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TM006: COOLflow4E Force Installation Manual - Fan and Filter

48V DC

Contents:

CTIL COOLflow4E Force Installation Manual – Fan and Filter 48v

Revision History:

Revision 0: Initial Release

www.4energy.co.uk © 4energy Ltd. 2013

COOLflow4E Force Installation

Fan and Filter

48V DC

MAY 2015 TM006

4energy Data- Commercial in Confidence: Confidential

As innovation is our priority, the company reserves the right

to alter the specification at any time without prior notice.

2 of 46 www.4energy.co.uk © 4energy Ltd. 2013

Document Revision History

Ref Title Date Status Change/Approver

TM006

CTIL

COOLflow4E

Force

Installation

Guide

12/05/15 Issue 1

(Revision 0) Stuart Nicholson (author)

Approval Date Status Approver

Pending

© 4energy Ltd. 2013 www.4energy.co.uk 3 of 46

Contents

1. Overview ........................................................................................................... 5

2. Health and Safety ..............................................................................................6

3. Preparation ...................................................................................................... 8

Tools Required for Installation ................................................................................................................. 9

Documentation Requirements for Installation ......................................................................................... 9

Isolate the Power Supply in the Equipment room .................................................................................... 9

Decommission the Existing Cooling System (Where Applicable) ........................................................... 10

Locate a Suitable Position for the COOLflow4E Force Unit ..................................................................... 12

Remove the Filters ................................................................................................................................ 12

4. Install COOLflow4E Force Fan and Filter Unit ...................................................... 13

Cut a Fan Hole in the Equipment Room Wall ......................................................................................... 14

Fit the COOLflow4E Unit and Earth Bonding .......................................................................................... 16

Fit the Filter Module & Sensors ............................................................................................................... 17

Fit the Fan Grille .................................................................................................................................... 18

Fit the Exit Vent(s) ................................................................................................................................. 19

5. Install the eController ....................................................................................... 20

6. Fit the Sensors ................................................................................................. 22

7. Wire the eController to the 48V DC Fan ............................................................. 23

8. Wire the eController to the DC Power Supply ..................................................... 24

9. Wire the eController to an Alarm System ........................................................... 26

10. Commission the eController .............................................................................. 28

Configuration Test ................................................................................................................................ 28

Re-Configure the eController ................................................................................................................ 29

Sensor Test ............................................................................................................................................ 31

Fan Speed Test ....................................................................................................................................... 31

Log Out .................................................................................................................................................. 31

Appendices ............................................................................................................ 33

A.1 Site Specific Settings..................................................................................................................... 34

A.2 Site-Specific Documentation Requirements ................................................................................... 35

A.3 eController Specification ............................................................................................................... 36

A.4 Connections on the eController ...................................................................................................... 37


A.5 COOLflow4E Force Drawings ......................................................................................................... 39

A.6 Wiring Colour Schemes ................................................................................................................. 42

A.7 Wiring Diagrams ........................................................................................................................... 42


1. Overview

Welcome to the Quick Reference COOLflow4E Force Installation Guide. This document provides a brief

overview of the installation process for COOLflow4E Force units that are installed on the outside of an

equipment room.

Future updates will include information on internal installs.

Please work through the sections of this guide in order:

1. Preparation (see page 8).

2. Install COOLflow4E Force Fan and Filter (see page 13).

3. Install the eController (see page 20).

4. Fit the Sensors (see page 22).

5. Wire the eController to the 48V DC Fan (see page 23).

6. Wire the eController to an Alarm System (see page 26).

7. Wire the eController to the DC Power Supply (see page 24).

8. Commission the eController (see page 28).


2. Health and Safety

4energy take the health and safety of staff and customers very seriously. All 4energy manufacturing and

installation staff are required to complete health and safety training and must follow safe working practices.

All works are to be carried out in accordance with current legislation including, but not limited to:

Health & Safety At Work Act 1974 (statutory)

Electricity At Work Act 1989 (statutory)

The Construction (Design and Management) Regulations 2007

Current Building Regulations (under powers provided in the Building Act 1984)

IET Wiring Regulations (BS 7671 – 17th edition IEE wiring regulations)

IET Guidance Notes 1 through to 7 inclusive plus IEE Code Of Practice - In Service Installation & Test , Electrical Maintenance and On Site Guide

BS EN 62305:2006 (All Sections – Protection Against Lightening)

BS EN 61857:2009 (All Sections – Electrical Insulation Systems)

BS 6423:1983 (Electrical switchgear and control gear of voltages up to 650 volts)

BS EN 61537:2007 (Cable management - Cable tray systems and cable ladder systems)

BS EN 1362 – Specification for General Purpose Fuse Links for Domestic & Similar Purposes

BS EN 60309-2 – Specification for Industrial Plugs, Socket-outlets and Couplers for AC and DC Supplies

BS EN 50085-1:2005 (Cable trunking systems and cable ducting systems for electrical installations.

