Rittal SK 3209. Series, SK 3210. Series Assembly And Operating Instructions Manual

R
SK 3209.xxx SK 3210.xxx
Montage-, Installations- und Bedienungsanleitung
Assembly and operating instructions
Manuel d’installation et de maintenance
Montage- en bedieningshandleiding
Istruzioni di montaggio e funzionamento
Instrucciones de montaje
Luft/Wasser­Wärmetauscher
Air/water heat exchangers
Echangeurs thermiques air/eau
Lucht/water­warmtewisselaars
Luft/vatten värmeväxlare
Scambiatori di calore aria/acqua
Intercambiadores de calor aire/agua
Rittal air/water heat exchanger assembly instructions 3
EN
Contents
1 Notes on documentation. . . . . . . . . . 4
1.1 Associated documents . . . . . . . . . . . . . . . . 4
1.2 CE Labelling . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Retention of documents . . . . . . . . . . . . . . . 4
1.4 Symbols used. . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety notes . . . . . . . . . . . . . . . . . . . . 4
3 Device description . . . . . . . . . . . . . . . 5
3.1 Functional description. . . . . . . . . . . . . . . . . 5
3.1.1 How it works. . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1.2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1.3 Bus mode (Comfort controller only). . . . . . . . 5
3.1.4 Safety equipment. . . . . . . . . . . . . . . . . . . . . . 6
3.1.5 Condensation. . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1.6 Leak detection . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1.7 Door limit switch. . . . . . . . . . . . . . . . . . . . . . . 6
3.1.8 Additional interface X3
(Comfort controller only) . . . . . . . . . . . . . . . . 6
3.2 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Scope of supply . . . . . . . . . . . . . . . . . . . . . . 7
4 Assembly and connection . . . . . . . . 7
4.1 Choosing the installation site . . . . . . . . . . . 7
4.2 Assembly instructions. . . . . . . . . . . . . . . . . 7
4.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.2 Layout of the electronic components
in the enclosure . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Assembling air/water heat exchangers . . . 9
4.3.1 Cutting out the enclosure. . . . . . . . . . . . . . . . 9
4.3.2 Assembling air/water heat exchangers . . . . . 9
4.4 Connecting the condensate discharge . . 10
4.5 Connecting the water connection . . . . . . 10
4.5.1 Notes on water quality . . . . . . . . . . . . . . . . . 11
4.6 Notes on electrical installation . . . . . . . . . 11
4.6.1 Connection data . . . . . . . . . . . . . . . . . . . . . 11
4.6.2 Overvoltage protection
and supply line load . . . . . . . . . . . . . . . . . . 11
4.6.3 Door limit switch. . . . . . . . . . . . . . . . . . . . . . 12
4.6.4 Notes on the flicker standard. . . . . . . . . . . . 12
4.6.5 Potential equalisation. . . . . . . . . . . . . . . . . . 12
4.7 Carrying out the electrical installation. . . 13
4.7.1 Bus connection (only when interconnecting several units
with a Comfort controller). . . . . . . . . . . . . . . 13
4.7.2 Installing the power supply . . . . . . . . . . . . . 15
4.8 Finalising assembly . . . . . . . . . . . . . . . . . . 17
4.8.1 Finalising air/water heat exchangers
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Commissioning . . . . . . . . . . . . . . . . 17
6 Operation . . . . . . . . . . . . . . . . . . . . . 18
6.1 Control using the Basic controller. . . . . . 18
6.1.1 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.1.2 Operating and error display . . . . . . . . . . . . 19
6.1.3 Basic controller test mode . . . . . . . . . . . . . 19
6.1.4 Setting the temperature . . . . . . . . . . . . . . . 20
6.2 Control using the Comfort controller . . . 20
6.2.1 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.2 Launching test mode . . . . . . . . . . . . . . . . . 21
6.2.3 General programming information . . . . . . . 21
6.2.4 Editable parameters . . . . . . . . . . . . . . . . . . 22
6.2.5 Programming overview . . . . . . . . . . . . . . . . 23
6.2.6
Defining system messages for evaluation
. . 24
6.2.7 Setting the master-slave identifier. . . . . . . . 24
6.2.8 Evaluating system messages . . . . . . . . . . . 25
7 Inspection and maintenance. . . . . . 26
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8 Storage and disposal. . . . . . . . . . . . 28
9 Technical specifications . . . . . . . . . 29
10 List of spare parts . . . . . . . . . . . . . . 31
11 Further
technical information. . . . . . . . . . . . 32
11.1 Hydrological data . . . . . . . . . . . . . . . . . . . 32
11.2 Characteristic curves . . . . . . . . . . . . . . . . 33
11.2.1 Water resistance . . . . . . . . . . . . . . . . . . . . . 33
12 Appendix 1:
Cut-out and hole sizes. . . . . . . . . . . 35
12.1 Dimensions for assembly . . . . . . . . . . . . 35
13 Appendix 2:
Preparation and maintenance of the water in
recooling systems . . . . . . . . . . . . . . 36
4 Rittal air/water heat exchanger assembly instructions
1 Notes on documentation
EN
1 Notes on documentation
These assembly instructions are aimed at tradesper­sons who are familiar with assembly and installation of the air/water heat exchanger, and are trained spe­cialists who are familiar with the operation of the air/ water heat exchanger.
