0410536 IPAC - IOM - Issue 4.0 - Lo-Res Colour

IPAC Air Handling Units

IPACEaton-Williams

INSTALLATION, OPERATION AND MAINTENANCE

Document 0410536Issue 4.0 : April 2008

IPAC

IPAC

(Invicta Precision Air Control)

15 to 120 kW, Upflow, Downflow,

Direct Expansion, Water-Cooled Direct Expansion, Chilled Water

ABOUT THIS DOCUMENT

Using This DocumentThis document has been designed for online viewing as a PDF file and double-sided printing(subject to copyright - see below) for hard copy.

Each section has its own contents list, to facilitate ease of use as a standalone document.

The online document contains hyperlinks (hotlinks) indicated as such. Please note that whenviewing a standalone section online, only those hyperlinks to within the standalone section willfunction. Only when viewing the entire document will all hyperlinks function.

The document’s hyperlinked contents can also be displayed by activating the bookmarksfunction of the PDF viewing application.

Copies of this document can be obtained from Eaton-Williams at the address shown below.

This is not a controlled document. Distributed copies will not be updated.

All specifications are nominal and subject to change without prior notice as designimprovements occur.

Copyright NoticeThe confidential information contained in this document is provided solely for use by Eaton-Williams Group employees and system owners, and is not to be released to, or reproduced for,anyone else. Neither is it to be used for reproduction of this unit or any of its components.

DisclaimerEaton-Williams Group shall not be liable for any damages resulting from mis-application ormisuse of its products.

E & OE

IPAC

Document 0410536

Issue 4.0 : April 2008

BUSINESS SYSTEMS AND STANDARDS

GENERAL STATEMENT

Quality Management SystemThe Eaton-Williams Group are a registered company to BS EN ISO 9002:1994 Qualitymanagement standard. This standard covers all manufacturing areas and associated processes.The Group are now currently in the transition process for accreditation to the new standard ISO9001: 2000. Target date for accreditation is December 2003.

Safety and Environmental ManagementIn addition to the above, the Group are currently working to implement an environmentalmanagement system in line with ISO 14001, which will be integrated with our existing Quality& Safety Management Systems.Target accreditation date is June 2004.

As part of the implementation, the Group have already carried out an audit of the business toidentify all significant environmental aspects. Targets and KPIs have been set forenvironmental impact reduction and the Group already complies with all current environmentallegislation identified during the environmental audit, and as required by the local authority.

HR Management and Staff DevelopmentThe Group was successfully accredited to the Investors in People standard in February 2000.

Product StandardsThe air conditioning products marketed and supplied by Eaton-Williams Limited, when installedand operated in accordance with EW information and instructions, conform to the EMCdirective and essential Health & Safety requirements of the machinery directive 91/368/EEC-93/44/EEC & 93/68/EEC. This includes the EMC compatibility directive 89/336/EEC. As standard,units comply with an IP21 rating. The standards are also met where compliance to TÜV, UL andCSA are specific market requirements attained for that product.

Document 0410536


IPAC

IPAC Eaton-Williams


This page is intentionally blankto facilitate double-sided printing.

Station Road, Edenbridge, Kent, TN8 6EG EnglandTelephone +44 (0)1732 866 055 Fax +44 (0)1732 866 053

Email [email protected] Website www.eaton-williams.com

Eaton-Williams

IPAC

CONTENTS

Document 0410536

SECTION 1 SAFETY AND GENERAL INFORMATION

SECTION 2 TECHNICAL MANUAL

SECTION 3 INVICTANET CONTROLLER USER MANUAL

SECTION 4 INVICTANET CONTROLLER TECHNICAL MANUAL

SECTION 5 INVICTANET CONTROLLER SETTINGS RECORD

SECTION 6 INSTALLATION - DX UNITS

SECTION 7 INSTALLATION - CHILLED WATER UNITS

SECTION 8 COMMISSIONING - DX UNITS

SECTION 9 COMMISSIONING - CW UNITS

SECTION 10 PREVENTATIVE AND GENERAL MAINTENANCE

SECTION 11 SERVICE AND PARTS INFORMATION

SECTION 12 FAULT FINDING PROCEDURES

SECTION 13 UNIT MAINTENANCE LOG

SECTION 14 UNIT MODIFICATION LOG


IPAC

This page is intentionally blankto facilitate double-sided printing.

Document 0410536


IPAC SECTION 1

IPACEaton-Williams

IPAC

Document 0410536 IPACIssue 4.0 : Aprill 2008

SAFETY AND GENERAL INFORMATION

SECTION CONTENTS

1.1 General 1 – 2

1.2 Safety Precautions - Refrigerant 1 – 21.3 Prevention of Legionnaires’ Disease 1 – 31.4 Installation and Handling 1 – 31.5 Application 1 – 31.6 Warranty 1 – 41.7 Electrical Connection 1 – 41.8 Maintenance 1 – 41.9 Service Parts 1 – 41.10 Codes of Practice 1 – 41.11 Drive Guards 1 – 41.12 Waste Disposal 1 – 4

IPAC

Document 0410536

Issue 4.0 : Aprill 2008Page 1-2


IPAC


General If any of the above initial symptoms are experienced, the

Document 0410536

Air conditioning equipment presents potential mechanical,electrical, noise or vibration hazards.Observe all safety, installation, operation and maintenanceinstructions.Installation, servicing and operation of the equipment only byfully trained and technically competent personnel.Eaton-Williams air conditioning equipment is designed tominimise mechanical and electrical hazards by fully restrictingaccess through unit casings, doors and covers whilst theequipment is operational.Some installations may require additional protective features toprevent accidental contact with components. Eaton-Williamscan provide advice and make recommendations for additionalprotection to suit the application.All installation work must be completed in accordance with thesafety, installation, operation and maintenance instructions, andthe unit correctly earthed before it is operated. Prior to anymaintenance work being carried out, ensure that:Equipment is switched OFF.Equipment and controls are isolated from the electrical supply.All rotating parts have come to rest.Air conditioning equipment may, in certain operating conditions,generate unacceptable noise and vibration levels. Eaton-Williams can advise on relevant sound level data, appropriateaction to be taken and supply suitable components to reducesound and vibration levels.If in any doubt as to the correct interpretation of performing anyof the safety, installation, operation and maintenanceinstructions, it is essential that Eaton-Williams, their agent orappointed distributor, is consulted for advice and clarification.

Safety Precautions - RefrigerantThe following information is provide for guidance.

R 407C - COSHH ConsiderationsThe refrigeration system in this equipment contains liquid andvapour refrigerant under pressure. Each system is hermeticallysealed and has been leak tested in production to help ensuresafe operation for its life cycle.However, in the unlikely event of a leak or maintenance thatrequires opening the refrigeration system envelope, thefollowing information must be considered.

Inhalation ToxicityRefrigerant R 407C poses no acute or chronic hazard whenhandled in accordance with the manufacturer’srecommendations and when exposures are maintained at orbelow recommended Acceptable Exposure Limits (AEL), of 1000ppm.Inhalation exposure, above the recommended exposure limit, tothe vapours of R 407C refrigerant, may cause physiologicaleffects that can include temporary depression of the nervoussystem, with effects such as dizziness, headache, confusion, lossof co-ordination and loss of consciousness.

affected person should be moved into fresh air and medicalattention sought as a precaution. Over-exposure can be fatal.

Cardiac IrregularitiesExposure levels above the recommended exposure limits canlead to cardiac irregularities, such as irregular pulse,palpitations, inadequate circulation and cardiac arrest. Theeffect level varies from person to person, but is likely to increaseif the person is under physical or emotional stress.If any of the above symptoms are experienced, move theaffected person to fresh air and seek medical attention as aprecaution. Overexposure can be fatal.NOTE: Do not treat affected persons with drugs, such asadrenaline, as this could increase the risk of cardiac problems.

Skin and Eye ContactAlways wear protective clothing when there is a risk of exposureto liquid refrigerantIn liquid form, refrigerant can cause severe frostbite and tissuedamage. Where there is possible risk of being splashed by liquidrefrigerant, always wear eye protection.If skin or eyes are splashed with liquid refrigerant, flush theaffected area with lukewarm water, (do not use hot water).If frostbite has occurred, call medical help. If eyes are splashed,immediately flush with plenty of water for at least 15 minutesand call medical help.

Spills or LeaksVapour from a spill or leak of R 407C will tend to concentratenear the floor or in low areas, displacing the oxygen available forbreathing, which can result in suffocation.Evacuate all personnel. Use blowers or fans to circulate fresh air.Do not re-enter the affected area until it has been thoroughlyventilated, unless wearing appropriate breathing apparatus.

Non-flammabilityRefrigerant R 407C is formulated such that it remains non-flammable during shipping, handling, storage, in use, or if leakedfrom a unit.

CombustibilityRefrigerant R 407C is not flammable in air at temperatures up to100 °C at atmospheric pressure. However, mixtures of R 407Cwith high concentrations of air at elevated pressure and/ortemperature can become combustible in the presence of a nakedflame.R 407C can also become combustible in an oxygen enrichedenvironment. R 407C MUST NOT BE MIXED WITH AIR UNDER

PRESSURE FOR LEAK TESTING OR OTHER PURPOSES.Refrigerants should not be exposed to naked flames or electricheating elements. High temperatures and flames can cause therefrigerant to decompose, releasing toxic and irritating fumes.Always recover refrigerants, evacuate equipment, and ventilatework areas properly before using any open flames.


IPAC


Prevention of Legionnaires’ Disease iii. Supply Authorities.

Document 0410536

For further information, please refer to "Prevention ofLegionnaires’ Disease” on page 3 of Section 10

Installation and HandlingThe installation and operation of the unit should be conducted inaccordance with local regulations and accepted codes of goodpractice.When moving and lifting the unit, caution must be observed atall times to ensure the safety of all personnel. Only appropriateand approved lifting equipment must be used.

ApplicationThe unit is only to be used in the application for which it wasdesigned.The unit is NOT to be used in a hazardous environment unless ithas been specially designed and approved for such application.

WarrantyFailure to comply with the manufacturer’s installationinstructions could affect the reliability and performance of theunit and invalidate the warranty.Warranty is also subject to the implementation of a plannedservice/maintenance agreement as stipulated in the warrantybooklet supplied with the unit and/or the sales contract.

Electrical ConnectionThe unit must be connected to an external isolator if one is notsupplied fitted to the unit.Electrical connections should be carried out in accordance withnational and local regulations. In the UK, standard BS 7671applies.Never make any connections in the unit circuits unless theelectricity supply has been switched OFF at the isolators.

MaintenanceFor further information, please refer to Section 10 - Preventativeand General Maintenance.

Service PartsService parts must of the same specification as those beingrenewed and should be obtained from Eaton-Williams’ ServiceDepartment. The use of incorrect service parts can affect unit operation andreliability and invalidate any warranty.

Codes of PracticeIt is important that equipment and products which have beeninstalled and commissioned by Eaton-Williams, are maintainedby or under supervision of technical competent personnel andthat all work is carried out in accordance with good engineeringpractice and strict adherence to:i. IEE Regulations.

ii. Codes of good engineering practice.

iv. Statutory requirements.

v. Manufacturers instructions and recommendations.

vi. All other relevant information, regulations and legislation.

Drive GuardsWhenever drive guards are to be removed to facilitatemaintenance, the electrical supply to the unit must first beisolated LOCKED OFF and fuses removed and retained by theperson carrying out the work.Any guards removed to facilitate maintenance, must be refittedimmediately work is completed.Refitting of guards, restoration of power, starting and restorationof plant into service are only to be carried out by properly trainedand authorised personnel.

Waste DisposalAll refrigerants, oils and other waste materials must be disposedof in a professional and responsible manner and in strictadherence to environmental regulations. For details, consultlocal environmental agencies.

DocumentationAll documentation must remain with the unit at all times.


IPAC SECTION 2

IPACEaton-Williams

IPAC

Document 0410536 IPACIssue 4.0 : April 2008

TECHNICAL MANUAL

IPAC

Technical Manual

Document 0410536Page 2-2

SECTION CONTENTS

Heading PageIntroduction 2 – 4

Application 2 – 4Duty Range 2 – 4Temperature Control 2 – 4Humidity Control 2 – 4

Reliability 2 – 4Serviceability 2 – 5Unit Identification 2 – 5Temperature Control 2 – 5Cooling Process 2 – 5

Air-cooled Direct Expansion (DX) System 2 – 15Water-cooled DX System 2 – 16Chilled Water Cooling System 2 – 17Economy Cooling Options 2 – 18

Humidity Control 2 – 18Dehumidification 2 – 18

Hot Gas Reheat 2 – 18

Network Control System 2 – 19Main Components 2 – 19

Unit Casing 2 – 21Finish 2 – 21Supply Air Fan(s) 2 – 21Air Filters 2 – 21Differential Pressure Switches 2 – 22Cooling Coil 2 – 22Condensate Drip Tray 2 – 22Eaton-Williams InvictaNET AHU Controller 2 – 22Electrical connections 2 – 23Volt-free Alarm Contacts 2 – 23Bottom Connections 2 – 23Compressor 2 – 23Filter / Drier 2 – 23Thermostatic Expansion Valve 2 – 23Moisture Indicating Sight Glass 2 – 24Evacuation and Refrigerant Charging Valves 2 – 24Pressure Safety Devices 2 – 24Modulating Flow Control Valve and Actuator 2 – 24Key Operated Cam-lock Removable Doors 2 – 24Airflow Failure Detection 2 – 24Cardboard Sleeve / Pallet Delivery Protection 2 – 24Contactors, MCBs and MPCBs 2 – 24Internal Unit Isolator 2 – 24Interconnecting wiring loom 2 – 24Integrated Water-Cooled Condenser 2 – 25

Features and Options 2 – 25Phase-failure relay 2 – 25Control panel cover 2 – 25Fresh Air Control 2 – 25Fresh Air Control, Including Smoke Detection 2 – 25Door-interlocked isolator 2 – 25Mains filter kit 2 – 25In-Room Remote Sensors 2 – 25


IPAC

Technical Manual

Duct Remote Sensors 2 – 25

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Water Detection Tape 2 – 25Audible Alarm 2 – 25Alternate Display Languages 2 – 25ModBus Network Interface 2 – 26Trend Controller 2 – 26Trend Network Interface 2 – 26

Heating Process 2 – 26Electric Heating 2 – 26Low Pressure Hot Water Heating System 2 – 26LPHW Heating Coil 2 – 27Capacity Control Hot Gas Injection System 2 – 272 Way or 3 Way Control Valve 2 – 27Liquid Receiver 2 – 27Oil Separator 2 – 28Compressor Acoustic Jacket 2 – 28Compressor Discharge Non-return Valve 2 – 28Split Coil Rapid Dehumidification 2 – 28Pressure Relief 2 – 28Water System Isolating Gate Valves 2 – 28Commissioning Set 2 – 28Flexible duct connectors (upflow units only) 2 – 28Back-draught dampers (upflow units only) 2 – 28Airflow Options 2 – 29Humidifier 2 – 2920% - 100% Proportional Output Humidifier 2 – 29Alarm Diagnostics Tools in Controller 2 – 29Different Bottle’s for Varying Water Qualities 2 – 29Remote Vapac Options 2 – 29Second Unit OEM Option 2 – 29Rear Cosmetic Cover Panel 2 – 29Multi-speed motors 2 – 29Side Gland Plates 2 – 30Stainless Steel Drip Tray 2 – 305 to 10 % fresh air intake, including volume damper control 2 – 30Anti-vibration mountings 2 – 30Dual Pulley Drives 2 – 30Low Display Mounting 2 – 30Lifting Channels 2 – 30Condensate Pump 2 – 30Class 1, energy-efficient motors 2 – 30Customised Colours 2 – 30Pipework 2 – 30Flood Detection 2 – 31Electrical Equipment 2 – 31Air Movement Options 2 – 32Emergency Shutdown 2 – 32Fire Shutdown 2 – 32

Ancillary Options 2 – 32Adjustable Feet 2 – 33Floor Support Angles 2 – 33Open frame 2 – 33Open Frame Base and Scoop 2 – 33Enclosed Section (for ducting, etc.) 2 – 33Turning Section (inc. double-deflection grilles) 2 – 34Fresh Air Modulating Section 2 – 34High-efficiency Filter Section 2 – 34

Issue 4.0 : April 2008Page 2-3

IPAC

Technical Manual

Document 0410536


IPAC

Technical Manual

Introduction All dual module interconnecting wiring is made to numbered


This section provides information about the main components ofInvicta Precision Air Control (IPAC) standard range air handlingunits (AHUs).

ApplicationIPAC units are designed as a modular range of both upflow anddownflow, floor-standing, air handling units for operation atroom temperatures from 18 °C to 30 °C as standard. Factory-added options can enable operation outside this range.These units provide highly reliable air handling systems forspace-cooling, where the air must be conditioned to be:

• Temperature controlled (heating is optional)

• Humidity controlled (optional)

• Filtered clean of particulates

Duty RangeBasic duty sizes for standard units in the IPAC range are asshown in Table 2-1, which also identifies which are single ortwin module units, together with matching condenser options.Twin module units can be positioned separately, offeringflexibility according to installation requirements; refer to Fig. 2-3for dimensions and weight data.

By offering a selection of various combinations of unitconfiguration, duty requirements can be matched accurately.The various standard unit configurations available are asillustrated in Fig. 2-3, while airflow path configurations areillustrated in Fig. 2-11.Units are manufactured with either upflow or downflow airdirection, to provide optimum comfort levels.For a dual module pair, the electrical section of the larger unitcontains the controls and switchgear for control of the other.

terminal rails in each unit for easy connection at site. To ease installation, an interconnecting wiring loom is availableas an optional extra.IPAC air handling units are designed for indoor installation only.Units can either be mounted within the space to be conditioned,or mounted elsewhere with air ducted to the room.As well as the standard unit configurations, a variety ofcustomising options can be factory-fitted or site-fitted, toprovide a system that precisely matches user requirements.

Temperature ControlTemperature can be precisely controlled, with cooling providedby the cooling coil(s).Where heating is required, mutli-stage electrical heating, or lowpressure hot water (LPHW) are available as options.Air temperature is controlled by two PID (Proportional Integraland Derivative) algorithms, one for heating, the other forcooling.Each algorithm includes the same adjustable dead band, whichequally spans each side of the room temperature set point.If I (Integral) and D (Derivitive) values are zero, control isproportional only.Proportional units are in °C.

Humidity ControlWhere dehumidification is required, a cooling coil is operatedbelow the dew point of the air to condense and remove watercontent from the air.To ensure optimum temperature control in conjunction withdehumidification, the options of hot gas or electric reheat areavailable.Where humidification is required, a factory-fitted Vapac®

humidifier unit is available as an option. This is a proportional-output humidifier that produces clean, sterile steam, that isentrained into the airflow to increase its humidity.The humidifier responds to a changing demand, using the waterlevel (WL) system of modulation. Output is varied by increasingor decreasing the level of water in the cylinder. Air humidity is similarly is controlled by two PID algorithms, onefor humidification, the other for dehumidification.Each algorithm includes the same adjustable dead band, whichequally spans each side of the room humidity set point.If I (Integral) and D (Derivitive) values are zero, control isproportional only. Proportional units are in % RH.

ReliabilityIPAC units are designed for high reliability with a calculatedmean-time between failure of not less than four years, providedthat routine maintenance procedures are carried out atprescribed intervals.

ServiceabilityThe maximum time required replacing Service Items, andreturning the unit to operational condition is approximately 1hour, excluding refrigeration circuit items, provided of course,that recommended service parts are held ready to use.

Table 2-1 : Duty range and matching air-cooled condensers

NOMINALDUTY kW

UNITSINGLE / TWINMODULE UNIT

Matching Air-cooledCondenser Models

Primary Secondary

15 IPAC 15-1 Single ICV1-18P -22 IPAC 22-1 Single ICV1-40P -30 IPAC 30-1 Single ICV2-40P -30 IPAC 30-2 Twin ICV1-18P ICV1-18P40 IPAC 40-1 Single ICV2-70P -45 IPAC 45-2 Twin ICV2-40P ICV1-18P50 IPAC 50-1 Single INCO3-2SGA -55 IPAC 55-2 Twin ICV2-70P ICV1-18P60 IPAC 60-1 Single INCO3-2SGA -60 IPAC 60-2 Twin ICV2-40P ICV2-40P70 IPAC 70-2 Twin ICV2-70P ICV2-40P80 IPAC 80-2 Twin ICV2-70P ICV2-70P90 IPAC 90-2 Twin INCO3-2SGA INCO2-2SGA

100 IPAC 100-2 Twin INCO3-2SGA INCO3-2SGA




IPAC

Technical Manual

For details of recommended service parts for each unit, together Temperature Control

Document 0410536

with contact and ordering details, please contact the Eaton-Williams Head Office.

Unit IdentificationVital data on a unit can be obtained from the serial numberplate, which can be found inside the cabinet, just below theelectrical chassis on the left hand side.

The following data is normally shown on the serial number plate:

Product - EW code number.Cooling Capacity - design cooling capacity in kW.Electrical Supply - for which the unit is rated.Wiring Diagram - relevant to the unit.Power - consumption at maximum load in kVa.Serial Number - of the unit.Short Circuit Capacity - in kA.Maximum Start Current - consumption in Amps.Refrigerant - type and quantity in kg, to be filled when

known; i.e on completion of commissioning.Full Load Current - consumption in Amps.

The temperature of supply air passing through the unit ismonitored by an Eaton-Williams InvictaNET AHU controller,which applies cooling or heating (optional) control strategy tocorrect and maintain room air temperature at a predeterminedset point.

The Cooling Process is described below. The Humidity Control is described on page 2-20.

The air passage through the unit is the same, whether in heatingor cooling mode.

Cooling ProcessThe cooling process is used for air cooling and/ordehumidification and is achieved by one of three types of coolingprocess:

Air-cooled Direct Expansion (DX) System on page 2-16,using refrigerant, normally R 407CWater-cooled DX System on page 2-17 using water/glycol

as a primary refrigerant, normally containing corrosioninhibitor additive (recommended)Chilled Water Cooling System on page 2-18, or other

similar cooled mediumThe type of cooling process required must be specified at thetime of ordering.

Fig. 2-1 : Serial No. plate (typical)

Fig. 2-2 : Approximate position of serial No. plate

Eaton-Williams Group LtdEdenbridge Kent England TN8 6EGTel. +44 (0)1732 866055 Fax +44 (0)1732 863461

Manufacturedto ISO 9000Quality System

Product

Cooling Capacity

Electrical supply

Wiring Diagram

Power

Serial No.

Short Cct. Cap.

Max. Start Current

Refrigerant

Full Load Current

DM 5001A

40.7

400 3 50

LAD983 0 DM5001A

AC06483 2004

14.4

0.0

0

183.0

R407C

34.5 Amps

Amps

kg

kA

kVA

v/ ~/ Hz

kW


IPAC

Technical Manual

Fig. 2-3 : IPAC Range unit configurations, dimensions and weights


IPAC Range Unit Configurations, Dimensions and Weights

NOTESDual units are shown with cabinets mated side-by-side; dashed red lines show unit mating positions.Unit mating positions can be left or right handed as required, and cabinets can be positioned separately to suit room layout.

Unit 15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2 60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2

Single and dual unit composition (P = Primary, S = Secondary)

UnitComposition

P 15 22 30 15 40 30 50 40 60 30 40 40 50 50 60 60

S - - - 15 - 15 - 15 - 30 30 40 40 50 50 60

Module

Widths (mm)

P 800 1300 1300 800 1700 1300 2050 1700 2050 800 1700 1700 2050 2050 2050 2050

S - - - 800 - 800 - 800 - 800 1300 1700 1700 2050 2050 2050

A - Height mm 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950

B - Width mm 800 1300 1300 1600 1700 2100 2050 2500 2050 2600 3000 3400 3750 4100 4100 4100

Depth mm 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800 800

Weight * kg (combined)

270 380 402 520 472 652 580 722 620 784 922 916 1027 1135 1170 1210

NOTE * Weights are estimated, dry and may vary according to unit configuration and options fitted, please contact Eaton-Williams for further assistance if required.

B

A

IPAC 15-1 IPAC 30-2 IPAC 40-1 IPAC 45-2

B B

A

A

B B

IPAC 50-1 IPAC 55-2 IPAC 60-2IPAC 60-1

B B B

IPAC 22-1IPAC 30-1

IPAC 70-2

B

IPAC 80-2

B

IPAC 90-2

B

IPAC 100-2IPAC 110-2IPAC 120-2

B


IPAC

Technical Manual

Table 2-2 : Technical data

Document 0410536

Technical Data

IPAC Model 15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2

DX unit - Total cooling1 kW 16.0 22.0 30.0 32.0 40.7 46.0 53.0 56.0

DX unit - Gross sensible cooling1 kW 14.8 20.9 28.1 29.6 37.4 42.9 46.1 52.2

DX unit - Sensible heat ratio 0.92 0.95 0.94 0.92 0.92 0.93 0.86 0.93

DX unit - Net sensible cooling kW 13.7 18.5 25.6 27.6 33.7 39.3 43.7 47.4

CW unit - Total cooling1 & 2 kW 23.6 32.1 42.5 47.2 59.8 66.1 67.4 83.4

CW unit - Gross sensible cooling kW 18.5 24.7 33.5 37.0 47.2 52.0 53.8 65.7

CW unit - Sensible heat ratio 0.78 0.77 0.79 0.78 0.79 0.78 0.81 0.78

CW unit - Net sensible cooling kW 17.3 23.0 30.9 34.6 43.5 48.2 50.8 60.8

CW unit - Chilled water flow rate l/s 1.12 1.53 2.02 2.24 2.85 2.65 3.21 3.97

CW unit - water pressure drop kPa 49 48 84 49 67 49 69 67

Airflowm3/s 1.25 1.70 2.25 2.50 3.20 3.50 3.50 4.65

m3/h 4,500 6,120 8,100 9,000 11,520 12,600 12,600 16,020

Design external pressure Pa 70

Maximum external pressure3 Pa 400 400 400 400 360 400 400 360

Air filter quality G4

Compressors - number fitted 1 1 1 2 1 2 1 2

Refrigerant4 R 407C

Estimated initial refrigerant charge5 kg 3.5 6.5 7.03.5+

3.510.0

7.0+

3.516.0

10.0+

3.5

Estimated initial refrigerant chargewith Water Cooled Condenser

kg 3.2 5.3 5.53.2+

3.27.3

5.5+

3.29.2

7.3+

3.2

Humidifier output - Vapac® 6 kg/hr 5 9 9 5 9 9 12 9

Electric heating6 - at 230 V kW 5 10 10 5 15 10 22 15

Standard colour - cabinet and doors BS 4800 Grey 00A05

Noise level3 & 7 - IPAC unit dB(A) 55 56 61 58 68 63 65 67

Condenser - matched Model 1-18P 1-40P 2-40P1-18P

+1-18P

2-70P2-40P

+1-18P

INCO3-2SGA

2-70P+

1-18P

Noise level8 - outdoor condenser dB(A) 58 58 61 58 61 61 61

NOTES1 Unit ratings at 24 °C / 50 % RH internal and 35 °C external ambient air conditions.2 Maximum duty rated at 7/12 ºC water on/off temperatures. For other water on/off temperatures consult Eaton-Williams.3 Higher external pressures are achievable by altering the supply fan speed by fitting a different ratio drive pulley (client to

specify at time of ordering). This may result in a larger drive motor than standard being required, and increased noise level.4 In compliance with the Montreal Protocol, units are designed for use with refrigerant R 407C. For non-compliant countries,

Eaton-Williams can supply units specially designed for use with R22. Do not mix refrigerants.5 Based on a pipe run length of 10 metres.6 Optional equipment.7 Sound pressure level, per cabinet, at a distance of 3 metres from the unit, with floor return and ducted supply (estimated).8 Sound pressure level, per condenser, at a distance of 3 metres from the unit, free-field conditions.


IPAC

Technical Manual

Table 2-2 : Technical data


IPAC Model 60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2

DX unit - Total cooling1 kW 61.7 60.0 70.6 81.4 93.7 106.0 114.7 123.4

DX unit - Gross sensible cooling1 kW 51.9 56.2 65.5 74.8 83.5 92.1 98.8 103.8

DX unit - Sensible heat ratio 0.84 0.94 0.93 0.92 0.89 0.86 0.85 0.84

DX unit - Net sensible cooling kW 47.9 51.2 59.3 67.4 76.9 86.4 91.1 95.8

CW unit - Total cooling1 & 2 kW 74.6 85.0 102.0 119.6 127.1 134.9 141.9 149.2

CW unit - Gross sensible cooling kW 58.9 67.0 80.7 94.4 101.0 107.6 112.7 117.8

CW unit - Sensible heat ratio 0.79 0.79 0.79 0.79 0.80 0.81 0.80 0.79

CW unit - Net sensible cooling kW 54.9 61.8 74.4 87.0 94.3 101.6 105.7 109.8

CW unit - Chilled water flow rate l/s 3.56 4.04 4.87 5.70 5.45 6.42 6.77 7.12

CW unit - water pressure drop kPa 82 49 67 67 69 69 82 82

Airflowm3/s 4.0 4.50 5.45 5.70 6.06 6.42 6.77 7.12

m3/h 14,400 16,200 19,620 23,040 24,300 25,200 27,000 28,800

Design external pressure Pa 70

Maximum external pressure3 Pa 400 400 360 360 400 400 400 400

Air filter quality G4, cleanable

Compressors - number fitted 1 2 2 2 2 2 2 2

Refrigerant4 R 407C

Estimated initial refrigerant charge5 kg 177+7

10+7

10+10

16+10

16+16

17+16

17+17

Estimated initial refrigerant chargewith Water Cooled Condenser kg 9.5

5.5+

5.5

7.3+

5.5

7.3+

7.3

9.2+

7.3

9.2+

9.2

9.5+

9.2

9.5+

9.5

Humidifier output - Vapac® 6 kg/hour 15 12 9 9 12 12 12 12

Electric heating6 - at 230 V kW 22 22 15 15 22 22 22 22

Standard colour - cabinet and doors BS 4800 Grey 00A05

Noise level3 & 7 - IPAC unit dB(A) 70 70 70 70 72 72 72 73

Condenser(s) - matched model INCO3-2SGA

2-40P+

2-40P

2-70P+

2-40P

2-70P+

2-70P

INCO3-2SGA

+INCO2-2SGA

INCO3-2SGA

+INCO3-2SGA

INCO3-2SGA

+INCO3-2SGA

INCO3-2SGA

+INCO3-2SGA

Noise level8 - outdoor condenser dB(A) 64 64 61 61 64 64 64 64

NOTES1 Unit ratings at 24 °C / 50 % RH internal and 35 °C external ambient air conditions.2 Maximum duty rated at 7/12 ºC water on/off temperatures. For other water on/off temperatures consult Eaton-Williams.3 Higher external pressures are achievable by altering the supply fan speed by fitting a different ratio drive pulley (client to

specify at time of ordering). This may result in a larger drive motor than standard being required, and increased noise level.4 In compliance with the Montreal Protocol, units are designed for use with refrigerant R 407C. For non-compliant countries,

Eaton-Williams can supply units specially designed for use with R22. Do not mix refrigerants.5 Based on a pipe run length of 10 metres.6 Optional equipment.7 Sound pressure level, per cabinet, at a distance of 3 metres from the unit, with floor return and ducted supply (estimated).8 Sound pressure level, per condenser, at a distance of 3 metres from the unit, free-field conditions.

Technical Data


IPAC

Technical Manual

Table 2-3 : Design conditions - DX units

Document 0410536

Design Conditions - DX Units awith air on at 24 °C / 50 % RH

R 407C R 22

Normal working pressures

at 35 °C external ambient

HP side:

LP side:

22.0 bar g (319 psi g)5.9 bar g (86 psi g)


Normal working pressures

at 40 °C external ambient

HP side:

LP side:



a. Nominal working pressures are shown averaged across the IPAC range. Actual design values vary according to unit size. Please contact the technical department for specific pressures.

Table 2-4 : Safety pressure switch settings - DX units

Safety Pressure Switch Settings - DX Units

Cut-out Tolerance Cut-in Tolerance

LP - low pressure safety 0.5 bar g (7 psi g) 5% 1.4 bar g (21 psi g) 5%

HP - high pressure safety 28 bar g (400 psi g) 5% 21 bar g (300 psi g) 5%


IPAC

Technical Manual

Table 2-5 : Current ratings


Current Ratings in Amps1

UNIT TYPEIPAC MODEL

15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2

DX /

A-C

Cooling-only unit

Max. running current 14 20 30 24 35 40 42 45

Fuse Rating 25 32 35 32 50 50 63 63

Max Starting Current 72 108 137 83 184 148 217 194

Temperature unit


Fuse Rating 25 35 35 32 50 50 63 63


Full air conditioning

unit


Fuse Rating 32 40 50 35 63 63 80 80


DX /

W-C

Cooling-only unit


Fuse Rating 25 32 35 32 50 50 63 63


Temperature unit


Fuse Rating 25 35 335 32 50 50 63 63



unit


Fuse Rating 32 40 50 35 63 63 80 80


CW

Cooling-only unit


Fuse Rating 10 16 16 10 20 16 25 20


Temperature unit


Fuse Rating 16 32 32 16 32 32 50 35



unit


Fuse Rating 20 40 40 20 50 40 80 50


NOTE All ratings shown are for units having standard configuration and operating at design conditions.


IPAC

Technical Manual

Table 2-5 : Current ratings

Document 0410536

UNIT TYPEIPAC MODEL

60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2

DX /

A-C

Cooling-only unit


Fuse Rating 80 63 63 80 100 100 100 100


Temperature unit


Fuse Rating 80 63 63 80 100 100 100 100



unit


Fuse Rating 100 63 80 100 125 125 160 160


DX /

W-C

Cooling-only unit


Fuse Rating 80 63 63 80 100 100 100 100


Temperature unit


Fuse Rating 80 63 63 80 100 100 100 100



unit


Fuse Rating 100 63 80 100 125 125 160 160


CW

Cooling-only unit


Fuse Rating 25 20 25 25 25 32 32 32


Temperature unit


Fuse Rating 63 35 40 40 50 63 80 80



unit


Fuse Rating 80 40 50 50 80 80 100 100


NOTE All ratings shown are for units having standard configuration and operating at design conditions.

Current Ratings in Amps1


IPAC

Technical Manual

Table 2-6 : Pipework connection sizes


Pipework Connection Sizes

LINEIPAC MODEL

15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2

Indoor liquid in. 3/81/2

1/23/8

3/85/8

1/2 3/87/8

5/8 3/8

Outdoor liquid in. 3/81/2

1/23/8

3/85/8

1/2 3/83/4

5/8 3/8

Indoor discharge in. 1/23/4

3/41/2

1/27/8

3/4 1/2 13/8

7/8 1/2

Outdoor discharge in. 3/47/8

7/83/4

3/47/8

7/8 3/4 11/87/8

3/4

Chilled water mm 28 35 35 28 28 42 35 28 42 42 28

Humidifier water mm 15

Condensate and humidifier drain, tube i/d

mm 13

LINEIPAC MODEL

60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2

Indoor liquid in. 7/81/2

1/25/8

1/25/8

5/87/8

5/85/8

5/87/8

7/87/8

7/8

Outdoor liquid in. 3/41/2 1/2

5/81/2

5/85/8

3/45/8

5/85/8

5/85/8

5/85/8

Indoor discharge in. 13/83/4

3/47/8

3/47/8

7/8 13/87/8 11/8 11/8 13/8 13/8 13/8 13/8

Outdoor discharge in. 11/87/8

3/47/8

7/87/8

7/8 11/8 11/8 11/8 11/8 11/8 11/8 11/8 11/8

Chilled water mm 42 35 35 42 35 42 42 42 42 42 42 42 42 42 42

Humidifier water mm 15

Condensate and humidifier drain, tube i/d

mm 13

NOTESExcept for the humidifier water supply and drain lines, all pipe connections are brazed as standard (options are available on request).Humidifier water feed line connection is push-fit for copper pipe.Each module of dual cabinets have independant service connections.


IPAC

Technical Manual

Table 2-7 : Discharge line and liquid line sizes guide - DX units

Document 0410536

Discharge Line and Liquid Line Sizes Guide - DX Units

PIPE RUN LENGTH

LINEIPAC MODEL

15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2

<10 mLiquid in. 1/2

1/21/2

1/21/2

5/81/2

1/27/8 5/8

1/2

Discharge in. 3/43/4

3/43/4

3/47/8

3/43/4 13/8 7/8

3/4

10 mto

30 m

Liquid in. 5/85/8

3/45/8

5/83/4

3/45/8

7/83/4

5/8

Discharge in. 7/8 11/8 11/87/8

7/8 11/8 11/87/8 13/8 11/8

7/8

30 mto

50 m

Liquid in. 5/85/8

3/45/8

5/87/8

3/45/8

7/87/8

5/8

Discharge in. 7/8 11/8 11/87/8

7/8 13/8 11/87/8 13/8 13/8

7/8

PIPE RUN LENGTH

LINEIPAC MODEL

60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2

<10 mLiquid in. 7/8

1/2 1/2

1/2 5/8

5/85/8

7/8 5/83/4 3/4 7/8

7/8 7/87/8

Discharge in. 13/83/4

3/43/4

7/87/8

7/8 13/8 7/8 11/8 11/8 13/8 13/8 13/8 13/8

10 mto

30 m

Liquid in. 7/83/4

3/43/4

3/43/4

3/4 7/8

3/47/8

7/87/8

7/87/8

7/8

Discharge in. 13/8 11/8 11/8 11/8 1

1/8 11/8 11/8 13/8 11/8 13/8 13/8 13/8 13/8 13/8 13/8

30 mto

50 m

Liquid in. 11/83/4

3/43/4

7/87/8

7/8 7/8

7/87/8

7/8 11/87/8 11/8 11/8

Discharge in. 15/8 11/8 11/8 11/8 1

3/8 13/8 13/8 13/8 13/8 13/8 13/8 15/8 13/8 15/8 15/8

NOTES:All pipe connections are brazed as standard (options are available on request).Sizes are provided for guidance only. Qualified personnel should specify pipework, subject to site layout and conditions.Each module of dual cabinets have independant service connections.


IPAC

Technical Manual

Table 2-8 : Water flow rates for integrated plate heat exchanger condensers


Standard Water Flow Rates for Integrated Plate Heat Exchanger Condensers

Water Flow Rates at 35 °C Supply and 45 °C Return

IPAC MODEL 15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2

Water Flow Rate l/s 0.46 0.69 0.93 0.93 1.26 1.4 1.7 1.12

Pressure Drop kPa 52 46 63 52 68 63 97 68

Optional Glycol Pressure Drop kPa t.b.a t.b.a t.b.a t.b.a t.b.a t.b.a t.b.a t.b.a

IPAC MODEL 60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2



Optional Glycol Pressure Drop kPa t.b.a t.b.a t.b.a t.b.a t.b.a t.b.a t.b.a t.b.a

Optional Water Flow Rates for Integrated Plate Heat Exchanger Condensers


IPAC MODEL 15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2



IPAC MODEL 60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2




IPAC MODEL 15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2



IPAC MODEL 60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2



NOTESSupply temperatures shown are typical for open loop water systems. 40 °C is typical for closed-loop water systems.For alternative water temperatures, refer to Eaton-Williams.

Table 2-9 : Service electrical connections - all units

Service Electrical Connections - All Units

Power supply 400 V, 3 ph, 50 Hz

Indoor unit power supply cable 5 core, 3ph / N / E

Outdoor (condenser) unit power supply cable 3 core, L / N / E


IPAC

Technical Manual

Air-cooled Direct Expansion (DX) System

Document 0410536

From the suction line, the compressor draws refrigerant gas(normally R 407C), compresses it and then discharges it into thedischarge line.The high pressure, superheated discharge gas flows through thedischarge line to the condenser, where the gas is cooled andcondensed by relatively cool air flowing on the other side of theheat exchange surface.The resulting liquid, still at high pressure, flows through theliquid line and through a filter/drier before reaching thethermostatic expansion valve.

NOTEDepending on system design external to the unit,it may be necessary to fit a liquid receiver in theliquid line, after the condenser; refer to “LiquidReceiver” on page 6-6 of Section 6.

To ensure that only liquid reaches the thermostatic expansionvalve, the liquid line continues from the liquid receiver via a diptube arrangement.

