Chiller IT 500 Series Installation, Operating, & Maintenance Instructions

IT 500 Appliance Series

Installation Instructions
Operating Instructions
Maintenance Instructions

Read this manual carefully before installing and operating the appliance.
Chiller Oy assumes no legal responsibility for any damages resulting from
installation or maintenance.

IT500-IOM27102002FIN

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Contents

1. Transport and storage

2. Warranty terms

3. Safety

4. Technical specification and data plate of the appliance

5. Dimension drawings

6. Operation of the appliance

7. Setting values of the sensors and safety devices

8. Installation of the appliance

9. Connecting the appliance to the power supply

10. Activating the appliance

11. Connection data of the electrical components

12. Maintenance of the appliance

13. Troubleshooting table

14. Manufacturer’s warranty

15. List of spare parts

16. Replacing the fans

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Important

This product has been designed not to cause any risks for the maintenance personnel installing the
appliance nor to the environment. It is important to observe the hereby provided instructions during
installation and maintenance works.
All maintenance procedures that require maintenance operations inside the appliance are to be
performed by the qualified personnel. The appliance contains pressurised cooling gases, hot
surfaces, moving components (e.g. fans) and various electrical components.

Always disconnect the power supply before attempting any maintenance operations.
Make sure the appliance has been provided with and connected to power supply specified on
the data plate.
Chiller Oy assumes no legal responsibility for any damages resulting from installation or
maintenance.

1. Transport and Storage

The appliance is shipped on a pallet. Use auxiliary machinery for transportation. Do not remove the
protective packaging before you begin with the installation procedures. Make sure the delivery
corresponds to your order. Always store the appliance in a dry and preferably warm room.
Make sure the delivery contains all accessories indicated in the documents. Any shipping damages
on the appliance are to be reported to the shipping company within 24 hours from the delivery of
the appliance. Shipping damages must always be recorded on the freight bill. Chiller Oy guarantees
the dispatch of a faultless appliance from the plant.

2. Warranty Terms

Chiller Oy warranties the appliance for 12 months from the date of commissioning or for 18 months
from the date of delivery, whichever occurs first. The warranty is valid provided that no
modifications have been performed on the appliance without the manufacturer’s written consent.
Warranty treatment presupposes advising the manufacturer of the full type and full serial number of
the appliance.

3. Safety

The cooling appliance produced by Chiller Oy is designed and manufactured in compliance with the
applicable legislation. Please read these instructions carefully before taking any measures. Always
employ qualified installation personnel and observe applicable local laws. Should the laws conflict
with the connections made and instructions given by Chiller Oy, observe the established law but
provide your measures with an approval from Chiller Oy.

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4. Technical Specifications of the Appliance

Operation / Appliance IT 540 IT 560

Total cooling capacity kW 4.5 6
Sensible cooling capacity kW 3 5
Power consumption kW 1.6 1.9
Power supply V-Ph-Hz 230-1-50 400-3-50
Evaporator air flow m3/h 1,100 1,100
Free cooling capacity + 10°C kW 4.5 4.5
Air flow through free cooling m3/h 800 800
Infiltration rate of intake air EU4 EU4
Cooling agent (standard supply) R407C R407C
Length L mm 1,620 1,620
Width B mm 800 800
Height H mm 450 450
Grille width BC 900 900
Grille height HC 550 550
Installation hole dimensions B*H mm 820*470 820*470
Weight of the appliance kg 147 153

Cooling capacity by indoor conditions 27°C, 50%; outside temperature 30°C.

Data plate information:

- Model and serial number

- Power supply

- Power consumption

- Setting values of the pressure switches

- Type and volume of cooling agent used for the appliance.

The data plate is attached to the cover of the electrical board.

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5. Dimension Drawings

A = ELECTRICAL BOARD F = CONDENSER FAN
B = SERVICE DOOR FOR THE FAN G = SERVICE DOOR FOR THE CONDENSER
C = SERVICE DOOR FOR THE COMPRESSOR H = EXHAUST AIR GRILLE
D = FREE COOLING WITH INTAKE AIR I = FREE COOLING IN
E = EXHAUST

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6. Operation of the Appliance

Wiring diagram of the IT500 appliance series.

The appliance is activated by the S1 switch in the electrical board. The TC regulator adjusts the
indoor temperature in 2 stages according to the indications of the room sensor TE1. The room
sensor TE1 is placed on the insulation layer on the end wall of the appliance.