1.1 Associated documents
There are two sets of instructions for the unit types described here: – Assembly and installation instructions enclosed
with the unit in the form of a paper document
– Assembly, installation and operating instructions
enclosed with the unit in the form of a PDF file
(Adobe Acrobat) on CD-ROM. 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.
1.3 Retention of documents
These instructions and all associated documents constitute an integral part of the product. They must be given to the plant operator. The plant operator is responsible for storage of the documents so they are readily available when needed.
1.4 Symbols used
Please observe the following safety instructions and other notes in this guide:
Symbol for an instructed action:
• The bullet point indicates that you should perform
an action.
Safety and other instructions:
2 Safety notes
Please observe the following general safety instruc­tions 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 and outside the enclosure (see also section 4.2.2).
– The heat loss of the components installed in the
enclosure must not exceed the specific useful cooling output of the air/water heat exchanger.
– The air/water heat exchanger must always be
transported in a vertical position. – 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. – Risk of burn injuries! For air/water heat exchangers
with automatic condensate evaporation, the sur-
face of the thermal element will get very hot during
operation, and will remain so for some time after-
wards. – The mains connector of the air/water heat ex-
changer must only be connected and disconnect-
ed with the system de-energised. Connect the
pre-fuse specified on the rating plate.
Danger! Immediate danger to life and limb!
Note! Potential threat to the product and its environment.
Note:
Useful information and special features.
3 Device description
Rittal air/water heat exchanger assembly instructions 5
EN
3 Device 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.
Fig. 1: Device description
Legend
1 Cover 2 Rating plate 3 Display 4 X2 master-slave connection (Comfort controller) 5 X1 terminal strip (underside of the unit) 6 X3 optional serial interface (underside of the unit) 7 Dispatch bag 8 Cooling water inlet 9 Cooling water return 10 Condensate discharge
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 +40°C to +70°C where comparable units, such as air/air heat exchangers, enclosure cooling units or filter fans, cannot be used for system rea­sons to effectively and economically dissipate heat loss. It is mounted on the roof of an enclosure.
3.1.1 How it works
The air/water heat exchanger comprises of three main components (cf. Fig. 2): Heat exchanger package (1), fan (2) and the magnetic valve (3) connected with each other using pipes.
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 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 flow regulator (3) controls the cooling output by changing the water flow volume depending on the required housing temperature and the water inlet temperature.
3.1.2 Control
Rittal enclosure 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 (display of the operating status via LED) or a Comfort controller (display plus extended functions, see chapter “6 Operation” page 18).
3.1.3 Bus mode (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. SK 3124.100). This allows you to implement the following functions: – Parallel unit control (the air/water heat exchangers
in the network can be switched on and off simulta-
neously) – 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”.
2
4, 5, 6
9
7
3
1
10
8
Cooling water return
Magnetic valve (3)
Temperature control
Cooling water inlet
Internal circuit
External circuit
Fan (2)
Heat exchanger (1)
6 Rittal air/water heat exchanger assembly instructions
3 Device description
EN
3.1.4 Safety equipment
– To protect against overcurrent and overtempera-
ture, the fan is equipped with a thermal winding protection.
– The unit has one (in the case of the Basic control-
ler) or two (in the case of the Comfort controller) in­tegral floating contacts on the connection terminal (system message relay with change-over contact, terminal 3 – 5) which may be used to retrieve mes­sages from the heat exchanger, e.g. via PLC.
– Units with Basic and Comfort controllers are also
equipped with a condensate alarm.