The thermostatic expansion valve meters the flow of refrigerantentering the evaporator in response to the temperature ofrefrigerant leaving the evaporator.On entering the evaporator, the refrigerant is a saturated vapourand liquid mixture at low pressure.As the refrigerant passes through the evaporator, any liquidpresent is vaporised by extracting heat from the relatively hightemperature supply air flowing on the other side of the heatexchange surface.From the evaporator, the superheated, low pressure gas entersthe suction line and flows to the compressor again.The process is continuous while the compressor is operating.To achieve evaporator capacity control, one of two types ofCapacity Control Hot Gas Injection System arrangements may befitted; refer to page 2-29 for more details.Depending on the unit model, there may be two independentrefrigeration systems fitted, so that high demand conditions canbe met.The controller has been designed to enable refrigeration systemoperation to be tempered to meet demand without inefficientshort-cycling of equipment.

Fig. 2-4 : Air-cooled DX refrigeration system basic circuit diagram

Air-cooled DX Refrigeration System Basic Circuit Diagram

S

FlowControl

TEV

Condenser

Compressor

Evaporator(air cooler)

Pilot line Capacityregulator

Sightglass

Oil separator1

Oil return line3

Filter /drier

Pressurerelief valve2


Liquid receiver1

Airflow

Airflow

Liquid line

Liquid line

Suction line Discharge line

Sensingbulb

Expansionline

Unit envelope

LP HP

LP HP

NOTES

Superheated vapour at discharge pressure

Subcooled liquid at discharge pressure

Subcooled liquid / vapour at suction pressure

Superheated vapour at suction pressure

Optional arrangement for fully automatic hot gasinjection for evaporator capacity control

Alternative optional arrangement of hot gasinjection for capacity reduction control, withmanually-set flow control and operationdetermined by controller strategy

1 This diagram illustrates a typical IPAC air-cooled DX refrigeration system, including oil separator and liquid receiver options.2 Safety pressure relief valves must be sized, rated and fitted according to refrigeration industry safety regulations, legislation and equipment manufacturer's instructions.3 If an oil separator is required to be fitted, the oil return line (customer supply and fit) must be sized and fitted according to the manufacturer's recommendations.


IPAC

Technical Manual

Water-cooled DX System


Cooling water (glycol solution or similar primary refrigerant) at aspecified rate and temperature (see Table 2-2) is pump-circulated (by customer system) through the plate heatexchanger.From the suction line, the compressor draws refrigerant gas(normally R 407C), compresses it and then discharges it into thedischarge line.The high pressure, superheated discharge gas flows through thedischarge line to the plate heat exchanger condenser, where thegas is cooled and condensed by relatively cool water (glycolsolution or similar primary refrigerant) flowing on the other sideof the heat exchange surface.The resulting liquid, still at high pressure, flows through theliquid line to the liquid receiver (fitted as standard), which isdesigned to accommodate all excess liquid not required in theevaporator (air cooler) when the unit is operated at belowmaximum load conditions.To ensure that only liquid reaches the thermostatic expansionvalve, the liquid line exits the liquid receiver via a dip tubearrangement.Note that because the liquid receiver cannot be isolated, there isno requirement for a pressure relief valve. However, it isrecommended that a suitably sized and rated fire-hazard safetypressure relief valve is fitted as an option.The thermostatic expansion valve meters the flow of refrigerantentering the evaporator in response to the temperature ofrefrigerant leaving the evaporator.

On entering the evaporator, the refrigerant is a saturated vapourand liquid mixture at low pressure.As the refrigerant passes through the evaporator, any liquidpresent is vaporised by extracting heat from the relatively hightemperature supply air flowing on the other side of the heatexchange surface.From the evaporator, the superheated, low pressure gas entersthe suction line and flows to the compressor again.The process is continuous while the compressor is operating.To achieve evaporator capacity control, one of two types ofCapacity Control Hot Gas Injection System arrangements maybe fitted; refer to page 2-29 for more details.Depending on unit model, there may be two independentrefrigeration systems fitted, so that high demand conditions canbe met.The controller has been designed to enable refrigeration systemoperation to be tempered to meet demand without inefficientshort-cycling of equipment.Cooling water flow and return connections are on the same faceof the plate heat exchanger and are arranged to contraflow thedirection of refrigerant flow. Because the DX refrigerant system is close-coupled within theunit and velocities are sufficient to carry oil round the system, anoil separator arrangement is not required.

Fig. 2-5 : Water-cooled DX refrigeration system basic diagram

Water-cooled DX System Basic Refrigeration Circuit Diagram

1 This diagram illustrates a typical IPAC water-cooled DX refrigeration system, including liquid receiver, water system isolating valves, and commissioning control valve and flow meter.2 An optional safety pressure relief valve must be sized, rated and fitted according to refrigeration industry safety regulations, legislation and equipment manufacturer's instructions.3 If an oil separator is required to be fitted, the oil return line (customer suppy and fit) must be sized and fitted according to the manufacturer's recommendations.

S

FlowControl

TEV

Compressor

Evaporator(air cooler)

Pilot line Capacityregulator

Sightglass

3-Wayvalve

Filter /drier


Liquid receiver1

Airflow

Liquid line

Suction line

Sensingbulb

Sensingbulb

Water return

Water flow

FlowmeterBypass

line

Expansionline

Unit envelope

LP HP

LP HP

Superheated vapour at discharge pressure

Subcooled liquid at discharge pressure

Subcooled liquid / vapour at suction pressure

Superheated vapour at suction pressure

KEY

Optional arrangement for fully automatic hot gasinjection for evaporator capacity control

Optional commissioning control valve and flowmeter

Optional water system isolating valves

Alternative optional arrangement of hot gasinjection for capacity reduction control, withmanually-set flow control and operationdetermined by controller strategy


IPAC

Technical Manual

Chilled Water Cooling System

Document 0410536

This system is illustrated in Fig. 2-6 - Chilled water cooling and LPHW heating diagram.In response to the temperature of air entering the unit, the InvictaNET controller modulates a flow control valve to meter the flow ofchilled water (or other suitable chilled medium) entering the heat exchange coil.

NOTEEffective control of air temperature relies upon the supply of low pressure chilled water at a specified constanttemperature being available to the unit.

As the chilled water passes through the cooling coil, heat is extracted from the relatively high temperature supply air flowing on the otherside of the coil’s heat exchange surface.Having passed through the cooling coil, the water then returns to the water chilling plant for re-cooling, before returning to the unitagain.Depending on the unit model, there may be two independent flow control valve / cooling coil systems fitted, so that high demandconditions can be met.As can be seen in Fig. 2-6, there is a choice of two types of optional modulating flow control valve arrangement:

• 2-way valve

• 3-way valve

For details of the modulating control valve, see page 2-25.

Fig. 2-6 : Chilled water cooling and LPHW heating diagram

Chilled Water Cooling and LPHW Heating Diagram

This diagram illustrates a typical IPAC chilled water system, including optional 3-way valve, 2-way valve, system isolating valves and commissioning flow control valve and combined flow meter.

1 If the system isolating valves option is fitted, but not the commissioning control valve and flow meter option, an isolating valve will be provided in the return line, to replace the isolating capability that would have been provided by the flow control valve.

2 The 3-way valve and 2-way valve are alternative options.

Air Heater (heat exchanger)

Airflow

Flow meter

Isolating valve1

2-Way Modulating

ValveM

3-Way Modulating

ValveM

Flow control Valve

Flow control valve1

3-WAY VALVE OPTION2

2-WAY VALVE OPTION2

Bypass line

To heating plant

From heating plant

HEATING

Air Cooler (heat exchanger)

Flow meter

Isolating valve1

2-Way Modulating

Valve M

3-Way Modulating

ValveM

Flow control Valve

Flow control valve1

3-WAY VALVE OPTION2

2-WAY VALVE OPTION2

Bypass line

To cooling plant

From cooling plant

COOLING

Airflow

KEY

Chilled water

Return water at cooling coil outlet temperature

LPHW (Low Pressure Hot Water) supply

Return water at heating coil temperature

Optional water system isolating valves1

Optional commissioning flow control valve1

and flow meter

Alternative optional arrangement of 2-waymodulating valve for basic cooling/heating capacity control

Optional 3-way modulating valve, bypass line andflow control valve for cooling orheating capacity control


IPAC

Technical Manual

Economy Cooling Options


There are two types of economy cooling option available for theIPAC range of AHUs, Fresh-Air Economy Cooling and GlycolEconomy Cooling.Both can be optimised to use the relevant cooling medium,where conditions allow, to achieve the required air condition,whilst minimising the running time of the compressor or coolingplant.The pay-back return period for the initial additional equipmentcost is achieved within two to three years typically.

Fresh-Air Economy Cooling OptionFresh-air economy cooling can be applied to either DX or chilledwater units, where the unit is either installed with its backagainst an outside wall (louvre required), or fitted with fresh-airduct (room pressure relief required).This system requires a separate modulating damper box fitted inthe return air path to the unit, plus an outside air temperaturesensor.The modulating damper box comprises a modulating damperplate and an G2 filter on the fresh-air side. The InvictaNETcontroller modulates the damper to vary the return-air /fresh-airmix to achieve optimum air temperature at a constant airflowvolume.

• For control details, refer to “Fresh-Air Economy Cooling” onpage 19 of Section 4.

Glycol Economy Cooling OptionGlycol (cooling by glycol/water solution cooled medium)economy cooling can be applied to water-cooled DX units, wherecooling coil heat rejection is capable of returning the coolingmedium at a temperature below that of room air.For this system, an additional coil, for the glycol / water coolingmedium, is included in the cooling heat exchanger coil block andfaces the DX cooling coil.

CAUTIONThe cooling medium must contain a suitableantifreeze mix otherwise the DX process mayfreeze the cooling medium and result in damage tothe unit. IPAC units have been designed for an80%/20% Ethylene Glycol mix by volume.

The arrangement is such that the return air passes through theeconomy cooling coil, where it is pre-cooled, before passingthrough the DX cooling coil, where the main cooling process, torequired temperature, takes place.

Fig. 2-7 : Glycol Economy Cooling Circuit Diagram

Glycol Economy Cooling Circuit Diagram

Flow meter

Isolating valve1

Isolating valve1

3-Way Modulating

Valve

M

Flow control Valve

Flow control valve1

To cooling plant

From cooling plant

Airflow

Chilled water

Return water at condenser coil outlet temperature

Return water at glycol cooling coil temperature

Optional water system isolating valves1

Optional commissioning flow control valve1

and flow meter3-way modulating valve, bypass line and flowcontrol valve for cooling or heating capacity control

Refrigerantreturn

Refrigerantflow

GLYCOL(Heat Exchanger)

This diagram illustrates a typical IPAC Glycol Economy cooling system, including 3-way valve, 2-way valve, system isolating valves and commissioning flow control valve and combined flow meter.

1 If the system isolating valves option is fitted, but not the commissioning control valve and flow meter option, an isolating valve will be provided in the return line, to replace the isolating capability that would have been provided by the flow control valve.

GLYCOL COOLING

3-Wayvalve

Sensingbulb

Bypass line

Bypassline

M

3-way valve, bypass line and on/off control for cooling and heating


IPAC

Technical Manual

The chilled glycol / water primary cooling medium, first passes Therefore, depending on unit application, after

Document 0410536

through the economy cooling coil, if the water temperature islower than the return air temperature, prior to passing throughthe plate heat exchanger to liquefy the refrigerant. If the water temperature is not lower than the return airtemperature, the InvictaNET controller opens a valve to divertthe cooling medium straight to the plate heat exchanger.• For control details, refer to “Glycol Economy Cooling” on

page 19 of Section 4.In this way, additional cooling by the cooling medium, that hasalready performed its condensing function, is achieved beforereturning to the cooling plant.

Humidity ControlHumidity control is an option for all units. The humidity of supplyair passing through the unit can also be monitored by thecontroller, which applies humidity control strategy to correct andmaintain air humidity at a predetermined set point.If a humidifier is fitted (see page 2-30), this can be controlled toproduce an increase in air humidity by introducing steam intothe airstream.Whether in humidifying or dehumidifying mode, the air passagethrough the unit is the same as for heating or cooling.

DehumidificationFor environments where high humidity is a problem, therefrigeration system is used to reduce and control air relativehumidity (RH %).This is achieved by passing the supply air across the evaporatorcoil, where moisture condenses onto the relatively cold surfaceof the heat exchanger.As the condensate accumulates, it forms water droplets, whichthen fall into the condensate drip tray. All resulting water thendrains from the condensate tray and passes, via a trap, toexternal drains.

NOTEBecause of the nature of the dehumidificationprocess, unless the heating option is fitted,accurate dehumidification may not achievablewithout overcooling the supply air.

dehumidification, reheating of the air may benecessary to control air temperature.

Hot Gas ReheatThis option is only applicable for DX units only and providesreheat of the air following dehumidification, when airtemperature is reduced to below the required set point.

NOTEIf primary heating is required (i.e other than fordehumidification reheat, electric heating must beinstalled in the second module (therefore notavailable on single module units).

When the controller evaluates that, because the air has beencooled to below the set point during dehumidification, reheat isrequired, a solenoid valve is energised (opened) to admitcompressor discharge gas (at high temperature and pressure) toenter the heating coil.In this way, air is reheated after cooling, by reclaiming heatdissipated from the compressor, which also saves energycompared to electrical or LPHW heating.

Network Control SystemIn multi-unit applications, where there is a master unitcontrolling several network slave units, each unit operatesindependently, but under the central control of the master unit.This ensures optimum performance of the total system and thatfailure of one unit will not affect the continued operation ofother units, provided that the power supply to the master unitcontroller remains live.To prevent excessive current from being drawn during starting,the controller starts units and their equipment in a staggered,delay-timed sequence.• For details of the starting sequence, refer to page 4-15 of the

INVICTANET CONTROLLER TECHNICAL MANUAL.

Main Components

Table 2-10 : Standard main components

Standard Main Components

Standard Main Components and Features Air-cooled DX Water-cooled DX Chilled Water

Unit CasingFinishSupply Air Fan(s)

‘V’ Belt Drive on Adjustable Slide-BasesAir Filters - G4, cleanableDifferential Pressure SwitchesCooling Coil (evaporator / heat exchanger)Condensate Drip Tray

Eaton-Williams InvictaNET AHU Controller


IPAC

Technical Manual

Table 2-10 : Standard main components


Electrical connections

Volt-free Alarm ContactsBottom ConnectionsCompressorFilter / DrierThermostatic Expansion ValveMoisture Indicating Sight GlassEvacuation and Refrigerant Charging ValvesPressure Safety DevicesModulating Flow Control Valve and Actuator

Key Operated Cam-lock Removable DoorsAirflow Failure Detection

Cardboard Sleeve / Pallet Delivery ProtectionContactors, MCBs and MPCBsInternal Unit Isolator (Handle Optional)Interconnecting wiring loomIntegrated Water-Cooled Condenser

Features and Options

Options Air-cooled DX Water-cooled DX Chilled Water

Electrical / Control Options

Phase-failure relay

Control panel coverFresh Air ControlFresh Air Control, Including Smoke DetectionDoor-interlocked isolatorMains filter kit

In-Room Remote SensorsDuct Remote SensorsWater Detection TapeAudible AlarmAlternate Display LanguagesModBus Network InterfaceTrend ControllerTrend Network Interface

Heating Options

Electric Heating - 5/10/15/22.5/30 kW Electric Finned ElementLow Pressure Hot Water Heating System

LPHW Heating Coil (heat exchanger) with 0 - 10 V Control Valve

Refrigeration Options

Capacity Control Hot Gas Injection SystemLiquid ReceiverModulating Flow Control Valve and Actuator

Standard Main Components


IPAC

Technical Manual



Oil Separator

Compressor Acoustic JacketCompressor Discharge Non-return Valve

Split Coil Rapid Dehumidification

Humidifying Options

Humidifier20% - 100% Proportional Output HumidifierAlarm Diagnostics Tools in ControllerDifferent Bottle’s for Varying Water QualitiesRemote Vapac OptionsSecond Unit OEM Option to increase dual unit options

General Options

Rear Cosmetic Cover PanelMulti-speed motors

Side Gland PlatesStainless Steel Drip Tray5 to 10 % fresh air intake, including volume damper controlAnti-vibration mountingsDual Pulley Drives (standard on modules > 40kW)

Low Display MountingLifting ChannelsCondensate PumpClass 1, energy-efficient motorsCustomised colours

Pipework

Airflow Options

Upflow - Bottom ReturnUpflow - Front ReturnUpflow - Rear Return (Not size 4)Downflow - Top ReturnDownflow - Front ReturnDownflow - Rear Return (Not size 4)

Filtration Options

Coil Face Filtration - G4 or F5. F6 or F7 with G4 pre-filterRemote Filtration - F6-H8 Deep Panel Filter in secondary section

Fluid Control Options

2 Way or 3 Way Control ValveWater System Isolating Gate Valves

Upflow Discharge Options

Flexible duct connectors (upflow units only)Non-Return Dampers

Options Air-cooled DX Water-cooled DX Chilled Water


IPAC

Technical Manual

Unit Casing NOTE


The IPAC units are constructed using pre-coated outer panels,light grey finish to BS 00A05.Internal metalwork is of galvanised steel construction. External panels are insulated with fire-retardant, vapour-proof,closed-cell, high-density foam, to maximise thermal insulationwhile minimising noise breakout.

FinishExternal metalwork surfaces are coated in a light-grey (BS 4800Grey 00A05), durable, protective paint as standard.Internal panels are of galvanised steel.

Customised coloursIf an alternative colour option is required, metalwork is primedwith etch primer and then given one coat of finish paint.

Supply Air Fan(s)Each room air supply fan will deliver air against an assumedstandard external static resistance pressure of 70 Pa.Alternative external pressure ratings can be achieved bychanging the fan drive ratio and, if necessary, the drive motor.IPAC 15-1, 22-1, 30-1 and 40-1 units have a single, forward-curved, centrifugal fan, coupled, via a wedge belt drive, to atotally enclosed, fan ventilated, IP54 rated, motor.IPAC 50-1 and 60-1 units have a duplex fan (two fans drivenfrom one shaft). Each unit has a single motor mounted on anadjustable base to enable correct tensioning of the wedge drivebelts.Each unit has been designed with the recommended number ofbelts for the shaft motor power. Redundancy in belts is availableas an option. Twin module units may have a combination of theabove.These drives contain alternative pulleys/taperlocks, belts and fanmotors, where required.

This may increase maximum running currentsshown in duty tables and increase noise levels.

Multi-speed motorsMulti-speed motors are available. Please contact Eaton WIlliamsfor further information.

Class 1, energy-efficient motorsAs an option, supply fan drive motors are available to Class 1Energy Efficiency.

‘V’ Belt DriveEach supply air fan is driven by ‘V’ belts for increasedperformance and reduced loss of power.

Air FiltersAs standard, air filters are fitted internal to the unit in the supplyair path, prior to the evaporator coil, to filter the air before it isconditioned and then discharged into the room, see Table 2-11on page 2-23.

As an option, filters may be installed externally to theunit, in a High-efficiency Filter Section - see page 2-36

There are various filter grade options, however, it is worth notingthat filters above grade F6 would require relatively frequentreplacements, as the holding capacity of panel filters at this highefficiency is low.For applications requiring such high-efficiency filtration, theexternal High-efficiency Filter Section (see page 2-36) should befitted.

NOTEThe fitting of panel filters instead of pad filters iseasily carried out and requires only a change ofretaining clips, with no alteration necessary to theframework.

Differential Pressure SwitchesBoth airflow detection and dirty filter condition are monitored inboth cabinets (where applicable). This is achieved by sensing thedifferential pressure across the filter / coil section of the units.

They are factory set but can be adjusted on site if required.

Table 2-11 : Alternative air filter options

Alternative Air Filter Options

Panel Description Fitting Notes

G4 (Standard) 50 mm thick panel G4 panel filter

Two spring clipsper filter

Cleanable, synthetic, cut pad, fire-rated to DIN 53438

F5 50 mm thick panel G5 panel filter -

F6Cleanable G4 pad pre-filter, with 50 mm thick F6 panel filter

This option initially reduces unit external pressure development by 55 Pa


This option initially reduces unit external pressure development by 130 Pa


This option initially reduces unit external pressure development by 220 Pa.Where necessary, the reduction in external pressure developed must be compensated by selecting an alternative fan drive to standard.


IPAC

Technical Manual

Cooling Coil Eaton-Williams InvictaNET AHU Controller

Document 0410536

The standard cooling coil is manufactured from copper tubeswith aluminium fins.

As an option, the coil can be supplied as copper/copper, orcopper/copper-electro-tinned; note that this will increasethe weight of the unit.

A water-tight drip tray, fitted below the coil, collects thecondensate. The cooling coil, condensate drain tray, plastic drainpipework and drain trap are illustrated in Fig. 2-8 and Fig. 2-9 onpage 2-24.As it accumulates, water is drained off via two outlets andpasses through the internal drain trap, before exiting the unit tothe external drain facility (by others).

NOTEThe unit has an internal drain trap. An externaltrap should NOT be fitted.

Condensate Drip TrayAs standard, the condensate tray is manufactured fromgalvanised steel plate, with stainless steel available as an option.

The InvictaNET AHU controller is a purpose-designedLONWORKS™ microprocessor, which fully complies with EECdirectives for electromagnetic compatibility (EMC).The controller includes the following features as standard:• Temperature and humidity set point adjustment• Dead band adjustment• Proportional band adjustment• Alarm band adjustment• Fault and service alarm volt-free contacts• Winter low pressure switch delay timer adjustment• Start delay timers (to minimise starting current demand)• Historical alarm logging• LONWORKS™ network communications• Stand-alone or Master/Slave control• Run/standby and duty rotationsThe controller is fully described in Section 4 - INVICTANETCONTROLLER TECHNICAL MANUAL.

Electrical connectionsAll terminals for customer connection of power supply andcontrol circuits are adjacent to the cable entry point, inside thelower left hand side of the unit.

Volt-free Alarm ContactsAs standard, all IPAC units are fitted with 2 sets of terminalconnections for urgent and non-urgent (fault and servicealarms). When the controller is in an alarm situation the alarmcontacts will be held in the unhealthy condition until the alarmis cleared.Remote alarms can either be closed or open circuit healthy.

Bottom ConnectionsThe standard service connections are at the bottom of the IPACunits, with the electrical connections located to the left and theservice to the right.Two blind gland plates are provided for site cutting to suitrequirements.As an option, side gland plates can be provided.

CompressorEach unit’s refrigeration system uses a high-efficiency scroll-typecompressor, fitted with an internally relieving pressure reliefdevice and integral sump.• Crankcase oil heaters are available as an option, for

circumstances that necessitate their use; refer to“Compressor Crankcase Oil Heater(s)” on page 6-7of Section 6

Compressors are installed on anti-vibration mountings tominimise noise and vibration levels.• Capacity control is as described under and Section 4 -

Compressor Capacity Control .

Fig. 2-8 : Drain pipe Layout (DX unit shown)

Fig. 2-9 : Condensate drain trap (DX unit shown)


IPAC

Technical Manual

Moisture Indicating Sight GlassFig. 2-10 : Liquid line components


Filter / DrierThe filter / drier is located before the sight glass and thethermostatic expansion valve, as shown in Fig. 2-10.The filter / drier ensures that any moisture, that may haveentered the system during charging, is removed.It is essential to ensure that there is no free moisture circulatinground the refrigerant system, otherwise:• The moisture may otherwise freeze and cause a blockage,

usually at the TEVOr, in the worst case:• Moisture may affect the insulation of the compressor drive

motor, causing a burn-out

Thermostatic Expansion ValveThe thermostatic expansion valve, which has a fixed orifice andadjustable superheat, maintains the design degree of superheatat the evaporator outlet.Liquid line main components are shown in Fig. 2-10.A remote sensing bulb is securely fixed to the evaporator outletpiping, in a position where the superheat can be correctlysensed. The thermostatic expansion valve incorporates anexternal equaliser line.

The sight glass is located between the Filter / Drier and theThermostatic Expansion Valve, as shown in Fig. 2-10.The sight glass performs two functions:• It enables the condition of the refrigerant to monitored and

provides visual indication of the presence of any moisture.Bubbles in the sight glass could be due tooperating under hot gas injection and may notnecessarily mean the system is undercharged.

Evacuation and Refrigerant Charging ValvesTo facilitate evacuation and refrigerant charging, and to allowmonitoring, two Schraeder type valves are fitted to eachrefrigeration circuit; one each on the high pressure (HP) and lowpressure (LP) sides of the system.

Pressure Safety DevicesIn adverse operating conditions, excessively high discharge orlow suction pressures can develop, which can reachunacceptable levels. To protect against this and consequentialdamage it may cause, high and low pressure cut-out safetycontrols are fitted as standard, as described in Section 4 -INVICTANET CONTROLLER TECHNICAL MANUAL.These pressure switches are non-adjustable and self-resetting.However, the system should only restart after the cause of theadverse condition has been rectified and the alarm is cleared atthe controller.

Modulating Flow Control Valve and ActuatorThis electronic valve and actuator illustrated, is used to controlthe flow of chilled water or low pressure hot water (LPHW) to thecooling coil or heating coil (if fitted).

The InvictaNET AHU Controlleruses a Proportion, Integral andDerivative (PID) algorithm todetermine control response andprovides a 0 to 10 volt signal tomodulate the flow control valveaccording to demand.The 0 to 10 volt signal providedby the controller is directlyproportional to the positioningrange of the flow control valve.The IPAC range offers a choice ofeither a two-way (standard) orthree-way control valve. Two-

way valves can be used on systems that have variable sppedpumps to maintain constant pressure drop through the circuit.For constant speed pump systems, the third outlet from thethree-way valve is used to bypass the coil.The bypass leg is designed to produce a balanced pressure dropthrough the system to match the coil, regardless of operatingmode.

1. Thermostatic expansion valve2. Equalising line3. Moisture indicating sight glass4. Liquid line5. Filter/drier6. Suction line7. Temperature sensing phial location8. Expansion line to evaporator


IPAC

Technical Manual

Key Operated Cam-lock Removable Doors Integrated Water-Cooled Condenser

Document 0410536

Each door is secured shut by means of three door-lockingmechanisms, which, compresses the door sealing gasket topreventing air and noise leakage.After unit installation, all access for maintenance is via the frontof the unit. Each unit is supplied with a door lock key.

Airflow Failure DetectionAs standard, each unit module is fitted with an air pressureswitch to monitor airflow.

Cardboard Sleeve / Pallet Delivery ProtectionAs standard, units and condensers are packed on pallets andhave cardboard protective sleeving and polystyrene cornerpacking.Export packing is available on request.

Contactors, MCBs and MPCBsTo protect against electrical damage, all unit electrical plant isindividually switched by contactors, MCBs and MPCBs.As shown in Fig. 2-12 on page 33, these items are located on afixed chassis, located directly behind the front access door.

Internal Unit IsolatorPositioned within the electrical chassis is a 3 phase isolator forcustomer connection.A door-interlocked handle is available as an option.

Interconnecting wiring loomTo facilitate interconnecting wiring between twin modules,easily accessible, rail-mounted terminal blocks for all necessarycircuits are provided in each cabinet.An optional, factory-made interconnecting wiring loom, suitablefor adjacent cabinets, is available as an option.

Any IPAC unit can be fitted with an integral, matched, stainlesssteel brazed plate heat exchanger, complete with pressuresensing diverter valves and associated pipework; see Fig. 2-5 onpage 2-17.There are two options for the diverting valve:

• 3-Way Valve - for constant flow pump systems

• 2-Way Valve - for variable flow systems

A commissioning set comprising a flow measuring variableorifice double regulating valve and shut-off valves is availablefor either of the units as an option. Due to space limitationssome of these components may need to be fitted on site externalto the units. • Water flow rates for integrated plate heat exchanger

condensers are shown in Table 2-8 on page 2-15.


Phase-failure relayThis option is recommended for any application where thequality of the electrical supply is not guaranteed.This DIN rail-mounted relay protects units and offers thefollowing features:• Monitors the phase-to-phase supply• Adjustable under-voltage and over-voltage trip levels• Phase sequence and Phase-failure detection• Adjustable time delayWhen the device is triggered, the individual unit enters shut-down mode, allowing other units in a network to operate tocompensate for the loss of duty.

Control panel coverThe electrical section is accessible behind a key-locked door.However for added protection (for example, to provide increasedelectrical safety for a Maintenance Engineer during routineservicing), an additional hinged cover can be fitted over theelectrical chassis.

Fresh Air ControlTo be used with the 100 % Fresh Air Modulating Section (seepage 2-36) or remote dampers (contact Eaton-Williams), thisoption utilises an additional sensor to control a 0 to 10 V outputfor a modulating damper.This is used to draw in outside air for cooling / heating and usedwhere energy savings can be made compared to onlyconditioning the return air.Control set points inhibit use of fresh air in close controlapplications when either the temperature or humidity areheading out of predetermined limits. If this option is selected,remote room pressure relief is required.


IPAC

Technical Manual

Fresh Air Control, Including Smoke Detection ModBus Network Interface


This option is the same as the Fresh Air Control (see page 2-26),but includes a smoke detector on the outside air path, as closeas possible to the point of entry.If smoke is detected in the incoming airstream, this controloverrides (via hard-wired relays) the unit controller and shuts thefresh air damper to prevent further entry of outside air. An alarmsignal is generated by the device, via its own volt-free relaycontacts.When the sensor detects that the air is clear of smoke, the deviceresets and normal operation resumes.

Door-interlocked isolatorFor safe electrical isolation of units, Eaton-Williams recommendsthat an optional, local door-interlocked isolator is fitted.This device will isolate the unit when the door handle is turnedto open the unit door panel.

Mains filter kitIPAC units fitted with the InvictaNET controller pass thefollowing EMC tests:• Immunity: EN61000-6-2:2001• Emissions: EN61000-6-3:2001Should an installation have known problems with its electricalsupply, then the factory-fitting of an EMC kit is recommended, tominimise any problems with regards to EMC interference.The EMC kit is also available as a site retro-fit kit, should a unitsuffer from EMC susceptibility after installation.

In-Room Remote SensorsShould the positioning of the IPAC units cause unsuitable roomcondition readings, a remote room sensor is available to provideaccurate location sensing (site fitted and wired).

Duct Remote SensorsShould the positioning of the IPAC units cause unsuitable roomcondition readings, a remote duct sensor is available to provideaccurate location sensing (site fitted and wired).

Water Detection Tapewater detection tape can be supplied for flood detection whichis 5 metres long - one per unit module, plus PCB for the mastermodule.

Audible AlarmAs part of the graphical display assembly, a buzzer can be fitted.This will be activated should the controller be in alarm condition.It can be muted by pressing the OK button (EW Controller only).

Alternate Display LanguagesThe InvictaNET controller can be configured to display in eitherEnglish or Chinese. Other languages may be available at a laterdate, please check with Eaton-Williams Head Office if required.

When interfacing with the InvictaNET Echelon network via a PCbased BMS system, a serial interface board is available. This is written using the ModBus protocol and has connectivityfor RS232 or RS485 (jumper settable).One interface board is required per network (up to 9 AHU’s). TheModBus interrogation software is by others.

Trend ControllerWhere required, the IPAC units can be provided with a TrendIQ204 controller with custom designed software to meet theindividual site requirements.Please note, if this option is used, separate documentation willbe required as this manual is solely based on the InvictaNETcontroller.Please contact Head Office for further information.

Trend Network InterfaceWhen interfacing with the InvictaNET Echelon network via TrendBMS system, a combination of the EW Serial Interface Board anda Trend Interface Device is available. Custom designed softwaremakes the InvictaNET network visible on the Trend Network asan IQ Device.Further details and compatibility information is available fromHead Office.

Heating Process

Electric HeatingSingle or two-stage electrical heating can be provided as anoption.As described under Dehumidification on page 2-20, where airtemperature and humidity are both critical, it is necessary toreheat the air after dehumidification. In this case, the correctamount of reheat capacity must be available.Heaters can of course be used for heating-only (i.e. nodehumidification) cycles.The design of the electric heating in IPAC units is flexible andcomprises multiples of 2.5 kW, finned resistance elements,balanced, where possible, over the three electrical phases.The standard heating option is a single bank of heaters in thefirst module of a twin unit. However, installed heating can beconfigured to match demand, with options for two-stage or four-stage heating.

For details of capacity and heater bank arrangements,refer to Table 2-13 on page 2-28For heater control philosophy, refer to Section 4 - ElectricalHeating

Where the electrical heat load is higher than standard for aparticular unit, some of the heating elements may be fitted intothe second module. Each applicable module is fitted with two self-resetting, over-temperature thermostats, to ensure safety, should a faultcondition arise.


IPAC

Technical Manual

Low Pressure Hot Water Heating System The duty of the LPHW coil is rated to match the dehumidification

Document 0410536

Both upflow and downflow master units can be supplied with anLPHW (Low Pressure Hot Water) coil fitted to the air-off side ofthe cooling coil. Duties are shown on Table 2-12 on page 2-28.This heating option includes a 2-way or 3-way modulating valve,proportionally controlled to enable the LPHW coil to act as theprimary heating source, as well as a re-heat coil during de-humidification duty.

available on the IPAC units. As a special, a larger coil andpipework arrangement could be installed if required; refer toEaton-Williams for details.

This system is illustrated in Fig. 2-6 - Chilled water cooling andLPHW heating diagram and comprises similar components,arrangement and flow control principles.In response to the temperature of air entering the unit, theInvictaNET controller modulates a flow control valve to meterthe flow of LPHW entering the heat exchange coil.

As the hot water passes through the heating coil, heat transfersfrom the hot water to the relatively low temperature supply airflowing on the other side of the coil’s heat exchange surface.Having passed through the heating coil, the water then returnsto the water heating plant for reheating, before returning to theunit again.

Table 2-12 : LPHW duties

LPHW DutiesRated at design airflow, with air on at 20 ºC and water temperatures on/off temperatures of 70/60 ºC

IPAC Model 15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2

Total Heating kW 9 13 16 17 22 24 35 30

Water Flow Ratel/s 0.21 0.33 0.38 0.42 0.53 0.59 0.86 1

l/hr 760 1177 1364 1519 1908 2124 3096 2668

Hydraulic Pressure Drop kPa 14 9 22 14 30 22 30 30

IPAC Model 60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2

Total Heating kW 42 31 37 44 57 71 78 85

Water Flow Ratel/s 1.03 0.76 0.91 1.06 1.39 1.72 1.89 2.06

l/hr 3708 2729 3272 3816 5004 6192 6804 7416

Hydraulic Pressure Drop kPa 40 14 30 30 30 30 40 40

Table 2-13 : Capacity and stages of electrical heating

Capacity and Stages of Electrical HeatingAll elements are 2.5 kW rating

CAPACITYkW

NUMBER OF ELEMENTS AND CONTROL BANKS

SINGLE STAGE MULTI-STAGE

5 2 elements in a single bank 1 element in the first bank, 1 element in the second bank

7.5 3 elements in a single bank 1 element in the first bank, 2 elements in the second bank

10 4 elements in a single bank 1 element in the first bank, 3 elements in the second bank

156 elements in a single bank

(not applicable to IPAC 15-1 or IPAC 30-2)3 elements in the first bank, 3 elements in the second bank

(not applicable to IPAC 15-1)

22.5 -1 element in the first bank, 6 elements in the second bank

(not applicable to units <40 kW)

30 -6 element in the first bank, 6 element in the second bank

(not applicable to units <60 kW)


IPAC

Technical Manual

LPHW Heating Coil Liquid Receiver


For LPHW heating, the standard heat exchange coil ismanufactured from copper tubes with aluminium fins.• As an option, the coil can be supplied as copper/copper, or

copper/copper-electro-tinned.

Capacity Control Hot Gas Injection SystemEither of two types of capacity control hot gas injectionarrangements may be fitted as an option.Only operative during cooling demand only, these arrangementsare both illustrated in:

• Fig. 2-4 - Air-cooled DX refrigeration system basic circuit diagram, see page 2-16

• Fig. 2-5 - Water-cooled DX refrigeration system basic diagram, see page 2-17

Options are:

Fully automatic hot gas injection

This system operates independently of the controller andmodulates in response to sensed suction pressure, to meterthe required volume of hot gas into the expansion line.

In this way a false evaporator load is created, which enablesthe compressor to continue operation at times of low load,when it would otherwise be stopped by the controller becauseof inadequate demand.

When correctly adjusted for optimum performance, thisarrangement offers superior control of evaporator capacityand, in turn, closer control of air temperature.

Manually preset hot gas injection flow control,with operation determined by the unit controller

This system provides master units with two stages of capacitycontrol and master/slave units with four stages;for further control details, refer to .“Compressor CapacityControl” on page 4-16 of Section 4.

The hot gas injection line is fitted with a solenoid valve and aflow control valve, which is set during commissioning toprovide the appropriate injection flow, which is adjustablefrom 0 % (valve shut) to approximately 40 % (valve fully open)of discharge gas flow.

At a predetermined low load condition, the controller opens(energises) the solenoid valve to allow discharge gas to enterthe expansion line.

2 Way or 3 Way Control ValveThe IPAC range offers a choice of either a two-way (standard) orthree-way control valve. Two-way valves can be used on systemsthat have variable spped pumps to maintain constant pressuredrop through the circuit.For constant speed pump systems, the third outlet from thethree-way valve is used to bypass the coil.The bypass leg is designed to produce a balanced pressure dropthrough the system to match the coil, regardless of operatingmode.

A horizontal liquid receiver is recommended for eachrefrigeration circuit having a pipe run of greater than 30 metres.• For further information, refer to: Air-cooled Direct Expansion

(DX) System on page 2-16, Water-cooled DX System onpage 2-17, and “Liquid Receiver” on page 6-6 of Section 6.

The liquid receiver is a site-fit option, which should be installedat the liquid outlet from the condenser.

NOTEIt is recommended that a suitable pressure reliefdevice is fitted with this option

Oil SeparatorAlthough not normally required on IPAC units, compressor-matched oil separators for long pipe runs are available for siteinstallation.One oil separator would be required for each refrigerationcircuit.

Compressor Acoustic JacketTo minimise noise breakout, an acoustic jacket can be fitted toeach compressors as an option.

NOTEThe fitting of an acoustic jacket is recommendedfor upflow front return units, where noisebreakout may be an issue.

Compressor Discharge Non-return ValveOn installations where there is risk of liquid (resulting fromcondenser low temperature) migrating to the compressor duringan off-cycle, the optional discharge non-return valve should befitted.

Split Coil Rapid DehumidificationSplit coil rapid dehumidification is available. Please contactEaton WIlliams for further information.

Pressure ReliefEaton-Williams recommends that a pressure relief kit option isfitted to each refrigeration circuit.

WARNINGDepending on system design and/or total chargeweight, pressure relief may be mandatoryaccording to safety legislation.Pressure relief devices must be sized, rated andinstalled according to industry safe practice andlegislation.

The pressure relief kit comprises a pressure relief device, burstingdisc and rupture indicator. If system pressure rises to a predetermined value, the pressurerelief device will open, exposing the bursting disc to systempressure.


IPAC

Technical Manual

If the bursting disc ruptures (at a predetermined pressure), Back-draught dampers (upflow units only)

Document 0410536

excess pressure will be relieved to atmosphere until systempressure returns to a safe level. The pressure relief valve willthen close so that further loss of refrigerant to atmosphere isavoided.The rupture indicator provides a visual signal that pressurerelieving has occurred and that a new kit is required to be fitted(after rectifying the cause of the excessively high pressurecondition).

Water System Isolating Gate ValvesTo enable the unit to be isolated from the water system, gatevalves can be provided as an option; for water chilled or chilledwater units only; refer to Fig. 2-5 and Fig. 2-6, as applicable.

Commissioning SetThis option can be used to set the design flow rate through theunit during commissioning of water chilled or chilled water unitsonly; refer to Fig. 2-5 and Fig. 2-6, as applicableComprising water system isolating gate valves and a D931 flow-measuring double-regulating balancing valve, complete withfixed orifice flow measurement tappings on the return leg.

Flexible duct connectors (upflow units only)For applications where an upflow unit is ducted straight from thefan outlet, optional flexible duct connectors are available, whichreduce vibration transmission through the ductwork and alsosimplify installation.The ductwork connection is a 30mm Doby 'slide-on' flangesystem, which conforms fully to HVCA specification DW142 forrectangular duct connections.

For applications where units discharge into common ducting, ifthere is the possibility of air recirculation while any unit is instandby or shut-down mode, it is recommended that optionalback-draught dampers are fitted at the fan discharge.

Airflow Options

HumidifierThe optional Vapac® humidifier is a fully integrated system formaintaining and controlling air humidity.The humidifier comprises a cylinder, in which electrodes areinserted. When electrical power is applied to the electrodes,energy passes between them, causing the water to boil andvaporise, producing steam.The steam leaves the cylinder from the top and is released, via amanifold, into the air stream passing through the unit.

