OC VERHULST Aqua Cool 100, Manual

Page 1: ...her documentation see http www oc verhulst nl OC Verhulst Albert Einsteinweg 10 5151 DL Drunen The Netherlands Tel 31 0 416 672 200 Fax 31 0 416 340 785 www oc verhulst nl OC Verhulst is a trade name of Verhulst Klimaattechniek B V part of Orange Climate ...

Page 2: ...tray maintenance 10 5 6 Droplet eliminator separator 10 5 6 1 Droplet eliminator maintenance 10 5 7 Siphon 11 5 7 1 Siphon maintenance 11 5 8 Fan 11 5 8 1 Fan maintenance 12 5 9 Housing 12 5 9 1 Maintenance of housing 12 5 10 Control panel 12 5 10 1 Control panel maintenance 13 5 11 Switch panel 14 5 11 1 Maintenance of electrical equipment and switches 14 6 Maintenance schedule for operating pers...

Page 3: ...t 20 8 3 Temporary storage 20 8 4 Final placement 21 8 5 Installation 21 8 6 Commissioning 22 8 7 Pre commissioning check 22 9 Starting 23 9 1 Decommissioning 23 10 Safety 24 10 1 General safety instructions 24 10 2 Statutory requirements 24 10 3 Safety measures 24 11 Display instruction 26 11 1 Graphical operating display 26 11 2 Display and operating buttons 26 11 3 P ID diagram 28 11 4 IO list ...

Page 4: ...g setting 34 11 9 5 Manual mode 35 11 10 Information 36 11 11 Table of alarm messages 38 11 12 Other functions 40 11 12 1 Indicator lights connected to digital output 40 11 12 2 Supply air sensor Automatic selection 40 11 13 Menu settings Programming 40 11 13 1 Fan 40 11 13 2 Belimo 40 11 13 3 Belimo 41 11 13 4 Configuring the unit 41 11 13 5 Alarm 41 ...

Page 5: ...n For clarity important items are indicated in bold along with the text CAUTION These are important instructions that protect you from danger or refer to the risk of damage to the unit Please bear all these comments in mind If you have any questions or would like further clarification on specific issues relating to the unit please do not hesitate to contact one of our team in the Repair Maintenanc...

Page 6: ...hout the prior written permission of OC Verhulst Settings and or safeguards have been changed without the prior written permission of OC Verhulst Non original parts or refrigerants or lubricants other than those prescribed are used The equipment has not been placed and or connected in accordance with the placement and installation instructions The equipment is used improperly incorrectly negligent...

Page 7: ...connections for defrosting the cooling battery for example The Aqua Cool can be connected with an electric plug Aqua Cool 100 16A 3P 3 1 Designtypes The Aqua Cool 100 has a nominal output of 100 kW maximum cooling capacity at 12 500 m3 h and is suitable for both indoor and outdoor installation 3 2 AquaCoolsystemprinciple Aqua Cool 100 D01 Outside air inlet damper manually operated TT01 Outside air...

Page 8: ...t by authorised and qualified personnel see chapter 6 For maintenance you can use the service organisation of OC Verhulst which offers you a maintenance contract for this If you notice any defects and or deviations please report this to our service organisation immediately When reporting it is important to mention the order number of the unit this number is indicated on the model plate of the unit...

Page 9: ...mponents are listed separately and the required maintenance is indicated 5 2 Aircontrol dampers The external air intake is equipped as standard with a volume control damper with manual operation and locking device The dampers in the air outlet are also manually operated with a locking device The dampers are standard contra rotating dampers with aluminium housing aluminium damper blades and plastic...

Page 10: ...ed by removing the filters You should check the coil annually for contaminants and clean the coil if necessary using a high pressure water jet or compressed air avoiding damage to the fins Repair any damage with a so called Fin comb When servicing coils be aware of the hazards of the medium used a neutral temperature is desired and the medium must be sufficiently cooled Even after switching off th...

Page 11: ...r flow through the heat exchangers is provided by directly driven plug fans with EC motors The fans are speed controlled by means of a rotary knob located on the control panel The fans are controlled by the PLC and communicate via ModBus Because EC motors are used there is no risk of the fans turning in the wrong direction Please note that a leakage current is present CAUTION Position number Descr...

Page 12: ...Aqua Cool consists of double walled sandwich panels made of Sendzimir galvanised sheet steel 1 mm thick with an internal and external 100µ powder coating in RAL7035 as standard The housing has a wall thickness of approximately 50 mm The insulation consists of expanded insulation material and is fully bonded to the inner and outer sheets of the sandwich panel The housing has 2 connections for air i...

Page 13: ... how to operate it see chapter 11 Display instructions 5 10 1 Control panel maintenance The control panel should only be cleaned periodically on the outside with a non aggressive cleaning agent Inspect the panel and if necessary report any damage and have it repaired by OC Verhulst ...

