Liebert Hiross HPS 10L, HPS 12L, HPS 14L, HPS060/A, HPS080/A Service Manual

H

P

S

SERVICE MANUAL

English

Cod. 273000

Rev. 16.02.2006

Issued by T.D.Service

Caution

Recommendations:

S the manual is retained for the entire service life of the machine;
S the user reads the manual carefully before carrying out any operations on the machine;
S the machine is used exclusively for the purpose for which it is intended; incorrect use of the machine shall release the

manufacturer from any liability.

This manual has been prepared to enable the end ---user to carry out only the operations that can made with the panels
closed. Any operations that require the opening of doors or equipment panels must be carried out only by qualified
personnel.
Each machine is equipped with an electric isolating device which allows the operator to work in conditions of safety. This
device must always be used to eliminate risks during maintenance (electric shocks, scalds, automatic restarting, moving
parts and remote control).
The panel key supplied with the unit must be kept by the person responsible for maintenance.

For identification of the unit (model and serial no.) in case of the necessity for assistance or spare parts, read the identification
label placed on the outside and inside of the unit.

IMPORTANT:

1

4

7

10

12

14

18

19

21

23

25

This manual may be subject to modification; for complete and up---to---date information the user should
always consult the manual supplied with the machine.

Attention: data relevant to the unit supplied
is indicated on the inboard label (see the blank facsimi­le below).
Data in the manual is referred to standard conditions
and can be modified without any advance notice.

POS. DESCRIPTION

1 Compressor Full Load Ampere [A]

2 Compressor Locked Rotor Ampere [A]

3 Compressor quantity

4 Evaporator fan Full Load Ampere [A]

5 Evaporator fan Locked Rotor Ampere [A]

6 Evaporator fan quantity

7 Condenser fan Full Load Ampere [A]

8 Condenser fan Locked Rotor Ampere [A]

9 Condenser fan quantity

10 Electrical heating Ampere

11 Electrical heating steps

12 Humidifier Ampere

13 Steam production capacity

14 Max. unit AC Ampere

15 Max. unit DC Ampere

16 Rated peak withstand current

17 Rated short --- time current

18 Refrigerant type

19 High pressure switch Stop

20 High pressure switch Restart

21 Low pressure switch Stop

22 Low pressure switch Restart

23 Min. room operation temperature

24 Max. room operation temperature

25 Min. room operation humidity

26 Max. room operation humidity

27 Max. refrigeration circuit pressure

15

11

2

5

8

3

6

9

13

16

17

20

22

24

26

27

Index

1 -- Preliminary operations pag. 1...............................................................

1.1 --- Foreword pag. 1.......................................................................................

1.2 --- Check operating limits pag. 1............................................................................

1.3 -- - Check sound pressure levels pag. 1.......................................................................

1.4 --- Conditioner inspection pag. 1............................................................................

1 . 5 --- Tr a n s p o r t pag. 1.......................................................................................

1 . 6 --- S e a l i n g t h e r o o m pag. 1.................................................................................

1.7 --- Servicing areas pag. 1..................................................................................

2 -- Installation pag. 1..........................................................................

2.1 --- Overall dimensions pag. 1...............................................................................

2.2 - -- Positioning the HPSE indoor unit pag. 1...................................................................

2.3 --- Positioning two inner HPSE units pag. 1...................................................................

2.4 --- Freecooling duct connections (optional) pag. 1.............................................................

2.5 --- Positioning the HPSC condensing unit pag. 2...............................................................

2.6 --- Refrigeration connections pag. 2.........................................................................

2.7 --- Condensate drain connection pag. 3......................................................................

2.8 --- Electrical connections and wiring diagram (supplied with the unit) pag. 3.......................................

2.9 --- User interface pag. 3....................................................................................

2.10 --- Emergency cooling version (EFC 48 VDC / 230 VAC) pag. 3.................................................

2.11 --- Electrical protection pag. 3..............................................................................

3 -- Starting and stopping pag. 3................................................................

3 . 1 --- F i r s t s t a r t --- u p ( o r af t e r a l o n g ha l t ) pag. 3..................................................................

3 . 2 --- S t a r t --- u p wi t h lo w o u t s i d e t e m p e r a t u r e (o n l y o n “ H P S C x x A / L” m o d e l s ) p a g . 3...................................

3 . 3 --- S e l f te s t pag. 3.........................................................................................

3.4 --- Starting and stopping pag. 4.............................................................................

4-- Operation pag. 4............................................................................

4.1 --- Control of the condenser fan speed (“HPSCxxA/L” models only) pag. 4.........................................

4.2 --- Emergency cooling (optional) pag. 4......................................................................

5-- Operatinglogic pag. 4......................................................................

5.1 --- Cooling only unit pag. 4.................................................................................

5.2 --- Unit with electric heating pag. 4..........................................................................

5.3 --- Unit with freecooling pag. 5..............................................................................

5.4 --- LAN local network management: Stand---by and Cascade modes pag. 5.......................................

5.5 --- Alarm control pag. 5....................................................................................

6 -- Settings pag. 5.............................................................................

7 -- Maintenance / Spare parts pag. 6............................................................

7.1 --- Routine maintenance pag. 6.............................................................................

7.2 --- Extraordinary maintenance pag. 6........................................................................

7.3 --- Dismantling the unit pag. 7..............................................................................

7.4 --- Spare parts pag. 7.....................................................................................

8 -- Appendix pag. 8............................................................................

8.1 --- Check the unit after the installation pag. 8..................................................................

Ta b l e s pag. 9....................................................................................

Drawings / Circuits pag. 17.......................................................................

1 --- Preliminary operations

1.1 --- Foreword

This manual covers the installation, operation and mainten­ance of HPS air conditioners, which are composed of an
evaporating unit (HPSE), positioned in the room, and a con­densing unit (HPSC), positioned outside.

IMPORTANT:

Also consult the manual for the microprocessor control.

1.2 --- Check operating limits

The units are designed to operate within specific working
ranges (see Tab. 1, Tab. 2, Tab. 3, Tab. 4, Tab. 5 and Tab. 6).
These limits are referred to new machines or for those that
have been correctly installed and serviced. The warranty
clauses are no longer valid for any damage or malfunction
that may occur during or due to operation outside the ap­plication range.