Table 2-14 : Flexible duct connection sizes

Flexible Duct Connection Sizes in mm

DUCT DIMENSION

IPAC MODEL

15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2

Height 150

Unit

Module

Width 420 457 457 420 667 457 1335 667

Depth 670 670 670 670 670 670 720 670

Unit

Module

Width - - - 420 - 420 - 420

Depth - - - 670 - 670 - 670

DUCT DIMENSION

IPAC MODEL

60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2

Height 150

Unit

Module

Width 1335 457 667 667 1335 1335 1335 1335

Depth 670 670 670 670 670 670 670 670

Unit

Module

Width - 457 457 667 667 1335 1335 1335

Depth - 670 670 670 670 670 670 670

Fig. 2-11 : Airflow path configurations

Airflow Path Configurations

DischargeAir

DischargeAir

DischargeAir

DischargeAir

DischargeAir

DischargeAir

FrontReturn

BottomReturn

TopReturn

BackReturn

BackReturn

Upflow Configurations

Downflow Configurations

FrontReturn

BackReturn


IPAC

Technical Manual

• For high humidification demand applications, the second Rear Cosmetic Cover Panel


module of a twin unit can also be fitted with a humidifier, asan option.

20% - 100% Proportional Output HumidifierThe InvictaNET Controller will attempt to balance the requiredhumidification demand by varying the output of the steamhumidifier from 20% to 100% of the available capacity. This is achieved by varying the water quantity and quality withinthe cylinder.

Alarm Diagnostics Tools in ControllerBy analysing feedback from the cylinder, the controllerrecognises various alarm states possible with the humidifier anddisplays them on the screen and extending remote alarms whennecessary.

Different Bottle’s for Varying Water QualitiesA medium conductivity cylinder is provided with the humidifieroption as standard. To suit particular site water qualities,alternastive cylinders can be provided.If the requirements are known prior to manaufacture, the unitcan be supplied with the most appropriate cylinder at this stage.Using the correct cylinder will both extend the life of the cylinderand provide better control of the environment.Please contact Head Office for further information.

Remote Vapac OptionsWhere the limited capacity of internal humidifier is insufficientfor the system design, a range of options are available. Aselection of Vapac standalone humidifiers can be networked tothe InvictaNET Controller and can discharge steam either directlyto the room (room distribution unit, RDU) or injected into thesupply duct of a system.Control and alarms from the remote humidifer are shared withthe AHU display.

Second Unit OEM OptionIn dual cabinet units a second OEM humidifier can be factoryfitted into the second cabinet to increase the units output.

Where the units are to be installed in the centre of a room,cosmetic cover panels to match the overall unit finish can befactory fitted.

Multi-speed motorsMulti-speed motors are available. Please contact Eaton WIlliamsfor further information.

Side Gland PlatesAs service connections may be required to pass throughenclosed sections, each section can be supplied with a glandplate on either side, for ease of site service connection.This design reduces the discharge pressure drop and under-floornoise levels. It can be used to discharge air to the rear of theunits, as an alternative to the normal front-supply arrangement.* Not available on water cooled condenser versions

Stainless Steel Drip TrayAs an option, the drip tray is available manufactured fromstainless steel.

5 to 10 % fresh air intake, including volume damper controlAn IPAC unit can have a 200 mm x 200 mm volume-controlleddamper fitted to either the rear or the side of the unit. Oncebalanced, the unit will draw approximately 5 % fresh air to theunit, to help attain the recommended air changes per hour for agiven room environment.The fresh air inlet is supplied complete with a replaceable pre-filter; for details of the exact location of the fresh air entry points,contact Eaton Williams or their authorised agents.

Anti-vibration mountingsAs an option, for applications where vibration transmission tosurroundings must be kept to a minimum, anti-vibrationmountings (AVMs) can be fitted to fan drive assemblies.

Dual Pulley DrivesFor cabinets of duties less than 40kw, the fan drives are selectedas single belts, these can be replaced by dual belt drives wherespecified.

Low Display MountingWhere the units are positioned above floor level, the display canbe lowered 600mm to compensate.

Lifting ChannelsA set of galvanised steel lifting channels is available to lift theunits off of their pallets without damaging the units. Please referto the Installation Section for correct use.

Condensate PumpTwo types of optional condensate pump are available:• Hot condensate pump• Cold condensate pump

Table 2-15 : Humidification capacities

Humidification Capacities

CAPACITYkg/hr

NUMBER OF ELECTRODES

< 53-electrode Vapac cylinderCan be fitted to all models

< 93-electrode Vapac cylinder

Not applicable to single module units <30 kWNot applicable to dual module units <45 kW

< 153-electrode Vapac cylinder

Not applicable to single module units <60 kWNot applicable to dual module units <100 kW


IPAC

Technical Manual

Application and suitability are dependent on whether drainage This pump is capable of holding 2 litres of water and can pump

Document 0410536

by gravity can be achieved and whether a humidifier is fitted.

Class 1, energy-efficient motorsAs an option, supply fan drive motors are available to Class 1Energy Efficiency.

Customised ColoursThe standard pre-coated steel used in the cabinet constructioncan be oversprayed with any RAL or BS colour at additional cost.

PipeworkPipework is manufactured from refrigeration quality coppertube. Connections are hermetically sealed by solder/brazedjoints. After pipework assembly, the system is pressure tested.Suction lines are insulated with a closed-cell, synthetic rubberinsulation material, which is jointed and vapour-sealed.

Auxiliary HumidificationOn twin module units, if humidification demand is greater thanthe standard output, a second humidifier can be fitted to thesecondary module. The secondary humidifier contains its ownEchelon controller works in tandem with the InvictaNETcontroller to meet demand. The size of the secondary humidifieris limited by module cabinet size into which it is being installed.Where the installation would benefit from steam being injecteddirectly into a duct, an additional (or alternative) humidifier,controlled by the InvictaNET controller, can be supplied; fordetails, refer to Eaton-Williams.

Hot condensate pumpFor use in full air-conditioning units, where the internally trappedcondensate pipe and Vapac humidifier outlet cannot be gravityfed to a suitable drain point.Pump component materials are suitable for water hightemperatures that can be produced by the humidifier.Although this is a site-fit option, terminals are fitted to the IPACunit for the power supply, and connection for the fault relay, intothe water detection input of the controllerThis pump is capable of holding 4 litres of water and can pumpagainst a nominal head of 6 metres.

NOTEPlease note that a non-return valve may need tobe fitted in the external pipework on site (byothers) as this is not supplied with this pump.

Cold condensate pumpFor use in non-humidifying units, where the internally trappedcondensate pipe cannot be gravity fed to a suitable drain pointa cold water condensate pump is supplied.

CAUTIONA cold condensate pump is not suitable for use inunits fitted with a humidifier, where water hightemperatures can damage pump components.

Although this is a site-fit option, terminals are fitted to the IPACunit for the power supply, and connection for the fault relay, intothe water detection input of the controller.

against a nominal head of 4 metres.

Flood DetectionIf required, an optional condensate flood detection device can befitted. This could be from either an optional water detectiontape (5 metres long - one per unit module, plus PCB for themaster module), or, an alarm signal from a condensate pump(optional).

NOTEIf supplied by a third party, the device mustprovide a volt-free digital input, where:

• Open circuit = healthy

• Closed circuit = fault

If a flood is detected, the cooling process and humidifier (iffitted) stop, so that further flooding is avoided (configurable).

For details on connection and operation, refer to Section 4- INVICTANET CONTROLLER TECHNICAL MANUAL and theunit wiring diagram.

Electrical EquipmentElectrical equipment, specifications and options are as follows:External electrical connections are:

380 to 415 volt, 5-wire, 3-phase, neutral andearth mains supply

Remote alarm monitoring.

Remote start/stop control functions.

Emergency and fire shutdown functions.

• IPAC units are all designed for minimum power input.• The control panel is wired via clearly labelled terminal blocks,

enabling easy modification / replacement of control systemcomponents.

• All components are internally wired to terminals. Anyexternal interconnecting wiring must be made, by customer,to local regulations.

• In a twin module unit, interconnecting wiring is terminated,in both modules, to a numbered terminal rail, for customerinterconnection at site.

• All controls are operated from a 24 V ac transformer supply.• The equipment will, under all conditions, function within the

limits required by Electromagnetic Compatibility StandardsBSEH50081-1 and BSEH50081-2.

• Wiring cable is PVC insulated to BS 623 or BS 6004, asappropriate, and installed in accordance with BS 7671.

• Conductors for auxiliary purposes have a minimum crosssection of 0.5 mm2.

• Except for the 3-phase supply, conductors are identified bycolour coded cables or by numbered ferrules, enabling easyidentification and reference to the circuit diagram.


IPAC

Technical Manual

Fig. 2-12 : Electrical chassis general arrangement


• Where cables are grouped together in runs and subject tomovement, they are suitably secured and protected frommechanical abrasion by a PVC sheath.

• Supply to the compressor(s), fans, heaters and Vapac unit isvia approved protective devices.

• All terminal blocks are mounted on rails, clamped tightlytogether using intermediate end-brackets, where required.

• Terminals are designed to accommodate oversized cables, toensure that voltage drops can be kept to a minimum.

• The standard service connections are through the base plinth.Where this is not convenient (i.e. an upflow front-return unit),as an option, side panels of the unit can have gland platesfitted for side service entry.

Air Movement Options

Front / Rear ReturnFront return air entry is available as an option on the majority ofthe range of IPAC units, however this option is not available onthe following small units: IPAC 15-1, 30-2, 45-2, 55-2For units with the front return option, rounded slots are punchedinto the front panels, to maximise return air area. Low PPI filtermedia is fitted behind these holes to enhance the appearance.It is recommended that the Compressor Discharge Non-returnValve option (see page 2-29) is fitted to units having upflowfront return, to minimise compressor breakout noise.Rear return air entry is available on the majority of the range ofIPAC units, however this option is not available on the following:

Units fitted with a water cooled condenser, IPAC 50-1, 60-1,90-2, 100-2, 110-2 or 120-2 units.

For these, the turning section should be used instead.

1. Internal wiring and fuses.2. MPCB's for: Fan 1 & 2 Compressor 1 & 2 Heater stages 1 & 2 Humidifier Condenser3. Internal wiring terminals.4. Earth Terminal Bar.5. Contactors for: Condensers 1 & 2 Humidifier Heater stage 1 & 2 Compressor 1 & 2 Fans 1 & 2

6. Power out for:Sump pumpModule 2 Fan 2 (if fitted)Module 2 Compressor 2 (if fitted)Module 2 CGH 2 (if fitted)Condensers

7. Incoming power supply to Isolator.8. Transformer 0 to 480/9/24 V ac.9. Flow & Filter Air Differential

Pressure switches.10. Internal wiring for Module 2.11. Wiring for Alarms, Shutdown

and Water Detect.12. InvictaNET controller daughter board.13. InvictaNET controller mother board.

21

5

13

12

4

3

9 611 8 710


IPAC

Technical Manual

On downflow units, the change from top to rear return is via a WARNING

Document 0410536

moveable plate. Configuration of upflow units must be specifiedat the time of ordering.Typically front return units will have a greater noise level thanfigures generally given for the rear return units.

* Not available on water cooled condenser versions

Emergency ShutdownIn an emergency, the unit must be shutdown by using thequickest means possible.

In an emergency, do NOT attempt to use controllerfunctions to shutdown equipment, as this willinitiate a controlled shutdown that is unlikely tobe effective immediately.

It is recommended that an optional external Emergency Stopbutton is fitted, which when pressed will interrupt the powersupply, shutting down the unit(s).

Fire ShutdownAn optional fire shut down facility may be fitted at the site andwired into unit terminalsIf a fire is detected and triggers the system, it will interrupt thepower supply to the controller, shutting down the unit and anynetwork slaves.

For details on connection and operation of both, refertoSection 4 - INVICTANET CONTROLLER TECHNICALMANUAL and the unit wiring diagram.

Ancillary OptionsA range of ancillaries is available for each of IPAC unit and themost suitable choice is dependent on the particular applicationand installation. Eaton-Williams Engineers will be pleased tooffer advice as to the most suitable selections.If a twin module unit is selected, the base is supplied in twosections, allowing for unit modules to be installed in separatepositions.All ancillaries are despatched with two locating pins, which fitinto corresponding holes in the IPAC unit frame, to locate theextra sections.

NOTEThe supplied gasket seal must be used betweenany mating sections to eliminate air by-pass noise.As standard, unit module sections are not boltedtogether.

Table 2-16 : Front / rear return availability

Front / Rear Return Availability

RETURN ARRANGEMENT

IPAC MODEL

15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2

Vertical

Front - Upflow

Front - Downflow

Rear - Upflow*

Rear - Downflow

RETURN ARRANGEMENT

IPAC MODEL

60-1 60-2 70-2 80-2 90-2 100- 110- 120-

Vertical

Front - Upflow

Front - Downflow

Rear - Upflow*

Rear - Downflow*

Table 2-17 : Available ancillaries and Section Heights

Standard available Ancillaries and Section HeightsDimensions in mm

DimensionOpen

Frame

Open

Frame with

Adj. Feet

Frame +

Scoop

Frame +

Scoop with

Adj. Feet

Enclosed

Sections

Turning

Sections

Fresh Air

Sections

High-Efficiency

Filter Sections

Nominal Height 350 450 350 450 600 600 600 700

Minimum Height 350 450 350 450 500 500 600 700

Maximum Height 1000 1100 1000 1100 1100 1100 1100 800

In Increments of 50 50 50 50 100 100 100 100

Adjustable Feet

Floor Support Angles

Side Gland Plates


IPAC

Technical Manual

Adjustable Feet Enclosed Section (for ducting, etc.)


The adjustable feet option is recommended for all under-floorbase plinth options. Providing 25 mm adjustability in cornerjacking height, adjustable feet make levelling of base plinthsections quick and easy, before fitting a unit into position.

CAUTIONIt is essential that units are level when installed,otherwise unit operation may be adverselyaffected and can result in damage to the unit.

Floor Support AnglesWhere any of the above sections are used under a false floor, theplinth can be supplied with suitably sized angles, which cansupport the floor local to the plinth.

Open frameThe Open Frame illustrated (shown with adjustable feet), isrecommended for floor return systems. This is the simplest baseoption and is designed to match each unit of the IPAC range.

Open Frame Base and ScoopThis base is of the same construction as the Open Frame, butwith the addition of side enclosure panels and a dischargescoop, to guide the air into a floor void from downflow units.

This design reduces the discharge pressure drop and under-floornoise levels. It can be used to discharge air to the rear of theunits, as an alternative to the normal front-supply arrangement.

An enclosed section can be used on either the supply or returnair path. A typical example of use would be to duct from anupflow unit into a vented ceiling.Front panels are removable, should access be required.

Turning Section (inc. double-deflection grilles)Either used as a header or a base plinth, the turning sectioncontains a scoop to aid airflow. This section is fully enclosed tomatch the unit design, with egg-crate return air grilles, ordouble-deflection supply grilles of satin anodised finish.


IPAC

Technical Manual

Fresh Air Modulating Section

Document 0410536

This is a 0 to 100% modulating fresh air mixing section.Either as a header (downflow) or a base plinth (upflow), thesection utilises outside air, where possible, to condition theroom.This optimises unit efficiency, reducing compressor loads by upto 60 % over a year.The fresh-air control facility (refer to Economy Cooling Optionson page 2-19 and “Economy Cooling Options” on page 4-19of Section 4) senses outside air temperature and internaltemperature / humidity levels and responds by modulating thefresh air damper to keep the room air at the required condition.

When room air is evaluated as heading away from being at therequired condition, the fresh air facility is inhibited by closure ofthe inlet damper. Each section is supplied complete with coarsegrade, F2 pre-filters.

High-efficiency Filter SectionThe high-efficiency filter section, which should be connected tothe outlet section IPAC unit, contains standard size, 300 mmdeep pleated front withdrawal panel filters to F5, F6, F7 or F8specification. The high-efficiency filter section is made from a450 mm filter section and a 250 mm spacer plenum section.


IPAC SECTION 3

IPACEaton-Williams

IPAC


INVICTANET CONTROLLER USER MANUAL

SECTION CONTENTS


Description 3 – 3Graphical Display and Keypad 3 – 4

Screen Navigation 3 – 4System Screen (default) 3 – 5Status Screen 3 – 6Alarm Screen 3 – 7Graphical Display Symbols and Icons 3 – 8Status Indicator LEDs 3 – 9

Text Screens 3 – 10Setup Menu 3 – 10Logon 3 – 10Status Menu (for information-only) 3 – 10Parameters (for settings adjustment) 3 – 10Historic Log 3 – 10

Using Text Screens 3 – 10Controller Settings 3 – 11Differential Settings 3 – 12Historic Log 3 – 12

Alarms 3 – 15Urgent alarm 3 – 15Non-urgent alarm 3 – 15Alarms remote monitoring 3 – 15

Identifying and Clearing Alarms 3 – 15Emergency Shutdown 3 – 15Fire Shutdown 3 – 15Troubleshooting 3 – 17

IPAC

INVICTANET Controller User Manual

Document 0410536


IPAC


Introduction Any queries or points of uncertainty should be referred to Eaton-

Document 0410536

The purpose of this document is to describe functionality andadjustments that are available to a user of an Eaton-WilliamsInvictaNET air handling unit controller.Information provided here is intended for guidance only and isnot exhaustive. Full details of the controller can be found in theSection 4 - INVICTANET CONTROLLER TECHNICAL MANUAL.

CAUTIONOnly authorised personnel should be permitted tooperate the controller.Do not attempt to operate the controller unless ithas been commissioned fully, otherwise damagemay result.Before operating the controller, the informationprovided here must be read fully and clearlyunderstood.Failure to operate the controller properly canaffect plant performance and may result indamage to any equipment that relies on unitoperation.

The information provided assumes that the display / keypadoption has been fitted and that the air conditioning system andcontroller(s) have been fully commissioned and is either readyfor operation or already operating.

Williams or their representative.

DescriptionThe Eaton-Williams AHU controller has been specificallydesigned to operate IPAC range units to provide air conditioningof rooms/areas of a building where a precision air-controlledenvironment is required.Depending on the unit(s) and options installed, the followingcontrol functions may be available:

• Cooling only

• Temperature control(heating option must be installed)

• Air Condition (heating and humidifier options must be installed)

The user interface is described under:

• “Graphical Display and Keypad” on page 4

• “Text Screens” on page 10

• “Using Text Screens” on page 10

On powering-up the controller, the display appears similar to asshown in Fig. 3-1.

Fig. 3-1 : Graphical display and keypad

Graphical Display and Keypad

Graphical DisplayArea

Status Indicator LEDs

Colours and state (flashing or steady)

indicate overall systemstatus

Arrow Buttons

For navigation and valueadjustment

OK Button

To enter or accept thedisplayed value or command.

To make audible alarm.

ESC Button

To return to the System(default) screen

POWER ON

HUM STATUS

AHU STATUS

ESCOK


IPAC


Graphical Display and Keypad Screen Navigation

Document 0410536

The combined display and keypad, illustrated in Fig. 3-1, is usedfor adjustment of settings and interrogation of the controller.The ‘EW’ logo (or optional customised logo) is displayed brieflyduring initialisation and whenever the unit is in standby mode.

Navigation of display screens is as shown in Fig. 3-2.By pressing the appropriate arrow buttons on the keypad, therequired screen can be displayed.Note that by pressing and arrow buttons simultaneously,at any time, the Setup / Logon / Status screen and subsequenttext-only screens can be accessed.

Fig. 3-2 : Graphical display screen navigation

Graphical Display Screen Navigation

alarm:- 1 2 3

2

1 1.

2.

status:- 1 2 3

2

1 1.

2.

1.

2.

20.6°C23.5°C41 %

setuplogonstatus

ahu 5 . 4 2

scroll to Status Screen

System Screen

Status Screen

Alarm Screen

Main Menu ScreenLogo Screenshown during initialisationor when in standby mode to logon

or

to scroll menu

scroll to Alarm Screen

Press at any time to return to the System Screen and to log off as a user.ESC


IPAC


System Screen (default) The System Screen is the default screen display and can be

Document 0410536

The System Screen screen provides an overview of system statusand is always displayed (after the EW logo screen) followingpower-up and initialisation of the controller / network.

accessed at any time, by pressing the escape button.Note that, for quick reference, pressing and holding down the

OK button will display the set point temperature andhumidity values in place of sensed actual values.

ESC

OK

Fig. 3-3 : System screen (default - typical shown)

System Screen (default - typical)

20.6˚C23.5˚C41 %

invictanet

Room / spacetemperature andrelative humidity

Alarm indicator(shown only when active)

- urgent alarm shown

Auxiliarytemperatureindicator *

Temperaturedemand

Humiditydemand

Systemoperational

Demandpercentageindicators

A non-urgentalarm appears as

NOTE:Auxiliary temperature indicator is only shown when an economy cooling option is used.For glycol economy cooling, the glycol / water temperature is shown.For fresh-air cooling, outside ambient temperature is shown.


IPAC


Status Screen • If there is an alarm on more than one unit, the Status screen

Document 0410536

Each unit in a network has its own Status screen.By default, the Status screen for the unit to which the controlleris fitted is displayed first; i.e. if the controller is fitted to networkunit No. 3, the status screen for unit 3 is displayed.The exception to the above is in the case of an alarm, when thecontroller behaves intuitively:• If an alarm is present, the Status screen for the unit having

the alarm will be displayed first.

for the unit having the first alarm is displayed first.The system number is reversed-out (green on black) to indicatewhich unit’s Status screen is currently being displayed.To navigate to the Status screen of any other unit on thenetwork, press either the or arrow button, asappropriate.Plant items are represented by icons, which animate to indicateoperation. The full range of icons is detailed under .For units fitted with two of the same type of plant (e.g. twocompressors), these are identified by numbers; i.e. ‘1’ or ‘2’.

Fig. 3-4 : Status screen (typical)

Status Screen (typical)

1 2 3

status:- 1 2 3

2

1 1. 1.

2.

1.

2.

Fan status

shown here as operating(animated rotation)

Compressor status

shown here as not operating(no animated flow arrow)

Heater status

(when operating,flame icons flash)

Humidifier status

shown here operating(vapour rising)

Flow control valve ordamper status

shown here as closed

Plant itemidentification

numbers

(within a unit)

Status screenidentifier

Special information displayed for network units only

System numbers of all other AHUs (up to 9)connected in the network.The number which flashes identifies the unityou are in front of.

Underline identifies any otherunits which are operating inthe network.Dot identifies the Master unit

of a network.

Reversed-out (green on black)number identifies the unit towhich the currently displayedStatus screen refers.


IPAC


Alarm Screen To navigate to the status screen of any other unit on a network,

Document 0410536

If an alarm is present, the appropriate plant icon is reversed-outas illustrated in Fig. 3-5, which shows a compressor 1 alarm onthe Alarm Screen for AHU 1.If there is an alarm present on any other unit, the number of theaffected unit(s) will be underlined to indicate this, as shownunder unit number ‘3’ in Fig. 3-5.

press either the or arrow button, as appropriate.Note that if a standby unit is not powered-up, this is consideredto be a fault condition (because it is unavailable for operation)and the alarm screen will display a question mark, ‘?’ in thecentre of the alarm screen for that unit.

Fig. 3-5 : Alarm screen showing a compressor alarm condition (typical)

Alarm Screen Showing a Compressor Alarm Condition (Typical)

alarm:- 1 2 3

2

1 1.

2.

1 2 3

Special information displayed for network units only

System numbers of all other AHUs (up to 9)connected in the network.The number which flashes identifies the unityou are in front of.

Underline identifies any otherunits which are operating inthe network.Dot identifies the Master unit

of a network.

Reversed-out (green on black)number identifies the unit towhich the currently displayedAlarm screen refers.

Compressor 1 shown in alarmicon reversed-out (green on black)

Plant itemidentification

numbers(within a unit)

Alarm screenidentifier


IPAC


Graphical Display Symbols and Icons

Document 0410536

Symbols that may appear in the graphical display are shown inTable 3-1, together with names and definitions.

Table 3-1 : Graphical display icons and symbols

Graphical Display Icons and Symbols

Icon Name Symbol Animated Alarm Comments

Demand

Percentage

Indicator

N/A Icon animates to show the percentage bar fill rising or falling according to demand.

Cooling Demand N/A Icon animates to show growth from the centre of the snowflake.

Heating Demand N/A Icon animates to show radiant lines from the sun.

Dehum. Demand N/A Icon animates to show droplets falling from the bottom of the half-snowflake.

Humidification

DemandIcon animates to show steam rising from the surface of the liquid.

FanFan icon rotates to indicate running status.On status or alarm screens, the number, ‘1’ or ‘2’, identifies the fan within the unit.

CompressorArrow animates to indicate running status.On status or alarm screens, the number, ‘1’ or ‘2’, identifies the compressor within the unit.

Heater

Demand

Icon animates to show flames rising.On the unit status screen, the number, ‘1’ or ‘2’, identifies the heater within the unit.

Flood Alarm N/A Alarm icon indicates that the water detection device is in the tripped state.

Air Filter N/A Alarm icon indicates that air filters are clogged and require servicing.

Urgent AlarmDisplayed whenever an urgent alarm is present.Icon animates to show the bell ringing.

Non-urgent Alarm N/A N/A Displayed whenever a non-urgent alarm is present.This icon does not animate.

Flow Control

Valve or

Mixing Damper closed modulating open

Shows the state of the flow control valve or mixing damper - closed, modulating or open.On the unit status screen, the number, ‘1’ or ‘2’, identifies the valve or damper within the unit.

Room temp., RH

and

outside ambient

temperature

Shows detected room air temperature and relative humidity. Icon flash reverses-out during temperature or humidity alarm.May also show outside ambient air temperature (outside the building icon), if option is utilised.

1. 1. 1.

1 1 1

1. 1. 1.

1. 1. 1.

20.6˚C23.5˚C41 %

27.4˚C54%


IPAC



Document 0410536

Three keypad-mounted LEDs provide indication of the conditionof the unit. Table 3-2 shows the meaning of each LED state.

Table 3-2 : Status indicator LED definitions

Status Indicator LED Definitions

LED State Definition

Power Status LED

Off Power supply is not live to the controller.

Red continuously Power supply is live to the controller.

AHU and Humidifier Status LEDs Both Together

Red/Amber flashing for 1 second periods Controller has entered site setup mode, which must be completed before the unit can be operated.

Red/Amber/Green flashing for 1 second periods Controller is unconfigured - Engineer required.

AHU Status LED

OffAHU is inoperative: Load shed input active, no 24 V ac supply, or humidifier control switch in OFF position.

Red continuously AHU running under normal control to meet demand.

Red flashing for 1 second periods AHU idle (no demand) or in standby mode.

Amber continuously HT cut-out tripped alarm on master or slave AHU.

Amber flashing for 1 second periods Compressor 1 fault alarm:HP cut-out, LP cut-out, or motor overload tripped.

Amber flashing for 2 second periods Compressor 2 fault alarm:HP cut-out, LP cut-out, or motor overload tripped.

Green continuously Condensate flood alarm.

Green flashing for 1 second periods Air filter blocked alarm on master unit 1.

Green flashing for 2 second periods Air filter blocked alarm on master unit 2.

Amber/Green flashing for 1 second periods Supply airflow fault alarm on master unit 1.

Amber/Green flashing for 2 second periods Supply airflow fault alarm on master unit 2.

Red/Amber flashing for 1 second periods AHU operating at full output on manual override.

Humidifier Status LED

OffHumidifier is inoperative: Load shed input active, no 24 V ac supply, or humidifier control switch is in the OFF position.

Red continuously Humidifier operating under normal control to meet demand.

Red flashing for 1 second periods Humidifier idle (no demand) or in standby mode.

Amber continuously Condensate flood alarm.

Amber flashing for 1 second periods Water supply fault to humidifier fault alarm.

Amber flashing for 2 second periods Over-current high fault alarm. Humidifier operation stopped.

Green flashing for 1 second periods Service interval expired alarm.

Green flashing for 2 second periods Automatic service routine in progress.

Green continuously Automatic service routine completed.

Red/Amber flashing for 1 second periods Humidifier operating at full output on manual override.


IPAC


Text Screens Historic Log

Document 0410536

For users, the following menu levels are accessible:

• Setup (set-up level)

• Logon (password logon level)

• Status (information-only level)

• Parameters (setting adjustment and historic log level)

The menu tree structure of text screens is outlined in Fig. 3-9 onpage 11, while the purpose of each level is described below.

Setup MenuThis menu level should not be adjusted by users, as it is used toattach slave modules to the system, configure a network, initiaterun/standby group control and enter fundamental configurationsettings.

CAUTIONUse of the Setup menu is a commissioning andservicing function and is not be altered by users.Unauthorised alterations made under the Setupmenu can severely disrupt plant operation.Use of the Setup level, by authorised personnel, isdescribed in the INVICTANET CONTROLLER TECHNICALMANUAL.

LogonThis is used to logon for access to password-protected controllerfunctions, settings adjustment and the historic log.

• The user level password is 4602

The logon procedure is described under - “Using Text Screens”on page 10. Non-user levels of access and adjustment, such asthose at Service level, are also password-protected and aredescribed in the INVICTANET Controller User Manual.

Status Menu (for information-only)This information-only menu level provides the user withinformation about prevailing conditions and enables viewing-only of certain control settings and the historical data log, aslisted in Table 3-3 on page 13.

Parameters (for settings adjustment)This menu level enables changes to be made to controllersettings.

CAUTIONApplying inappropriate setting values forprolonged periods can adversely affect room aircondition and may result in damage to anyenvironment-sensitive equipment that relies onunit operation.

Access to this menu level should only be entrusted to personnelwho are competent in process control of air handling units.Settings are listed in Table 3-4 on page 14.

This menu level enables a user to view the alarm history of aunit. The history log shows date, time and type-of-eventinformation; for details see . A password is required to view thismenu item.

Using Text ScreensThe basic principles of accessing and using the text features ofthe graphical display are described below. By following theseprinciples, a user will quickly become familiar with operating thekeypad to access required menus, information and settings.Fig. 3-9 on page 11 shows the Text-only screens tree structureoutline.

1. At any time, press the and arrow buttons simultaneously to display the Main Menu screen.

View-only data can now be accessed by using the arrow buttons to select Status or Parameters and

to navigate.

Alternatively, to change a setting value, view the historic log, or accept and clear an alarm, proceed as follows.

2. With ‘logon’ selected, press to enter the logon password screen, as shown in Fig. 3-7.

3. Key in user level password 4602 by using the and

arrow buttons to adjust the value of each digit; see Fig. 3-8 on page 11. The currently adjustable digit is reversed-out (green on black).

Enter the completed password by pressing OK.

Fig. 3-6 : Main menu screen

Fig. 3-7 : Logon password screen

setuplogonstatus

ahu 5 . 4

OK

logonpassword

0000

OK


IPAC


Provided that the password entered is correct, the Main Fig. 3-8 : Keying in the password

Document 0410536

Menu screen will be displayed again (with user level password permissions enabled), otherwise, the ‘Invalid Password’ message will be displayed.

4. Use the arrow buttons to navigate as required.

5. To terminate a logon session, press the escape button to return to the System screen. Once the System screen has been returned to, it is necessary to logon again before settings can be adjusted,

Controller SettingsController settings are configured during commissioning, toobtain optimum performance.

NOTEThere are two types of settings - System and AHU:

• System settings apply to all AHUs in a network

• AHU settings apply only to individual AHUs

logonpassword

4602ESC

Fig. 3-9 : Text-only screens tree structure outline

Text-only Screens Tree Structure Outline

Setup

LogonEnterPasswordUser = 4602

Status

Service

Parameters System Temp Setpoint Setting

RH Setpoint

High Temp Diff

Low Temp Diff

High RH Diff

AHU1

AHU2

AHU3

Engineering

Historic Log

1

2

3

(4)

4 (5) 4-0

4-1

4-2

4-3

4-0-1

4-0-2

4-0-3

4-0-4

4-0-5

(6)

5 (7)

Press + toenter text screens at

any time afterpowering-up and

initialisation

Tree structure shown down to Setting level

Sub-menu Sub-sub-menu

Etc. for up toten AHU's

4-0-6 etc.

NOTE:Screen numbers in brackets are applied

under Service and Engineering password access

Colour Key to Password-based AccessUser levelService levelEngineering(E-W authorised)


IPAC


This means that networked AHUs are able to run Each event is allocated a number and this, together with the

Document 0410536

independently, as required; for example, if theMaster unit controller is off-line for any reason, orif zone control is required.

Any adjustment to setting values should be recorded, togetherwith the date changed.It is recommended that a copy of each appropriate settingsrecord is kept with the plant log book. Having this informationto hand will keep any down time period to a minimum, shouldcontroller settings need to be input again.• Always keep the settings record up to date and in a safe

place, preferably with the unit log record.For a complete listing of adjustable settings available at userlevel, refer to Table 3-4 on page 14.Note that settings cannot be adjusted at Status menu level,which is view-only for information.

Differential SettingsWhile the majority settings are self-explanatory, it is worthdetailing how differential setting values are determined.The following examples are provided for guidance.

Example 1:This example is for the Room High Temperature Alarm setting,which determines at which temperature the high temperaturealarm is generated.

If the Room Temperature set point value is 20 °C and the HTalarm is required to be set at 25 °C, the calculation todetermine the setting value is:

25 °C minus 20 °C = 5 °C

Therefore:Room High Temperature Alarm setting value = 5.00

Example 2:This example is for the Room Low Temperature Alarm setting,which determines at which temperature the low temperaturealarm is generated.

If the Room Temperature set point value is 20 °C and the LTalarm is required to be set at 17 °C, the calculation todetermine the setting value is:

20 °C minus 17 °C = 3 °C

Therefore:Room Low Temperature Alarm setting value = 3.00

By using this method, positive and negative value offsets fromset points can be determined for any differential setting.

Historic LogThe log provides a list of up to approximately forty alarm events(determined by available memory).To view the historic log, it is necessary to logon as describedunder . The historic log is then shown in the Main Menu.On entering the history alarm log, the latest occurring event isshown first. Use the arrow button to scroll the display toearlier events in descending chronological order.

total number of events logged, is shown to the right in the firstline of text. Therefore, in the example screens shown in Fig. 3-10and Fig. 3-11 on page 12, the number 11-11 indicates that thisis alarm event eleven of eleven events (i.e. the most recent eventin the history log).• The first line shows that the screen information relates to

either when the alarm was active (first generated), as inFig. 3-10, or was cleared, as in Fig. 3-11.

NOTEThe term ‘activated’ does not mean that thealarm event still exists, but only that it wasoriginally generated at the date and timeshown.If a particular alarm has been cleared, asdescribed under , there will be a corresponding‘cleared’ event screen of a later date for thesame alarm condition.

• The second line, shows the date DD-MM-YY and time, hour: minute : second.

• The third line identifies the AHU number.• The fourth line identifies the plant item and the nature of the

alarm (e.g. high temperature) indicates that air handlingunit No. 1 has an air high temperature condition (i.e. airtemperature is excessive and has reached or exceeded theRoom High Temperature Alarm set point.

Fig. 3-10 : Historic log of an activated alarm

Fig. 3-11 : Historic log of a cleared alarm

active 11-11

ahu 1high temp

22-09-03 17:50:21

cleared 11-11

ahu 1high temp

22-09-03 17:55:31


IPAC


Table 3-3 : Status menu points list

Document 0410536

Status Menu Points List

SYSTEM POINTS

Point No.

(Screen)Screen Text Description Units

3-0-1 temperature Room temperature (sensed actual) °C

3-0-2 rel humidity Room relative humidity (sensed actual) % RH

3-0-3 temp demand Cooling or heating demand (where ‘–’ = cooling, ‘+’ = heating) %

3-0-4 rh demand Humidification or dehum. demand ( ‘–’ = dehum, ‘+’ = hum ) %

AHU NOS. 1 TO 10 POINTS

Point No. Screen Text Description

3-x-1 ahu mode AHU operating mode (online or standby)3-x-2 vap mode Humidifier operating mode (online or standby)3-x-3 temperature Room temperature (sensed actual) °C

3-x-4 rel humidity Room relative humidity (sensed actual) % RH

3-x-5 temp demand Cooling or heating demand (where ‘–’ = cooling, ‘+’ = heating) %

3-x-6 rh demand Humidification or dehum. demand ( ‘–’ = dehum, ‘+’ = hum ) %

3-x-7 free cool temp Temperature of economy cooling medium °C

3-x-8 air on-coil temp Temperature of air sensed before entering the coil °C

3-x-9 free cool demand Economy cooling demand %

3-x-10 unit run hours Accumulated hours run of each unit module hrs

3-x-11 vapac run hours Accumulated hours run of the Vapac unit hrs

3-x-12 comp run hours Accumulated hours run of each compressor in a unit hrs

3-x-13 factory setup Factory set-up sub-menu (comprising points 3-x-13-1 to 3-x-13-8)3-x-13-1 ahu config index Configuration index number (two digits) of the unit xx

3-x-13-2 free cooling Whether economy cooling function is implemented active /

3-x-13-3 led operation LED regional operating mode; e.g. ‘eu’ for European mode3-x-13-4 heater control Heating control mode number

3-x-13-5 vapac fitted Whether a Vapac unit is fitted yes / no

3-x-13-6 max current Maximum operating current configuration of the Vapac unit Amps

3-x-13-7 cylinder o/p Rated output of the Vapac cylinder kg/hr

3-x-13-8 num electrodes Number of heating electrodes fitted to the Vapac unit number

3-x-13-9 num of turns Number of turns of the torod sensor winding number

3-x-13-10 cylinder size Humidifier cylinder size (rated 5, 9, or 18) number

3-x-14 sw version Software version current installed in the controller

3-x-15a digital ioDigital Input (0 = Open, 1 = Closed) DI1 - DI9 24v Digital Output (0 = Inactive, 1 = Active) DO1 - DO10 Daughter Board Digital IO (as above) DI11 - DI15 DO11 - DO15

3-x-16a analogue ips Analogue Inputs AI1 - AI4

3-x-17a resistive ips Resistive Inputs AI5 - AI8

3-x-18a analogue ops Analogue Outputs AO1 - AO43-x-19 current Measured current being drawn by the humidifier Amps

NOTE ‘x’ shown in a point / screen number represents the designated number of an AHU on a network.

a. For further information, please see“Input / Output Schedule” on page 4-29 of Section 4


IPAC


Table 3-4 : Settings list (user level)

Document 0410536

Settings List (User Level)User password = 4602

SYSTEM SETTINGS

Setting

(Screen)Screen Text Setting

Range Default Units

Min. Max.

4-0-1 temp setpoint Room temperature set point 0 39 22 °C

4-0-2 rh setpoint Room humidity set point 5 95 50 % RH

4-0-3 high temp diffRoom high temperature alarmdifferential from room temperature set point 4-0-1

0 10 10 °C

4-0-4 low temp diffRoom low temperature alarmdifferential from room temperature set point 4-0-1

0 10 10 °C

4-0-5 high rh diffRoom high humidity alarmdifferential from room humidity set point 4-0-2

0 10 10 % RH

4-0-6 low rh diffRoom low humidity alarmdifferential from room humidity set point 4-0-2

0 10 10 % RH

4-0-7 date . timeDate and timereal-time clock setting adjustmentDD-MM-YY HH:MM:SS

4-0-8 dehum o/rDehumidification override controlenables/disables implementation of Dehum. override temperature differential setting 4-0-9

enable disable enable -

4-0-9 dehum o/r

Dehumidification override temperature differentialdifferential from room temperature setting 4-0-1 Inhibits dehumidification if temperature is low, to prevent overcooling.

0 40 3 °C

AHU SETTINGS

Setting


Range Default Units

Min. Max.

4-x-1 temp setpoint Room temperature set point 0 39 22 °C

4-x-2 rh setpoint Room humidity set point 5 95 50 % RH

4-x-3 high temp diffRoom high temperature alarmdifferential from room temperature set point 4-0-1

0 10 10 °C

4-x-4 low temp diffRoom low temperature alarmdifferential from room temperature set point 4-0-1

0 10 10 °C

4-x-5 high rh diffRoom high humidity alarmdifferential from room humidity set point 4-0-2

0 10 10 % RH

4-x-6 low rh diffRoom low humidity alarmdifferential from room humidity set point 4-0-2

0 10 10 % RH

4-x-7 man o/r resetManual override reset controlAHU manual override reset control setting enable or disable

enable disable enable -

4-x-8 input voltageSpecified input voltage to the AHUi.e. 380 V ac, 415 V ac, or 440 V ac

380 440 440 Volts

NOTE ‘x’ shown in a point / screen number represents the designated number of an AHU on a network.