Page 14: ...operating instructions of the control system used in your unit and if applicable the electrical diagram for details on how to operate and reset the various protection devices CAUTION Work on the electrical system may only be carried out by trained and certified personnel 5 11 1 Maintenance of electrical equipment and switches Maintenance is mainly limited to removing dust and dirt at least twice a...

Page 15: ...nections for tightness 1 Control panel switch panel Check that the controller compartment is clean and dry 2 Check the condition of the cables worn burned damaged 2 Check the condition of the insulation dirt moisture damage 2 Check that the controller compartment is clean and dry 1 Check the condition of the switches dirt corrosion 1 Check the condition of the contacts dirt corrosion burns 1 Check...

Page 16: ...ts Secure before opening OC Verhulst model plate Missing or damaged pictograms should be re affixed as follows When affixing pictograms proceed as follows Clean the surface with a non aggressive degreaser Heat this section with a hairdryer until it is hand warm Remove the protective sheet and stick the pictogram in the correct position Press the pictogram firmly and make sure that no air bubbles f...

Page 17: ...uresensor Temperature sensor is mounted in the space between outdoor air inlet dampers and filters 7 2 Supplyairtemperature internal external sensor The internal temperature sensor is mounted in the space between the fans and supply dampers It is also possible to connect an external temperature sensor via a connection outside the cabinet When this is connected the control strategy automatically ch...

Page 18: ... It is also possible to log graphs tables 7 10 ControlTechnologyerrormessages The display has the possibility to switch on three lights green orange and red The various combinations are error messages or confirmation of being in operation On On Off Off Off Off On On Off Off Off Off On On Off Unit is on Works according to settings Unit is on Non urgent dirty filter message Unit is off Dirty filter ...

Page 19: ...a Cool can be put into operation all inlet and outlet openings must be fitted with ducts or grilles All inspection doors hatches must be closed This is to prevent physical injury CAUTION To ensure that the unit functions properly it must be set up completely level height should be compensated with shims under the unit or vibration dampers If you have any questions or doubts about the set up option...

Page 20: ...ol cannot be set up immediately all the medium and air openings must be temporarily closed and all valves closed If the Aqua Cool is taken out of operation for a longer period of time the following points should be noted The unit must be switched off properly see chapter 9 1 All dampers and valves must be closed If a glycol mixture is used it must be drained off This also applies to the cooler and...

Page 21: ...lable at the front The unit must be able to suck in and extract air freely Ensure good and safe accessibility and where necessary provide railings and or fall protection e g when positioning the unit close to the roof edge The Aqua Cool should be set up level and placed flush with the ground frame on a stable surface so that the inspection panels doors can be opened and closed easily 8 5 Installat...

Page 22: ...ing the Bauer couplings The supply is the female the return is the male 8 7 Pre commissioningcheck Check the points mentioned in chapter 8 If present check the water circuit and especially all connections for leaks Check whether there is sufficient water pressure in the hydraulic system Check that air inlet and outlet can take place unhindered Check that the correct supply voltage is present Check...

Page 23: ...s until the ducts and supply hoses and inlet covers grilles have been correctly fitted as any dirt sucked in will leave the fans at high speed Refer to the electrical diagram and the operating instructions of the control system to familiarise yourself with the control of the unit Depending on the prevailing conditions the unit will start in the desired operating mode When checking the operating co...

Page 24: ...he Aqua Cool is not permitted It is recommended that a maintenance contract be taken out so that the Aqua Cool can be checked regularly Keep the operating instructions near the Aqua Cool for the duration of its service life Your Aqua Cool is fitted with a main switch that also serves as an emergency stop button The switch therefore has a red control on a yellow background Switch off the unit by tu...

Page 25: ...k into the ventilation hood of an operating unit as the airflow can blow out dust particles forcefully risk of damaging the eyes The Aqua Cool is designed for a maximum ambient temperature of 50ºC both in storage and in use The safety of installers and operating personnel is ensured by the following devices The main switch can be locked in the zero position off All live parts are designed to be to...

Page 26: ... Graphical operatingdisplay The control unit contains 6 operating keys and a graphical LED lit display It offers the possibility of an alarm log and four interfaces 11 2 Displayandoperatingbuttons In normal condition the display shows an overview of the current time date and day In addition the following data are visible ...

Page 27: ...01 G Current status Fan F02 H Current status Fan F03 not applicable to Aqua Cool 100 I Current status Fan F04 not applicable to Aqua Cool 100 J Current status Belimo K Current unit mode Heating Cooling Defrosting L Current status of the unit Off On On by task scheduler In the external Quickstart you will find a brief user explanation In the following chapters you will find the detailed description...

