INSTALLATION, USER AND MAINTENANCE MANUAL

EN

Chilled water direct expansion Rack

Cooler

CRCX + i-HCAT
CRCC

CRCX + i-HCAT
0051-0071-0121

CRCC
0020-0025-0035-0036
INDEX U I A

U I A Documents 3 U I A Commissioning and testing 20

U I A General characteristics 3 I A Condensate drain 22
I A i-HCAT outdoor unit 4 U I A Instruments and alarms 22
U I A Rating plate 5 U I A Calibrating the control and safety devices 22
U I A General technical specifications 6 U I A Calibrating the air flow sensor 22
I A Receipt, transport and handling 8 U I A Calibrating the dirty filter sensor 23
I A Operating limits 9 U I A Operation and control 23
I Dimensional drawings 10 U I A Modulating water valve 23
I A Overview diagram 12 U I A 2-way on/off valve (optional) 24
I Installation 13 U I A Temperature and humidity probe (optional) 25
I A Recommended installation for CRCX/i-HCAT 14 U I A Flow meter (optional) 26
I A Refrigerant connections (CRCX / i-HCAT) 15 U I A Maintenance 27
I A Water connections (CRCC) 16 U I A Troubleshooting 29
I A Correction factors 16
I A Electrical connections 18
I A Electrical specifications and minimum power cable sizes 20

The following symbols are used in this publication and inside the unit:

U User Important

I Installer Prohibition

A Assistance

The following symbols are used in some parts of this booklet: Specialist personnel Person with in-depth knowledge
(electrician) and experience such as to be able
to recognise risks and avoid dan-
WARNING = for actions that require special care and gers that may derive from elec-
suitable preparation tricity (IEV 826-09-01, amended).
PROHIBITED = for actions that absolutely MUST NOT
be performed

2 English 01-2012 CRCX - CRCC

 DOCUMENTS U I A

DOCUMENTS ENCLOSED WITH THE UNIT

Each unit is delivered complete with the following documents: • CE declaration with list of European directives and standards that
• Air-conditioner installation, user and maintenance manual; the unit is compliant with;
• Wiring diagram; • Warranty conditions.
• List of spare parts;

GENERAL CHARACTERISTICS U I A

RACK COOLER CRCC / CRCX INDOOR UNIT FILTERS

Regenerable polyester fibre filtering media treated with synthetic
DESCRIPTION OF THE UNIT resins, supported by a frame with protective metal mesh.
The CRCC/ CRCX air-conditioning unit is an innovative and effi- G2/G4 efficiency according to CEN-EN 779 standard with aver-
cient system for managing hot spots in data centers, guaranteeing age separation efficiency 90.1% ASHRAE (G4). The filtering media
low energy consumption and possibility to be used with HIGH is flame retardant.
DENSITY racks that generate extremely high loads, up to and
over 40 kW/m2 per rack. AIR-SOURCE HEAT EXCHANGER
Available both in the chilled water version, where cooling is pro- Finned coil with large frontal surface area, made from mechanical-
vided by an external chiller, and the direct expansion version ly expanded tubes and aluminium fins with hydrophilic treatment
combined with an outdoor condensing unit featuring new FULL and high heat transfer area.
INVERTER technology, suitable for R410A refrigerant. The coil is placed upstream of the fans for optimum air distribu-
The use of the latest generation EC fans with brushless motors tion.
ensures excellent performance in terms of low power consump-
tion and low noise. ELECTRICAL PANEL
N+1 dynamic management of the EC fans to optimise consump- Built and wired in compliance with IEC 204-1/EN60204-1 stan-
tion and cooling system redundancy are available as standard dards, complete with fan contactor and overload protection.
These are individual units to be positioned in the rows between
the racks, so as to dissipate server heat load locally. MICROPROCESSOR CONTROL SYSTEM
On the InRow versions (CCRC-I and CCRX-I) the warm air is The microprocessor, by managing the compressor for the direct
taken in from the rear of the unit directly from the hot aisle in expansion unit and the modulating 3-way valve for the water
the data center (35°C), with considerable benefits in terms of chiller, controls cooling capacity and operating alarms, with the
energy efficiency and cooling capacity, and is then cooled and possibility of connection to supervisory systems.
delivered to the cold aisle (18-20°C), in other words the front of
the server racks where the air intakes are located.
In the Enclosure versions (CCRC-E and CCRX-E), the racks and
air-conditioning units are combined into a single air-tight structure
to prevent mixing with the surrounding air and a consequent
decline in air-conditioning efficiency.
The air is taken into the enclosed racks directly from the rear
(46°C) and then once cooled (25-30°C) delivered directly to the
servers, with significant savings in energy due to the lower quanti-
ty of conditioned air handled.

STRUCTURE
Extremely compact structure that reduces overall dimensions,
made from galvanised steel plate with RAL9005 epoxy powder
coating.
The panelling is coated with an innovative double layer of plastic,
is lined on the inside with special soundproofing material.

FANS
The use of latest generation 225 mm diameter axial-flow fans
with EC brushless motors ensures excellent performance and
low power consumption.
N+1 dynamic management of EC fans is featured as standard,
allowing operation at reduced flow-rate to optimise power con-
sumption. Moreover, in the event of a fault on one fan, the other
fans are operated at maximum speed to ensure the same cooling
performance.
The fan section has been designed to allow rapid replacement in
the event of faults, thus reducing system downtime.

CRCX - CRCC English 01-2012 3

 I-HCAT OUTDOOR UNIT I A

For direct expansion versions, the i-HCAT outdoor condensing CONDENSER FAN
unit combined with the CRCX indoor unit, is air-cooled with External impeller axial-flow fans, statically and dynamically bal-
axial-flow fans, fitted with INVERTER-DRIVEN HERMETIC anced at low speed.
SCROLL compressor for operation on R410A refrigerant, mount- Six- or four-pole electric motor with built-in thermal cut-out.
ed on rubber vibration dampers, complete with oil charge, sup- Housed in aerodynamic tubes with accident prevention grill.
plied with oil separator to ensure correct lubrication even at min- Device for operation at low outside air temperatures: continuous
imum speed, and fitted with thermal protector. fan speed control according using a pressure transducer.
EC axial-flow fan available as an option.
STRUCTURE
Powder coated metal plate base panelling and inside structure. REFRIGERANT CIRCUIT
Non-flammable closed cell polyethylene foam thermal insulation Unit fitted with one refrigerant circuit, complete with the follow-
and soundproofing on the inside. ing components: filter-drier, liquid indicator, safety pressure switch
for controlling high discharge pressure.
INVERTER-DRIVEN COMPRESSORS Unit supplied pre-charged with refrigerant and factory tested.
High efficiency hermetic scroll compressor with brushless DC
motor, complete with thermal protector, with electronic capacity
control managed by INVERTER.
This ensures unit operating efficiency even at part loads, which
represent more than 75% of normal operating time, meaning
effective overall average energy savings of up to 50% compared to
traditional ON/OFF technology.
Mounted on rubber vibration dampers, complete with sump
heater, oil charge and oil separator to prevent migration of the
gas charge and ensure lubrication of the compressor sump during
operation at minimum speed.
Complete with thermal protector and sump heater installed as
standard on all versions.

ELECTRICAL PANEL
Power and control electrical panel constructed in accordance
with IEC 204-1/EN60204-1, complete with control and terminal
blocks for connection to the power supply and auxiliary controls.

PROTECTION GRILL
The unit comes with a protection grill on the condenser coil.

HEAT EXCHANGE COILS

Made using copper tubes mechanically expanded onto aluminium
fins with a high heat exchange area.

2
3

4
1

1 Finned coil
2 Electrical panel
3 Gas valve
4 Scroll compressor
5 5 Fan

4 English 01-2012 CRCX - CRCC

 RATING PLATE U I A

The CRCC/CRCX air-conditioner rating plate is positioned on a

panel inside the unit, and provides the following information:
- Model and serial number of the unit;
- Power supply (voltage, phases and frequency);
- Power consumption of the unit and the individual components;
- Current draw of the unit and the individual components: OA
(Operating current), FLA (Full load current) and LRA (Locked
rotor current);

The i-HCAT condensing units can be identified by the:

Packaging label
Showing the data identifying the product. De' Longhi S.p.a. - 31100 Treviso / Italia
Via L.Seitz, 47 - tel. 04224131 fax 0422413659

MODEL:
Rating plate VOLTAGE:
Showing the unit technical and performance data. CODE:

If this is lost, ask After Sales Service for a replacement.