1.3 --- Check sound pressure levels

Tab. 1, Tab. 2, Tab. 3, Tab. 4, Tab. 5 and Tab. 6 show the in­ternal (HPSE) and external (HPSC) sound pressure levels for
units in standard configuration, in continuous operation, at
2m from the front surface of the machine, 1m above base
level, and referred to free field conditions.

1.4 --- Conditioner inspection

On receiving the equipment immediately inspect its condi­tion; report any damage to the transport company at once.

(e.g. acid vapours).

S Position the internal evaporating unit (HPSE) so as to op-

timise the indoor air distribution and avoid hot spots.

S Position the indoor unit preferably in the centre of the

room ceiling.

S Fix the unit to the ceiling by inserting expansion or

through clamps (in this case ensure the clamp is sealed)
using the slots on the two side brackets (see Fig. 2a,
Fig. 2b and Fig. 2c).

S Make sure the airflow circulates freely.
S To allow the servicing of the unit, the Service Area shown

in Fig. 2a and Fig. 2b, has to be left unobstructed (in
Fig. 2a the 300 mm minimum clearance from the back of
the evaporating unit is compulsory).

S Check if the unit is horizontal on both sides ”A” and

”B” (see. Fig. a).

Fig. a) Horizontal level control

“A” “B ”

1 . 5 --- Tr a n s p o r t

S Always keep the unit vertically upright and do not leave

it in the open.

S While carrying the unit, avoid exerting any pressure on

the upper corners of the package.

S Unpack the unit as close as possible to its installation

position. Once unpacked, avoid any impact to its internal
components.

1.6 --- Sealing the room

To create stable thermohygrometric conditions within the
room, proceed as follows:

S vapour seal the walls, floor and ceiling using an imperme-

able material;

S make sure that the room is airtight by sealing all gaps,

cable entries, etc.

1.7 --- Servicing areas

The unit must be provided with a suitable service area (see
Fig. 4).
All maintenance of the evaporating unit can be carried out as
shown in Fig. 2a and Fig. 2b.
Access to the condensing unit is provided by removable pan­els with screw fixings.

2 --- I n s t a l l a t i o n

CAUTION:

The evaporating unit (HPSE) must never be installed out­doors.

2.1 --- Overall dimensions

See Fig. 1a, Fig. 1b, Fig. 1c, Fig. 1d, Fig. 1e and Fig. 1f for
the overall dimensions of the evaporating unit (HPSE) and
external condensing unit (HPSC).

2.2 --- Positioning the HPSE indoor unit

S Unpack the unit as close as possible to the place where

it has to be installed. Once unpacked, avoid stress and
any impact to its internal components.

S The indoor unit can be installed in any indoor location

provided it is not exposed to an aggressive environment

2.3 --- Positioning two inner HPSE units

The ceiling installation of two units operating in the same
room must be carefully evaluated, considering the following
factors:

1) each intake side of the machine must be able to intake as
much as the other two;

2) possible ”Freecooling” function;

3) the thermal loads to be dissipated can be true hot air
flows hitting the intake sides of the machines: in this case,
the two intake sides of the two machines can be arranged
even at a short distance (up to 300 mm) to intake the ther­mal load where it is highest.

2.4 --- Freecooling duct connections

(optional)

The air conditioner may be supplied with an integrated Free­cooling device (optional), which uses fresh air from outside to
cool the room without starting up the compressor. The device
provides the correct cooling capacity required, using a
motorised, modulating damper. In this case, the rear of the
unit is equipped with connections which draw in the outside
air, as follows:

S double circular holes, for 202 mm (HPSE 06) or 252 mm

( H P S E 0 8 --- 1 0 --- 1 2 --- 1 4 ) d i a m e t e r f l e x i b l e d u c t s t o b e
fixed with metal clamps;

S single rectangular hole with flange for 560x190 mm

(HPSE 06) or 600x250 mm (HPSE 08 --- 10 --- 12 --- 14) duct
(not supplied by Liebert --- HIROSS).

Inbothcases,theholesinthewallhavetobeprotectedby
rainproof grilles with a prefilter, to avoid water or foreign
bodies getting into the conditioner.

Outside air, taken into the room by the fan, is exhausted
through an overpressure damper, which is installed on the
wall of the room and protected by an external rainproof grille .

2.4.1 --- External air temperature probe installation

Install the external air temperature probe at the end of the
freecooling duct.

pag. 1

IMPORTANT:

The bulb must be positioned as much outside as possible but
must not be exposed to direct sunlight or weather agents
such as rain or snow.The unit operation could be jeopardized
if these precautions are not applied.

2.5 --- Positioning the HPSC condensing
unit

Available condensing unit versions:
HPSC “0”: base version

HPSC “A”: advanced version
HPSC “L”: long piping version (see Fig. 12)

S The condensing unit must be positioned outside to en-

able its cooling (see Fig. 3).

S It is connected to the air conditioner through the re-

frigerant pipelines. Keep the refrigerant lines as short
as possible and anyway follow the indications in
Tab. a, Tab. b, Fig. 11 and Fig. 12, considering that in ­stallations with equivalent length of the refrigerant
pipelines over 10 m are possible only for HPSCxxL
units.

S Install the condensing unit in a level position, able to bear

its weight and vibrations and away from contaminating
agents (e.g. dust, leaves) to ensure the best efficiency
over time. Avoid any place containing flammable gases.