1. Stage
When the indoor temperature rises above the setting value of the room sensor TE1, the intake air
fan P1 is activated to provide free cooling intake air into the room, and the damper motor M opens
the exhaust and intake air dampers that are positioned on the same axle. Outside temperature
exceeding the setting value of the sensor TE3, the fan P1 is not allowed to operate. When the
temperature in the intake air duct falls below the setting value of sensor TE2, the TC regulator
controls the damper motor so as to prevent declining under the setting value of sensor TE2.
The intake air fan is placed under the maintenance cover between the electrical board and the
damper motor. The damper motor M is placed uncovered on the same side as the electrical board.
The sensor TE2 is placed in the exhaust duct and the sensor TE3 in the intake duct close to the
intake grille.

2. Stage

Continuing rise in the indoor temperature activates compressor circulation. The compressor K1 and
the condenser fan P3 are activated and accompanied by the air circulation fan P2 of the evaporator
coil.

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Breakdown:

- Power failure

- The thermal relay of the compressor trips (to be acknowledged)

- The high pressure switch of the compressor trips (to be acknowledged)

- The low pressure switch of the compressor trips (to be acknowledged).

When a breakdown occurs, the relay D1 deactivates the compressor. When the indoor temperature
exceeds its setting value, the free cooling fan P1 is activated and the damper controlling the free
cooling is opened.

Alarm:

When a breakdown occurs, the relay D2 gives an alarm (contact data). When the breakdown is
cleared, the alarm stays on until it is switched off by the S2 switch.

Electrical board of the appliance

Sensor TE1 Sensor TE2

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Sensor TE3

Fan P1 Fan P2

Fan P3 Motorized damper M

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High pressure switch - Compressor – Low pressure switch

Grille

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7. Setting Values of the Sensors and Safety Devices

Appliance Setting value °C

TE1 + 25

TE2 + 12

TE3 + 18

Appliance Setting value bar

LPS 2…3.5

HPS 17.5…24

LPS = low pressure switch
HPS = high pressure switch

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8. Installation of the Appliance

The IT500 series appliance is mounted directly into horizontal position, leaving ab. 10 cm of space
between the top of the appliance and the ceiling. On both sides of the appliance the presence of a
servicing space of ab. 1 metre is required. Observe the local safety regulations, if these prescribe
otherwise. The appliance must not be installed in a room where there are inflammable or explosive
substances or in rooms with chemicals that are aggressive to plastic, copper or aluminium.
Do not install the appliance above electronic devices or furniture, as condense water may
accidentally drip from the appliance. Make sure the condense pipe allows the water a free flow out
of the appliance. The supply of cooled air into the room is to be unobstructed. The blowing grids are
to stand at 45° angle to the grille, with only one of the grilles closed.
It is recommended to install the appliance in the opening made above the entrance door, in order to
save the valuable floor area and provide the appliance with natural safety distances.

Saw into the wall an opening of 820*470 mm.
Chiller Oy assumes no legal responsibility for any damages appearing during the installation
or maintenance.

A = OUTSIDE GRILLE
B = INSTALLATION SLATS

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Installation Opening

Place an ab. 10 mm thick strip of mineral wool on the bottom of the installation opening, as close to
the surface of the external wall as possible. Lift the appliance into the opening so that its outer
surface is in line with the external surface of the wall (use an installation stop on the outer surface
of the opening to make the installation easier) and fasten it to the ceiling with 8 mm threaded bars.
Lock the fastenings on both sides. There have to be 4 fastening points. Fastening is to be performed
using the supplied mounting bars. Place the insulation (mineral wool) entirely between the
appliance and the installation opening, so as to provide a tight insulation. Should vandalism be a
threat, fasten the l-formed sheet metal strips between the appliance and the wall. The metal sheets
are fastened with 7 mm self-tapping screws. Supporting of the appliance requires special attention
in cases when the appliance has been installed in a space that is transported from one place to
another. The above-described method of supporting does not suffice then. Fasten the grille to the
external side and make sure the condensate pipe extends out of the appliance. Finally, fasten the air
intake grille that accompanies the appliance in a separate cardboard box together with eight screws.
Provided the supply air filter is panel shaped, it is already installed in the appliance. A bag filter is
delivered separately and needs to be fastened on the installation site. Chiller Oy assumes no legal
responsibility for any damages appearing during the installation or maintenance.

Method of installation of the appliance

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Fastening with a locking nut

A = NUT
B = WASHER
C = TWIN NUT

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9. Connecting the Appliance to the Power Supply

The electrical connection may only be performed by a respectively qualified person. Make sure the
power supply corresponds to the specifications on the data plate (voltage, frequency, phases). Make
sure mains cable is not connected to the electric system of the house. Lead the power supply cable
through the purposive opening to the electric board and make sure the protection switch of the
appliance is in the OFF position. The maximum allowed voltage fluctuation is 5% and the
maximum voltage difference between the phases is 2%. Should the mentioned limit values be
exceeded, the warranty of the appliance is not applicable.
The fans of the appliance operate on single phase but the compressor may be single-phase or three­phase.

