Instruction For Shor Startup Cooling System 2NK6770

Glen Dimplex Deutschland GmbH Proj.
: 2NK6 770-K
Instruction
for Short Startup
454507.66.01
Cooling system water - water - air

2NK6 770-K (active)
consisting of:
Indoor unit: 2NK6 770-W
Hose set: 2NK6 770-S
External fan unit: 2NK6 770-A
Contents
1. Water side connection

1.1 Primary circuit
1.2 Secondary circuit
2. Electrical connection
2.1 External fan unit
2.2 Indoor unit
2.3 Connection of communication cable to MR-System
2.4 Adjustments on Transformer and motor protection switch
2.5 Connection of power cable to the indoor unit
3. Connecting of the He-compressor
3.1 Specifications
3.2 Compressor location
3.3 Electrical supply connection
3.4 Coolant connection
3.5 Install the HE-compressor
4. Water side filling
4.1 Primary circuit
4545076601-03 Short Instruction 2NK6 770K.doc

GDD Zeichnungsnummer: 454507.66.01 Page 1 / 21 02.02.12
Glen Dimplex Deutschland GmbH Proj.: 2NK6 770-K
1. Water side connection

Please pay attention to bending radius of hoses (see page 18)
1.1 Primary circuit
External fan unit

(side view)
From Indoor unit To Indoor unit
From
External Fan Unit
Indoor unit
(top view)
To
External Fan Unit
Front side

1.2 secondary circuits
To GC
Indoor unit
From GC
(Top view; front side)
To RFPA
From RFPA
Indoor unit
To GPA
From GPA
(Front view; left side)
To He-
compressor Indoor unit
From He-
compressor
(Inside the unit; left side)
Use only for this cooling system specified and validated hoses!

2. Electrical connection
2.1. Outdoor unit
- The connection cable ( 5-poles and ground wire ) is included in the indoor unit.
- Run the cable in parallel to the connecting hose between indoor and outdoor units.
- Please use a conduit or cable channel to protect the power supply
cable.
- Attention: Please note your local installation requirements!
- After electrical connection, the cable shall be fixed with cable ties to the fan housing.
Fixing the cable on the hoses is acceptable.
Wire labels
Terminal marking Remarks
(number on wire)
Groundig point Green-yellow
TB 4
TB 5
W2
U1 1
Connection to second fan *)
U2
V1 2
V2
W1 3
*) only by two fan variance

Connecting the cable on the external fan unit:
Number on wires 4 5 1 2 3
Connection for PE
Green/
Yellow
connection
Water side
Fixing cable with

cable ties

2.2 Connection between indoor and external fan unit

- Please use a conduit or cable channel to protect the power supply
cable.
- Attention: Please note your local installation requirements!
Wire labels
Terminal marking Remarks
(number on wire)
GNYE Green-yellow
1 1
2 2
3 3
4 4
5 5
Front view
Cable from
external fan unit
Number on wires 1 2 3 4 5 Green/

Yellow

2.3 Connection of communication cable to MR

The communication cable has to be connected to the printed circuit board location in the
electronic box.
The cover of the electronic box must be dismounted.
Connection of
communication cable
Communication cable
Cable feed through

2.4. Adjustments on Transformer and motor protection switch

This adjustment is necessary, because the unit is suitable for 400V / 50Hz and 480V / 60
Hz.
The cover of the electronic box must be dismounted.
Motor protection switch Q2 und Q3 must be adjusted.
400V / 50Hz 480V / 60Hz Comment

Q2 2.6A 2.6A Secondary pump
Q3 2.6A 2.6A Primary pump
The jumper on the transformer must be placed.

400V / 50Hz 480V / 60Hz
Position 3 4
See also pictures below!
Q2 Q3 Transformer

Adjustment on Transformer
Jumper
(not connected)
400V / 50Hz 480V / 60Hz

Position of Jumper
Adjustment on motor protection switch Q2 and Q3
480V
60Hz
400V 2,6A 2,6A
50Hz

2.5. Connection of the power cable to the indoor unit
Entry of power cable Terminal connecting

from below
PE, L1, L2, L3

3. Connecting of the He-compressor

Instruction manual of Helium Compressor
3.1. Specifications
Figure 1 F-70H and F-70L Compressors, Front View

3.2 Compressor Location
Place the compressor in a location that is protected from the elements and
where the ambient temperature will always be within the range of 4° C to 40° C
(40° F to 104° F). The compressor must be installed base down, within 5
degrees of horizontal, and preferably at a height convenient for making
connections and reading the pressure gauge. Allow 600-mm (24”) space in front
of the compressor for access to electrical, water and gas connections.
The whole compressor is to be fixed by two screw in the front side of
compressor (Fig. 2).
Figure 2 F-70H Compressors location

3.3 Electrical Supply Connection
Please see Fig. 3
The F-70 compressor must be installed in a circuit capable of supplying the

specified voltage and power. The wiring method used for connection to the front
panel power connector must meet applicable codes.
1X5
Figure 3: Connect Mains Power Supply Cable to Mains Power

Receptacle

3.4 Coolant Connections
Open-end wrench to suit customer’s water lines fittings

Using two wrenches connect coolant supply and return lines to the water in and
water out fittings on the front of the compressor. See Fig. 4. Ensure that the
Water In connection is connected to the supply line from the user’s cooling
water or coolant supply. Turn on the coolant and check the water lines for leaks.
Tighten the fittings if necessary. See Specifications for cooling requirements.
Figure 4 Connect and Remove the Water Lines
PREVENT EQUIPMENT DAMAGE. Always thoroughly drain the

coolant from the cooling circuit if the compressor is to be shipped
or stored.

