREEN Normal No alarms present YELLOW Warning indicates that there was an alarm It is normalized by pressing X for a few seconds in the alarm menu RED Fail Indicates that an alarm...

Page 42: ...ng the first unit ES2 being the second etc Temperature shows the highest temperature of the unit s input or output sensors configurable the selected sensors are the ones used as reference for the setpoint Current relative humidity the sensor is in the suction of the unit If there is an alarm it is indicated by a blinking sign SENSORS STATES Selec Selec INPUT OUTPUT 27 5 C 14 4 C 27 5 C 14 4 C 30 9...

Page 43: ...umidity value is within the programmed range Humidity Alarm High 85 0 Low 25 0 In this screen the programmed values for the humidity alarm are displayed if the humidity exceeds any of these values the unit will fail The reset of this alarm is automatic when the ambient humidity value is within the programmed range Low pressure switch Retry Yes Time between Retries 5 Min In this screen you can see ...

Page 44: ...ram version recorded in the controller Alarm History Display From the main screen enter the main menu press enter Alarm History press enter Then pressing the or arrows you can see up to 50 historical faults each with a description of the fault date and time in which it occurred and date and time at which it was normalized After occupied position 50 the oldest ones are overwritten In addition to th...

Page 45: ...ff Compressor Starts in 59s Alarms Outputs Non Urgent Alarm On Urgent Alarm On The normal state of the alarm outputs is both outputs turned on that is both outputs with closed contacts under normal conditions You can request to the factory to switch these outputs when ordering the unit ...

Page 46: ...ge Non Used Login in User Settings User Settings L1 Settings Time Date Config Counters Reset On this screen you can enter to erase the hours of operation of the fans compressor resistance humidifier optional Also erase the operating hours with dirty filter Settings Select temperatura sensors Input or Output SES Input Selection of the sensors to be used by the setpoint Input Hot Aisle Suction Outpu...

Page 47: ...n the heating elements they lower the relative humidity and reheat the air this causes the compressor to start up in less time The electrical heater are never lit together with the compressor The option to dehumidify with resistors is optional and the user can enable or disable it It is only available in unit with resistors SetPoint Humidification SeH 30 0 When the humidity is below this Setpoint ...

Page 48: ... activated an alarm is activated the unit does not stop and a timer starts operating that counts hours of operation with dirty filter alarm if the timer arrives at the scheduled time the unit gives a new alarm and stops ATTENTION When replacing or cleaning the filter you must enter the settings to erase the operating hours counter with dirty filter if this task is not performed the unit will not s...

Page 49: ...ing it next to the field to be edited Press enter raise or lower with the arrows to adjust and then press enter again to accept the new value Resetting counters In this section of screens you can individually delete the operating hours of Compressor Resistance and each of the fans this deletion is indicated if you replace any of these components Resetting hours of dirty filter BHf NO Resetting hou...

Page 50: ... adjustments are already set at the factory this is done based on the data provided by the customer at the time of purchase they are also enabled so that trained personnel can modify them if necessary Unit Number Jer ES1 Unit number configuration all must have a correlative numbering N C Do not use Additional Units CEs 1 With this parameter it is indicated how many additional unit is in this netwo...

Page 51: ...e we observe the current parameters of the expansion valve controller Only available on models with electronic expansion valve controller integrated in the PLC Pwd change 2nd Level Second level installer password in this screen you can change the second level password ATTENTION If you are going to change the password please keep the new one in a place where you can recover it in case of forgetfuln...

Page 52: ...ressed at the same time for a few seconds In the menu place the parameters as shown below STARTUP MODE Remote application COM SELECTION CAN MCX SELECTION Auto detect CAN NODE ID select number according to the PLC to which it is connected see table CAN BAUDRATE 50K PLC CAN SCREEN UNIT 1 ES1 21 UNIT 2 ES2 22 UNIT 3 ES3 23 UNIT 4 ES4 24 ...

Page 53: ...r the state of the system from a remote location HTML pages can be easily customized and downloaded by the end user Widely used programs can be used to create custom HTML pages for example Macromedia DreamWeaver or Microsoft FrontPage or to download them to the Web server via FTP Loading the web page The website is already loaded from the factory Anyway we detail below how to do it The web page is...

Page 54: ...new files Turn off and then turn on the PLC wait 1 minute Login to the website To enter the PLC website for the first time you must enter with the following information IP 192 168 0 250 User admin Password admin Configuration of the Web server parameters Login to Settings System Here you can change the parameters to access the PLC Web server By default the IP address is 192 168 0 250 and the subne...

Page 55: ...rd maintenance Level 2 service password service Level 3 admin password admin Each level has access to different parameters and the ability or not to modify them Administrator admin is the one who can define the names of all users their passwords and access levels You also have access to all the parameters and the right to change them Service You can edit and add users from levels 0 and 1 You can c...

Page 56: ...all the unit connected to the network Units In View of the network when you click on a computer you enter the section with all the data of that unit Overview Here we can visualize the parameters that we consider most relevant and for which we want to have faster access By clicking on Manage you can add or remove the parameters that we see here ...

Page 57: ...able PLC data divided into folders We have the current parameters inputs outputs and alarms Edit a value When clicking on the value of a parameter that can be edited a window will appear to edit it Alarms Here we see all the active alarms of the selected unit ...

