G-Volution IOM v3.1

Precision Ⴠ Efficient Ⴠ Innovation
Content
1.0 Introduction ....................................................................................................................... 1
2.0 Pre-Installation .................................................................................................................... 2
2.1 Site Preparation ................................................................................................................ 2
2.2 Receiving Equipment ........................................................................................................ 3
2.3 Noise Consideration ......................................................................................................... 4
3.0 Installation ........................................................................................................................... 5
3.1 Installation illustration ....................................................................................................... 5
3.2 Unit positioning .............................................................................................................. 7
3.3 Refrigerant Pipework ........................................................................................................ 9
3.4 Chilled And Condenser Water Pipework ........................................................................14
3.5 Humidifier Connection ....................................................................................................16
3.6 Drain Connection ............................................................................................................17
3.7 Electrical Connection ......................................................................................................17
4.0 Commissioning .................................................................................................................20
4.1 Pre-Operation .................................................................................................................20
4.2 General .......................................................................................................................21
4.3 Electrical/Controller .........................................................................................................21
4.4 Differential Pressure Switches ........................................................................................22
4.5 Fans ................................................................................................................................22
4.6 Electric Heaters ..............................................................................................................22
4.7 Humidifier ........................................................................................................................22
4.8 Direct Expansion System................................................................................................ 23
4.9 Chilled Water System .....................................................................................................23
4.10 Dehumidification ...........................................................................................................24
5.0 Service & Maintenance ....................................................................................................26
5.1 Belt Driven Fans .............................................................................................................26
5.2 EC Fans ......................................................................................................................27
5.3 Compressors ..................................................................................................................27
5.4 Humidification System ....................................................................................................27
5.5 Air Filters .........................................................................................................................32
5.6 Fan Speed Controllers ....................................................................................................34
5.7 Differential Pressure Switches ........................................................................................34
5.8 Electronic Expansion Valve ............................................................................................35
5.9 Electric Heaters ..............................................................................................................36
5.10 Water-cooled Condensers ............................................................................................37
5.11 High Pressure Switch ...................................................................................................38
5.12 Servicing .....................................................................................................................38
6.0 Trouble Shooting ..............................................................................................................40
7.0 Unit Dimension & Weight .................................................................................................52
G-Volution IOM Manual
1. INTRODUCTION
Thank you for purchasing Citec Air Conditioning Products.
These products have been designed, for indoor use only, to cool, heat, humidify, dehumidify
and filter air at atmospheric pressure using (a) a Direct ExpaQVLRQ6\VWHP³$´RU³:´XWLOL]LQJ
R22, R407C or R410A, (b) a Chilled Water System ("CW") using Chilled Water or an
Ethylene Glycol solution. These products are not authorized for use in any other way.
This manual has been compiled to help ensure the correct installation and commission of the
equipment. Please read it fully BEFORE COMMENCING THE WORK. All installation work,
including the running and connecting of services, must be carried out only by COMPETENT
PERSONS.
The equipment has been designed and manufactured within a Quality Assurance System
conforming to ISO 9001, and Quality Controlled to ensure that it reaches you in perfect
condition. A full functional test was performed prior to dispatch. A complete set of electrical
schematic diagrams is secured inside the electrical panel for your information.
It is important for you to appreciate that failure to follow the instructions in this manual may
result in damage, incorrect operation or danger to health and safety, and may invalidate the
warranty. Any works planned that are not covered in this Manual must be discussed with, and
are subjected to the approval of CITEC.
Important Note烉烉
The data in this booklet refers to equipment with STANDARD CATALOGUE SPECIFICATIONS.
Variations sometimes occur depending on specific contract requirements.
In case of any doubt, please refer to Contract schematic wiring diagrams and dimensional
drawings supplied by Citec, copies of which will be found inside the electrical panel, and to
other contract documentation.
Legionnaires'Disease
An Approved Code of Practice HS(G) 70 "The prevention or control of legionellosis, including

legionnaires' disease" [HMSO 1991 IBSN 0 11 885660 X (formerly Guidance Note EH48) ]
came into effect on 15th January 1992.
For further full guidance on minimizing the risk of Legionnaires' Disease in Air Conditioning
systems (i.e. installation and maintenance guidance) reference should be made to Technical
Memorandum TM 13 "Minimizing the Risk of Legionnaires' Disease" published by the
Chartered Institute of Building Services Engineers (CIBSE). The sketches detail typical
schematic arrangements.
-1-
᧪PRE-INSTALLATION
2᧪
The following describes actions to be taken to prepare site for installation of the unit:
2.1 Site Preparation

z Verify that path for transporting the unit to the final location is accessible and free
from obstructing. Ensure that the unit can pass through and fit into any lifts, corridors,
etc along the path. Refer to section on General Installation Drawing for unit
dimensions.
z Verify the floor is level, solid and sufficient to support the unit. See tables in General
Installation Drawing for unit weights.
z Prepare suitable floor stand for the unit.
z Confirm that the room is properly insulated and has a sealed vapour barrier烊For
proper humidity control, keep outside or fresh air to an absolute minimum.
z Avoid locating units in an alcove or at the end of a long narrow room. Locate the units
as close as possible to the largest heat load.
z Allow minimum recommended clearances for routine maintenance and service.
Refer to section on General Installation Drawing for unit dimensions.
2.1.1 Air Distribution
Downflow Units
Verify the raised floor has been properly sized for unit airflow and is free of any
unintended restrictions.
Perforated floor tiles or aluminum air grilles in the raised floor should ensure
minimal pressure loss while maintaining sufficient under floor pressure.
Avoid floor elevations less than 300mm (12"). Note: a minimum floor height of
400mm (15.7") is required for downflow units with underfloor EC fan option.
For ECL models, the minimum floor height is 500mm.
8QLWWRSFOHDUDQFHKDVWRPDLQWDLQKHLJKWPLQLPXP³<´
- ES / EC / EH range : Y > 350mm
- ECL range : Y > 450mm
Seal floor openings to maximize raised floor airflow efficiency.
Ensure that unit has sufficient space for return air and that path is not
obstructed.
Min.
Min. 350mm
Y mm Min.
Min.350mm
Y mm
Upflow Units
Upflow units are available for horizontal discharge air plenum or ducted
operation and are manufactured to support a nominal external static pressure
(ESP) specific to the selected air path. Due to variations in applications, a speed
change may be required to obtain the desired air flow.
Upflow units must be connected to field ductwork or factory discharge plenum
with grille for proper operation.
Ensure ductwork complies with good design practice.
Note: Min. 300mm Min. 400mm

Placement of air diffusers is important. If located too close to the unit, supply air may be
re-circulated back directly to the unit causing error in the reading of the return air condition.
-2-
Please perform CFD computations for the site if in doubt.
2.1.2 Connections
z Plan the routing of wiring, piping and ductwork to the unit.
z The unit requires a drain, which must comply with all applicable codes. When
unit have humidifier option, the drain line must be capable of withstanding
temperature of boiling water. See chapter 3.0 Installation.
z Three-phase electrical power supply is required for all models. Electrical service
must conform to national and local electrical codes. Please ensure site has
suitable and sufficient power supply for the unit.
2.2 Receiving the Equipment

On receipt, the equipment should be carefully checked against the Despatch Note and
examined carefully for damage. Any shortage or damage should be reported to the freight
carrier immediately. Please note that Direct expansion (DX) units (versions ȾWȿ and ȾAȿ)
are supplied with a nitrogen holding charge. Units should always be stored indoors in a dry
location away from freezing temperature and moisture in an upright (vertical) position prior to
installation.
2.2.1 Storage
If the units are required to be stored for a period of time, the following storage
condition must be observed:
x Ensure the units are stored in a dry (< 85%RH), dustless indoor environment.
x Temperature must be kept between 0 to 50ƱC.
x Units shall be remained in upright position.
x Ensure all pipe connections are covered properly.
2.2.2 Off Loading & Lifting

It is recommended that wherever possible all lifting and handling of equipment
should be carried out with the packing pallet in position. When using a fork-lift or
pallet jacks to lift the unit, the two support points should be sufficiently apart to give
stability when lifting and suitably placed to distribute the load on the forks. When
lifting by crane, use spreader bars to prevent compressing the top of the equipment.
Care should be taken not to drop the unit and should this inadvertently happen, it
should be immediately unpacked and inspected for damage. When moving the unit,
ensure that the unit is level and in a vertical position to prevent damage to the unit.
Note烉
There is risk of equipment damage, injury or death due to mishandling of the unit. Please
ensure all proper safety precaution is taken when moving and lifting the unit. Personnel should
wear appropriate safety equipment when attempting to move, lift or prepare the unit for
installation.
2.2.3 Unpacking
Standard packing is with the unit wrapped with bubble pack and plastic wrapping and
covered with a cardboard case with securing strap around it and the pallet. A wooden
crate is available as an option to replace the cardboard case for better protection. The
securing straps and wooden crate (if applicable) should be removed using appropriate
tools and care should be taken not to damage the unit within. The cardboard case should
then be lifted from the unit, after first removing the inner securing straps wrapping around
the unit to the pallet. The unit is attached to the pallet by means of M6 bolts passing
through existing holes in each corner of the base of the unit. The pallet may be removed
without removing the cardboard case by the removal of the M6 bolts securing unit base to
the pallet.
-3-
2.3 Noise Consideration
It is important that the problems of noise are considered at all points in the
installation of equipment, i.e. :
z The acoustic properties of the room - soft furnishings, curtains and carpets tend to
deaden reflections. Bare walls, vertical cabinets etc. tend to produce reflections
which result in higher noise levels.
z Equipment placed hard against a wall can transmit noise through and along the wall
into adjacent areas.
z Floors with high deflections e.g. wooden floors, can amplify the noise produced by
the unit.
z Inadequately fastened pipe runs can transmit vibrations along their full length.
In order to reduce these problems, the following measures are suggested,

dependent upon site conditions:
z Ensure that any vertical planes directly in front of the unit are acoustically dead.
z Acoustic pads may be placed behind equipment to reduce wall transmissions.
z In new buildings steel floor framing to match equipment supports may be used to
transmit loads to the building columns.
z In existing buildings, supplementary steel framing may be necessary.
z Acoustic pads (cork, felt, good quality carpet) may be used beneath the equipment.
z Abrupt bends in pipework should be avoided by fitting long turn elbows or forming
long radius bends.
z Where units are situated in equipment rooms, acoustic treatment of the walls of the
equipment room should be considered.
z All pipes should be rigidly supported to a solid structure.
z Where pipes pass through walls or partitions, provide an oversize sleeve and pack
with fiberglass or similar insulation material.
z Insulate pipes, and box in with sound-deadening material to solid structures.
z Connect ductwork via attenuators and flexible make-up pieces (if necessary).
-4-
᧪INSTALLATION
3᧪
3.1 Installation Illustration

3.1.1 Air-cooled System
5
Max. 20m
Max. 6m
1 2
3
4
3
4
1
1. Discharge Pipe Max. 5m
2. Liquid Pipe
3. Humidifier Feed 2
4. Drain Pipe
5. Oil Trap (every 6m vertical distance)
-5-
3.1.2 Water-cooled System
1 2
7 5
3
4
8 6
1. Condenser water supply pipe

2. Condenser water return pipe
3. Humidifier Feed
4. Drain pipe
5. Stop valve
6. Balancing valve
7. Water Filter
8. Flushing Cock
-6-
3.2 Unit Positioning

Damage can occur to the unit when positioning, in particular, to the paneling and exterior
paintwork. It is therefore necessary to use an adequate number of personnel and the correct
moving equipment.
IT IS ADVISABLE TO USE THE POLYTHENE COVER AS PROTECTION THROUGHOUT THE
INSTALLATION PERIOD AND IT MAY BE ADVISABLE TO INITIALLY USE THE CARDBOARD PACKING
AS ADDITIONAL PROTECTION IF BUILDING OR OTHER CONSTRUCTIONAL WORK IS OCCURRING IN
THE AREA WHERE THE UNIT IS TO BE SITED.
Three or four short lengths of 40 mm or 50 mm steel pipe, used as rollers, will aid positioning.
When pushing the unit, try to apply pressure near to the base and at the corners.
The unit is designed to remain upright and therefore care should be taken when lifting the unit
up steps, or onto plinths. Citec will take no responsibility for damage caused by mishandling
during the positioning of the equipment.
It is recommended that tall Air Handling Units with a small footprint be suitably
stabilized by attachment to an adjacent wall etc. This is especially necessary if the units
are standing on a tall plinth or bottom section.
3.2.1 Unit Leveling

The unit should be set in an upright position - level in both directions. Failure to carry out
leveling correctly may cause operational problems, particularly with regard to the
drainage of the equipment. The units are assembled on a level base and any
misalignment of panels will indicate that the unit is not level.
Always use a spirit level for this operation and if packing pieces are used, put them at the
corners of the unit. In the case of very large vertical units, it is advisable to add additional
intermediate packing pieces under the main vertical struts.
Plinths / Base Stands / Top Sections etc. may be part of the system supplied, ensure that
adequate gasketing or sealing is provided between each section and that they are
securely bolted together.
Gaskets between
unit and base stand
Gasket at the side

of base stand
Gaskets under
the base stand
-7-
3.2.2 Lowering Underfloor EC Fan into Position
When units is in position, secure a chain block to the support rail as shown and secure
the chains to the holding U-bolts on the fan mounting bracket. Once the fan assembly is
secured to the chain block, remove the transit holding brackets holding the EC fan
assembly in place. Lower the fan assembly slowly using the chain block until the fan
assembly sits on the bottom support plate of the unit.
-8-
3.3 Refrigerant Pipework
Refrigerant pipe connections are located at the bottom of the units, however, pipe connections
for some customized units might be located at side or rear. Care must be taken when doing
pipe routing. Avoid obstructing the airflow entering the units, especially when the airflow is
mainly through the unit base stand. All refrigeration pipework should be installed to national
and local standards.
3.3.1 Refrigerant Pipes
The sizes of refrigerant pipe are depending on the capacity of individual circuit and the
distance between the indoor units and the outdoor units. Pipes must be properly sized to
ensuring oil return to compressors and avoidance of excessive pressure drops in
discharge and/or liquid lines. The recommended pipe sizes for different equivalent length
are listed in the tables below.
ES Range ± Standard Compressor
Recommended Discharge Pipe Sizes (R22/R407C)

