These assembly instructions are aimed at
– tradespersons who are familiar with assembly and
installation of the air/water heat exchanger
– trained specialists who are familiar with the
operation of the air/water heat exchanger
1.1 Associated documents
Assembly and operating instructions exist as paper
documents and/or on CD-ROM for the unit types described here and are enclosed with the equipment.
We cannot accept any liability for damage associated with failure to observe these instructions. Where
applicable, the instructions for any accessories used
also apply.
1.2 CE labelling
The declaration of conformity is supplied with the unit
as a separate document.
13ReteJtiKJ Kf dKcuIeJts
These instructions and all associated documents
constitute an integral part of the product. They must
be given to the plant operator. The operator is responsible for storage of the documents so they are
readily available when needed.
14SyIbKHs used
The bullet point indicates
an action to be performed.
2Safety notes
Please observe the following general safety notes
when assembling and operating the unit:
– Assembly, installation and servicing may only be
performed by properly trained specialists.
– The minimum water inlet temperature of +1°C must
not be reduced at any point in the water cycle.
Otherwise there is danger of frost damage!
– Use antifreeze agents only with the manufacturer’s
consent.
– Do not obstruct the air inlet and air outlet of the
air/water heat exchanger inside the enclosure
(see also section “4.2.2 Layout of the components
in the enclosure”, page 6).
– The heat loss of the components installed in the
enclosure must not exceed the specific useful
cooling output of the air/water heat exchanger.
– Use only original spare parts and accessories.
– Do not make any changes to the air/water heat
exchanger other than those described in these
instructions or associated instructions.
– The mains connector of the air/water heat
exchanger must only be connected and
disconnected with the system de-energised.
Connect the pre-fuse specified on the rating
plate.
– Always disconnect the unit from the supply
voltage before servicing or maintenance work.
– Readily flammable objects/materials must not
be stored in the immediate vicinity of the air/water
Non-return
valve (5)
(for units with
e-Comfort
controller
only)
Fan (2)
Heat
exchanger
(1)
EN
3Device description
Depending on the model chosen, your air/water
heat exchanger may vary in appearance from the
illustrations contained in these instructions.
However, the functions are identical in principle.
3.1.1 How it works
The air/water heat exchanger comprises of the following main components (cf. fig. 2): Heat exchanger
package (1), fan (2), magnetic valve (3), temperature
control (4) and non-return valve (5).
Fig. 2:Air/water heat exchanger
The heat loss of the enclosure is dissipated in
a membrane heat exchanger to the water coolant.
A fan (2) blows the internal enclosure air over the
heat exchanger (1); except for the inlet and outlet
water and the condensed water discharge, the unit
is closed to the environment. The magnetic valve (3)
controls the cooling output by changing the water
flow volume depending on the required setpoint
temperature and the water inlet temperature.
3.1.2 Control
Fig. 1:Device description
Key
1Cover
2Display (controller)
3X1 terminal strip (unit rear)
4X2 master/slave connection (e-Comfort controller)
5X3 optional serial interface (unit rear)
6Potential equalisation
7Rating plate
8Cooling water inflow (underside of the unit)
9Condensate discharge (underside of the unit)
10Cooling water return (underside of the unit)
11Dispatch bag
Rittal air/water heat exchangers are fitted with a
controller for setting the functions of the heat exchanger. Depending on the design, this is either
a Basic controller or an e-Comfort controller (display
plus extended functions, see chapter “6 Operation”,
page
13
).
3.1.3 Bus mode (e-Comfort controller only)
The serial unit interface X2 allows you to create a bus
connection with up to ten air/water heat exchangers
using the master/slave cable (shielded, four-wire
cable, Model No. 3124.100). This allows you to
implement the following functions:
3.1 Functional description
Air/water heat exchangers are designed and built to
dissipate heat from enclosures by cooling the air inside the enclosure and so protect the temperaturesensitive components. Air/water heat exchangers
are particularly appropriate for the temperature
range of up to +70°C where comparable units, such
as air/air heat exchangers, enclosure cooling units or
fan-and-filter units, cannot be used for system reasons to effectively and economically dissipate heat
loss. The air/water heat exchanger may be externally
– Parallel unit control
(the air/water heat exchangers in the network
can be switched on and off simultaneously)
– Parallel door status message (“door open”)
– Parallel collective fault message
Data is exchanged via the master-slave connection.
During commissioning, assign an address to each
unit that also includes the identifier “master” or
“slave”.
(See also chapter “6.2.9 Setting the master-slave
identifier”, page 21).
and internally mounted on all enclosure outer walls.
whether an AC or EC fan is used), the fan is
equipped with thermal winding protection.
– The device has floating contacts on the connection
terminal (terminals 3 – 5), which may be used to
retrieve system messages from the device, e.g. via
PLC (1 x change-over contact Basic controller,
2 x normally open contacts e-Comfort controller).
