Installation Manual Uniflair™ LE Chilled Water HDCV4500, HDCV5000 208-230V/3Ph/60Hz 460V/3Ph/60Hz 575V/3Ph/60Hz 990-9621-001 Publication Date: August 2014 Schneider Electric IT Corporation Legal Disclaimer The information presented in this manual is not warranted by the Schneider Electric IT Corporation to be authoritative, error free, or complete. This publication is not meant to be a substitute for a detailed operational and site specific development plan. Therefore, Schneider Electric IT Corporation assumes no liability for damages, violations of codes, improper installation, system failures, or any other problems that could arise based on the use of this Publication. The information contained in this Publication is provided as is and has been prepared solely for the purpose of evaluating data center design and construction. This Publication has been compiled in good faith by Schneider Electric IT Corporation. However, no representation is made or warranty given, either express or implied, as to the completeness or accuracy of the information this Publication contains. IN NO EVENT SHALL SCHNEIDER ELECTRIC IT CORPORATION, OR ANY PARENT, AFFILIATE OR SUBSIDIARY COMPANY OF SCHNEIDER ELECTRIC IT CORPORATION OR THEIR RESPECTIVE OFFICERS, DIRECTORS, OR EMPLOYEES BE LIABLE FOR ANY DIRECT, INDIRECT, CONSEQUENTIAL, PUNITIVE, SPECIAL, OR INCIDENTAL DAMAGES (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS, CONTRACT, REVENUE, DATA, INFORMATION, OR BUSINESS INTERRUPTION) RESULTING FROM, ARISING OUT, OR IN CONNECTION WITH THE USE OF, OR INABILITY TO USE THIS PUBLICATION OR THE CONTENT, EVEN IF SCHNEIDER ELECTRIC IT CORPORATION HAS BEEN EXPRESSLY ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. SCHNEIDER ELECTRIC IT CORPORATION RESERVES THE RIGHT TO MAKE CHANGES OR UPDATES WITH RESPECT TO OR IN THE CONTENT OF THE PUBLICATION OR THE FORMAT THEREOF AT ANY TIME WITHOUT NOTICE. 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Table of Contents Safety ............................................................................................. 3 Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Warnings for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 General Information ................................................................... 6 Inspecting the Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Storing the Cooling Unit Before Installation. . . . . . . . . . . . . . . . . . . . . . .6 Cross-reference Symbol Used in this Manual . . . . . . . . . . . . . . . . . . . . .6 Equipment Guidelines............................................................... 7 Working Conditions and Environmental Limits . . . . . . . . . . . . . . . . . . . .7 Lifting and Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Unit Overview .............................................................................. 8 Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fan module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cooling unit and fan module . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Service clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Installation Area Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Component Identification.......................................................15 External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Uniflair LE Chilled Water Installation Manual i Display Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation .................................................................................. 19 Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disconnect Switch, Door, and Removing Panels . . . . . . . . . . . . . . . . . 23 Main Disconnect Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opening the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical panel access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 23 24 25 26 Unit Connections...................................................................... 27 Drainage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Placing and connecting the condensate pump to the drain . . . Connecting the fan module flexible tubing . . . . . . . . . . . . . . . Connecting to building gravity drains (without humidifier) . . . . Chilled water piping connections . . . . . . . . . . . . . . . . . . . . . . . Filling the chilled water circuit . . . . . . . . . . . . . . . . . . . . . . . . . 27 29 30 30 31 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Connecting power to the unit . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring a single power supply . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring a dual power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . Power source and power supply voltage settings . . . . . . . . . . Cooling unit electrical and communications connections . . . . 33 33 33 33 34 Network Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Accessories ............................................................................... 37 Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Supply water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Humidifier connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Drainage line and water supply line connections . . . . . . . . . . 39 ii Uniflair LE Chilled Water Installation Manual Safety Important Safety Information Read the instructions carefully to become familiar with the equipment before trying to install, operate, service, or maintain it. The following special messages may appear throughout this manual or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of this symbol to a Danger or Warning safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. 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 NOTICE addresses practices not related to physical injury including certain environmental hazards, potential damage or loss of data. Guidelines Schneider Electric will only consider itself responsible for the safety, reliability, and performance of the unit if: • Repair work has only been carried out by authorized personnel. • Electric installation conforms to the National Electric Code (NEC) and/or local code. • Devices are used in conformity with the appropriate instructions. Uniflair LE Chilled Water Installation Manual 3 WARNING VIOLATION OF SAFETY STANDARDS • Removal of or tampering with safety devices is a violation of safety standards and will void all warranties. Failure to follow these instructions can result in death, serious injury, or equipment damage. Carefully read this manual before performing any maintenance or work on the units. Installation, maintenance, and usage must meet all work safety standards. The operator responsible for the mentioned services must possess expert knowledge of the devices. Schneider Electric refuses all responsibility for damage resulting from the failure to follow safety standards. WARNING PERSONAL PROTECTIVE EQUIPMENT REQUIRED • During installation authorized personnel must wear approved personal protective equipment (PPE). Failure to follow these instructions can result in death, serious injury, or equipment damage. Electrical Safety Read and adhere to the following important safety considerations when working with this cooling unit. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Turn off all power supplying this equipment before working on the equipment. All electrical work must be performed by licensed electricians. Practice Lockout/Tagout procedures. Do not wear jewelry when working with electrical equipment. Failure to follow these instructions will result in death or serious injury. Warning for Lifting and Transportation Lifting and transporting the units must be carried out by specialized personnel as described in this manual. WARNING DAMAGE TO EQUIPMENT OR PERSONNEL • The equipment is heavy and can easily be tipped. For safety purposes, adequate personnel must be present when moving this equipment. • The load must always be solidly anchored to the bearing element of the lifting equipment and means of transport. • No one should be near the suspended load, nor in the working area of the crane, forklift, truck, or any other lifting equipment or means of transport. Failure to follow these instructions can result in death, serious injury, or equipment damage. Use all relevant safety standards to prevent any possible damage to people or objects. 