Model 5 12 15 20 25 30 35 40
Equi. Length Circ. 1 1 1 1 1 1 1 1
10m All 1/2" 5/8" 5/8" 3/4" 7/8" 7/8" 7/8" 7/8"
20m All 1/2" 3/4" 3/4" 3/4" 7/8" 7/8" 1 1/8" 1 1/8"
30m All 1/2" 3/4" 3/4" 3/4" 7/8" 7/8" 1 1/8" 1 1/8"
Horz 1/2" 3/4" 3/4" 7/8" 7/8" 7/8" 1 1/8" 1 1/8"

40m
Vert 1/2" 3/4" 3/4" 3/4" 7/8" 7/8" 1 1/8" 1 1/8"
Horz 1/2" 3/4" 7/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

50m
Vert 1/2" 3/4" 3/4" 3/4" 7/8" 7/8" 1 1/8" 1 1/8"
Horz 1/2" 3/4" 7/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

60m
Vert 1/2" 3/4" 3/4" 3/4" 7/8" 7/8" 1 1/8" 1 1/8"
Horz 1/2" 3/4" 7/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

70m
Vert 1/2" 3/4" 3/4" 3/4" 7/8" 7/8" 1 1/8" 1 1/8"
Model 45 50 60 70 80 90 100
Equi. Length Circ. 1 1 1,2 1,2 1,2 1,2 1,2

10m All 1 1/8" 1 1/8" 7/8" 7/8" 7/8" 1 1/8" 1 1/8"
20m All 1 1/8" 1 1/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"
30m All 1 1/8" 1 1/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"
Horz 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

40m
Vert 1 1/8" 1 1/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"
Horz 1 1/8" 1 3/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 3/8"

50m
Vert 1 1/8" 1 1/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"
Horz 1 3/8" 1 3/8" 1 1/8" 1 1/8" 1 1/8" 1 3/8" 1 3/8"

60m
Vert 1 1/8" 1 1/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"
Horz 1 3/8" 1 3/8" 1 1/8" 1 1/8" 1 1/8" 1 3/8" 1 3/8"
70m
Vert 1 1/8" 1 1/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"
-9-
Recommended Liquid Pipe Sizes (R22/R407C)

Model 5 12 15 20 25 30 35 40
Equi. Length Circ. 1 1 1 1 1 1 1 1

10m All 3/8" 1/2" 1/2" 1/2" 5/8" 5/8" 5/8" 5/8"
20m All 3/8" 1/2" 1/2" 1/2" 5/8" 5/8" 5/8" 5/8"
30m All 3/8" 1/2" 1/2" 5/8" 5/8" 5/8" 5/8" 3/4"
40m All 3/8" 1/2" 5/8" 5/8" 5/8" 5/8" 3/4" 3/4"
50m All 1/2" 5/8" 5/8" 5/8" 5/8" 3/4" 3/4" 3/4"
60m All 1/2" 5/8" 5/8" 5/8" 3/4" 3/4" 3/4" 7/8"
70m All 1/2" 5/8" 5/8" 5/8" 3/4" 3/4" 3/4" 7/8"
Model 45 50 60 70 80 90 100
Equi. Length Circ. 1 1 1,2 1,2 1,2 1,2 1,2

10m All 3/4" 3/4" 5/8" 5/8" 5/8" 3/4" 3/4"
20m All 3/4" 3/4" 5/8" 5/8" 5/8" 3/4" 3/4"
30m All 3/4" 3/4" 5/8" 5/8" 3/4" 3/4" 3/4"
40m All 3/4" 3/4" 5/8" 3/4" 3/4" 3/4" 3/4"
50m All 7/8" 7/8" 3/4" 3/4" 3/4" 7/8" 7/8"
60m All 7/8" 7/8" 3/4" 3/4" 3/4" 7/8" 7/8"

70m All 7/8" 7/8" 3/4" 3/4" 7/8" 7/8" 7/8"
ES Range ± DC Inverter Compressor
Model 20 25 30 35 40 45 60 70 80 90
Equi. Length Circ. 1 1 1 1 1 1 1,2 1,2 1,2 1,2
Recommended Discharge Pipe Sizes (R410A)
10m All ´ ´ ´ ´ ´ ´ ´ ´ ´ ´
20m All ´ ´ ´ ´ ´ 7/8" ´ ´ ´ 7/8"
30m All ´ ´ ´ ´ ´ 7/8" ´ ´ ´ 7/8"
Horz ´ ´ 7/8" 7/8" 7/8" 1 1/8" 7/8" 7/8" 7/8" 1 1/8"
40m
Vert ´ ´ ´ ´ ´ 7/8" ´ ´ ´ 7/8"
Horz ´ ´ 7/8" 7/8" 7/8" 1 1/8" 7/8" 7/8" 7/8" 1 1/8"
50m
Vert ´ ´ ´ ´ ´ 7/8" ´ ´ ´ 7/8"
Horz ´ ´ 7/8" 7/8" 7/8" 1 1/8" 7/8" 7/8" 7/8" 1 1/8"
60m
Vert ´ ´ ´ ´ ´ 7/8" ´ ´ ´ 7/8"
Horz ´ ´ 7/8" 7/8" 7/8" 1 1/8" 7/8" 7/8" 7/8" 1 1/8"
70m
Vert ´ ´ ´ ´ ´ 7/8" ´ ´ ´ 7/8"
Recommended Liquid Pipe Sizes (R410A)
10m All ´ 5/8" 5/8" 5/8" 3/4" 3/4" 5/8" 5/8" 3/4" 3/4"
20m All 5/8" 5/8" 5/8" 5/8" 3/4" 3/4" 5/8" 5/8" 3/4" 3/4"
30m All 5/8" 5/8" 5/8" 5/8" 3/4" 3/4" 5/8" 5/8" 3/4" 3/4"
40m All 5/8" 5/8" 5/8" 3/4" 3/4" 3/4" 5/8" 3/4" 3/4" 3/4"
50m All 5/8" 5/8" 5/8" 3/4" 3/4" 3/4" 5/8" 3/4" 3/4" 3/4"
60m All 5/8" 5/8" 3/4" 3/4" 3/4" 7/8" 3/4" 3/4" 3/4" 7/8"
70m All 5/8" 5/8" 3/4" 3/4" 3/4" 7/8" 3/4" 3/4" 3/4" 7/8"
- 10 -
Required Tube Wall Thickness for R410A System:

Minimum wall Half hard Horizontal discharge pipes should lean
Line Size Soft towards condensers to prevent liquid
thickness (mm) or hard
3/8" 0.80 Yes Yes refrigerant flow back to compressors
during off cycle. Purpose made oil traps
1/2" 0.80 Yes Yes
must be fitted to vertical discharge lines
5/8" 1.00 Yes Yes every 6 m when lifting refrigerant from
3/4" 1.00 Yes No compressor to condenser. Air cooled
7/8" 1.00 Yes No Condensers should not be sited more
than 20 m above or 5 m below the base of
1 1/8" 1.00 Yes No the Air Handling Unit. (Please refer to the
1 3/8" 1.10 Yes No air-cooled system illustration). Please
1 5/8" 1.25 Yes No consult Citec if the pipe run is exceeding
the length stated above.
EH Range ³A Version´
Recommended Discharge Pipe Size

Equi. Length Model 60 70 85 95
10m All 7/8" 7/8" 7/8" 1 1/8"
20m All ´ 7/8" 1 1/8" 1 1/8"
30m All ´ 1 1/8" 1 1/8" 1 1/8"
Hor. 1 1/8" 1 1/8" 1 1/8" 1 1/8"

40m
Vert. ´ 1 1/8" 1 1/8" 1 1/8"
Hor. 1 1/8" 1 1/8" 1 1/8" 1 3/8"

50m
Vert. ´ 1 1/8" 1 1/8" 1 1/8"
Hor. 1 1/8" 1 1/8" 1 1/8" 1 3/8"

60m
Vert. ´ 1 1/8" 1 1/8" 1 1/8"
Hor. 1 1/8" 1 1/8" 1 3/8" 1 3/8"

70m
Vert. ´ 1 1/8" 1 1/8" 1 1/8"
Recommended Liquid Pipe Size

Equi. Length Model 60 70 85 95
10m All 5/8" 5/8" 3/4" 3/4"
20m All 5/8" 5/8" 3/4" 3/4"
30m All 5/8" 3/4" 3/4" 3/4"
40m All 3/4" 3/4" 3/4" 3/4"
50m All 3/4" 3/4" 3/4" 7/8"
60m All 3/4" 3/4" 7/8" 7/8"
70m All 3/4" 7/8" 7/8" 7/8"
- 11 -
3.3.2 Refrigerant Pipe Installation
Extreme care should be taken to keep refrigeration tubing clean and dry prior to installation
and the following procedures will help to adhere to good practice:
1. Only refrigeration grade copper tubing correctly sealed against contamination should
be used.
2. Do not carry out installation outside whilst it is raining.
3. Always cap the free end of tubing whilst carrying out installation.
4. Do not leave dehydrated compressors or filter/driers open to the atmosphere.
5. Use only copper eutectic or specialist soft solders containing at least 3.5% silver on
suction and liquid lines and high temperature copper eutectic rods or silver solder on
discharge lines. It is suggested that one of the following are used:
a. Copper to copper - Eutectic 1805 (2% silver) - no flux.
b. Copper to brass - Eutectic 1805 - flux 1802.
c. Copper to steel - Eutectic 1810 (2% silver) - flux 1820.
NB: STANDARD SOFT SOLDER MUST NOT BE USED.
6. With any high temperature rod where oxidisation is liable to take place use an inert
gas such as dry nitrogen or carbon dioxide to avoid scale formation inside the tubing.
Dry nitrogen is preferred.
7. When using soldering paste or flux, use the minimum required to prevent
contamination of the filter and joint. Flux only the male part of the connection - never
the female. After making the joint, remove the surplus flux with a damp cloth.
8. Where vibration eliminators are used the ends should be wrapped with a damp cloth
and rods with a melting temperature of no greater than 650oC (1200oF) should be used
to avoid damage to the internal joints.
3.3.3 Leak Test

Units are factory checked for leaks before shipment from factory and provided with a
50psig nitrogen holding charge. However, after installation of the unit at site, another leak
test should be carried out. This should be performed after all lines are connected, but
before they are insulated. The use of an electronic leak detector or halide torch is
recommended. For a satisfactory installation, the system MUST be leak tight.
Leak testing should be carried out before initial charging and after any service work that
require disassembly of the piping has been carried out, and prior to evacuation. This is
done by charging with dry nitrogen until system pressure of 26bar for R22/R407C system
or 42bar for R410A system. Please ensure that the LP switch (if present) is isolated during
this test. Refer to section Control of Refrigerant Discharge.
3.3.4 Refrigerant Charge

Refrigerant charge of the system may be approximated by summing up charge of the
indoor unit, outdoor unit and the piping length between the two. Table below shows
approximate refrigerant charges for Citec Units.
- 12 -
Approximate R22 And R407C Refrigerant Charges烉
³$´9HUVLRQ ³:´9HUVLRQ ³$´9HUVLRQ ³:´9HUVLRQ

ES Range ES Range
kg kg kg kg
ES_5 1.2 2.2 ES_45 9.6 12.3
ES_12 2.5 4.6 ES_50 9.6 12.3
ES_15 5.0 7.2 ES_60 14.2 19.1
ES_20 5.0 7.3 ES_70 14.2 19.1
ES_25 5.2 7.7 ES_80 14.2 19.5
ES_30 6.0 8.4 ES_90 19.1 24.4
ES_35 6.0 8.6 ES_100 19.1 24.4
ES_40 9.6 12.3
ES Range ³$´9HUVLRQ ³:´9HUVLRQ R22/R407C/R410A

Condenser (50Hz)
Inverter R410A (kg) R410A (kg) (kg)
ES_20 4.5 6.5 HEC 234 1.4
ES_25 4.5 6.7 HEC 274 1.6
ES_30 5.2 7.3 HEC 314 2.5
ES_35 5.2 7.5 HEC 374 3.5
ES_40 8.4 10.7 HEC 574 3.5
ES_45 8.6 10.9 HEC 654 5.3
ES_60 12.3 16.6 HEC 904 7.0
ES_70 12.3 16.6
ES_80 12.8 17.4 R22/R407C/R410A
Condenser (60Hz)
ES_90 17.0 21.6 (kg)
HEC 256 1.7
HEC 286 2.4
³$´9HUVLRQ ³:´9HUVLRQ
EH Range HEC 326 2.9
R22/R407C (kg) R22/R407C (kg) HEC 416 5.4
EHD60 12.5 17.4 HEC 596 4.7
EHD70 14.9 20.2 HEC 716 7.4
EHD85 17.4 22.7 HEC 836 6.2
EHD95 19.7 24.9
EHU60 11.8 16.7
EHU70 14.0 19.3
EHU85 16.4 21.7
EHU95 18.5 23.8
烉
Note烉
Figures shown above are TOTAL for Units and do not include for any inter-connecting
pipework, liquid receivers, Air Cooled Condensers.
Estimated external copper pipe refrigerant charge烉
Refrigerant Charge, kg/m