3.5. Install the Helium Lines
Tool required: Open-end wrenches, 1", 1 1/8", 1 3/16"

Helium lines are shipped with protective dust plugs. Do not remove the plugs until the
helium lines are ready to be attached. All bending and routing of helium lines should
take place with plugs in place. See Fig:5
Figure 5 Connect and Remove the helium Lines

4. Water side filling

Attention see 1. Water side connection
Secondary circuit Primary circuit
2
5
4
5
1 3
2
1 Filling and draining valve (Flushing option)
2 Filling and draining valve
3 Ball valve main branch
1
3 4 Pressure gauge
5 Air bleeder
4.1 Primary circuit

After assembling all connections between indoor and external fan unit and
closing of all filling and draining valves, the system can be filled by performing
the following steps:
Only the glycol - water mixture of mixing ratio 40 % glycol / 60 % water (scope of
delivery) has been used for the filling of primary circuit, otherwise warranty
expires.
Check, if all the filling/draining valves and the ball valve in the
01
main branch (3) are closed. If not close the valves.
Fill the contents of the containers into the filler device
02
(pressurizing station; not scope of delivery).
Connect the hose of the filler device to the filling and draining
03
valve (2).
Open the filling and draining valve (2) and the valve for flushing
option (1).
Attention: Connect the filling and draining
04 valve for flushing option (1) to a pan by
using a lucent hose in order to collect the
escaping liquid. Do not discharge the glycol
mixture into the sewage.
Activate the filler device and fill the system till the liquid that
05 escapes from the hose connected to the filling and draining valve
(1) is free of air (only pure glycol mixture escapes)
If only glycol mixture escapes from the valve (1) close this valve
06
and open the ball valve in the main branch (3)
Fill the system up to a filling pressure of about 2,6 bar (see
07 pressure gauge (4) ) then turn off the filler device (air bleeder
vents the system (5) ).
08 Close the filling and draining valve and turn off the filler device.
Watch the filling pressure about 10 min and check the system for
leakage. If the pressure is reducing (see pressure gauge) and no
leakage is visible is this because of the air in the system that
escapes through the air bleeder (5)
09 Attention: If pressure is reducing please
open the filling and draining valve (2) again
and raise the pressure up to about 2.6 bar.
Repeat this action till the pressure of the
system is constant for about 10min.
Connect the hose to the filling and draining valve (2) and put the
10 open end in a pail or container. Do not discharge the glycol
mixture into the sewage.
Open the filling and draining valve to reduce the filling pressure
11
of the system to 1,7 bar while watching the pressure gauge (4).
12 Close the filling and draining valve (2).
Close the filling and draining valve and Check the system
pressure while pump is running. If pressure in operation mode is
13 lower than about 4bar (see pressure gauge on high pressure side
of pump) turn off the pump and fill the circuit again by using the
filler device (open filling and draining valve before)
15 Disconnect the hose and make a final visible inspection.
Open the vent screw of the pump till only liquid

escapes, before putting the pump into operation!
Be aware that the filling procedure is done as
described so that pump can not run dry.
Check pressure level of pump (high pressure side) if
pressure is still about 4bar.
Put the cooling system into operation only after the
installation of the MR is completed.
Do not discharge Glycol-mixtures into the sewage.
Attention
Put the system in operation only after
installation is completed
After starting the system, watch the pressure

gauge of ICS for checking the pressure

After completion of all connections between indoor unit and MR and closing of all
filling and draining valves fill the system by performing the following steps:
Check, if all the filling/draining valves and the ball valve in the
01
main branch (3) are closed. If not close the valves.
Fill the contents of the containers into the filler device
02
(pressurizing station; not scope of delivery).
Connect the hose of the filler device to the filling and draining
03
valve (2).
Open the filling and draining valve (2) and the valve for flushing
option (1).
Attention: Connect the filling and draining
04 valve for flushing option (1) to a pan or
sewage by using a lucent hose in order to
collect the escaping liquid.
Activate the filler device and fill the system till the water that
05 escapes from the hose connected to the filling and draining valve
(1) is free of air (only pure water escapes)
If only pure water escapes from the valve (1) close this valve and
06
open the ball valve in the main branch (3)
Fill the system up to a filling pressure of about 2,6 bar (see
07 pressure gauge (4) ) then turn off the filler device (air bleeder
vents the system (5) ).
08 Close the filling and draining valve and turn off the filler device.
Watch the filling pressure about 10 min and check the system for
leakage. If the pressure is reducing (see pressure gauge) and no
leakage is visible is this because of the air in the system that
escapes through the air bleeder (5)
09 Attention: If pressure is reducing please
open the filling and draining valve (2) again
and raise the pressure up to about 2.6 bar.
Repeat this action till the pressure of the
system is constant for about 10min.
Connect the hose to the filling and draining valve (2) and put the
10
open end in a pail or container.
Open the filling and draining valve to reduce the filling pressure
11
of the system to 1,7 bar while watching the pressure gauge (4).
12 Close the filling and draining valve (2).