IPAC


Alarms Alarms remote monitoring

Document 0410536

The controller monitors for various fault conditions according toconfiguration and signal inputs.In response to a detected fault condition, controller generatesone of two types of alarm, namely, an ‘urgent alarm’, or a ‘non-urgent alarm’. These are defined as follows:

Urgent alarm (animated bell icon)An urgent alarm (see Fig. 3-12) is generated in response to afault condition which prevents unit operation; e.g. AirflowFailure alarm.

The cause of an urgent alarm requires immediate action tocorrect the fault condition before the unit can restart. Anycontrol function that is unaffected by the fault will continue tobe operative.

Non-urgent alarm (static icon, reversed-out icon)A non-urgent alarm (see Fig. 3-13) is generated in response to afault condition, which requires attention, but does notimmediately prevent a unit from operating.Note that if the building icon is flashing reversed-out (Fig. 3-13),the alarm relates to air temperature, humidity, or both.

The cause of a non-urgent alarm should be attended to at theearliest opportunity, otherwise, if ignored, a more serious faultcan develop, resulting in an urgent alarm, which prevents unitoperation.

Example:If a blocked filter alarm is ignored and the filter continues toclog-up, an airflow failure fault will ultimately stop the plantand generate an urgent alarm, perhaps at critical moment.

Urgent and non-urgent alarm conditions may be monitoredremotely; refer to the INVICTANET CONTROLLER TECHNICALMANUAL .

Identifying and Clearing AlarmsAssuming that a fault condition has arisen, adopt the proceduredescribed in Fig. 3-14 to identify and then, after the cause hasbeen corrected, clear the alarm.

CAUTIONSome fault conditions, such as temperature orpressure trips, will seem to rectify themselves asconditions return to normal when the unit stopsoperating. DO NOT reset the controls and restartthe unit without first identifying and rectifying thecause of the fault.Repeatedly resetting and restarting can damagethe unit and may invalidate any warranty.

WARNINGFault investigations, diagnosis and remedialactions that necessitate opening up the unitcabinet can involve potentially hazardousprocedures and must only be undertaken byproperly trained and authorised personnel.

When all alarms have been cleared, the controller will resumenormal operation and restart the unit, provided that no faultsexists.Note that compressor restarting may be subject to its Starts PerHour Limiting Time setting; refer to the INVICTANETCONTROLLER TECHNICAL MANUAL for details.If the fault condition still exists, the controller will detect thisduring its next data scan cycle and will indicate the same faultagain.


CAUTIONIn an emergency, do NOT attempt to use controllerfunctions to shutdown equipment, as this willinitiate a controlled shutdown that is unlikely tobe effective immediately.

If an external Emergency Stop button is fitted (asrecommended), pressing this will interrupt the power supply tothe controller and stop the plant (including paired slave, if fitted)immediately

Fire ShutdownIf a fire shutdown remote switching device is fitted (andinterlocked as recommended), when triggered, it will interruptthe power supply to the controller and stop the plant (includingpaired module, if fitted) immediately.

Fig. 3-12 : System screen urgent alarm

Fig. 3-13 : System screen non-urgent alarm

20.6˚C23.5˚C41 %

invictanet

27.4°C24˚C54%

invictanet


IPAC


Fig. 3-14 : Identifying and clearing alarms

Document 0410536

Identifying and Clearing Alarms

20.6°C23.5°C41 %

invictanet

20.6°C23.5°C41 %

invictanet

alarm:- 1 2 3

2

1 1.

2.

setuplogonstatus

ahu 5 . 4 2

!! alarm !!ahu 1compressor hpmodule 1

!! alarm !!ahu 1compressor hpmodule 1

logonpassword

0000

logonpassword

4602

Alarm condition reported on theSystem screen.

Press to view the Alarm screenand identify affected plant item.In this case - compressor 1 of unit 1.

Press + to enter theMain Menu screen.

Alarm Detail screen is shown automaticallywhen data next refreshes (a few seconds).Press to return to the Main Menu.OK

Press to view the Logon screen.OK

Press to enter the password.OK

Press to clear the alarm.OK

Press to return to the System Screen.ESC

Investigate and rectify the cause of the reported fault conditionbefore proceeding to clear the alarm.

NOTE If the cause of the alarm has not been eliminated, the alarm condition will be reported again, when data next refreshes.

If necessary, repeat step 2 to view theMain Menu screen.

Press to key in userpassword 4602.

The Main Menu screen is displayed againduring a data refresh period (a few seconds).The Alarm Detail screen is then displayedautomatically.

Normal operation should now resume.

1

2

3

4

5

67

IDENTIFYANDCORRECTTHECAUSE

CLEARTHEALARM


IPAC


Troubleshooting

Document 0410536

Table 3-5 : Troubleshooting guide

Troubleshooting Guide

DISPLAY PROBLEM

Condition Reason / Remedial Action

Display

corruption

The controller has been designed to be robust and reliable in operation. However, communications faults or interruptions can, in certain circumstances, corrupt the display.If the display is suspected of not functioning normally, power to the affected unit(s) should be switched OFF to power-down the controller for a period of 30 seconds, before switching it back ON.On restoration of power, the controller and display should re-initialise and operate normally.If the problem recurs and causes a nuisance, the communications wiring and connections should be checked for integrity by and Engineer.

AHU NOT OPERATING

Condition /

ConsiderationReason / Remedial Action

Is power

available to the

controller?

Check that any external interlocks, (such as Fire Shutdown and “Emergency Shutdown” on page 15, are in a healthy state. Note that if the fire shutdown facility is utilised, the display will continue to function after the fire shutdown device is triggered. Therefore the display being ‘live’ does not mean that the controller power supply is healthy. Check that the unit operating mode is healthy. Do this by interrogating the controller:

Healthy =• AHU online - see Status | AHU x | Ahu mode• AHU standby - see Status | AHU x | Ahu mode

Unhealthy =

• an alarm exists; e.g. Comp 1 HP• Shutdown, where either the Remote Start/Stop or the Fire Shutdown are OFF - see Status | AHU

x | Ahu mode• Not configured - this message means an engineer is required to re-configure the unit/network

setup

Is there a

demand?

Check that there is truly a demand. For example, if demand has been satisfied, the controller will not initiate the unit process (cooling, heating, humidification or dehumidification) to operate. Check that demand exists by viewing the Status screen (see “Status Screen” on page 6), which shows demand and percentage indicators, and by interrogating System Status points 3-1-4 or 3-1-5 as appropriate; see Table 3-3 on page 13.

Demand exists,

but the unit is

idle

If demand is present (see above), but the appropriate process is not operating, a normal delay time may be in effect. If system status points 3-0-3 and 3-0-4 show no demand and this is unexpected, check temperature set point 4-0-1 or 4-0-2 (humidity) and compare this to the actual measured value shown for status point 3-0-1 (temperature) or 3-0-2 (humidity), as appropriate.Remember to take into account:

• Dead band control settings• Override controls• Compressor starts per hour limiting• External interlocks (if fitted) are in a healthy state; such as “Fire Shutdown” on page 15 and “Emergency Shutdown”

on page 15.Refer to the INVICTANET CONTROLLER TECHNICAL MANUAL for details.

AHU NOT OPERATING

Condition /

ConsiderationReason / Remedial Action

Is the AHU idle in standby mode?

A unit in standby mode will only operate to take over the duty of another unit that becomes unavailable, or when due to take over according to run/standby rotation control settings.On the Status > AHU menu, check AHU operating mode point 3-x-1, or humidifier operating mode point 3-x-2 for the humidifier (where ‘x’ is the AHU’s system number on the network), as appropriate; see Table 3-3. The unit process will only be operative if status is shown as ‘online’.


IPAC

Document 0410536



IPAC SECTION 4

Eaton-Williams


IPAC

INVICTANET CONTROLLERTECHNICAL MANUAL

IPAC

INVICTANET CONTROLLER TECHNICAL MANUAL

SECTION CONTENTS


Description 4 – 5User Interface 4 – 5Passwords 4 – 5Servicing and Maintenance Facility 4 – 5Engineering Level Information 4 – 5Setup 4 – 12

Control Functions 4 – 13Power-up condition 4 – 14Starting and operation - basic overview 4 – 14Temperature and Humidity PID control 4 – 14Humidity PID control 4 – 14

Compressor and Condenser - Starting Operation 4 – 14Condenser operation 4 – 14Low pressure (LP) cut-out inhibit 4 – 14Hot gas injection system 4 – 14Compressor 2 starting 4 – 16Compressor starts per hour limiting 4 – 16

Compressor Capacity Control 4 – 16Built-in Hysteresis 4 – 16

Chilled Water Unit Cooling Duty Control 4 – 18Economy Cooling Options 4 – 19

Fresh-Air Economy Cooling 4 – 19GlyCool Economy Cooling 4 – 19

Electrical Heating 4 – 19Heating capacity control 4 – 20

Humidifier Control 4 – 20Dehumidification Control 4 – 21

Cooling control override 4 – 21

Commissioning 4 – 21Network Master / Slave Control 4 – 21

Duty Rotation 4 – 21

Local Networking 4 – 21System Networking 4 – 22

External Interface Protocol 4 – 22

Document 0410536


IPAC


ModBus Network Interface 4 – 22

Document 0410536

Trend Controller 4 – 22Trend Network Interface ( <5 Units ) 4 – 22Alternative Language (ASCII) 4 – 22

Fault Conditions, Alarms and Response 4 – 22Urgent alarm 4 – 22Non-urgent alarm 4 – 23Alarm remote monitoring 4 – 23

Fault Conditions 4 – 23Fault Conditions, Alarms and Reset 4 – 23

Air temperature alarms 4 – 23Air humidity alarms 4 – 23High pressure (HP) cut-out tripped 4 – 23Low pressure (LP) cut-out tripped 4 – 24Air filter blocked 4 – 24Airflow failure 4 – 25Compressor drive motor overload tripped 4 – 25Condensate flood alarm 4 – 25

Emergency Shutdown 4 – 25Fire Shutdown 4 – 25Troubleshooting 4 – 25

Display Corruption 4 – 25AHU Not Operating 4 – 25

AHU Configuration Index 4 – 27

Configuration Plug (early units) 4 – 29

Input / Output Schedule 4 – 29External Interface Protocol 4 – 32


IPAC


Introduction Please note that this section here contains information

Document 0410536

The purpose of this section is to provide technical andcommissioning information for an Eaton-Williams InvictaNETController for AHU (air handling units).Information provided here is intended for guidance only and isnot exhaustive. This section should be read in conjunction withSection 3 - INVICTANET Controller User Manual and Section 5 -INVICTANET Controller Settings Record.This section has been written assuming that the principles ofusing the controller, as described in the INVICTANET ControllerUser Manual, are understood.

appertaining to the Engineering level menu, which is onlyaccessible by, or with permission of, Eaton-Williams’ personnel.This menu level enables access to and adjustment of low levelsettings, which are determined and configured by Eaton-Williams prior to despatch. Information about the Engineeringlevel is provided for reference only.Any queries or points of uncertainty should be referred to Eaton-Williams or their representative.

Fig. 4-1 : Graphical display and keypad

Graphical Display and Keypad

Graphical DisplayArea


Colours and state (flashing or steady)

indicate overall systemstatus

Arrow Buttons

For navigation and valueadjustment

OK Button

To enter or accept thedisplayed value or command.

To make audible alarm.

ESC Button

To return to the System(default) screen

POWER ON

HUM STATUS

AHU STATUS

ESCOK


IPAC


Description Passwords

Document 0410536

The Eaton-Williams AHU controller has been specificallydesigned to operate IPAC range units to provide air conditioningof room/areas of a building that require a precision air-controlledenvironment.Depending on the unit(s) and options installed, the followingcontrol functions may be available:

• Cooling only

• Temperature control(heating option must be installed)

• Air Condition (heating and humidifier options must be installed)

Factory-set configuration modes of the controller allow the samehardware and software to be used throughout the IPAC range,whilst allowing each variation of combination of internalcomponents to be optimally controlled for efficiency and closecontrol.When on site, controllers can either be configured as stand-aloneunits, or be networked into a system of up to ten units, by usingthe unit’s LONWORKS® open protocol networking capabilities.For clarity, the following terminology and definitions are used:

• Network Master

A unit/controller, either stand-alone, or in a system andconfigured (during commissioning) to be the NetworkController.

• Network Slave

A unit/controller, in a system and configured (duringcommissioning) to be a slave of the Network Master; i.e. theunit receives its control from the Network Master, to ensureoptimal control of a networked area.

Should the network control signal fail, a Network Slave willreturn to stand-alone control, thereby ensuring that operationcontinues.

• Master Module / Primary Module

Either a Network Master or any Network Slave unit, fitted withan InvictaNET controller.

• Slave Module / Secondary Module

A unit containing mechanical components and local controls,but no InvictaNET controller. All components are controlled bythe unit's matching Master Module. Therefore, a slave moduleis not seen by the LON Network.

User InterfaceThe InvictaNET combined display and keypad, illustrated inFig. 4-1, is fitted to all IPAC units.The display uses a backlit LCD screen and provides informationand control facilities. The display offers a user-friendly interface,with the benefits of animation and icon representations of plantitems, plus features such as historical alarm logging.For general information on using the graphical display / keypad,together with user-specific information refer to Section 3 -INVICTANET Controller User Manual .

Passwords are provided for two menu levels:

• User level password = 4602

To enable adjustment of user level settings, viewing of the history log, and clearing of alarms; see Section 3 - INVICTANET Controller User Manual.

• Service menu level password = 5699

For manual control and service functions; see Servicing and Maintenance Facility below.

• Site Setup menu level password = 1111

To access site network setup functions; see Setup on page 4-12.

CAUTIONUse of passwords must only be entrusted toauthorised personnel. Eaton-Williams cannot beheld responsible for any consequence ofunauthorised use of passwords.

Servicing and Maintenance FacilityThe Service level menu, accessed via password 5699, enablesmanual control and override functions to be implemented sothat scheduled maintenance and servicing tasks can be carriedout without needing to adjust and then restore user-defined andengineering-defined settings.Service level menu system settings are listed in Table 4-1.

Engineering Level InformationThe Engineering level menu is only accessible by, or withpermission of, Eaton-Williams’ personnel. This menu levelenables access to and adjustment of low level settings, whichare determined and configured by Eaton-Williams prior todespatch.To enable the controller’s full functionality and controlphilosophy to be understood, all Engineering menu settings areshown in Table 4-2.


IPAC


Table 4-1 : Service level menu system settings

Document 0410536

Service Level Menu SettingsMaintenance password* = 5699

AHU No. 1 (Master) through AHU Nos. 2 to 10 (Slaves)

Setting (Screen)Screen Text Setting

Range Default

Maint. E-W Min. Max.

4-x-1 5-x-1 ahu manual

AHU control selectionOptions are:

• Auto control• Override ON - forces AHU to start• Override OFF- forces AHU to stop / prevents starting

overrideoff

overrideon

auto

4-x-2 5-x-2 air flow o/r

Airflow failure overrideOptions are:

• Auto control• Override ON - inhibits shutdown caused by an airflow

switch trip.

auto override

onauto

4-x-3 5-x-3 compressor 1

Compressor 1 manual control selectionOptions are:

• Auto control• Override ON - operates compressor continuously

autooverride

onauto

4-x-4 5-x-4 hot gas

Compressor 1 hot gas injection selectionOptions are:

• Auto control• Override ON - operates the hot gas valve to implement

minimum capacity

autooverride

onauto




autooverride

onauto




autooverride

onauto

4-x-7 5-x-7 heater stage 1

Heating stage 1 manual control selectionOptions are:

• Auto control• Override ON - operates stage 1 heating continuously

autooverride

onauto




autooverride

onauto




autooverride

onauto



• Auto control*• Override ON - operates stage 1 heating continuously

autooverride

onauto


IPAC


Table 4-1 : Service level menu system settings

Document 0410536

4-x-11 5-x-11 free cool valve

Economy cooling valve controlOptions are:

• 0 % - override OFF

• range from 1 % (minimum open) to 100 % (fully open) - for minimum to maximum opening of the valve

• 101 % - operates forces the valve closed

0 % 101 % 0 %

4-x-12 5-x-12 vapac

Humidifier controlOptions are:

• 0 % - override OFF

• range from 1 % (minimum output), to 100 % (maximum output) - for humidifier output control

• 101 % - operates the humidifier at maximum output continuously

0 % 101 % 0 %

4-x-13 5-x-13 manual drain

Humidifier manual drain2

Implements a manual drain cycle for the humidifier cylinder.Note that the humidifier status LED illuminates green continuously to indicate that the cycle is complete.

No(ESC)

Yes(OK)

-

4-x-14 5-x-14 auto flush

Humidifier auto-flush2

Initiates a single automatic flush of the humidifier cylinder and its associated system pipework.Note that the humidifier status LED illuminates green continuously to indicate that the cycle is complete.

No(ESC)

Yes(OK)

-

4-x-15 5-x-15 force rotation

Force unit run rotationIncrements run / standby duty rotation of all units on a network.This function is only applicable to a network.Note that the final run / standby state will continue after completion of servicing.

No(ESC)

Yes(OK)

NOTES E-W settings are only to be accessed and adjusted by Eaton-Williams personnel or their authorised agents.User level password does not provide access to the Service level menu.‘x’ shown in a setting (screen) number represents the AHU’s designated number on the system network.

* Maintenance password also permits access to a limited number of Engineering menu settings; see Table 4-2.

Service Level Menu SettingsMaintenance password* = 5699

AHU No. 1 (Master) through AHU Nos. 2 to 10 (Slaves)

Setting (Screen)Screen Text Setting

Range Default

Maint. E-W Min. Max.


IPAC


Table 4-2 : Engineering menu settings

Document 0410536

Engineering Menu SettingsE-W password full access and Maintenance password 5699 part access (indicated by asterisk) only

SYSTEM SETTINGS

Setting


Range Default Units

Min. Max.

*6-0-1 sensor operation

Sensor operationSpecifies temperature / humidity sensor / data handling - options are:

• Average - for averaging of data from several sensors• Individual - for individual sensor• From master - for using only the Master unit’s sensor data

*6-0-2 num run unitsNumber of run unitsSpecifies the number of units allowed to run in the network at any time

*6-0-3 rotation periodDuty rotation cycle periodHours between each rotation of duty for pairs of units

00000 99999 00000 hours

*6-0-4 rotation timeDuty rotation timeTime of day that duty rotation is executed for pairs of units;inhibit setting = 00:00

00:00 24:00 00:00hours / mins.

*6-0-5 run on period

Run-on time at changeoverSpecifies the period that a unit due to go on standby unit is permitted to keep running, to eliminate any issues caused by start delays of the starting unit.

0 mins.

*6-0-6 standby tempTemperature deviation required to start standby unitOffset from the temperature set point that will initiate starting of the standby unit

0 10 10 °C

*6-0-7 standby periodStandby run periodThe period that the standby unit is required to run after being started in response to setting 6-0-6

0 240 0 mins.

*6-0-8 level 1 alarmUrgent alarm output typeSpecifies the type of alarm signal - pulsed or continuous

pulse cont. cont. -

*6-0-9 level 2 alarmNon-urgent alarm output typeSpecifies the type of alarm signal - pulsed or continuous

pulse cont. cont. -

*6-0-10 temp alarms

Temperature alarms displaySpecifies whether temperature alarms are shown automatically on the displayshown = enablednot shown = disabled

dis-abled en-abled en-abled

*6-0-11 rh alarms

Relative humidity alarms displaySpecifies whether RH alarms are shown automatically on the displayshown = enablednot shown = disabled



IPAC



Document 0410536

AHU SETTINGS

Setting


Range Default Units

Min. Max.

6-1-1 man o/r periodManual override run periodDuration of manual override (for service) before unit reverts to normal operation

0 120 60 mins.

6-1-2 setpoint source

Set point sourceSpecifies whether each unit controls to the system setpoint, or individual AHU values. - options are:

• System• AHU

- - AHU -

6-1-3 fan start delayFan start delay timeDelay period before fan starting is permitted, following unit start initialisation

0 300 5 secs.

6-1-4 temp d/b

Temperature deadband valueNo PID control is applied while the temperature is within the deadband, which is an offset value from the temperature set point.

1 10 1 °C

6-1-5 heating loopHeating control loop menuEnters the heating PID control loop menu comprising the next three settings

- - - -

6-1-5-1 proportionalHeating proportional band valueFor PID control

1 10 2 °C

6-1-5-2 i actionHeating integral time valueFor PID control

0 250 0 mins.

6-1-5-3 i responseHeating derivative time valueFor PID control

0 250 0 mins.

6-1-6 cooling loopCooling control loop menuEnters the heating PID control loop menu comprising the next three settings

- - - -

6-1-6-1 proportionalCooling proportional band valueFor PID control

1 10 2 °C

6-1-6-2 i actionCooling integral time valueFor PID control

0 250 0 mins.

6-1-6-3 i responseCooling derivative time valueFor PID control

0 250 0 mins.

6-1-7 rh d/bHumidity deadband valueNo PID control is applied while RH is within the deadband, which is an offset value from the RH set point

1 10 2 %RH

6-1-8 hum loopHumidification control loop menuEnters the humidification PID control loop menu comprising the next three settings

- - - -

6-1-8-1 proportionalHumidification proportional band valueFor PID control

1 10 3 % RH

6-1-8-2 i actionHumidification integral time valueFor PID control

0 250 0 mins.



IPAC



Document 0410536

AHU SETTINGS (continuation)

Setting


Range Default Units

Min. Max.

6-1-8-3 i responseHumidification derivative time valueFor PID control

0 250 0 mins.

6-1-9 dehum loopDehumidification control loop menuEnters the dehumidification PID control loop menu comprising the next three settings

- - - -

6-1-9-1 proportionalDehumidification proportional band valueFor PID control

1 10 2 % RH

6-1-9-2 i actionDehumidification integral time valueFor PID control

0 250 0 mins.

6-1-9-3 i responseDehumidification derivative time valueFor PID control

0 250 0 mins.

6-1-10 compressor 1Compressor 1 control settings menuEnters the compressor control menu comprising the next five settings

- - - -

6-1-10-1 start delayCompressor 1 start delay timeDelay period, following start initiation, before the compressor is permitted to start

0 300 15 secs.

6-1-10-2 winter start dlyCompressor 1 winter start delay timeFor problem-free starting during winter, when ambient temperature is low

0 300 180 secs.

6-1-10-3 start to startCompressor 1 starts per hour limitingEnsures that compressor starts per hour are limited to manufacturer’s recommendations

0 500 300 secs.

6-1-10-4 hot gas st dlyCompressor 1 hot gas start delay timeDelays hot gas implementation following compressor starting

0 120 45 secs.


- - - -

6-1-11-1 start delay Compressor 2 start delay time 0 300 15 secs.

6-1-11-2 winter start dly Compressor 2 winter start delay time 0 300 180 secs.

6-1-11-3 start to start Compressor 2 starts per hour limiting 0 300 180 secs.

6-1-11-4 hot gas st dly Compressor 2 hot gas start delay time 0 120 45 secs.


- - - -





6-1-13 comp rotationCompressor rotation periodFor equalisation of hours run between compressors

0 60100 - hours



IPAC



Document 0410536

AHU SETTINGS (continuation)

Setting


Range Default Units

Min. Max.

6-1-14 free cool d/b

Economy cooling deadband valueNo PID control is applied while economy cooling medium temperature is within the deadband, which is an offset value from the room temperature set point

0 5 °C

6-1-15 free cool propEconomy cooling proportional band valueFor proportional control

0 20 °C

6-1-16 free cool inhibitEconomy cooling inhibit %RH valueFor economy cooling override in favour of minimising the need to control humidity

50 100 %RH

6-1-17 heater start dly

Heater start delay periodEnsures that excessive temperature is avoided, by delaying heater operation until the airflow switch is deemed to be ‘made’ (healthy)

0 300 90 secs

6-1-18 vapac start dlyHumidifier start delay periodDelays humidifier operation until the airflow switch is deemed to be ‘made’ (healthy)

0 900 60 secs

6-1-19 filter block dyFilter blocked alarm delay periodDelays the filter blocked alarm from being reported

0 240 mins.

6-1-20 airflow periodAirflow failure alarm delay periodDelays the airflow failure alarm from being reported

mins.

6-1-21 reset hoursHours run counters resetResets all counters to zero

- - - -



IPAC


Setup • Adding or removing units from a network

Document 0410536

Setup menu settings, shown in Table 4-3, are normally factory-set and should not be adjusted at site unless a networkconfiguration is being set up.Setup is carried out during installation and not normally alteredthereafter. However, use of certain setup functions isoccasionally necessary, to enable the following to actions becarried out:• Run any units of a network as standalone units

• Assign an alternative unit to be the Master in a network• Assign or change run / standby arrangements• Attach or unattach units of a network• Breaking down a network to create zones of control, by

creating additional Master units and assigning slave units tothose zone Masters

• Reassigning slave units to alternative zones

The setup procedure descriptions which follow are provided forinformation: • To prevent inadvertent changes from being made, the

message ‘are you sure?’ is displayed whenever appropriate.• Only clear this message by pressing if certain that

changes being made are correct, otherwise press .

CAUTIONWhenever making any changes under the Setupmenu, always continue through to the finish; i.e.do not attempt to backtrack or press (except inresponse to ‘are you sure’), otherwise corruptioncan result.For the same reason, do not interrupt power to thecontroller while making changes under the Setupmenu.

Table 4-3 : Setup menu settings

Setup Menu SettingsPassword not required

Setting No.(Screen)

Screen Text Description

1-1 languages Languages - enables selection of the native language for text display

1-2 attach to unitUnit attachment - attaches the display to the controller motherboard; this requires the service pin on the motherboard PCB to be pressed.

1-3 site setup Setup unit - enables the next three items to be configured

1-3-1 no. run unitsNumber of run units - used to specify the number of units allowed to run in the network at any time, under normal conditions

N/A rotation periodRun rotation period - used to specify the number of hours (up to 99999) before duty changeover, to equalise hours run between units

N/A sensor operation

Sensor operation - used to specify temperature / humidity sensor / data handling - options are:• Average - for averaging of data from several sensors• Individual - for individual sensor in each of all AHUs in the network• From master - for using only the Master unit’s sensor data

1-4 ahu serv. msg AHU service message - executes the service message required to attach to the Master unit

1-5 network setup Network setup - enables attachment of units to make up a network

1-6 reset display Display reset - enables the display screen to be reset or refreshed

1-7 (1-10) display type Display type - used to specify whether the display is either local or remote (special option)

(1-7) factory defaults Restores the controller to factory installed default settings

(1-8) resync system System resynchronisation - enables resynchronisation of a slave unit’s settings

(1-9) select logoEnables logo selection for display splash screen during initialisation;i.e. ‘InvictaNET’ or ‘EW’

NOTE Setting numbers in brackets are accessed by using the E-W password and are provided here for information only.

OK

ESC

ESC


IPAC


If is pressed inadvertently, or power is Setting 1-4 AHU service messageESC

Document 0410536

interrupted, to rectify any corruption, it may benecessary to setup the controller / network fromfirst principles.After making any changes under the Setup menu,always complete the process by executing theReset Display command from the Setup Menu, foreach unit in the network. This synchronisesdisplays with controllers. Displays that are notsynchronised do not show up-to-date informationand can cause confusion.Note that interrupting power to a controller willnot reset or synchronise the display after changeshave been made under the Setup menu.

Setting 1-1 LanguagesThis is used to select the native language for the text-onlydisplay, as follows:

1. Select the required language (e.g.) and then press .

2. Press to implement the choice and exit the menu.

Setting 1-2 Attach to unitThis is used to attach, in software, the display to the motherboard, as follows:

1. Select attach to unit and then press .

The Waiting for service message is now displayed.

2. Press the <Service> pin button on the motherboard PCB.

3. Press to exit the menu.

Setting 1-3 Site SetupThis enables three sequenced setting configurations to bespecified:

NOTEConfiguration settings made under setting 1-3 areapplied to all units in a network

Number of run units - to specify the number of units thatare allowed to run in the network at any time, under normalconditions.

Rotation period - to specify the number of whole hoursbefore ‘running duty’ changeover takes place, to equalisehours run between units.

Sensor operation - to specify temperature / humidity sensor/ data handling - options are:

• Average - which controls from an average value calculated from all operating unit sensor readings

• Individual - for control in response to an individual sensor• From Master - for control in response to the Master unit’s

sensor only

Input voltage - set the main incoming voltage to the unit.There are various options - typically:

• 380 V ac, 415 V ac, 440 V ac

Set this to the most appropriate value for the site.

With this selected, press .to provide the service messagerequired to attach the unit to a network Master unit.

Setting 1-5 Network setupWhen executed by pressing , this command instructs thecontroller to expect a service message (see ) from a slave unit, tocreate, or add to, a network.

Setting 1-6 Reset displayWith this selected, press .to refresh the display.

NOTEAfter carrying out any operations under the Setupmenu, it is important to reset the display of eachunit in a network, otherwise, the display may notreflect changes made.

The Reset Display function is also useful to refresh the display inthe unlikely event that it has become corrupted for any reason.

Setting 1-7 Display typeThis is used to specify the type of display, according toinstallation preference. Options are:• Local - for unit-based display (standard)• Remote - for off-unit display, enabling remote monitoringNote that via the E-W password logon, the screen number forthis setting is 1-10.

Setting 1-7 Factory defaultsExecuting this command restores the controller to factorydefault setting values.Note that this setting is only available via the E-W passwordlogon.

Setting 1-8 Resync systemThis is command is used to synchronise a network slave unit tothe system settings configured on the Master unit.Note that this setting is only available via the E-W passwordlogon.

Setting 1-9 Select logoThis setting enables the logo to be specified for the splash screendisplayed during initialisation; i.e. ‘InvictaNET’ or ‘EW’.Note that this setting is only available via the E-W passwordlogon.

Control FunctionsA controller start-up timing diagram is shown in Fig. 4-2 and itwill be found helpful to refer to this while reading the followingcontrol descriptions.

Power-up conditionAssuming that the controller has already been commissioned, onpowering-up, the controller is in a reset state, ready for normaloperation.Operational status following power-up depends on whether anexternal start/stop control is fitted:• No external start/stop.

OK

ESC

OK

ESC

OK

OK

OK


IPAC


• If an external start/stop control is not fitted, plant equipment Compressor and Condenser - Starting

Document 0410536

will be operational, subject to controller starting strategy.• External start/stop or optional door switch.• If an external start/stop control is fitted, plant equipment will

remain idle on standby until the start signal is provided.• Upon receipt of the start signal, plant equipment will be

operational, subject to controller starting strategy.

Starting and operation - basic overviewEach AHU starts operation subject to control as follows:

1. Master unit control power ON, or network slave unit signal to RUN received.

Network units are started in sequence according to pre-selected order.

2. The supply fan starts when the Fan Start Delay Time setting of 30 seconds (default) expires.

3. Airflow failure alarm is inhibited for a further 20 seconds (non-adjustable default), to enable airflow to established and make the airflow switch.

Provided that airflow is correct on expiry of the alarm inhibit period, normal operational control is enabled.

If the airflow switch fails to make, an Airflow Failure urgent alarm is generated and starting is aborted.

4. Sensed air temperature is compared to the room temperature set point, to establish whether cooling or heating is required. Heating or cooling is then initiated as appropriate, according to PID control; for details refer to .

Sensed air humidity is compared to the room humidity set point, to establish whether humidification or dehumidification is required. Humidification or dehumidification is then initiated as appropriate, according to PID control; for details refer to .

Temperature and Humidity PID controlAir temperature is controlled by two PID (Proportional Integraland Derivative) algorithms, one for heating, the other forcooling.Each algorithm includes the same adjustable dead band, whichequally spans each side of the room temperature set point.If I (Integral) and D (Derivative) values are zero, control isproportional only.Proportional units are in °C.

Humidity PID controlAir humidity is similarly is controlled by two PID algorithms, onefor humidification, the other for dehumidification.Each algorithm includes the same adjustable dead band, whichequally spans each side of the room humidity set point.If I and D values are zero, control is proportional only.Proportional units are in % RH.

OperationCompressor starting and condenser enablement are initiatedsimultaneously in response to a demand for cooling and/ordehumidification.Starting is only permitted when:• Supply fan has been running for the Compressor Start Delay

Time period of 60 seconds (default) and the airflow switch ismade (healthy).

• Condensate drain sensor (if fitted) signals that the drain isnot blocked.

• High pressure HP cut-out is made (safe).

And:

Low pressure LP cut-out is made (safe).

And:

Compressor drive motor overload is made (healthy).

If any of these are control circuits are not made, theappropriate urgent alarm is generated and starting is aborted.

Assuming that all the above conditions are met, compressor andcondenser starting is initiated and the following controlstrategies implemented during the start period.

Condenser operationApart from start/stop signals provided by the controller,condenser operation is wholly subject to control by its owncontroller and starter panel.Condenser control enablement and stopping is simultaneouswith compressor starting and stopping.

Low pressure (LP) cut-out inhibitDuring compressor starting, the LP cut-out is effectivelybypassed for the Winter Start Delay Time setting period of 150seconds (default). This period enables normal operationalsuction pressure to be established during periods of low ambienttemperature, when the LP cut-out might otherwise trip andprevent compressor starting.If normal operational suction pressure is not achieved by thetime the setting period expires, an LP cut-out tripped urgentalarm is generated and starting is aborted.

Hot gas injection systemThe hot gas injection system (if fitted) is only operative forcooling demand.When the master compressor is required to operate at part loadbecause there is only a small demand for cooling, the hot gasinjection system is used to create a false load. In this way, asillustrated in Fig. 4-3, the minimum stage of capacity control isachieved.However, during the start period, hot gas injection is undesirablebecause of the possibility of high discharge pressure beinggenerated quickly and tripping the HP cut-out.Therefore, during the start period, hot gas injection is inhibitedfor the Hot Gas Start Override Time setting period of 30 seconds(default).


IPAC


Fig. 4-2 : Controller start-up timing diagram

Document 0410536

Controller Start-up Timing Diagram

Supply ON, controller initialised and operative. Control enabled for cooling,heating, humidification and dehumidification (master unit only).

Supply Fan Start Delay Time of 30 seconds expires - supply fan starts.Airflow Failure Alarm Inhibit Time of 20 seconds starts.

Airflow Failure Alarm Inhibit Time of 20 secondsexpires. Provided airflow switch is made(healthy), starting control is enabled.

If airflow switch is not made (healthy),controller generates an Airflow Failureprompt alarm and starting is aborted.

If cooling or dehumidification is required, Compressor Start Delay Time of 60 seconds starts.If heating is required, Heating Start Delay Time of 90 seconds starts.If humidification is required, Humidifier Start Delay Time of 300 seconds starts.

Compressor Start Delay Time of60 seconds expires.Provided that HP and LP cut-outs,compressor drive motor overloadand airflow switch are made(healthy), compressor starts andcondenser is enabled.

If HP cut-out, LP cut-out,compressor drive motoroverload, or airflow switchare not made (healthy), thecorresponding promptalarm is generated andstarting is aborted.

First stage capacity Hot Gas Bypass1 Start Override Time of 30seconds starts.Winter Start Delay Time2 of 150 seconds starts.

If compressor 21 is also required to start, the Compressor 2 Start Delay Time of 60 seconds starts.

Heating start delay time of 90 seconds expires - heating control enabled.

First stage capacity Hot Gas Bypass1 StartOverride Time of 30 seconds expires - hot gasbypass solenoid valve energises (opens).

Winter Start Delay Time2 of 150 seconds expires - LP cut-out control nolonger inhibited.

If LP cut-out is not made(healthy), compressorstops and a prompt alarmis generated.

Humidifier StartDelay Time of 300seconds expires - humidifier controlenabled.

WinterStart Delay Time2 of 150 seconds expires - LP cut-out control nolonger inhibited.

If LP cut-out is not made(healthy), compressor 2stops and a prompt alarmis generated.

Compressor 21 Start Delay Time of60 seconds expires.Provided that HP and LP cut-outs,compressor drive motor overloadand airflow switch made (healthy),compressor starts and condenseris enabled.

If HP cut-out, LP cut-out,compressor drive motoroverload, or airflow switch arenot made (healthy), thecorresponding prompt alarmis generated and starting ofcompressor 2 is aborted.

Winter Start Delay Time2 (compressor 2) of 150 seconds starts.

Normal events.

Compressor start event.

Fault conditions and response.

Timed event path from source.

0 60 120 180 240 300 360

NOTES:Values shown for timed eventsare controller default settings.1If fitted.2If utilised (default is utilised).

TIME IN SECONDS

COLOUR KEY:


IPAC


On expiry of this period, the hot gas injection solenoid valve is Fig. 4-3 : Compressor capacity stage control diagram

Document 0410536

energised (opened) to bring the system into operation.The hot gas injection system is not implemented fordehumidification demand.

Compressor 2 startingFor units fitted with dual refrigeration circuits, compressor 2 isonly started when required to meet cooling demand and canonly start if:• Compressor 1 has been running for the Compressor 2 Start

Delay Time of 60 seconds (default). Or:• It is required to run in place of compressor 1, which is not

running because of a fault condition (e.g. overload tripped).Or:

• Humidity override is set to <ON>.All pre-start control conditions described under Compressor andCondenser - Starting Operation on page 4-14 must be met.Control strategies described under Low pressure (LP) cut-outinhibit and Hot gas injection system on page 4-14 are applied asappropriate.

Compressor starts per hour limitingOnce a compressor has been started and then stopped (by a faultor temporary drop in demand), it cannot restart for the Starts PerHour Limiting Time setting of 360 seconds (default).This delay period prevents short-cycling, which could otherwisecause the compressor drive motor to burn out.

CAUTIONFailure to observe the compressor manufacturer’srecommendations for starts per hour limiting mayresult in the drive motor burning out andconsequential contamination of the entirerefrigeration system.The Starts Per Hour Limiting Time defaultsetting(s) should not be adjusted withoutpermission from Eaton-Williams.

Compressor Capacity ControlFig. 4-3 illustrates how stages of compressor capacity arecontrolled, for two compressors, in response to an increasingcooling demand, from zero to maximum.Table 4-4 shows control response for units fitted with one, two,or three compressors, with or without hot gas injectioncompressor capacity reduction.Fig. 4-3 and Table 4-4 show how a closer match to coolingdemand can achieved by using more than one compressor, andthat capacity can be matched even more closely by using a hotgas injection system on one compressor.

Built-in HysteresisOn reduction of cooling demand, control OFF signals will lag ON

signals by approximately 20 to 30 % of cooling demand asfollows:

Example:

Formula for calculation of cooling demand:

Where:

CD = Cooling Demand %

RT = Return/room air Temperature °C

SP = Set Point = 21 °C

DB = Dead Band = 2 °C

PB = Proportional Band = 5 °C

Therefore, if return air temperature = 25 °C:

By referring to Fig. 4-3 and applying this example to a singlecompressor unit, it can be seen that 60 % capacity equates tothe compressor running + hot gas.Whereas, applying the example to a two compressor unit, 60 %capacity equates to compressor 1 running (no hot gas).

Compressor Capacity Stage Control Diagram

20 21 22 23 24 25 26 27

70 % - Stage2Comp. (no hot gas)

30 % - Stage1Comp + hot gas

SINGLE COMPRESSORCONTROL

TWO COMPRESSORCONTROL

Stage 4 - 95%Comps.1 + 2 (no hot gas)

Stage 3 - 70%Comp.1 + hot gas + comp. 2 (no hot gas

Stage 1 - 30%Comp.1 + hot gas

Stage 2 - 50%Comp.1 (no hot gas)

Air Temperature ˚C

Proportional bandDead band

Set point

NOTES:The example shown here is for information only and assumes that a Room Temperature Set Point of 21˚C isrequired, with a Dead Band of 2˚C and a cooling Proportional Band of 5˚C.Values shown here have been selected for clarity. The default value for the Dead Band is 2˚C.The default value for the Proportional Band is 3˚C.Because Dead Band and Proportional Band setting values are both offsets from the Set Point, their true valueis adjusted automatically to follow any adjustment made to the Set Point value.