Pipe Size
Liquid (R22/407C) Discharge (R22/407C) Liquid (R410A) Discharge (R410A)
´ 0.174 0.011 0.046 0.005
1/2´ 0.105 0.007 0.091 0.009
5/8" 0.174 0.011 0.151 0.016
3/4" 0.262 0.016 0.227 0.024
7/8" 0.346 0.022 0.300 0.031

1 1/8" 0.584 0.036 0.507 0.053
1 3/8" 0.931 0.058 0.808 0.084
- 13 -
3.3.5 Refrigerant Oil
Standard units are pre-charged with POE oil (PVE oil for variable speed compressor).
Initial charge should be sufficient for installation with pipe run less than 30m. For longer
pipe run, additional oil is required. As a guide, 25g of oil should be added for every
additional 1.0kg charge of refrigerant. Additional oil should be added for the correct
operation of oil trap (if fitted).
Please ensure correct oil is used and never mix POE/PVE oil with mineral oil or oil of
different grade. Note that polyester oil is very hygroscopic and should not be exposed to
air for any length of time.
3.3.6 Control of Refrigerant Discharge

By international agreement, the world-wide use of certain refrigerants will be reduced in
stages. To this end listed below are suggestions on how refrigeration engineers can
contribute by the discontinuing of releasing any refrigerant gas to the atmosphere.
DO NOT烉烉 DO烉烉
1) Blow off refrigerants to 1) Pump down into a receiver or empty cylinder using Reclaim
atmosphere. Equipment.
2) Use refrigerants to clean coils 2) Clean coils etc. using a hand brush, vacuum or compressed
etc. air.
3) Leak test using pure refrigerant. 3) Leak test using Nitrogen and just a trace of refrigerant gas.
4) Recharge before mending leaks. 4) Find and mend leaks before recharging system.
5) Dispose refrigerant gas to waste. 5) Send used refrigerant gas back for reprocessing.
3.4 Chilled and Condenser water Pipework
All chilled and condenser water pipework should be designed to good practice. The following
should be observed on chilled water units, drycooler or cooling tower systems:
z Lines should be adequately sloped to drain away, by gravity, water that is accumulated
from condensing, defrosting or cleaning operations.
z All plumbing connections should be made in accordance with local Water Board
recommendations.
z Drain lines from drip trays etc., must be trapped and run to open drains. They must not
be connected directly to the sewer system (See "Legionnaires' Disease").
z Control devices such as solenoid valves, modulating valves or hand valves, which may
cause hydraulic hammer, should be protected by a standpipe and air pocket to absorb
shock.
z Pipes for chilled water or condenser water should be sized in accordance with accepted
practice. Care must be taken when sizing pipework and pumps to make sufficient
allowance for the pressure drops.
z A 40-mesh strainer should be provided at the inlet to each water cooled ("W" version)
unit to protect the plate type heat exchangers from fouling.
3.4.1 Chilled and Condenser Water Pipe Installation Guide烉烉

z All pipework should be installed to local and national standards.
z Whenever possible it is recommended that "reverse return" piping be used for
multiple installations to ensure an easily balanced system.
z Isolating valves should be provided at all individual items of equipment to enable
servicing of the equipment to be carried out without draining down the system.
z Regulating valves, preferably with pressure test points should be used at
strategic points including all coils to enable balancing of water flow rates.
z All high points and coils should be provided with vent cocks to enable adequate
system venting and to prevent air locks. All coils and low points should be
- 14 -
provided with drain cocks to enable adequate draining of the system.

z Pipe expansion and contraction should be allowed for by the installation of
expansion bellows (where necessary).
z A closed type expansion tank should be provided for the system.
z A strainer with an adequate mesh should be installed prior to the pump inlet.
z Thermometers and pressure gauge test points should be strategically located at
coils, chillers and towers for commissioning and normal service checks.
z Systems not designed to operate on ethylene glycol should have any external
pipework trace heated to give frost protection.
z Pipework must be properly cleaned and flushed. Refer to BSRIA Technical
Memorandum TM 2 / 84.
z Condenser water, particularly if served by an open evaporative cooling tower,
should be treated to prevent the deposit of hard water scale or biofilm on the
condenser surfaces and filtered to prevent the circulation of other solid
materials.
z On systems that are designed to operate on ethylene glycol solutions to prevent
freezing, the solution strength must be adequate for the minimum ambient
temperatures that are likely to be encountered.
z All chilled water and condenser water pipework should be insulated. Additionally
chilled water pipework and valves should be vapour sealed to avoid
condensationˤ
3.4.2 Freeze Prevention of Water Pipework
If water piping is installed in a space where the temperature may drop below freezing, it
must be arranged so that it can be easily and completely drained. Condensers or water
coils are difficult to drain completely and therefore, to be safe; it is advisable to remove
any remaining water by blowing through with compressed air. If systems are to remain out
of operation for long periods, then it is recommended that they be refilled with an
anti-freeze solution to prevent corrosion of the inner surfaces of the piping, condensers
and coils. The anti-freeze solution should contain inhibitors to ensure it is not aggressive
towards any of the materials of construction of the coil or pipework, and the advice of the
anti-freeze supplier should be sought.
On re-commissioning the equipment, the anti-freeze solution must be drained and the
system refilled with water.
3.4.3 Chilled Water Volumes
The Chilled Water Air Handling Unit volumes shown below include coils, valves and
pipework.
Water Volume Water Volume

Model Model
(Liter) (Liter)
ECD/U 25 9.4 ECL 125 49.5
ECD/U 30 10.9 ECL 140 59.3
ECD/U 50 17.8 ECL 180 70.8
ECD 60 22.8 ECL 200 85.0
ECD 70 27.4 EHD 60 A/W 22.6
ECD 80 34.2 EHD 70 A/W 27.2
ECD 95 40.2 EHD 85 A/W 32.0
ECD 110 45.6 EHD 95 A/W 36.3
ECD 125 54.7 EHU 60 A/W 21.2
ECD 135 61.6 EHU 70 A/W 25.5
- 15 -
ECD 150 68.8 EHU 85 A/W 30.0

ECU 60 21.4 EHU 95 A/W 34.0
ECU 70 25.7 EHD 60 C 21.3
ECU 80 32.1 EHD 70 C 25.8
ECU 95 37.7 EHD 85 C 30.6
ECU 110 42.8 EHD 95 C 34.9
ECU 125 51.3 EHU 60 C 19.9
ECU 135 57.7 EHU 70 C 24.2
ECU 150 64.5 EHU 85 C 28.7
ECL 70 28.9 EHU 95 C 32.7
ECL 80 34.7
3.4.4 Leak Test

Units are factory checked for leaks before shipment from factory. However, after
installation of the unit at site, another leak test should be carried out. This should be
performed after all lines are connected, but before they are insulated. It is recommended
that the unit be isolated from the rest of the system using field installed shutoff/isolation
valves before carrying out the leak test.
3.5 Humidifier Connection
The humidifier unit may be connected to a standard piped cold water supply observing local
regulations where applicable. DO NOT USE demineralised water. Pre-treatment of water fed to
the humidifier is unnecessary. Where a salt exchange plant is in use at a site, the feed water to
the unit should by-pass this.
Beware of the following danger areas within the unit when running烉
z Hot humidifier bottle and humidifier sparge pipework.
z Condensate drain could contain hot humidifier discharge during the humidifier drain cycle.
z Steam being emitted from humidifier sparge pipe.
Steam Output Capacity 8 kg/hr 15 kg/hr

Steam Output Range烉 5 ± 8 kg/hr 10 ± 15 kg/hr
General Specifications
Steam outlet pressure limits (Pa) 0-500 0-600
Supply water temperature limit (ƱC) 1 ± 40
Max. drain water temperature (ƱC) 100
Supply water pressure limits (bar) 1- 8
Low 125 - 350ȝ6FP
Water Conductivity Medium 350 ± 750 ȝ6FP
High 750 ± 1250ȝ6FP
Drain Pipe Min. I.D. 32 mm
Max. drain instant flow rate l/min 4
Max. supply instant flow rate l/min 0.6 1.2
Feed water connection 3/4ȿ G male
Feed pipe min. I.D. mm 6
- 16 -
3.5.1 Humidifier Feed Water Connection

The water feed valve of humidifier has a ƿȿG male connector, at the right hand side of
humidifier base. It can be connected to brass connector, plastic pipe or flexible pipe. An
isolating valve should be installed in the feed water line. All installation should comply with
local codes and regulations.
3.5.2 Humidifier Drain

Humidifier drain and condensate water drain are not connected inside the unit, therefore
they need to be connected separately. Humidifier drain pipe must be able to withstand
high temperature (up to 100°C). If the condensate drain pipe and humidifier drain pipe are
to be connected together, the common pipe must satisfy the above requirement. A trap
must be fitted on the humidifier drain pipe external to the unit.
3.6 Drain Connection
All cooling coil drip tray(s) have a drain connection which is connected to a 22mm main
condensate drain pipe. The drain pipe is fitted with a flexible hose near the bottom of the unit.
A trap is fitted between the drain tray connection and the unit exit termination.
The drains should run into a 35 mm or larger drain within 3 metres of the unit and should be
discharged into a trapped air break as detailed in the section "Legionnaires' Disease".
The external drain should be run in copper tubing to BS 2871 Table X or equivalent, or high
temperature rigid plastic tubing. Drain pipe runs should be adequately supported at regular
intervals to avoid bowing and have a slope of at least 1 in 50 to ensure proper drainage. If the
run is long and has a number of bends the tube should be adequately sized and suitable
cleaning (Roding) eyes installed at bends. The pipework should be tested for any leakage
upon completion of installation.
Drain pipe should not be exposed to freezing temperatures. Prior to unit start-up, pour some
water into the condensate drain pan to fill up the trap and prevents air from being drawn up
from the drain lines.
3.7 Electrical Connection
WARNING烉烉DANGEROUS VOLTAGE LEVELS EXIST WITHIN THIS EQUIPMENT. USUAL

ELECTRICAL SAFETY PRECAUTIONS MUST BE OBSERVED. THIS EQUIPMENT MUST
BE EARTHED
3.7.1 Mains Supply
x The Mains Supply for this unit is shown on the wiring diagrams. Voltage tolerance
should not exceed tolerances of ±10%.
x This equipment in its standard form is designed to operate with an electrical supply of
400-415V/3 phase/4 wire/50 Hz.
x Models with non-standard power supply however are available as an option. Please
refer to the unit data on the nameplate and the wiring diagram for confirmation.
x The classification of this equipment is Class 1, as defined in the IEE Regulations and
BS 2754 (1976).
x Appropriate holes are provided in the gland plate for cable termination. Use the correct
size gland; do not remove any blanking plugs from unused holes.
IMPORTANT: NEVER cut additional entry holes into the top of the electrical enclosure.
x Terminate all site earth cable conductors to gland plate earth bolt(s) provided.
x Ensure that the mains electrical supply is of the correct voltage, frequency, phase and
rating.
- 17 -
x Ensure that the cable sizes are of adequate size for the maximum load of the
equipment under normal automatic running conditions. Recommended supply fuses
should be to BS 88. The fuse size should be determined from the worst FLA shown on
the schematic wiring diagram.
x Before connection to the equipment, check each installed cable for continuity and
short circuit. Check the tightness of all electrical connections prior to switching on
supply.
IMPORTANT烉The condensate/humidifier drain pipework should be earthed using

the electrical bonding strap. This connection should be as close to the unit as
possible.
3.7.2 Wiring Colour Codes
烉
The wiring colour code for cables within this equipment is as follows烉
Green/Yellow Earth continuity conductors

Black AC and DC power circuits
Black with Blue Sleeve Neutral conductors of power circuits
Red AC control circuits
Blue M.E.L.V. and DC power circuits (M.E.L.V. Machine Extra Low Voltage
not > 25 AC RMS or 60V DC with 10% maximum ripple)
Orange External interlocks which may remain live when isolator is off
NOTE: This colour code DOES NOT apply to electronics wiring.
3.7.3 Cable Segregation
IMPORTANT烉烉 Ensure that segregation is maintained between control

wiring (24V AC or DC) and mains potential wiring (415V/240V AC)
throughout the entire installation.
z Where it is unavoidable that power and signal/control cables run in close proximity,
ensure that there is a gap of AT LEAST 30 mm between each category throughout
the cable run.
z Ideally power and signal/control cables should never cross, but if unavoidable,
o
ensure that they cross at 90 (right angles) to each other.
IMPORTANT烉烉Any additional equipment installed in the unit, or supplied

from it, will render the warranty invalid, unless it complies with current
EMC Standards in force and any equipment fitted is approved by Citec.
z The alarm volt free contacts can be connected to 250Vac maximum 8A (res.).
z When interrogating the volt free contacts of the alarm relay ensure that the cable is
installed in the appropriate trunking (low voltage or high voltage).
3.7.4 Electrostatic Discharge (ESD)
When working inside the electrical enclosure, that person MUST ensure that they have
taken sufficient precautions for electrostatic discharge protection. Inside the electrical
enclosure, there is an electrostatic discharge connection point to fit a suitable ESD
protection strap.
- 18 -
3.7.5 Remote Air-cooled Condenser
For air cooled models that come with remote air cooled condenser, a field wiring
connection is required between the indoor unit and the outdoor condenser. Refer to the
electrical drawing supplied with the unit for size and connection details.
3.7.6 Underfloor Water Detection
An underfloor water detection tape can be supplied loose as an option for the unit. This
should be connected to the appropriate terminal block to function. Refer to the electrical
drawing supplied with the unit for size and connection details.
- 19 -
᧪COMMISSIONING
4᧪
4.1 Pre-Operation
AFTER ALL NECESSARY INSTALLATION WORK HAS BEEN COMPLETED AND BEFORE THE MAINS
SUPPLY IS APPLIED TO THE UNIT, ENSURE YOU HAVE READ ALL THE PREVIOUS SECTIONS OF THIS
MANUAL, AND THAT THE RELEVANT PARTS HAVE BEEN FULLY COMPLIED WITH.
z If the unit has been stored in a colder environment than its final permanent site, allow an
adequate period for acclimatization and evaporation of any condensation that may have
occurred before the mains power supply is connected to the unit.
z Keep ALL access doors and panels closed as much as possible to prevent the unnecessary
ingress of dust or other particles.
z Ensure that all exterior access panels or cover plates have been replaced and secured in
position to ensure the correct airflow when unit is switched on.
z When the unit is running, if switched off do not switch back on for a period of at least 20
seconds.
IMPORTANT烉
Danger exists from fans running on following the unit being switched off. It is
recommended that no panels be removed for at least 2 minutes to allow the
fans/pulleys rotational momentum to cease.
烉
WARNING烉
DANGEROUS VOLTAGE LEVELS EXIST WITHIN THIS EQUIPMENT. USUAL
ELECTRICAL SAFETY PRECAUTIONS MUST BE OBSERVED.
4.1.1 Operating Environment