Position of the power cable of the appliance

10. Starting the Appliance

Having completed the installation, perform the following checks before starting the appliance.

- The appliance has been installed in horizontal position on the proper point of installation.

- The appliance is provided with the minimum safety distances.

- The condense water flows out through the external grille as required.

- Power supply has been lead to the appliance correctly.

- Voltage, frequency and phases correspond to the values given on the data plate.

- The cables are fixed to their places.

- See that the appliance is not missing any cooling agent.

The pressure on the cooling agent side is to conform to the corresponding temperature. Pressure of
7 bar corresponds to the temperature of 15 °C and the 11 bar pressure to the temperature of 23 °C,
provided cooling agent R22 is used.

1. Make sure voltage is provided to the control unit.

2. Turn the main switch of the appliance to the ON position.

3. Make sure the fans and compressors rotate in the correct direction.

4. Set the desired room temperature.

5. Check the appliance for abnormal noise.

A = POWER SUPPLY
B = LOCKING OF THE HEATING
C = EXTERNAL ALARM

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6. Test the damper motor to check its proper operation.

7. Make sure power consumption corresponds to the provided values.

Operate the appliance ab. 2 hours to let the pressures become even.

11. Maintenance of the Appliance

Before starting the maintenance make sure the appliance has been unplugged and no voltage
is supplied.
Chiller Oy assumes no legal responsibility for any damages appearing during the installation
or maintenance.

Make sure the control equipment operates correctly.
Make sure cooling agent is not missing from the appliance.
Make sure the control damper operates correctly.
Make sure there are no loose electric connections.

Open the suction grid of the plastic grille under the appliance. The grid is fastened with four screws,
each of which is to be turned 90°. There are hinges on one edge of the grille. Do not break the
hinges loose. Remove the filter under the grille and replace it with a new one. Wash the old filter in
order to get an exchange filter. There is an intake air filter at the end of the appliance. Remove the
filter and replace it with a new one. If this filter is quickly clogged, immediately start using the bag
filter, that can be fastened to the end of the appliance.
Open on both sides of the appliance the maintenance hatches nearest to the wall and vacuum the
condenser element clean.
The axle of the damper motor rotates in the opening made into the damper. Apply a thin layer of
petrolatum to both sides of the openings, if dry.
If for some reason you need to add some cooling agent to the appliance, measure the substance
accurately. Make sure undercooling is 3…5 °C below the condensation temperature and
overheating in the exhaust pipe of the evaporator is ab. 5…8 °C. This work may be performed by a
professional refrigerator fitter only.

If oil needs to be added to the appliance, we recommend the following types of oil:

Cooling agent Oil

R22 Sunico 3GS or Texaco WF32

R407C Mobil EAL Arctic 22CC, ICI Emkarate RL 32S

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12. Connection Data of the Electrical Components

IT540

Component Voltage Connection capacity kW Operating current A
Compressor 230-1-50 1.34 6.6

Evaporator fan 230-1-50 0.043 0.2
Condenser fan 230-1-50 0.35 2.8
Free cooling fan 230-1-50 0.09 0.9

IT560

Component Voltage Connection capacity kW Operating current A
Compressor 400-3-50 1.8 4.5

Evaporator fan 230-1-50 0.043 0.2
Condenser fan 230-1-50 0.35 2.8
Free cooling fan 230-1-50 0.09 0.95

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13. Troubleshooting table

Fault Cause Remedy

The appliance does not operate There is no power supply Check the power supply

The appliance does not start The regulator does not start the appliance Check the functioning of the regulator

Room temperature is high The appliance does not operate Detect the cause of not starting
Wrong setting values Change the setting values
Air volume too low Check the filters
The compressor does not start

See the item ‘compressor does not operate’

The automatics does not function Check the regulating equipment
The load exceeds the nominal load Accept the small rise in heat

Room temperature is low Wrong setting value Change the setting value
The regulator does not function Check the regulator and the sensors

Low air volume No power supply Check the power supply
The filter is clogged Clean the filter
The thermal protection of the fan is

switched on Switch off the thermal protection, detect the
cause

High pressure switch switches on The control of the condensation

pressure does not function Check the control of the condensation pressure
The fan of the condenser has stopped Detect the cause of stopping
The high pressure switch is set incorrectly Replace the switch

Low pressure switch switches on The low pressure switch is set incorrectly Replace the switch
The condensation pressure is too low Increase the setting of the regulator
The battery is frozen Defrost the appliance, check the freezing protection
board
The filter of the evaporator is clogged Clean the filter