S If different locations are available, preferably install the

condensing unit in places sheltered from rain, with suit­able air circulation and not subject to strong sun expo­sure; the latter precaution enables performance opti­misation and compliance with the operating limits. For in­stallationsinplaceswithwindspeedsover5m/s(e.g.
building tops) consider that such conditions can offer re­sistance to the air outlet from the condensing unit, reduc­ing the air delivery and thus the heat exchange capacity,
or they can make the fan run too fast jeopardizing its oper­ation, as well as increasing the hazard of the machine tilt­ing if it is not properly fixed. To lessen the problem of
strong gusts of wind, position the condensing unit close
to a wind barrier (e.g. building or enclosing wall) and in
a direction perpendicular to the flow of the discharge air.
To prevent tilting ensure that the unit is securely fixed, if
necessary through additional supports or tie---rods, thus
ensuring stability even in case of earthquakes. Position
the unit so that the ejected hot air and the sound
emissions do not disturb people. In case of snow, make
sure that the unit is not completely covered and that the
inlet sections are always clear. To enable sufficient air de­livery through the unit/s and to have sufficient space for
maintenance, it is necessary not to obstruct the air inlet
and discharge sections of the condensing unit, position­ing it, or several machines, to maintain the minimum ser­vice areas and distances indicated in Fig. 4, for some
possible installation configurations.

S Fig. 3 shows some examples of how to install the con-

densing unit. For wall --- mounted installation the con­densing unit can be supplied with an optional mounting
kit, comprising a pair of galvanised steel angle brackets,
painted with RAL9002 polyester powder with a smooth
finish; suitable elastomer anti---vibration mounts and
stainless steels fixings, including anchor screws for wall
fastening (see Fig. 2d).
NOTE: The anchor screws included in the kit are to be
used only when fastening the brackets to a concrete or
brick wall (including hollow bricks). Do not use them on
sandwich walls (e.g. a container) or walls of unknown
composition. In these cases the most suitable fastening
system for the special material must be used. If the above
mentioned optional kit is not used, suitable anti --- vibra­tion mounts must always be fitted between the condens­ing unit and the mounting brackets, to avoid the trans­mission of vibrations. Also make sure that the brackets
used are suitable for supporting the condensing unit in all

conditions (e.g. in case of temporary abnormal loads on
the unit).

2.6 --- Refrigeration connections

THIS OPERATION MUST BE CARRIED OUT BY AN EX­PERT TECHNICIAN.

The condensing and evaporating units are pre---charged
with Nitrogen and have to be charged with refrigerant (see
Chap. 7.2.2 – Refrigerant charging).

a) Pipeline positioning
Connect the air conditioner to the condensing unit using re-

frigerant lines in hard or soft copper.
S Limit the number of pre --- shaped bends. If this is not

possible, every bend must have a radius of at least 100
mm.

S The gas line must be insulated.
S The liquid line must be kept away from heat sources. If

this is not possible it has to be insulated.

S If the condensing unit is located above the evaporating

unit, the last segment of the suction line (insulated pipe­work) must be inclined towards the condensing unit.

If, on the other hand, the condensing unit is located below the
air conditioner it is advisable to create a trap on the suction
line.

Tab. a --- HPSCxx0/A: external standard

Model

HPS060/A 2m<L≤10m φ 16 x 1 φ 12 x 1 1% with 10 m

HPS080/A 2m<L≤10m φ 16 x 1 φ 12 x 1 3% with 10 m

HPS100/A 2m<L≤10m φ 18 x 1 φ 12 x 1 2% with 10 m

HPS120/A 2m<L≤10m φ 18 x 1 φ 12 x 1 4% with 10 m

HPS140/A 2m<L≤10m φ18x1 φ 12 x 1 5% with 10 m

Tab. b --- HPSCxxL: external standard diameters

Model

HPS06L

HPS08L

HPS10L

HPS12L

HPS14L

diameters for external refrigerant
pipelines --- R407C

Equivalent

length

“L”

Gas
line

Liquid

line

Cooling capacity

drop vs. the std.
installation (2m)

for external refrigerant pipelines--- R407C

Equivalent

length

“L”

2m<L≤10m
10m<L≤20m
20m<L≤30m
30m<L≤40m
40m<L≤50m

2m<L≤10m
10m<L≤20m
20m<L≤30m
30m<L≤40m
40m<L≤50m

2m<L≤10m
10m<L≤20m
20m<L≤30m
30m<L≤40m
40m<L≤50m

2m<L≤10m
10m<L≤20m
20m<L≤30m
30m<L≤40m
40m<L≤50m

2m<L≤10m
10m<L≤20m
20m<L≤30m
30m<L≤40m
40m<L≤50m

Gas
line

φ 16 x 1
φ 16 x 1
φ 18 x 1
φ 18 x 1
φ 18 x 1

φ 16 x 1
φ 18 x 1
φ 18 x 1
φ 18 x 1
φ22 x1

φ 18 x 1
φ 22 x 1
φ22 x1
φ22 x1
φ22 x1

φ 18 x 1
φ22 x1
φ22 x1
φ22 x1
φ28 x1

φ18 x1
φ22 x1
φ22 x1
φ28 x1
φ28 x1

Liquid

φ 12 x 1
φ 12 x 1
φ 12 x 1
φ 12 x 1
φ 12 x 1

φ 12 x 1
φ 12 x 1
φ 12 x 1
φ 12 x 1
φ 16 x 1

φ 12 x 1
φ 12 x 1
φ 16 x 1
φ 16 x 1
φ 16 x 1

φ 12 x 1
φ 16 x 1
φ 16 x 1
φ 16 x 1
φ 16 x 1

φ 12 x 1
φ 16 x 1
φ 16 x 1
φ 16 x 1
φ 16 x 1

line

Cooling capacity

drop vs. the std.
installation (2m)

1% with 10 m
4% with 20 m
3% with 30 m
5% with 40 m
6% with 50 m

3% with 10 m
3% with 20 m
5% with 30 m
6% with 40 m
3% with 50 m

2% with 10 m
3% with 20 m
5% with 30 m
6% with 40 m
7% with 50 m

4% with 10 m
3% with 20 m
4% with 30 m
5% with 40 m
2% with 50 m

5% with 10 m
3% with 20 m
5% with 30 m
2% with 40 m
3% with 50 m

pag. 2

Tab. c --- Equivalent lengths (m) of: curves,

(mm

)

shut---off and non ---return valves

Nominal

diameter

(mm)

90° 45° 180° 90°

12 0.50 0.25 0.75 2.10 1.90

14 0.53 0.26 0.80 2.20 2.00

16 0.55 0.27 0.85 2.40 2.10

18 0.60 0.30 0.95 2.70 2.40

22 0.70 0.35 1.10 3.20 2.80

28 0.80 0.45 1.30 4.00 3.30

b) Evacuation of the refrigerant lines
The evacuation operation must be carried out with a special

(quality) vacuum pump, using the 1/4” SAE connectors, lo­cated on the unit on---off valves,

2.7 --- Condensate drain connection

During the cooling cycle part of the moisture in the air con­denses on the evaporating coil. The condensate is collected
in the tank fitted under the coil and must be drained outside.