4 Uniflair LE Chilled Water Installation Manual Warnings for Installation All work on the electrical installation must be carried out by licensed technicians only. Technical personnel must use appropriate equipment when checking the grounding of devices. Installation locations should be secure and limited to site authorized personnel or trained service technicians. WARNING HAZARD FROM MOVING 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 can result in death, serious injury, or equipment damage. Intended Use The cooling units have been designed and produced to provide air conditioning within the limits and methods described in this manual. The cooling units must be used exclusively indoors. No modifications may be made to the units or their parts without explicit written consent from Schneider Electric. Use the cooling units for the purpose for which they were designed. Any mechanical or electrical modification voids factory warranty. Uniflair LE Chilled Water Installation Manual 5 General Information The Uniflair chilled water cooling unit is a precision air conditioner designed to control environments for telecom rooms, Internet hubs, and data processing centers. This manual covers the chilled water precision cooling units. This manual describes the cooling units with 208-230V/3-phase/60Hz, 460V/3-phase/60Hz, and 575V/3-phase/ 60Hz power supply. It supplies general information, safety instructions, and unit installation procedures. The descriptions and illustrations in this manual are owned by Schneider Electric. Schneider Electric reserves the right to make any alterations it sees fit in order to improve the product without having to update this document. The illustrations in this manual are examples only and may differ from your product. All component locations depend on model type and configuration. Inspecting the Cooling Unit The two sections of HDCV units are packaged in wooden crates or anchored to a pallet and covered with transparent film. Upon delivery, check to make sure the unit is intact and immediately notify the carrier in writing of any damage that can be attributed to careless or improper transportation. Check for any damage on the area upon which the user terminal is mounted. In case of shipping damage, do not operate the cooling unit. Keep all packaging for used by the shipping company for inspection and contact Schneider Electric. Storing the Cooling Unit Before Installation NOTICE WEATHER DAMAGE Leaving the cooling unit uncovered and exposed to possible damage from the environment will void the factory warranty. Failure to follow these instructions can result in equipment damage. If storing the unit for a period of time, the following procedures must be followed: • The storage area must be dry (<85% R.H.) and protected against extreme temperatures 50°C (122°F). • The unit should remain in its original packaging if stored for long periods of time. Cross-reference Symbol Used in this Manual See another section of this document or another document for more information on this subject. 6 Uniflair LE Chilled Water Installation Manual Equipment Guidelines Working Conditions and Environmental Limits HDCV4500/5000 Limit Working Conditions Power supply voltage D: 208-230V/3Ph/60Hz G: 460V/3Ph/60Hz L: 575V/3Ph/60Hz V ±10% Unit power input tolerance Chilled Water Circuit Maximum inlet cold water temperature Minimum inlet cold water temperature Maximum glycol percentage Maximum operating pressure cold water circuit 25°C (77°F) 4.4°C (40°F) 50% 2400 kPa (348 psi) Air Temperature Maximum inlet air temperature Minimum inlet air temperature Maximum inlet relative humidity Minimum inlet relative humidity 38°C (100°F) 18°C (64°F) 70% 25% Maximum Three-way Valve Differential Pressure 320 kPa (47 PSI) is recommended to maintain normal operation of the valve actuator. * Mixtures HDCV units operate with pure water and with glycol mixtures. Glycol mixtures with water ethylene glycol or propylene glycol must not exceed a 50% volume. * Recommended 200kPa (29 PSI) to maintain normal operations of the valve actuator. Lifting and Rigging Using a forklift, pallet jack, or sling (spreader bar), move the fan module close to the required installation location. Pallet Jack Uniflair LE Chilled Water Installation Manual Forklift Sling Spreader Bar 7 Unit Overview The Uniflair LE Chilled Water with Underfloor Fans series is available in the following models: • HDCV4500D/G/L • HDCV5000D/G/L Downflow units are designed to distribute air through a void under a raised access floor or a front supply subbase plenum when a raised floor is not available. Return air enters the top of the unit directly from the environment or through a duct system. na5308a RAISED FLOOR UNDER FLOOR CONFIGURATION 8 ABOVE FLOOR CONFIGURATION Uniflair LE Chilled Water Installation Manual Model Nomenclature H D C V 45 0 0 D IDENTIFYING H = HIGH CAPACITY AIRFLOW PATTERN D = DOWNFLOW HEAT OF REJECTION TYPE C = CHILLED WATER UNITS FAN TYPE V = CENTRIFUGAL (EC) FANS WITH BACKWARD-CURVED