General requirements (AMD Corrigendum 17252)

BS EN 5588-9:1999 – (Fire precautions in the design, construction and use of buildings. Code of practice

for ventilation and air conditioning ductwork (AMD 14993) (No longer current but cited in the Building

Regulations))

Health & Safety Executive Guidance Notes (non-statutory)

BS EN 61010 -1: 2001 – Safety requirements for electrical equipment for measurement, control, and

laboratory use

BS EN 61326 – Electrical equipment for measurement, control and laboratory use. EMC requirements

BS EN 60439 – Low voltage switchgear and control gear

BS EN 61558 – Power transformers, assemblies, power supply units and similar

NRASWA (New Roads and Street Works Act) Code of Practice

BS 5720:1979 – (Code of practice for mechanical ventilation and air conditioning in buildings (No longer

current but cited in Building Regulations))

HSE '6 pack' of legislation (latest issues):


L21 Management of Health and Safety at Work. (0717624889)

L22 Safe Use of Work Equipment. (9780717662951)

L23 Manual Handling. (071762823X)

L24 Workplace Health, Safety and Welfare. (0717604136)

L25 Personal Protective Equipment at Work. (0717661393)

L26 Work with display screen equipment. (0717625826)

HSE Guidance Note: GS38 Electrical test equipment for use by electricians

RIDDOR – The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995.


3. Preparation

Before you install the COOLflow4E Force unit, make sure that you are wearing the correct PPE, have the

appropriate tools for the job, and that the equipment room is clear of any obstacles.

You can then complete these sections, in order:

1. Conduct a risk assessment of the site. You should only begin the installation process if the COOLflow4E

system can be installed safely and appropriately.

2. Make sure you have the Tools Required for Installation (see page 9) and are aware of the Documentation

(see page 9).

3. Isolate the Power Supply in the Equipment room (see page 9).

4. Decommission the Existing Cooling System (Where Applicable) (see page 10).

5. Locate a Suitable Position for the COOLflow4E Force Unit (see page 12).


Tools Required for Installation

You will need to use the following tools to install the COOLflow4E Force system:

18v Battery drill and drill bits (10mm & 5mm)

Spirit level

Pen/Pencil

Aluminium tape

File

Hacksaw

18v Battery jigsaw and metal blades (Bosch T118A recommended)

Insulated screwdriver

Insulated pliers

Crimping tools and cable cutters (for wiring)

IDC termination tool (for wiring to an external alarm system)

Multi-function tester (Megger MFT 1720 recommended)

You also need various fixings and sealants for the COOLflow4E unit.

Documentation Requirements for Installation

As part of the installation process, you may need to complete various forms, for example, you may need to

complete a Duty of Care Waste Disposal form. The documentation that is required varies, depending on the

policy and regulations in place at the site (and country).

For details on the documentation required for your specific install, see Appendix A.2 Site-Specific

Documentation Requirements on page 35.

Isolate the Power Supply in the Equipment room

To install a COOLflow4E Force system, you will ALWAYS need to isolate the power supply, ensure that it s locked off and the circuit has been proved dead. Prior to any works commencing.


Decommission the Existing Cooling System (Where Applicable)

If the site has an existing cooling system, you will need to remove it before you can install a COOLflow4E Force

Fan and Filter. Prior to any decommissioning of the existing system, the supply should be isolated, locked off

and proven dead. Before proceeding with the following steps:

6. Identify the type of cooling system to be decommissioned:

Split air conditioning

Packaged system, for example, Airedale

Free-air only, for example, 4Energy DAC MK1.

When you identify the type of cooling system, you will be able to determine if refrigerants need to be

removed.

7. Decommission the cooling system by following the relevant Method Statement for the site/type of

system.

8. If the cooling system uses refrigerant, you will need to reclaim the refrigerant before opening the pipes

and removing the system.

WARNING. Wear safety goggles and gloves when decommissioning

air conditioning systems. Exposure to refrigerants can cause physical

harm.

WARNING. Air conditioning systems should only be decommissioned

by FGas registered refrigeration engineers (or local equivalent outside

UK). Incorrect decommissioning of refrigerant systems could result in

equipment damage or failure, injury or death.