Page 58: ... selected unit Backup Here we can select the parameters that we want to store in a backup copy of the unit in question Pressing Backup configuration will be stored in a file on the Web server Restore In the case of having made a backup of the PLC parameters the file will be seen in order to restore the stored values ...

Page 59: ...otice 1 Select the Alarm and Warning boxes 2 Configure the network where the PLC is located Fill network parameters Configure the e mail server Configure the data of the E mail server Name of the Site is the name that the E mail will show it is recommended that it identify the unit s in question While the level of security and configuration will be the responsibility of the client we provide below...

Page 60: ...76 5276 05 Page 60 of 82 Settings for Gmail ...

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Page 62: ...76 5276 05 Page 62 of 82 Place Allow unsafe applications access in YES Configuration for Yahoo ...

Page 63: ...76 5276 05 Page 63 of 82 Activate Allow applications with less secure deposit methods Then save and reset the web server Settings System Reset Test the configuration by sending an e mail test ...

Page 64: ...work cable connection 54 MAIL_FAIL_SSL_CONFIG_DEFAULT Contact Agent 55 MAIL_FAIL_SSL_CONF_OWN_CERT Contact Agent 56 MAIL_FAIL_SSL_SETUP Contact Agent 57 MAIL_FAIL_SSL_SET_HOSTNAME Contact Agent 58 MAIL_FAIL_HANDSHAKE Contact Agent 59 MAIL_FAIL_GET_HEADER_FROM_SERVER Contact Agent 60 MAIL_FAIL_EHLO Contact Agent 61 MAIL_FAIL_START_TLS The E mail server does not support TLS mode Check the configurat...

Page 65: ... is not cooling Check if the ambient temperature is higher than the value preset in the program The unit is not heating Check if the ambient temperature is lower than the value preset in the program The unit is not dehumidifying Check if the humidity of the environment is higher than the preset value ...

Page 66: ...with the water and therefore the flow of current Clean the electrodes mechanically or chemically with some existing descaling product in the market If the electrodes do not allow their regeneration the cylinder must be replaced the replacement consists only of the cylinder body and the lining Renew the cylinder following the previous operations in the opposite direction after checking or replacing...

Page 67: ...pipe to the unit open the water source and let water run for a few minutes to clean the pipe of any impurities that may clog the fill or drain valves or that may cause damage to the electrodes The humidifier is controlled by a system that automatically loads water into the drum measures the conductivity of the water and based on the current flowing through the electrodes adds or drains water to wo...

Page 68: ... conductivity limit values for submerged electrode humidifiers Limits Min Max Hydrogen ions pH 7 8 5 Specific conductivity at 20 C σR 20 C μS cm 125 500 Total dissolved solids TDS mg l 1 1 Dry waste at 180 C R180 mg l 1 1 Total hardness TH mg l CaCO3 50 2 250 Temporary hardness mg l CaCO3 30 3 150 Iron Magnesium mg l Fe Mn 0 0 2 Chlorides ppm Cl 0 20 Silicon dioxide mg l SiO2 0 20 Residual chlorin...

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Page 70: ...6 High water conductivity alarm threshold Increase the high water conductivity alarm threshold with parameter b6 AUTO yes signal only humidif stopped Conductivity of the water higher than 1250 μS cm Treat the supply water with RO and ensure the minimum supply water requirements see the KUE manual The water conductivity must be between 75 and 1250 μS cm Softening the water may worsen the problem Co...

Page 71: ... is detached from the valve the water may ﬂow directly to the drain through the ﬁll tank as the ﬂow rate is too high If this is the case replace the valve 3 Replace the board Red LED on board if terminal not connected description cause solution reset press alarm relay activation action 4 slowﬂashes Low steam ﬂow rate during reduced production The steam ﬂow rate is estimated by the TAM circuit Cond...

Page 72: ...etergents in the supply water at times the water hoses are dirty after installation Wash all water supply hoses thoroughly The water conductivity must be between 75 and1250 μS cm Softening the water may worsen the problem ESC no signal only Softened water High level sensor short circuited If possible open the cylinder and clean it Malfunction of the high level sensor electrical circuit Make sure t...

Page 73: ...76 5276 05 Page 73 of 82 Drain Pump Optional ...

Page 74: ...operates continuou sly and insufficie ntly 1 The unit is not enough to cool the room 1 Make a heat balance determine capacity to be added 2 Damaged component malfunction 2 Replace damaged switches adjust loose blowers clean dirty coils 3 Gas leaks 3 Repair gas leaks install and or adjust service valve caps and nuts Charge additional gas 4 Defective compressor 4 Replace compressor 5 Clogged air fil...

Page 75: ...76 5276 05 Page 75 of 82 PLC Electrical connection diagram with remote display ...

Page 76: ...76 5276 05 Page 76 of 82 IW 005 006 Control Electrical Diagram ...

Page 77: ...76 5276 05 Page 77 of 82 IW 005 Power Electrical Diagram ...

Page 78: ...76 5276 05 Page 78 of 82 IW 006 Power Electrical Diagram ...

Page 79: ...76 5276 05 Page 79 of 82 IW 005 Power Electrical Diagram no humidifier no resistors Ext Digital Comp ...

Page 80: ...76 5276 05 Page 80 of 82 IW 005 Power Electrical Diagram with or without humidifier Ext Digital Comp ...

Page 81: ...76 5276 05 Page 81 of 82 IW 005 Control Electrical Diagram with or without humidifier Ext Digital Comp ...

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