1. Room conditions for the switchgear / controls of Air Handling Units are as follows烉
o
Maximum Standing Ambient 35 C
o
Minimum Standing Ambient 5C
Maximum. Humidity 90% non condensing
Maximum Working Pressure - Refrigerant 25 bar
Maximum Working Pressure - Water 25 bar
2. The exterior of an Air Handling Unit is generally dust and damp-proof to IP 41. Do not
install unit in areas where the environment contains large concentrations of dust, as this
will tend to deposit on the electronic circuit boards (PCB's) and can cause malfunctions.
3. The humidity sensor can be damaged by aggressive vapours (chlorine, acetone) and
must not be used in rooms where the environment contains these vapours.
4. The return air temperature and humidity sensor is dust and damp-proof to IP 20 and
therefore the airflow side of the unit is designed to IP 20.
- 20 -
4.2 General
1. All commissioning work must only be entrusted to personnel who are COMPETENT in the
necessary refrigeration, water pipework and electrical engineering.
2. The following equipment will be required to fully commission a unit烉
o Amprobe
o Multimeter (preferably digital)
o Anemometer
o Manometer炷0-1000 Pa炸
o Complete set of unit schematic wiring diagram
o Vacuum pump (Direct Expansion System Only)
o Vacuum gauge (Direct Expansion System Only)
o Oil pump (Direct Expansion System Only)
o Manifold gauge (Direct Expansion System Only)
3. Check the mechanical installation for烉
a. It is necessary before starting the fans to ensure that the mechanical adjustment
of the fan drive arrangement is correct. This involves the checking, and perhaps
adjustment, of the fan belt tension and the adjustment of the driving and driven
pulleys.
b. External refrigeration and any water pipework and drains are connected correctly.
Pay particular attention to the refrigeration pipework for remote condensers.
c. Unit panels are not damage during installation.
d. All transit brackets must be removed from the unit.
4. Check the electrical installation for :
a. Segregation of signal and main potential (240V/415V) cabling.
b. Correct termination and integrity of signal and mains cabling connections. Pay
particular attention to the controls cabling for remote Condensers, which should
be run separately to Mains supply.
c. Understand function and operation of remote interlocks.
d. Function of auxiliary alarm (if utilised).
IMPORTANT烉
Air cooled Condensers need to be separately commissioned PRIOR to the
commissioning of the refrigeration components in the Air Handling Unit. See
the relevant Installation Manual for this action.
4.3 Electrical/Controller
z (QVXUHWKDWDOO0&%VDQGLVRODWRUDUHLQWKH³2))´SRVLWLRQ
z Remove all Silica Gel and unwrap the filters.
z Check control panel and other terminal if all cables have been wired to proper position.
Ensure all wires are tightly secured.
z Use Mega-ohm meter to check if the compressors, heaters, humidifier and fan motors are
short to ground. Ensure that all ohm value is normal.
z :LWKWKHLVRODWRULQ³2))´SRVLWLon, check power supply voltage as below烉
Red ± Yellow Red - Neutral
Yellow ± Blue Yellow - Neutral
Blue ± Red Blue ± Neutral
z ,ISRZHUVXSSO\LVRND\VZLWFK³21´WKHLVRODWRU&KHFNSRZHUVXSSO\YROWDJHDIWHUWKH
isolator and the inlet of all MCBs as mentioned above.
z 6ZLWFK³21´&RQWURO0&%&KHFNWKHYROWDJHDWERWKSULPDU\DQGVHFRQGDU\ZLQGLQJRI
the transformer. Check if the display panel is displaying correct messages.
z Check all the setting inside Level I and II. Make sure they are set according to factory
setting by referring to the Controller Factory Setting Sheet (attached with unit). Please
refer to pCO5 Controller User Manual for more details on the interface.
- 21 -
4.4 Differential Pressure Switch
z Block part of the air filters with cardboard or paper. Check if Filter Block alarm is activated.
Reset the alarm.
z 6ZLWFK³2))´RQHof the blowers. Check if Air Flow Fail alarm is activated. Reset the
alarm. (If this alarm is activated, compressor, heater and humidifier will be de-activated).
4.5 Fans
z Disable fan fail alarm by rewiring connection to Airflow Switch (B2) as 1-2 instead of 1-3.
6ZLWFK³21´)DQ 0&%3UHVV³21´EXWWRQRQWKHFRQWUROSDQHO2SHQenclosure plate(s)
at front to ensure that the motor rotation is correct and free from obstruction.
z Check the fan motor current and observe if there is any unusual noise from fan and motor.
z Repeat the above test for all fans.
,)7+()$102725¶6527$7,21,6,1&255(&77+(1&+$1*(7+(3+$6(
CONNECTIONS AT THE MOTOR TERMINALS.
z On FRPSOHWLRQRIDERYHWHVWVZLWFK³2))´DOOIDQ0&%V.
4.6 Electric Heaters
z Increase the temperature set point to 4°C above the true reading. All Heating Contactors
will energize and Controller display heating mode.
z 6ZLWFK³21´+HDWHU0&%DQGWDNHWKHcurrent ampere reading.
z Ensure that the Heater Klixon operates and that the Heater Contactor de-energize, the
alarm activates and audible sounds.
z Reset the Heater Klixon alarm and ensure that Heater 1 Contactors re-energize.
z 6ZLWFK³2))´+HDWHU0&%.
z Repeat the above test for all Heaters.
z 2QVDWLVIDFWRU\FRPSOHWLRQRIWKHDERYHWHVWVZLWFK³2))´DOOKHDWHU0&%V.
z Rewire the Airflow Switch to original connection i.e. 1-3. Reset the temperature setpoint to
original setting.
4.7 Humidifier
z Check if there is water from water supply hose.

z 6ZLWFK ³21´ WKH +XPLGLILHU 0&% ,QFUHDVH WKH 5+ VHW SRLQW WR DERYH WKH WUXH
reading.
z The Humidifier Contactor and Feed Solenoid Valve will be energized and the Controller
will show that humidification mode is active. Observe if the water level rises in the
humidifier bottle.
z Bring the humidifier to the boil & check the current reading at the display.
Note烉烉Low water conductivity may prolong the period until full steam output is
reached. The Humidifier control algorithm always de-energizes the contactor for
the humidifier during the drain down cycles.
z Check if there is water leak at any part of humidifier system.
z Shut off the water supply valve. Drain out water from the cylinder via the display interface
by accessing to level 2 -!KXPLGLI\FRQWURO VHWWKHPDQXDOGUDLQWR³<HV´.
z Check the water level left in humidifier cylinder, when cylinder is emptied, set the manual
GUDLQWR³1R´
z :DLWIRUDERXWPLQXWHV&KHFNLIWKHUHLV³/DFN:DWHU´$ODUPRQWKHGLVSOD\SDQHO
z When the alarm appeared, open the water supply valve and reset the alarm.
z Decrease the RH setpoint to be the same as the true reading. This will de-energize the
Humidifier Contactor and Solenoid Valve.
z 6ZLWFK³2))´WKH+XPLGLILHU0&%
- 22 -
4.8 Direct Expansion System
IMPORTANT:
The direct expansion models incorporate scroll compressors that will only compress in one
rotational direction. The rotational direction is dependent upon the phasing of the power to
motor terminal connections (L1, L2 and L3). Verification of correct rotational direction is made
by observing that the suction pressure drops and discharge pressure rises when the
compressor is energised. Reserve rotation results in a sound level above that with correct
rotation, as well as substantially reduced current drawn compared to tabulated values. There
is no negative impact on durability caused by operating the scroll compressors in the reverse
direction; however, after several minutes the compressor internal protection will trip. THIS
PROTECTIVE DEVICE SHOULD NEVER BE BY-PASSED FOR ANY REASON.
z Ensure that the compressor MCB's are in the "OFF" position.

z Ensure that the crankcase heater (if fitted) and condenser supply MCB's are in the "OFF"
position ("A" version). If crankcase heater is fitted, it should be turned on at least 12 hours
prior to start-up.
z Select a lower temperature setpoint compared to the return air temperature. Check that
the 24V AC signal is present to operate the compressor contactor. After checking that
contactor for the respective compressor(s) are working, reset the temperature setpoint.
z For models with mechanical HP pressure switch fitted, set the switch to烉
o R407C ²² 26bar炷380psig炸
o R22 ²² 24bar炷350psig炸
o R410A ²² 42bar炷610psig炸
z Ensure that all compressor valves and any interconnecting pipework shutoff valves are
opened.
z Test thoroughly for leaks and evacuate refrigerant systems to 500 microns before
proceeding to charge the prescribed amount of refrigerant and oil.
z Switch on all compressors MCBs. You may operate the compressor in manual mode by
entering the software at Level 2 (or Advance Setting for PGD Touch) -> Forced Output ->
Cooling 1, 2 aQG VHW WR ³PDQXDO´ DQG ³21´ WR PDQXDOO\ IRUFH WKH respective
compressor(s) to run. Each number refers to a separate refrigerant circuit and follows the
circuit labeling at the unit.
z For units with optional water regulating valve (water-cooled models) or fan speed
controller (air-cooled models), after the compressor is up running, make the necessary
adjustments to achieve the design condensing temperature depending on whether a
water cooled or air cooled condenser is fitted:
(a) Water cooled condenser: Adjust water flow rate to condenser and adjusting setting at
water valve.
(b) Air cooled condenser: Adjust condensing pressure setpoint for fan speed controller
and check fan operation.
z Ensure that the condensing pressure is within design limits.
z Check and adjust (if necessary), the expansion valve superheat setpoint (default 6°C).
Suction pressure should be within design limits. Check to ensure that there is no freezing
at the coil.
z Switch back compressor operation to auto mode and adjust setpoint to the required
design room condition and check that the unit is operating within room design limits.
z Fill up T&C Report and warranty card. Send to the factory.
4.9 Chilled Water System
z Set the temperature set point to 3°C higher than return air temperature. Check if the
modulating valve is totally close.
z Set the temperature set point to 3°C lower than the return air temperature. Check if the
modulating valve is totally open.
z For 3-way control valve, by manually opening valve, balance the chilled water pipework to
- 23 -
achieve the design flow rate through the cooling coils and by-pass arrangement.
NOTE烉The best method of measuring water flow is by incorporating orifice and double
regulating valves at each unit, so enabling readings to be taken on the orifice valve and
regulating flow on the double regulating valve. Alternatively, a double regulating valve with
pressure tappings can be used. If these valves have not been installed, pressure drop
readings should be taken across the coil and across the 3-way valve. The double
regulating valve in the by-pass line should be set to correspond to the coil pressure drop,
thus ensuring correct control by the 3-way valve and constant flow through the system.
z Commission the chiller and associated equipment in accordance with manufacturers

recommendations.
4.9.1 Pressure Independent Balancing Control Valve
For optional 2 way pressure independent balancing control valve (PIBCV), first set the
desired flow rate going into the unit at the dial on the top of the valve. This will be the flow
rate going into the unit when it is operating at 100%. You will first need to remove the
actuator from the valve before having access to the dial. Please refer to diagram &
instruction below for the setting the flow rate of the PIBCV valve. Once the desired flow
rate is set, no other system balancing would be required.
Presetting
1. The desired flow can be adjusted easily

without using special tools.
2. To change the presetting:
a. Remove the blue protective cap or the
mounted actuator.
b. Raise the grey plastic ring and turn to
new presetting.
c. Release the white plastic ring and the
presetting is locked.
3. The presetting scale indicates a value
from 100% flow to 0% closed.
4. Counter clockwise turning would increase
the flow values while clock wise would
decrease it.
5. When valve is set to 80% or more the red
ring (belowȾ'1PD[IORZ´VLJQEHFRPHVYLVLEOH.
6. If the valve is DN 15 then the max flow = 450l/h = 100% presetting. To set a low of
270l/h you have to set 270/450 = 60%.
7. The amount by which the cooling valve opens on demand for dehumidification
depends upon the level set on the percentage of dehumidification set in Software
Level 2 (or Advance Setting for PGD Touch). Select a low value humidification setpoint
compared to control air humidity to check if valve opens the required amount. When
satisfied with operation, reset the setpoint to normal operating condition.
8. Fill up T&C Report and warranty card. Send to the factory.
4.10 De-humidification
z Set the temperature set point to be the same with return air temperature. Ensure that the
cooling demand is zero.
z Decrease the RH setpoint to 10% below true reading to induce a dehum demand and
Controller display de-humidification mode.
- 24 -
DX SYSTEM ONLY
z When in de-hum mode of operation, the superheat of the EEV will increase
according to superheat setpoint of dehum mode, i.e. 12 °C.
z Increase the humidity setpoint to true reading, the superheat of the EEV will revert to
its normal cooling mode superheat setpoint, i.e. 6° C.
ALL CW SYSTEM
z When in de-hum mode of operation, the cooling valve actuator will drive open to 70%
opening (setting in Level 2 -> Dehum. Control -> Valve Opening When Dehum).
z Increase the humidity setpoint to true reading, the cooling valve actuator will drive
fully close.
- 25 -
᧪SERVICE & MAINTENANCE

