Swegon CoolDX 08-1, CoolDX 20-1, CoolDX 08-2, CoolDX 12-2, CoolDX 20-2 Installation And Maintenance Instructions Manual
...
GB.COOLDX.INST.090301
CoolDX COOLING UNIT
Installation and Maintenance Instructions
Sizes 08-60
GB.COOLDX.INST.090301
We reserve the right to alter specifications.
2
www.swegon.com
CONTENTS
1. General Survey 3
1.1 General 3
1.2 Basic function diagram 4
2 Safety instructions 5
2.1 Safety switch/mains power switch 5
2.2 Risks 5
2.3 Electrical equipment 5
2.4 Authorisation 5
2.5 Identification decals 5
3 Installation 6
3.1 Unloading/transport within the building site 6
3.1.1 Lifting using a forklift truck 6
3.1.2 Lifting using a crane 6
3.2 Arrangement 6
3.3 Docking configurations 7
3.3.1 Height adjustment to height of GOLD/water trap 8
3.3.2 Connection to GOLD Units, CoolDX Size 08-12 8
3.3.3 Connection to GOLD Units, CoolDX Size 20-60 9
3.3.4 Duct connection, CoolDX size 08-12 9
3.3.5 Duct connection, CoolDX sizes 20-60 9
3.3.6 Condensate drainage from cooling coil 9
5 Commissioning 12
5.1 Preparations 12
5.1.1 Before initial start up 12
5.1.2 Starting up 12
5.1.3 In-service pressure switches 12
5.1.4 Phase-sequence monitor 12
5.1.5 Remedial action if wrong phase sequence 12
6 Alarms 12
7 Maintenance 13
7.1 Cleaning 13
7.2 Handling of refrigerant 13
7.3 Annual inspection 11
7.4 Servicing 13
8 Troubleshooting and leakage tracing 14
8.1 Troubleshooting Schedule 14
9 Dimensions 15
9.1 CoolDX 08 15
9.2 CoolDX 12 15
9.3 CoolDX 20-40 15
9.4 CoolDX 60 15
3.3.7 Supply air filter 9
3.3.8 Condensation barrier mat 10
4 Electrical connections 11
4.1 Connection to power supply 11
4.2 To connect the communication cable 11
10 General technical data 16
11 Electrical equipment 17
12 Internal Wiring Diagram 18
12.1 CoolDX 08-40, all capacity variants, and size 60,
capacity variant 1 18
12.2 CoolDX 60 Capacity variant 2 19
12.3 CoolDX 60 Capacity variant 3 20
13 Commissioning Record 21
GB.COOLDX.INST.090301
We reserve the right to alter specifications.
www.swegon.com
3
1. GENERAL SURVEY
1.1. General
Cooling unit CoolDX
Cooling unit CoolDX is a complete cooling unit for comfort cooling in air handling systems. All the components
are fully wired, have fully connected refrigeration circuits
and are collected inside a common casing. The casing is
fabricated of aluminium profiled sections held together by
plastic corner pieces. The panels are of sandwich design
and consist of a 0.7-1 mm thick galvanized sheet steel
outer skin with painted visible surfaces (colour: NCS 2005
Y 30R), 1 mm thick aluminium-zinc plated sheet steel
inner skin and 35 mm thick intervening expanded polyurethane isolation.
The cooling coil and condenser are fabricated of copper
tubes and profiled aluminium fins; the casing is made of
galvanized sheet steel.
The cooing units are tested prior to delivery.
The CoolDX is available in 16 output variants which are
divided into six physical sizes, specially suited for the size
08-60 GOLD units.
Compressors
Size 60 units in output variant 2 and 3, contain a piston
compressor and a scroll compressor, all other sizes/output
variants contain two piston compressors each.
Completely direct-acting system
The CoolDX has a completely direct-acting system. It has
an evaporation coil for direct-evaporating refrigerant on
the cold side and a condenser coil on the hot side.
Refrigerant
The CoolDX has double refrigerant circuits separated from
each other. Type R407C refrigerant is used. The refrigerant
circuits are charged on the delivery. At present, this refrigerant has no known influence on the ozone layer and no
known future restrictions are anticipated.