Tampering with or the removal or absence of rating plates or

other means enabling the unit to be identified causes prob-
COOLING CAPACITY ------------------- kW
lems during installation and maintenance. HEATING CAPACITY
REFRIGERANT TYPE
-------------------
-------------------
kW

REFRIGERANT CHARGE ------------------- Kg

MAXIMUM PRESSURE ------------------- bar
MAIN POWER SUPPLY ------------------- V---Hz
AUXILIARY POWER SUPPLY ------------------- V---Hz
AUXILIARY POWER SUPPLY ------------------- kW
MAX CURRENT DRAW ------------------- A
PEAK CURRENT ------------------- A
WIRING DIAGRAM ------------------- NO.
OPERATING WEIGHT ------------------- Kg
YEAR OF FABRICATION -------------------

CRCX - CRCC English 01-2012 5

 GENERAL TECHNICAL SPECIFICATIONS U I A

RACK COOLER INROW DX

CRCX-I 0051 0071 0121
Power supply V-Ph~Hz 230/1N/50 230/1N/50 230/1N/50
Refrigerant R410A R410A R410A
No. of circuits no. 1 1 1
CAPACITY DELIVERED MAX MIN MAX MIN MAX MIN
Total capacity kW 1 10,63 4,72 16,59 6,78 28,62 11,76
Sensible capacity kW 1 9,61 4,72 15,67 6,78 27,37 11,76
SHR 0,90 1 0,94 1 0,96 1
EER (CRCX + i-HCAT) 3,44 4,25 3,04 3,70 3,09 3,79
FANS
Fan air flow-rate m3/h 1500 900 2700 1200 4200 1800
Inverter-driven EC radial fan power consumption kW 0,16 0,04 0,304 0,064 0,86 0,09
No. of inverter-driven EC radial fans no. 2 4 5
Std. available static pressure Pa 20 20 20
AIR FILTER
Filtration grade G2 G2 G2
DIMENSIONS
L mm 300 300 300
P mm 1020 1020 1020
H mm 2050 2050 2050
i-HCAT 0051 0071 0121
Power supply V-Ph~Hz 230/1N/50 400/3N/50 400/3N/50
Compressor power consumption kW 1 2,63 0,77 4,56 1,17 7,19 1,81
FANS
Fan air flow-rate m3/h 6400 8640 15768
Fan power consumption kW 0,3 0,6 1,2
No. of fans no. 2 1 2
DIMENSIONS
L mm 900 1507 1507
P mm 420 570 570
H mm 1240 1200 1700
1 Inside air conditions 35°C/27% RH - Outside air temp.: 35°C

RACK COOLER ENCLOSURE DX

CRCX-E 0051 0071 0121
Power supply V-Ph~Hz 230/1N/50 230/1N/50 230/1N/50
Refrigerant R410A R410A R410A
No. of circuits no. 1 1 1
CAPACITY DELIVERED MAX MIN MAX MIN MAX MIN
Total capacity kW 1 11,84 5,64 18,71 8,19 33,02 14,09
Sensible capacity kW 1 11,84 5,64 18,71 8,19 33,02 14,09
SHR 1,00 1 1,00 1 1,00 1
EER (CRCX + i-HCAT) 3,77 5,27 3,37 4,51 3,49 4,55
FANS
Fan air flow-rate m3/h 1500 900 2700 1200 4200 1800
Inverter-driven EC radial fan power consumption kW 0,16 0,04 0,304 0,064 0,86 0,09
No. of inverter-driven EC radial fans no. 2 4 5
Std. available static pressure Pa 20 20 20
AIR FILTER
Filtration grade G2 G2 G2
HUMIDIFIER
Capacity kg/h 3 3 3
Power consumption kW 2,25 2,25 2,25
DIMENSIONS
L mm 300 300 300
P mm 1190 1190 1190
H mm 2050 2050 2050
i-HCAT 0051 0071 0121
Power supply V-Ph~Hz 230/1N/50 400/3N/50 400/3N/50
Compressor power consumption kW 1 2,68 0,73 4,65 1,15 7,4 1,81
FANS
Fan air flow-rate m3/h 6400 8640 15768
Fan power consumption kW 0,3 0,6 1,2
No. of fans no. 2 1 2
DIMENSIONS
L mm 900 1507 1507
P mm 420 570 570
H mm 1240 1200 1700
1 Inside air conditions 46°C/16% RH - Outside air temp.: 35°C

6 English 01-2012 CRCX - CRCC

 GENERAL TECHNICAL SPECIFICATIONS U I A

RACK COOLER INROW CW

CRCC-I 0020 0025 0035 0036
Power supply V-Ph~Hz 230/1N/50 230/1N/50 230/1N/50 230/1N/50
CAPACITY DELIVERED
Total capacity kW 1 16,14 20,52 24,6 20,95
Sensible capacity kW 1 16,14 20,52 24,6 20,95
SHR 1,00 1,00 1,00 1,00
EER 31,28 29,83 28,60 24,36
WATER SIDE
No. of water circuits no. 1 1 1 2
Water flow-rate l/h 2770 3530 4230 3600
Valve KVS 16 16 16 16
Total unit pressure drop kPa 14 21 29 55
Water connections IN / OUT 1" 1" 1" 1"
FANS
Fan air flow-rate m3/h 2520 3360 4200 4200
Inverter-driven EC radial fan power consumption kW 0,516 0,688 0,86 0,86
No. of inverter-driven EC radial fans no. 3 4 5 5
Std. available static pressure Pa 20 20 20 20
Sound pressure dB(A) 2 64 65 66 66
AIR FILTER
Filtration grade G2 G2 G2 G2
DIMENSIONS
L mm 300 300 300 300
P mm 1020 1020 1020 1020
H mm 2050 2050 2050 2050
1 Inside air conditions 35°C/27% RH - Water temp. 10°/15°C
2 measured at a height of 1.5 m, 2 m in front of the unit in a free field

RACK COOLER ENCLOSURE CW

CRCC-I 0020 0025 0035 0036
Power supply V-Ph~Hz 230/1N/50 230/1N/50 230/1N/50 230/1N/50
CAPACITY DELIVERED
Total capacity kW 1 20,44 26,04 31,25 26,80
Sensible capacity kW 1 20,44 26,04 31,25 26,80
SHR 1,00 1,00 1,00 1,00
EER 39,61 37,85 36,34 31,16
WATER SIDE
No. of water circuits no. 1 1 1 2
Water flow-rate l/h 2930 3740 4490 3850
Valve KVS 16 16 16 16
Total unit pressure drop kPa 14 21 28 58
Water connections IN / OUT 1" 1" 1" 1"
FANS
Fan air flow-rate m3/h 2520 3360 4200 4200
Inverter-driven EC radial fan power consumption kW 0,516 0,688 0,86 0,86
No. of inverter-driven EC radial fans no. 3 4 5 5
Std. available static pressure Pa 20 20 20 20
Sound pressure dB(A) 2 64 65 66 66
AIR FILTER
Filtration grade G2 G2 G2 G2
DIMENSIONS
L mm 300 300 300 300
P mm 1190 1190 1190 1190
H mm 2050 2050 2050 2050
1 Inside air conditions 46°C/16% RH - Water temp. 14°/20°C
2 measured at a height of 1.5 m, 2 m in front of the unit in a free field

CRCX - CRCC English 01-2012 7

 RECEIPT,TRANSPORT AND HANDLING I A

Move the air-conditioner as near as possible to the site of installa-

tion before removing the packaging and the pallet.
Remove the unit from the pallet using the special slides supplied
in the packaging.
The units can be lifted:
- using a forklift, sliding the forks through the openings in the pal-
let;
- using fabric slings through the pallet underneath the unit, using
spacers to make sure that when the slings are in tension these
do not apply pressure on the top edges.