5᧪
5.1 Belt Driven Fans
z A belt driven blower system consists of a forward curve DIDW centrifugal fan, a TEFC
motor, a fixed diameter fan pulley and a fixed diameter motor pulley. The fan motor is
mounted on an adjustable frame on the blower fan itself.
z Fan motor should be inspected at regular intervals. Listen for any unusual noise or
condition. Inspect fan bearing for tightness of set screws and collar. Check if fan wheel is
mounted tightly on the fan shaft. Rotate wheel by hand to check whether any difficulties
due to misalignment and in fan rotation.
z Both the fan and motor is accessible from the front of the unit.
IMPORTANT烉烉ISOLATE ELECTRICAL POWER TO THE UNIT AND WAIT TILL FAN HAS
COME TO A STOP BEFORE ATTEMPTING TO INSPECT OR CHANGE THE FAN,
PULLEYS AND/OR MOTOR.
5.1.1 Belt and Pulley System
As a guide for the correct tensioning of the SPA

belts proceed as follows:
1. Measure the span length in metres.
2. At the centre of the span apply a force at
right angles to the belt to deflect ONE belt 16
mm per metre of span length.
3. Compare this measured force with the value
listed below:
x SPA belt: 2.4 to 3.1 kgf
4. If the measured force falls within these
values the tension should be satisfactory.
A measured force below the lower value
indicates under-tensioning. A new drive
should be tensioned to the higher value to
allow for normal drop in tension during the running-in period. After the drive has been
running for a few hours the tension should be checked and re-adjusted to the higher
value. The drive should be subsequently tensioned at regular maintenance intervals.
It is recommended that a "Fenner" tensioning tool be used to ensure correct tensioning (if
available).
Always inspect the pulleys and pulley system for wear and alignment when inspecting
belts. If belts are wearing out frequently then first check pulley wear and alignment. If okay
then check with Citec International Sdn. Bhd. that the pulley system is sized correctly for
the application and motor size.
IMPORTANT烉Always electrically isolate the system before any maintenance is carried

out on a pulley system.
- 26 -
5.2 EC Fans
A. For a unit with EC fan, the system consists of a stationary inlet nozzle and the fan
attached to the EC motor which is secured to a mounting bracket. A grille at the fan inlet
nozzle and enclosure plates is used to prevent accidental contact with the fan when it is in
operation. To access the EC fan, remove the enclosure plates.
B. To remove the fan from the unit, first move the inlet nozzle clear from the EC fan. Next
remove the bolt securing the fan bracket in position. With the inlet nozzle clear from the
path of the EC fan and its bracket, it shall be possible to slide the entire fan assembly out
from the unit along the guide & support rails. The EC fan can be removed from the fan
bracket once it is out of the unit.
C. For units with underfloor EC fan assembly, the fan assembly needs to be moved up from
its underfloor position via the same process highlighted earlier for installing the underfloor
assembly using chain block. Reverse the process until the entire fan assembly is above
the level of the bottom mounting plate of the unit. Move the entire fan assembly out of the
unit & remove the chain from the fan assembly. The EC fan can then be removed from the
fan mounting.
D. Any adjustment to the fan speed and settings can be made through the display interface.
Please refer to the Genius Controller Engineering Data for more details on the fan
settings.
IMPORTANT: ISOLATE ELECTRICAL POWER TO THE UNIT AND WAIT TILL FAN HAS COME TO
A STOP BEFORE ATTEMPTING TO INSPECT OR CHANGE THE FAN.
5.3 Compressor
IMPORTANT: ISOLATE ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING TO

CHANGE COMPRESSOR. TAKE NOTE THAT SURFACE OF COMPRESSOR NEAR THE
DISCHARGE PORT AND THE DISCHARGE PIPING MAY BE HOT IF IT WAS RECENTLY IN
OPERATION.
z Compressors are fully accessible from the front of the unit. For certain configurations, the
compressors are located behind enclosure plates which need to be opened for access. All
compressors are fitted with rotalock connection for easy removal. All the hermetic
compressors are without oil sight glass.
z In the event of compressor burn-out, a full system clean-up is required or residual
problem will occur even if new compressor is installed.
z To replace the compressor, reclaim all refrigerant from the system as per local codes and
disconnect all electrical connection at the compressor terminal box. For models with
optional rotalock valves, the system may be isolated by shutting off the rotalock valves.
Remove the compressor by opening the rotalock connections and replace with with new
compressor after removing old compressor out from the unit. Evacuate & charge
accordingly before restarting compressor. For models with optional rotalock valves,
remember to re-open rotalock valves after installing the new compressor.
5.4 Humidifying System
The humidifier operating parameters are selected in software. Appropriate voltages, phases
and steam output of humidifier fitted are set in Software Level 3 (or Factory Setting for PGD
Touch) - Humidifier Setup. This configuration is set up during factory configuration and
normally shall not need to be reset.
Two sizes of cylinder are fitted to Citec's range of Air Handling Units. The sizes are given as
the maximum steam output in kilograms per hour (kg/hr).
- 27 -
No. Description
1 Fill solenoid valve
2 Flow rate limiting device
3 Supply pipe
4 Fill pipe
5 Overflow pipe
6 Conductivity measuring electrodes
7 Fill tank ± overflow device*
8 High water level electrodes
9 Steam outlet
10 Electrodes
11 Cylinder casing
12 Bottom filter
13 Drain solenoid valve
*Device used to prevent water overflowing from the fill tank above the safety level (e.g., due to
a controller malfunction, fills solenoid valve overflowing or back pressures).
The fill tank is equipped with an overflow diaphragm that discharges the excess water through
a special pipe.
The overflow diaphragm is located in a lower position with respect to the fill one (-40mm) in
order to prevent back-flow into the fill pipe.
IMPORTANT WARNING: the drain pipe must be free, without back pressure and must be
equipped with a drain trap downstream of the connection to the humidifier.
A cut-off cock and a mechanical filter should be installed to trap any solid impurities.
5.4.1 Humidifier Operating Principle
+XPLGL¿FDWLRQLVDFKLHYHGZLWKHOHFWURGHERLOHUW\SHKXPLGL¿HU,QWKLVW\SHRIKXPLGL¿HU
the steam is produced by boiling the water contained inside the cylinder. This occurs by
VLPSO\¿OOLQJWKHF\OLQGHU with water and applying voltage to the electrodes. According to
the Joule effect, the current will tend to heat the water until boils. The aim of the algorithm
is to maintain the current that runs through the electrodes at a reference value so as to
ensure the percentage of steam production required according to the readings of the
humidity probes and the parameters set by the user. To maintain the current within a
FHUWDLQUDQJHDURXQGWKHUHIHUHQFHYDOXHZDWHU¿OO and evaporation cycles are repeated.
The other factor that determines the current level is the conductivity of the water inside
the cylinder.
The initial quantity of the flowing current strongly depends on the type of water coming
from the supply network. Normally, a recently-started cylinder has low current. With the
passing of time, the quantity of the salts contained in the water increases (as a matter of
fact, evaporation does not include salts); this feature allows reaching the required current
level so that the machine can provide for the required steam quantity.
Under stable operation conditions, the required production level is automatically obtained
by controlling the boiler water level. This control allows having higher or lowers.
Parts of the salts introduced in the water by automatic refills settles inside the boiler as
- 28 -
limestone, contributing to the progressive wear of the cylinder; the remaining salts keep
dissolved in the water. In order to prevent excessive salt deposits, some water is
periodically and automatically drained and then with renewal water.
5.4.2 Humidifier Alarms
Alarm Symptoms Action

Alarm High 1. Supply water 1. Supply water must be within the water
Current conductivity too high conductivity range of cylinder.
2. High water level due to 2. Verify the drain valve is properly working.
drain valve malfunction 3. Check for any leakage of the fill valve when
3. High water level due to not switched on.
fill valve leakage 4. Replace cylinder.
4. Electrode malfunction
Alarm Lack 1. Lack of water supply 1. Check that the fill pipe from the mains to the
water 2. Low mains pressure humidifier and the internal pipe are not
blocked or bent and that there is sufficient
supply pressure(0.1/0.8 MPa);
2. Check the fill valve is properly working;
3. Check for counter-pressure onto the steam
hose higher than maximum limit, preventing
the entry by gravity of supply water into the
cylinder;
4. Check that the steam outlet pipe is not
choked and there is no condensate inside it.
Drain Alarm Drain Malfunction Check the drain circuit and the proper operation of
the drain valve.
Alarm 1. No steam production but 1. Check for any leaks from the fill valve.
Cylinder full cylinder Full 2. Check that the level sensors are clean.
2. High water level sensor
bridged
5.4.3 Cylinder Replacement Procedures烉烉

1. With the unit on, completely empty the cylinder by entering to software Level 2 (or
Advance Setting for PGD Touch) -> Humidity Control, set the Manual Drain function to
YES.
2. When the cylinder is fully empty, set the manual drain function to NO.
3. Isolate the unit from the incoming electrical supply by means of the local mains
isolator.
4. Disconnect all electrical circuits connected to the Humidifier before carry out any work.
5. Loosen the hose clamp and disconnect the hose from the top of the steam cylinder.
6. Carefully remove the used cylinder from the unit.
7. Insert new cylinder.
8. Reconnect the steam hose.
9. Reconnect electrical circuits to the Humidifier as before.
10. After a cylinder exchange, it is important to replace the cables to their original route.
5.4.4 Service & Maintenance
As the operation of the Humidifier is entirely automatic, it normally requires no attention on

a day-to-day basis. General cleaning and maintenance of the component parts are
recommended at intervals of approximately one year, but this is largely dependent upon
the frequency of its use and the quality of the water being supplied.
5.4.5 Steam and Condensate Hoses
- 29 -
The steam, condensate and water hoses used with and in the Humidifier should be
inspected at the normal service visits as part of normal maintenance. At the first signs of
deterioration, a hose should be removed and replaced with identical hoses.
IMPORTANT WARNING: the cylinder might be hot, before touching it, let it cool or
use protective gloves.
5.4.6 Periodical Checks
z After one hour of operation

o For both the disposable and serviceable cylinders, check that no significant water
leak is present.
z Every fortnight and no more than 300 working hours
o For both the disposable and serviceable cylinders, check that no significant water
leak is present and verify cylinder operation and the general conditions of the
container. Also check that no arc or spark originate between the electrodes when
the machine is operating.
z Every three months and no more than 1,000 working hours
o For disposable cylinders, verify cylinder operation, check that no significant water
leak is present and replace the cylinder if required. For serviceable cylinders,
check the container for markedly blackened areas: in case they are present,
check the scale condition of the electrodes and, if necessary, replace them
together with the O-rings and the cover gasket.
z Every year and no more than 2,500 working hours
o For disposable cylinders, replace the cylinder. For serviceable cylinders, check
that no significant water leak is present; verify cylinder operation and the general
conditions of the container. Also check the container for markedly blackened
areas: in case they are present, replace the electrodes together with the O-rings
and the cover gasket.
z After 5 years and no more than 10,000 working hours
o For both the disposable and serviceable cylinders, replace the cylinder.
After extended use or due to the use of water with a high salt content, the solid deposits
that form naturally on the electrodes might spread until they cover the cylinder internal
wall. In case particularly conductive deposits form, the heat consequently produced might
overheat plastic and melt it; in the most severe cases, heat might perforate plastic,
causing the water to leak from the cylinder to the tank.
As a precaution, check the quantity of deposits and verify that no deformation or

blackening is present on the wall of the cylinder, otherwise replace it.
WARNING: in case of leak, disconnect the appliance before touching the cylinder,
as current might be present in water.
5.4.7 Maintenance of the other hydraulic components
IMPORTANT WARNINGS:
Do not use detergents or solvents for plastic components cleaning. Scale can be
removed using a solution with 20% vinegar or acetic acid and then rinsing with
water.
- 30 -
The only steam humidifier component that

requires periodical replacement is the steam
production cylinder. Replacement is required
when the limestone deposits that form inside
the cylinder prevent current from flowing
properly. In this case, an alarm signal is
displayed on the controller. The frequency of
this operation depends on the supply water:
the more water contains salts or impurities,
the more cylinder replacement will be
frequent.
No. Description
1 Bearing frame
2 Cylinder lock belt
3 Fill tank + conductivity meter
4 Overflow pipe
5 Cylinder fill pipe
6 Tank fill pipe
7 Fill solenoid valve(24 Vac)
8 Fill/drain manifold
9 Gasket
10 90Ʊ elbow drain union
11 Straight drain union (supplied)
12 Drain solenoid valve
z Fill solenoid valve (Fig.2, part no. 7)

o After disconnecting cables and pipes, remove the solenoid valve and check
cleaning of the inlet filter; if required; clean it using water and a soft brush.
z Fill and drain manifold (Fig.2, part no. 8)
o Check that no solid deposit is present inside the cylinder seat; remove impurities,
if any.
o Check that the O-ring is not damaged or cracked; replace it if necessary.
z Drain solenoid valve (Fig. 2, part no. 12)
o Cut power off, remove the coil and disassemble the valve body after having
unscrewed the two screws fastening it to the manifold; remove impurities, if any,
and rinse.
z Fill tank + conductivity meter (Fig.2, part no. 3)
o Verify that no clog or solid particle is present and check the conductivity
- 31 -
measuring electrodes for proper cleaning; remove impurities, if any, and rinse.
z Supply, fill and overflow pipes (Fig.2, parts no. 4, 5, 6)
o Check the pipes for proper clearing and cleaning; remove impurities, if any, and
rinse.
IMPORTANT WARNING: after replacing or checking the hydraulic parts, verify the
connections for proper execution. Start the machine again and carry out some fill
and drain cycles; upon cycles completion, check for water leaks, if any, in
compliance with the safety procedure.
5.5 Air Filter
A dirty filter can seriously affect the efficiency of a plant and torn filters can seriously foul the
conditioned space, the cleaning of which can be extremely expensive. Units fitted with
microprocessor controls will indicate by visual alarm when a filter change is necessary.
When replacing filters ensure that:

1. The system is shut down for filter changing.
2. The dirty filters are put into plastic bags and sealed so avoiding dust inside and
outside the conditioned environment.
3. New filters are of the correct size and seal correctly.
4. The system is put back into operation and that it operates correctly.
For down flow unit, the filters are situated in the top of the unit, on the air return side of the
system. For up flow unit, the filters are situated at the front bottom of the unit. For ECL and ES
5 and 12 models, the filters are situated parallel to the cooling coil. Access to the filters is via
the front access panel(s) or from the top of the unit. Each door is retained by 3 compression
latches and should be operated using the 4mm allen key.
IMPORTANT: care must be taken when opening the access door containing the
microprocessor display module as this is attached to the controller in the electrical
panel by display cable. No excess strain should be applied to this cable as this may
damage PCB's in the display module or controller.
To replace the filters, first ensure that the airflow direction on the filter when fitted will face
downwards (towards the unit) or inward (for upflow unit). Use the rail on the filter frame to slide
the filter in towards the rear of the unit. After that, close back the front access door(s) if it was
opened for filter removal.
After replacement of the air filter, check the operation of the filter blocked switch (differential
pressure switch) located within the control/ electrical panel. Note that all access panels must
be in place and closed for proper measurement. New air filter should not trigger the switch.
Adjust setting if necessary (please refer to section on Airflow Failure & Filter Blocked
Differential Pressure Switch).
- 32 -
Filter Size
ES Range
Model 5 12 15 20 25
Downflow:WxHxD (Qty) mm 455x455x50(1) 510x288x50(3) 632x700x100(1)
Upflow:WxHxD (Qty) mm 455x455x50(1) 510x288x50(3) 637x572x100(1)
Model 30 35 40 45 50
Downflow:WxHxD (Qty) mm 350x700x100(2) 565x700x100(2)
Upflow:WxHxD (Qty) mm 722x572x100(1) 547x572x100(2)
Model 60 70 80 90 100
Downflow:WxHxD (Qty) mm 501x700x100(1), 565x700x100(2) 398x700x100(2), 501x700x100(3)
Upflow:WxHxD (Qty) mm 387x572x100(1), 547x572x100(2) 722x572x100(3)
EC Range
Model 25 30 50 60 70 80
301x700x100(2) 301x700x100(2)
Downflow:WxHxD (Qty) 632x700x100(1) 350x700x100(2) 565x700x100(2) 350x700x100(4)
350x700x100(3) 350x700x100(3)
mm
633X850X100(1) 633X850X100(1) 633X850X100(1)

Upflow:WxHxD (Qty) 637x572x100(1) 722x572x100(1) 547x572x100(2)
633X582X100(2) 384X582X100(4) 384X582X100(4)
mm
Model 95 110 125 135 150

301x700x100(4) 350x700x100(1) 350x700x100(1) 301x700x100(3)
Downflow:WxHxD (Qty) 350x700x100(2) 301x700x100(6) 301x700x100(6)
301x700x100(8)
350x700x100(5)
mm
633X850X100(1) 633X850X100(1)
633X850X100(1) 633X850X100(1) 633X850X100(1)
Upflow:WxHxD (Qty) 540X582X100(4)) 633X582X100(4) 633X582X100(4)
384X582X100(4) 540X582X100(4)
mm 633X582X100(2) 633X582X100(2)
EH Range
Model 60 70 85 95
Downflow:WxHxD (Qty) mm 421x800x100(3) 504x800x100(3) 444x800x100(3) 504x800x100(4)
633X582X100(2) 540X582X100(4)
Upflow:WxHxD (Qty) mm 633X582X100(4)
384X582X100(4) 633X582X100(2)
633X582X100(6)
ECL Range
Model 70 80 125 140 180 200
512X348X50(6) 872X348X50(6) 829X348X50(9)
WxHxD (Qty) mm
514X523X50(4) 874X523X50(4) 832X523X50(6)
Standard air filters are of washable type with metal frame is of G4 rating. Non-standard air
filters of different rating are available on request. Please contact your local Citec
representative on replacement air filters. Citec will not be responsible for any problems which
arise from usage of any air filters not from Citec.
- 33 -
5.6 Fan Speed Controller
The fan speed controller (FSC) is single-phase electronic voltage

regulators which utilize the phase-cutting principle in order to regulate
the output active voltage as a function of the control signal being
applied to the inputs.
The FSC are equipped with a protection against the short circuit by
means of a fuse placed on the external part of the card so as to be
easily inspected and, if required, replaced (refer to the table of the
technical characteristics for a proper replacement).
Technical characteristics
Single phase power supply 230V +10%/-15%
Frequency 50/60Hz
Driving Signal 0Ǹ10Vdc
Power supply for possible manual driving (+V terminal) 20 Vdc 40 mA
Operating Temperature -10Ǹ50ƱC
Storage temperature -20Ǹ70ƱC
Model Nominal Current [A] In-rush Current [A] Fuse [A]

FCSM0423L0 4 4 x Nominal C. Ceramic 5x20 5 A.T.
FCSM0823L0 8 3 x Nominal C. Ceramic 6,3x32 8 A.T.
FCSM1223L0 12 3 x Nominal C. Ceramic 6,3x32 12 A.T.
Settings for the FSC may be changed via the display interface. Please refer to the pCO5
Controller User Manual on settings for the FSC.
5.7 Differential Pressure Switches
The switches sense a change in the differential

pressure across:
a) The Fan(s) (to detect airflow failure) and/or

b) The Filters (to detect a blocked filter)
Each differential pressure, as sensed by the two

sensing ports, is applied to the two sides of a
diaphragm in the control section. The spring-loaded
diaphragm moves and actuates the switch.
The differential switch setting is changed by removing the plastic cover and rotating the
pressure-adjusting knob. Clockwise rotation increases the setting whilst anti-clockwise rotation
reduces the setting.
Airflow Failure Pressure Switch (Switch Designation - B2)
The default setting for Airflow Failure is:

G-Volution Series: 150Pa (EC Fans)
250Pa (Belt Driven Fans)
The high-pressure entry (+) is coupled, via a red marking plastic tube, to a connector
positioned after the fan discharge. The low-pressure entry (-) is coupled, again via a
non-marking plastic tube, to a connector positioned before the fan suction.
- 34 -
Filter Blocked Differential Pressure Switch (Switch Designation - B1)
The default settings for Standard (G4) Filters and High Efficiency (F6) Filters are as follows:
G-Volution Series:
Standard Filters (G4): 3D
High Efficiency Filters (F6): 3D
Ƈ - The above values are factory set and represent approximately 1.5 times the clean filter
pressure drop.
The high-pressure entry (+) is coupled, via a red marking plastic tube, to a connector
positioned before the filters.
The low-pressure entry (-) is coupled, again via a non-marking plastic tube, to a connector
positioned after the filters (between the filters and coils).
Note: The settings of these two differential pressure switches should be fine-tuned at
site depending on the site condition.
5.8 Electronic Expansion Valve
Electronic expansion valve (EEV) is installed in the refrigerant circuit of all DX units. It controls
distribution of the refrigerant in the system via the superheat of the refrigeration circuit which is
calculated by a pressure and temperature probe located at evaporator outlet. Below is the
operating diagram of the internal mechanism for electronic expansion valve烉
5.8.1 Welding and handling of EEV
For replacement of EEV, proceeding as follows烉

1. unscrew the nut fastening the stator and remove the stator;
2. wrap a wet rag around the valve and weld the fillings, without overheating the valve;
3. when the valve has cooled down, insert the stator and retighten the fastening nut.;
Do not twist or strain the valve or the connection pipes.

Do not strike the valve with hammers or other objects.
Do not use pliers or other tools that may deform the external structure or damage
the internal parts.
Never point the flame at the valve.
Never bring the valve near magnets or magnetic fields.
- 35 -
Do not install or use the valve in the event of烉

x deformation or damage to the external structure;
x heavy impact, for example due to dropping;
x damage to the electrical parts (stator, contact carrier, connector,...).烊
CITEC does not guarantee the operation of the valve in the event of deformation of the
external structure or damage to the electrical parts.
5.8.1 Electrical Connection
White
Yellow
Brown
Green
5.9 Electric Heater
Heating of the air is carried out as necessary by a bank of stainless steel finned elements. The
number of these depends on the particular model and all phases are balanced. Automatic
reset over-temperature thermostats are fitted to the heater to prevent the heater elements from
overheating.
These heater elements are non-serviceable and in case of a failure, the reason should be
ascertained before fitting new heater elements. Care should be taken to ensure that the
replacement heater elements are the same rating as those that are removed. When ordering
the heater elements with Citec for replacement purpose, please mention the unit model and
serial no.
5.9.1 Operation烉烉
i Ensure that all heater stage MCB's are set to the "ON" position.
i Select a higher temperature setpoint than the current return air temperature (so that
the heaters will cut in) or alternatively manually force the heater to run by going to
Level 2 (or Advance Setting) of the software and then check that the heaters are
operating.
i Set the required design setpoint and ensure that the operation is within room design
limits.
i Stages of heater are activated and de-activated by the control system. Stages of
heater are switched on in a last in first out (LIFO) mode. The last stage of heating
switched on is the first stage switched off.
5.9.2 Access to Heaters & Over-temperature Thermostats
i Electrically isolate the unit, and open the front access door(s), each secured with ¼
turn compression locks. Use the key supplied with the unit to operate locks.
- 36 -
i IMPORTANT: care must be taken when opening the front access door containing the
display module as this is attached to the controller in the electrical panel by a display
cable. No undue strain should be applied to this cable as this may damage PCB's in
the display module or controller.
i IMPORTANT: please ensure that the heater is cool before touching or removing the
elements or the thermostat.
For ES models (as well as EC 25 & 50 models) except model 5 and 12, downflow units,
the heaters and over-temperature thermostats are located between the cooling coil(s)
while for upflow units, the heater and over-temperature thermostats are located above the
cooling coils and can be accessed from the front. Open the front enclosure panel for the
fan section to access the heater. The heater assembly is mounted on a plate held in place
by 3 screws. Removal of these screws will allow the complete assembly to slide down
from its mounting position. At this point, the heaters, over-temperature thermostats and
electrical connections are easily accessible for any necessary maintenance, replacement,
etc. For models with belt driven fan, the fan motor has to be removed in order to access
the heater assembly.
For the EH and EC models besides EC 25 & 50, there are different locations for the
heaters assembly:
i Down flow unit (standard belt driven fan): the heaters are located at the rear
portion of the unit behind the fan(s).
i Down flow unit (EC fan/plug fan): the heaters are located between the cooling
coil and the fan(s).
i Up flow unit: the heaters assembly is located between the fans and the cooling
coil.
For ES 5 & 12, the heaters are located at the rear of unit.
The heater assembly is mounted on a plate, fixed by screws. Removal of the screws will
allow the complete assembly to be withdrawn. At this point, the heaters, over-temperature
thermostats and electrical connections are easily accessible for any necessary
maintenance, replacement, etc. For models with belt driven fan, the fan and motor has to
be removed in order to access the heater assembly.
Note: For down flow unit (EC fan/plug fan), cover the fan inlet with cardboard etc. to
prevent any dropping of screws into the fan.
5.10 Water Cooled Condenser
A #16-20 mesh (1mm) strainer shall be placed on the supply water piping before the plate heat
exchanger to protect the heat exchanger from getting blocked by particles. Regular inspection
& cleaning of the strainer is required to prevent high pressure losses.
The plate heat exchanger has a self cleaning effect in the channels due to a very high degree
of turbulence. However, proper maintenance & treatment of the cooling water system is
important to reduce the risk of scaling particularly in open water systems or where the degree
of fouling is high. It is possible to clean the heat exchanger by circulating a cleaning liquid
through the heat exchanger. A 5% phosphorus acid solution (or 5% oxalic acid if frequently
cleaned) may be used as the cleaning liquid. For optimum cleaning, the flow rate for the
cleaning solution should be a minimum of 1.5times the normal flow rate, preferably in a
black-flush mode. Rinse carefully with clean water afterwards. A solution of 1-2% sodium
hydroxide (NaOH) or sodium bicarbonate (NAHCO3) before the last rinse will ensure that all
acid is neutralized.
- 37 -
5.11 High Pressure Switch
The pressure switch is fitted in the Air Handling Unit on DX versions. A non adjustable fixed
setting switch is provided unless an adjustable HP or dual LP & HP switch option is taken.
Pressure setting for standard default HP switch is 380 ± 14psig.
5.12.1 Adjustable Setting Pressure Switch (if fitted)
Pressure range for the adjustable HP switch is 8.0 to 32.0 bar, differential fixed at 3.0bar.
Set the stop pressure on "CUT-OUT" scale (range scale). It can be locked and sealed by
means of the lock plate and lock screw. The HP switch needs to be manually reset when
tripped on high pressure, using the manual reset button on the top of the pressure switch.
High pressure controls can be manually reset when the pressure is equal to the stop
pressure minus the differential.
Recommended Switch Setting

R22 R407C R410A
High Pressure Cut Out 350 psig (24.1 bar) 380 psig (26.2 bar) 610 psig (42.1 bar)
5.12 Servicing
5.12.1 Daily
Inspect indicator panel on face of unit to ensure satisfactory operation.
5.12.2 Two Monthly
x Check operation of all safety devices such as airflow sensors, pressure switches etc.
x Check operation of complete control system.
x Check operation of all on/off switches.
x Check filter condition and change if required.
x Check fan and motor bearings.
x Check drains and ensure that they are clear.
x Isolate switchgear and controls and inspect contactors, relays etc. for signs of
overheating or arcing.
x Tighten all electrical terminals and connections inside and outside the unit.
Item Frequency Action Note