BLADES WITH ELECTRONIC COMMUTATION MODEL NUMBER 45 = 150 kW, 50 = 180 kW NUMBER OF COMPRESSORS INSTALLED POWER SUPPLY VOLTAGE D = 208–230V/3Ph/60Hz G = 460V/3Ph/60Hz L = 575V/3Ph/60Hz na4900a NUMBER OF REFRIGERATION CIRCUITS Name Plate The units can be identified by the name plate which is placed in the electrical panel of the unit. The model and any additional accessories installed are indicated by an “X” in the corresponding box. The plate carries the following data: • Model and serial number • Type of power supply • Manufactured date • Overall electrical rating • Individual load electrical ratings • Revision details The following drawing provides an example of an HDCV unit name plate. Uniflair LE Chilled Water Installation Manual 9 ® 1660 Scenic Avenue Costa Mesa CA. 92626, USA Model Number HDCV5000L Section Number A Serial Number Manufacturing Date 07/14 Wiring diagram: Design pressure: Max outlet air temperature Max external static pressure (Max fan speed - Min airflow): 06SE0355 [0S-5063] / B [00] 24 bar / 348 PSI 35 °C / 95 °F 770 Pa / 3.09 im.w.g. Short-circuit current: 5 kA rms symmetrical, 600 V maximum Rev D SUPPLY VOLTAGE (LINE A) SUPPLY VOLTAGE (LINE B) Vers C 575V/3Ph/60Hz 575V/3Ph/60Hz NO. 24V/115V AUX VOLTAGE(V) FLA(A)[/1] RLA(A)[/1] LRA(A)[/1] P(kW/HP)[/1] )$1ĺĺ TRANSFORMER *TR1* TRANSFORMER *TR2+TR3* TRANSFORMER *TR4/TR5* TRANSFORMER *TR6a/TR6b* UNIT MCA MOP UNIT (+CONDENSATE DRAIN PUMP) MCA (+CONDENSATE DRAIN PUMP) MOP (+CONDENSATE DRAIN PUMP) 10 ĺĺ NO. 1 2 1 2 VOLTAGE(V) FLA(A)[/1] ĺĺ ĺĺ ĺĺ ĺĺ P(kW/HP)[/1] 0.35 0.10 0.20 3.00 FLA(A)[/1] 17;17;15.7 20A 20A P(kW/HP)[/1] 12.32/16.52 17.9;17.9;15.7 21A 20A 12.69/17.02 na5280a CONDENSATE DRAIN PUMP (OPTIONAL) Uniflair LE Chilled Water Installation Manual Dimensions and Weight Cooling unit C B na4891a A Frame Size Model Airflow 7 8 4500 5000 Downflow Downflow Uniflair LE Chilled Water Installation Manual Dimensions mm (in.) A B C Net Weight (Dry) kg (lb) 1960 (77.2) 1960 (77.2) 2580 (101.5) 3110 (122.4) 865 (34) 865 (34) 810 (1785) 890 (1962) 11 Fan module C na4841a B A Frame Size Model Airflow 7 8 4500 5000 Downflow Downflow Dimensions mm (in.) A B C Net Weight kg (lb) 550 (21.6) 550 (21.6) 2580 (101.5) 3110 (122.4) 865 (34) 865 (34) 260 (573) 310 (683) Cooling unit and fan module C B na4890a A 12 Frame Size Model Airflow 7 8 4500 5000 Downflow Downflow Dimensions mm (in.) A B C Net Weight kg (lb) 2510 (98.8) 2510 (98.8) 2580 (101.5) 3110 (122.4) 865 (34) 865 (34) 1200 (2645) 1350 (2976) Uniflair LE Chilled Water Installation Manual Service clearance na4834a 800 mm (32 in.) Installation Area Requirements The unit is designed for installation on raised access flooring using appropriate floor stands, supplied on request from Schneider Electric, or in non-raised floor environments. The installation area requires the following: • 800 mm (32 in.) of clearance on the front side of the assembled HDCV unit • Chilled water distribution piping • A drainage system • Air intake and discharge paths that are not blocked • Installation on a flat, level surface Uniflair LE Chilled Water Installation Manual 13 Component Identification na5256a External Components Item Uniflair LE Chilled Water Installation Manual Description Cover panels Display interface Electrical panel door handle Main disconnect Rubber seal Fan module 15 Display Interface Display Reset 10/100 USB Console 16 na4820a Micro SD Service Port Item Description Function LCD display 7-inch touch-screen color display. Power LED The display is powered when the LED is illuminated. Check Log LED When this LED is illuminated, a new entry has been made to the event log. Alarm LED Displays current alarm condition of unit. Status LED Displays current network management card status. Display Reset button Resets the display microprocessor. This has no effect on the air conditioner controller. Link-RX/TX (10/100) LED Displays current network link status. Micro SD card slot Memory card expansion slot. Service port USB-B port used only by service personnel. USB-A port Supports firmware upgrades and data extraction. Serial Configuration port Connects the display to a local computer to configure initial network settings or access the command line interface (CLI). Uniflair LE Chilled Water Installation Manual na5281a Internal Components Item Description Electrical panel door Junction box door (ATS) Junction box door Transformers (L version only) Fan Humidifier (optional) Condensate pump (optional) 2/3-way