The air-conditioner must be stored indoors, preferably in its own

packaging, and protected against excessive humidity (<85% RH)
and temperature (< 50°C).
CRCX-E 0051 0071 0121
L mm 1272 1272 1272 H
H mm 2212 2212 2212
P mm 473 473 473
Gross weight Kg 200,00 215,00 217,50
CRCX-I 0051 0071 0121
L mm 1100 1100 1100
H mm 2212 2212 2212
P mm 473 473 473
Gross weight Kg 190,00 205,00 207,50
CRCC-E 0020 0025 0035 0036
L mm 1272 1272 1272 1272
H mm 2212 2212 2212 2212
P mm 473 473 473 473
Gross weight Kg 215,00 217,50 220,00 230,00
CRCC-I 0020 0025 0035 0036 P L
L mm 1100 1100 1100 1100
H mm 2212 2212 2212 2212
P mm 473 473 473 473
Gross weight Kg 205,00 207,50 210,00 220,00

The i-HCAT condensing units are supplied complete with:

The instruction manual is an integral part of the unit and
- instruction manual.
should therefore be read and kept carefully..
- warranty certificate.
- CE declaration. Do not dispose of packaging materials in the environment
contained in a plastic bag (A) attached to the top of the unit. or leave them within reach of children as they may represent
a hazard.
The unit must be handled by qualified and suitably equipped per-
The weight of the condensing unit is biased towards the
sonnel only using equipment appropriate for the weight of the
compressor side (side of the packaging with the bar code,
condensing unit.
see the figure at the bottom).
If a forklift truck is used, insert the forks under the base, spacing
During transport, the condensing unit should be kept in
the forks as wide apart as possible.
a vertical position.
If a crane is used, pass the cables through the bottom of the base,
making sure they do not exert pressure on the unit.
Once the packaging has been removed, the unit can be lifted and
moved by inserting two metal tubes (max. diameter 1/2”) into the
feet, and using suitable handling equipment.

Size 0051 0071 0121

Dimension L 1060 1630 1630
Dimension P 510 650 650
Dimension H 1380 1420 1920
Gross weight 120 180 350

A
BARCODE

L
P

8 English 01-2012 CRCX - CRCC

The meanings of the symbols shown on the packaging are described in the table.

FRAGILE: handle with care. TOP: indicates the correct position of the pack-
aged unit.

TEMPERATURE LIMITS: indicates the tem-

KEEP DRY: indicates that the packaged unit perature limits for storing and handling the pack-
must be kept in a dry place. aged unit.

CENTRE OF GRAVITY: indicates the centre USE NO HOOKS: indicates that hooks cannot
of gravity of the packaged unit. be used to handle or lift the packaged unit.

KEEP AWAY FROM HEAT: indicates that the

packaged unit must be kept away from sources of DO NOT STACK the packages.
heat.

RECEIVING THE UNIT

Check, upon delivery, that the air-conditioner is intact and in per- In particular, check that the panel where the user terminal is fitted
fect condition; immediately notify the carrier in writing of any has not been damaged.
damage that may be due to transport.

OPERATING LIMITS I A

The unit CRCX and CRCC units are designed for operation with-
in the following operating ranges (the limits are considered for t

new units that have been correctly installed and maintained): 46°C
OUTSIDE AIR TEMPERATURE

Environmental conditions: 35°C

CRCX OPERATING RANGE

Environmental conditions from 18.0°C, 70% RH to 55°C 9% RH

Outdoor conditions from -20.0°C to +45°C
CRCC modulating version
-20°C
Environmental conditions from 16°C, 57% RH to 55.0°C, 9% RH
Fluid temperature 10°C - 20°C
Maximum operating pressure 16 bars
18°C/70% ROOM TEMPERATURE 28°C 55°C/9% t

CRCX - CRCC English 01-2012 9

DIMENSIONAL DRAWINGS I

Bottom view

50

50
70,5
70,5
67,5
270 98

67,5
456 260

CRCC-E 0020-0025-0035 CRCC-I 0020-0025-0035

50 260
70

50
67,5

50 260 87,79

67,5
70
456 260

CRCC-E 0036 CRCC-I 0036

9 1172 9
97 125 200 117 306 9 1000 9 306
102
1745

1949

1949
2000

2000

60 449
Top view 60 277
50 260
50 88
71,5

71,5
92
301
92

120
120

71,5
71,5

307
479

CRCC-E 0036 CRCC-I 0036

60 449 60 277
270 98
70,5
70,5
92

301

92
50

50
120

307
120

479

CRCC-E 0020-0025-0035 CRCC-I 0020-0025-0035

ENCLOSURE CRCC version INROW CRCC version

ICW1 chilled water IN CIRC. 1 OCW2 chilled water OUT CIRC. 2 AUX auxiliary IN
OCW1 chilled water OUT CIRC. 1 IP1 MAIN power supply IN OC condensate drain OUT
ICW2 chilled water IN CIRC. 2 IP2 SECONDARY power supply IN

10 English 01-2012 CRCX - CRCC

 DIMENSIONAL DRAWINGS I

67,5

67,5
456 260
9 1172 9
97 125 200 117 306 9 1000 9 306
102
1745

1949

1949
2000

2000
60 449 60 276,8
92

92
301

120
120

478,77 307

ENCLOSURE CRCX-E version INROW CRCX-I version

i-HCAT
C A
Dimension 0051 0071 0121
A 900 1450 1450
B 990 1200 1700
C 370 550 550
D 430 550 550
B

E 91,5 93 43/143
F 102 140 152
G

G 202 240 /
F

H 400 497 497

E I 580 1470 1470
Clearances
= I = L 900 900 900
L

W1 W2 M 150 150 150

N 600 600 600
Weight distribution
D
H

W1 43 43 43
W2 18 18 18
W3 14 14 14
W4 W3
M

W4 34 34 34
=

N M TOT 109 109 109

CRCX - CRCC English 01-2012 11

OVERVIEW DIAGRAM I A

CRCC / i-HCAT i-HCAT 0051

3

2
8 2
4 1
7
5

10 9

2 14
12 13
15

11

i-HCAT 0071-0121
3

1 2-WAY VALVE WITH MANUAL CONTROL

2 8 2 (3/4" FLARE)
8 2
4 1 2 PRESSURE TEST FITTING 1/4 SAE
3 ROTARY COMPRESSOR
5 4 SUMP OIL HEATER
5 OIL SEPARATOR
17
6 MESH FILTER
7 CAPILLARY TUBE
6 16 8 HIGH PRESSURE SWITCH (AUTOMATIC
RESET)
9 CONDENSER
10 9
10 FAN
11 LIQUID RECEIVER
12 FILTER-DRIER
14 2 13 LIQUID AND MOISTURE INDICATOR
12 13 14 CONDENSING PRESSURE CONTROL
15 15 2-WAY VALVE WITH MANUAL CONTROL
(1/2" FLARE)
16 CAPILLARY TUBE
17 LIQUID SEPARATOR
11

CRCX CRCX-I/CRCX-E 0051-0071-0121 1 WELDED FITTING

0051 = Ø18 mm
0071 = Ø 22 mm
0121 = Ø 28 mm
2 HIGH PRESSURE TRANSDUCER
3 SYSTEM ELECTRONIC VALVE
4 FANS
8 10 7 6 9 5 HEAT EXCHANGER (EVAPORATOR)
5
6 LOW PRESSURE SWITCH (AUTOMATIC
RESET)
7 LOW PRESSURE TRANSDUCER
4
8 COMPRESSOR SUCTION TEMPERATURE
PROBE
9 WELDED FITTING
0051 = Ø 12 mm
0071 = Ø 16 mm
0121 = Ø 18 mm
10 PRESSURE TEST FITTING 1/4 SAE
3 2 10 10 1

12 English 01-2012 CRCX - CRCC

 CRCC CRCC-I/CRCC-E 0025÷0035 CRCC-I/CRCC-E 0036

MP MP MP

BA x x x
BA

TO TI TO TI
DIRECTION OF AIRFLOW

DIRECTION OF AIRFLOW
TO TI TO TI

V TO TI V TO TI

TO TI TO TI

TW TW TW
TO TI TO TI

MV MV MV

I
WATER IN WATER OUT WATER IN WATER IN WATER OUT WATER OUT

MV 3-WAY MODULATING VALVE MP WATER FLOW METER (OPTIONAL)