0

50

100

Cooling Demand %

CD = RT SP 0.5 DB ) ]×(+[–PB

-------------------------------------------------------------- 100×

CD = 25 21 0.5 2 ) ]×(+[–5

---------------------------------------------------- 100×

CD = 35--- 100× 60 %=


IPAC


Table 4-4 : Cooling Duty Control Response - DX units

Document 0410536

Cooling Duty Control Response - DX Units

DEM

AN

D

UNIT OPERATING STATE

COOLING DEMAND %

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

1 C

OM

PRES

SOR

UN

IT

Rise

Hot gas injection

Compressor

Output % - with HGI 60 60 60 60 60 60 60 60 100 100 100 100 100 100 100

Output % - no HGI 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100

Fall

Compressor

Hot gas injection

Output % - with HGI 60 60 60 60 60 100 100 100 100 100 100 100 100 100 100 100 100 100 100

Output % - no HGI 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100

2 C

OM

PRES

SOR

UN

IT Rise

Hot gas injection

Compressor 1

Compressor 2

Output % - with HGI 30 30 30 30 50 50 50 50 80 80 80 80 80 100 100

Output % - no HGI 50 50 50 50 50 50 50 50 100 100 100 100 100 100 100

Fall

Compressor 2

Compressor 1

Hot gas injection

Output % - with HGI 30 30 30 30 30 50 50 50 50 80 80 80 80 80 80 100 100 100 100

Output % - no HGI 50 50 50 50 50 50 50 50 50 100 100 100 100 100 100 100 100 100 100

3 CO

MPR

ESSO

R U

NIT

Rise

Hot gas injection

Compressor 1

Compressor 2

Compressor 3

Output % - with HGI 20 20 20 33 33 33 53 53 53 67 67 67 87 87 87 87 100 100

Output % - no HGI 33 33 33 33 33 33 67 67 67 67 67 67 100 100 100 100 100 100

Fall

Hot gas injection

Compressor 3

Compressor 2

Compressor 1

Output % - with HGI 20 20 20 33 33 33 53 53 53 67 67 67 87 87 87 87 100 100 100

Output % - no HGI 33 33 33 33 33 33 67 67 67 67 67 67 100 100 100 100 100 100 100

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

NOTESHGI = Hot Gas Injection for capacity reduction.Tick denotes that the function is operating.Output % values shown in columns are percentage values of whole unit capacity.


IPAC


Chilled Water Unit Cooling Duty

Document 0410536

ControlFor chilled water units, the cooling duty control response isdirectly proportional to the demand.The controller uses the cooling Proportion, Integral andDerivative (PID) algorithm to determine control response andprovides a 0 to 10 volt signal to modulate the flow control valveaccording to demand.The 0 to 10 volt signal provided by the controller is directlyproportional to the positioning range of the flow control valve,where:

0 volts = valve fully closed100 volts = valve fully open


IPAC


Economy Cooling Options GlyCool economy cooling (cooling air by using glycol and water

Document 0410536

There are two types of economy cooling control option availablefor the IPAC range of AHUs.

Fresh-Air Economy CoolingGlycol Economy Cooling

Both systems can be optimised to use the relevant coolingmedium, where conditions allow, to achieve the required aircondition, whilst minimising the running time of the compressoror cooling plant.Basic control of fresh-air economy cooling adopts a simplestrategy, which is subject to both cooling and humidity controlalgorithms and defined by the following settings in theEngineering AHU Menu:

Economy cooling deadband value setting 6-x-14Economy cooling proportional band value setting 6-

x-15Economy cooling inhibit %RH value setting 6-x-16

Where ‘x’ = the AHU number.

• Refer to Section 5 - INVICTANET Controller Settings Record

Fresh-Air Economy CoolingFresh-air economy cooling control requires that the followingitems of optional equipment are installed:• A mixing box with modulating damper, in the return air path• A modulating damper actuator, 0 to 10 V dc• An outside air temperature sensorAlthough energy-efficiency is the reason for utilising this option,control of air condition is the primary concern. Therefore,various control features will override fresh-air cooling, whenappropriate, to ensure that air is maintained in a satisfactorycondition.If air humidity reaches a predetermined limit, defined by theEconomy Cooling Inhibit %RH Value setting, demand foreconomy cooling is overridden until the controller deems thateconomy cooling can resume without adversely affecting the aircondition.Standard control philosophy operates at all times, unless the anyof the following events occur.

• Temperature differential between outsideambient air and return air is 13 °C or greater.

In this case, control response is to permit damper modulationto meet economy fresh-air cooling demand(if required)

• Fire shutdown

In this case, control response is to shut down the unit andforce the fresh-air inlet damper to the maximum closedposition.

• Smoke extract

In this case, control response is to force the fresh-air inletdamper to the maximum open position.

Glycol Economy CoolingThis option is applicable to water-cooled DX units only.

cooling medium) control requires that the following items ofoptional equipment are installed:• A modified air cooling coil block, which has an airflow-facing

economy cooling coil, before the DX main cooling coil.• A 3-way modulating valve• A modulating valve actuator, 0 to 10 V dc• A temperature sensor strapped to the cooling medium pipeStandard control philosophy operates at all times, unless:

• The temperature of the cooling medium enteringthe unit is at a predetermined value (derivedfrom the Room Temperature Set Point) or lower.

In this case, control response is to permit modulation of the 3-way valve to meet GlyCool economy cooling demand (ifrequired). The required volume of cooling medium is divertedthrough the economy cooling coil of the coil block, beforereturning to the cooled medium circuit.In this way, whenever favourable conditions exist, compressorduty is supplemented by the surplus duty performed by the drycooler.When optimum conditions exist and all air-cooling duty can bemet by the dry cooler, the controller stops the compressor. Thisis when GlyCool economy cooling is at its most energy-efficient.The controller will then not restart the compressor until the drycooler is no longer able to meet the increase in cooling demand.

Electrical HeatingElectrical heater operation is only permitted when:• The supply fan has been running for the Heating Start Delay

Time period of 90 seconds (default).• The relevant airflow switch is made (healthy).• The relevant high temperature (HT) cut-out monitoring circuit

is made (healthy).Up to six stages of heating can then be bought into operationand controlled according to the temperature PID algorithm; see .The controller considers the heater elements as being in twobanks and controls heater contactors to give stages of zero, onethird and two thirds of the full heating demand. • Where a single heater bank is fitted, this is bought into

operation at two-thirds of the full demand.• Where two heater banks are fitted, on a rising demand, the

first bank is bought into operation at one-third of the fulldemand.

At two-thirds of full demand, the first bank is switched OFF

and the second bank is bought into operation.

At a full-demand condition, the first bank is bought intooperation is also bought into operation.

In this way, near proportional control of the heater banks isachieved. If a high temperature condition causes the HT cut-outto trip, heaters are de-energised and an urgent alarm isgenerated at the customer terminals and on the unit display (iffitted).


IPAC


Heating capacity control

Document 0410536

Heating capacity control is as shown in Table 4-5 or Table 4-6,depending on whether a hot gas reheat system is fitted.Note that for only one stage of electrical heating, control for thisis to be connected to the second stage (heater 2) output.

Humidifier ControlHumidifier operation is only permitted when:• The supply fan has been running for the Humidifier Start

Delay Time period of 300 seconds (default).• The airflow switch is made (healthy).For a Vapac® WL humidifier, control is as follows:Note that in addition to the following description, humidificationis subject to control according to the humidity PID algorithm;refer to for details.If air humidity falls below the Room Humidity Set Point of 50 %RH (default) and is below the PID dead band lower limit, thehumidifier is bought into operation, initially at 20 % of itscapacity.The humidifier is then capacity-modulated (range 0 to 100 %capacity), to meet humidity demand.

If humidity increases to within the PID dead band, modulation ofhumidifier capacity ceases.On increasing humidity, capacity is modulated downwards untilit is reduced to 19 %, at which point, humidifier operationceases.Note that if demand current is lower than running current by 10%, the humidifier will switch off until demand is 5 % higher thanthe demand current was at switch-off; this is part of the VapacWL humidifier control strategy.For a combined master/slave AHU, if humidity demand is greaterthan 80 % of capacity and only the master unit compressor isoperating on cooling demand, control will be overridden to stopmaster unit compressor 1 and start slave unit compressor 2 tomeet cooling demand.This is done to maximise absorption of steam generated by thehumidifier in the master section of the unit.

Table 4-5 : Heating capacity control strategy - without hot gas reheat

On rising demand from 0 to 100 %

Capacity 0 % 20 % 35 % 50 % 65 % 80 % 95 % 100 %

Master unit heater 1 Off On On Off Off On On On

Master unit heater 2 Off Off Off On On On On On

Slave unit heater 1 Off Off On On Off Off On On

Slave unit heater 2 Off Off Off Off On On On On

On falling demand from 100 to 0 %

Capacity 100 % 80 % 65 % 50 % 35 % 20 % 5 % 0 %

Master unit heater 1 On On Off Off On On Off Off

Master unit heater 2 On On On On Off Off Off Off

Slave unit heater 1 On Off Off On On Off Off Off

Slave unit heater 2 On On On Off Off Off Off Off

Table 4-6 : Heating capacity control strategy - with hot gas reheat

On rising demand from 0 to 100 %

Capacity 0 % 20 % 45 % 50 % 60 % 75 % 95 %

Master unit heater 1 Off Off On Off Off Off On

Master unit heater 2 Off Off Off On On On On

Slave unit heater 1 Off Off Off On Off On On

Slave unit heater 2 Off On On Off On On On

On falling demand from 100 to 0 %

Capacity 100 % 80 % 65 % 50 % 35 % 20 % 5 %

Master unit heater 1 On Off Off Off On Off Off

Master unit heater 2 On On On On Off Off Off

Slave unit heater 1 On On Off On Off Off Off

Slave unit heater 2 On On On Off On On Off


IPAC


If cooling demand then increases, requiring both compressors to In this way, the AHU of a master unit does not have to be the first

Document 0410536

run stage 3 cooling, then compressor 1 will be started to meetstage 3 duty.If humidity demand reduces to 30 %, the cooling resets tostandard operation.

Dehumidification ControlOn rising humidity, where a demand for dehumidification risesfrom 0 to 100 %, dehumidification is bought into operation atfull capacity and then modulated down to zero to match fallingdemand and according to the dehumidification PID controlalgorithm.

Cooling control overrideAt times when compressor 1 + hot gas is operating (i.e. atminimum capacity) to meet cooling demand, if demand fordehumidification rises to 80 %, then cooling demand isoverridden and the hot gas solenoid valve is de-energised(closed). Compressor 1 is now operating at maximum capacity tomeet dehumidification demand.When demand for dehumidification falls to 20 %, the hot gassolenoid valve is permitted to energise (open) to allowcompressor 1 to return to minimum capacity cooling duty (ifrequired).To prevent the air from being overcooled unacceptably during aperiod of cooling override, if air temperature falls to the valuedetermined by the Dehumidification Override TemperatureDifferential setting, cooling control override ceases. This allowsair temperature to rise toward the Room Air Temperature SetPoint.When air temperature has risen to halfway between the valuedetermined by the Dehumidification Override TemperatureDifferential setting, Room Air Temperature Set Point and theRoom Air Temperature Set Point, cooling control override isagain permitted (if required), so that maximum dehumidificationcan be resumed.

CommissioningCommissioning must only be carried out by Eaton-Williamsauthorised personnel.All commissioning is carried out at Setup and Service levelmenus.

Network Master / Slave ControlUp to ten AHUs can be networked together as an overall system.For connection details, refer to wiring diagrams for theinstallation and to .For network control to function, supply must be live to the unitcontroller(s).Each unit will start operation in the same order of sequence as itwas ‘attached’ to the master unit during commissioning.Future modifications to overall network operation can beachieved by nulling controllers to stand-alone and then re-attaching them in the preferred order, including extra units (ifapplicable).

to be installed.To avoid unacceptable surges in electrical demand during startperiods, each unit follows the same sequence of equipment startdelay times (e.g. supply fan, compressor, condenser, heating andhumidifier) as illustrated in Fig. 4-2.Therefore, using Engineering menu level default settings,starting of units is sequential and staggered, so thatsimultaneous starting of units and their equipment is avoided.For standby units, starting is as described under .

Automatic starting of standby units in response to a fault conditionOnce running, if a unit develops a type of fault that generates anurgent alarm and there are standby units available to run, theunit will be switched <OFF>.This event will be detected by the master units, as the ‘unitsrunning count’ will be less than the required number.In this case, the first-in-sequence standby unit will start,regardless of its position in the normal start sequence. In thisway, the duty of the stopped unit is replaced at the next shorteststart delay

Automatic starting of standby units in response to an air high temperature conditionIf air temperature rises to the extent that the Standby Overrideon Temperature Rise setting is reached, this causes the numberof each unit required to run on the zone to be increasedautomatically by 1, resulting in the next standby unit beingstarted.This standby unit is then run for 2 hours and then switched offuntil the next high temperature condition arises (should one doso), whereupon the override strategy is repeated.

Duty RotationWhere two units operate as run / standby, to equalise run times,automatic rotation of units is available.

Local NetworkingIf a group of up to ten AHUs (comprising a master and up to ninenetwork slave AHUs) are to be locally networked, each controllermust be connected to at least one other controller on thenetwork, in any desired configuration.Connections between controllers are made using twin-corecommunications cable, which can be either screened orunscreened.Two terminals, Net A and Net B, are provided on eachcontroller for making these network connections.

NOTETo minimise the risk of poor connection, networkcabling is to be connected direct to the controllerterminals provided, not via customer terminalrails.


IPAC


System Networking Trend Network Interface ( <5 Units )

Document 0410536

Multiple network zones, each comprising a master and up tonine network slave AHUs, may be monitored and controlled froma control centre.The control centre can be either local or remote and may benetworked to each zone via telecommunications links, which canbe either hard-wired or wireless, depending on requirements,location, etc.Unattended control centres can also incorporate remote alarmreporting. Such a system typically includes an automatic voice-dialler, which can be configured to ring a sequence ofpredetermined telephone contact numbers in turn, untilanswered. A PC fitted with a modem can then be connected tothe system, which, after correct password entry, can beinterrogated to evaluate the alarm and how it should beresponded to.For further information on system networking, requirements andprotocols for single or multiple network zones and/or remotealarm reporting, please contact Eaton-Williams.

External Interface ProtocolVapac is LONMARK™ PARTNER and LonMark® compliant.For details of external interface protocol, refer to Table 4-11.All Eaton-Williams coding is fully LON Interruptible compliant tothe LONWORKS® Echelon Local Operating Network (LON)standard and therefore meets registered requirements.

ModBus Network InterfaceThis gateway allows proprietary control and monitoring systemsto interface to E-W LonWorks AHU network.The gateway provides a EIA-232 serial port, which can be usedto communicate at the application layer via the MODBUSprotocol.Acting as a MODBUS slave, it will respond to queries from amaster device. The gateway utilises ASCII serial transmissionmode.• Full exception processing is implemented • One gateway is required for up to nine units in a network

Trend ControllerFor units that are fitted into an area controlled by a Trend BMSsystem, a Trend Network Interface is available.Should this be unsuitable, a Trend IQ204 controller can be fittedinstead. By default, such units are fitted with a Trend FPKdisplay.

NOTECertain IPAC range options may not be availablewith the Trend control option. Please contactEaton-WIlliams for further details.

This option is a network add-on to the InvictaNET system.Consisting of the Modbus Network Interface, as well as a TrendXNC device, with custom written software (I/O available fromEaton-Williams). The XNC device can sit directly on a Trend IQnetwork and can be directly seen by a Trend 945 or 962Supervisor.

Alternative Language (ASCII)The InvictaNET graphical user interface can be supplied with alltext screens switchable between two languages, with Englishalways residing on the display for E-W Engineer access.When exported, the display can be changed to display one otherEuropean language by default.Non-ASCII character languages can be supported, but mayrequire additional programming.

Fault Conditions, Alarms and ResponseThe controller monitors for various fault conditions according toconfiguration and signal inputs.In response to a detected fault condition, controller generatesone of two types of alarm, namely:These are defined as follows; also refer to “Alarms” on page 3-15 of Section 3.

Urgent Alarm

Indicated by an animated bell icon being automaticallydisplayed on the System screen.

An urgent alarm is generated in response to a fault conditionwhich prevents unit operation; e.g. Airflow Failure alarm.


Non-urgent Alarm

Indicated by a static bell icon, reversed-out, beingautomatically displayed on the System screen.

A non-urgent alarm is generated in response to a faultcondition, which requires attention, but does not immediatelyprevent a unit from operating.

Both types of alarm can be monitored remotely; see Alarmremote monitoring on page 4-23 for details.Controller Response to an Alarm

Urgent alarm This is indicated by an animated bell icon being displayed on theSystem screen.An urgent alarm (see Fig. 4-4) is generated in response to a faultcondition which prevents unit operation; e.g. Airflow Failurealarm.


IPAC


Fault Conditions, Alarms and ResetFig. 4-4 : System screen urgent alarm

Document 0410536


Non-urgent alarm This is indicated by a static bell icon, reversed-out, beingdisplayed on the System screen)A non-urgent alarm (see Fig. 4-5) is generated in response to afault condition, which requires attention, but does notimmediately prevent a unit from operating.Note that if the building icon is flashing reversed-out (as shownin Fig. 4-5), the alarm relates to air temperature, humidity, orboth

Alarm remote monitoringBoth urgent and non-urgent alarm conditions can be remotelymonitored, via volt-free contacts, by making appropriate wiringconnections to the customer terminals provided. Refer to theunit wiring diagram for details.

CAUTIONThe low voltage alarm circuit from the controllerMUST be isolated from high voltage, otherwise thecontroller may be damaged.

Urgent and non-urgent alarms can each be configured to provideeither pulsed or continuous signals.

Fault ConditionsThe controller monitors for fault conditions and responds asdetailed in Table 4-7.Urgent and non-urgent alarm types are described under“Alarms” on page 3-15 of Section 3.

The controller monitors for various fault conditions, according toconfiguration and signal inputs.On detection of a fault condition, the controller responds by:• Stopping items of plant equipment, such as the compressor,

as appropriate.• Initiating urgent or non-urgent alarms as appropriate;

described under Fault Conditions, Alarms and Response onpage 4-22.

• Automatically changing the display to indicate the fault; fordetails refer to “Alarms” on page 3-15 of Section 3. Fordetails of the Alarm Screen, refer to .“Alarm Screen” onpage 3-7 of Section 3.

After correction of a fault condition, the fault must be cleared bypressing OK on the keypad; refer to Fig. 4-1.Text menu levels must be accessed to view and clear alarms;refer to “Identifying and Clearing Alarms” on page 3-15of Section 3.If the fault no longer exists, the controller will resume normaloperation.Note that compressor restarting may be subject to the Start PerHour Limiting Time setting, as described under .If the fault condition still exists, the controller will detect thisduring its next scan cycle and will indicate the same fault again.The controller monitors for the following fault conditions:

Air temperature alarmsShould air temperature rise to the Room High TemperatureAlarm setting, a non-urgent alarm is generated at the customerterminals and on the unit display (if fitted).Should air temperature fall to the Room Low Temperature Alarmsetting, a non-urgent alarm is generated at the customerterminals and on the unit display (if fitted).Note that this alarm is inhibited for two hours following startingand for five minutes after the alarm has been accepted.

Air humidity alarmsShould air temperature rise to the Room High Humidity Alarmsetting, a non-urgent alarm is generated at the customerterminals and on the unit display (if fitted).Should air temperature fall to the Room Low Humidity Alarmsetting, a non-urgent alarm is generated at the customerterminals and on the unit display (if fitted).Note that this alarm is inhibited for two hours following startingand for five minutes after the alarm has been accepted.

High pressure (HP) cut-out trippedIf discharge pressure rises to the extent that the high pressure HPcut-out trips, the compressor stops and an urgent alarm isgenerated at the customer terminals and on the unit display (iffitted).

Fig. 4-5 : System screen non-urgent alarm

20.6˚C23.5˚C41 %

invictanet

27.4°C24˚C54%

invictanet


IPAC


Table 4-7 : Fault conditions and response

Document 0410536

Low pressure (LP) cut-out trippedIf suction pressure falls to the extent that the low pressure LPcut-out trips, the compressor stops and an urgent alarm isgenerated at the customer terminals and on the unit display (iffitted).

Air filter blockedIf the air filter becomes choked to the extent that the airdifferential pressure switch trips, the display changes to indicatethat the filter is blocked.

For units fitted with multiple filter banks, each bank is separatelymonitored by a differential pressure switch.A blocked filter condition initiates the Filter Blocked Alarm Delaysetting period of 60 minutes (default).If the blocked filter condition is not rectified within the delayperiod, a non-urgent alarm is generated at the customerterminals. The display (if fitted) will indicate which filter bank(s)are affected. The unit continues to operate.

Fault Conditions and Response

Fault Description Response and Alarm Type Notes

Air high temperatureAir temperature rises to the Room High Temperature Alarm setting.

Non-urgent alarm.

Alarm is inhibited for two hours after starting and for five minutes after clearing the alarm.

Air low temperatureAir temperature falls to the Room Low Temperature Alarm setting.

High humidityAir temperature rises to the Room High Humidity Alarm setting.

Low humidityAir temperature falls to the Room Low Humidity Alarm setting.

High pressure

(HP) cut-out tripExcessive discharge pressure trips the high pressure HP cut-out.

Compressor stops.

Urgent alarm.

Low pressure

(LP) cut-out tripExcessively low suction pressure trips the low pressure LP cut-out.

Compressor stops.

Urgent alarm.

Air filter blockedAir filter choked to the extent that the air differential pressure switch trips.

Display changes to indicate that the filter is blocked. The Filter Blocked Alarm Delay setting period of 60 minutes (default) is initiated.

Failure to rectify the condition within delay period results in a non-urgent alarm.

Display identifies affected filter bank(s).

Airflow failureAirflow reduces to the extent that the airflow switch trips

Unit stops operating.

Urgent alarm.

Compressor overload

tripCompressor overload trips, stopping the compressor.

Respective compressor is switched OFF.

Urgent alarm.

Condensate flood Condensate flood is detected.Refrigeration system and humidifier stop.

Urgent alarm.

Supply fan continues to operate.


IPAC


Airflow failure If the fire detection system is triggered, it will interrupt the

Document 0410536

If supply airflow reduces to the extent that the airflow switchtrips, the unit stops operating and an urgent alarm is generatedat the customer terminals and on the unit display (if fitted).

Compressor drive motor overload trippedIf a compressor overload trips, stopping the compressor, therespective compressor is switched <OFF> and an urgent alarmgenerated.

Condensate flood alarmIf required, an optional condensate flood detection device can befitted. This could be, for example, a water detection sensor, oran alarm signal from a condensate pump.Signal contact function is:

Open circuit (contact breaks) = HealthyClosed circuit (contact makes) = Alarm

If a condensate flood is detected, the refrigeration system andhumidifier stop and an urgent alarm is generated at thecustomer terminals and on the unit display (if fitted). The supplyfan continues to operate.


CAUTIONIn an emergency, do NOT attempt to use controllerfunctions to shutdown equipment, as this willinitiate a controlled shutdown that is unlikely tobe effective immediately.

It is recommended that an optional external Emergency Stopbutton is fitted and connected into the master AHU controllerpower supply interlock; for details, refer to the unit wiringdiagram.

NOTEEach network slave AHU controller must beindividually connected to an Emergency Stopbutton, which may be a common device.

When the Emergency Stop button is pressed, it will interrupt thepower supply to the controller and stop the plant (includingpaired slave, if fitted) immediately.

Fire ShutdownIf required, a fire shutdown remote switching device (bycustomer) can be connected into the master AHU controllerpower supply interlock; for details, refer to the unit wiringdiagram. The switching device may be, for example, a functionof the building’s fire alarm system controller.

NOTEEach network slave AHU controller must beindividually connected to the fire shutdownswitching device.

power supply to the controller and stop the plant (includingpaired slave, if fitted) immediately. The display will continue tofunction.Note that because the signal circuit is low voltage, line lossesmust be allowed for, do not exceed 20 metres length of 0.5 mm2

core wiring. For longer distances, install a suitable relay device.

CAUTIONThe low voltage circuit from the controller MUSTbe isolated from high voltage, otherwise thecontroller may be damaged.

TroubleshootingThe following information is provided for guidance should aproblem arise relating to the controller or display.

Display CorruptionThe Eaton-Williams AHU controller has been designed to berobust and reliable in operation. However, communicationsfaults or interruptions can, in certain circumstances, corrupt thedisplay.If the display is suspected of not functioning normally, power tothe affected unit(s) should be switched OFF to power-down thecontroller for 30 seconds, before switching it back ON.On restoration of power, the controller and display shouldre-initialise and operate normally.If the problem recurs and causes a nuisance, thecommunications wiring and connections should be checked forcontinuity.

CAUTIONDo not apply high voltage to any circuit connectedto the controller.

AHU Not OperatingBefore assuming that a fault exists and attempting to locate thecause, the following possibilities should be eliminated:

Is power supply available to the controller?Check that any external interlocks, such as Fire Shutdown onpage 4-25, are in a healthy state.Note that if the fire shutdown facility is utilised, the display willcontinue to function after the fire shutdown device is triggered.Therefore the display being ‘live’ does not mean that thecontroller power supply is healthy.

Is there a demand?Check that there is truly a demand. For example, if demand hasbeen satisfied, the controller will not initiate the unit process(cooling, heating, humidification or dehumidification) tooperate.Check that demand exists by viewing the Status screen (see“Status screen (typical)” on page 3-6 of Section 3), whichshows demand and percentage indicators, and by interrogatingSystem Status points 3-0-3 or 3-0-4 as appropriate; see “Statusmenu points list” on page 3-13 of Section 3.


IPAC


Demand exists, but the unit is idle

Document 0410536

If demand is present (see Is there a demand? on page 4-25), butthe appropriate process is not operating, a normal delay timemay be in effect; see Fig. 4-2.If system status points 3-0-3 and 3-0-4 show no demand and thisis unexpected, check the set point, 4-0-1 (temperature) or 4-0-2(humidity) and compare this to the actual measured value shownfor status point 3-0-1 (temperature) or 3-0-2 (humidity), asappropriate.Remember to take into account:• Dead band control settings; see Control Functions on page 4-

13 • Override controls; see Control Functions on page 4-13• Compressor starts per hour limiting on page 4-16• Are external interlocks (if fitted) in a healthy state; e.g. Fire

Shutdown on page 4-25

Is the AHU idle in standby mode?A unit in standby mode will only operate to take over the duty ofanother unit that becomes unavailable, or when due to take overaccording to run/standby rotation control settings.On the Status > AHU menu, check AHU operating mode point 3-x-1, or humidifier operating mode point 3-x-2 for the humidifier(where ‘x’ is the AHU’s system number on the network), asappropriate; see “Status menu points list” on page 3-13of Section 3. The unit process will only be operative if status isshown as ‘online’.


IPAC


AHU Configuration Index CAUTION

Document 0410536

Table 4-8 shows controller configurations that are available,together with the Eaton-Williams part number.Basic configuration for the system is automatically implementedin the controller by fitting the appropriate UCP (UnitConfiguration Plug).

The configuration index must only be altered byEaton-Williams approved personnel.Incorrect configuration may damage the controlleror implement inappropriate control strategy

Table 4-8 : AHU configuration index

AHU Configuration Index

Cooling Type Heating Type Reheat Valve FittedDehumidification

ControlNumber of Modules Configuration Index

DXRefrigerant

Electric

No

No

1 1

2 2

3 3

Yes

1 4

2 5

3 6

Yes

No

1 7

2 8

3 9

Yes

1 10

2 11

3 12

LPHW

No

No

1 13

2 14

3 15

Yes

1 16

2 17

3 18

Yes

No

1 19

2 20

3 21

Yes

1 22

2 23

3 24

NOTESThe appropriate configuration index for the application is input during factory setup. prior to despatch.Fresh air and glycol cooling are also factory setup options, which are set independently of the configuration index.


IPAC


Table 4-8 : AHU configuration index

Document 0410536

ChilledWater

Cooling

Electric

No

No

1 25

2 26

3 27

Yes

1 28

2 29

3 30

Yes

No

1 31

2 32

3 33

Yes

1 34

2 35

3 36

LPHW

No

No

1 37

2 38

3 39

Yes

1 40

2 41

3 42

Yes

No

1 43

2 44

3 45

Yes

1 46

2 47

3 48

NOTESThe appropriate configuration index for the application is input during factory setup. prior to despatch.Fresh air and glycol cooling are also factory setup options, which are set independently of the configuration index.

AHU Configuration Index

Cooling Type Heating Type Reheat Valve FittedDehumidification

ControlNumber of Modules Configuration Index


IPAC


Configuration Plug (early units) CAUTION

Document 0410536

Table 4-9 shows controller configurations that are available forearly units, together with the Eaton-Williams part number.Basic configuration for is automatically implemented in thecontroller by fitting the appropriate UCP (Unit ConfigurationPlug).

Configuration plugs must only be fitted by Eaton-Williams approved personnel.Incorrect fitting may damage the controller orimplement inappropriate control strategy.

Input / Output ScheduleAll analogue and digital I/Os (Inputs and Outputs) that may(dependent on unit configuration) be connected to terminals onthe controller mother board and daughter board are listed inTable 4-10.

NOTEThe I/O schedule shown in Table 4-10 is exhaustive.Which I/Os are permitted to be used for aparticular unit is determined by the configurationindex - see Table 4-8.For early units, I/Os are determined by the UCP(Unit Configuration Plug) - see Table 4-9.

For alternative, non-standard application configurations, consultEaton-Williams.Any unused I/Os that must be linked out can be identified on thewiring diagram for the unit.

Table 4-9 : Unit configuration plug identification

Unit Configuration Plug Identification

UCPx Ref.ID*

UCPPart No.

No. ofModules

Cooling System Heating System Reheat Valve Fitted Dehum. Control

A 1160457 1 DX Electric or LPHW No No

B 1160458 2 DX Electric or LPHW No No

C 1160459 1 DX Electric or LPHW No Yes

D 1160460 2 DX Electric or LPHW No Yes

E 1160461 1 DX Electric or LPHW Yes Yes

F 1160462 2 DX Electric or LPHW Yes Yes

G 1160463 1 Chilled water Electric N/A No

H 1160464 2 Chilled water Electric N/A No

I 1160465 1 Chilled water Electric N/A Yes

J 1160466 2 Chilled water Electric N/A Yes

K 1160467 N/A Chilled water LPHW No No

L 1160468 N/A Chilled water LPHW No Yes

NOTE * UCP Cross Reference ID provided for cross-referencing to Table 4-10.


IPAC


Table 4-10 : Input / output schedule

Document 0410536

Input / Output Schedule

Ident Terminals

Function Description

Input / OutputDevice Properties

DX Cooling WithElectrical Heating

CW Cooling WithElectrical Heating

CW Cooling + LPHW Heating / Fresh Air Inlet

Damper

UCP x Ref. IDa

A, B, C, D, E, FUCP x Ref. IDa

G, H, I, JUCP x Ref. IDa

K, L

MOTHER BOARD ANALOGUE INPUTS

AI 1 CR3/3 Humidity sensor Humidity sensor Humidity sensor0 to 18 V dc,0 to 20 mA

AI 2 CR3/1Current input

from humidifierCurrent input

from humidifierCurrent input

from humidifier0 to 18 V dc,0 to 20 mA

AI 3 Not for use

AI 4 CR2/13Condensate flood sensor /

alarmCondensate flood sensor /

alarmCondensate flood sensor /

alarm0 to 18 V dc,0 to 20 mA

AI 5 CR4/1 - 2 Room air temp. Room air temp. Room air temp.2K2 to 180K Ohm

resistive

AI 6 CR4/3 - 4 Air filter(s) blocked Air filter(s) blocked Air filter(s) blocked2K2 to 180K Ohm

resistive

AI 7 CR4/5 - 6 Outside air temp. Outside air temp. Outside air temp.2K2 to 180K Ohm

resistive

AI 8 CR4/7 - 8 Glycol temp. Glycol temp.2K2 to 180K Ohm

resistive

MOTHER BOARD DIGITAL INPUTS

DI 1CR1/16 -

CR2/1 Airflow switch - fan 1b Airflow switch - fan 1b Airflow switch - fan 1b Volt-free / 9 to 24 V ac or dc

DI 2CR2/2 -CR2/1 Airflow switch - fan 2b Airflow switch - fan 2b Airflow switch - fan 2b Volt-free / 9 to 24 V ac or

dc

DI 3 CR2/3 - 4 Heating HT cut-out 1b tripped Heating HT cut-out 1b tripped Heating HT cut-out 1b trippedVolt-free / 9 to 24 V ac or

dc

DI 4 CR2/5 - 4 Heating HT cut-out 2b tripped Heating HT cut-out 2b tripped Heating HT cut-out 2b trippedVolt-free / 9 to 24 V ac or

dc

DI 5 CR2/6 - 7HP cut-out / O/L tripped -

compressor 1bVolt-free / 9 to 24 V ac or

dc

DI 6 CR2/8 - 7LP cut-out tripped - compressor

1bVolt-free / 9 to 24 V ac or

dc

DI 7 CR2/9 - 10HP cut-out / O/L tripped -

compressor 2bVolt-free / 9 to 24 V ac or

dc

DI 8 CR2/11 - 10 Humidifier water cylinder full Humidifier water cylinder full Humidifier water cylinder full volt-free

DI 9 CR2/12 - 10LP cut-out tripped - compressor

2b volt-free

CR1/13 - 14External interlock

for remote Start/Stopor Fire Shutdown

External interlockfor remote Start/Stop

or Fire Shutdown

External interlockfor remote Start/Stop

or Fire Shutdownvolt-free

NOTESa UCP x Ref. IDs provided for cross-referencing to Table 4-9.b ‘1’ refers to the master module equipment, while ‘2’ refers to the slave module equipment.


IPAC


Table 4-10 : Input / output schedule

Document 0410536

MOTHER BOARD DIGITAL OUTPUTS

DO 1 CR1/4 - 3 Humidifier contactor Humidifier contactor Humidifier contactor 24 V ac, 30 VA

DO 2 CR1/6 - 5 Humidifier water feed valve Humidifier water feed valve Humidifier water feed valve 24 V ac, 30 VA

DO 3 CR1/8 - 7Compressor 1b and

condenser 1b runModule 1b heating stage 1 Module 1b heating stage 1 24 V ac, 30 VA

DO 4 CR1/10 - 9 Compressor 1b

hot gas valve openModule 1b

heating stage 2Module 1b

heating stage 224 V ac, 30 VA

DO 5 CR3/7 - 8Module 1b

heating first stage (for two-stage heating only)

Module 1b

cooling inhibit 9 V dc, 150 mA

DO 6 CR3/9 - 10Module 1b

heating second stageor single stage only

Module 1b

dehum. overrideModule 1b

dehum. override9 V dc, 150 mA

DO 7CR6/6 - 4 (no)CR6/6 - 5 (nc)

Urgent alarmfault relay



Volt-free c/o, 7 A,com/no/nc

DO 8CR6/3 - 1 (no)CR6/3 - 2 (nc)

Non-urgent alarm fault relay

Non-urgent alarmfault relay

Non-urgent alarmfault relay


DO 9CR5/6 - 4 (no)CR5/6 - 5 (nc)

Humidifier pump run Humidifier pump run Humidifier pump runVolt-free c/o, 7 A,

com/no/nc

DO 10CR5/3 - 1 (no)CR5/3 - 2 (nc) Fan 1b run Fan 1b run Fan 1b run

Volt-free c/o, 7 A, com/no/nc

DAUGHTER BOARD ANALOGUE OUTPUTS

AO 1 CR11/1 - 2Module 1b

LPHW valve, fresh air inlet damper,or glycol valve position

Module 1b

CW valve position

Module 1b

LPHW valve, or fresh air inlet damper position

0 to 10 V dc

AO 2CR11/3 -CR11/4

Module 2b

LPHW valve positionModule 2b

CW valve positionModules 1b and 2b

CW valve position0 to 10 V dc

DAUGHTER BOARD DIGITAL OUTPUTS

DO 11CR2/1 - 3 (no)CR2/1 - 2 (nc) Fan 2b run Fan 2b run Fan 2b run


DO 12CR2/4 - 6 (no)CR2/4 - 5 (nc)

Compressor 2b and condenser

2b runModule 2b

cooling inhibitVolt-free c/o, 7 A,

com/no/nc

DO 13 Not for use

DO 14CR4/1 - 3 (no)CR4/1 - 2 (nc)

Module 2b

heating first stage onModule 2b

heating first stage onModule 1b

heating inhibit Volt-free c/o, 7 A,

com/no/nc

DO 15 CR4/4 - 6 (no)CR4/4 - 5 (nc)

Module 2b heating 2nd stage on, or unit 1b reheat on

Module 2b heating 2nd stage on, or unit 1b reheat on

Module 2b

heating inhibit Volt-free c/o, 7 A,

com/no/nc

NOTES: a UCP x Ref. IDs provided for cross-referencing to Table 4-9.b ‘1’ refers to the master module equipment, while ‘2’ refers to the slave module equipment.

Input / Output Schedule

Ident Terminals

Function Description

Input / OutputDevice Properties

DX Cooling WithElectrical Heating

CW Cooling WithElectrical Heating

CW Cooling + LPHW Heating / Fresh Air Inlet

Damper

UCP x Ref. IDa

A, B, C, D, E, FUCP x Ref. IDa

G, H, I, JUCP x Ref. IDa

K, L


IPAC


External Interface Protocol

Document 0410536

Table 4-11 : External interface protocol

External interface protocol

Network Variable Format Description

nviRequest SNVT_obj_request Node object request; see LONMARK™ application guidelines for details.

nvoStatus SNVT_obj_status Node object request; see LONMARK™ application guidelines for details.

Nvo00FileDir SNVT_address File description; see LONMARK™ application guidelines for details.

NviSysEnable SNVT_switch System enable via network.

NviInterlock SNVT_switch System interlock via network.

NviEnergyHoldOff SNVT_switch Energy hold-off.

NviHVACTemp SNVT_temp_p Input provides current temperature, when a network sensor is used.

NviHVACRH SNVT_lev_percent Input provides current humidity, when a network sensor is used.

NvoSysStatus SNVT_switch AHU status.

NvoHVACTemp SNVT_temp_p Current temperature.

NvoHVACRH SNVT_lev_percent Current humidity.

NvoTempDemand SNVT_lev_percent Temperature demand; +ve heating, -ve cooling.

NvoHumDemand SNVT_lev_percent Humidity demand; +ve humidification, -ve dehumidification.

NvoUnitEnable[10] SNVT_switch Slave enable signals; used in network systems.

NviTempDemand SNVT_lev_percent Temperature demand input; used by slaves.

NviHumDemand SNVT_lev_percent Humidity demand; used by slaves.

NvoCylDemand SNVT_lev_percent Vapac Cylinder demand

NvoHoursRun SNVT_count Vapac hours run.

NvoCurrent SNVT_amp Vapac current.

NvoPower SNVT_power_kilo Vapac instantaneous power.

NvoDuty SNVT_elec_kwh Vapac power used.

NvoAIs SNVT_analogue 4 * analogue inputs, 0 to 4096.

NvoRIs SNVT_analogue 4 * resistance inputs, 0 to 2096.

NvoDIOStatus SNVT_state_64Bits 0 to 9 digital inputs.Bits 10 to 23 digital inputs.

NviMORComp1 SNVT_count

Manual override inputs; used for commissioning.0 = auto control.non-zero = manual override ON.

NviMORHotGas SNVT_count

NviMORComp2 SNVT_count

NviMORHeater1 SNVT_count




NviMORVapac SNVT_count Vapac demand manual override 0 to 100 %.

NviMORAHU SNVT_count AHU manual override 0 to 100 %.


IPAC SECTION 5

Eaton-Williams


IPAC

INVICTANET CONTROLLER SETTINGS RECORD

SECTION CONTENTS

Heading Page5.1 Introduction 5 – 3Table 5-1 : User-adjustable system settings 5 – 4Table 5-2 : User-Adjustable AHU settings 5 – 5Table 5-3 : Engineering menu system settings 5 – 10Table 5-4 : Engineering menu AHU settings 5 – 11

IPAC

INVICTANET Controller Settings Record

Document 0410536


IPAC


Introduction Note that adjustment to Engineering level settings must only be

Document 0410536

The controller is fully described in Section 4 - INVICTANETCONTROLLER TECHNICAL MANUAL.Controller settings are configured during commissioning, toobtain optimum performance.On completion of commissioning, the controller settings recordis to be completed for each unit before handover.Any setting that are adjusted from default values are to berecorded in the Input Value column.Any adjustment to User level setting values should be recorded,together with the date changed.• Always keep the settings record up to date.• Always keep the settings record in a safe place, preferably

with the unit log record.

carried out by personnel who are competent in refrigerationcontrol system configuration.

WARNINGInappropriate setting values can adversely affectplant performance and/or operation and mayresult in damage to the unit or any environment-sensitive equipment that relies on unit operation.