Refrigerant volume
See section 10. General technical data.
Duty to report
If the total volumetric weight of the refrigerant filled into
the cooling system exceeds 10 kg, a report must be submitted to the local supervisory authority.
Annual inspection
If the volumetric weight of the refrigerant in the cooling
unit exceeds 3 kg, an annual inspection by an accredited
inspectorate is required. All the CoolDX units (except size
8, output variant 1) should be checked once a year.
ISO 9001 Quality Management and ISO 14001 Environmental Management Systems
We at Swegon are deeply involved in the maintenance of
our certified quality management system defined by ISO
9001 and our certified environmental management system defined by ISO 14001.
GB.COOLDX.INST.090301
We reserve the right to alter specifications.
4
www.swegon.com
1.2 Basic function diagram
COND
VSH2
FD1FD2
HP
HP
BP1-3
IPL1IPL2
M1 M2
VET1VET2
EVAP
VSL1
LP
BP1
VSL2
COND Condenser
VSH1 Overpressure protection
VSH2 Overpressure protection
BP1-3 Pressure limiting switch for high pressure 26 bar
BP1 Pressure limiting switch for low pressure 2,5 bar
BP2-3 Pressure limiting switch for high pressur 26 bar
BP2 Pressure limiting switch for low pressure 2,5 bar
BP1-2 Alarm pressure switch for high pressure 28 bar
BP2-2 Alarm pressure switch for high pressure 28 bar
M1 Compressor
M2 Compressor
VSL1 Underpressure protection
VSL2 Underpressure protection
EVAP Evaporator
VET1 Expansion valve with thermostat
VET2 Expansion valve with thermostat
IPL1 Sight glass, refrigerant circuit 1
IPL2 Sight glass, refrigerant circuit 2
FD1 Filter drier
FD2 Filter drier
Operation
There are two refrigerant circuits in the cooling unit. The
circuits are separate from one another.
Each circuit is equipped with a finned condenser, a finned
evaporator and a compressor.
The two compressors have different capacity, which enables control in 3 steps.
The gaseous refrigerant is compressed by compressors M1
and M2 and from there moves on to condenser COND,
where it is chilled by the extract air and is condensed to
liquid form.
The pressure and the temperature decrease as the refrigerant in fluid form flows through expansion valves VET1
and VET2.
HP
BP2-2BP1-2
HP
BP2-3
LP
BP2
From the expansion valves the refrigerant moves on to
evaporator EVAP, where the refrigerant evaporates and
chills the outdoor air.
From evaporator EVAP, the evaporated refrigerant is conveyed further to the suction side of the compressors where
it is again compressed.
Control
The cooling capacity is regulated in three binary steps by
having one or two compressors in operation.
The cooling compressors are controlled from the GOLD
unit via relays on the IQnomic Plus module mounted in the
CoolDX.
Step 1: When cooling is needed, Compressor M1 is started.
Step 2: If more cooling is needed, Compressor M2 starts
and at the same time Compressor M1 stops. An adjustable time delay (a step duration of 300 seconds) ensures
that Compressor M2 will not start until Compressor M1 is
operating at full capacity.
Step 3: If even more cooling is needed, Compressor M1 is
restarted and is run at the same time as Compressor M2.
This third cooling step is also delayed by a preset time delay setting. In addition, the restarting time (480 seconds)
for Compressor M1 shall have expired.
If less cooling is needed and the compressors are subsequently switched out step-by-step, there will be no delay
between compressors. The restarting time (480 seconds)
for Compressor M1 shall have expired to enable it to start
again in Step 1 after it has been operated in Step 3.
If any compressor is stopped, the restarting time must
expire before a restart can take place. The restart time is
calculated from one start to the next start.
Low pressure switches BP1/BP2 and high pressure switches
BP1-3/BP2-3 (in-service pressure switches for the respective circuit) ensure that the system pressure is within predetermined limits.
If the pressure in the cooling circuit becomes too low, or
if the pressure in the condenser circuit becomes too high,
the compressor is stopped and the text PRESSURE LIMITING is displayed alternately in the hand-held micro terminal of the GOLD air handling unit.
When the restart time has expired, the compressors will try
to restart.