1 2 Monthly Generally inspect unit for any problems, -
including noise, sealing, leaks, insulation,
bearings, drains etc.
2 2 Monthly Check pulleys and belts for wear, correct -
tension and alignment.
3 2 Monthly Check fan mounts, cleanliness and -
operation.
4 2 Monthly Check cleanliness of filters, inspect for -
break up, and correct sealing.
5 2 Monthly Check cleanliness of grilles (if fitted). -
6 2 Monthly Check unit for rust especially around Clean off any rust,
cooling and humidifying sections. prime and topcoat
7 2 Monthly Check pipe work connections for leaks, also -
condition of local insulation.
- 38 -
8 2 Monthly Check coil for build-up of dust Clean with stiff brush if
dirty
9 2 Monthly Clean unit inside and out with vacuum
cleaner and wipe down with damp cloth.
Rectify any paint damage externally.
10 2 Monthly Check that electrical connections on motor -
and electric heater are tight.
11 2 Monthly Check anti-vibration mounts are okay (if Pay particular
fitted). attention to rubber
mounts.
12 2 Monthly Check operation of electric heater -
over-temp thermostat.
13 2 Monthly Check pressure drops air / water and -
compare with commissioning details.
- 39 -
᧪TROUBLESHOOTING
6᧪
6.1 General Notes
6.1.1 Use of Sheets烉

In the following tables it is assumed that the mechanical and electrical services, to which
these refer, have been commissioned correctly and run without significant faults for a
reasonable period since the commissioning, (i.e. the design settings were initially correct,
and plant is of the correct size for the application).
Any repeated faults in the initial warranty period should be relayed to the contractor and
consultant (where applicable).
Plant settings should not be altered as the balance of the complete system can be
affected resulting in a costly rebalancing operation. Rebalancing should only be carried
out by a competent Engineer.
Carrying out maintenance as described in the servicing sections can cut down
significantly nuisance fault finding problems; however maintenance should be carried
out by COMPETENT AND TRAINED STAFF - bad maintenance is often worse than no
maintenance at all.
The fault finding tables have been prepared in logical sequence, with the most likely
faults first.
Generally speaking electrical or electrically associated problems are more frequent than
mechanical.
Ensure that the person(s) fault finding is competent in attending to all aspects of the
equipment and that they know the location of all items of plant.
Remember that due to the psychrometric inter-relationship between temperature and

humidity, high temperature and low humidity or low temperature and high humidity can
occur simultaneously. In such cases, resolve the temperature problem first as it will
probably also rectify the humidity problem.
6.1.2 Electrical Control Panels and Wiring etc.
As it will be necessary for panels to be worked on "live" for fault finding only QUALIFIED
AND COMPETENT ELECTRICAL STAFF should be used on this Section. Refer to "The
Electricity at Work Regulations" for guidance.
Always fault find with schematic wiring diagrams at hand.
It is necessary to ensure that all isolators are in the "OFF" position before any covers are
removed.
- 40 -
6.2 Alarms
6.2.1 Unit Alarms

Alarms Triggered when Remedy
(A) High Return Return air temperature is See 6.4 Air handling unit: section (D)
Air higher than temperature
Temperature setpoint + alarm band.
(B) High Return Return air humidity is See 6.4 Air handling unit: section (F)
Air Humidity higher than humidity
setpoint + alarm band.
(C) Low Return Air Return air temperature is See 6.4 Air handling unit: section (E)
Temperature lower than temperature
setpoint + alarm band.
(D) Low Return Air Return air humidity is lower See 6.4 Air handling unit: section (G)
Humidity than humidity setpoint +
alarm band.
(E) Airflow Failed Lack of airflow See 6.4 Air handling unit: section (I)
(F) Heater Heater over temperature Check airflow. See 6.4 Air handling unit:
Overheat protection activated section (I)
Faulty Klixon. See 6.5 Electric Heater
(G) Compressor x Compressor system x low See 6.7 Direct Expansion System:
Low Pressure pressure tripped Section (E)
(H) Compressor x Compressor system x high See 6.7 Direct Expansion System:
High Pressure pressure tripped Section (C) and (G)
(I) LOP Time Out Unit system x operate at See 6.7 Direct Expansion System:
(EEV Dx) low suction pressure for a Section (E)
pre-set time delay
(J) MOP Time Out Unit system x operate at See 6.7 Direct Expansion System:
(EEV Dx) high suction pressure for a Section (F)
pre-set time delay
(K) Low Superheat Unit system x operate at 1. EEV stuck open. Check and replace
(EEV Dx) low superheat for a pre-set EEV if necessary.
time delay 2. Compressor not pumping. Check
compressor.
(L) Probe S1 Error System x EEV suction 1. Check suction pressure probe cable
(EEV Dx) pressure probe signal out contact and continuity. Replace if
of range necessary.
2. Suction pressure probe faulty.
Replace accordingly.
(M) Probe S3 System x EEV suction 1. Check suction temperature probe
Error (EEV Dx) temperature probe signal cable contact and continuity. Replace
out of range if necessary.
2. Suction temperature probe faulty.
Replace accordingly.
(N) HiT asp (EEV Unit system x operate at Check if the suction temperature sensor is
Dx) high suction temperature correctly installed.
for a pre-set time delay
(O) Filter Blocked High pressure drop across Filter dirty. Replace filters.
the filter
(P) Water On Water detected on floor by Check water leak in the unit.
Floor water sensor tape. Check if there is moisture carry over.
Reduce airflow if necessary.
(Q) Drip Tray Full High water level in the Drain pan outlet clogged
- 41 -
condensate drain pan

(R) LAN Fail to communicate with Network cable disconnected. Check
Disconnected other units in the network cable.
One or more units in the network being
switched off.
(S) Water In High Inlet water temperature is Check water supply system.
Temperature higher than a pre-set value
(T) Unit Run Unit exceed pre-set Reset the unit expired date.
Expired operation validity period
(U) Unit Health Unit exceed pre-set time for Reset the unit health check date.
Check maintenance or health
check.
Note: x indicate the refrigeration circuit/system number
6.2.2 Humidifier Alarms

Alarms Triggered when Remedy
(A) High Current Excess current in the 1. check the operation of the drain valve.
Alarm electrodes 2. check the seal of the supply solenoid
valve when not energised.
3. drain some of the water and restart.
4. check for bridges between the
electrodes.
5. cylinder replacement and/or
maintenance
(B) Low Current When the humidifier is With the unit off and disconnected from
Alarm activated, no steam is the mains, check the electrical
produced. connections inside.
(C) Lack of Water No supply water 1. check that the supply hose from the
Alarm mains to the humidifier and the
internal hoses are not blocked or
choked and that there is sufficient
pressure (0.1 to 0.8 MPa, 1 to 8 bar)
2. check the operation of the fill solenoid
valve
3. check that the steam outlet is not
operating with excessive
backpressure, preventing the flow of
water into the cylinder by gravity
4. check that the steam outlet hose is
not choked and that there are no
pockets of condensate
(D) Cylinder Full The cylinder is full with the Check for any leaks from the fill solenoid
Alarm unit off valve or the condensate return from the
hose. Check that the water level sensors
are clean.
(E) High High conductivity supply Switch the unit off and clean the
Conductivity water electrodes that measure of the
Alarm conductivity of the water; if the problem
persists, change the origin of the supply
water or use a suitable treatment system
(partial demineralisation).
- 42 -
(F) Low Excessive reduction in Cylinder completely depleted or water

Production production with excessive foam. Perform
Alarm maintenance on the cylinder
(G) Drain Alarm Drain malfunction Check the water drain circuits and the
correct operation of the drain valve, and
check the condition of the strainer inside
the cylinder
(H) Warning The cylinder life is ending Perform maintenance and/or replace the
Pre-exhaustio cylinder
n Presence
(I) Warning Foam Excessive foam in the 1. Flush the water supply lines;
Presence cylinder when boiling 2. Clean the cylinder, make sure a
softener is not used (if so, use
another source of water or reduce the
softening).
(J) Warning Cylinder depleted Perform maintenance and/or replace the
Cylinder cylinder
Exhaustion
- 43 -
6.3 Electrical Mains
Fault Possible Cause Remedy

(A) Supply 1. Generating Board failure. Check supply on Main board.
Failure
2. Main breaker out. (a) Check for fault in line to Main board or
even further back - report fault only.
(b) Breaker fault - call in local Electricity
Board.
3. Loss of continuity.
Check supply.
(B) Low Voltage 1. Mains supply low. Check at main breaker. If low then check
with local Electricity Board.
2. Bad contact in breaker, Visually check - replace part or in whole.

switch or isolator.
3. High voltage drops in Check voltage either end, also could be:
cable. (a) bad terminals as above - tighten
(b) faulty insulation - check by insulation
test.
(c) faulty conductor (local overheating), if
so replace.
(d) Additional load added - cable too small
for length - update.
4. Breakdown of Insulation on Check using continuity tester - replace.

3 phase wiring.
5. Conductor core breakdown Check cable for local heat spot - replace
cable or all if suspect.
(C) Continuity 1. Break in circuit. Check all connections on busbars, fuses,
Loss isolators, switches, etc. - repair faulty
connection inside Air Handling Unit only.
2. Open circuit on isolator or Visually check that switches / isolators are

switch. operating correctly - use meters as
required and then repair or replace.
3. Open circuit on conductor. Find approximate position of break using

instrumentation and repair or replace
conductor.
- 44 -
6.4 Air Handling Unit

(A) Unit Not Operating. 1. Mains supply isolator(s) in "OFF" Check all isolators for Mains supply to unit.
Mains Power LED position.
Off Or No backlit
on graphical 2. Mains supply fuse(s) failed. Check all fuses in Mains supply and
display replace after correcting fault. (Check for
loose wires).
3. Control circuit 240V supply Check control circuit MCB. Reset after
absent. investigation. Check neutral wiring
connection.
4. Control circuit 24V supply absent Check supply fuse. Replace after
investigation.
(B) Unit Not Operating 1. Unit not switched on. Switch "ON" at front panel switch.
Mains Power LED
On[Fan(s) not 2. Fire detection / remote interlock Investigate and correct as necessary. NB:
running] not made. Stopped by remote Do not link out fire alarm without
Or On Graphical source. FXVWRPHUV¶ZULWWHQFRQVHQW
Display: display
backlit but no Fan 3. Fan overload / MCB tripped. Reset overload / MCB and monitor current
Icon displayed drawn. If overload / MCB trips again check
fan motor and contactor.
4. Faulty contactor or motor. Replace as necessary.
(C) Unit Operating but 1. Control circuit 24V AC supply not Check the components are operating in
NOT Heating, present at appropriate contactor "AUTO". Check appropriate stage supply
Cooling, /solenoid valve. fuses on controller.
Humidifying or
Dehumidifying 2. Appropriate MCB tripped. Reset after investigation.
3. Airflow fail Check Airflow Fail alarm(s).

Check for flooding.
4. Water detection alarm interlock
active (only applicable to
Humidifying).
5. Electric heater over-temp alarm Check for electric heater over-temp alarm.
interlock active (only applicable Check operation / continuity of electric
to Heating). heater over-temp thermostat circuit.
6. Software interlocks active (e.g. Refer to software setting at Level 2 (or

Dehum disabled due to low Advance Setting) -> Dehum. On/Off
temperature).
(D) High Temperature 1. Control function incorrect Check setpoints and operational
Indication operation. parameters. Reset if necessary. See
Section (C).
2. Condenser not operating. See Fault Finding: Direct Expansion
Systems.
3. Filters blocked or other airflow See Section (I).
restrictions.
- 45 -

(E) Low Temperature 1. Control function incorrect operation. Check setpoints and operational
Indication parameters. Reset if necessary. See
Section (C).
2. Filters blocked or other airflow See Section (I).
restrictions.
3. Failure of electric heater(s).

See Fault Finding: Electric Heaters.
(F) High Humidity 1. Control function incorrect operation. Check setpoints and operational
Section (C).
2. Too much fresh air input, Check fresh air quantity.
particularly in summer months.
3. Condenser not operating See Fault Finding: Direct Expansion

Systems.
(G) Low Humidity 1. Control function incorrect operation. Check setpoints and operational
Section (C).
2. Humidifier fault.
See Fault Finding: Humidifier.
3. Low airflow.
See Section (I).
(H) High Airflow 1. Filters left out or damaged. Replace and investigate cause if
damaged.
2. Fan speed too high. Check speed against original
commissioning data.
(I) Low Airflow 1. Filters blocked. Replace. Check operation of Filter
Differential pressure switch and Filter
Blocked alarm.
2. Fan(s) running backwards. Check direction of fan and change 2
phases of the fan supply.
6.5 Electric Heater

Room Temp. 1. Faulty sensor. Check operation and if faulty, replace it.
not as required
2. Faulty controller. See Fault Finding: Air Handling Unit
section.
3. Air circulation poor. See Fault Finding: Air Handling Unit
section.
4. Faulty heater relay / contactor. Check operation and if faulty, replace it.
5. Faulty heaters. Check power supply to heaters.

Check resistance of heaters.
Check heater insulation.
6. Faulty Klixon (over-temperature Check operation and if faulty, replace it.
thermostats)
7. Sensor Calibration setting Check Sensor calibration at Level 2.

incorrect.
- 46 -
6.6 Humidifier Control System
The trouble shooting tables have been prepared in logical sequence, with the most likely faults
first.
Generally speaking electrical problems are more frequent than mechanical therefore it is
suggested that an electrician is first on most fault finding problems. Ensure that the persons
fault findings are competent in attending to all aspects of the equipment and that they know the
location of all items of plant.
Remember that due to the psychrometric relationship between temperature and humidity, high
temperature and low humidity or low temperature and high humidity can occur simultaneously.
In such cases, resolve the temperature problem first as it will probably rectify the humidity
problem.