BA HEAT EXCHANGER TI AIR INTAKE TEMPERATURE PROBE
TW WATER TEMPERATURE PROBE TO AIR OUTLET TEMPERATURE PROBE

INSTALLATION
CRCC / CRCX To avoid the slings damaging the unit, place protection between
The CRCC / CRCX indoor unit can rest directly on the floor, the slings and the unit.
perfectly level, using the adjustable feet: incorrect levelling may Position the unit in the site indicated by the customer; place
cause condensate to overflow from the collection pan. either a layer of rubber (min. thickness 10 mm) or vibration
damper feet between the base and support surface..
WARNING
Fix the unit, making sure it is level and that there is easy access to
the air-conditioner must be installed indoors and in non-
refrigerant and electrical components.
aggressive environments.
If the site is installed in a place exposed to strong winds, fix the
CLIMAVENETA accepts no liability for incorrect installation
unit adequately using tie rods if necessary.
when positioning the unit.
The following should be avoided:
i-HCAT
- Installing the unit in pits and/or air vents;
Before installing the i-HCAT unit, verify the following points:
- Obstacles or barriers that could cause the exhaust air to be
- check that the support surface is adequate to support the
recirculated;
weight of the unit.
- Installation in sites with an aggressive atmosphere
- respect safety distances between the unit and other equipment
- Installation in confined spaces where the sound levels of the
or structures so that the fan air intake and outlet are not
unit could be amplified by reverberation or resonance
blocked in any way.
- Installation in corners where dust, leaves or other materials
- the unit must be placed in an equipment compartment sized
tend to collect. These could obstruct the passage of air, thus
according to standards in force in the country concerned, and
reducing the efficiency of the unit.
large enough to allow access for maintenance.
- Air discharged by the unit entering inhabited rooms through
doors or windows causing unpleasant conditions for the inhabi-
POSITIONING
tants.
Before handling the unit, check the capacity of the lifting equip-
- Air discharged by the unit being obstructed by a wind blowing
ment used, respecting the instructions on the packaging.
in the opposite direction;
To move the unit horizontally, make appropriate use of a fork lift
- Direct exposure of the unit to sunlight
truck or similar, bearing in mind the weight distribution of the unit.
To lift the unit, insert pipes long enough to allow positioning of
the lifting slings and safety pins in the special holes in the base of
the unit.

CLEARANCES

CRCX - CRCC English 01-2012 13

RECOMMENDED INSTALLATION FOR CRCX/I-HCAT I A

insulation
thermal
1/100 air-conditioner

intake

max 50 metri

insulation
thermal
1/100 air-conditioner

CRCX / i-HCAT 0051

max 15 m

CRCX / i-HCAT 0071-0121 intake

max 30 m

intake

1/100
insulation
thermal

max 9 m air-conditioner

max 3 m

N.B.: the liquid pipes must be protected against sunlight

14 English 01-2012 CRCX - CRCC

 REFRIGERANT CONNECTIONS (CRCX / I-HCAT) I A

DIAMETERS OF THE CONNECTIONS INSIDE THE UNIT

The diameter of the refrigerant lines between the air-conditioner and the condensing unit must be complied with, otherwise the warranty
will be void. Avoid tight bends in the pipes (the radius of curvature should be at least equal to the diameter of the pipe).

Model CRCX 0051 0071 0121 Model i-HCAT 0051 0071 0121
liquid line dia. (mm) 12 16 18 liquid line dia. (mm) 12,7-1/2" 15,9-5/8" 18
gas suction dia. (mm) 18 22 28 gas suction dia. (mm) 19,05-3/4" 22,7-7/8" 28
Pipe diameter in mm Pipe diameter in mm

RECOMMENDED OUTSIDE DIAMETERS OF THE LINES (for equivalent lengths up to 50 m)

Model 0051 0071 0121
Liquid line (mm) 14 16 16
Gas suction line (mm) 22 28 35
Pipe diameter in mm

NOTE: The diameter of the refrigerant lines between the air-conditioner and the condensing unit must be chosen according to the length
of the lines, and therefore this will not always coincide with the inside diameter of the fitting to be welded supplied by the manufacturer.
Special care must be paid to insulation of the gas suction lines to avoid condensation.

Equivalent lengths in metres of curved sections, on-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

CONTENT PER LINEAR METRE

Pipe diameter 10 12 16 18 22 28 35 42
Gas suction line g/m gr/m - - 3,9 5,1 8,0 13,6 21,6 30
R410A
Liquid line g/m - gr/m 59 90 160 209 327 - - -
N.B.: add lubricating oil equivalent to 10% of the weight of the gas calculated only for the refrigerant connection lines between indoor and outdoor unit.

SUCTION LINES LIQUID LINES

The fittings are flare couplings for all sizes. For the connections, The fittings are flare couplings for all sizes.
proceed as follows: For the connections, proceed as follows:
1. Prepare the end of the pipe by flaring it to the right shape. 1. Prepare the end of the pipe by flaring it to the right shape.
2. Connect the prepared line to the on-off valve on the suction 2. Connect the prepared line to the on-off valve on the liquid line
line using two spanners, as illustrated in the figure below. using two spanners, as illustrated in the figure below.

Bocchettone
Bocchettone
Tronchetto flangiato

Tronchetto flangiato

Linea gas Linea liquido

Note: Flaring the pipes directly helps limit impurities inside the or dry air before connecting to the two units) and free from
lines. All the pipes must be perfectly clean (clean using nitrogen moisture to allow efficient venting.

CRCX - CRCC English 01-2012 15

 WATER CONNECTIONS (CRCC) I A

The following are recommended for all water connections:

- flexible connections (available from the options in the price list)
to avoid transmitting vibrations and allow small movements of
the air-conditioner;
- joints in three pieces, near the fittings, to simplify removal of the
unit;
- on-off valves to disconnect the unit from the water circuit: where
possible use ball valves with full opening to minimise pressure
drop.

The water pipes can be connected either from the top or the
bottom. On the side uses, remove the cap from the inlet and out-
let manifolds and connect the flexible piping.

Make sure that the cross-section of the chilled waterlines and

the characteristics of the circulating pump are suitable: an insuffi-
cient water flow-rate affects performance of the air-conditioner. To select the pipes see the tables on “Continuous pres-
Check that the water inlet and outlet connections are correct. sure drop for STEEL PIPES”
Insulate all the chilled water lines with closed cell material (e.g.:
Armaflex or equivalent), to prevent condensation; the insulation N.B.: the unit uses PN16 connections
must allow access to the valves and the three-piece joints.
Make sure that the water circuit has been filled with an antifreeze
mixture containing the right percentage of ethylene glycol.

CORRECTION FACTORS I A

ETHYLENE GLYCOL SOLUTIONS

Water and ethylene glycol solutions used as a heat carrier in the place of water reduce the performance of the unit.
Multiply the performance figures by the values given in the following table.

Freezing point 0 -5 -10 -15 -20 -25

Percentage of ethylene glycol by weight 0 12% 20% 28% 35% 40%
Flow-rate correction factor cQ 1 1,02 1,04 1,075 1,11 1,14
Pressure drop correction factor cdp 1 1,07 1,11 1,18 1,22 1,24

16 English 01-2012 CRCX - CRCC

Continuous pressure drop for STEEL PIPES (inches) - Water temperature = 10°C

Water flow l/h 1 2 3 4 5 6 7 8 9 10 12 14 16 18 20 30 40 50 60 70 80 90100 200 300 400 500

500.000 500.000
400.000 ” 400.000
Ø5

0,8

1,0

1,2

1,4

1,6

1,8

2,0

2,5

3,0

3,5

4,0
m/

m/

m/

m/

m/

m/

m/

m/

m/

m/

m/
300.000 300.000

s
”
200.000
0,6 Ø4 200.000

”
Ø3
m/

100.000 100.000
s

90.000 90.000
80.000 80.000
70.000 1/2” 70.000
60.000
Ø2 60.000
50.000 50.000
40.000 40.000
”
Ø6
” Ø2
30.000 30.000

”
20.000 Ø5 1/2” 20.000
Ø1

” 1/4”
Ø4 Ø1
10.000 10.000
9.000 9.000
8.000 8.000
7.000 7.000
” ”
6.000 Ø3 Ø1 6.000
5.000 5.000
4.000 1/2” 4.000
Ø2
/4”
3.000 Ø3 3.000

2.000 ” 2.000
Ø2
Ø 1/2”

1.000 1/2” 1.000

900 Ø1 900
3/8”
800 800
700 1/4” Ø 700
600 Ø1 600
500 500
400 400
”
300 Ø1 300

200 200
/4”
Ø3
0,2

0,4

0,6

0,8
m/

m/

m/

m/
s

100 100
1 2 3 4 5 6 7 8 9 10 12 14 16 18 20 30 40 50 60 70 80 90100 200 300 400 500
Linear Pressure Drops, (mm w.c./m)

SELECTION EXAMPLE:
• consider a limit speed inside the pipe of 1-1.2m/s
• cross-reference the required water flow-rate (in the example 5,000 l/h)
• determine the pressure drop according to the selected diameter (in the example 35 mmWC/m)

CRCX - CRCC English 01-2012 17

 ELECTRICAL CONNECTIONS I A

Correct electrical connection, performed in a workmanlike man- ELECTRICAL PANEL

ner and in compliance with the standards in force, is important The electrical panel is located inside the unit at the top of the
for the prevention of accidents and the good and long-lasting technical compartment where the various components of the
operation of the air-conditioner. refrigerant circuit are also to be found.
To access the electrical panel, remove the front panel of the unit
CRCX / i-HCAT by undoing the self-tapping screws.
Before performing any work on the electrical parts, make sure To access the components in the electrical panel and the terminal
that there is no live voltage and that the disconnecting switch on blocks, undo the four screws on the panel itself.
the i-HCAT is open (in position “O”).