Tab. d --- Condensate drain connection

CONNECTOR DIMENSIONS

Condensate drain φ 21 mm

To drain the condensate:

S Use galvanized steel, PVC or flexible polythene pipe.
S CAUTION: DO NOT INTERCONNECT THE OUTLETS OF

DIFFERENT MACHINES.

S Make sure there is at least a 2% gradient towards the

drain outlet.

S There must beadraintrapplacedatleast30mmbelow

the drain tank.

S Fill the drain trap with water by pouring it into the conden-

sate tank.

2.8 --- Electrical connections and wiring

diagram (supplied with the unit)

For the electric connections of the indoor units HPSE and
outdoor units HPSC, refer to Fig. 5, Fig. 6 and Fig. 7.

Before connecting or disconnecting the fast couplers be­tween the indoor unit and outdoor unit, make sure that the
main switch is in the “OFF” position and that:

S all electrical components are not damaged;
S allterminalscrewsaretight;
S thesupplyvoltageandfrequencyareasindicatedonthe

unit;

S there are no live components.

IMPORTANT:

The 48 Vdc supply (in the version ”Emergency Free Coo­ling”) must be delivered through a shielded cable, with the
connection of the shielding braid on the evaporating side.
The signal connection cable between the evaporating unit
and the condensing unit must be shielded, with the connec­tion of the shielding braid on the evaporating side.

2.9 --- User interface

The standard control system on HPS is based on a micropro­cessor board mounted inside the electrical panel, which can
be connected to a user interface (remote display) that can be
positioned inside the room as required. The user interface
(remote display), when installed, is mounted in a painted
metal box and connected to the air conditioner using a
multi---pole screened cable (optional accessory).

2.10 --- Emergency cooling version

(EFC 48 VDC / 230 VAC)

When this option is used install the supply cable as described
in the electrical diagram.

In the 48VDC units respect the polarity “+” and “ --- ”.

2.11 --- Electrical protection

CAUTION: For the electrical protection of the conditioner an

adequate switch with current protection must be installed in
the power supply line. For the selection of the disconnect
switch please refer to Tab. 7.

3 --- Starting and stopping

3 . 1 --- F i r s t s t a r t --- u p

(or after a long halt)

Before starting the air conditioner check if the power supply
voltage and frequency comply with those on the identifica­tion plate of the unit. After this, it is possible to power the unit
by operating the main switch. For units equipped with Power­Face microprocessor control, it is possible to start and stop
the unit by following the instructions given below.

For units equipped with POWERFACE interface only:

S The unit is started by pressing the main switch ON.
S The unit is stopped by pressing the main switch OFF.

For units equipped with a local or remote display interface:

S The unit is started by pressing the switch with LED.
S The unit is stopped by pressing the switch with LED.

For units supplied with a HIROMATIC interface:
S Start by pressing the ON --- OFF push button on the Hiro-

matic (confirmed by SYS.ON on the display).

S Stop by pressing the ON --- OFF push button on the Hiro-

matic (confirmed by SYS.OFF. on the display).

IMPORTANT:

In both cases it is extremely important to consider the status
of the digital input to the PowerFace microprocessor control
managing the unit ON ---OFF (see relevant handbook and wir­ing diagram). Indeed, for the unit to start (operating on the
unit main switch, or on the ON --- OFF button of the HIROMA­TIC interface), the digital input must be bridged (see wiring
diagram). Check that there are no active alarms; wait until the
system reaches the standard operation and then make the
following checks:

S Check that the fans are working correctly.
S Make sure that the temperature is controlled and the

compressor and the heaters (optional) work when re­quired.

S Make sure that the condensing unit fan speed controller

regulates the fan operation (only on “HPSCxxA/L” mo­dels).

3 . 2 --- S t a r t --- u p w i t h l o w o u t s i d e t e m p e r a -

ture (only on “HPSCxxA/L” models)

In case of low outside temperature (<0_C), the unit start---up
is helped by the delay time of the low pressure alarm, within
which the pressures in the refrigerating circuit reach the stan­dard operation values.

3 . 3 --- S e l f t e s t

The self---test function is possible only when a unit has the re­mote or local display installed. The self --- test function, per­forms a sequential, automatic check of components such as
the compressor, fan, heaters, Freecooling damper, alarm
relay and warning relay. This eliminates the need for manual
control and leads to a remarkable decrease in the time
needed for starting the unit, with the ability to carry out a quick
check of the main components for the correct conditioner
operation.

pag. 3

3.4 --- Starting and stopping

For the units provided with the POWERFACE control, you
can switch on/off using the main switch.
For the units provided with HIROMATIC interface:

S Start up the unit by pressing the Hiromatic ON --- OFF

push button (confirmed by SYS.ON on the display).

S Stop the unit by pressing the Hiromatic ON --- OFF push

button (confirmed by SYS.OFF on the display).

4 --- O p e r a t i o n

The unit operation is completely automatic. The sequence
below explains (with the assistance of Fig. 8 ---Operation
diagram) how the unit operates (see also Fig. 9 and Fig. 10

--- Refrigerating circuit):

1) The temperature sensor, positioned inside the HPSE
evaporating unit, informs the control about the condition
of the return air.