(A) Main MCB 1. Cylinder damage (shorted Test with meter. Should read infinity between
tripped when electrode). electrodes when bottle is empty.
initially
switched on
(B) Water in 1. Control MCB tripped. Clear fault and reset.
cylinder,
contactor in,
but will not
produce
steam
(C) Humidity 1. Water not available at cylinder. (a) Check all stop cocks in water supply line
demand, but ±open them if closed.
cylinder not 2. Water available, cylinder not (b) Check strainer and clean if necessary.
filling filling (c) Check operation of solenoid and coil.
(d) Renew coil or control board as necessary.
(e) Solenoid valve jammed. Replace solenoid.
(f) Water pressure over 8 bar (116 psig). Reduce
to 8 bar.
3. Water on floor Alarm disables Drain valve leaking, clean or replace.
humidification cycle. Check cause of alarm. Action as necessary.
(D) Cylinder 1. Low conductivity due to:
operating at (a) Output setting not correct. Set correctly.
low current or (see Software Level 2 or
output Advance Setting) Allow to operate to bring up conductivity. In
(b) Conductivity has not risen extreme cases decrease steam output in
enough due to new bottle or Software Level 2 (or Advance Setting) until
service. conductivity has been increased.
Clean or renew.
(c) Drain valve leaking.
Change cylinder.
2. Cylinder nearing end of life.
(E) Cylinder 1. High conductivity due to (a) Check drain and drain manifold - clean if
operating at inadequate draining. required.
high current (b) Check drain valve, clean or replace
- 47 -

(F) High Room 1. Faulty sensor. Check operation or replace.
Humidity 2. Humidifier permanently on. (a) Humidity sensor faulty.
(b) Humidifier relay or contactor jammed.
Replace if necessary.
(c) Humidifier output has been set to Manual On.
Set it to auto mode.
3. Dehum cycle not operative. Check control system.
(G) Low Room 1. Faulty sensor. Check operation or replace.
Humidity 2. Faulty humidifier. (a) Check (A) - (C) in section (F)
(b) Check operation and replace as required.
3. Humidity output is in Manual Off Set Humidify output to AUTO. (Software level 2
position. or Advance Setting ± Forced output)
(H) High Humidity 1. Control function incorrect Check setpoints and operational parameters.
Indication operation. Reset if necessary.
2. Too much fresh air input, Check fresh air quantity.
particularly in summer months. See Fault Finding: Direct Expansion Systems.
3. Condensing Unit / Condenser not
operating.
(J) Low Humidity 1. Control function incorrect Check setpoints and operational parameters.
Indication operation. Reset if necessary.
2. Low airflow. See 6.4 Air Handling Unit Fault Finding.
(K) Water 1. Steam output setting too high. Check humidifier steam output setting in
carry-over Software Level 2 or Advance Setting.
from
Humidifier
sparge pipe
(L) Humidity 1. Humidifier and heater interlock Ensure that this is not a design feature before
demand but enabled. disabling interlocks in Software Level 2 (or
Humidifier not Advance Setting) ± Humidify Control.
working
- 48 -
6.7 Direct Expansion System

(A) Compressor 1. Loss of refrigerant charge. Repair leak and recharge system. Evacuate
will not start or if replacing total charge.
tripped
2. HP / LP pressure switch(es) Attach gauges, reset then watch for fault.
activated.
3. Seized compressor. Replace compressor and ensure cause is

thoroughly investigated.
4. Overload tripped. Reset and watch for further tripping. If so,

investigate and rectify cause.
5. Burnt out compressor motor. Replace compressor. If burnt out, follow burn
out procedure using drier in suction line and
always replace compressor contactor.
Investigate cause.
6. MCB in OFF" position. Check why isolator turned off/tripped. If no

apparent or obvious reason, turn on.
7. Set to "Manual - OFF" in Reset to "AUTO" position.

Software Level 2 (or Advance
Setting) ± Forced Output
(B) Noisy 1. Lack of oil. (a) Repair leaks if any and add oil.
Compressor Remember, too much oil is as bad as too
little.
(b) If no significant leaks, pump down system
to recover oil from evaporator -
investigate cause.
2. Compressor pumping liquid. Possibly low superheat or expansion valve

stuck open. Ensure NTC sensor (or sensing
bulb for TXV) for suction temperature is tight
on suction line (evaporator outlet). Check the
superheat.
3. Broken or damaged valves. Replace compressor.
4. Worn or scored compressor Replace compressor.

bearings.
5. Scroll compressor wrong Check that current drawn is not substantially

rotational direction down on tabulated data (see Wiring
Diagram), if so then check power phasing to
compressor motor terminals and correct as
necessary.
- 49 -

(C) High Head 1. Blocked or dirty condenser fins. Remove debris and clean fins.
Pressure
(air-cooled 2. Head pressure control at Check operation of pressure switch or fan
system) condenser unit fan not operating. speed controller - adjust or replace.
3. Condenser fan not operating or Check capacitor and repair or replace. Also
operating inefficiently. check blades and change if required.
4. Air or other non-condensable gas Evacuate system and recharge. Install new
in system. drier.
5. Overcharge of refrigerant. Remove excess from system.

(D) Low Head 1. Faulty fan motor control. (a) Check operation of pressure switch and
Pressure change or adjust.
(air-cooled (b) Check operation of fan speed controller
system) and replace if faulty.
2. Fan operating too fast in low Adjust fan speed controller or replace if
ambient conditions faulty.
(E) Suction 1. Low airflow across evaporator

Pressure too due to:
low (a) Dirty filters. Replace.
(b) Broken or slipping fan belts. Replace or tighten.
(c) Faulty fan motor or capacitor. Inspect and rectify the motors and replace it
if necessary.
2. Insufficient refrigerant charge Investigate for leaks, repair if necessary and

(bubbles in sight glass). recharge system.
3. Clogged liquid line components Inspect components along liquid line by

observation. If there is a great temperature
difference before and after the component,
possibility the component has clogged and
need replacement.
4. Faulty expansion valve. Inspect and replace if necessary.
5. Pressure transducer shows Replace pressure transducer.

inaccurate reading.
6. Dirty or freezing coil. Clean and / or de-frost coil. Investigate

reasons for icing.
(F) Suction 1. Excessive load on evaporator. Operate standby unit(s) if possible.
pressure too
high 2. Broken or damaged valves. Replace compressor.
3. Expansion valve passing too Check NTC sensor & pressure transducer (or
much refrigerant. sensing bulb for TXV) is securely fastened.
Check superheat. For EEV, check whether
valve respond to manual override.
4. Overcharge of refrigerant. Remove excess charge.
- 50 -

(G) High Head 1. Faulty water supply. (a) Condenser water too warm.
Pressure (b) Insufficient condenser water.
(water-cooled (c) Faulty control valve (if fitted)
system)
2. Scaled or blocked condenser. Flush system.
3. Air or other non-condensable gas Evacuate system and recharge. Install new
in system. drier.
4. Overcharge of refrigerant. Reclaim excess refrigerant from system.

(H) Low Head 1. Faulty water supply. (a) Condenser water too cool.
Pressure (b) Faulty control valve (if fitted).
(water-cooled
system)
6.8 Chilled Water System

(A) High Water 1. Chiller thermostat set too high. Check calibration and reset. Check
Temperature control system and setpoints.
2. Mixing valve malfunction. Re-calibrate, repair or replace.
3. Chiller tripped. Investigate and rectify

(B) Low Water 1. Chiller thermostat set too low. Check calibration and reset. Check
Temperature control system and setpoints.
2. Mixing valve malfunction. Re-calibrate, repair or replace.

(C) High System 1. Vent pipe isolated. Check vent valve is fully open.
Pressure
(D) Low System 1. Leaks in System. Visually check and if not immediately
Pressure evident pressure test and then repair.
(E) Circulation Too High 1. System out of balance. Check system balancing valves against
commissioning details - rebalance if
required.
(F) Circulation Too Low 1. System out of balance or valves (a) Ensure all shut-off valves are fully
closed / partially closed. open.
(b) As Section (E) ± 1
2. Air in System. Vent. For repeated problems -

investigate.
3. Pipework blockage. Investigate by taking spot temperature

and/or pressure readings. After finding
cut out / disconnect appropriate section
and renew.
4. Pump developing insufficient duty Check pressure drop across pumps and
compare with commissioning data.
- 51 -
᧪UNIT DIMENSION & WEIGHT

7᧪
ES Range ± Standard Compressor
Model 5 12 15 20 25 30 35 40
Weights (kg): Version A 165 255 290 295 315 340 345 405
Weights (kg): Version W 175 270 298 305 325 353 361 420
Model 45 50 60 70 80 90 100
Weights (kg): Version A 410 415 600 615 620 730 735
Weights (kg): Version W 425 443 630 645 650 760 791
- 52 -
ES Range - DC Inverter Compressor
Model 20 25 30 35 40 45 60 70 80 90
Weights (kg): Version A 315 316 345 360 424 425 612 620 622 730
Weights (kg): Version W 327 331 358 376 440 441 638 646 654 762
- 53 -
EC Range
Model 25 30 50 60 70 80 95 110 125 135 150
Weight (kg) 255 285 345 455 535 570 785 850 890 935 980
- 54 -
ECL Range
Model 70 80 125 140 180 200
Weight (kg): 375 395 615 645 855 900
- 55 -
EH Range ³$:9HUVLRQ´
Model 60 70 85 95
Weights (kg): Version A 802 898 1010 1098
Weights (kg): Version W 817 918 1030 1128
- 56 -
EH Range ³&9HUVLRQ´
Model 60 70 85 95
Weights (kg) 535 625 885 965
- 57 -
- 58 -
Version
Version3.1/2016/GVIOM
3 3/2016/GVDX

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Precision Ⴠ Efficient Ⴠ Innovation

An Approved Code of Practice HS(G) 70 "The prevention or control of legionellosis, including

2.1 Site Preparation

2.1.1 Air Distribution

Note: Min. 300mm Min. 400mm

Please perform CFD computations for the site if in doubt.

2.2 Receiving the Equipment

2.2.2 Off Loading & Lifting

2.3 Noise Consideration

In order to reduce these problems, the following measures are suggested,

3.1 Installation Illustration

3.1.2 Water-cooled System

1. Condenser water supply pipe

3.2 Unit Positioning

3.2.1 Unit Leveling

Gasket at the side

3.2.2 Lowering Underfloor EC Fan into Position

3.3 Refrigerant Pipework

3.3.1 Refrigerant Pipes

ES Range ± Standard Compressor

Recommended Discharge Pipe Sizes (R22/R407C)

Equi. Length Circ. 1 1 1 1 1 1 1 1

Horz 1/2" 3/4" 3/4" 7/8" 7/8" 7/8" 1 1/8" 1 1/8"

Horz 1/2" 3/4" 7/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

Horz 1/2" 3/4" 7/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

Horz 1/2" 3/4" 7/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

Equi. Length Circ. 1 1 1,2 1,2 1,2 1,2 1,2

20m All 1 1/8" 1 1/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

30m All 1 1/8" 1 1/8" 7/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

Horz 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

Horz 1 1/8" 1 3/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 3/8"

Horz 1 3/8" 1 3/8" 1 1/8" 1 1/8" 1 1/8" 1 3/8" 1 3/8"

Recommended Liquid Pipe Sizes (R22/R407C)

Equi. Length Circ. 1 1 1 1 1 1 1 1

Equi. Length Circ. 1 1 1,2 1,2 1,2 1,2 1,2

20m All 3/4" 3/4" 5/8" 5/8" 5/8" 3/4" 3/4"

30m All 3/4" 3/4" 5/8" 5/8" 3/4" 3/4" 3/4"

40m All 3/4" 3/4" 5/8" 3/4" 3/4" 3/4" 3/4"

50m All 7/8" 7/8" 3/4" 3/4" 3/4" 7/8" 7/8"

60m All 7/8" 7/8" 3/4" 3/4" 3/4" 7/8" 7/8"

ES Range ± DC Inverter Compressor

Required Tube Wall Thickness for R410A System:

Recommended Discharge Pipe Size

30m All ´ 1 1/8" 1 1/8" 1 1/8"

Hor. 1 1/8" 1 1/8" 1 1/8" 1 1/8"

Hor. 1 1/8" 1 1/8" 1 1/8" 1 3/8"

Hor. 1 1/8" 1 1/8" 1 1/8" 1 3/8"

Hor. 1 1/8" 1 1/8" 1 3/8" 1 3/8"

Recommended Liquid Pipe Size

20m All 5/8" 5/8" 3/4" 3/4"

30m All 5/8" 3/4" 3/4" 3/4"

40m All 3/4" 3/4" 3/4" 3/4"

50m All 3/4" 3/4" 3/4" 7/8"

60m All 3/4" 3/4" 7/8" 7/8"

70m All 3/4" 7/8" 7/8" 7/8"

3.3.2 Refrigerant Pipe Installation

3.3.3 Leak Test

3.3.4 Refrigerant Charge

Approximate R22 And R407C Refrigerant Charges烉

³$´9HUVLRQ ³:´9HUVLRQ ³$´9HUVLRQ ³:´9HUVLRQ

ES Range ³$´9HUVLRQ ³:´9HUVLRQ R22/R407C/R410A

Estimated external copper pipe refrigerant charge烉

Refrigerant Charge, kg/m

30m All ´ 1 1/8" 1 1/8" 1 1/8"

´ 0.174 0.011 0.046 0.005

3.4.1 Chilled and Condenser Water Pipe Installation Guide烉烉

IMPORTANT烉烉 Ensure that segregation is maintained between control

IMPORTANT烉烉Any additional equipment installed in the unit, or supplied

5.4.3 Cylinder Replacement Procedures烉烉