The i-HCAT condensing units leave the factory fully wired and
simply require connection to the mains power supply and the
remote switch (ON OFF), operations that must be carried out by
qualified personnel in compliance with current legislation.
For all electrical work, refer to the electrical wiring diagrams in
this manual.
It is also recommended to check that:
- The characteristics of the mains electricity supply are adequate
for the power ratings indicated in the electrical specifications
below, also bearing in mind the possible use of other equipment
at the same time.
Power to the unit must be turned on only after installation
work (refrigerant circuit and electrical) has been completed.
All electrical connections must be carried out by quali-
fied personnel in accordance with legislation in force in the
country concerned
Respect instructions for connecting phase, neutral and
earth conductors.
The power line should be fitted upstream with a suitable
device to protect against short-circuits and leakage to earth,
isolating the installation from other equipment.
Voltage must be within a tolerance of ±10% of the rated
power supply voltage for the unit (for three phase units, the
unbalance between the phases must not exceed 3%).
If these parameters are not respected, contact the electricity
supply company.
For electrical connections, use double insulation cable in
conformity with legislation in force in the country con-
cerned.
Install, if possible near the unit, an appropriate protection
device to isolate the unit from the mains power supply. This
should have a delayed characteristic curve, contact opening
of at least 3 mm and a suitable switching and residual current
protection capacity..
If these devices are not visible from the electrical panel
of the unit, they should be lockable
An effective earth connection is obligatory.
The manufacturer cannot be held liable for any damage
caused by the failure to correctly earth the unit.
In the case of three phase units, ensure the phases are
connected correctly.
Do not use water pipes to earth the unit.

18 English 01-2012 CRCX - CRCC

 ELECTRICAL CONNECTIONS I A

Power supply to the CRCX indoor unit is provided by the i-

power supply
HCAT condensing unit.
Connect the 3 x 1.5 mm2 power cable to the IEC male plug sup-
plied with the CRCX unit (see the photo on the side) and plug signal
this into socket "P", shown in the figure, located on the top of the
unit. Also connect the signal and auxiliary cable (as indicated on
the wiring diagram supplied with the unit) to connector S on the
top of the unit.

IEC male plug

CRCC
Before performing any work on the electrical parts, make sure
that there is no live voltage.
Check that the mains voltage corresponds to the rated val-
ues for the unit (voltage, no. of phases, frequency) shown on the
electrical panel.
The power supply voltage must be between ± 10% of the
rated value: operation at voltages outside of these limits may void
the warranty.
Connect the 3 x 1.5 mm2 power cable to the IEC male plug sup-
plied with the CRCC unit (see the photo on the side) and plug
this into socket "P", shown in the figure, located on the top of the
unit.
Also connect the signal and auxiliary cable (as indicated on the
wiring diagram supplied with the unit) to connector S on the top
of the unit.

ACCESS TO THE CONTROL BOARD

To access the board, open the front panel and remove the electri-
cal panel cover.
Slide the panel out as illustrated in the figure below.
The electronic components are sensitive to discharges of static
electricity from the human body.
Touch an earthed object before handling any electronic compo-
nent.

CRCX - CRCC English 01-2012 19

 ELECTRICAL SPECIFICATIONS AND MINIMUM POWER CABLE SIZES I A

The cross-section of the power cable must be chosen according be between ± 10% of the rated value).
to the length of the cable and the type of installation, based on The following table shows the minimum recommended power
the maximum current draw of the air-conditioner and so as to cable sizes.
prevent excessive voltage drops (the power supply voltage must

POWER CONSUMPTION OF INDIVIDUAL COMPONENTS

i-HCAT i-HCAT + CRCX
Inverter-driven COMPRESSOR Condenser fan FLA tot
Size V/Ph/Hz Ptot (kW) mm²
FLI (kW)* FLA (A)* LRA (A)* Qty. FLI (kW)* FLA (A)* LRA (A)* Qty. (A)
0051 230-1-50 4,7 14,8 7,5 1 0,145 0,64 - 2 5,28 18,97 4
0071 400-3N-50 9,4 18 45 1 0,61 2,65 - 1 10,69 26,42 6
0121 400-3N-50 14,4 27,4 48 1 0,61 2,65 - 2 16,51 39,90 10

CRCX-E / CRCX-I
Evaporator FAN
Size V/Ph/Hz mm²
FLI (kW)* FLA (A)* Qty. Ptot (kW) FLA tot (A)
0051 230-1-50 0,17 1,45 2 0,34 2,9 1,5
0071 230-1-50 0,17 1,45 4 0,68 5,8 1,5
0121 230-1-50 0,17 1,45 5 0,85 7,25 2,5

CRCC-E / CRCC-I kW = Power consumption in kilowatts

Evaporator FAN FLA = Maximum current
Size V/Ph/Hz mm² LRA = Peak current
FLI (kW)* FLA (A)* Qty. Ptot (kW) FLA tot (A)
0020 230-1-50 0,17 1,45 3 0,51 4,35 1,5
* Values for each individual component
0025 230-1-50 0,17 1,45 4 0,68 5,8 1,5
0035 230-1-50 0,17 1,45 5 0,85 7,25 2,5
The data refer to maximum power
0036 230-1-50 0,17 1,45 5 0,85 7,25 2,5 consumption.

COMMISSIONING AND TESTING U I A

CRCX / i-HCAT
The i-HCAT units are pre-charged with a sufficient amount of R410A refrigerant for the CRCX indoor unit and up to 5 metres of refriger-
ant lines.
Refrigerant Type of oil
R410A (POE) mod. 0051-0071-0121 FV50S
R410A
Keeping the valves on the i-HCAT condensing unit closed, open any valves on the CRCX unit or in the system to ensure that all the com-
ponents are included in the emptying operation;
Connect a high efficiency vacuum pump to the Schrader fittings or to the 1/4” SAE fittings on the suction and liquid lines.
Empty the lines, ensuring an absolute pressure of less than 10 Pa (0.07 mm Hg) for an extended period, so as to remove the air and any
traces of moisture.
The circuit should be emptied slowly and maintained for an extended period, rather than performed too quickly.
Wait 100 seconds and check that the absolute pressure does not rise above 200 Pa.
In general, if there is the chance of significant moisture content in the circuit or for very large systems, the vacuum must be “broken” with
nitrogen dioxide and then repeat the emptying operations as described.
Open all valves that had previously been closed.
If the refrigerant lines are more than 5 m long, connect a cylinder of refrigerant to the charge fittings and after having started the com-
pressor, complete the charge slowly, until the pressure stabilises in the lines and the gas bubbles disappear from the flow indicator;
The charge must be checked at the environmental design conditions and with a discharge pressure of around 28 bars (R410A); for units
with on-off condenser control, partially close the intake to stop the condenser fan from repeatedly starting-stopping.
Make sure that the subcooling of the liquid at the thermostatic valve inlet is between 3 and 5°C less than the condensing temperature
read on the pressure gauge and that the superheat of the vapour at the evaporator outlet is around 5-8°C.

If a circuit already charged with refrigerant needs to be emptied, the first operation required is the removal of the refrigerant from the cir-
cuit using a special appliance with dry compressor for recovering the refrigerant.
If available, also switch on the sump heaters during the emptying operation.

CHECKING FOR LEAKS

1. Check that the valves on the outdoor unit are completely 1 2
OUTDOOR L H
closed; UNIT R410A N
2. Connect the pressure gauge to the service outlet on the two INDOOR UNIT
outdoor unit valves;
3. Charge with R410A gas (Freon) to a pressure of 250 kPa;
4. Connect the nitrogen cylinder to the valves and bring the circuit
up to a pressure of 1200 kPa;
5. Using a leak detection light or other electronic instrument, make
sure there are no leaks.When complete, discharge the unit.