chilled water valve (optional) Electrical reheat (optional) 2-way dehumidification valve (optional) Cooling coil Filter Uniflair LE Chilled Water Installation Manual 17 Electrical components TSR1 TSR2 F1 F2 F3 F5 F6 F9 F10 F11 CPY pCOE uCAP SI SPD FS F4 F7 F12 RFF SAS TR2 R1 S1 T1 TR3 PFS SM4 CT1 CT2 SM5 SM6 CL1 SM7 CL2 CR1 CR1A CR2 CR2A TR4 CU IG IG na4889a TR1 RFS RD RMS CV RSR TR5 SEL TAM Item Description UPC5+s controller CPY module Expansion board Ultra capacitor Intermediate board AFPS (optional) Line contactors Main disconnect switch Transformers Contactors TAM (humidifier-optional) Line selector (optional) Item Description Time relay Selector 208-230 Overload cutout Clogged filters pressure switch Terminal block Auxiliary fuses Air flow pressure switch Flooding detector (optional) Distribution block Fuses Heaters thermostats (optional) NOTE: The location of components in the electrical panel depends on the unit type and configuration. 18 Uniflair LE Chilled Water Installation Manual Installation NOTICE EQUIPMENT DAMAGE RISK Install the unit in an area that is protected from adverse conditions. Failure to follow these instructions can result in equipment damage. NOTICE RISK OF SPILLAGE Installing the unit on an uneven surface may result in overflow spilling from the condensate tray. Failure to follow these instructions can result in equipment damage. Uniflair LE Chilled Water Installation Manual 19 Power Supply Requirements Review the electrical rating label on the equipment to determine the maximum possible draw of the equipment. Installation WARNING TIPPING HAZARD The equipment is heavy and can easily be tipped. For safety purposes, adequate personnel must be present when moving this equipment. Failure to follow these instructions can result in death, serious injury, or equipment damage. NOTICE EQUIPMENT DAMAGE Fan unit electrical/communication covers, chains, and screws must be removed before mounting the cooling unit on top of the fan unit. Failure to follow these instructions can result in equipment damage. 1. If using a stand, place it at the required installation location. NOTE: The stand is optional. 2. Using a forklift, pallet jack, or sling (spreader bar), move the fan module close to the required installation location. na4780a 3. Unbolt the fan module from the pallet. na5254a 4. Remove the electrical/communications covers, chains, and attaching screws on the fan unit. Safely discard this hardware away from the fan and cooling units. 5. If using a stand, place the fan module top of the stand. 20 Uniflair LE Chilled Water Installation Manual na4990a 6. Bolt the fan module to the stand with the bolts provided. NOTE: If placing the cooling unit above a raised floor, support must be provided for the unit. 7. The fan module can be placed above or below a raised floor. The following graphic shows the fan module beneath a raised floor. RAISED FLOOR na4935a FAN MODULE FLOOR STAND 8. Using the pallet jack or forklift, move the cooling unit close to the installation location. na5171a 9. The following illustration provides an example of the steps required to place the cooling unit on top of the fan unit. 10.Lift the cooling unit on top of the fan module. It is recommended that a flexible rubber seal at least 5 cm Uniflair LE Chilled Water Installation Manual 21 (2 in.) thick be placed between the raised floor panels and the cooling unit. RUBBER SEAL na4923a COOLING UNIT RAISED FLOOR PANELS FAN MODULE na4840a 11. Fasten the cooling unit to the fan module using the supplied screws. 22 Uniflair LE Chilled Water Installation Manual Disconnect Switch, Door, and Removing Panels WARNING ELECTRICAL HAZARD Before servicing, disconnect the power supply Failure to follow these instructions can result in death, serious injury, or equipment damage. WARNING HEAVY EQUIPMENT The panels are heavy. Use extreme caution when moving. Failure to follow these instructions can result in death, serious injury, or equipment damage. Main Disconnect Handle NOTE: The main disconnect handle must be turned to OFF before opening the door. Each cooling unit provides an external pistol-handle main disconnect switch and interlocking door. na4948a INTERLOCKING DOOR MAIN DISCONNECT HANDLE Opening the door 1. Turn the unit disconnect handle to the OFF position before opening the front panel. 