2) The control compares the information received with the
programmed Set Point value (= minimum indoor tem­perature) and Proportional Band (and Differential in the
versions with optional Freecooling), activating the condi­tioner’s air treatment modes as follows:

Cooling (Fig. 8a)

After switching the unit on, the evaporator fan starts immedi­ately whereas the compressor is started only when the tem­perature of the room to be conditioned exceeds the set value.
In the HPSCxxA/L unit versions, the condensing unit fan
starts automatically if the condensing pressure increases
(control through Variex), while in the other versions the fan/s
is/are controlled by a pressure switch ensuring a limit lower
than the condensing pressure. The air taken in by the evapor­ator fan enters the unit through the side intakes, passing
through the filters, and then reaches the evaporator. The cold
refrigerant flows inside the evaporator pipes, thus cooling the
air passing through it. The treated air is conveyed into the
conditioned room through the supply outlet. The heat taken
from the room and that generated by the conditioner motor
operation is rejected through condensing coil located in the
external condensing unit and cooled with outside air by the
condenser fan. For the operation logic of the controls see
chapter 5.

Heating (optional)

Heating of the air is achieved by means of electric heaters,
located in the air flow and activated according to the logic set
on the controls (see chapter 5).

Freecooling (optional)

When the temperature of the outside air is sufficiently below
that of the inside air it is possible to use this difference to pro­vide cooling inside the room by direct intake of the outside air,
i.e. without using the compressor. In this way it is possible to
achieve considerable energy savings. When the required
conditions occur, the servo --- motor, managed by the Power­Face control, opens the modulating damper which separates
the flow of the inside air and outside air. Outside air, drawn
into the room by the fan, is exhausted through an overpres­sure damper* which is installed on an outside wall of the
room and is protected by an external rainproof grille*. The
degree of opening of the damper is determined as a function
of the temperature set point and the return air temperature.

4.1 --- Control of the condenser fan speed

(“HPSCxxA/L” models only)

A sensor is positioned so as to detect the condensing pres­sure of the refrigeration gas. On the basis of this information,
an electronic device (Variex) modulates the fan speed in
order to keep the condensing pressure within the permitted
range. In this way, besides optimizing the compressor oper­ation, you can have a reduction of the sound pressure level
(mainly during the night), easier start --- up of the compressor
at low temperatures and some energy saving.

For the calibration of the speed controller refer to chap. 6.

4 . 2 --- E m e r g e n c y c o o l i n g (optional)

4.2.1 --- Emergency cooling 48VDC

With the 48VDC emergency cooling option, the evaporator
fan, freecooling damper actuator and controls are always
supplied at 48VDC, while the compressor, the condenser fan
and the heaters are connected to the AC mains. If the AC
mains supply fails, the conditioner does not stop but con­tinues to circulate the air, activating the Freecooling as soon
as the relevant conditions are reached, automatically optim­ized in the event of mains failure.

IMPORTANT:

For proper operation, the unit must always be fed by 48VDC.

4.2.2 --- Emergency cooling 230VAC --- 50Hz

In case of AC mains failure, the evaporator fan, freecooling
damper actuator and controls are supplied by a second
230V/1Ph/50Hz supply, arranged by the user (UPS/gener­ator), ensuring operation in the same way as the 48VDC ver­sion.

CAUTION:

For safety reasons open the main switch.

5 --- Operating logic

The different unit versions feature different automatic operat­ing logic, as described below.

5.1 --- Cooling only unit

5.1.1 --- Control logic

The control algorithm is based on single --- step regulation for
the mechanical cooling, i.e. compressor start/stop. The con­trol manages all the activation delays, ensuring correct oper­ation and extending the operating life as much as possible.

Fig. a) Operation of the cooling only unit

PBand

Cooling only
unit

Set Cooling °C

5.2 --- Unit with electric heating

5.2.1 --- Control logic

For the heating and cooling version the control algorithm is
based on single---step regulation for the electric heating and
single step regulation for the compressor (mechanical cool­ing). The control manages all of the compressor activation
delays as previously described, ensuring its correct oper­ation and maximising run times.

5.2.2 --- Dead band

In this version the “Dead band” parameter, in the “optional
devices” menu of the PowerFace microprocessor control is
very important, enabling the heating semi--- band to be
shirted by inserting a non --- sensitive area (ventilation only)
between the set point temperature and the start of the heat­ing semi --- band (see Fig. b). In this way, without having to
alter the proportional band, the electric heating can be acti­vated at lower temperatures (according to the value set for
the dead band) compared to the standard setting, conse­quently reducing the energy consumption of the heaters and
optimizing their operation according to the site requirements.

pag. 4

Fig. b) Unit operation with electrical heating

1

/2Band

1

/2Band

Dead Band

Set point CoolingHeating

PBand

Set point

1

/2Band

CoolingHeating °C

1

/2Band

Cooling and

heating unit

Cooling and
heating unit

with Dead band

°C

5.3 --- Unit with freecooling

5.3.1 --- Control logic

The control algorithm is based on single--- stage regulation
for the heating and mechanical cooling (compressor), with
modulating proportional --- integral control for the Freecooling
(see Fig. c). The control manages all of the compressor ac­tivation delays, as we have seen in the 2 previous cases, in
order to guarantee the proper operation and to extend its life.

The activation of the Freecooling mode occurs as a function
of the difference (that can be set) between the inside tem­perature and the outside temperature. This means that if the
difference between the two temperatures increases beyond
the set value, the unit automatically initiates the Freecooling
function; the compressor is deactivated and an analogue
output controls the 3 --- point servomotor of the damper. The
damper opening is determined as a function of the difference
between the outdoor and indoor temperatures and as a func­tion of the intake air temperature, which cannot be lower than
a preset safety value. If the indoor temperature exceeds the
proportional band by more than 20% for over 10 minutes, the
unit reverts to compressor --- aided cooling and the Freecoo­ling mode remains de --- activated for

1

/2hour. If the inside
temperature exceeds the proportional band by more than
50% for over 2 minutes, the Freecooling mode is de --- acti­vated for 1 hour, and the unit reverts to cooling by means of
the refrigeration circuit.