Page 28: ...air inlet intake temperature ΔP Delta P dirty filter switch Filter Filter Coil Battery MV01 Belimo 3 way valve TT04 Return water temperature TT05 Supply water temperature TT02 Supply air temperature internal TT03 Supply air temperature external F01 F02 Fans 2 pcs Aqua Cool 100 D02 Supply air damper 2x manually operated ...

Page 29: ...emark U1 Air inlet intake temperature sensor TT01 NTC10K U2 Supply air temperature internal TT02 NTC10K U3 Supply air temperature external TT03 NTC10K U4 Supply temperature element TT04 NTC10K U5 Drain temperature element TT05 NTC10K U6 External speed controller F01 F04 0 10V U7 See digital input U8 Reserve U9 Reserve U10 Reserve Communication Description Remark BMS2 Connection Terra Modbus RTU Sl...

Page 30: ... alarm log plus four different menu levels Information Operation Service and Factory These menus allow the user to easily view control and configure the operational parameters for the unit 11 5 1 Function keys 11 5 2 Adjusting the contrast Hold down the Alarm and Prg buttons then use the Up Down arrow to adjust the contrast 11 5 3 Alarm messages All alarm messages work as follows When an alarm mes...

Page 31: ...ssages are active they will be stored in the logbook 11 6 Selectionofmenus The controller provides the user with menus that can be selected for displaying operating data and entering setpoint values for the system These menus can be accessed from a browsable main menu by pressing the programming key Prg The default password for all levels is provided by email upon delivery to the hire company This...

Page 32: ...t internal B Current supply temperature C Current air inlet intake temperature D Fan speed setting by analogue input E Counter for defrosting activated by push button F Current status Fan F01 G Current status Fan F02 H Not applicable to Aqua Cool 100 I Not applicable to Aqua Cool 100 J Current status Belimo K Current unit mode Heating Cooling Defrosting L Current status of the unit Off On On by ta...

Page 33: ... the user can switch on the unit The corresponding menu screen is as follows The unit can now be used when the following conditions are met Either the external On Off is set or the task scheduler must be activated The task scheduler can be opened by pressing config unit in the main menu ...

Page 34: ... this menu to set a 0 10V signal for the analogue output 11 9 4 Defrosting setting The defrosting cycle is started manually by means of a push button After pressing the button the digital output is executed When you press the start button for the first time the defrosting cycle starts for a period of 10 minutes Each press of the button increases the defrosting time by 10 minutes So if the defrost ...

Page 35: ...me 7 not used at the moment Defrost start time 8 not used at the moment Defrosting starts at 8 00 and stops at 8 20 The same applies to 12 00 13 00 and 23 00 The screens are as follows 11 9 5 Manual mode The Belimo valve and the fans can be set to Off Manual or Automatic mode Off Means off under all circumstances Man The user can manually set values and alarm messages where other conditions do not...

Page 36: ...the digital and analogue input and output signals and the unit s status Description Screen standard Current values readable by analogue input signals Current analogue and digital output signals Current digital input signals Current status and fan data This data is available for all fans depending on the number of fans ...

Page 37: ...Version 5 2_2022 January 26 2022 37 Current number of operating hours of the unit Measured time of power outage of the unit Time Duration ...

Page 38: ... 1 24 Automatic reset Output limit power supply EBM 1 25 Automatic reset Current limit power supply EBM 1 26 Automatic reset Braking mode EBM 1 27 Automatic reset Cable break EBM 1 28 Automatic reset Ice protection EBM 1 29 Automatic reset Heating motor stop EBM 1 30 Automatic reset Speed below limit EBM 1 31 Automatic reset DC voltage high EBM 1 32 Automatic reset Supply voltage high EBM 1 33 Aut...

Page 39: ... high EBM 3 87 Automatic reset Line resistance high EBM 3 88 Automatic reset Offline EBM 4 89 Manual reset Phase fault EBM 4 90 Manual reset Motor blocked EBM 4 91 Manual reset Undervoltage power supply EBM 4 92 Manual reset Overvoltage power supply EBM 4 93 Manual reset Overvoltage DC connection EBM 4 94 Manual reset Undervoltage DC connection EBM 4 95 Manual reset Overheating motor EBM 4 96 Manu...

Page 40: ...light does not go off Defrosting light same output as defrosting light The light comes on when defrosting is activated 11 12 2 Supply air sensor Automatic selection Supply air temperature sensor internal external The internal temperature sensor is mounted in the space between the fans and the outlet It should be possible to connect a second temperature sensor via a connector from the outside of th...

Page 41: ...guration of the unit the mode for the unit can be selected This affects the PI controller for the Belimo valve Selecting cooling or heating changes the control direction of the PI controller algorithms In addition the number of fans can be selected 11 13 5 Alarm Enter this menu to view the Alarm history Reset alarms by holding down the alarm button for 5 seconds ...