If the pressure increases more, high pressure switches
BP1-2 and BP2-2 will trip and stop the GOLD unit and the
CoolDX cooling unit.
Alarms 85 and 86 will be displayed in the hand-held micro
terminal of the GOLD unit.
Pressure switches BP1-2 and BP2-2 can be manually reset
by pressing a button under each protective sock on the
upper side of the pressure switch. This can be done without removing the protective sock.
GB.COOLDX.INST.090301
We reserve the right to alter specifications.
www.swegon.com
5
2 SAFETY INSTRUCTIONS
2.1 Safety switch/mains power switch
The safety isolating switch is positioned on the inspection
side of the cooling unit.
The safety isolating switch should not be used for starting
or stopping of the cooling unit.
To ensure that the CoolDX is switched off: stop the air
handling unit or briefly switch off the cooling unit via the
hand-held micro terminal. See the GOLD Operation and
Maintenance Instructions.
On completing the above, the safety isolating switch can
be used for switching off the power supply.
Caution!
Always switch off the safety switch whenever you
service the unit, unless otherwise stated in relevant
instructions
2.2 Risks
Warning
Always isolate the power supply before starting any
work in the refrigerant circuit or the electrical system.
Warning
The inspection door of the GOLD unit may not be opened while the unit is in operation. Positive pressure inside the unit will cause the door to fly open and possibly
cause personal injury.
2.3 Electrical equipment
The electrical equipment of the cooling unit is housed in
a separate cubicle located behind one of the inspection
doors.
2.4 Authorisation
Only qualified and authorised electricians shall be permitted to install electrical wiring in the unit.
Only an accredited refrigeration company shall be permitted to modify or repair the refrigeration circuits.
Other modifications in the unit should only be made by
service personnel trained by Swegon.
2.5 Identification decals
The unit identification decal indicating type designation,
serial number, refrigerant volume, etc. is affixed to the
door of the cooling unit.
Type designation: COOLDX-aa-A-c-d-e
GOLD size
Warning
Under no circumstances may the refrigerant circuits be
opened by unauthorised personnel, since they contain
gas under high pressure.
Risk areas where exposure to refrigerant could occur
Practically the whole area inside the cooling unit is a risk
area. For particulars on how to deal with leakage, see
Section 7.2.
Type R 407C refrigerant is used.
Capacity variant
GB.COOLDX.INST.090301
We reserve the right to alter specifications.
6
www.swegon.com
3 INSTALLATION
3.1 Unloading/transport
within the building site
Important!
All transport should be carried out with the cooling unit
in the horizontal position.
3.1.1 Lifting using a forklift truck
Warning
The unit has a high centre of gravity! Carefully lift the
cooling unit!
3.1.2 Lifting using a crane
Position two line spreaders at the upper side of the cooling
unit and two under the underside of the pallet or under
the cooling unit and lift in the pallet (or in the base frame
of the cooling unit if the unit is not delivered on a pallet).
3.2 Arrangement
Position the CoolDX cooling unit at suitable place in the
fan room.
Allow an open space around the safety isolating switch/
mains power switch for servicing in accordance with applicable electrical safety regulations.
The unit can be positioned with its backside against a wall;
however it is advisable to position it at a distance of approx. 1 metre away from a wall to make it easier to service
the rear compressor.
See sketch.
GB.COOLDX.INST.090301
We reserve the right to alter specifications.
www.swegon.com
7
3.3 Docking configurations
The design of the CoolDX cooling unit enables it to be
docked to the outdoor air and exhaust air side of the
GOLD air handling unit. See sketch!
The dimensions and capacities of the CoolDX are designed
for connection to size 08-60 GOLD air handling units.
For a list of the cooling unit sizes and capacities that
match a given size of GOLD unit, see Section 10. General
Technical Data.
CoolDX 08
CoolDX 12-60
Cooling coil in lower level/GOLD fan arrangement 1 Cooling coil in upper level/GOLD fan arrangement 2
Right hand version Left hand version
Right hand version
Left hand version
Cooling coil in upper level/GOLD fan arrangement 1 Cooling coil in lower level/GOLD fan arrangement 2
Outdoor air Supply air Extract air Exhaust air
Loading...