Fig. c) Compressor, heater and damper opening

operation

PBand

Set CoolingHeating

PBand

Set CoolingHeating

Freecooling
mode

_C

Compressor
cooling mode

_C

5.4 --- LAN local network management:

Stand---by and Cascade modes

The control of the units in stand ---by can be completely auto­matic, thanks to the possibility of connection with the Power­Face control. A unit in stand --- by is automatically activated in
case of an alarm causing the main unit to lock --- out. This also
occurs if the main unit is switched off or disappears from the
system due to a failure on the control connecting network
(bus). Rotation of the stand--- by units can be set to occur
automatically every 24 hours, so as to enable an even wear of
the system components. If the system is connected to a Hiro­matic interface, it is possible to set timed daily or weekly rota­tion functions. When the Cascade function is activated, if sev-

eral units are simultaneously on, with the same Set Point, the
temperature used for the control is the average of those de­tected. In mechanical cooling mode, the proportional semi--­band is divided by the number of units in the system, in order
to share the total available cooling capacity. The activation of
the Freecooling mode (if installed) is sequential on the differ­ent units forming the system, and precedes the possible ac­tivation of compressor for mechanical cooling.
Fig. d) shows an example, illustrating the operation of a sy­stem formed by three units.

Fig. d) System with 3 units in cascade ---

PowerFace control

Freecooling mode

PBand

3

3

1

2

Set _CCoolingHeating

Compressor cooling mode

PBand

11

223

Set _CCoolingHeating

5.5 --- Alarm control

Two sets of alarm contacts (each n.c. or n.o.) are available on
the terminal board of the electrical panel board for:

1) General Alarm (highest priority), including:

S Compressor alarm (high and low pressure).
S Sensor fault.
S Memory fault.
S Evaporator fan fault.

2) General Warning (lowest priority), including:

S High temperature.
S Low temperature.

A further General Warning is available in the unit equipped
with heating, signalling the following abnormal condition:

S Electrical heater fault.

NOTE:

S An alarm causes the unit to stop and the unit in stand --- by

(if available) to intervene.

S A warning does not stop the unit.
S Both the alarm and the warning activate visual and aud-

ible indication (on unit with Hiromatic).

S Both the alarm and the warning must be reset manually

on the PowerFace (or Hiromatic if installed).

Should the thermofuse intervene, the electrical heaters must
be replaced.

6 --- S e t t i n g s

S The air conditioner has already been factory --- tested and

set as described below (see Tab. 8).

S For the microprocessor control settings please refer to

the relevant manual (to avoid incorrect operation do not
use temperature and relative humidity set points or pro­portional bands which differ excessively from the stan­dard settings).

pag. 5

7 --- Maintenance / Spare parts

For safety reasons, always isolate the unit using the mains switch OFF, before opening the panels.

If installed:
AS THE MICROPROCESSOR CONTROL FEATURES AUTO-

MATIC RESTART (AFTER A SUPPLY INTERRUPTION), IT IS
RECOMMENDED THAT THIS FUNCTION IS DISABLED AND
THE MAINS SWITCH IS OPENED WHEN PERFORMING
ANY MAINTENANCE.

7.1 --- Routine maintenance

Maintenance program --- Monthly check

Check that the fan motor rotates freely without any abnormal noise, and ensure that the

FANS

AIR FILTERS

ELECTRICAL CIRCUIT

REFRIGERATION CIRCUIT

bearings are not running hot.
Also check the current absorption.

Check the conditions of the filters (3 for the recirculation air and 1 for the freecooling
air, if this option is included), if necessary, clean or replace them.
Toreplacethefiltersfortherecirculationair:

S Rotate the two filter ---locking fasteners securing each filter.
S Remove the filters.
S Fit the spare parts.
S Lock the filters by rotating the two fasteners in the opposite direction to secure each

filter.

To replace the filter for the freecooling air (if this option is included):

S Remove the unit lower panel.
S Remove the fastening bracket and pull the filter vertically downwards.
S Fit the spare part.
S Reposition the bracket and close the panel.

S Check the power supply on all phases.
S Ensure that all electrical connections are tight.

S Check the evaporating pressures (to be performed by a refrigeration technician).
S Check the compressor current absorption, the head pressure and the presence of

any unusual noise.

S Ensure that there is no ice formation on the evaporator.

S On a daily basis, check the control readings for tempera-

ture and, if shown, relative humidity.

S The Maintenance Programme described below should

be carried out by a skilled technician, preferably working
under a maintenance contract.

7.2 --- Extraordinary maintenance

CAUTION:

If you need to intervene immediately after the
unit stops, wait 5 minutes before accessing the
inner parts, as you could get burnt.

7.2.1 --- Check of the system vacuum and leaks

NOTE:

Before proceeding, recover all the refrigerant, according to
the local laws.

1) Switch the unit off (main switch on OFF).

2) Remove the panels necessary for inspecting the refriger-

ating circuit.

3) Connect a high efficiency vacuum pump to the needle

valves (Schräder) on the gas and liquid lines; also ar­range a connection with a nitrogen bottle.

4) Load the circuit with nitrogen (7 bar/700 kPa). Find poss-

ible leaks in the circuit by soapy water or other specific
product (foaming agents), and repair as necessary.

5) Drain the circuit by a vacuum of 0.3 mbar absolute.

6) After 3 hours check not to have exceeded 1.3 mbar abso-

lute; this condition ensures a humidity lower than 50 ppm
inside the system. If the vacuum is not kept there are still
leaks; repeat the operations from point 4.

7.2.2 --- Refrigerant charging

After having eliminated the humidity from the refrigerating cir­cuit (see 7.2.1), proceed as follows:

1) Make sure all the unit components are in operating order.

2) Using a charging hose, connect the cylinder to the liquid
line of the circuit. Drain the substances that cannot be
condensed from the hose.

Charge the circuit exclusively with the
refrigerant indicated on the identification
label.

Charge the quantity of refrigerant indicated in Tab. e.

3) Set the main switch on ON.

4) Start the compressor.

5) The charge operation can be considered finished when,
keeping the condensation temperature at a steady level
(~ 50_C, if necessary partially clog the condensing coil),
no more bubbles appear for at least ten minutes. Check
if the superheat in these conditions is 7---8 degrees.