The compressor does not operate The fuse has switched on Check the fuse and detect the cause
The thermal protection has switched on Check the thermal protection and detect the cause
The contactor does not function Replace the contactor
The compressor does not receive a starting

command Check the automatics

The free cooling does not function The damper motor does not operate Repair or replace the damper motor
Wrong setting values in the regulator Change the setting values
The control system does not function Repair the control system

The damper motor remains open The damper motor is damaged Repair or replace the damper motor

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EC Declaration of Conformity

Directive 98/37/-II A

Chiller Oy, Louhostie 2, 04300 Tuusula Finland

Declares under its sole responsibility that the construction of the units:

IT540, IT560,

To which this declaration relates, is in conformity with the following directives:

98/37/EEC; 73/23/EEC; 89/336/EEC.

Tuusula 28.10.2002

Heikki Lahdenperä
Managing Director

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15. List of Spare Parts

IT540

Code Description Quantity in the appliance pcs.

COM540I Compressor 1
FAN014F Evaporator fan 1
FAN021I Condenser fan 1
FAN031I Free cooling fan 1
CH200F Freezing protection board 1
CH300I Control board 1
MOT100I Damper motor 1
FLR001F Evaporator filter 1
FLR100I Free cooling horizontal filter 1
FLR200F Free cooling bag filter 1
GRL003F Intake grille 1
KNO001F Screws of the intake grille 4
DIFF003F Blowing grid 4
PAN006I Condensation neck 1
COV003F Suction cone 1
EVP100I Evaporator 1
CDS200I Condenser 1

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IT560

Code Description Quantity in the appliance pcs.

COM560I Compressor 1
FAN014F Evaporator fan 1
FAN021I Condenser fan 1
FAN031I Free cooling fan 1
CH200F Freezing protection board 1
CH300I Control board 1
MOT100I Damper motor 1
FLR001F Evaporator filter 1
FLR100I Free cooling horizontal filter 1
FLR200F Free cooling bag filter 1
GRL003F Intake grille 1
KNO001F Screws of the intake grille 4
DIFF003F Blowing grid 4
PAN006I Condensation neck 1
COV003F Suction cone 1
EVP100I Evaporator 1
CDS200I Condenser 1

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17. Replacing the Fan Assemblies

Before starting the maintenance, make sure the appliance has been unplugged and no voltage
is supplied.
This maintenance work may be performed by a professional only.
Chiller Oy assumes no legal responsibility for any damages appearing during the installation
or maintenance.

Fan P1 (free cooling fan)
Switch the power of the appliance off. Open the maintenance hatch B. Disconnect the cable of the

fan motor from the terminal box. Loosen the two screws of the wall fastening flange of the fan. To
remove the fan, pull it towards yourself. Install a new fan using the same mounting bars. Make sure
the fastening is tight. Connect the cable to the terminal box. Close the maintenance hatch B. Start
the appliance.

Fan P2 (evaporator fan)
Switch the power of the appliance off. Remove the central grid of the plastic grille under the

appliance. See the instructions for changing the filter. Open and remove the frame flange. The
flange is fastened with eight screws. Remove the suction cone and mark its position. Loosen the
screws fastening the condensation neck of the appliance. These are located in the corners of the
styrox-part.
Disconnect the motor from the appliance electrically. Loosen the screw in the centre of the fan and
pull the fan straight downwards. Be careful as the fan may be tightly fixed. Loosen the screws in the
corners of the motor stand. The motor is fastened by the rear side of the motor stand. Mount the
motor in the stand and fasten the motor stand to its place. Fasten to the motor the new blade that
was supplied. It is important not to mix the blades up as the motor and the blade are balanced
together. Connect the motor to the appliance electrically and make sure the cables will not be loose
in the appliance. Fix the condensation neck to its place. Install the suction cone to its place,
preferably to the same position as before. Turn the fan by hand and make sure it can rotate freely.
Fix the frame flange, filter and central grid to their places. Having accomplished the work, start the
appliance.

Fan P3 (condenser fan)
Switch the power of the appliance off. Remove the outside grille in front of the appliance. Behind

the grille the fan to be changed can be found. The fan is fastened to the frame of the appliance with
a fixing flange. Loosen the screws of the fixing flange and pull off the fan. To enable this operation,
some loose cable is left inside the appliance. Disconnect the motor from the appliance electrically.
Attach the old fixing flange to the new fan. Fasten the fan assembly to its place. Turn the fan by
hand and make sure it can rotate freely. Fix the outside grille to its place. Start the appliance.