It is recommended that a copy of each appropriate settingsrecord is kept with the plant log book. Having this informationto hand will keep any down time period to a minimum, shouldcontroller settings need to be input again.

Table 5-1 : User-adjustable system settings

User-Adjustable System SettingsUser password = 4602

MASTER UNIT Serial No. __________________ Site Unit No. / Location __________________

Setting No. (Screen)Screen Text Setting

Range Fact. Set

UnitsInputValueUser Maint. E-W Min. Max.

4-0-1 5-0-1 5-0-1 temp setpoint Room temperature set point 0 39 22 °C

4-0-2 5-0-2 5-0-2 rh setpoint Room humidity set point 5 95 50 % RH

4-0-3 5-0-3 5-0-3 high temp diffRoom high temperature alarm(differential from room temperature set point 4-0-1)

0 10 10 °C

4-0-4 5-0-4 5-0-4 low temp diffRoom low temperature alarm(differential from room temperature set point 4-0-1)

0 10 10 °C

4-0-5 5-0-5 5-0-5 high rh diffRoom high humidity alarm(differential from room humidity set point 4-0-2)

0 10 10 % RH

4-0-6 5-0-6 5-0-6 low rh diffRoom low humidity alarm(differential from room humidity set point 4-0-2)

0 10 10 % RH

4-0-7 5-0-7 5-0-7 date . timeDate and time(real-time clock setting adjustment)DD-MM-YY HH:MM:SS

4-0-8 5-0-8 5-0-8 dehum o/rDehumidification override control(enables/disables implementation of Dehum. override temperature differential setting 4-0-9)

en-able dis-able en-able -

4-0-9 5-0-9 5-0-9 dehum o/r

Dehumidification override temperature differential(differential from room temperature setting 4-0-1) Inhibits dehumidification if temperature is low, to prevent overcooling.

0 40 3 °C


IPAC


Table 5-2 : User-Adjustable AHU settings

Document 0410536

User-Adjustable AHU SettingsUser password = 4602

Setting No. (Screen)Screen Text Setting

Range Def. Units

Input ValueUser Maint. E-W Min. Max.

AHU No. 1 - MASTER Serial No. __________________ Site Unit No. / Location __________________




0 10 10 °C


0 10 10 °C


0 10 10 % RH


0 10 10 % RH

4-1-7 5-1-7 5-1-7 man o/r resetManual override reset controlAHU manual override reset control setting enable or disable


4-1-8 5-1-8 5-1-8 input voltage Specified supply voltage to AHU 380 440 440 Volts

AHU No. 2a - SLAVE Serial No. __________________ Site Unit No. / Location __________________




0 10 10 °C


0 10 10 °C


0 10 10 % RH


0 10 10 % RH

4-2-7 5-2-7 5-2-7 man o/r resetManual override reset controlAHU manual override reset control setting enable or disable


4-2-8 5-2-8 5-2-8 input voltage Specified supply voltage to AHU 380 440 440 Volts

a. The AHU number will correspond to the setting number at each level, ie. AHU 5 Room Temp Set Point will be under setting No. 4-5-1.


IPAC


Table 5-3 : Engineering menu system settings

Document 0410536

Engineering Menu SYSTEM SettingsE-W password access and Maintenance password access only

Setting No. (Screen)

Screen Text SettingRange

Def. UnitsInput ValueMin. Max.

MASTER UNIT Serial No. __________________ Site Unit No. / Location __________________

6-0-1 sensor operation

Sensor operationSpecifies temperature / humidity sensor / data handling - options are:

• Average - for averaging of data from several sensors• Individual - for individual sensor• From master - for using only the Master unit’s sensor

data

6-0-2 num run unitsNumber of run unitsSpecifies the number of units allowed to run in the network at any time

6-0-3 rotation periodDuty rotation cycle periodHours between each rotation of duty for pairs of units

00000 99999 00000 hours

6-0-4 rotation timeDuty rotation timeTime of day that duty rotation is executed for pairs of units;inhibit setting = 00:00

00:00 24:00 00:00hours / mins.

6-0-5 run on period

Run-on time at changeoverSpecifies the period that a unit due to go on standby unit is permitted to keep running, to eliminate any issues caused by start delays of the starting unit.

0 mins.

6-0-6 standby temp

Temperature deviation required to start standby unitOffset from the temperature set point that will initiate starting of the standby unit

0 10 10 °C

6-0-7 standby periodStandby run periodThe period that the standby unit is required to run after being started in response to setting 6-0-6

0 240 0 mins.

6-0-8 level 1 alarmUrgent alarm output typeSpecifies the type of alarm signal - pulsed or continuous

pulse cont. cont. -

6-0-9 level 2 alarmNon-urgent alarm output typeSpecifies the type of alarm signal - pulsed or continuous

pulse cont. cont. -

6-0-10 temp alarms

Temperature alarms displaySpecifies whether temperature alarms are shown automatically on the displayshown = enablednot shown = disabled


6-0-11 rh alarms

Relative humidity alarms displaySpecifies whether RH alarms are shown automatically on the displayshown = enablednot shown = disabled



IPAC


Table 5-4 : Engineering menu AHU settings

Document 0410536

Engineering Menu AHU SettingsE-W password full access and Maintenance password 5699 limited access (indicated by asterisk) only


Screen Text Setting Range


AHU No. 1 - MASTER Serial No. __________________ Site Unit No. / Location__________________

*6-1-1 man o/r periodManual override run periodDuration of manual override (for service) before unit reverts to normal operation

0 120 60 mins.

*6-1-2 setpoint source

Set point sourceSpecifies the control sensor to which the set point is applied - options are:

• AHU• System

- - -

6-1-3 fan start delayFan start delay timeDelay period before fan starting is permitted, following unit start initialisation

0 300 5 secs.

6-1-4 temp d/b

Temperature deadband valueNo PID control is applied while the temperature is within the deadband, which is an offset value from the temperature set point.

1 10 1 °C

6-1-5 heating loopHeating control loop menuEnters the heating PID control loop menu comprising the next three settings

- - - - -

6-1-5-1 proportionalHeating proportional band valueFor PID control

1 10 2 °C

6-1-5-2 i actionHeating integral time valueFor PID control

0 250 0 mins.

6-1-5-3 i responseHeating derivative time valueFor PID control

0 250 0 mins.

6-1-6 cooling loopCooling control loop menuEnters the heating PID control loop menu comprising the next three settings

- - - - -

6-1-6-1 proportionalCooling proportional band valueFor PID control

1 10 2 °C

6-1-6-2 i actionCooling integral time valueFor PID control

0 250 0 mins.

6-1-6-3 i responseCooling derivative time valueFor PID control

0 250 0 mins.

6-1-7 rh d/bHumidity deadband valueNo PID control is applied while RH is within the deadband, which is an offset value from the RH set point

1 10 2 %RH

6-1-8 hum loopHumidification control loop menuEnters the humidification PID control loop menu comprising the next three settings

- - - - -

6-1-8-1 proportionalHumidification proportional band valueFor PID control

1 10 3 % RH

6-1-8-2 i actionHumidification integral time valueFor PID control

0 250 0 mins.


IPAC



Document 0410536




AHU No. 1 - MASTER Serial No. __________________ Site Unit No. / Location__________________

6-1-8-3 i responseHumidification derivative time valueFor PID control

0 250 0 mins.

6-1-9 dehum loopDehumidification control loop menuEnters the dehumidification PID control loop menu comprising the next three settings

- - - -

6-1-9-1 proportionalDehumidification proportional band valueFor PID control

1 10 2 % RH

6-1-9-2 i actionDehumidification integral time valueFor PID control

0 250 0 mins.

6-1-9-3 i responseDehumidification derivative time valueFor PID control

0 250 0 mins.


- - - - -

6-1-10-1 start delayCompressor 1 start delay timeDelay period, following start initiation, before the compressor is permitted to start

0 300 15 secs.

6-1-10-2 winter start dlyCompressor 1 winter start delay timeFor problem-free starting during winter, when ambient temperature is low

0 300 180 secs.

6-1-10-3 start to startCompressor 1 starts per hour limitingEnsures that compressor starts per hour are limited to manufacturer’s recommendations

0 300 180 secs.

6-1-10-4 hot gas st dlyCompressor 1 hot gas start delay timeDelays hot gas implementation following compressor starting

0 120 45 secs.


- - - - -






- - - - -





6-1-13 comp rotationCompressor rotation periodFor equalisation of hours run between compressors

0 60100 - hours



IPAC



Document 0410536




AHU No. 1a - MASTER Serial No. __________________ Site Unit No. / Location__________________

6-1-14 free cool d/b

Economy cooling deadband valueNo PID control is applied while economy cooling medium temperature is within the deadband, which is an offset value from the room temperature set point

0 5 °C

6-1-15 free cool propEconomy cooling proportional band valueFor proportional control

0 20 °C

6-1-16 free cool inhibitEconomy cooling inhibit %RH valueFor economy cooling override in favour of minimising the need to control humidity

50 100 %RH

6-1-17 heater start dly

Heater start delay periodEnsures that excessive temperature is avoided, by delaying heater operation until the airflow switch is deemed to be ‘made’ (healthy)

0 300 90 secs

6-1-18 vapac start dlyHumidifier start delay periodDelays humidifier operation until the airflow switch is deemed to be ‘made’ (healthy)

0 900 60 secs

6-1-19 filter block dyFilter blocked alarm delay periodDelays the filter blocked alarm from being reported

0 240 mins.

6-1-20 airflow periodAirflow failure alarm delay periodDelays the airflow failure alarm from being reported

mins.

6-1-21 reset hoursHours run counters resetResets all counters to zero

- - - -

a. The AHU number will correspond to the setting number at each level, ie. AHU 5 Economy cooling deadband value will be under setting No. 6-5-14.



IPAC SECTION 6

IPACEaton-Williams

IPAC


INSTALLATION - DX UNITSSECTION CONTENTS


Persons Permitted to Carry Out Installation 6 – 4Arrival at Site 6 – 4Off-loading and Handling 6 – 4Off-loading by Crane 6 – 4Off-loading by Forklift 6 – 4Moving a Unit 6 – 4

Storage 6 – 4Installation Obstructions 6 – 5

Noise 6 – 5Condensate Drain 6 – 6

Positioning 6 – 6Floor Mounting 6 – 6Base Plinth Mounting 6 – 6

Installation Clearances 6 – 6Piping up the System 6 – 6Refrigerant Pipework and System Components 6 – 6Interconnecting Refrigerant Pipework 6 – 7Liquid Receiver 6 – 7Pressure Relief Valve 6 – 7Humidifier Mains Water Supply 6 – 7Condensate Drain 6 – 7Power Supply 6 – 8Emergency Stop 6 – 8Electrical Connections 6 – 8

Air-cooled Condenser 6 – 8Remote Start / Stop Signal 6 – 8Fire Shutdown Signal 6 – 8Compressor Crankcase Oil Heater(s) 6 – 9Combined Strength and Leak Pressure Test 6 – 9

Evacuation and Dehydration 6 – 10Initial Charging With Refrigerant 6 – 11

IPAC

Document 0410536


Installation - DX Units

IPAC


Introduction Fig. 6-1 : Unit lifting brackets

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The purpose of this section is to provide an overall guide for theinstallation of IPAC range AHUs and is not an exhaustive step-by-step installation guide. Each site will vary in requirementsregarding layout and obstacles to overcome.If there are queries or points of uncertainty, refer to Eaton-Williams for clarification. Also refer to any special instructionsissued by Eaton-Williams, or their appointed distributor, for aspecific project.

Persons Permitted to Carry Out InstallationOnly personnel who have been properly trained in theinstallation of refrigeration equipment should be permitted tocarry out installation of the equipment covered by this manual.

Arrival at SiteIf any damage is found, this must be reported to Eaton-Williams,or their appointed distributor, immediately.Units are normally despatched enclosed in suitable packagingfor protection during transit. The arrangement and type ofpackaging will vary according to the method of transportation,site location, unit type and quantity, etc.Before Acceptance: • Before unpacking, check all packaging for any evidence of

damage that could indicate possible damage to a unit within.• Carefully remove all packaging and then thoroughly check

each unit for damage.Do not allow the unit to become wet.

• Each unit is supplied containing a holding charge of drynitrogen, nominal pressure 3.4 Bar g (50 psi g). Fit acalibrated test pressure gauge and check that the holdingcharge is intact.

• Report any damage or escape of holding charge to the carrierand to Eaton-Williams immediately.

Eaton-Williams cannot be held responsible for any damageoccurring during transit.

Off-loading and HandlingBefore moving units, check the weight by referring to “IPACRange unit configurations, dimensions and weights” on page 2-7 of Section 2. Add an adequate allowance for any significantpackaging, such as wooden crating.

CAUTIONAt NO time is the unit to be laid on its back, side orfront. Doing this will cause irreparable damage.

• To facilitate lifting by crane or hoist, Eaton-Williams canprovide specially designed lifting brackets on request.

• These brackets are to be fitted to the top of the unit, one ateach end, as shown in Fig. 6-1.

WARNINGLifting eyes must not be used, otherwise they maystrip-out during the lift and the unit may fall.

To avoid damage to the unit or injury to personnel, observe thefollowing points:• Ensure that all lifting and handling gear, including any slings,

etc., are of adequate specification and have relevant safetycertificates.

• If the unit is to be lifted by crane or hoist, correctly sized loadspreaders must be used.

• Ensure that the lift is vertical.• Do not allow the unit to drop.

Off-loading by Crane

CAUTIONTo avoid damage, load spreaders must always beused when lifting the unit by hoist or crane.Always use the specially designed lifting bracketsprovided by Eaton-Williams; refer to Fig. 6-1.

Off-loading by Forklift

CAUTIONThe unit can be off-loaded and moved using a forklift,provided that the lift is from under the pallet; refer toFig. 6-2.Lifting directly against the unit bottom will causeirreparable damage.

Moving a UnitThe unit can be moved around using appropriate equipment asillustrated in Fig. 6-2 and Fig. 6-3.

StorageUnits that are not installed directly following arrival at site mustbe stored in a weatherproof, dry, well-ventilated and vermin-freearea.


IPAC


Fig. 6-2 : Off-loading by crane (generic unit shown) and Off-loading by forklift (generic unit shown)

Document 0410536

To prevent Brinelling of bearings, units must be stored in avibration-free area, otherwise adequate steps must be taken toprevent such damage.

CAUTIONAny leakage of holding charge must be rectifiedimmediately.Failure to maintain the holding charge willinvalidate the warranty for the unit.

After rectifying the cause of any leakage, the unit must beevacuated and a holding charge of industrial grade dry nitrogenthen installed to a nominal pressure of 3.4 Bar g (50 psi g).

Installation ObstructionsA number of factors must be assessed regarding the installationof air handling units.• Hot water pipework - must be properly lagged to minimise

heat transfer.• Radiators or night storage heaters positioning.• Electrical fittings and installations.• Telecommunications equipment positioning.• Cable tray and busbar support drop rod positioning.• Cable tray and busbar distribution systems.The proximity of these items must be taken into consideration,especially in respect of any adverse affect they may have on theflow of return air.

NoiseThe installation must be checked regarding noise levelsgenerated during operation, to ensure that local requirementsand limitations are adhered to.

Condensate DrainCondensate must be arranged to discharge directly into aproperly designed drain, which should be lagged. Refer toCondensate Drain on page 6 for further details.

PositioningIPAC units are designed for indoor use only, and to locate eitherdirectly on to raised floor jacks, or onto a base plenum.

Fig. 6-3 : Using pallet trucks (generic unit shown)


IPAC


CAUTION Site refrigerant system connections (discharge line and liquid

Document 0410536

For downflow units with top or back return,BEFORE positioning the unit, ensure that theaperture blanking plate is correctly positioned forairflow direction.

Multiple Section AssemblyTo provide an air seal, use a layer of gasket above and below theplinth.

CAUTIONIt is essential that all appropriate gaps are sealedto prevent bypassing, otherwise unit performancewill be impaired.

Before assembling multiple sections, ensure that the lowersection is perfectly level in both planes and will remain so whenthe unit is mounted.Mount additional sections using the two locating pins provided.Fit the pins in opposite corners of the mating section.

Base Plinth MountingIf the floor is uneven, it is recommended that a suitable flooring-levelling screed is applied.To provide an air seal, use a layer of gasket above and below theplinth.

Floor MountingFront-return units can be located directly onto the floor.Before locating the unit in place, remove any flooring material.To provide an air seal, use a layer of gasket between the floorand the unit.

CAUTIONIt is essential that all appropriate gaps are sealedto prevent bypassing, otherwise unit performancewill be impaired.

If it is suspected that the installation will be susceptible tovibration, it is recommended that the unit is seated on a 15 x 30mm continuous strip of Tico anti-vibration packing. This will alsoprovide a good seal.

Installation Clearances Because the full-height doors provide full access formaintenance purpose, a unit can be installed against a wall atthe back and sides as required. • A clear distance of 800 mm must be allowed at the front for

maintenance access.• To ensure unobstructed flow of return air to the unit, a

minimum distance of 300 mm must be allowed between thetop of unit and the ceiling.

Piping up the SystemIPAC range units are despatched complete with expansionvalve(s), moisture indicating sight glass(es), filter/drier(s) andevacuation/charging connection points.

line) are terminated and capped off in the base of the unit. Eachunit is despatched containing a holding charge of nitrogen.If a matched air-cooled condenser is supplied by Eaton-Williams,this is also despatched with site connections capped off and aholding charge of nitrogen. For further details, refer to theseparate instruction publication for the condenser.After units have been correctly positioned and installed,interconnecting pipework can be installed between the unit andthe condenser.

Refrigerant Pipework and System ComponentsThroughout connecting up the system and components, observethe following practices.

WARNINGEnsure that all pipework, connections and systemcomponents are suitably pressure rated.

• Each refrigerant system within a unit is capped and filled witha holding charge of nitrogen, at a nominal pressure of 3.4 Barg, before despatch from the factory. The holding charge mustbe vented to atmosphere immediately before opening thesystem envelope.

WARNINGThe holding charge represents a pressure hazard.Therefore, before breaking into the systemenvelope, ensure that the holding charge has beenvented and that the system is at atmosphericpressure.

• Do not leave any part of the system exposed to atmosphereany longer than is strictly necessary.

• When routing the pipework through the base into the unit,ensure that pipework does not obstruct airflow unnecessarily.Use only clean, hard drawn, refrigeration quality coppertubing, with wrought copper fittings.

• Route pipework to produce the minimum length refrigerantcircuit, with swept bends. Gradient lines and install traps asshown on the pipework diagram for the site.

• When brazing, ensure that flux does not get inside thetubing. To prevent oxidation of the copper, a constant streamof dry nitrogen should be passed through the pipeworkduring brazing.

• When installing pipework, allowance must be made forthermal movement. Piping must be arranged so thatconnections are not stressed.

• To eliminate vibration transfer, flexible connections must beused at the compressor discharge.

• Piping runs should be supported at 1.5 m intervals by suitablehangers or brackets. Ensure that pipework is isolated fromsupports by using foam insulation or similar. This will also benecessary where pipework passes through floors or walls.Where refrigerant lines are run in close proximity, they mustbe insulated from each other.


IPAC


Interconnecting Refrigerant Pipework WARNING

Document 0410536

Pipework connection sizes are shown in“Pipework connectionsizes” on page 2-13 of Section 2.Discharge line and liquid line sizes are as shown in“Dischargeline and liquid line sizes guide - DX units” on page 2-14of Section 2 , which is provided for guidance only.Observe the following points:• Where vertical lift between compressor and condenser

exceeds 3 metres, traps are to be fitted to return oil to thecompressor.

• Where horizontal runs exceed 25 metres, traps should befitted to prevent excessive oil hold-up in the system.

• Thereafter, ‘U’ bend traps should be formed in the verticalriser at 4 metre intervals.

On shutdown, these traps will retain oil and prevent it from re-entering the compressor.• For excessive pipe lengths, the diameter of pipes should be

calculated using accepted refrigeration practice.

The following information is provided as a guide:

Velocities in horizontal discharge lines should be 2.6 to 12.0 m/sec.

Velocity in vertical lines should be 5.0 to 15.0 m/sec.

Pressure drops between compressor and condenser must not exceed 41 kPa (6 psi).

Liquid ReceiverIf pipe runs are excessively long, a liquid receiver may berequired. This is to ensure that only liquid refrigerant is suppliedto the thermostatic expansion valve.

WARNINGThe liquid receiver must be designed toaccommodate all excess liquid not required in theevaporator (air cooler) when the unit is operatingat below maximum load conditions.Depending on the design and installation of theliquid receiver, it may be necessary to fit a suitablysized and rated safety pressure relief valve. Thismust be installed according to refrigerationindustry safety regulations, legislation andequipment manufacturer’s instructions.

On a system having long enough runs of pipework to warrantthe fitting of a liquid receiver, an additional volume of oil mayneed to be added to the compressor to allow for wetting of thesystem.If there is any doubt regarding the fitting of a liquid receiver,consult Eaton-Williams, or their appointed distributor for advice.

Pressure Relief ValveTo protect against system pressure rising to a level that could behazardous, it is recommended that a pressure relief valve,venting to a safe area, is fitted in the discharge line.

Do NOT attempt to test relief valve openingpressure while fitted to the system.Pressure relief valves must not be isolated. Do NOTfit isolating valves.

As pressure relief valves must be arranged to relieve safely toatmosphere, it is recommended that at least one is fitted in thedischarge line, near the condenser and in a safe area. If a relief valve is fitted inside the building, pipework must beinstalled to vent to a safe area. This pipework must beadequately sized for relief purposes, according to industry safepractice.

Humidifier Mains Water SupplyThe Vapac® humidifier is an electrode boiler operating atatmospheric pressure and is designed for connection to standardmains water supply, provided local regulations for this type ofequipment are observed.To eliminate possible contamination of the water supply, thehumidifier has a tundish which incorporates a 25 mm verticalgap over the maximum overflow level of the fill cup and belowthe end of the feed pipe. Subject to local regulations, thisarrangement should eliminate the need for a static tank in thesupply water feed.A Water Authority approved stop cock and strainer must befitted in the supply from the water main; use 15 mm diametercopper tube or approved equivalent material.Pre-treatment of the feed water is unnecessary, as Vapachumidifiers are designed to operate on a wide range of waterqualities.The standard Vapac humidifier is not suitable for connection toa fully demineralised water supply.The water quality range of the Vapac humidifier is:

Hardness 50 to 500 ppm (mg/l)Conductivity 80 to 1000 microsiemensWater Pressure 0.30 to 8.00 bar g

Condensate DrainThe condensate drain runs from the condensate tray to the baseof the unit in 13 mm internal diameter clear, flexible hose, whichis looped within the unit to from a trap.If a humidifier is fitted, the condensate and humidifier drain linesare commoned-up, before the trap, using an equal tee piece toprovide a single 13 mm internal diameter drain connection.The external drain line must be connected to the drain line hoseand should provide a continuous fall to an open drain.

CAUTIONThe unit is fitted with an internal condensate trap,do not fit an external trap.

If a Vapac humidifier is installed, any plastic piping and fittingsmust be rated for use at 100 °C.


IPAC


Power Supply Fig. 6-4 : Electrical connection points

Document 0410536

Units must be provided with a reliable power supply of 380/415Vac, 3 ph, 50 Hz. Ensure that the supply is adequately rated tomeet maximum demand; for details refer to unit wiringdiagrams.It is recommended that an external local isolator is fitted,preferably one that incorporates an Emergency Stop button.

Emergency StopTo enable the unit to be shutdown quickly in an emergency, it isrecommended that an Emergency Stop button is fitted, either aspart of an external isolator or as a separate control.

Electrical ConnectionsAll IPAC units have bottom left hand cable entry as standard.Connection points are shown in Fig. 6-4 and Fig. 6-5.Main incoming power supply is connected to a main isolator,fitted master units only. Slave units are powered via controls in the master unit.All terminals for customer connection of power supply andcontrol circuits are adjacent to the cable entry point, inside thelower left hand side of the unit.Note the following points:• Do not run power and signal wiring close together.• If it is necessary for signal wiring to cross power cables,

ensure that they cross at right angles to each other.For details of mains power supply and control circuits, refer tospecific unit wiring diagrams.

WARNINGThe unit isolator must remain in the OFF positionuntil pre-commissioning checks have been carriedout, which are part of the commissioningprocedure.

Air-cooled CondenserThe power supply (normally single phase) to the condenser istaken from the dedicated terminal in the unit (master).

WARNINGIf a voltage hazardous to life is connected to thevolt-free contacts of the fault relay at themotherboard, this voltage may be present evenwhen the unit isolator is switched OFF.Appropriate notices must be fixed to the unit towarn of this hazard.

Remote Start / Stop SignalThis optional facility is linked out as standard.If this function is required, a volt-free contact of the Start / Stopcontrol device should be connected to the customer terminalsspecified on the schematic wiring diagram for the unit.Contact function is:

Closed circuit (contact makes) = Unit RunOpen circuit (contact breaks) = Unit Stop

Fire Shutdown SignalThis optional facility is linked out as standard.If this function is required, a volt-free contact of the FireShutdown control device should be connected to the customerterminals specified on the schematic wiring diagram for the unit.Contact function is:

Closed circuit (contact makes) = NormalOpen circuit (contact breaks) = Shutdown

Compressor Crankcase Oil Heater(s)

Compressor crankcase oil heaters are normally required to driveliquid refrigerant out of the oil if:

Fig. 6-5 : Interconnecting wiring connection points


IPAC


Table 6-1 : Crankcase oil heater requirement criteria

Document 0410536

• The system has been inoperative for a period of time, or:• During an off-cycle, when refrigerant can migrate back to the

crankcase due to prevailing system temperatures; e.g. if thecompressor is cooler than the condenser or evaporator.

Because compressors fitted to IPAC units are able to cope withlimited quantities of liquid refrigerant in flooded conditions, nocrankcase oil heater is required when the system charge doesnot exceed the appropriate value in Table 6-1. Provided that there is no down time (i.e. normal operation iscontinuous throughout the year) and the system charge does notexceed the appropriate value in the table above, then crankcaseoil heating is not a requirement.When installing heaters, follow the manufacturers instructions.Make electrical connections to the existing sleeved-off wiring inthe unit. Refer to the electrical schematic wiring diagram foreach unit, including slave units (where applicable).

Combined Strength and Leak Pressure TestThe following procedure must be carried out in turn for eachrefrigeration circuit of the unit.Because the system comprises components, such asinterconnecting pipework, that are made up and fitted at site,these must be strength and leak pressure tested. As it is notpractical to test such assembled components separately, thepressure test must be applied to the whole system.

WARNINGBefore carrying out the combined strength andleak test, consideration must be given to therelieving pressure of any additional pressure reliefdevices, such as bursting discs, that may be fittedby a third party, etc.The combined strength and leak test requires thesystem to be pressurised to 31.0 bar g (440 psi g).

Carry out a combined strength and leak pressure test on eachrefrigeration system as follows:

CAUTIONPressure testing is a potentially hazardousprocedure and involves applying high pressure tothe system.

Before carrying out the procedure, ensure that allpersonnel not essential for testing are at a safedistance.Place warning notices wherever appropriatearound the site, advising of the hazard.

1. To avoid the need to open up the system later, first checkthe compressor oil level sight-glass to ensure that the oillevel is correct.

2. Remove the system HP and LP (suction) pressure switchesand in their place fit calibrated test pressure gauges. Fordetails, refer to the system piping and instrument schematicdiagram for the unit.

3. Connect a cylinder of test gas, such as Protec 5 (for an R22system, use industrial grade dry nitrogen), to the chargingpoint in the discharge line.

WARNINGDo NOT use any gas other than either aproprietary test gas, such as Protec 5 or drynitrogen (as appropriate).Do NOT use oxygen or acetylene.Ensure that the charging line is adequatelypressure rated and designed for use withrefrigerant.

Purge the charging line of air and then initially charge thesystem to a gauge pressure of 1.4 bar g (20 psig).

Over a period of 15 minutes, monitor pressure gauges forindication of any leakage.

Use leak disclosing fluid to locate the source of any leakage.

WARNINGDo NOT attempt to carry out repairs or rectifyleaks while the system is under pressure.

In the case of any leakage, the test charge must be removed,the cause of leakage rectified and then steps 2 and 3repeated.

4. Provided that there has been no leakage, continue to chargethe system, gradually and in stages, until a test gaugepressure of 31.0 bar g (440 psi g) is reached.

Compressor Crankcase Oil HeaterRequirement Criteria

CompressorZR61

ZR61/90ZR11ZR12

ZR16 ZR19/250

Maximum permitted refrigerant charge

without crankcase heaters

4.5 kg(9.9 lb)

10 kg(22 lb)

7.7 kg(17 lb)

11.3 kg(25 lb)

Heater Part Number 2050050 2050049 2050049 2050049x

Electrical Rating220/240 Vac, 1 ph, 50 Hz,

59/70 W

NOTE Identify the compressor by referring to the data plate on the compressor.


IPAC


WARNING 5. Start the vacuum pump and evacuate the system down to

Document 0410536

Do NOT raise system pressure straight up totest pressure. Raise the pressure gradually andin stages, allowing pressure to stabilise at eachstage.

At each stage of pressurisation, monitor pressure gauges forany indication of leakage.

When the test pressure is reached, disconnect and removethe test charge cylinder.

Note the pressure and ambient temperature.

Leave the system to stand and over a period of 24 hours,monitor pressure gauges, from a safe distance, for indicationof any leakage.

WARNINGDo NOT approach any part of the system whileit is undergoing pressure testing.

At the end of 24 hours check that pressure has been held,taking into account any variations caused by changes inambient conditions.

In the case of any leakage, at any time during pressurisationor while standing under test pressure, the test charge mustbe removed, the cause of leakage rectified and then steps 2to 4 repeated.

5. On satisfactory completion of the pressure and leak test,vent the system down to a pressure just above atmospheric,ready for evacuation prior to charging.

If the system is not to be evacuated and then charged withrefrigerant immediately following strength and leak pressuretesting, only reduce system pressure to a holding chargepressure of 3.4 bar g (50 psi g).

On completion of the combined strength and leak pressure test,each refrigeration circuit must undergo Evacuation andDehydration on page 9.

Evacuation and DehydrationThe following procedure must be carried out in turn for eachrefrigeration circuit of the unit.Prior to charging, the system must be evacuated and dehydratedas follows:

WARNINGDo NOT operate the compressor while the systemis under vacuum.Do NOT use the compressor to evacuate thesystem.

1. If the system still contains a holding charge, vent the systemdown to a pressure just above atmospheric.

2. Remove the HP and LP pressure gauges.3. Fit a barometrically compensated vacuum test gauge to the

system.4. Connect a suitable vacuum pump to the HP and LP sides of

the system.

0.5 Torr.

Note that for dehydration to be effective, an ambienttemperature of at least 7 °C is required. If necessary, useheaters to warm the surroundings.

6. Leave the unit to stand for approximately 4 hours.

Any rise in pressure during this period indicates that there iseither moisture in the system, or a leak.

Repeat the evacuation at intervals until the system can standfor 4 hours without pressure rising by more than 0.25 Torr.

Failure to maintain a vacuum without pressure rising bymore than 0.25 Torr indicates that there is a leak, which mustbe rectified and then the pressure and leak testing procedurerepeated.

7. Switch off and disconnect the vacuum pump and vacuumtest pressure gauge.

8. Refit the system HP and LP pressure switches.Provided that the evacuation has been successful, the system isnow ready for Initial Charging With Refrigerant.

Initial Charging With RefrigerantThroughout the charging procedure, observe the followingpoints:• Only use the correct refrigerant for the system.• Never mix refrigerants.• Only use fresh refrigerant. NEVER use reclaimed or

contaminated refrigerant.• Accurately weigh cylinders of refrigerant, before and after

charging, to establish how much charge has been installed.• Record the volume of refrigerant charged into the system.

This is essential information for future reference.• The charging line must be fitted with a non-return valve.• A pressure gauge must be fitted to the charging cylinder, so

that its condition can be monitored.• To prevent moisture or other contaminants from entering the

system, the charging line must be fitted with a new filter/drier.

• Refrigerant R 407C, which is a ‘blend’, must be added asliquid only, otherwise characteristics of the refrigerant will bealtered by fractional evaporation of its components in thecylinder. Therefore, ensure that the cylinder is arranged tocharge liquid only.

The following procedure must be carried out in turn for eachrefrigeration circuit of the unit.

1. Ensuring that the charging line is fully purged of air, connecta cylinder of the correct refrigerant to the charging point inthe discharge line. For details, refer to the schematicdiagram for the system.

2. SLOWLY open the liquid charging valve to break the vacuumand admit refrigerant into the system.


IPAC


CAUTION Fresh air intake

Document 0410536

Until system pressure has been raised above atmospheric, only admit small quantities of refrigerant, otherwise violent cooling may cause thermal shock to system components.

The system needs to be charged on the HP ANDLP sides of the compressor.

Add the charge gradually and in stages, until as much aspossible of the estimated charge has been added to thesystem.

For the estimated weight of initial charge, refer to “Technicaldata” on page 2-8 of Section 2.

During charging, if system and cylinder pressures equalise,the flow of refrigerant into the system will cease. Toencourage further charge to enter the system, place thecylinder in a bucket of warm water to increase cylinderpressure.

WARNINGDo NOT use a flame or heat gun to warm thecylinder, otherwise it may rupture.

When as much as possible of the estimated weight of chargehas been added, stop charging, isolate the cylinder ofrefrigerant at the cylinder and disconnect the cylinder.

WARNINGThe charging line contains liquid refrigerantunder high pressure. Adequate precautionsmust be taken to avoid freeze burns to theface, eyes and skin.

3. Record the weight of refrigerant charged into the unit.

Any final charging must be carried out (by customer) duringcommissioning.

4. When pressure has stabilised throughout the system, recordHP and LP pressure gauge readings; these should be equal.

At regular intervals, monitor pressure gauges for anyindication of leakage.

5. Disconnect and remove the cylinder of refrigerant.Initial charging is now complete and this also completes theinstallation procedure.If necessary, any final charging is carried out duringcommissioning.The unit is now ready for commissioning as described inSection 8 - Commissioning - DX Units.

Installation of optional accessories

High efficiency filter housingActual fitting of filters.

Side service entryRemoval of gland plates, drill to suit.

Suitable for Ø250 ducting, drill and fix to suit. Recommendfiltration.

Condensate pumps

Cold waterPosition underneath outlet. Site fit.

Hot waterAs above but non-return valve needs to be fitted after dischargepump. All materials used must be suitable for use up to 100°C.

Oil separatorsSite fitted, follow manufacturers installation instructions.

Fresh air controlIf the fresh air is ducted, then the outside air sensors are to bemoved from their standard position and wiring extended to alocation as close as possible to the outside air source.As the IPAC unit will draw the design quantity of fresh air intothe system, the overall design should inhibit water ingress intothe building. For optimum system performance the fresh airpressure drop should be kept to a minimum.

Mains filter kitSee Alan!!!

Remote sensorsSee Alan!!!

Water Detection tapeTerminals are provided within the electrical chassis forconnection of the water detection tape. The sensing length of thetape should be positioned in the unit or underfloor where watermay collect.In multi-module units a tape should be fitted to each section.

ICV Condensor InterlockPlease see wiring diagram for additional control wiring to befitted for this option.

Flexible duct connectionThe ductwork connection is a 30mm Doby 'slide-on' flangesystem, which conforms fully to HVCA specification DW142 forrectangular duct connections.

Floor support anglesThese are supplied loose with certain base plinth options. Thebase plinth should be drilled to suit exact floor height allowingfor anti-vibration gasket to be installed between the angles andthe floor tiles.


IPAC SECTION 7

IPACEaton-Williams

IPAC


INSTALLATION - CHILLED WATER UNITS

SECTION CONTENTS


Persons Permitted to Carry Out Installation 7 – 4Arrival at Site 7 – 4Off-loading and Handling 7 – 4

Off-loading by Crane 7 – 4Off-loading by Forklift 7 – 4Moving a Unit 7 – 4

Storage 7 – 4Installation Obstructions 7 – 5

Noise 7 – 5Condensate Drain 7 – 5

Positioning 7 – 5Floor Mounting 7 – 5Base Plinth Mounting 7 – 6

Installation Clearances 7 – 6Piping up the System 7 – 6Filling the System 7 – 6Humidifier Mains Water Supply 7 – 6Condensate Drain 7 – 7Power Supply 7 – 7Emergency Stop 7 – 7Electrical Connections 7 – 7

Remote Start / Stop Signal 7 – 7Fire Shutdown Signal 7 – 7

Completion of Installation 7 – 7

IPAC

Document 0410536


Installation - Chilled Water Units

IPAC


Introduction Fig. 7-1 : Unit lifting brackets

Document 0410536

The purpose of this section is to provide an overall guide for theinstallation of IPAC range AHUs and is not an exhaustive step-by-step installation guide. Each site will vary in requirementsregarding layout and obstacles to overcome.If there are queries or points of uncertainty, refer to Eaton-Williams for clarification. Also refer to any special instructionsissued by Eaton-Williams, or their appointed distributor, for aspecific project.

Persons Permitted to Carry Out InstallationOnly personnel who have been properly trained in theinstallation of refrigeration equipment should be permitted tocarry out installation of the equipment covered by this manual.

Arrival at SiteIf any damage is found, this must be reported to Eaton-Williams,or their appointed distributor, immediately.Units are normally despatched enclosed in suitable packagingfor protection during transit. The arrangement and type ofpackaging will vary according to the method of transportation,site location, unit type and quantity, etc.

Before Acceptance:

• Before unpacking, check all packaging for any evidence ofdamage that could indicate possible damage to a unit within.

• Carefully remove all packaging and then thoroughly checkeach unit for damage. Do not allow the unit to become wet.

• Each unit is supplied containing a holding charge of drynitrogen, nominal pressure 3.4 bar g (50 psi g). Fit acalibrated test pressure gauge and check that the holdingcharge is intact.

• Report any damage or escape of holding charge to the carrierand to Eaton-Williams immediately.

Eaton-Williams cannot be held responsible for any damageoccurring during transit.

Off-loading and HandlingBefore moving units, check the weight by referring to “IPACRange unit configurations, dimensions and weights” on page 2-7 of Section 2. Add an adequate allowance for any significantpackaging, such as wooden crating.

CAUTIONAt NO time is the unit to be laid on its back, side orfront. Doing this will cause irreparable damage.

To facilitate lifting by crane or hoist, Eaton-Williams can providespecially designed lifting brackets on request.These brackets are to be fitted to the top of the unit, one at eachend, as shown in Fig. 7-1.

WARNINGLifting eyes must not be used, otherwisethey may strip-out during the lift.

To avoid damage to the unit or injury to personnel, observe thefollowing points:• Ensure that all lifting and handling gear, including any slings,

etc., are of adequate specification.• If the unit is to be lifted by crane or hoist, correctly sized load

spreaders must be used.• Ensure that the lift is vertical.• Do not allow the unit to drop.

Off-loading by Crane

CAUTIONTo avoid damage, load spreaders must always beused when lifting the unit by hoist or crane.Always use the specially designed lifting bracketsprovided by Eaton-Williams; refer to Fig. 7-1.

Off-loading by Forklift

CAUTIONThe unit can be off-loaded and moved using aforklift, provided that the lift is from under thepallet; refer to Fig. 7-2.Lifting directly against the unit bottom will causeirreparable damage.

Moving a UnitThe unit can be moved around using appropriate equipment asillustrated in Fig. 7-2 and Fig. 7-3.

StorageUnits that are not installed directly following arrival at site mustbe stored in a weatherproof, dry, well-ventilated and vermin-freearea.To prevent Brinelling of bearings, units must be stored in avibration-free area, otherwise adequate steps must be taken toprevent such damage.


IPAC


Fig. 7-2 : Off-loading by forklift (generic unit shown) and Off-loading by crane (generic unit shown)

Document 0410536

Installation ObstructionsA number of factors must be assessed regarding the installationof air handling units.• Hot water pipework - must be properly lagged to minimise

heat transfer.• Radiators or night storage heaters positioning.• Electrical fittings and installations.• Telecommunications equipment positioning.• Cable tray and busbar support drop rod positioning.• Cable tray and busbar distribution systems

The proximity of these items must be taken into consideration,especially in respect of any adverse affect they may have on theflow of return air.

NoiseThe installation must be checked regarding noise levelsgenerated during operation, to ensure that local requirementsand limitations are adhered to.

Condensate DrainCondensate must be arranged to discharge directly into aproperly designed drain. Refer to for further details.