– Air/water heat exchangers with e-Comfort control-
ler possess a leakage sensor and a condensate
warning.
3.1.5 Condensation
At high levels of humidity and low cooling water temperatures inside the enclosure, condensation may
form on the heat exchanger.
Any condensation that forms on the heat exchanger
(with high humidity and low water temperatures)
is routed to the bottom and out of the unit via a drain
opening in the heat exchanger tray. For this purpose,
a hose must be connected to the condensate nozzle
(see “4.4 Connecting the condensate discharge”,
page 9). The condensate must be able to run off
freely. The hose used for draining off condensate
must be laid free from kinks and checked for correct
drainage.
Air/water heat exchangers with e-Comfort controller
possess a leakage sensor and a condensate
warning.
Condensate hoses are available as accessories
(refer also to Accessories in the Rittal Catalogue).
3.1.6 Leak detection
(e-Comfort controller only)
If a leakage or pipe breakage occurs in the water
circuit of the air/water heat exchanger, a magnetic
valve immediately stops the cooling water supply,
the floating change-over contact is activated and the
fan switched off.
3.1.7 Door limit switch
(e-Comfort controller only)
The air/water heat exchanger may be operated with
a door limit switch connected. The door limit switch
is not included with the supply (available as an
accessory, Model No. 4127.010).
The door limit switch function causes the fan and the
magnetic valve in the air/water heat exchanger to be
switched off after approximately 15 seconds when
the enclosure door is opened (contacts 1 and 2
closed). This prevents the formation of condensation
inside the enclosure while the enclosure door is
open.
The fan will start up after about 15 seconds on
closure of the door. The connection is made at terminals 1 and 2. The extra-low voltage is supplied
by the internal power pack; the current is approx.
30 mA DC.
Note:
The door limit switches must only be
connected free from potential.
No external voltages!
The electrical signals at the interface
are of an extra-low voltage
(not extra-low safety voltages to EN 60 335).
An additional interface card may be connected to
the 9-pole SUB-D connector X3 in order to incorporate the air/water heat exchanger into higher-level
monitoring systems (available as an accessory,
interface card Model No. 3124.200).
3.2 Proper use
Rittal air/water heat exchangers were developed and
designed in accordance with the state of the art and
the recognised rules governing technical safety.
Nevertheless, if used improperly, they may pose a
threat to life and limb or cause damage to property.
The unit is only intended for cooling enclosures.
Any other use is deemed improper. The manufacturer will not be liable for any damages caused as
a result of improper use, or for incorrect assembly,
installation or use. All risk is borne solely by the user.
Proper usage also includes the observation of all
valid documents and compliance with the inspection
and servicing conditions.
3.3 Scope of supply
The unit is supplied in a packaging unit in a fully
assembled state. Please check the scope of supply
for completeness.
QuantityDescription
1Air/water heat exchanger
1
1
1
4
4
1
1
1
1Drilling template
Tab. 1: Scope of supply
Dispatch bag:
– Sealing tape
– Plug-in terminal strip
– Spacer bolts including assembly parts
– Sealing bungs (not with unit types
3363.XXX/3364.XXX)
– Assembly, installation and
operating instructions
– Declaration of conformity
– Safety notes
When choosing the installation site for the enclosure,
please observe the following:
– The air/water heat exchanger must be installed
and operated in a vertical position (maximum
deviation: 2°).
– The ambient temperature must not exceed +70°C.
– It must be possible to fit a condensate discharge
(see “4.4 Connecting the condensate discharge”,
page 9).
– It must be possible to fit a cooling water supply and
return (see “4.5 Connecting the water connection”,
page 9).
– The mains connection data as stated on the rating
plate of the unit must be guaranteed.
– For ease of servicing, appropriate access to the
device must be guaranteed.
4.2 Assembly instructions
4.2.1 General
–
Check the packaging carefully for signs of damage.
Any packaging damage may be the cause of a
subsequent functional failure.
– The enclosure must be sealed on all sides (IP 54).
Increased condensation will occur if the enclosure is
not airtight.
– The air inlet and outlet must not be obstructed on the
inside of the enclosure.
4.2.2 Layout of the components in the enclosure
Fig. 3:Never direct the cold airflow at active components
Exercise particular caution with the airflow from the
blowers of built-in electronic components (see fig. 3).
Note:
The air/water heat exchangers should
never be fitted directly behind the mounting
plate. If it is not possible to install the unit
any other way, appropriate air baffle plates
should be used, and air inlet and outlet
openings should be provided in the mounting plate.
It is important to ensure even air circulation
inside the enclosure. Under no circumstances should air inlet and outlet openings
be obstructed, otherwise the cooling performance of the unit will be reduced. Ensure
a suitable distance from electronic components and other installed enclosures
so that the required air circulation is not
obstructed and prevented.