WARNING. You must lock off/Isolate the electrical supply and fix an

isolation warning label to the distribution board or point of isolation.

This is to ensure that the supply cannot be re-energised during the

decommissioning process.


9. Repair any holes that are left in the equipment room as a result of removing the air conditioning system.

To make the repairs on a metal or GRP site, rivet each screw hole and fix pre-cut metal plates over any

pipe holes. Use small-head 5mm rivets for both types of repair. From outside the equipment room, fit

the metal plate so that the coated side is facing you. When fitting a metal plate from inside the cabin,

turn the plate around so that the uncoated side is facing you. Once secured, a silicone seal should be

applied around the edge of the plates, to provide a waterproof seal.

To make the repairs on a brick site, use mortar to fill in the holes. Mix the mortar according to the

mortar manufacturer's instructions and use a trowel to apply the mortar to the wall.

10. If the existing air conditioning system had any fittings, such as condenser bolts, brackets or cages,

remove them. All decommissioned equipment and associated fixings, must be removed from site. Thus

eliminating potential hazards.

11. Prepare the cooling system for removal from site, in accordance with the Method Statement for the

site.

12. Complete any required documentation (waste disposal forms, etc.). For details, see Appendix A.2 Site-

Specific Documentation Requirements, on page 35.

Uncoated Coated


Locate a Suitable Position for the COOLflow4E Force Unit

You need to position the COOLflow4E Force unit so that it is on a clear section of the equipment room wall,

where there is enough room for a complete COOLflow4E Force. If you are fitting a COOLflow4E Force Fan and

Filter, you should still allow enough space for the larger COOLflow4E Full System as this will make it easier to

upgrade in the future. The CTIL cooling calculator / Survey document, should also be adhered to when

positioning the system.

Ideally, you should aim for a total space of 2m. The COOLflow4E Force Fan and Filter unit needs a minimum of

0.3m space below the filter module, and the Fan and Filter unit is approximately 1.55m in height.

You also need to consider:

Is there enough space for the eController? The eController needs to be installed inside the equipment

room and has to be wired to the power supply, the fan, and any other systems or devices (alarm systems,

actuators, etc.). We recommend that you position the eController above the COOLflow4E Force fan or to

the side of it.

Are there struts or supports in the equipment room wall? In metal and GRP equipment rooms, it is

possible to saw through the struts using a jigsaw, but we recommend that you avoid supports where

possible.

Where is the vent grille going to be fitted? COOLflow4E systems in the UK require two 295 x 295mm vents

to be fitted in a high position on another wall of the equipment room. For best results, the vent should be

on the opposite wall to the COOLflow4E Force unit, but in some equipment rooms can be fitted to an

adjacent wall. It should never be fitted to the same wall as the COOLflow4E Force unit. The CTIL cooling

calculator, should be taken into account during this process.

Remove the Filters

The COOLflow4E Force unit contains one maintenance free filter, which is rated to F7 standard. You need to

remove this filter before you install the unit, so that you can reach inside and secure the fixings.


4. Install COOLflow4E Force Fan and Filter Unit

To install a COOLflow4E Force unit on an external wall of an equipment room, complete the following sections

in order:

1. Cut a Fan Hole in the Equipment Room Wall (see page 14).

2. Fit the COOLflow4E unit and Earth Bonding (see page16).

3. Fit the Filter Modules (see page 17).

4. Fit the Fan Grille (see page 18).

5. Fit the Exit Vent(s (see page 19).


Cut a Fan Hole in the Equipment Room Wall

Use the supplied COOLflow4E Force template to create the hole in the equipment room wall. The hole is

needed for the fan.

1. From inside the equipment room, estimate the centre of the area where the COOLflow4E unit will be

positioned. From that central position, use a tape measure to measure from the floor to a height of

1000mm. Use a pencil to make a mark at 1000mm.

2. Use a spirit level and pencil to draw a level, horizontal line at 1000mm from the floor. The line should be

at least 600mm in length (300mm each side of the central mark you made in step 1).

3. Using the line you have drawn as the bottom of the rectangle, draw a rectangle that is 210mm high and

535mm wide. Use the spirit level to make sure the lines are level.

4. Use a drill with 10mm bit to drill a hole in each corner of the rectangle you have drawn. The drill holes

should be inside the rectangle and need to go all of the way through the wall of the equipment room.

5. Take the COOLflow4E Force template and remove at least two of the three cut-outs above the fan hole

cut-out. We recommend that you remove the central cut-out hole where possible. These cut-out holes

will be used for feeding the cables from the COOLflow4E Force unit into the equipment room, and the

eController should be positioned close to it (within 2m, but ideally, above or to the side of the hole).