Superheat calculation

a) With the unit operating in standard conditions,

measure the temperature of the suction line in the
point where the bulb of the thermal expansion valve
is fastened, in case of ”HPSCxxA/L” version unit, in the
compressor inlet, in case of other versions.

b) Detect the evaporation pressure gauge temperature

from a pressure gauge placed on the compressor
suction.

c) Subtract the obtained temperature value from the

one measured in point a).
The difference is the superheat value.

pag. 6

7.2.3 --- R407C refrigerant units

Onl

l

ing/FC/EFC

Onl

l

i

FC/EF

C

HPSE1

0

HPSE1

0

HPSE1

2

HPSE1

4

7.2.3.1---Features of the refrigerating fluid R407C

At standard temperature and pressure it is a colourless gas
with low toxicity, non---flammable, and it has an allowed ex­posure limit value (AEL/TLV)corresponding to 1000 ppm (av­erage value measured on 8 hours/day). In the event of leak­age, air the room before use.

Tab. e --- R407C refrigerant charge

Internal

unit

HPSE 06

ycoo

HPSE 08

ycoo

ng

HPSE 08

HPSE 10

Only cooling

HPSE 10
FC / EFC

HPSE 12

Only cooling / FC / EFC

HPSE 14

Only cooling / FC / EFC

IMPORTANT:

The charges indicated in Tab. e refer to a 2 m length for the
gas and liquid pipes: Tab. f shows the indications for longer
measures on the additional charge in grams of refrigerant
R407C by each pipe meter of the gas and liquid lines, accor­ding to the diameters indicated in Tab. a.

External

unit

HPSC 060 2.2

HPSC 06A 2.7

HPSC 06L 3.7

HPSC 080 2.7

HPSC 08A 2.7

HPSC 08L 3.7

HPSC 080 3.0

HPSC 08A 3.0

HPSC 08L 4.0

HPSC 10A 2.7

HPSC 10L 3.7

HPSC 10A 3.0

HPSC 10L 4.0

HPSC 12A 3.6

HPSC 12L 4.6

HPSC 14A 3.6

HPSC 14L 4.6

R407C charge

(kg)

The oil to be used when topping up is EMKARATE RL
32--- 3MA or MOBIL EAL ARTIC 22CC, if it’s unavailable use
an oil with the same characteristics (see Tab. g and Tab. h).
NEVER M IX DIFFERENT OILS TOGETHER. CLEAN THE PIP­ING COMPLETELY BEFORE CHANGING THE TYPE OF OIL
USED.

Ta b . g --- E M K A R A T E RL 3 2 --- 3 M A o i l

viscosity at 40 _C
viscosity at 100 _C
viscosity index (ISO Grade)

:

31.2 cST

:

5.6 cST

:

32

Tab. h --- MOBIL EAL ARTIC 22CC oil

approx. specific weight (at 15_C)
flash point (C.O.C.)
pour point
viscosity index
viscosity at 40_C
viscosity at 100_C

:

0.99 kg/l

:

245 _C

:

< --- 5 4 _C

:

116

:

23.6 cST

:

4.7 cST

7.3 --- Dismantling the unit

The machine has been designed and built to ensure continu­ous operation.
The working life of some of the main components, such as
the fan and the compressor, depends on their maintenance.
If the unit has to be dismantled, this must be done by skilled
refrigerator technicians.
The refrigerating fluid and the lubricating oil in the circuit must
be disposed of in conformity with the laws in force in your
country.

7.4 --- Spare parts

We recommend the use of original spare parts.
When placing an order please refer to “Component List” en­closed with the machine and specify the unit model and serial
no.

Tab. f --- Additional charge in grams of refrigerant

R407C by meter of each line

Liquid line Gas line

Ø pipeline

(mm)

φ 12 x 1 85.0 φ 16 x 1 4.0

φ 16 x 1 160.0 φ 18 x 1 5.5

---

---

Add

charge

R407C g/m

--- φ 22 x 1 8.5

--- φ 28 x 1 14.5

Ø pipeline

(mm)

Add

charge

R407C g/m

pag. 7

8 --- A p p e n d i x

8.1 --- Check the unit after the installation

The following list includes the checks to carry out to verify that HPS is intact after the installation.

IMPORTANT:

EVERY UNIT IS TESTED IN OUR PLANTS BEFORE DELIVERY.

A) STATIC CHECK

A.1) Evaporating unit HPSE

A.1.a) Sight check that the panels and rivets are in-

tact and well fixed.

A.1.b) Checkforthepresenceofacondensatedrain

for each machine and of the discharge pipe
supplied separately.

A.1.c) Check that the (optional) Freecooling air in-

take ducts (rigid or flexible) and the rainproof
external grille, with metallic prefilter (optional)
are available and fixed.

A.1.d) Check that the unit is fixed firmly to the ceiling

or to the wall, and that any fastening devices
passing along the walls of the room to be
conditioned are sealed.

A.1.e) Put the electrical board of the room in the

”OFF” position.

A.1.f) Check for the correct connection of the sup-

ply cables and of the Bus cable between the
PowerFacecardandtheremotedisplayor
between the PowerFace and Hiromatic (if in­stalled, optional).

A.1.g) Check the fastening of cables, electronic

components and fuses.

A.1.h) Check the correct position of the air filter.

A.2) Motor ---condensing unit HPSC

A.2.a) Remove the panels of the compressor com-

partment to access the refrigerating circuit (if
the weather conditions allow this; prevent
water from entering the electric board and the
compressor compartment).

A.2.b) Check that the refrigerating circuit is intact

and that there are no oil stains in the com­pressor compartment and along the ducts.

A.2.c) Check the evaporating fan by turning it by

means of a screwdriver: it must be free to ro­tate without any abnormal noise.

A.2.d) Check that the electrical board is free from

foreign bodies, the correct connection to the
evaporating unit and that all electrical con­nections are tightened.

B) DYNAMIC CHECK

B.1) Check the ground connection.
B.2) Put the electrical board of the room in the

”ON” position.
B.3) Set the main switch of the indoor unit ”ON”.
B.4) Check the voltage at the main supply cables.
B.5) Check the voltage at the emergency supply

cables.
B.6) Only for the units equipped with Hiromatic re-

mote interface, set the wished system con-

figuration, such as set point, network (only for

”Advanced” versions, by assigning an

identification number for each unit), para-

meter sharing, stand --- by, freecooling differ-

entials (if installed), and so on.
B.7) Measure the current absorbed by the evapor-

ating fan only.
B.8) Start up the compressor (if necessary force

the system via the control) and wait until the

system is stable. Measure the absorbed cur-

rent,withbothfanandcompressoroperat-

ing.
B.9) Check all these values comparing them with

those shown in the machine plate.
B.10) Check the delivery temperature with a digital

thermometer.
B.11) Verify the superheating, according to par.