2. Push the button and gently pull the handle outwards. Uniflair LE Chilled Water Installation Manual 23 na4947a 3. Turn the handle downwards until the door opens. Front panel removal 1. Firmly hold the panel at the top and pull straight out. na4906a 2. Lift and incline the panel outwards until it is completely removed. NOTE: After removing the side panels, a non-removable protective internal panel blocks access to the inside of the unit. 24 Uniflair LE Chilled Water Installation Manual Rear panel removal WARNING MOVING PARTS HAZARD Do not remove rear panels if the equipment is operating. Failure to follow these instructions can result in death, serious injury, or equipment damage. na4932a The mechanical compartment, the electric heaters (if present) and the humidifier (if present) are protected by internal protection panels for safety reasons and to allow the opening of the external panels without triggering the safety alarms. Uniflair LE Chilled Water Installation Manual 25 Electrical panel access 1. Loosen the screws securing the panel. 2. Firmly hold the panel. na4894a 3. Slowly pull the panel away from the unit until removed. DOOR ELECTRICAL PANEL COVER ELECTRICAL PANEL 26 Uniflair LE Chilled Water Installation Manual Unit Connections Drainage Connections Placing and connecting the condensate pump to the drain 1. Move the box containing the condensate pump from the cooling unit to the opening in the fan module . 2. Attach the box containing the condensate pump to the fan module with the two provided screws . na5155a 3. Remove the front panel . 4. Cut off any excess hose when connecting the condensate pump to the drain. The drain hose from the condensate pump to the drain must not have a trap or bend. na5327a NO TRAPS OR BENDS IN THE HOSE TO THE DRAIN Uniflair LE Chilled Water Installation Manual 27 na5328a 5. Connect the condensate pump drain to the drain line and secure with a clamp. 6. Replace the panel. 28 Uniflair LE Chilled Water Installation Manual Connecting the fan module flexible tubing Water from the exchanger coil drains into a condensate tray. This water drains through two, 22-mm (0.86-in.) flexible tubes. Flexible tubes are located on each side of the fan module, and both must be connected. 1. Remove the plastic clamp holding the flexible tubes to the fan module frame. There are drains on both sides of the units. Do not remove the plastic clamps that form the flexible tube traps. FLEXIBLE TUBE na4988a DO NOT REMOVE THE PLASTIC CLAMP FORMING THE TUBE TRAP FLEXIBLE TUBE 2. Connect the flexible tubing on both sides of the units to the condensate drain tray. na4997a FLEXIBLE TUBE 3. After connecting the flexible tubes on both sides, fill the flexible tubing with water for proper siphoning. Uniflair LE Chilled Water Installation Manual 29 na4737a Connecting to building gravity drains (without humidifier) Item Description Drain Trap Minimum slope 1. Connect the unit drainage tube to the building drains using a rubber or plastic tube with a 1 in. internal diameter. 2. Use a trap on the external drainage tube in order to avoid unpleasant odors and to allow the condensate pan to drain properly. Consult local building codes for drain requirements. 3. Once the connections have been made, pour water into the condensate drain until the trap inside the unit is full. See “Humidifier connections” for information about connecting to building drains on units with a humidifier. Chilled water piping connections NOTICE USE OF QUALIFIED TECHNICIANS • The laying of the lines and the water connections must be performed by a qualified technician. • All lines must be properly supported, insulated, and isolated to avoid premature joint failures due to system vibrations. Failure to follow these instructions can result in equipment damage. NOTE: Draining the unit is recommended after prolonged inactivity. NOTE: The following procedures do not apply to the condensate drain. For all water connections: 1. Use shutoff valves (not supplied) to isolate the unit from the water circuit. If possible, use full port-ball valves to minimize the pressure drop. 2. Check that the water pipe sizes and the circulating pump quality are adequate; insufficient water flow affects unit performance. 3. Check that the water flow directions are verified and connected properly between the unit and building. NOTE: Assure that all pipes are free of debris and assure all system strainers are in place and oriented in the correct direction. 4. Insulate all water pipes with closed cell insulating material (for example, Armaflex™ or equivalent), avoiding air gaps and condensation. The insulation must allow accessibility to the valves and threepiece joints. 