Choose the cut-out that is in the most appropriate position in relation to the inside of the equipment

room.

6. From outside the equipment room, place the template on the wall so that the inner corners of the fan

hole cut-out align with the holes you drilled from inside. Place the template on the wall so that the fan

hole cut-out is closer to the left-hand side (as shown above).

7. Use a pen or pencil to mark the:

Inner side of the fan hole cut-out

Screw positions

Cut-out position.

8. From inside the equipment room, use an 18v jigsaw and blade to cut along the lines of the rectangle.

You should cut through the inner skin and the insulation if possible.

9. From outside the equipment room, drill out:

The cut-out for the cables

10. Cut along the edge of the fan cut-out.


For metal equipment rooms, use a jigsaw to cut along the edges of the marked cut-out area. When you

have cut along all of the edges, you can remove the cut-out.

11. Use a file to smooth down the edges of the hole.

12. Fit the metal insert provided, within the cut out. Ensuring the lip is secured to the external wall of the

cabin, using a 5mm rivet, at the centre point of each edge.

13. Apply aluminium tape around the internal edges of the hole, so that it doesn t have any sharp edges. Sharp edges could cause cables to become frayed (if they come into contact with the edges).


Fit the COOLflow4E Unit and Earth Bonding

The COOLflow4E Force unit uses a fan to draw in cool air. The rear of the fan module has an open rectangle

that should match the size of the hole you created in the equipment room wall. The rear also has three cut-

outs, which you will use to feed cables from the COOLflow4E Force unit into the equipment room. You will

need to fit a 25mm open grommet to each cable cut-out you use, so that the cable is protected from the edge

of the metal.

You also need to fit supplementary earth bonding between the base of the fan module and the main earthing

terminal in the equipment room. Following the steps below:

1. Fit self-adhesive pre-compressed seal to the rear of the COOLflow4E

unit (the side with the fan cut-out).

2. Fit M10 bolts to the upper section of the mounting holes. The bolts need

to protrude from the cabin around 5mm, to allow the unit to be hung.

While the remaining fixings are made to secure the unit to the cabin.

Once all fixings are present fully tighten the M10 bolts, to complete

hanging.

3. Inside the equipment room, fit a 25mm open grommet to the cable cut-

out hole in the wall. Do not fit a grommet on the outside of the wall.

4. Take a correctly sized length of supplementary bonding cable to reach

from the Fan Module to the main earthing terminal in the equipment room. Which must be

clipped/cable tied throughout its length.

5. Fit ring crimps to both ends of the supplementary bonding cable.

Attach it to a pre-drilled hole on the base (around which the

powder coating should be removed, exposing bare metal), of the

fan module. This should then be labelled. The supplementary

bonding should always be made, in the same location. To

maintain continuity of installation. See right.

6. Reach inside the fan module and fit a 25mm open grommet to

the cable-cut out. When pressed into position, it should cover

the edge of the cable cut-out on the fan module and the cable cut-out on the exterior wall of the

equipment room.

7. Feed the fan cables and the supplementary bonding (housed in copex) through one of the cable cut-out

hole in the equipment room wall.

8. Use tamper-proof screws or rivets to attach the rear of the fan unit to the equipment room wall. If you

are installing onto a brick or concrete wall, you will need to use wall plugs.

9. Attach the supplementary bonding cable to the main earth terminal in the equipment room.


Fit the Filter Module & Sensors

COOLflow4E systems have filter modules that contains 4Energy s patented filtration system. You need to fit

the filter variation that you removed earlier at the bottom of the COOLflow4E Force unit

To install the filter module and sensors follow these steps:

1. The external temperature sensor and pressure tubing should be fed through the holes in the left and

right of the under-tray of the unit respectively

2. Once the sensors are secure the COOLfilter4E can be placed back in the unit. And unit panels reattached.

Diagram shown is for the Unifilter variant, Maintenance free version doesn t require differential pressure sensor.

IMPORTANT. Make sure that the sensor will not rest on any other

part of the COOLflow4E unit. If the sensor comes into contact with the

unit, its readings may be inaccurate and so will affect the

performance of the COOLflow4E Force.


Fit the Fan Grille

When you have fitted the COOLflow4E Force unit and sealed it to the wall, you need to fit the grille over the fan

inside the equipment room. The grille helps protect the fan from debris and also prevents engineers and

cables coming into contact with the fan accidentally.