7.2.3.

B.12) Close the panels of the evaporating and mo-

tor---condensing units.

The unit is ready for the dynamic check.

pag. 8

Tab. 1 -- 50 Hz Technical data for “COOLING ONLY” and “COOLING + HEATING” unit versions

(*)

(F and F + C) coupled with “HPSCxx0”

Model HPS 06 HPS 08

Operating limits

Main power supply voltage 230V ±10% / 1Ph / 50Hz 400V±10% / 3Ph+N+PE / 50Hz

Outdoor conditions

*

Indoor conditions with compressor running

Storage conditions

Sound pressure level

Outdoor sound pressure level

(1)

Indoor sound pressure level dB(A) 58.0 62.5

Standard electrical features

Compressor --- AC power input

Compressor --- AC operative current (OA)

(2)

(2)

Compressor --- AC max. current (FLA) A 11.4 5.1

Compressor --- AC starting current (LRA) A 47.0 32.0

Condenser fan --- AC power input

(2)

Condenser fan --- AC max. power input kW 0.08 0.10

Condenser fan --- AC operative current (OA)

(2)

Condenser fan --- AC max. current (FLA) A 1.4 1.4

Condenser fan --- AC starting current A 1.6 1.6

Evaporator fan --- AC power input

Evaporator fan --- AC operative current (OA)

Evaporator fan --- AC max. current (FLA)

(2)

(2)

(3)

Evaporator fan --- AC starting current A 1.3 2.7

Electric heating (optional)

Heating capacity kW 1.5 3.0

H e a t i n g --- m a x . cu r r e n t A 6.5

OA: Standard Operating Ampère
FLA: Full Load Ampère
LRA: Locked Rotor Ampère

Notes:

(*)

Maximum outdoor temperature referred to 30ûC / 35% R.H. indoor unit air suction (HPSE).

(**)

Conditions referred to the suction sections of the inner unit (HPSE); the min. indoor temperature is referred to 30% of indoor relative humidity and to the min.
outdoor temperature; for higher relative humidity and/or outdoor temperatures, the min. indoor temperature is higher than the table data.

(1)

Measured with 35ûC outdoor temperature at 2m far from the unit; free field conditions.

(2)

Indoor reference conditions: 30ûC / 35% R.H. at the HPSE indoor unit air suction sides; 35ûC outdoor. Nominal power supply.

(3)

It refers to nominal speed (Factory setting).

from: 10°C

to: 47°C 45°C

from: 24°C, 30% R.H. / 80% R.H.

(**)

to: 35°C, 40% R.H. 30°C, 40% R.H.

from: --- 4 0 °C, 5% R.H.

to: 55°C, 90% R.H.

dB(A) 50

kW 1.58 2.18

A 7.6 3.9

kW 0.08 0.10

A 0.6 0.7

kW 0.18 0.35

A 0.8 1.5

A 1.0 2.0

pag. 9

Tab. 2 -- 50 Hz Technical data for “FREECOOLING” and “230V/1Ph/50Hz EMERGENCY FREECOOLING”

(**

)

unit versions (FC and EFC -- AC) coupled with “HPSCxx0”

Model HPS 06 HPS 08

Operating limits

Main power supply voltage 230V ±10% / 1Ph / 50Hz 400V±10% / 3Ph+N+PE / 50Hz

Emergency power supply voltage

Outdoor conditions

**

Indoor conditions with compressor running

Storage conditions

from: 10°C

to: 48°C 45°C

from: 24°C, 30% R.H. / 80% R.H.

to: 35°C, 40% R.H. 30°C, 40% R.H.

from: --- 4 0 °C, 5% R.H.

to: 55°C, 90% R.H.

Sound pressure level

Outdoor sound pressure level

(1)

dB(A) 50

Indoor sound pressure level dB(A) 59.0 62.5

Standard electrical features

Compressor --- AC power input

Compressor --- AC operative current (OA)

(2)

(2)

kW 1.57 2.18

A 7.3 3.9

Compressor --- AC max. current (FLA) A 11.4 5.1

Compressor --- AC starting current (LRA) A 47.0 32.0

Condenser fan --- AC power input

(2)

kW 0.08 0.10

Condenser fan --- AC max. power input kW 0.08 0.10

Condenser fan --- AC operative current (OA)

(2)

A 0.6 0.7

Condenser fan --- AC max. current (FLA) A 1.4 1.4

Condenser fan --- AC max. current (FLA) A 1.6 1.6

Evaporator fan --- AC power input

Evaporator fan --- AC operative current (OA)

Evaporator fan --- AC max. current (FLA)

(2)

(2)

(3)

kW 0.14 0.39

A 0.6 2.8

A 0.6 2.4

Evaporator fan --- AC starting current A 1.2 5.3

Electric heating (optional)

Heating capacity kW 1.5 3.0

H e a t i n g --- m a x . cu r r e n t A 6.5

OA: Standard Operating Ampère
FLA: Full Load Ampère
LRA: Locked Rotor Ampère

Notes:

(*)

The emergency cooling option (EFC) is required.

(**)

Maximum outdoor temperature referred to 30ûC / 35% R.H. indoor unit air suction (HPSE).

(***)

Conditions referred to the suction sections of the inner unit (HPSE); the min. indoor temperature is referred to 30% of indoor relative humidity and to the min.
outdoor temperature; for higher relative humidity and/or outdoor temperatures, the min. indoor temperature is higher than the table data.

(1)

Measured with 35ûC outdoor temperature at 2m far from the unit; free field conditions.

(2)

Indoor reference conditions: 30ûC / 35% R.H. at the HPSE indoor unit air suction sides; 35ûC outdoor. Nominal power supply.

(3)

It refers to nominal speed (Factory setting).

230V ±10% / 1Ph+PE / 50Hz

(with emergency cooling)

(*)

(***)

pag. 10