20 English 01-2012 CRCX - CRCC

PREPARING FOR FIRST START UP - Replace the inspection panel
Before starting up the condensing unit, make sure that:
- All safety conditions have been respected;;
- The condensing unit is adequately fixed to the surface it rests
on;
- Clearances have been respected;
- Refrigerant connections have been carried out as indicated in
the instruction manual;
- The circuit has been emptied.
- The refrigerant circuit valves are open.
- Electrical connections have been carried out correctly;
- Voltage is within a tolerance of 10% of the rated voltage for the - Move the mains switch QF (outside the unit) to the “ON” posi-
unit; tion
- The unit is correctly earthed;
- All electrical and refrigerant connections are tight.
STARTING AND STOPPING THE UNIT
Before starting up, power up the unit for at least two hours by - Move remote switch SA1 (if featured) to the ON position.
switching QF and QS to ON, so as to allow the oil in the com-
pressor sump to heat up.
ON
COMMISSIONING (after the 2 hours)
Before starting the condensing unit:
- Make sure the mains remote switch QF is in the OFF position
- Remove the inspection panel OFF

- The operations for STARTING and STOPPING the unit are

ON
controlled by the combined HED indoor unit.

OFF COMMISSIONING PROCEDURE

Arm the circuit breaker in the auxiliary circuits;
Arm all the circuit breakers on the electrical panel;
Power up the air-conditioner electrical panel and close the main
disconnect switch on the unit (position 'I');
- Remove the door from the electrical panel by moving QS to OFF Check that the control board is powered.
After having powered up the air-conditioner, wait at least 12
hours before starting so as to suitably heat the oil in the com-
pressors.
During extended shutdown there may be spontaneous migration
of refrigerant to the compressor sump, which at the start may
cause the oil to foam and consequent damage due to insufficient
lubrication.
As a result, do not disconnect power when shutting down during
the week;
Open the on-off valves in the refrigerant circuits and check that
the air-cooled remote condensers are powered (air-cooled mod-
- Switch the compressor circuit breaker QM1 ON els);

AT LEAST 12 HOURS AFTER POWER UP:

Start the air-conditioner using the buttons on the user terminal
(ENTER +USER PASSWORD) and the fans will start automatically.
If an alarm is activated refer to the controller instruction
manual.

CRCC
If an alarm is activated, refer to the control panel instruction When power is supplied to the unit, wait around 35 seconds
manual. (time taken for the program to load) and then start the unit from
- Close the electrical panel again and tighten the fastening screws the keypad (ENTER + USER PASSWORD) and the fans will start
- Move the main unit switch QS to the ON position automatically.
Make sure that the chilled water valve is working correctly;
Check that the sections of corrugated pipe for draining
condensate have been filled with water during installation.

CRCX - CRCC English 01-2012 21

 CONDENSATE DRAIN I A

Condensate is removed from the pan located underneath the During installation, pour water into the condensate collection pan
unit; the end of the drain pipe should be connected to the sewer- so as to fill the drain trap with water.
age system in the building via a rubber or plastic hose with an
inside diameter of 16 mm.

INSTRUMENTS AND ALARMS U I A

The air-conditioner is fitted with the following instruments: The following optional instruments may also be fitted:
- Flood sensor made up of:
i-HCAT unit a) FSD device to be inserted in the special socket on the electri-
- High pressure switch F1 with manual reset; cal panel;
- Low pressure switch F2 with automatic reset; b) FLOE sensor (or sensors, connected in parallel) to be posi-
tioned at the points monitored;
CRCX / CRCC units - Fire and smoke sensors SFFS and SFFF;
- Air flow sensor F3 and dirty filter sensor F4 (differential pres-
sure switches);
- Temperature sensor BT2 or room temperature and humidity
sensor BH1 (on units with humidity control);

CALIBRATING THE CONTROL AND SAFETY DEVICES U I A

After starting the air-conditioner, make the following adjustments The calibration values of the control and safety devices must not
(see the microprocessor controller manual): be altered.
- Room temperature (cooling set point).
- Dirty filter differential pressure switch: see the paragraph on
"CALIBRATING THE DIRTY FILTER SENSOR".
Symbol Description
F1 High pressure switch
F2 Low pressure switch

Symbol Activation Differential Reset

F1 42 bar (opening) - Manual reset
F2 3 bar (opening) 1,4 bar 3,9 bar (automatic)

CALIBRATING THE AIR FLOW SENSOR U I A

The differential pressure switch F3 must be activated if the fan is • if the device is not activated, progressively increase the calibra-
not working (when there is one fan) or one of the fans is not tion value of the pressure switch.
working. The factory calibration of the differential pressure switch
to control the air flow (F3) is 0.5 mbars (=50Pa). To calibrate the pressure switch, remove the plastic cover (A) by
As the difference in pressure between the fan intake and outlet unscrewing the two screws (B).
depends on air flow-rate, the instrument may need to be recali- the adjustment screw (E) to calibrate the differential pressure
brated after installation, checking that the contact closes when switch on a scale from 0.5 to 4.0 mbars (50 to 400Pa).
the fan is operating normally. If having to replace the pressure switch, unscrew the two fasten-
ing screws (D), remove the rubber hoses connected to the pres-
To calibrate the pressure switch: sure test points (+) and (-) and remove the electrical cables con-
• simulate a fault in the fan system (stop the fan - if there is just nected to terminals 1, 2 and 3. To install the new pressure switch,
one - or one of the fans on the unit) and check that the pres- perform the same operations in the reverse order, inserting the
sure switch is activated; cables from point (C).

Pressure test points + - A D

B

3
mbar mbar
2

B C D

22 English 01-2012 CRCX - CRCC

 CALIBRATING THE DIRTY FILTER SENSOR U I A

The factory calibration of pressure switch F4 is 3 mbars (=300Pa). - progressively cover the surface of the air filter and make sure
Pressure switch F4 must be calibrated according to the pressure that the pressure switch is activated when around 50-60% cov-
drop, which depends not only on how dirty the filter is, but also ered;
the air flow-rate. - if the device is not activated, progressively reduce the calibra-
tion of the pressure switch;
Calibration must be performed with a clean filter, as follows: - if the device is activated too early, increase the calibration.
- switch the unit on

OPERATION AND CONTROL U I A

ELECTRONIC VALVE
The CRCX units feature electronic expansion valves as standard.
These valves have a much wider modulation capacity than tradi-
tional mechanical thermostatic valves; this feature is essential in
applications with operation at part load.
The electronic expansion valve does not require calibration in the
field, as all the parameters are set directly in the factory.

MODULATING WATER VALVE U I A

The CRCC chilled water units are fitted with a 2- or 3-way mod- Auto-calibration - SSC619
ulating valve, complete with 3-position or 0 to 10V signal servo- When 24V AC/DC is supplied, the servomotor automatically
motor. and independently performs auto-calibration, regardless of the
signal.
WARNING: Disconnect power before working on the This process takes around 60 seconds.
servomotor.
The servomotor position is proportional to the control voltage
applied, between 0 and 10 Vdc.
The servomotor stops:
- automatically at the end of its travel; 1
- in the position corresponding to the control voltage;
- in the current position if power is cut off.
2

Travel time at Control Manual override

Type supply
50 Hz signal
The knob on the servomotor can be used to move the actuator
SSC619 AC/DC 24 V 30 s DC 0...10 V to all positions between 0 and 1.
If the control signal is applied, this has priority in determining the
Description valve position.
This servomotor with 0-10 V control is used to drive 2- or 3-
way valves with 5.5 mm travel.
A B A B
Functions
1
0

When the actuator is powered at 0-10 Vdc or with a 3 posi-

tion signal, it transmits motion to the valve. 1 0

Controllers with 0-10 V signal, SSC619

• The valve is open or closed in proportion to the power sup-
(Y, Y1) A B (Y2)
ply signal Y
• 0 volts: the valve is completely closed and the servomotor
remains in the current position.
• If no power is supplied the actuator maintains its current in position 1: in position 0:
valve open valve closed
position

CRCX - CRCC English 01-2012 23

Maintenance Repair
The servomotors are maintenance-free. The servomotor cannot be repaired and if necessary must be
If maintenance is required on the system, remember to: replaced completely.
• disconnect power (unplugging the connector)
• the servomotor must only be tested when the valve has
been installed correctly.