Caution! Risk of condensation!
When arranging the components inside
the enclosure, please ensure that the cold
airflow from the air/water heat exchanger
is not directed at active components.
Please also ensure that the cold airflow is
not directed at the warm exhaust airflow
from active components such as inverters.
This may lead to an air short-circuit and
therefore prevent adequate climate control, or may even cause the air/water heat
exchanger’s internal safety devices to
cease cooling operation.
The air/water heat exchanger can be mounted on the
outer walls or the door of the enclosure.
For this purpose, the appropriate enclosure panel
or door must be cut out using the supplied drilling
template.
4.3.1 Preparing the mounting cut-out
Stick the supplied drilling template onto the side
panel or door of the enclosure using adhesive
tape. The heat exchanger is suitable for both external and internal mounting.
There are dimensioning lines on the drilling template
to suit the installation type for your air/water heat
exchanger.
Risk of injury!
Carefully deburr all cut-outs to prevent
injuries caused by sharp edges.
Make the cut-outs including the line width as per
the drilling template. Deburr the cut-outs.
Note:
In order to achieve a permanent seal
between the air/water heat exchanger and
the enclosure, the mounting surface should
be reinforced or supported if necessary.
External mounting
Step 1:
Stick sealing tape to all four edges at the rear of
the device.
1.
Fig. 5:Stick sealing tape to all four edges
Step 2:
Insert the 4 spacers (external thread) into the
mounting surface through the holes, and secure
from the inside of the enclosure using the relevant
washers and nuts.
2.
Fig. 6:Insert the spacers through the holes and secure
Step 3:
Push the device over the spacers and secure with
the relevant rubber washers, washers and screws
(observe the correct assembly sequence).
3.
4x
EN
4.3.2 Assembling the air/water heat exchanger
Note:
For both types of mounting (internal and
external), use the assembly parts supplied
in the pack.
Rubber
Fig. 7:Push the device over the spacers and screw-fasten
Note:
For models 3373.XXX, 3374.XXX and
3375.XXX, steps 4 and 5 are additionally
required.
A flexible condensate discharge hose Ø 12 mm (1/2˝)
can be fitted to the air/water heat exchanger
(see fig. 14).
The condensate discharge
– must be laid with a suitable and constant gradient
(no siphoning).
– must be laid without kinks.
–
must not have a reduced cross-section if extended
The condensate hose is available as an accessory
(refer also to Accessories in the Rittal Catalogue).
4 Assembly and connection
EN
.
3
Fig. 14:Connecting the condensate discharge
Key
Cooling water connection (inlet)
Cooling water connection (return)
Condensate discharge
Connect a suitable hose to the condensate nozzle
(at the bottom of the unit) and secure it with a hose
clip (with 2 Nm torque).
Lay the condensate hose, e.g. into a drain.
To prevent the water from backing up, the hose
cross-section must not be restricted!
4.5 Connecting the water connection
There are 4 different options for connecting water to
the air/water heat exchanger.
1
Fig. 15:Connecting the cooling water inlet and return
Key
Cooling water connection (inlet)
Cooling water connection (return)
Condensate discharge
2
b) Fixed pipework with G 3/8˝ external thread
(included with the supply)
In its delivered state, fixed pipework with a G
3
/8˝
external thread may be connected to the air/water
heat exchanger for both the inlet and the return.
To this end, you will need to remove the connector
sleeve attached to the device (see fig.
The fixed pipework should be tightened with
16
).
25 Nm.
1
a)
/2˝ connector sleeve (included with the supply)
In its delivered state, a compression-proof, flexible
cooling water hose Ø 12 mm (
1
/2˝) may be connected
Fig. 16:Remove the connector sleeve
to the air/water heat exchanger for both the inlet and
the return.
The cooling water hose
– must be laid without kinks
– must not have a reduced cross-section if extended
and, if necessary, must be insulated.
Note:
When loosening the connector sleeve, it is
vital to ensure that the fitting on the device
end is fixed with an SW22 open-jawed
spanner. The connection inside the device
could develop a leak.
/8˝ internal thread adaptor, available as an
accessory, allows you to connect fixed pipework to
the air/water heat exchanger for both the inlet and
the return.
To this end, you will need to remove the connector
sleeve attached to the device (see fig. 16, page 9).
d) Fixed pipework with 1/2˝ NPT
(Model No. 3201.930)
1
The
/2˝ NPT adaptor, available as an accessory,
allows you to connect fixed pipework to the air/water
heat exchanger for both the inlet and the return.
To this end, you will need to remove the connector
sleeve attached to the device (see fig. 16, page 9).
Note:
The water circuit should be protected
from ingress of dirt or excess pressure
(maximum permitted operating pressure
10 bar)!