5. Check that the water circuits are supplied with a maximum water pressure of 2068 kPa (350 psi). Install a safety valve with a setpoint of no more than 2068 kPa (300 psi). 30 Uniflair LE Chilled Water Installation Manual OUT na4998a IN Filling the chilled water circuit NOTE: Water used to fill the chilled water circuit must be filtered with a minimum 20 mesh stainless steel screen. NOTE: Filling the chilled water circuit must be done by a qualified mechanical contractor. 1. Disconnect the power supply. 2. Clean the primary circuits before filling the units (a particulate strainer should be installed in the supply water piping within close proximity to the unit). Uniflair LE Chilled Water Installation Manual 31 3. Check that all unit bleed air valves (on the upper part of the unit) are closed. na4979a BLEED AIR VALVES 4. Open the isolation valves (field installed) and fill the chilled water circuit. 5. Open the bleed air valve and wait for the water to flow. 6. Repeat step 5 if necessary to remove all air. Electrical Connections DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Turn off all power supplying this equipment before working on the equipment. All electrical work must be performed by licensed electricians. Practice Lockout/Tagout procedures. Do not wear jewelry when working with electrical equipment. Failure to follow these instructions will result in death or serious injury. WARNING USE OF QUALIFIED PERSONNEL • Electrical connections from the unit to the power supply must be performed by a licensed electrician. • Electrical lines must be installed in compliance with all local and national codes. Failure to follow these instructions can result in death, serious injury, or equipment damage. 32 Uniflair LE Chilled Water Installation Manual Connecting power to the unit 1. Use suitable equipment to check grounding system efficiency. 2. Ensure that the facility voltage and frequency correspond to those of the unit (see the name plate). 3. Ensure the main power switch is in the OFF position. 4. If locked, press the button on the door latch and rotate the handle downward to open the door. 5. Remove the panel (see “Front panel removal” on page 24). 6. Remove the metal cover of the main field wiring junction box. Wiring a single power supply 1. Route the power supply cable through the knock-out panel to the terminal block. 2. Connect the power cable to the terminal block using the diagram provided below. IG L1 L2 L3 L1 L2 L3 T1 T2 T3 T1 T2 T3 L1 L2 L3 PE POWER CABLE KNOCK-OUT PANEL SINGLE SOURCE POWER SUPPLY L10 L20 L30 PE na4899a IG ATS (DUAL POWER SOURCE) Wiring a dual power supply 1. Route the power cable through the knock-out panel to the terminal block. 2. Connect the power cable to the terminal block using the diagram provided in “Wiring a dual power supply” on page 33. Power source and power supply voltage settings Uniflair LE chilled water units provide a primary A, or backup B power supply. The power selector switch allows you to select the active power source. Note the following: • The switch does not physically move if the active power source changes. • If the active power A is selected and fails, B automatically supplies power. • If the active power B is selected and fails, A automatically supplies power. Uniflair LE Chilled Water Installation Manual 33 Uniflair LE chilled water units use 208V or 230V power voltage settings. The power voltage setting switch allows you to select the required voltage. POWER VOLTAGE SETTING SWITCH 208V 230V BACKUP PRIMARY B na4996a A PRIMARY (A) AND BACKUP POWER (B) SOURCE SWITCH Cooling unit electrical and communications connections The connection between the cooling unit and fan section is made with two cables: one for electrical power (Ma) and one for communication (Mb). Make these connections after installation is complete. Note the following when connecting the cables: • In order to ensure proper wiring, it is necessary to tighten the nut. • Do not connect or disconnect connectors under load. • During the connection and disconnection phases, avoid improper strains on the contacts. 