Close the filling and draining valve and Check the system
pressure while pump is running. If pressure in operation mode is
13 lower than about 4bar (see pressure gauge on high pressure side
of pump) turn off the pump and fill the circuit again by using the
filler device (open filling and draining valve before)
14 Disconnect the hose and make a final visible inspection.
Open the vent screw of the pump till only liquid

escapes, before putting the pump into operation!
Be aware that the filling procedure is done as
described so that pump can not run dry.
Check pressure level of pump (high pressure side) if
pressure is still about 4bar.
Put the cooling system into operation only after the
installation of the MR is completed.
Do not discharge Glycol-mixtures into the sewage.
Attention
Put the system in operation only after
installation is completed
After starting the system, watch the pressure

gauge of ICS for checking the pressure

5. Bending radius
The bending radius has to be greater then the following:
Naming 2NK6 770 (active) 2NK6 771 (passive)

[ mm ] [ mm ]
Primary circuit > 300 > 220
RFPA > 130
He - compressor > 120
GC / Filter plate > 180
Attention!
Put the cooling system into operation only after the installation of the MR is
completed.
After startup watch the pressure gauge and refill the respective circuit in case of
declining the system pressure.
End of Instructions
Distribution list: 1 - 9 - 17 - 18 - 22 - 25
Index Änderung Datum Name Index Änderung Datum Name
02 8949 21.01.2009 PG
01 filling/draining valves 22.01.2008 NMI
and filling pressure
- WPK52/07 17.12.07 PG 03 9509 17.01.12 RT


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Glen Dimplex Deutschland GmbH Proj.

Cooling system water - water - air

1. Water side connection

4545076601-03 Short Instruction 2NK6 770K.doc

1. Water side connection

External fan unit

From Indoor unit To Indoor unit

4545076601-03 Short Instruction 2NK6 770K.doc

1.2 secondary circuits

(Top view; front side)

(Inside the unit; left side)

4545076601-03 Short Instruction 2NK6 770K.doc

*) only by two fan variance

4545076601-03 Short Instruction 2NK6 770K.doc

Connecting the cable on the external fan unit:

Fixing cable with

4545076601-03 Short Instruction 2NK6 770K.doc

2.2 Connection between indoor and external fan unit

Number on wires 1 2 3 4 5 Green/

4545076601-03 Short Instruction 2NK6 770K.doc

2.3 Connection of communication cable to MR

The cover of the electronic box must be dismounted.

Cable feed through

4545076601-03 Short Instruction 2NK6 770K.doc

2.4. Adjustments on Transformer and motor protection switch

The cover of the electronic box must be dismounted.

Motor protection switch Q2 und Q3 must be adjusted.

400V / 50Hz 480V / 60Hz Comment

The jumper on the transformer must be placed.

See also pictures below!

4545076601-03 Short Instruction 2NK6 770K.doc

400V / 50Hz 480V / 60Hz

Adjustment on motor protection switch Q2 and Q3

4545076601-03 Short Instruction 2NK6 770K.doc

2.5. Connection of the power cable to the indoor unit

Entry of power cable Terminal connecting

4545076601-03 Short Instruction 2NK6 770K.doc

3. Connecting of the He-compressor

Figure 1 F-70H and F-70L Compressors, Front View

4545076601-03 Short Instruction 2NK6 770K.doc

3.2 Compressor Location

Figure 2 F-70H Compressors location

4545076601-03 Short Instruction 2NK6 770K.doc

3.3 Electrical Supply Connection

Please see Fig. 3

The F-70 compressor must be installed in a circuit capable of supplying the

Figure 3: Connect Mains Power Supply Cable to Mains Power

4545076601-03 Short Instruction 2NK6 770K.doc

3.4 Coolant Connections

Open-end wrench to suit customer’s water lines fittings

Figure 4 Connect and Remove the Water Lines

PREVENT EQUIPMENT DAMAGE. Always thoroughly drain the

4545076601-03 Short Instruction 2NK6 770K.doc

3.5. Install the Helium Lines

Tool required: Open-end wrenches, 1", 1 1/8", 1 3/16"

Figure 5 Connect and Remove the helium Lines

4545076601-03 Short Instruction 2NK6 770K.doc

4. Water side filling

4.1 Primary circuit

Open the vent screw of the pump till only liquid

After starting the system, watch the pressure

4545076601-03 Short Instruction 2NK6 770K.doc

4.2 Secondary circuit