Note:
Observe the flow direction
and check for leaks!
The following criteria for the cooling water must be
observed:
– Water with high gypsum content is unsuitable for
cooling purposes because it has a tendency to
form boiler scale that is particularly difficult to
remove.
– The cooling water should be free from iron and
manganese, because otherwise deposits may
occur that accumulate in the pipes and block
them.
– At best, organic substances should only be
present in small quantities, because otherwise
sludge deposits and microbiological contamination may occur.
4.5.2 Preparation and maintenance of the water
in recooling systems
Depending on the type of installation to be cooled,
certain requirements are placed on the cooling water
with respect to purity. According to the level of contamination and the size and design of the recooling
systems, a suitable process is used to prepare and/
or maintain the water.
The most common types of contamination and most
frequently used techniques to eliminate them in
industrial cooling are:
Contamination
of the water
Procedure
Note:
The units do not have any separate
ventilation.
For pressure-sealed systems, install the
appropriate ventilation equipment on the
water side.
4.5.1 Notes on water quality
To ensure the reliable operation of the abovementioned units, the VBG guidelines for cooling
water must be observed (VGB-R 455 P).
The cooling water must not contain any limescale
deposits; in other words, it should have a low level of
hardness, in particular, a low level of carbonate
hardness. For recooling within the plant, the carbonate hardness should not be too high. On the other
hand, the water should not be so soft that it attacks
the materials. When recooling the cooling water, the
salt content should not be allowed to increase excessively due to the evaporation of large quantities of
water, since electrical conductivity increases as the
concentration of dissolved substances rises, and the
water thereby becomes more corrosive.
Always add the appropriate volume of fresh water.
Always remove part of the enriched water.
Mechanical
contamination
Excessive hardnessWater softening
Moderate content
of mechanical
contaminants and
hardeners
Moderate content of
chemical contaminants
Biological contaminants,
slime bacteria and algae
Tab. 2: Water contaminants
Filter the water using:
– Mesh filter
–Gravel filter
– Cartridge filter
– Precoated filter
via ion exchange
Addition of stabilisers
and/or dispersing agents
to the water
Addition of passifiers
and/or inhibitors
to the water
When performing the electrical installation, it is important to observe all valid national and regional regulations as well as the provisions of the responsible
power supply company. Electrical installation must
only be carried out by a qualified electrician who
is responsible for compliance with the existing
standards and regulations.
4.6.1 Connection data
– The connected voltage and frequency must cor-
respond to the values stated on the rating plate.
– The air/water heat exchanger must be connected
to the mains via an all-pin isolating device which
ensures at least 3 mm contact opening when
switched off.
– No additional temperature control may be con-
nected upstream of the unit at the supply end.
– Install the pre-fuse cited on the rating plate
(miniature circuit-breaker or gG/(gL) fuse) to
protect the cable and equipment from shortcircuits.
– The mains connection must ensure low-noise
potential equalisation.
4.6.4 Potential equalisation
Rittal recommends connecting a conductor with
a nominal cross-section of at least 6 mm
potential equalisation connection point on the air/
water heat exchanger and incorporating it into the
existing potential equalisation system.
According to the standard, the PE conductor in
the mains connection cable is not classified as an
equipotential bonding conductor.
4.6.5 Installing the power supply
Complete the electrical installation in accordance
with the wiring plan to be found on the rear of the
air/water heat exchanger.
For devices 3363.XXX and 3364.XXX in special
voltage variants, an external transformer is required (see also Rittal system accessories).
To be able to evaluate the system messages of the
air/water heat exchanger via the system message
relay, a corresponding low-voltage cable must be
connected additionally on terminals 3 – 5.
2
to the
EN
4.6.2 Overvoltage protection
and supply line load
– The unit does not have its own overvoltage protec-
tion. Measures must be taken by the operator at
the supply end to ensure effective lightning and
overvoltage protection. The mains voltage must
not exceed a tolerance of ±10%.
– The fans in single-phase units are intrinsically safe
(thermal winding protection). The same also
applies to all transformer versions and to specialvoltage units which are likewise equipped with
a transformer.
4.6.3 Door limit switch
(e-Comfort controller only)
– Each door limit switch must only be assigned to
one air/water heat exchanger.
– Several door limit switches may be connected
in parallel and operated on one air/water heat
exchanger.
– The minimum cross-section of the connection
cable is 0.3 mm
We recommend the use of a shielded cable.
– The line resistance to the door limit switch must
not exceed a maximum of 50 1.
– The door limit switch only supports a floating
connection; no external voltages.
– The contact of the door limit switch must be closed
when the door is open.
The safety extra-low voltage for the door limit switch
is provided by the internal power pack: current
approx. 30 mA DC.
Connect the door limit switch to terminals 1 and
2 of the connector.
The door limit switch is available as an accessory