90° 90°
A AB AB A
A AB
B B

A  AB 0…100%

B  AB 100…0%
B


 

H


H2
H1
1
2 G

L3
L2
L1

G H H1 H2 L1 L2 L3 L4 VVP... VXP...
DN
[″] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] [kg]
VXP45.32-16 32 G2B > 280 69 ≈ 78 105 52,5 52,5 62,5 1,95 1,70

2-WAY ON/OFF VALVE (OPTIONAL) U I A

Assembly
For correct assembly of the valve any position is allowed, except
where the servo control is facing downward.

OK OK Incorrect

The on-off valve shuts off water flow into the CRCC unit (see
OVERVIEW DIAGRAM) in the event of a flood alarm.
The 2-way ON/OFF valve kit comprises:
- Valve body
- 24 VAC electric servo control with limit switch
- 2 x 3-piece joints

Connect the servomotor power cable to the special terminals in

the CRCC electrical panel (see wiring diagram).

24 English 01-2012 CRCX - CRCC

 TEMPERATURE AND HUMIDITY PROBE (OPTIONAL) U I A

The temperature/humidity probe is required in order to use the For the probe electrical connections use shielded cable; the con-
IDM (Integrated Dynamic Management) function. This measures nections to the terminals on the board are shown in the wiring
the dew point of the intake air to the CRCC and activates a spe- diagram.
cial alarm signal if the water temperature is below dew point and
consequently there is the risk of dehumidification and condensate
forming.

The figure shows the optional temperature and humidity probe.

In the event of replacement, release the white plastic cover by
pressing point (A) with a screwdriver or other pointed object; lift
the cover (B) to access the fastening screws (C) and terminals
(D).

A D
C
80

OUT

OUT
M

H
T
+
126 mm Shielded cable Fastening
inlet holes

CRCX - CRCC English 01-2012 25

 FLOW METER (OPTIONAL) U I A

Specifications
Flow
Measuring range 5 to 100 l/min
Accuracy (±1σ), 0 to 100 °C ±1.5 % FS
Response time (63.2 %) <1s
Resolution 0.5 l/min
Temperature
Measuring range 0 to 100 °C
Accuracy (±1σ), 25 to 80 °C ±1 °C
Accuracy (±1σ), 0 to 100 °C ±2 °C
The flow meter directly measures and displays the volume of fluid Response time
<1s
transiting the unit, simplifying unit configuration during commis- (63.2 % at 50 % FS flow)
sioning, as well as displaying the cooling capacity delivered if com- Resolution 0.5 °C
bined with the modulating water valve kit. Media and environment
The sensor is compatible with liquids
Media types
Technical information (kinematic viscosity ≤ 2 mm2/s)
The vortex flow meter exploits the sequence of vortices pro- Media temperature (operation) 0 to 100 °C
duced by the fluid that comes into contact perpendicularly with a Media temperature (peak) –25 to 120 °C, non-freezing
bluff body. The frequency of such vortices is proportional to the Ambient air temp. (operation) –25 to 60 °C
Ambient air temp. (peak) –55 to 90 °C
flow rate of the fluid.
Humidity 0 - 95 % (relative), non-condensing
A special detector converts this frequency into an electrical signal
System burst pressure > 16 bar
for determining the fluid flow-rate.
If the equipment is used in a manner not specified by the manu-
facturer, the protection provided by the equipment may be impai-
red.

Dimensions (mm) Sensor output signals

Dimensional sketches of sensing element Flow response

Flow output signal (V)

Flow (l/min)

Dimensional sketch of flow pipe Temperature response

Temperature output signal (V)

Temperature (°C)

26 English 01-2012 CRCX - CRCC

 MAINTENANCE U I A

This section is extremely important for correct operation of the Replacing the fans
appliance. Just a few operations completed scrupulously and regu- If maintenance or replacement of the fans is required, these can
larly will avoid serious damage to the components. be removed without having to power down the entire unit.
Access to the unit is only allowed to authorised and specifically Open the front door and remove the quick-connect power to the
trained personnel. fault fan that has to be replaced (see photo pos. A).
The maintenance operations can be summarised as follows: When the fan is stopped, unscrew the screws securing the fan
- Cleaning the air filter. support (see photo pos. B) and remove it from the unit.
- Checking and cleaning the drains.
- General examination of overall appliance operation.
- Visual check of the condition of pressurised vessels. WARNING, BEFORE REMOVING THE FAN FROM
THE FRAME, MAKE SURE IT HAS COMPLETELY
STOPPED.
General examination of operation
This is a general examination aimed at comparing the operation
The remaining fans will operate at maximum speed to compen-
of the appliance with the last check performed.
sate for the missing fan during maintenance.
Consequently, any differences in the operating characteristics
over time can be highlighted.
A detailed and periodical visual check of the appliance and general
cleaning are always important to ensure correct operation.
The above-mentioned operations can in general be performed
once a month.
A
Naturally, in special situations and specific installations the fre-
quency may change.
A well maintained system is unlikely to cause disruptions and
stoppages to the production cycles.
After 10 years of operation a complete inspection should be per-
formed to check, and if necessary replace any damaged/worn
components.

CRCX - CRCC English 01-2012 27

 MAINTENANCE U I A

Every components replacement (compressor, safety presso- Checking and cleaning the drains
stat, liquid receiver, ecc.) have to consider the main compo- All the water drains (humidifier and condensate) must ensure
nent list enclosed in the unit. perfect drainage, to avoid flooding in the room.
When the humidifiers drain the water, they discharge a quantity
This section, aimed above all for the end user, is extremely impor- of lime scale that depends on the hardness of the supply water.
tant for the correct operation of the appliance. This lime scale may accumulate in the bottom of the drain hose
Just a few operations completed scrupulously and regularly will and block the flow of water. If cleaning is required, add ordinary
avoid serious damage to the components. Only authorized and descaler to the section of circuit involved. This operation must be
specialist personnel can operate into the units. carried out with the unit off and after having made sure that the
The maintenance operations can be summarised as follows: appliance is disconnected from the power supply.
- Clean the air filter.
- Check and clean the condenser coils General examination of operation
- Check the water-cooled condensers for fouling. This is a general examination aimed at comparing the operation
- Check and clean the drains. of the appliance with the last check performed. Consequently, any
- Check the humidification system. differences in the operating characteristics over time can be high-
- General examination of the overall operation of the appliance. lighted. A detailed and periodical visual check of the appliance and
- Visual check of the condition of the pressurised containers. general cleaning are always important to ensure correct opera-
tion. The above-mentioned operations can in general be per-
Cleaning the air filter formed once a month. Naturally, in special situations and specific
The gradual fouling of the filters reduces the flow-rate of the con- installations the frequency may change. A well maintained system
ditioned air, with a consequent reduction in cooling capacity. is unlikely to cause disruptions and stoppages to the production
In the direct expansion units, a reduction in the air flow-rate may cycles. After 10 years working a complete checking is recom-
cause the activation of the low pressure switch and/or cause seri- mended.
ous damage to the compressor.
This can be avoided by the periodical cleaning of the filters. Visual check of the condition of the pressurised contain-
The frequency at which the filters must be checked exclusively ers
depends on the amount of dust in the environment. Check the condition of the pressurised containers at least once a
In any case, the following are recommended: year (if these are fitted). It is very important to check that rust
- Every week check that the filters are clean does not form on the surface, that there is no corrosion and that
- Every two weeks clean the filters with a vacuum cleaner there are no visible deformations. If not controlled and stopped,
- Every month wash the filters with soapy water surface oxidation and corrosion will over time cause a decrease
- Every 6 months replace the filters. in the thickness of the container and a consequent reduction in
It is clear that the recommended times are purely indicative, and its mechanical strength. Protect with paint and/or corrosion
in some cases it may be necessary to increase the frequency of proofing products. In the event of visible deformations, stop the
the checks and maintenance operations. unit and contact the nearest service centre.
These operations must be carried out with the unit off and after
having made sure that the appliance is disconnected from the
power supply.