PositioningIPAC units are designed to locate either directly on to raised floorjacks, or onto a base plenum.

CAUTIONIPAC range AHUs are designed for indoor use only.For downflow units with top or back return,BEFORE positioning the unit, ensure that theaperture blanking plate is correctly positioned forairflow direction.

Fig. 7-3 : Using pallet trucks (generic unit shown)


IPAC


Floor Mounting • Piping runs should be supported at 1.5 m intervals by suitable

Document 0410536

Front-return units can be located directly onto the floor.To provide an air seal, use a layer of gasket between the floorand the unit.If it is suspected that the installation will be susceptible tovibration, it is recommended that the unit is seated on a 15 x 30mm continuous strip of Tico anti-vibration packing. This will alsoprovide a good seal.

Base Plinth MountingIf the floor is uneven, it is recommended that a suitable flooring-levelling screed is applied.To provide an air seal, use a layer of gasket above and below theplinth.Before mounting the unit, ensure that the plinth is perfectly levelin both planes and will remain so when the unit is mounted.Mount the unit onto the plinth, using the two locating pinsprovided. Fit the pins in opposite corners of the base plinth; theunit has matching clearance holes for location.Use screw fixings to secure the unit to the wall.

Installation Clearances Because the full-height doors provide full access formaintenance purpose, a unit can be installed against a wall atthe back and sides as required. • A clear distance of 800 mm must be allowed at the front for

maintenance access.• To ensure unobstructed flow of return air to the unit, a

minimum distance of 300 mm must be allowed between thetop of unit and the ceiling.

Piping up the SystemSite chilled water system connections (flow and return) areterminated and capped off in the base of the unit.After units have been correctly positioned and installed,interconnecting pipework can be installed between the unit andthe chilled water system.Throughout connecting up the system, observe the followingpractices.• To protect the modulating flow control valve from being

affected by sludge or debris, a fine mesh strainer should beinstalled before the flow connection to the unit.

NOTEFailure to protect the flow control valve fromsystem sludge and debris can adversely affectplant performance.

The ideal arrangement is for two full-capacity strainers to befitted in parallel, with isolating valves, so that unit operationwill not be interrupted during strainer maintenance.

• When routing the pipework through the base into the unit,ensure that pipework does not obstruct airflow unnecessarily.Use only clean, hard drawn, refrigeration quality coppertubing, with wrought copper fittings.

• Route pipework to produce the minimum length circuit, withswept bends.

hangers or brackets. Ensure that pipework is isolated fromsupports by using foam insulation or similar. This will also benecessary where pipework passes through floors or walls.Where lines are run together, they must be insulated fromeach other.

• When installing pipework, allowance must be made forthermal movement. Piping must be arranged so thatconnections are not stressed.

Filling the SystemAfter all pipework has been installed, the system can be filled.Only potable water should be used to fill the system.To prevent sludging, it is recommended that a corrosion inhibitor/ anti-sludging agent is used in the chilled water system.

NOTEAny antifreeze or corrosion inhibitor must besuitable for system materials.

During and after filling the system, check thoroughly for leaks,paying particular attention to all connections and unions.Leakage at a compression fitting can sometimes be remedied bytightening the fitting.To repair leakage at a soldered or brazed connection, the systemmust be drained to empty the section of pipework beforecarrying out the repair. The system can then be re-filled and thenre-checked for leaks.

Humidifier Mains Water SupplyThe Vapac® humidifier is an electrode boiler operating atatmospheric pressure and is designed for connection to standardmains water supply, provided local regulations for this type ofequipment are observed.To eliminate possible contamination of the water supply, thehumidifier has a tundish which incorporates a 25 mm verticalgap over the maximum overflow level of the fill cup and belowthe end of the feed pipe. Subject to local regulations, thisarrangement should eliminate the need for a static tank in thesupply water feed.A Water Authority approved stop cock and strainer must befitted in the supply from the water main; use 15 mm diametercopper tube or approved equivalent material.Pre-treatment of the feed water is unnecessary, as Vapachumidifiers are designed to operate on a wide range of waterqualities.The standard Vapac humidifier is not suitable for connection toa fully demineralised water supply.The Vapac humidifier water quality range is:

Hardness 50 to 500 ppm (mg/l)Conductivity 80 to 1000 microsiemensWater Pressure 0.30 to 8.00 bar g

After connecting the water supply to the humidifier, fill thepipework and check for leaks; repair as necessary, adopting theprocedure described under .


IPAC


Condensate Drain Fig. 7-4 : Electrical connection points

Document 0410536

The condensate drain runs from the condensate tray to the baseof the unit in 13 mm internal diameter clear, flexible hose, whichis looped within the unit to from a trap.If a humidifier is fitted, the condensate and humidifier drain linesare commoned-up, before the trap, using an equal tee piece toprovide a single 13 mm internal diameter drain connection.The external drain line must be connected to the drain line hoseand should provide a continuous fall to an open drain.

CAUTIONThe unit is fitted with an internal condensate trap,do not fit an external trap.

If a Vapac humidifier is installed, any plastic piping and fittingsmust be rated for use at 100 °C.

Power SupplyUnits must be provided with a reliable power supply of 380/415Vac, 3 ph, 50 Hz. Ensure that the supply is adequately rated tomeet maximum demand; for details refer to unit wiringdiagrams.It is recommended that an external isolator is fitted, preferablyone that incorporates an Emergency Stop button.

Emergency StopTo enable the unit to be shutdown quickly in an emergency, it isrecommended that an Emergency Stop button is fitted, either aspart of an external isolator or as a separate control.

Electrical ConnectionsAll IPAC units have bottom left hand cable entry as standard.Connection points are shown in Fig. 7-4 and Fig. 7-5.Main incoming power supply is connected to a main isolator,fitted master units only. Slave units are powered via controls in the master unit.All terminals for customer connection of power supply andcontrol circuits are adjacent to the cable entry point, inside thelower left hand side of the unit.Note the following points:• Do not run power and signal wiring close together.• If it is necessary for signal wiring to cross power cables,

ensure that they cross at right angles to each other.For details of mains power supply and control circuits, refer tospecific unit wiring diagrams.

WARNINGThe unit isolator must remain in the OFF positionuntil pre-commissioning checks have been carriedout, which are part of the commissioningprocedure.

Remote Start / Stop SignalThis optional facility is linked out as standard.If this function is required, a volt-free contact of the Start / Stopcontrol device should be connected to the customer terminalsspecified on the schematic wiring diagram for the unit.

Contact function is:

Closed circuit (contact makes) = Unit RunOpen circuit (contact breaks) = Unit Stop

Fire Shutdown SignalThis optional facility is linked out as standard.If this function is required, a volt-free contact of the FireShutdown control device should be connected to the customerterminals specified on the schematic wiring diagram for the unit.Contact function is:

Closed circuit (contact makes) = NormalOpen circuit (contact breaks) = Shutdown

Completion of InstallationOn completion of installation, the unit is now ready forcommissioning as described in Section 9 - Commissioning - CWUnits.

Fig. 7-5 : Interconnecting wiring connection points


IPAC SECTION 8

IPACEaton-Williams

IPAC


COMMISSIONING - DX UNITS

SECTION CONTENTS


Persons Permitted to Carry Out Commissioning 8 – 4Pre-commissioning Checks - Unit Non-operational 8 – 4Unit Operational Checks 8 – 5

Electrical 8 – 5Fan(s) and Airflow 8 – 5Air Filter Blocked Function 8 – 5Fault Detection and Control Functions 8 – 5Condenser 8 – 6Start-up Control 8 – 6High Pressure Cut-out 8 – 6Final Charging 8 – 6System Checks 8 – 7Smoke alarm test (if applicable) 8 – 7Test of Vapac humidifier operation (if applicable) 8 – 7Finalising operational tests 8 – 7

Room Balancing 8 – 7Leaving Site 8 – 7

IPAC

Commissioning - DX Units

Introduction 5. Check that the main isolator and all circuit breakers in the

Document 0410536

The purpose of this section is to describe pre-commissioning,checking and final commissioning for a typical installationequipped with IPAC air handling units fitted with DX cooling.Information provided in this section is intended for guidanceonly and is not an exhaustive step-by-step commissioning guide.Although similar in function, each installation will havecharacteristics peculiar to it.Any queries or points of uncertainty should be discussed with theEaton-Williams Commissioning Supervisor for clarification.All results and readings, observed or calculated, should berecorded in a logbook.For multiple installations, these instructions are to be carried outfor each separate unit and (where applicable) for eachrefrigeration circuit of the unit.For each test that generates an alarm, restore normal conditionsand then clear the alarm before moving on to next step.

Persons Permitted to Carry Out CommissioningOnly personnel who have been properly trained in thecommissioning of refrigeration equipment should be permittedto carry out commissioning of the equipment covered by thismanual.

Pre-commissioning Checks - Unit Non-operationalDuring this procedure, note the following points:• Ensure that the area around the air handling unit, including

grilles, is clear of any obstruction, e.g. builder’s rubbish,packing material or other debris.

• The area must be swept of light litter, such as sawdust orpaper particles, that may become airborne, enter the unit andfoul air filters.

• Removal of any obstruction from the area around the unitmust be done in co-operation with the Site Manager.

Carry out the following procedure steps in order of sequence:

1. Remove any remaining packing material from the outside ofthe unit.

2. Ensure that the power supply is of the correct voltage andthat all electrical connections made at site are correct.

3. Ensure that external controls, such as Fire Shutdown, andSmoke Detection (if fitted) are in the MADE (closed circuit)state. If these functions are not installed, ensure that theappropriate terminals are linked-out in accordance with thewiring diagram.

4. Check that the power supply to the unit is switched OFF atthe external isolator or distribution board. For increasedsafety, remove any fuses in the power supply to the unit.

WARNINGTo prevent personnel from restoring power tothe unit, place warning notices whereapplicable.

unit are in the OFF position.6. Check the unit casing for damage and check that all doors

and covers seal correctly against mating surfaces.7. Unlock and open front access doors.8. Check all items within unit to ensure that they have not

become loose, dislodged, or damaged in transit.9. Check that the earth connection is correctly made to both

the isolator and the unit.10. Check that the earth connection is made correctly to any

metal drain and water supply pipes for the Vapac humidifier,(if fitted).

11. Check that all mains electrical connections are tight andsecure.

12. Check for free rotation of fans. Inspect for damage andremove any debris.

WARNINGAlthough a fan may be OFF, its impeller may stillbe induced to rotate at considerable speed,driven by inlet/outlet pressure differencescaused by other equipment or local conditions.Beware of this potential hazard and takeprecautions to avoid injury - DO NOT usefingers to check for free rotation, instead, use apiece of stiff card. Do not use a material thatmay damage the impeller or break up.

13. If ductwork is fitted to supply or discharge, check thatmating surfaces are sealed.

14. Check that insulation is securely fastened to panels.15. Check the external drain connection by pouring water into

the condensate tray to prime the trap. Check for leaks andthat the water drains correctly.

NOTEThe unit is fitted with an internal condensatetrap, do not fit an external trap.

16. Check water supply and drain connections for the Vapachumidifier (if fitted).

17. Check the steam line and its connections (units fitted with aVapac humidifier).

18. Check the unit log record for the pressure and chargeweight that was recorded during the last stages ofinstallation. If there any is indication of leakage, this mustbe rectified (by customer) before commissioning canproceed further.

19. Check that air filters are fitted correctly.20. Check that refrigeration system pressure switches and their

connections are secure.21. Inspect all internal electrical wiring and terminations.22. Check for free operation of all contactors.23. Check that fuses are in position and correctly rated

according to the wiring diagram.


IPAC


24. For ducted systems, check that any manually operated 8. If airflow is incorrect, check possible causes. If incorrect

Document 0410536

dampers are correctly positioned to achieve designoperation.

25. Close all windows and doors to the equipment room.

Unit Operational ChecksCarry out the following checks in order of sequence:

Electrical1. Check that the main isolator and all circuit breakers in the

unit are in the OFF position

2. Disable compressor starting by disconnecting compressor(s)supply from the contactor(s).

3. At the external isolator or distribution board, switch ON thepower supply to the unit.

4. Check that the mains supply voltage at the unit inputterminals is correct:

5. Phase to Phase = 380 to 415 V ac6. Phase to Neutral = 220 to 240 V ac7. Check that connections to the transformer are correct for

the supply to the unit according to the wiring diagram.

WARNINGIncorrect connection to the transformer mayresult in damage to the control system.

8. Check the function of each EMERGENCY SHUTDOWN facility(where fitted).

9. Check for correct operation of the controller display on thefront of the unit; refer to Section 4 - INVICTANETCONTROLLER TECHNICAL MANUAL for details.

Fan(s) and Airflow1. Switch ON unit at external isolator switch or distribution

board.

WARNINGRemember that the unit is now live - extremecaution must be exercised at all times.

2. Switch ON fan MPCBs in the control section. This enablesfan(s) operation on automatic control.

3. Switch ON control circuit MCBs. Unit is now underautomatic control.

4. After a period of 30 seconds (nominal), fan(s) will start.Airflow failure monitoring alarm is delayed for a further 20seconds.

5. Check for direction of fan rotation and listen for any adversenoises.

6. Using an anemometer, check supply fan airflow at thereturn air grille/opening.

7. Check that airflow is within 10 % of design; refer to“Technical data” on page 2-8 of Section 2.If airflow is correct, record the reading in the unitcommissioning log.

airflow is due to non-standard external resistance, checkwhether this is acceptable, or whether the fan drive rationeeds to be modified to obtain design airflow.

9. Using a clip-on ammeter, measure fan operating currentsand record readings in the commissioning log.

10. Switch all circuit breakers to ON.11. Check the Airflow Failure control function:12. Adjust the air switch up to 5.0 mbar. A ‘prompt’ alarm is

generated at the customer terminals and the unit display (iffitted).

13. After testing, re-adjust the airflow switch setting to 0.5mbar.

Air Filter Blocked FunctionTo check the Filter Blocked control function:

1. Cover air filters with suitable material to simulate a chokedfilter. With 75 % (approx.) of filter covered, the airflowswitch should trip. A ‘deferred’ alarm is generated at thecustomer terminals and on the unit display (if fitted).

2. Remove the blockage after testing.

Fault Detection and Control FunctionsTo check the Flood Detection control function:

Flood detection

1. Simulate a water flood by operating the flood detectionsensor (if fitted), or connect a link across the waterdetection terminals. A ‘prompt’ alarm is generated at thecustomer terminals and on the unit display (if fitted).

2. After testing remove the link (if one was fitted)

Supply fan failureIn turn, manually trip each supply fan MPCB. A ‘prompt’ alarm isgenerated at the customer terminals and on the unit display (iffitted). Also check each overload setting.

Compressor failureIn turn, manually trip each compressor MPCB. A ‘prompt’ alarmis generated at the customer terminals and on the unit display (iffitted). Also check each overload setting.


IPAC


Fig. 8-1 : Temperature controls and heating 1. Check the high pressure trip and control function:

Document 0410536

1. So that changes in air temperature can be simulated fortesting, connect a variable resistance box, or 0 to 20 k ohmpotentiometer, to the return air sensor connection on theunit controller; refer to the unit wiring diagram.

2. Heater check (if applicable):3. Adjust temperature simulation resistance to 5.5 °C, at

which point the heating is brought into operation. This ischecked using a clip-on ammeter and the reading thenrecorded.

4. Check that the overheating cut-out functions correctly bysetting the temperature simulation resistance to 24 °C.

5. Adjust temperature simulation resistance to:• 40 °C - check high temperature alarm.• 05 °C - check low temperature alarm.

6. Switch OFF the main isolator. Reconnect compressor wiringto the contactor.

CondenserSwitch the condenser isolator ON and then carry outcommissioning checks according to the condenser instructionmanual.

Start-up Control1. Switch the main isolator ON.

2. Adjust temperature simulation resistance to 35 °C - togenerate a cooling required / start refrigeration condition.Check that start delays are correct for the controller.

High Pressure Cut-outThe following procedure must be carried out in turn for eachrefrigeration circuit of the unit.

NOTEIf the unit is undercharged and therefore lowoverall system pressures exist, it may not bepossible to check the HP cut-out trip function untilFinal Charging has first been carried out as describedunder .

WARNINGDuring this procedure, do NOT permit pressureto rise above the leak test pressure of 31.0 barg (440 psi g).If necessary, stop the unit immediately.

With the unit running in cooling mode, partly cover thecondenser coil, or switch OFF the condenser fan.

2. Check that check that HP pressure switch operates at thecorrect pressure and shuts down the relevant compressor. A‘Prompt’ alarm is generated at the customer terminals andon the unit display (if fitted).

3. After testing, restore condenser cooling.4. Disconnect and remove the temperature simulation

resistance that was installed at step 1 of 8-1.

Final ChargingFor this type of DX system, the maximum volume of refrigerantcharge is required when the unit is running at design loadconditions.The system is fully charged when the point is reached that thereare no bubbles visible in the moisture indicating sight glass inthe liquid line.Top-up the system charge as follows:

1. Arrange a cylinder of the correct refrigerant for the unit sothat only liquid will be charged.

NOTEThe weight of charge added to the unit must berecorded.

2. Operate the unit at design load conditions. 3. Add liquid-only refrigerant via manifold into the suction

line, gradually and in stages, allowing system operatingconditions to stabilise each time after adding liquid.

WARNINGDo not overcharge the system.

Do not add any more refrigerant than is necessary to producea bubble-free moisture indicating sight glass, otherwise thesystem will be overcharged and likely to result in highpressure cut-out trips when the unit is run at maximum load.

4. Update the unit log record to show the charge weight andpressure.

System Checks1. Allow system to operate normally for at least ten minutes to

stabilise. Ideally, with room air temperature at design,record the following data:

• Evaporating pressure.• Condensing pressure.• Compressor operating current.

2. For 2 compressor control, adjust temperature simulationresistance to stage-out each compressor and observedamper operation.

3000 8000 13000 18000 23000 280000

5

10

15

20

25

30

35

40

45

Tem

pera

ture

OHMS


IPAC


3. Disconnect the temperature simulation resistance and • Ensure that any witness signatures are obtained before

Document 0410536

reconnect the temperature sensor.

Smoke alarm test (if applicable)Check smoke alarm function as specified by the manufacturer.

Test of Vapac humidifier operation (if applicable)1. Check the MPCB overload setting.

2. Set humidity demand.3. Check that the cylinder fills and there are no leaks.4. Check and record the operating current.5. Reduce humidity demand and check that the humidifier

cuts-out correctly.

Finalising operational tests1. Reset the unit to automatic control.

2. Reset all default settings, unless specifically requestedotherwise.

3. If any controller settings have been changed from defaultvalues, record these values in the appropriate table(s)provided under Section 5 - INVICTANET Controller SettingsRecord.

4. Check operation of the display screen by scrolling throughall screens and levels.

5. Observe and record:• Return air temperature• Outside ambient air temperature• Unit run time• Relative humidity (if applicable)

6. The function of all alarms should be checked at the:• Unit • Remote display (if applicable) • Remote Monitoring Centre (if applicable)

7. Record any alteration to default settings.

Room BalancingIt is recommended that the entire environmental controlinstallation is fully commissioned (by customer) before beingbrought into service.

Leaving SiteBefore leaving site:• Ensure that all covers are located and fitted correctly, are

airtight and locked.• Finally check that unit(s) are left in good order and (if

required) switch OFF the supply at the external isolator ordistribution board.

• Ensure that all tools and test instruments are removed fromsite.

• Finally check through the documentation to ensure that allaspects have been covered.

handover.• Keys should be handed over to the Officer or Site Manager in

charge.


IPAC


Document 0410536


IPAC SECTION 9

IPACEaton-Williams

IPAC


COMMISSIONING - CW UNITS

SECTION CONTENTS


Persons Permitted to Carry Out Commissioning 9 – 4Pre-commissioning Checks - Unit Non-operational 9 – 4Unit Operational Checks 9 – 5Finalising operational tests 9 – 6Room Balancing 9 – 6Leaving Site 9 – 6

IPAC

Commissioning - CW Units

Introduction 5. Check that each cooling and heating pipework circuit has

Document 0410536

The purpose of this section is to describe pre-commissioning,checking and final commissioning for a typical installationequipped with IPAC air handling units.Information provided in this section is intended for guidanceonly and is not an exhaustive step-by-step commissioning guide.Although similar in function, each installation will havecharacteristics peculiar to it.Any queries or points of uncertainty should be discussed with theEaton-Williams Commissioning Supervisor for clarification.All results and readings, observed or calculated, should berecorded in a logbook.For multiple installations, these instructions are to be carried outfor each separate unit and (where applicable) for each systemcircuit of the unit.For each test that generates an alarm, restore normal conditionsand then clear the alarm before moving on to next step.

Persons Permitted to Carry Out CommissioningOnly personnel who have been properly trained in thecommissioning of refrigeration equipment should be permittedto carry out commissioning of the equipment covered by thismanual.

Pre-commissioning Checks - Unit Non-operational• Ensure that the area around the air handling unit, including

grilles, is clear of any obstruction, e.g. builder’s rubbish,packing material or other debris.

• The area must be swept of light litter, such as sawdust orpaper particles, that may become airborne, enter the unit andfoul air filters.

• Removal of any obstruction from the area around the unitmust be done in co-operation with the Site Manager.

This part of the commissioning procedure is carried out with theunit(s) non-operational and before the power supply is turnedon.

WARNINGDo NOT supply power to the unit while carryingout this part of the commissioning procedure.

Carry out the following in order of sequence.1. Remove any remaining packing material from the outside of

the unit.2. Check that the earth connection is correctly made to the

unit.3. Check that the earth connection is correctly made to flow

and return pipework and any metal condensate drain pipes(where fitted).

4. Ensure that all units, duct work and louvres are clean andfree of any installation debris.

The area must be made clean of light litter, such as sawdustor paper particles, that may become airborne and clog the airfilter(s).

been connected correctly and that flow and returnconnections are correct.

This may seem obvious, but it is surprisingly easy for systempipework to be inadvertently cross-connected duringinstallation.

6. Check that all pipework is insulated correctly, including anythrough-wall pipework.

7. Check that all unit coil vent and drain valves are closed.8. Fill the cooling system circuit by opening appropriate

isolating valves.

Purge as much air as possible from the system by using thehighest of any manually operated external vent valves.

Check the system for leaks and make any repairs asnecessary.

9. After allowing the system to fill as much as possible, startthe cooling system circulating pump.

Continue to purge as much air as possible from the system.

10. Purge air from the coil by partially opening the cooling coilvent valve.

When all air has been purged from the coil, close the ventvalve.

For multiple installations, purge all air from the unit closestto the pump in the system circuit flow first. Then proceed tothe next closest and so on round the system circuit until eachunit has been purged of air.

NOTEFailure to purge all air from the system and coilblock will result in poor performance from theunit.

11. Repeat steps 8 to 10 for the heating system and each unitheating coil (if fitted).

12. Ensure that the power supply is of the correct voltage andthat all electrical connections made at site are correct.

13. Ensure that external controls, such as Fire Shutdown, andSmoke Detection (if fitted) are in the MADE (closed circuit)state. If these functions are not installed, ensure that theappropriate terminals are linked-out in accordance with thewiring diagram.

14. Check that the power supply to the unit is switched OFF atthe external isolator or distribution board. For increasedsafety, remove any fuses in the power supply to the unit.

15. Check that the main isolator and all circuit breakers in theunit are in the OFF position.

16. Check the unit casing for damage and check that all doorsand covers seal correctly against mating surfaces.

17. Unlock and open front access doors.18. Check all items within unit to ensure that they have not

become loose, dislodged, or damaged in transit.19. Check that the earth connection is correctly made to both

the isolator and the unit.


IPAC


20. Check that the earth connection is made correctly to any WARNING

Document 0410536

metal drain and water supply pipes for the Vapac®

humidifier, (if fitted).21. Check that all mains electrical connections are tight and

secure.22. Check for free rotation of fans. Inspect for damage and

remove any debris.23. If ductwork is fitted to supply or discharge, check that

mating surfaces are sealed.24. Check that insulation is securely fastened to panels.25. Check the external drain connection by pouring water into

the condensate tray to prime the trap. Check for leaks andthat the water drains correctly.

CAUTIONThe unit is fitted with an internal condensate trap, do not fit an external trap.

26. Check water supply and drain connections for the Vapachumidifier (if fitted).

27. Check steam line and connections (units fitted with a Vapachumidifier).

28. If there any is indication of leakage, this must be rectified(by customer) before commissioning can proceed further.

29. Check that air filters are fitted correctly.30. Inspect all internal electrical wiring and terminations.31. Check for free operation of all contactors.32. Check that fuses are in position and correctly rated

according to the wiring diagram.33. For ducted systems, check that any manually operated

dampers are correctly positioned to achieve designoperation.

34. Close all windows and doors to the equipment room.

Unit Operational Checks1. Check that the main isolator and all circuit breakers in the

unit are in the OFF position.

2. At the external isolator or distribution board, switch ON thepower supply to the unit.

3. Check that the mains supply voltage at the unit inputterminals is correct:

Phase to Phase = 380 to 415 V ac

Phase to Neutral = 220 to 240 V ac

4. Check that connections to the transformer are correct forthe supply to the unit according to the wiring diagram.

CAUTIONIncorrect connection to the transformer may result in damage to the control system.

5. Switch ON unit at external isolator switch or distributionboard.

Remember that the unit is now live - extremecaution must be exercised at all times.

6. Switch ON fan MPCBs in the control section. This enablesfan(s) operation on automatic control.

7. Switch ON control circuit MCBs. Unit is now underautomatic control.

8. After a period of 30 seconds (nominal), fan(s) will start.Airflow failure monitoring alarm is delayed for a further 20seconds.

9. Check for direction of fan rotation and listen for any adversenoises.

10. Using an anemometer, check supply fan airflow at thereturn air grille/opening.

11. Check that airflow is within 10 % of design; refer to“Technical data” on page 2-8 of Section 2. If airflow iscorrect, record the airflow reading in the commissioning log.

12. If airflow is incorrect, check possible causes. If incorrectairflow is due to non-standard external resistance, checkwhether this is acceptable, or whether the fan drive rationeeds to be modified to obtain design airflow.

13. Using a clip-on ammeter, measure fan operating currentsand record readings in the commissioning log.

14. Check the function of each EMERGENCY SHUTDOWN facility(where fitted).

15. Switch all circuit breakers to ON.16. Check for correct operation of the controller display on the

front of the unit; refer to Section 4 - INVICTANETCONTROLLER TECHNICAL MANUAL for details.

17. Check the Airflow Failure control function:18. Adjust the air switch up to 5.0 mbar. A ‘prompt’ alarm is

generated at the customer terminals and the unit display (iffitted).

19. After testing, re-adjust the airflow switch setting to 0.5mbar.

20. Check the Filter Blocked control function:21. Cover air filters with suitable material to simulate a choked

filter. With 75 % (approx.) of filter covered, the airflowswitch should trip. A ‘deferred’ alarm is generated at thecustomer terminals and on the unit display (if fitted).

22. Remove the blockage after testing.23. Check the Flood Detection control function:24. Simulate a water flood by operating the flood detection

sensor (if fitted), or connect a link across the waterdetection terminals. A ‘prompt’ alarm is generated at thecustomer terminals and on the unit display (if fitted).

25. After testing remove the link (if one was fitted)26. Check Supply Fan Failure control function:27. In turn, manually trip each supply fan MPCB. A ‘prompt’

alarm is generated at the customer terminals and on theunit display (if fitted). Also check each overload setting.


IPAC


28. So that changes in air temperature can be simulated for • Remote Monitoring Centre (if applicable)

Document 0410536

testing, connect a variable resistance box, or 0 to 20 k ohmpotentiometer, to the return air sensor connection on theunit controller; refer to the unit wiring diagram.

29. Heater check (if applicable):30. Adjust temperature simulation resistance to 5.5 °C, at

which point the heating element is brought into operation.This is checked using a clip-on ammeter and the readingthen recorded.

31. Check that the overheating cut-out functions correctly bysetting the temperature simulation resistance to 24 °C.


33. Adjust temperature simulation resistance to:• 35 °C - to generate a cooling required condition.

34. Check that start delays are correct for the controller.35. Record unit operating current(s) in cooling mode.36. Record unit operating current(s) in heating mode (if

applicable).37. Switch OFF the unit at the isolator and then disconnect the

temperature simulation resistance and reconnect thetemperature sensor.

Smoke alarm test (if applicable)Check smoke alarm function as specified by the manufacturer.

Test of Vapac humidifier operation (if applicable)

1. Check the MPCB overload setting.

2. Set humidity demand.3. Check that the cylinder fills and that there are no leaks.4. Check and record the operating current.5. Reduce humidity demand and check that the humidifier

cuts-out correctly.

Finalising operational tests1. Reset the unit to automatic control.

2. Reset all default settings, unless specifically requestedotherwise.

3. If any controller settings have been changed from defaultvalues, record these values in the appropriate table(s)provided underSection 5 - INVICTANET Controller SettingsRecord.

4. Check operation of the display screen by scrolling throughall screens and levels.

5. Observe and record:• Return air temperature.• Outside ambient air temperature.• Unit run time.• Relative humidity (if applicable).

6. The function of all alarms should be checked at the:• Unit • Remote display (if applicable)

7. Record any alteration to default settings.

Room BalancingIt is recommended that the entire environmental controlinstallation is fully commissioned (by customer) before beingbrought into service.

Leaving SiteBefore leaving site:• Ensure that all covers are located and fitted correctly, are

airtight and locked.• Finally check that unit(s) are left in good order and (if

required) switch OFF the supply at the external isolator ordistribution board.

• Ensure that all tools and test instruments are removed fromsite.

• Finally check through the documentation to ensure that allaspects have been covered.

• Ensure that any witness signatures are obtained beforehandover.

• Keys should be handed over to the Officer or Site Manager incharge.


IPAC SECTION 10

IPACEaton-Williams

IPAC


PREVENTATIVE AND GENERAL MAINTENANCEIncludes Decommissioning and Disposal Procedure

SECTION CONTENTS


Persons Permitted to Carry Out maintenance 10 – 4Preventive Maintenance Objectives 10 – 4Tools and Consumables 10 – 4Alarm Monitoring Centres 10 – 4Prevention of Legionnaires’ Disease 10 – 4Maintenance Checklist 10 – 4Preventive Maintenance Tasks 10 – 9

Pressure Relief Valve(s) (if fitted) - DX Units 10 – 9Air Filters 10 – 9Unit Cabinet and Components 10 – 9Vapac Humidifier (if fitted) 10 – 10System Strainers - Chilled Water Units 10 – 10Water Quality - Chilled Water Units 10 – 10Chilled Water System Circuits - Chilled Water Units 10 – 11

Unit Operational Checks 10 – 11Air Supply Fan(s) 10 – 11Airflow Failure Test 10 – 11Filter Blocked Test 10 – 11Flood Detector Test (if fitted) and Condensate Pump (if fitted) 10 – 11HP Cut-out Test - DX Units 10 – 11LP Cut-out Test - DX Units 10 – 12Compressor Fail Test - DX Units 10 – 12Heater (if fitted) 10 – 12Temperature Controls 10 – 12Controller Functions 10 – 13Emergency and Fire Shutdown Controls (if fitted) 10 – 13Vapac Humidifier (if fitted) 10 – 13Refrigeration System - DX Units 10 – 13Earth Wiring and Connections 10 – 13Door Panel Locks and Seals 10 – 13Finalising Preventive Maintenance Checks 10 – 13

Documentation 10 – 13Before Leaving Site 10 – 13Renewing a Vapac Steam Cylinder 10 – 13

Decommissioning Procedure 10 – 16Disposal 10 – 16

IPAC

Document 0410536


Preventative and General Maintenance

IPAC


Introduction Prevention of Legionnaires’ Disease

Document 0410536

The purpose of this section is to provide an overall guide for firstline preventive maintenance tasks for standard IPAC range unitsand is not an exhaustive step-by-step maintenance guide.

WARNINGFailure to carry out maintenance can result incomponent failure.Eaton-Williams cannot be held responsible fordamage, injury or death resulting from failure tocarry out maintenance and testing procedurescorrectly at specified or recommended intervals.

If there are any points of uncertainty, refer to Eaton-Williams forclarification. Also refer to any special instructions issued byEaton-Williams for a specific project.Maintenance Checklists are provided under and should also becompleted by the Service Engineer, following routinemaintenance.

Persons Permitted to Carry Out maintenanceOnly personnel who have been properly trained in themaintenance of refrigeration equipment should be permitted tocarry out maintenance of the equipment covered by this manual.Tasks should be programmed initially to take place at quarterlyintervals. However, the frequency with which louvres, air filtersand Vapac® steam cylinders require attention will vary,depending on site location, height above ground, air and waterquality, humidity demand, etc.The frequency of preventive maintenance checks and tasksshould therefore be adjusted upwards or downwards accordingto local conditions and based on practical experience.

Preventive Maintenance ObjectivesPerforming the tasks in this section will ensure that:• Air filters are changed before contamination restricts airflow.• Vapac steam cylinders are cleaned/renewed before they scale

up (only units fitted with this option).

Tools and ConsumablesThe following items are required:• Standard tool set.• Socket key to open unit door panels.• Polythene dustbin liner for disposal of old filters.• Adhesive tape or string to seal the dustbin liner and prevent

dust escaping.• New panel filters. For details, refer to “General Parts List” on

page 11-4 of Section 11.• Vacuum cleaner.

Alarm Monitoring CentresIf alarms are extended beyond the unit, the Alarm MonitoringCentre should be informed that maintenance work is beingcarried out.

For any system that uses an evaporative condenser or coolingtower, it is essential that maintenance is carried out rigorouslyand at intervals specified by the equipment manufacturer.

WARNINGFailure to carry out correct maintenance of anyevaporative condenser or cooling tower can resultin an outbreak of Legionnaires’ Disease, whichcauses serious illness and death.Eaton-Williams cannot be held responsible forconsequences arising from failure of the owner/user to carry out maintenance correctly and atspecified intervals according to the manufacturer’sinstructions and current legislation covering thistype of plant.Before carrying out any maintenance, alwayscheck to establish the type of primary coolingsystem.Wherever an evaporative condenser/cooling toweris used, establish the maintenance status.If it is suspected that maintenance of anevaporative condenser or cooling tower haslapsed, DO NOT carry out any work untilmaintenance has been carried out on theevaporative condenser/cooling tower according tothe manufacturer’s instructions and currentlegislation covering this type of plant.NEVER operate a unit if it is suspected that there isrisk of air contaminated with Legionnella bacteriabeing produced or drawn into the building.

For information on the prevention of Legionnaires’ disease,consult the local water authority or appropriate governmentdepartment.

Maintenance ChecklistThe following Maintenance Checklists are provided:• DX units - see Table 10-1 on page 4• Chilled water units - see Table 10-2 on page 6These are designed for quick reference and contain all relevantitems detailed in the above procedures. Cross references areprovided for each topic.Checkboxes are provided so that each item can be ticked oncompletion.It is recommended that a copy of the appropriate checklist ismade so that checkboxes can be ticked against each item as it iscompleted. The checklist should then be signed and dated.A copy of each completed checklist should be kept with thelogbook for the unit.


IPAC


Table 10-1 : Maintenance checklist - DX units


Maintenance Checklist - DX Units

Refer to Page Task Description

page 10-8 Air Filters - clean or renew

page 10-8

Unit Cabinet and Components

Vacuum and clean internally

Condensate tray - clean and check drainage

Inspect fan impeller(s), bearings and belts for wear and movement

Check heater element electrical connections for tightness

Check all wiring for insulation damage and tightness of connections

Inspect compressor anti-vibration mountings for wear

page 10-9

Vapac Humidifier (if fitted)

Clean or renew strainer in the water supply solenoid valve

Drain pump - clean and inspect

Steam cylinder - inspect and renew if necessary

page 10-10

Air Supply Fan(s)

Check for noise or vibration

Check operating current(s) value

Check fan overload setting(s) value

page 10-10 Airflow Failure Test

page 10-10 Filter Blocked Test

page 10-10 Flood Detector Test (if fitted) and Condensate Pump (if fitted)

page 10-10 HP Cut-out Test - DX Units

page 10-10 LP Cut-out Test - DX Units

page 10-11

Compressor Fail Test - DX Units

MPCB trip and alarm

Overload setting value

page 10-11

Heater (if fitted)

MPCB trip and alarm


page 10-11

Temperature Controls

Heater ON temperature control value

Heater OFF temperature control value

High temperature cut-out function value

High temperature alarm function value

Low temperature alarm function value


IPAC


Table 10-1 : Maintenance checklist - DX units


page 10-11

Controller Functions

Supply air fan(s) start delay time value

Compressor(s) start delay time value

Heater(s) (if fitted) start delay time value

Humidifier (if fitted) start delay time value

Compressor stage-in (two compressor unit only)

Compressor stage-out (two compressor unit only)

Re-connect air temperature sensor

page 10-11

Emergency and Fire Shutdown Controls (if fitted)

Emergency shutdown function (if fitted)

Fire shutdown function (if fitted)

page 10-11 Earth Wiring and Connections

page 10-11

Refrigeration System - DX Units

Evaporating pressure value

Condensing pressure value

Compressor operating current value

Check for refrigerant leaks and oil leaks

page 10-11 Door Panel Locks and Seals

page 10-11

Finalising Preventive Maintenance Checks

Return the unit to normal operation

Record return air temperature value

Record unit run time value

Record relative humidity (if applicable) value

Record room temperature set point value

Record relative humidity set point value

Update the settings record to reflect any changes made

Maintenance carried out by:

Printed Name

Organisation

Signature

Date

Maintenance Checklist - DX Units



IPAC


Table 10-2 : Maintenance checklist - chilled water units

Document 0410536

Maintenance Checklist - Chilled Water Units


page 10-8 Air Filters - clean or renew

page 10-8

Unit Cabinet and Components

Vacuum and clean internally

Condensate tray - clean and check drainage

Inspect fan impeller(s), bearings and belts for wear and movement

Check heater element electrical connections for tightness

Check all wiring for insulation damage and tightness of connections

page 10-9

Vapac Humidifier (if fitted)

Clean or renew strainer in the water supply solenoid valve

Drain pump - clean and inspect

Steam cylinder - inspect and renew if necessary

page 10-9 Water Quality - Chilled Water Units

page 10-9 Chilled Water System Circuits - Chilled Water Units

page 10-10

Air Supply Fan(s)

Check for noise or vibration

Check operating current(s) value

Check fan overload setting(s) value

page 10-10 Airflow Failure Test

page 10-10 Filter Blocked Test

page 10-10 Flood Detector Test (if fitted) and Condensate Pump (if fitted)

page 10-11

Heater (if fitted)

MPCB trip


page 10-11

Temperature Controls

Heater ON temperature control value

Heater OFF temperature control value

High temperature cut-out function value

High temperature alarm function value

Low temperature alarm function value


IPAC


Table 10-2 : Maintenance checklist - chilled water units

Document 0410536

page 10-11

Controller Functions

Supply air fan(s) start delay timevalue value

Heater(s) (if fitted) start delay time value

Humidifier (if fitted) start delay time value

Cooling stage-in (two-circuit unit only)

Cooling stage-out (two-circuit unit only)

Re-connect air temperature sensor

page 10-11

Emergency and Fire Shutdown Controls (if fitted)

Emergency shutdown function (if fitted)

Fire shutdown function (if fitted)

page 10-11

Earth Wiring and Connections

Check wiring and connections

Shut and lock the unit door(s) and return the unit to normal operation

page 10-11 Door Panel Locks and Seals

page 10-11

Finalising Preventive Maintenance Checks

Return the unit to normal operation

Record return air temperature value

Record unit run time value

Record relative humidity (if applicable) value

Record room temperature set point value

Record relative humidity set point value

Update the settings record to reflect any changes made

Maintenance carried out by:

Printed Name

Organisation

Signature

Date

Maintenance Checklist - Chilled Water Units



IPAC


Preventive Maintenance Tasks One at a time, carefully remove each filter panel from the

Document 0410536

Carry out preventive maintenance by adhering to the followingprocedures:

NOTEIf the installation comprises a master withnetwork slave units, when the master unit powersupply is isolated, all slave units will continue tooperate under their own default control.Where possible, avoid switching OFF more than oneair handling unit at a time.

Pressure Relief Valve(s) (if fitted) - DX UnitsEaton-Williams recommend that, to protect the system andcomponents against unacceptably high pressure, a suitably ratedpressure relief valve is fitted in the discharge line and close to thecondenser.Where these are fitted, it is the responsibility of the user toensure that all pressure relief valves are periodically tested inaccordance with local and national regulations.