34 Uniflair LE Chilled Water Installation Manual ELECTRICAL POWER CABLE Ma na4878a Mb COMMUNICATION CABLE Ma Uniflair LE Chilled Water Installation Manual Mb 35 Network Connection IG CPY pCOE uCAP SI SPD The microprocessor controller connects through the interface module to the Network Management Card (NMC), which is embedded in the touch screen display interface. CR1A CR2 CR2A TAM CR1 Network Display na4831a na4943a SEL RFS RD RMS CV CU SM4 SM5 SM6 SM7 TR1 TR3 T1 S1 R1 SAS F4 F12 RFF FS Com D1+D0Modbus INTERFACE MODULE LOCATION RJ-45 PORT FOR CUSTOMER CABLE 36 A-Link Display Interface RSR TR2 24VAC Uniflair LE Chilled Water Installation Manual Accessories na5091a Humidifier Item Description Steam outlet Humidifier cylinder Water supply solenoid valve Uniflair LE Chilled Water Installation Manual Item Description Water supply connections Water drain connection Cylinder drain solenoid valve 37 Supply water The following table provides values for the feed water for medium-high level of conductibility of a humidifier with immersed electrodes. Limits Description Units Minimum Maximum pH - 7 8.5 σ R, 20°C μS/cm 300 1250 Total dissolved solids TDS mg/l (1) (1) Residual fixed at 180°C R180 mg/l (1) (1) TH mg/l 100(2) 400 mg/l 60(3) 300 mg/l Fe + Mn 0 0.2 ppm Cl 0 30 Silica mg/l 0 20 Residual chloride mg/l 0 .2 Calcium sulphate mg/l 0 100 Metallic impurities mg/l 0 0 Solvents, soaps, and lubricants mg/l 0 0 Hydrogen ion activity Specific conductibility at 20°C Total hardness Temporary hardness Iron + manganese Chlorides (1) (2) (3) 38 Values dependent on the specific conductibility; in general: TDS @ 0,93 * s20; R180 @ 0,65 * s20 Not lower than 200% of the Chloride content in mg/l di ClNot lower than 300% of the Chloride content in mg/l di Cl- Uniflair LE Chilled Water Installation Manual Humidifier connections If a humidifier is installed, the unit requires a potable cold water supply. Condensate must be removed by a gravity drain using proper P-traps, or by an optional condensate pump. Humidifier installation requires connection to the water drain feed tubes. NOTE: A factory-supplied water hose connects the humidifier to the piping on site. 32 mm 1.25 in. 20 mm .78 in. na5257a min 5° Item Description Drain line Trap Filter replaceable water cartridge filter (recommended) Valve Feed tube Drainage line and water supply line connections WARNING HOT WATER HAZARD • Use caution when servicing the humidifier. The water discharged from the humidifier is at a very high temperature. • Use a drainage tube designed to withstand temperatures of at least 100°C (212°F). • Keep the drainage tube away from all electrical cables and refrigerant lines. Failure to follow these instructions can result in death, serious injury, or equipment damage. 1. Route the humidifier drainage line into a basin or drain pan using a rubber or plastic tube that is resistant to high temperatures with a minimum of 100°C (212°F) and a 20 mm (.78 in.) internal diameter. 2. Use a trap on the external drainage tube to avoid unpleasant odors and water overflow from the humidifier tray. Consult local building codes for drain requirements. 3. Once the connections are complete, pour water into the unit condensate collection tray and fill the in the humidifier condensate collection tray until the trap is full. Uniflair LE Chilled Water Installation Manual 39 Worldwide Customer Support Customer support for this or any other product is available at no charge in any of the following ways: • Visit the Schneider Electric Web site to access documents in the Schneider Electric Knowledge Base and to submit customer support requests. – www.schneider-electric.com (Corporate Headquarters) Connect to localized Schneider Electric Web sites for specific countries, each of which provides customer support information. – www.schneider-electric.com/support/ Global support searching Schneider Electric Knowledge Base and using e-support. • Contact the Schneider Electric Customer Support Center by telephone or e-mail. – Local, country-specific centers: go to www.schneider-electric.com > Support > Operations around the world for contact information. For information on how to obtain local customer support, contact the representative or other distributors from whom you purchased your product. As standards, specifications, and designs change from time to time, please ask for confirmation of the information given in this publication. © 2014 Schneider Electric. All Rights Reserved. Uniflair and the Schneider Electric logo are trademarks owned by Schneider Electric Industries SAS S.A.S., or its affiliated companies. All other trademarks are the property of their respective owners. 990-9621-001 8/2014
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