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 right and/or rear out of the unit via a drain opening in the evaporator tray. For this pur­pose, a hose must be connected to one of the two condensate nozzles (see “4.4 Connecting the con­densate discharge”, page 10). The drain which is not required should be tightly sealed. 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. Units with Basic and Comfort controllers are also equipped with a condensate alarm. Condensate hoses are available as accessories (refer also to the accessories section in the Rittal Catalogue).
3.1.6 Leak detection
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 activated and the fan switched off.
3.1.7 Door limit switch
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. PS 4127.000). 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. Connection is made at the terminals 1 and 2. The extra-low voltage is supplied by the in­ternal power pack; the current is approx. 30 mA DC.
3.1.8 Additional interface X3 (Comfort controller only)
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. SK 3124.200).
3.2 Proper usage
Rittal enclosure air/water heat exchangers were de­veloped and designed in accordance with the state­of-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.
Note:
The door limit switches must only be connected free from potential. No external voltages!
Note:
For air/water heat exchangers with basic control, the fan continues to run even when the door is open.
Note:
The electrical signals at the interface are of an extra-low voltage (not extra-low safety voltages in accordance with EN 60 335).
4 Assembly and connection
Rittal air/water heat exchanger assembly instructions 7
EN
3.3 Scope of supply
The unit is supplied in a packaging unit in a fully as­sembled state. Please check the delivery for completeness:
Tab. 1: Scope of supply
4 Assembly and connection
4.1 Choosing the installation site
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.
– 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 10).
– It must be possible to fit a cooling water supply and
return (see “4.5 Connecting the water connection”, page 10).
– The mains connection data as stated on the rating
plate of the unit must be guaranteed.
4.2 Assembly instructions
4.2.1 General
– Check the packaging carefully for signs of damage.
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.
– In order to avoid excessive condensation inside
the enclosure, we recommend installing a door lim­it switch (e.g. PS 4127.000) which deactivates the air/water heat exchanger when the enclosure door is opened (see “3.1.7 Door limit switch”, page 6).
Qty.
Designation
1 Air/water heat exchanger
1 1 1 1 1
1
Dispatch bag: – Plug-in terminal strip – Sealing frame – Assembly and installation instructions – Assembly, installation and operating
instructions on CD-ROM
– Declaration of conformity
1 Drilling template
8 Rittal air/water heat exchanger assembly instructions
4 Assembly and connection
EN
4.2.2 Layout of the electronic 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 (cf. Fig. 3). Components for targeted air routing are available as accessories – please refer to the chapter on “System climate control” in the Rittal Catalogue.
Fig. 4: Targeted air routing inside the enclosure
Note: 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 converters. 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.
Note:
When using an air duct system, care must be taken to ensure that it is laid straight and without kinks wherever possible. This mini­mises the resistance to the cold air flow. 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 compo-
nents and other installed
enclosures so that the required air circulation is not obstructed and prevented.
One cold air outlet from the air/water heat exchanger must be kept open at all times when operating with the air duct, to prevent the accumulation of cold air inside the unit.
4 Assembly and connection
Rittal air/water heat exchanger assembly instructions 9
EN
Fig. 5: Cover bungs
4.3 Assembling air/water heat exchangers
The enclosure air/water heat exchanger is fitted on the roof of the enclosure. To this end, the roof plate must be cut-out as per the drilling template included with the supply.
4.3.1 Cutting out the enclosure
• Stick the supplied drilling template onto the roof of the enclosure using adhesive tape.
There are dimensioning lines on the drilling template to suit the installation type for your air/water heat ex­changer.
• Make the cut-outs including the line width as per the drilling template. Deburr the cut-outs.
4.3.2 Assembling air/water heat exchangers
• Stick the supplied sealing frame onto the cut-out roof plate.
Fig. 6: Sealing frame on roof plate
• Mount the air/water heat exchanger on the enclosure roof.
• Screw the supplied twin-threaded bolts into the holes in the plastic base on the underside of the device.
• Secure the unit using the supplied washers and nuts.
Fig. 7: Roof plate reinforcement for the TS 8 enclosure
Accessories for roof plate reinforcement with TS:
Punched rail U nut Fastening bracket Threaded block (refer also to Accessories in the Rittal Catalogue)
Note:
When using the cover bungs, no more than 2 cold air outlets should be sealed.
Note:
Pre-configured, reinforced roof plates with cut-outs to match your enclosure are available as accessories; refer to “System climate control” in the Rittal Catalogue.