Checking and cleaning the condenser coils

In the hotter period, when the unit operates at maximum capaci-
ty, the condensing coils must be able to offer the maximum heat
exchange. Normally installed outside or communicating with the
outside, these may pick up dirt such as paper, dry leaves and dust,
thus reducing the heat exchange.
Make sure that this situation does not arise.
Failure to perform maintenance will cause the activation of the
high pressure switch and the unit to shutdown.
Frequently check the condition of the heat exchanger during the
poplar pollination period or the autumn (falling leaves).
Remove any objects accumulated on the coil and wash with a jet
of water. These operations must be carried out with the unit off
and after having made sure that the appliance is disconnected
from the power supply.

28 English 01-2012 CRCX - CRCC

 TROUBLESHOOTING U I A

Troubleshooting is simplified by the information provided by the If required, contact the nearest service centre, indicating the
microprocessor controller: if an alarm is signalled, refer to the probable causes of the fault.
control panel instruction manual.

FAULT CAUSE SOLUTION

THE AIR-CONDITIO-
The electrical panel is not powered Check for voltage; close the main switch.
NER DOESN'T START

Check that the cutout IM in the auxiliary cir-

The auxiliary circuits are not powered cuits is armed.
Check the fuse on the main board.

The control panel does not start the

Check for DC power.
air-conditioner.

ROOM TEMPERATURE The parameter settings on the microprocessor

See the controller manual.
TOO HIGH controller are not correct.

The air flow-rate is too low or null. See “LOW OR NO AIR FLOW”.

Check the electrical connections and the

The probe isn't working.
configuration of the controller.

Check the thermal load in the room being

Thermal load higher than expected.
air-conditioned.

The compressor/compressors don't start, See “THE COMPRESSOR/COMPRESSORS

despite being activated by the controller. DON'T START”.

ROOM TEMPERATURE The parameter settings on the

See the controller manual.
TOO LOW microprocessor controller are not correct.

The power of the heaters is not sufficient or Check that the heater thermal cutout is armed.
the heaters aren't working. Check the power supply to the electric heaters.
If the heater safety thermostat is activated,
resolve the causes and reset the alarm.

Check the flow-rate and the temperature of

The hot water coil isn't working correctly.
the water hot.
Check the operation of the control valve
and the servomotor.

The hot gas post-heating system isn't working Check the operation of the hot gas three-way
during the dehumidification plus post-heating valve;
phase Check the operation of the compressor used
for post-heating: in this case, see “THE
COMPRESSOR/COMPRESSORS DON'T
START”.

CRCX - CRCC English 01-2012 29

 FAULT CAUSE SOLUTION

AMBIENT HUMIDITY The parameter settings on the

See the controller manual.
TOO HIGH microprocessor controller are not correct.

Latent load higher than expected Check and calculate the latent load; check the
flow-rate and the conditions of the outside air;
check the inflow of outside air.

The compressor isn't working during the See “THE COMPRESSOR/COMPRESSORS

dehumidification phase. DON'T START”.

Check the operation of the solenoid valve that

The dehumidification valve doesn't close.
controls the dehumidification circuit.

See the controller manual; check the

The control system isn't working.
operation of the panel and/or the probe.

AMBIENT HUMIDITY The parameter settings on the microprocessor Check the room temperature setting (see the
TOO LOW controller are not correct. control panel manual).

Latent load lower than expected. Verificare la consistenza del carico latente.

Check the pressure of the supply water;

The humidifier isn't working.
Check the operation of the manual control
system and the steam production unit (see the
control panel manual)

See the control panel manual; check the

The control system isn't working.
operation of the panel and/or the probe.

LOW OR NO AIR
The fans are not powered. Check the power supply to the fans.
FLOW

The filters are blocked (possible activation of

the dirty filter alarm). Clean the filter using a vacuum cleaner after
having shaken off the larger particles of dust.
Replace the filter if excessively clogged.
Check the correct calibration of the dirty filter
differential pressure switch F4.

Obstructions to the air flow. See the paragraph on AIR DISTRIBUTION

Check the resistance of the fan windings; after

The fan thermal cutout has tripped. resetting, measure the voltage and power
input.

EC radial fan speed set too low

Excessive pressure drop in the air distribution Check the sizing of the air distribution system
system. (ducting, false-ceiling, underfloor plenum, grills)

30 English 01-2012 CRCX - CRCC

 FAULT CAUSE SOLUTION

HEATER SAFETY
Insufficient air flow-rate See “LOW OR NO AIR FLOW”.
THERMOSTAT
ACTIVATED
Check the continuity of the connection from
Thermostat connection wire cut or broken
the safety thermostat to the control system.

Faulty thermostat Replace the heater safety thermostat.

HIGH COMPRESSOR
A) Air or incondensable gas in the refrigerant
DISCHARGE Empty and recharge the circuit.
circuit, seen by the presence of bubbles, despite
PRESSURE
measuring a high subcooling.

B) Insufficient air flow-rate to the remote heat Check the operation and the correct direction
exchanger or air too hot of rotation of the fans on the outdoor heat
exchanger.
Check that the exchanger is not dirty and
remove any material that may be blocking it
(leaves, paper, seeds, dust, etc.) with a jet of
compressed air or with a brush;
Check the outdoor unit for any obstacles to
the flow of air and any recirculation of the coo-
ling air;
Check that the temperature of the cooling air
does not exceed the design value.

Check the flow-rate, the pressure and the

Insufficient water flow-rate to the condenser
temperature of the cooling water in the clo-
or water too hot.
sed circuit;
Check the calibration and the operation of the
pressure control valve.

Excessive refrigerant charge; condenser

Remove refrigerant from the circuit.
partially flooded. Excessive subcooling of the
liquid at the condenser outlet.

Valves on the high pressure side of the circuit

Check the opening of the valves.
partially closed.

HIGH PRESSURE Check the operation of the condenser fans

The condensing pressure control system
SWITCH ACTIVATED and the corresponding protection device;
isn't working.
(high compressor repair or replace the faulty fans;
discharge pressure) Check the calibration and the operation of the
remote condenser fan pressure switch or the
speed controller.
(See CONTROLLING THE CONDENSING
PRESSURE)

The system is affected by an excessive See “HIGH COMPRESSOR DISCHARGE

discharge pressure PRESSURE”.

CRCX - CRCC English 01-2012 31

 FAULT CAUSE SOLUTION
LOW COMPRESSOR Check the calibration and the operation of the
The condensing pressure control system
DISCHARGE condenser fan pressure switch or the speed
isn't working (see the control panel manual).
PRESSURE controller;

Excessive water flow-rate to the condenser

or water too cold. Check the temperature of the cooling water.
Check the calibration and the operation of the
pressure control valve (if fitted).
Install a pressure control valve to manage the
flow-rate of water according to the conden-
sing pressure.

See “LOW COMPRESSOR SUCTION

Suction pressure too low
PRESSURE”.

HIGH COMPRESSOR Check the ambient thermal load; check, above

Thermal load higher than expected
SUCTION PRESSURE all for intense dehumidification, the flow-rate
and the conditions of the outside air; check
the inflow of outside air.

The system is affected by an excessive See “HIGH COMPRESSOR DISCHARGE

discharge pressure PRESSURE”.

Too much refrigerant in the circuit. Remove refrigerant from the circuit

Return of liquid refrigerant to the Check that the thermostatic valve superhea-
compressor intake ting value is correct; check that the valve sen-
sor bulb is not discharged and that it is cor-
rectly positioned, secured and insulated”.a

LOW COMPRESSOR Room temperature too low See “ROOM TEMPERATURE TOO LOW”.
SUCTION PRESSURE
(and possible defrosting
of the coil)
The air flow-rate is too low or null See “LOW OR NO AIR FLOW”.

Liquid receiver outlet valve not

Check the opening of the valve.
completely open

Check that the thermostatic valve superhea-

Refrigerant filter blocked ting value is correct; check that the valve sen-
sor bulb is not discharged and that it is cor-
rectly positioned, secured and insulated”.

Check the liquid subcooling at the condenser

Insufficient refrigerant charge
outlet; if necessary, restore the charge.

Thermostatic valve not correctly calibrated Check that the thermostatic valve superheating
LOW PRESSURE
or faulty value is correct (around 5°C).
SWITCH ACTIVATED
(low compressor suction
pressure) Check and if necessary replace the dewatering
Dewatering filter cartridge dirty filter cartridge; the temperature difference
measured upstream and downstream of the
filter must be less than 2°C.

The system is affected by an excessively See “LOW COMPRESSOR DISCHARGE

low discharge pressure PRESSURE”.

32 English 01-2012 CRCX - CRCC

 COD. C01001848H_00
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