WARNINGYou should NEVER attempt to test a pressure reliefdevice.

Air FiltersAll air filters in a unit should be cleaned or renewed at the sametime and at a frequency that, from experience of operating theunit, is known to just precede a FILTER BLOCKED alarm.

NOTEDiscolouring is not a cause for changing the filters,as filter efficiency increases as they becomeslightly dirty. Not until airflow is restricted, shouldfilters be changed. A FILTER BLOCKED alarm isindicated when airflow becomes too restricted.If it is necessary to renew any air filter, all otherair filters of a unit should also be renewed at thesame time, otherwise airflow through unit will beimbalanced and could adversely affect unitperformance.

Clean or renew air filters as follows:

1. Switch OFF the unit external isolator (if fitted).

WARNINGLock the isolator in the OFF position. If thiscannot be done, place a suitable notice toprevent the isolator from being inadvertentlyswitched ON by other personnel.

2. Open the unit door panel(s).3. Switch OFF the internal isolator (if fitted).4. Filters are released for removal by sliding the retaining bar

upwards until it can pass outwards through the slot in theframework and be removed.

framework, taking care not to release any dust. See Figs.10-1 to 10-3.

Ideally, bag-up filters and take them to a suitable area wherecleaning can take place.

5. Use a vacuum cleaner to clean each filter in turn. Ifnecessary, loosen particles by gently rapping the filteragainst a wall; ensure that a mask is worn while doing this.

NOTECleaning will not remove all discolourationfrom the filter surface. Standard filters are notwashable.

6. If filters are to be renewed instead of cleaned, seal them ina dustbin liner for disposal.

7. Install cleaned or new filter panels by placing them into theunit frame and fitting the retaining bar.

NOTEEnsure that air filter surfaces are fitted in thecorrect orientation for the airflow, otherwise,when the unit next starts, residual dustparticles will be driven from filter surfaces andenter the supply airflow to the room.The plain (or ‘dirty’) surface of the filter mustface into the airflow.

Unit Cabinet and ComponentsCarry out the following cleaning and inspection procedures:

WARNINGThe unit must remain electrically isolated whilecarrying out these procedures.

1. Vacuum and clean out the inside of the cabinet, payingparticular attention to all surfaces.

Fig. 10-1 : Filter arrangement


IPAC


5. Check the condition of electrical connections to heaterFig. 10-2 : Removing a filter retaining bar

Document 0410536

2. Clean out the condensate tray and check for blockages.Pour 1.5 litres of disinfected water into the tray and checkthat the water flows to drain.

3. On larger units, condensate trays are fitted with two drainoutlets, one at each end. Ensure that each outlet drainscorrectly.

4. Inspect impellers and bearings of the air supply fan(s), anddrive belts, for wear and mechanical movement.

WARNINGAlthough a fan may be OFF, its impeller may stillbe induced to rotate at considerable speed,driven by inlet/outlet pressure differencescaused by other equipment or local conditions.Beware of this potential hazard and takeprecautions to avoid injury - DO NOT usefingers to check for free rotation, instead, use apiece of stiff card. Do not use a material thatmay damage the impeller or break up.

elements (if fitted).6. Check all wiring for damage to insulation and tightness of

electrical connections.7. For DX units, closely inspect compressor anti-vibration

mountings for signs of wear or failure.

Vapac Humidifier (if fitted)Carry out the following cleaning and inspection procedure

WARNINGThe unit must remain electrically isolated whilecarrying out this procedure.

NOTEIn units fitted with a Vapac humidifier option,water condition and humidity demands determinethe effective life of the steam cylinder. Forexample, areas with soft water will have longerservice life from a steam cylinder than areas withhard water.

1. Remove and clean the strainer in the water supply solenoidvalve; renew if necessary.

2. Clean and inspect the drain pump.3. Inspect the Vapac steam cylinder; renew if necessary.4. Restore the unit to operational condition.

Water Quality - Chilled Water UnitsObtain a sample of water from the chilled water system andcheck that it is not contaminated with sludge.

NOTESludge in the chilled water system can adverselyaffect the flow control valve and performance ofthe unit. If in doubt, consult Eaton-Williams foradvice.

Chilled Water System Circuits - Chilled Water UnitsThoroughly check the unit’s chilled water circuit(s) for evidenceof leakage.Any leaks must be repaired by adopting the following procedure:

1. Isolate the unit from the chilled water system by closing theunit’s flow and return isolating valves.

2. Drain all water from the affected section of pipework byopening vent and drain cocks provided on the unit.

3. Repair or renew the leaking component(s), resoldering orrebrazing, where necessary.

4. Shut the vent and drain cocks.5. Open the flow isolating valve. Do not open the return

isolating valve, otherwise air will be driven into the chilledwater system.

6. Purge air from the unit’s pipework by opening the vent cockSLOWLY until air can pass out.

When all air has been purged and water begins to appear,shut the vent cock.

Fig. 10-3 : Removing a filter panel from the frame


IPAC


7. Open the return isolating valve to re-unite the unit with the DO NOT permit pressure to rise above the pressure

Document 0410536

chilled water system.8. Recheck for leaks and, if necessary, repeat the procedure

until satisfied that the unit is free of leaks.

Unit Operational ChecksFirst, prepare the unit for operation by switching ON the unitexternal isolator (if fitted) and the internal isolator (if fitted).After allowing the unit controller to initialise and stabilise, carryout unit operational checks as described under each headingfollowing:

WARNINGThe following procedures are carried out while theunit power supply is live.Beware of electrical hazards and rotatingmachinery.Adopt safe working procedures at all times.

Air Supply Fan(s)1. With the air supply fan(s) operating, listen for any adverse

noises or vibrations.

If necessary, use controller override settings to force thefan(s) to start.

2. Check each fan overload setting.

Airflow Failure TestCheck airflow by gradually opening the unit door. A ‘Prompt’alarm is generated at the customer terminals and on the unitdisplay (if fitted).

Filter Blocked TestSimulate a choked air filter condition by using a suitable sheetmaterial to cover the air filter. A ‘Prompt’ alarm is generated atthe customer terminals and on the unit display (if fitted).Remove the sheet material used for simulation.

Flood Detector Test (if fitted) and Condensate Pump (if fitted)Manually trip the flood detection circuit by linking it out. A‘Prompt’ alarm is generated at the customer terminals and onthe unit display (if fitted).Check and operate the condensate pump.

HP Cut-out Test - DX UnitsCheck the HP high pressure switch trip and control function foreach refrigeration circuit of the unit:

WARNINGThe following procedure is potentially hazardous.Adequate safety precautions must be taken toguard against damage or injury being caused bycomponent failure at high pressure.Steps 3, 4 and 5 must be carried out in a safe area.

switch setting.

1. Stop the unit and switch OFF the unit isolator.

WARNINGLock the isolator in the OFF position. If thiscannot be done, place a suitable notice toprevent the isolator from being inadvertentlyswitched ON by other personnel.

2. Disconnect and remove the HP high pressure cut-out fromthe unit.

3. Connect the HP cut-out, via a pressure regulator thatincorporates a test pressure gauge, to a cylinder of nitrogen.

4. Connect a meter or test lamp to the cut-out terminals, sothat cut-out function can be monitored.

5. While monitoring the gauge pressure, gradually increasepressure to the HP cut-out until the trip setting of 28 bar g(400 psi g) is reached and the cut-out contacts break circuit.

WARNINGDO NOT permit pressure to rise above thepressure switch setting

If the cut-out fails to trip at the correct setting, it must bereplaced by one that does.

WARNINGNEVER allow the unit to operate with a faultyHP pressure switch or one that is not setcorrectly.

6. Provided that the HP cut-out trips at the correct setting, refitit to the unit and ensure that electrical connections areremade correctly.

7. Start the unit and check that when the HP pressure switchcircuit trips, the control system shuts down the relevantcompressor. A ‘Prompt’ alarm is generated at the customerterminals and on the unit display (if fitted).

WARNINGDO NOT permit pressure to rise above thepressure switch setting. If necessary, shutdown the plant immediately.

8. Repeat the above procedure for each HP switch fitted.

LP Cut-out Test - DX UnitsCheck the LP low pressure switch trip and control function foreach refrigeration circuit of the unit:

NOTEIt is not possible to check the LP cut-out while it isfitted to the unit. However, the trip setting andcontrol function can be checked as follows:

1. With the unit stopped, switch OFF the unit isolator.

2. Disconnect and remove the LP cut-out from the unit.3. Connect the LP cut-out, via a pressure regulator that

incorporates a test pressure gauge, to a cylinder of nitrogen.


IPAC


4. Connect a meter or test lamp to the cut-out terminals, so 4. Check that the high temperature cut-out functions correctly

Document 0410536

that cut-out function can be monitored.5. While monitoring the gauge pressure, gradually increase

pressure to the LP cut-out until just above the trip setting of0.5 bar g (7 psi g) and the cut-out contacts make circuit.

WARNINGDO NOT permit pressure to rise above thepressure switch setting.

6. Turn on the unit isolator and allow the unit to start.

WARNINGThe unit is now operating without theprotection of the LP cut-out. Do not allow theunit to operate like this any longer thanabsolutely necessary.

7. Gradually reduce pressure to the LP cut-out setting. Verifythat the control system shuts down the relevant compressor.A ‘Prompt’ alarm is generated at the customer terminalsand on the unit display (if fitted).

If the cut-out fails to trip at the correct setting, it must bereplaced by one that does.

WARNINGNEVER allow the unit to operate with a faultyLP pressure switch or one that is not setcorrectly.

8. Provided that the LP cut-out trips at the correct setting, refitit to the unit and ensure that electrical connections areremade correctly.

Compressor Fail Test - DX UnitsIn turn, manually trip each compressor MPCB. A ‘Prompt’ alarmis generated at the customer terminals and on the unit display (iffitted).Check each compressor overload setting.

Heater (if fitted)1. In turn, manually trip each heater MPCB to check operation.

2. Check each heater overload setting.

Temperature Controls1. So that changes in air temperature can be simulated for

testing, connect a variable resistance box, (or 0 to 20 k ohmpotentiometer) to the return air sensor connection on theunit controller; refer to the unit wiring diagram.

2. Adjust temperature simulation resistance to reflect a lowtemperature to bring the heating element (if fitted) intooperation.

3. Adjust temperature simulation resistance to reflect a risingtemperature and note at which point the heating element (iffitted) ceases operation. This is checked using a clip-onammeter.

by setting the temperature simulation resistanceaccordingly.


Controller Functions1. Adjust temperature simulation resistance to 35 °C and

check start delay times for:

• Supply air fan(s) - all units• Compressor(s) and condenser(s) - DX units• Heater(s) (if fitted)• Humidifier (if fitted)

2. For two-circuit chilled water units, check that coolingcircuits stage-in and stage-out correctly by adjustingtemperature simulation resistance accordingly.

3. For two-compressor DX units, check that compressors stage-in and stage-out correctly by adjusting temperaturesimulation resistance accordingly.

4. Disconnect the temperature simulation resistance and thenre-connect the air temperature sensor.

Emergency and Fire Shutdown Controls (if fitted)In turn, check that emergency and fire shutdown controls stopthe unit correctly.

Vapac Humidifier (if fitted)1. Check function of the Vapac drain and condensate pump.

2. Check function of the Vapac humidifier.

Refrigeration System - DX UnitsAllow system to operate normally for ten minutes to settle down.Then, carry out the following:

1. With room temperature at nominal 24 °C, check thefollowing values for each refrigeration circuit in turn:

• Evaporating pressure• Condensing pressure• Compressor operating current

2. Check the system for refrigerant leaks and oil leaks.

Earth Wiring and ConnectionsCheck the integrity of all earth connections, including externalconnections.

Door Panel Locks and Seals1. Shut and lock the unit door(s), checking that door lock(s)

operate correctly.

2. Start the unit and check that door seals are effective.

Finalising Preventive Maintenance Checks1. Return the unit to normal operation.


IPAC


2. Observe and record: Fig. 10-4 : Vapac cylinder with connections

Document 0410536

• Return air temperature.• Unit run time.• Relative humidity %, (units fitted with the Vapac humidifier

option).3. Check and adjust as required:• Temperature set point• Relative humidity % (units fitted with a with Vapac

humidifier option)4. Update the unit settings record to reflect any changes

made; refer to Section 13 - Unit Maintenance Log.

DocumentationAny necessary documentation should be completed; e.g.Logbook, etc.An example maintenance log record is provided in Section 13 -Unit Maintenance Log.The Maintenance Checklist provided under should also becompleted.

Before Leaving SiteEnsure that:• All air handling unit access panels are properly closed and

secured.• Mains power has been restored to all air handling units.• No alarm is showing on any unit or remote display.• Any necessary documentation is handed over to the

appropriate person.• The Alarm Monitoring Centre is advised of completion of

maintenance and departure from site.

Renewing a Vapac Steam CylinderTo renew a Vapac humidifier, referring to Fig. 10-4 carry out thefollowing procedure:

1. Turn OFF the water supply to the unit.

2. With power still connected to the unit, use the HumidifierManual Drain setting of the unit controller Service levelsettings to initiate a the manual drain (setting 4-x-13) toempty the steam cylinder. Refer to “Service level menusystem settings” on page 4-6 of Section 4.


WARNINGPlace a suitable notice to prevent the isolatorfrom being inadvertently switched ON by otherpersonnel.

4. Open the unit door panel(s).5. Switch OFF the unit internal isolator6. Carefully ease off the red electrode caps and the white cap

off the level switch.7. With a twisting movement, lift and remove the cylinder

clear of the feed/drain manifold.8. Clean feed/drain manifold of sediment and scale.

9. Check and clean drain pump. After placing drain pumpback in position, insert the steam cylinder and press firmlyinto position.

10. Re-connect electrode caps in accordance with the details onthe collar supplied with the new cylinder; see Fig. 10-5.

11. Close and secure access doors.12. Restore power to unit.13. Test the function of the Vapac humidifier.14. Return the unit to normal service.

Cleanable Vapac CylindersVapac steam cylinders are available in cleanable versions. Theseare similar in design to standard Vapac units, but the cylindercomprises two halves that can be separated to enable theremoval of loose scale deposits.

Fig. 10-5 : Sequence of connection


IPAC


WARNING 10. Restore mains power to the unit.

Document 0410536

NEVER touch an operating cylinder, as any leakwater will be at mains voltage.

The two halves are sealed buy an O-ring and are held togetherby two clamping rings and quick-release fasteners; see Fig. 10-6.A cleanable cylinder can be ordered by quoting same order codeas standard cylinders, but with letters CC instead of CM or CD.When cleaning out loose deposit, make sure to clean any build-up on the level switch.

WARNINGDo not disturb the electrodes. If they are badlyeroded and/or the internal positioning ring is free,the cylinder must be replaced.

During assembly, always use a new seal and ensure that matingsurfaces are clean and from scars that will prevent propersealing.

Vapac Feed Solenoid Valve and Strainer1. Turn OFF the water supply to the unit.

2. With power still connected to the unit, use the HumidifierManual Drain setting 4-x-13 of the unit controller Servicelevel settings to initiate a the manual drain to empty thesteam cylinder; refer to “Service level menu systemsettings” on page 4-6 of Section 4.

3. Switch OFF the unit external isolator (if fitted).4. Open the unit door panel(s).5. Switch OFF the unit internal isolator. 6. Unscrew the hose connection to the water supply; refer to

Fig. 10-7. 7. Using long-nosed pliers, pull out the push-fit strainer and

clean; refer to Fig. 10-8.8. Re-assemble in reverse order of the above steps.9. Turn ON the water supply to the unit.

11. Test the function of the Vapac humidifier.12. Close and lock unit panel doors.13. Return unit to normal service.

Vapac Drain PumpThe drain pump should be inspected at regular intervals and atleast at each change of steam cylinder.

1. Turn OFF the water supply to the unit.

2. With power still connected to the unit, use the HumidifierManual Drain setting 4-x-13, of the unit controller Servicelevel settings to initiate a the manual drain to empty thesteam cylinder; refer to “Service level menu systemsettings” on page 4-6 of Section 4.


WARNINGPlace a suitable notice to prevent the isolatorfrom being inadvertently switched ON by otherpersonnel.

4. Open the unit door panel(s).5. Carefully ease off the red electrode caps and the white cap

off the level switch.6. With a twisting movement, lift and remove the cylinder

clear of the feed/drain manifold.

Fig. 10-6 : Cleanable Vapac cylinder

Fig. 10-7 : Vapac water connection

Fig. 10-8 : Strainer removal


IPAC


7. Clean feed/drain manifold of sediment and scale. Fig. 10-11 : Dismantled pump

Document 0410536

8. Remove the pump by pushing it back until it clears themanifold.

9. Remove the water hose and twist the top of the pump bodyto access the impeller; refer to Fig. 10-10.

10. Check that the impeller is clean and rotates freely. De-scaleand clean as required; refer to Fig. 10-11.

11. Ensuring that the O-ring is correctly seated, re-assemble thepump by following the above steps in reverse order.

12. Following re-assembly of the pump, ensure that the pumpcoil is dry before reinstating the electrical supply.

13. Turn ON the water supply to the unit.14. Restore mains power to the unit.15. Test the function of the Vapac humidifier.16. Close and lock unit panel doors.17. Return unit to normal service.

Decommissioning and Disposal ProcedureDecommissioning, dismantling and disposal of air handling unitsshould be undertaken only by experienced personnel and in fulladherence to all safety rules, in particular, with respect toprotection of lungs, eyes and skin from refrigerant, dust etc.Only approved lifting gear and power tools should be used andaccess to the work area restricted to authorised personnel only.

Decommissioning ProcedureAll refrigerant, oil and other waste materials must be disposedoff in a professional and responsible manner in strict adherenceto legislation and environmental regulations.Greatest possible care should be taken at all times to avoid therelease of refrigerant into the atmosphere.

1. Disconnect the unit from the electrical supply.

2. A chilled water unit must be drained of all water, which may contain additives, such as glycol and corrosion inhibitors. This water must be contained and disposed of safely, with strict regard to the environment and in accordance with additive manufacturers’ instructions and current legislation/regulations.

3. For a DX unit, reclaim ALL refrigerant from the unit by using approved reclaiming equipment in accordance with the manufacturer’s instructions. Recovery of refrigerant must be carried out only by personnel registered for refrigerant safe handling.

Disposal1. Dispose of reclaimed refrigerant and oil through an

approved recycling facility.

2. Separate unit sections (where applicable) and remove to approved recycling facilities.

Fig. 10-9 : Pump and manifold

Fig. 10-10 : Opening pump


IPAC SECTION 11

IPACEaton-Williams

IPAC


SERVICE AND PARTS INFORMATION

SECTION CONTENTS

Heading Page11.1 General 11 – 4

11.2 Contact Details for Service and Parts 11 – 411.3 Ordering Spares 11 – 5

11.4 Recommended Spares 11 – 511.5 Service Parts 11 – 5

IPAC

Document 0410536


Service and Parts Information

IPAC


General WARNING

Document 0410536

It is essential that service and maintenance parts are of the samespecification as those they replace and should be obtained fromEaton-Williams, or their appointed distributor. Whereapplicable, suitable alternatives will provided to replaceobsolete parts.Parts fitted to a refrigeration system must be suitable for suchuse. Items such as gaskets and ‘O' rings must be compatiblewith the system refrigerant, lubricating oil, pressure andtemperature. Parts must comply with design specifications,current regulations and legislation.

Never fit inferior or unsuitable parts.The fitting of incorrect parts can adversely affectplant performance and/or operation and mayresult in damage to the unit and could cause injuryor death of personnel.

Contact Details for Service and Parts

Maintenance / Service Contracts

Contact Tel. No. 1: 01732 869 600 International: +44 1732 869 600


Fax No: 01732 869 630 International: +44 1732 869 630

E-mail [email protected]

General Service and Repair



Fax No.: 01732 869 630 International: +44 1732 869 630

Emergency Service

Freephone number, available to clients with a service contract.

Service Parts

Contact Tel No.: 01732 869 614 International: +44 1732 869 614

Fax No.: 01732 865 709 International: +44 1732 865 709

Website

http:\\www.eaton-williams.com


IPAC


Ordering Spares Recommended Spares

Document 0410536

When ordering spares, always provide the unit serial number asit appears on the serial No. plate; refer to “Unit Identification”on page 2-6 of Section 2 for location.

Table 11-1 lists the site recommended minimum holding ofconsumable service parts. The number of spares held isdependent on the unit type and number of units installed.

NOTEAlways quote the unit serial number to identifyparts correctly.

Service PartsService parts must be to the same specification as those theyreplace and should be obtained from Eaton-Williams, or anappointed distributor.Where applicable, obsolete parts will be replaced by suitablealternatives.

NOTETable 11-2 is not exhaustive and does not include alloption equipment.Always quote the unit serial number to identifyparts correctly

Table 11-1 : Site stock recommended spares list

Site Stock Recommended Spares List

COMPONENT DESCRIPTION

Air filter G4 as standard. Optional alternatives are available

Belt - Fan drive, wedge type

Fuse 3.15 A, anti-surge, 20 x 5 mm

Fuse - controller mother board PCB 2 A rating

Fuse - controller mother PCB 1 A rating

Fuse - controller daughter PCB, rating 1 A

Humidifier cylinder* Vapac, size 2

NOTE *If fitted.

Table 11-2 : General parts list

General Parts List

COMPONENT DESCRIPTION / NOTES

Compressor Scroll type

Air filter

Fan - air circulating Forward curved, centrifugal

Belt - fan drive Wedge type

Pulley - motor

Bush - motor pulley Taperlock

Pulley - fan

Bush - fan pulley Taperlock


IPAC



Document 0410536

Evaporator Cooling coil block

Thermostatic expansion valve To suit refrigerant

Filter/drier To suit refrigerant

Moisture indicating sight glass Solder fitting

Pressure switch - HP

Pressure switch - LP

Air differential pressure switch Range 0.5 to 4.0 mbar

Room air temperature sensor

Room air temperature and humidity sensor

Valve - evacuation / charging Schraeder type, 0.25 in. flare

Humidifier Vapac OEM assembly

Humidifier cylinder Vapac, Size 2

Lifting bracket For hoisting the unit

Key - cabinet door 8 mm triangular recess

ELECTRICAL / ELECTRONIC COMPONENTS (master units only)

Isolator

Main, 30 A, 3 pole

Main, 55 A, 3 pole

Main, 125 A, 3 pole

Isolator cover For each isolator

Level sensor PCB - Vapac humidifier

Controller mother board Echelon, E/Boil

ELECTRICAL / ELECTRONIC COMPONENTS (master units only) continuation

Controller daughter board Echelon

Graphical display board Echelon

Keypad label Graphical display

Keypad label Text-only

Filter resistor

10 k ohm, 0.25 W, +/- 1 %

15 k ohm, 0.25 W, +/- 1 %

20 k ohm, 0.25 W, +/- 1 %

General Parts List



IPAC



Document 0410536

Contactor

8 A, 24 Vac, N/O aux.

12 A, 24 Vac, N/O aux.

22.5 A, 24 Vac, 50/60 Hz, N/O aux.

Fuse 3.15 A, anti-surge, 20 x 5 mm

Fuse - controller mother board PCB2 A

1 A

Fuse - controller daughter board PCB 1 A

MCB

4 A, DP

6 A, SP

10 A, SP

2.5 - 4 A

6.3 - 10 A

10 - 16 A

MPCB16 - 20 A

20 - 25 A

Link 3-phase

Terminal shroud

Auxiliary contacts

RelaySPDT, 9 V dc

4PDT, 5 A, 24 V ac, 50/60 Hz

Relay Base5 pin

14 pin

ELECTRICAL / ELECTRONIC COMPONENTS (master units only) continuation

Transformer200 - 440 V power, 9-24 V supply

Current, 200T, torod

Current set plug

Heater electric element 2.5 kW, finned

Thermostat Rod type, max. 80 °C, 178 mm lg

Pump 24 V ac

Solenoid valve 24 V ac, 1.2 l/min

Manifold - feed/drain

General Parts List



IPAC



Document 0410536

Strainer - water feed

O-Ring 4.5 x 1.75 mm cross section, nominal

General Parts List



IPAC


Document 0410536


IPAC SECTION 12

IPACEaton-Williams

IPAC


FAULT FINDING PROCEDURES

SECTION CONTENTS


Fault Finding Procedure 12 – 4Is Power Available? 12 – 4

Should the Unit Process be Operating? 12 – 4Is the Unit Idle in Standby Mode? 12 – 4Is the Unit Being Operated Within Design Conditions 12 – 4

Fault Finding Tables 12 – 4Correcting Fault Conditions That Involve Opening a DX Refrigerant System 12 – 5

IPAC

Document 0410536


Fault Finding Procedures

IPAC


Introduction • If the controller display is blank, see “Display Corruption” on

Document 0410536

This section provides basic information on fault diagnosis forvarious types of air handling units in the IPAC range.

WARNINGBefore carrying out any work on the unit, ensurethat it is electrically isolated.Lock the isolator in the OFF position. If this cannotbe done, place a suitable notice to prevent theisolator from being inadvertently switched ON byother personnel.

The information provided here is not exhaustive, but is designedto assist and minimise the effort required to identify a faultcondition, should one arise.Carrying out fault diagnosis requires a thorough understandingof the operation and requirements of the plant.

CAUTIONSome fault conditions, such as temperature orpressure trips, will seem to rectify themselves asconditions return to normal when the unit stopsoperating. DO NOT reset the controls and restartthe unit without first identifying and rectifying thecause of the fault.Repeatedly resetting and restarting can damagethe unit and may invalidate any warranty.

Fault Finding ProcedureFault diagnosis is made considerably easier for a unit or anetwork of units that is fitted with an Eaton-Williams AHUcontroller/display, as it has been specially designed to indicatethe existence of a fault and identifies the affected item; forexample, a low airflow rate caused by a blocked filter.

WARNINGNever allow or risk the possibility of mains voltagereaching any controller connection.For this reason, be especially careful if using lowimpedance instruments for checking voltage etc.No field repairs to the controller /display should beattempted.

If an Eaton-Williams AHU controller/display is not fitted,identifying the cause of a fault may involve a lengthy andpainstaking process of elimination.Fault finding procedures described in this section assumes thatan Eaton-Williams AHU controller is fitted and can beinterrogated to identify the affected item of plant and prevailingconditions, such as air temperature and humidity.When this has been done, the Fault Finding Tables shown undermay be used to assist in fault diagnosis, identification of possiblecauses and suggested remedial action.• If the controller is displaying a fault condition, each affected

item is identified; refer to Section 4 - INVICTANETCONTROLLER TECHNICAL MANUAL for details.

page 4-25 of Section 4.• If the controller display is functioning and not showing a fault

alarm, but the unit is not operating when it is suspected thatit ought to, see and .

• If the unit is a network slave and not fitted with a controllerdisplay, check the unit’s status on the network master.Depending on the unit’s status, see , and , as appropriate.

Before moving to more in-depth fault finding, it is always worthchecking the following points:

Is Power Available?If the unit is apparently ‘dead’, eliminate these obviouspossibilities:• Check that the unit isolator is switched ON.• Check that the power supply is live to the unit.

Check external and internal circuit breakers and externalinterlocks; e.g. “Fire Shutdown” on page 4-25 of Section 4

• If the unit is a network slave, visually check that controllercommunications cable has not been damaged ordisconnected.

• Check door interlocked isolators (if fitted).

Should the Unit Process be Operating?Check that there is truly a demand. For example, if demand hasbeen satisfied, the unit process should not be expected tooperate; for further details, see “AHU Not Operating” on page 4-25 of Section 4.

Is the Unit Idle in Standby Mode?A unit in standby mode will only operate to take over the duty ofanother unit that becomes unavailable, or when due to take overaccording to run/standby rotation control settings.

Is the Unit Being Operated Within Design ConditionsIPAC AHUs are designed for operation within certain designconditions (dependent on unit model) and must not be operatedoutside these conditions.Attempting to operate a unit outside its design conditions willresult in fault conditions arising.

Fault Finding TablesThe following fault finding tables are provided for assistance andguidance in fault diagnosis, identification of possible causes andsuggested remedial action.The information provided here is not exhaustive, but is designedto assist and minimise the effort required to identify a faultcondition, should one arise.Once the controller has been interrogated and the process typeaffected by the fault condition identified, the fault finding tablescan be used to make informed decisions as to what action isrequired.For clarity and ease of use, information is grouped by topic:• Airflow - fault finding - Table 12-1


IPAC


• Heating systems - fault finding - Table 12-2 After repairs have been carried out, the following

Document 0410536

• DX cooling / dehumidification - fault finding - Table 12-3• Chilled water cooling / dehumidification - fault finding -

Table 12-4• Humidification system - fault finding - Table 12-5

Correcting Fault Conditions That Involve Opening a DX Refrigerant SystemObserve the following caution:

CAUTIONFor a DX system, whenever it is necessary to breakinto the system envelope, the refrigerant chargemust first be recovered by using proprietaryrecovery equipment.

procedures must be adopted:

• “Combined Strength and Leak Pressure Test” on page 6-8of Section 6

• “Evacuation and Dehydration” on page 6-9 of Section 6

• “Initial Charging With Refrigerant” on page 6-9 of Section 6

• “Final Charging” on page 8-4 of Section 8

DO NOT forego these procedures, otherwiseextensive damage to the unit will result.

Table 12-1 : Airflow - fault finding

AIRFLOW - FAULT FINDING

Symptom Possible Cause Action / Remedy

Supply fan -not running

a. MPCB tripped.

b. No control signal.

c. No line supply.

d. Contactor fault.

a. Check fan bearings, casing clearances and general integrity.Check fan resistance in ducts etc.Check windings for insulation and continuity.If fan can be run, check its running current.

b. Check for poor connections and controller output.

c. Check power feed to motor.

d. Check for correct operation.

Supply fanairflow alarm

a. Clogged air filter(s).

b. Distribution grilles closed or not open enough.

c. Blockage or partial blockage in ducting.

d. Airflow switch fault.

e. Pressure sensor tubing trapped, damaged or missing.

f. Fan impeller loose on drive shaft.

g. Slack belt drive(s).

h. Fan drive motor fault.

i. Unit door panel not closed properly, or inadequate sealing of mating surfaces.

a. Clean or renew filter(s).

b. Open grilles further to allow more air volume to pass.

c. Clear any blockage.

d. Check wiring, continuity and airflow switch function - repair or renew as necessary.

e. Re-route tubing or renew as necessary.

f. Tighten the impeller on its drive shaft.

g. Tighten drive belt(s), or renew if worn.Never over-tighten, otherwise bearing damage is likely to result.

h. Renew the fan drive motor.

i. Close the door panel properly. Ensure that mating surfaces are sealed properly and that air escape is not occurring.


IPAC


Table 12-2 : Heating systems - fault finding

Document 0410536

HEATING SYSTEMS - FAULT FINDING


Electrical heatingoutput low

a. Air temperature sensor fault.

b. Line switching relay(s) faulty.

a. Check operation and wiring continuity - renew if necessary.

b. Check for correct operation.

Electrical heatingnon-operational


b. Faulty heating element(s).

c. Heater over-temperature safety thermostat(s) tripped due to excessive local heat.

d. No control signal.

e. No power.

f. Contactor fault.


b. Check operation and wiring continuity - renew if necessary.

c. Check airflow; refer to Table 12-1.Note that thermostat(s) will auto-reset on returning to normal temperature.

d. Check for poor connection.

e. Check MPCB(s) and correct the cause of any trip.

f. Check for correct operation - renew if necessary.

LPHW heatingoutput low

LPHW flow rate low due to:


b. LPHW temperature lower than design.

c. Stop valve partly closed in the LPHW circuit.

d. Clogged strainer(s).

e. Circulating pump fault.

f. Flow control valve partly blocked with debris / scale.

g. Flow control valve seizing.

h. Poor signal to the flow control valve actuator.


b. Check LPHW heating system temperature control - adjust as necessary.

c. Check that stop valves throughout the LPHW circuit are open.

d. Clean strainer(s).

e. Refer to pump manufacturer’s instructions.

f. Remove the valve, clear the blockage. Check the flow line strainer mesh for damage - renew if necessary.

g. Repair / renew the flow control valve.

h. Check the valve actuator control circuit for continuity and resistance - correct the cause of any poor continuity / high resistance.

LPHW heatingnon-operational

Zero flow of LPHW due to:


b. LPHW heating system boiler or circulating pump not operating.

c. Stop valve closed in the LPHW circuit.

d. Clogged strainer(s).

e. No signal to the flow control valve actuator.

f. No power feed to the flow control valve actuator.

g. Flow control valve blocked with debris / scale.

h. Flow control valve actuator faulty.

i. Flow control valve seized.


b. Refer to LPHW heating system / pump instruction manual for fault diagnosis and remedial action.

c. Check that stop valves throughout the LPHW circuit are open.

d. Clean strainer(s).

e. Check the valve control circuit for continuity and resistance - correct the cause of any poor continuity / high resistance.

f. Check power supply and wiring for continuity - correct as necessary.

g. Remove the valve, clear the blockage. Check the flow line strainer mesh for damage - renew if necessary.

h. Check actuator operation - renew if necessary.

i. Check operation - renew if necessary.


IPAC


Table 12-3 : DX cooling / dehumidification - fault finding

Document 0410536

DX COOLING / DEHUMIDIFICATION - FAULT FINDING


Compressorwill not run

HP switch tripped due to:

a. Inadequate flow of condenser cooling air / water.

b. Condenser not operating.

c. Condenser efficiency impaired.

a. Refer to the condenser manufacturer’s instructions for diagnosis and remedial action.Rectify cause before resetting the unit controller.

b. Refer to the condenser manufacturer’s instructions for diagnosis and remedial action.Rectify cause before resetting the unit controller.

c. Air-cooled condenser - clean the heat exchange coil; refer to the manufacturer’s instructions.Water-cooled condenser - remove scaling / debris and then flush according to manufacturer’s instructions.

LP switch tripped due to:

a. Low refrigerant charge - inadequately charged or partial loss of charge.

b. Filter / drier clogged.

c. TEV fault.

a. Check for leaks, repair any leakage point, then carry out all procedures necessary to re-charge the system; see Correcting Fault Conditions That Involve Opening a DX Refrigerant System on page 4.

b. Renew the filter / drier; see Correcting Fault Conditions That Involve Opening a DX Refrigerant System on page 4.

c. Renew the TEV; see Correcting Fault Conditions That Involve Opening a DX Refrigerant System on page 4.

Pressure switches in healthy (normal) condition:

a. Compressor MPCB tripped due to motor overload.

b. Compressor motor HT thermistor tripped.

c. No control signal.

d. Contactor fault.

a. Investigate and rectify the cause before resetting the MPCB. Check the overload setting.

b. Investigate and correct the cause of the trip - HT thermistor device is auto-resetting when it has cooled sufficiently; allow up to one hour. Motor will then restart automatically.

c. Check for poor connections and/or replace controller card.

d. Check for correct operation.

Cooling coil (evaporator)

loss of capacity

a. Low airflow due to dirty filter.

b. Low airflow.

c. Cooling coil / fins dirty.

d. Filter / drier partially clogged.

e. Thermostatic expansion valve (TEV) strainer blocked.

f. Cooling coil iced up.

g. Thermostatic expansion valve (TEV) incorrectly adjusted / faulty.

h. Hot gas injection (HGI) valve fault.

i. Low refrigerant charge.

a. Clean or renew air filters.

b. Refer to Table 12-1 - see Supply fan airflow alarm on page 4.

c. Clean the heat exchange coil.

d. Renew the filter / drier; see page 12-4e. Remove and clean; see page 12-4

f. Ensure that the TEV sensing bulb is fitted correctly and in good physical / thermal contact with the compressor suction line at the refrigerant outlet from the cooling coil.

g. Check that the TEV is adjusted to give the correct amount of superheat. If adjustment does not remedy the condition, repair or renew the TEV, as appropriate; see page 12-4

h. Check that the HGI valve (if fitted) is able to close properly - renew if necessary; see page 12-4

i. Check the moisture indicating sight glass in the liquid line. If bubbles are visible, indicating loss of charge, check for leaks, reclaim the refrigerant charge, repair any leakage point, then carry out all procedures necessary to re-charge the system; see page 12-4


IPAC


Table 12-4 : Chilled water cooling / dehumidification - fault finding

Document 0410536

CHILLED WATER COOLING / DEHUMIDIFICATION - FAULT FINDING


CW coolingoutput low

a. Low demand.

b. CW temperature higher than design.

c. Stop valve partly closed in the circuit, reducing flow to or from the unit.

d. Clogged filter before the water flow control valve.

e. Poor signal to the flow control valve actuator.

a. Check demand status; refer to “Is there a demand?” on page 4-25 of Section 4.

b. Refer to the cooling system manufacturer’s instruction manual for diagnosis and remedial action.

c. Check all stop valves throughout the circuit are open.

d. Clean filter(s).

e. Check valve actuator control circuit for continuity and resistance - correct the cause of any poor continuity /high resistance.

CW coolingnon-operational

a. No demand signal to the flow control valve actuator.

a. Check:

• Demand status; refer to “Is there a demand?” on page 4-25of Section 4

• Valve control circuit for continuity and resistance; correct the causeof any poor continuity / high resistance

• Strainer is not choked - remove, clean and check strainer mesh -renew if necessary

b. CW cooling plant or circulating pump not operating.

c. Stop valve closed in the CW circuit.

d. No power feed to the flow control valve actuator.

e. Flow control valve blocked with debris / scale.

f. Flow control valve actuator faulty.

g. Flow control valve seized.

b. Refer to the cooling system / pump manufacturer’s instruction manualfor diagnosis and remedial action.

c. Check that all stop valves in the circuit are open.

d. Check power supply and wiring for continuity - correct as necessary.

e. Remove the valve, clear the blockage. Check the flow line strainermesh for damage - renew if necessary.

f. Check actuator operation - renew if necessary.

g. Repair or fit new flow control valve.

Table 12-5 : Humidification system - fault finding

HUMIDIFICATION SYSTEM - FAULT FINDING


Humidity low -no water

a. Loss of water supply. a. Check that water supply:

• shut-off valve is open• pressure is adequate (i.e. positive); refer to the

manufacturer’s instructions for the humidifier.• strainer is not clogged - remove and clean

b. Solenoid valve malfunction. b. Check 24 volt supply, renew the solenoid.

Humidity low -water supply correct

a. Lack of maintenance - internal arcing.

a. Renew steam cylinder.

Humidifier -not operating

a. No control signal.

b. No power supply.

c. Contactor faulty.

a. Check connections and control voltage.If necessary, renew controller.

b. Check power supply, MPCB and settings.

c. Check for correct operation.

Humidifier -draining does not operate manually or automatically

a. No 240 volt supply to pump.

b. Drain pump seized.

a. Check and repair supply.

b. Dismantle and clean or renew the drain pump - see “Vapac Drain Pump” on page 10-13 of Section 10.

Humidifier -steam supply low

a. Faulty electrodes.

b. Poor steam supply.

a. Renew cylinder.

b. Check steam pipe and installation.

Humidifier - water in duct

a. Faulty supply. a. Check installation.


IPAC


Document 0410536


IPAC SECTION 13

IPACEaton-Williams

IPAC


UNIT MAINTENANCE LOG

Unit Serial No. ____________ Site Unit No. / Location ___________

IPAC

Unit Maintenance LogTable 13-1 : Unit maintenance log


DATE DESCRIPTION OF WORK CARRIED OUT

ORGANISATION,

SIGNATURE

AND

PRINTED NAME


IPAC




ORGANISATION,

SIGNATURE

AND

PRINTED NAME


IPAC




ORGANISATION,

SIGNATURE

AND

PRINTED NAME


IPAC SECTION 14


IPACEaton-Williams

IPAC

UNIT MODIFICATION LOG

Unit Serial No. ____________ Site Unit No. / Location ___________

User Notes

IPAC

Unit Modification Log

Document 0410536


IPAC


Table 14-1 : Unit modification log

Document 0410536


ORGANISATION,

SIGNATURE

AND

PRINTED NAME


IPAC


Table 14-1 : Unit modification log

Document 0410536


ORGANISATION,

SIGNATURE

AND

PRINTED NAME


IPAC

Document 0410536


Eaton-Williams Air ConditioningStation Road, Edenbridge, Kent, TN8 6EG England

Telephone +44 (0)1732 866 055 Fax +44 (0)1732 866 053Email [email protected] Website www.eaton-williams.com

Eaton-Williams

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Issue 4.0 : April 2008 Document 0410536

Constant & Variable Air Volume Units

0410536 IPAC - IOM - Issue 4.0 - Lo-Res Colour

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