Risk of injury! Carefully deburr all cut-outs to prevent injuries caused by sharp edges.
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. This is particularly applicable with large roof areas.
10 Rittal air/water heat exchanger assembly instructions
4 Assembly and connection
EN
4.4 Connecting the condensate discharge
A flexible condensate discharge hose (Ø 1/2˝) can be fitted to the air/water heat exchanger. 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 extend-
ed. The condensate hose is available as an accessory (refer also to Accessories in the Rittal Catalogue).
Fig. 8: Connect the condensate discharge to the side
of the unit
• Connect a suitable hose from the right or rear to the
condensate nozzle screwed into the unit, and
secure it with a hose clip (with 2 Nm torque).
• Lay the condensate hose, e.g. into a drain.
Fig. 9: Lay the condensate discharge to the side of the unit
4.5 Connecting the water connection
A compression-proof flexible condensate discharge hose (Ø 1/2˝) for both the supply and the return can be fitted to the air/water heat exchanger. The cooling water hose – must be laid without kinks – must not have a reduced cross-section if extended
and, if necessary, must be insulated.
Fig. 10: Connect the cooling water inlet (top) and
return (centre) to the side of the unit
• Reseal the connection nozzles using teflon tape or hemp and sealing paste.
• Connect a suitable hose to each of the two cooling water connection nozzles (at the side or rear of the unit) and secure each one with a hose clip (with 15 Nm torque).
The unused cooling water connecting pieces must be closed appropriately with sealing bungs (with 15 Nm torque).
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!
4 Assembly and connection
Rittal air/water heat exchanger assembly instructions 11
EN
Fig. 11: Lay the cooling water hose
4.5.1 Notes on water quality
To ensure the reliable operation of the above-men­tioned units, the VBG guidelines for cooling water must be observed (VGB-R 455 P). The cooling water must not contain any limescale de­posits or loose debris; in other words, it should have a low level of hardness, in particular, a low level of calcium hardness.
In particular, for recooling within the plant, the calcium 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.
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.
4.6 Notes on electrical installation
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. The electrical installation may only be performed by a qualified electrician who is responsible for compliance with the applicable standards and regulations.
4.6.1 Connection data
– The connected voltage and frequency must corre-
spond 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 that 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 specified on the rating plate
(miniature circuit-breaker “K” characteristic or slow fuse) to protect the cable and equipment from short-circuits.
– The mains connection must ensure low-noise
potential equalisation.
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%.
– In accordance with IEC 61 000-3-11, the unit is
intended solely for use at sites with a continuous current-carrying capacity (incoming mains power supply) of more than 100 A per phase and with a supply voltage of 400/230 V. If necessary, the power supply company must be consulted to en­sure that the continuous current-carrying capacity at the point of connection to the public grid is sufficient for connection of such a unit.
– The fans in single- and three-phase units are intrin-
sically safe (thermal winding protection). The same also applies to all transformer versions and to spe­cial-voltage units which are likewise equipped with a transformer.
– Install the slow pre-fuse specified on the rating
plate (miniature circuit-breaker with “K” character­istic, motor circuit-breaker or transformer circuit­breaker) to protect the cable and equipment from short-circuits. Select a suitable motor circuit­breaker/transformer circuit-breaker in accordance with the information specified on the rating plate: Set it to the minimum specified value. This will achieve the best short-circuit protection for cables and equipment. Example: Specified setting range MS/TS 6.3 – 10 A; set to 6.3 A.
12 Rittal air/water heat exchanger assembly instructions
4 Assembly and connection
EN
4.6.3 Door limit switch
– 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 mm2 for a cable length of 2 m. We recommend the use of a shielded cable.
– The line resistance to the door limit switch must not
exceed a maximum of 50 Ω.
– 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.
4.6.4 Notes on the flicker standard
The flicker limits specified in standard EN 61 000­3-3 or -3-11 are adhered to, provided the supply impedance is less than approx. 1.5 Ω. Where necessary, the unit operator should measure the connected impedance or consult the responsible power supply company. If there is no way of influenc­ing the supply impedance and sensitive installed components (e.g. BUS) are subjected to interfer­ence, a line reactor or starting-current limiting device should be connected upstream of the air/water heat exchanger to restrict the startup current of the air/ water heat exchanger.
4.6.5 Potential equalisation
Rittal recommends connecting a conductor with a nominal cross-section of at least 6 mm2 to the poten­tial equalisation connection point on roof-mounted air/water heat exchangers 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.
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