From inside the equipment room:

1. Place the grille over the fan cut-out hole. Use a spirit-level to make sure it is level.

2. Use 5mm screws to secure the fan grille in place.


Fit the Exit Vent(s)

COOLflow4E Force systems need to have an exit vent installed on a wall that is opposite or adjacent to the

COOLflow4E unit (The engineer should always follow the CTIL cooling calculator/survey document, for

guidance). The vent allows warm air to be directed out of the equipment room and should be positioned high

up the wall (as the warm air will be at the top of the equipment room).

On some sites, more than one exit vent may be required. Please refer to the site documentation for

information on how many exit vents are needed. If you need to install multiple vents, position them on the

wall opposite or adjacent to the COOLflow4E unit, as far apart as possible.

To fit an exit vent:

1. Choose a suitable position for the exit vent. The engineer should always follow the CTIL cooling

calculator, for guidance.

Where possible, we recommend that the vent is fitted to the wall that is opposite to the COOLflow4E

Force unit. If this is impractical, you can use walls that are adjacent to the COOLflow4E Force unit

instead. But do not fit the exit vent to the same wall as the COOLflow4E Force unit as this will affect the

air flow.

2. From inside the equipment room, measure and draw a 295mm × 295mm rectangle for the position of

the exit vent. Use a spirit level to make sure the rectangle is level.

3. Use a drill fitted with a 10mm bit (metal or GRP equipment rooms) to drill out the corners of the

rectangles. Make sure that for each hole, the entire hole is inside the edges of the rectangle.

4. From outside the equipment room, use a spirit level and marker to draw the rectangle on the outside of

the wall.

5. Cut out the rectangle (use a good quality jigsaw for metal or GRP equipment rooms. Note that low

quality jigsaws will struggle to cut through the inner and outer shell of a metal or GRP equipment room.

6. Fit the metal insert, into the hole, ensuring the lip is on the

internal wall of the cabin. Secure it in place using a small head

aluminium rivet in the centre of each insert lip.

7. Clear out any debris from the hole and then fit a 295mm ×

295mm gravity grille into the hole. From outside to in. Secure it

in place with screws or small-headed aluminium rivets. And seal

using a clear silicone.

8. Repeat steps 2-7 inclusive for any additional exit vents that are

required for the site.


5. Install the eController

The eController has a plastic casing with removable panels. To mount the eController to the equipment room

wall, you will need to remove the top and bottom panels and then fix screws:

1. Identify a suitable position for the eController on the equipment room wall. It needs to be mounted on a

flat surface and within 2m of the COOLflow4E Force fan module.

We recommend that you try to fit the eController above the COOLflow4E fan inside the equipment

room. If this is impractical, try and fit the eController to the side of the fan.

When planning the location, you need to consider the route for the wiring from the DC power supply to

the eController, access, operation and maintenance.

For details on the eController s dimensions and specification, see A.3 eController Specification, on page

36.

2. Use a cross-head screwdriver to remove the screws in the centre of the top and bottom panels.

3. Remove the top and bottom plates by gently pulling the rear of the side section of the panel away from

the eController and then slide the panel off.

WARNING. Do not remove the central panel. Incorrect removal of the

central panel could damage the eController and affect its operation.


4. Use a power drill, with 25mm core cutter, to drill holes to allow fan cables, earth bonding and

temperature sensor to enter the controller. Take care not to damage the eController.

5. Make appropriate openings to install an un-switched fused spur, to allow local isolation.

6. Place the eController on the equipment room wall, at the position you have identified. And secure with

appropriate fixings.

7. Feed the power supply and sensor cables through, a length of flexible conduit (finishing 2-3mm inside

the controller). Then through the cable glands and into the eController box. For tidiness, you can feed

the sensor cables through the cable channel at the side of the eController.

WARNING. Do not allow the screws to make direct contact with the

printed circuit board. The metal screws could cause an electrical short

and may cause equipment damage, physical injury or death.

IMPORTANT. Route the power supply cables through a different hole

than the sensor cables. If both sets of cables are fed through the same

hole, this could cause interference and your COOLflow system may

not function correctly.

This diagram shows all of the

recommended positions for

cable holes. Choose the

positions that are suitable for

the equipment room and the

position of the eController (you

do not need to drill all of the

holes).


6. Fit the Sensors

To function as designed, the COOLflow4E Force system needs to be connected to an internal temperature

sensor and an external temperature sensor. These are the minimum requirements, as the eController needs to

use the temperature inside the equipment room and the ambient temperature outside in its calculations. You

can attach the internal and external temperature sensors to the RJ45 terminals in the top section of the

eController. You can also attach a Frost sensor and Humidity sensor, although these are optional (whereas the

temperature sensors must be installed).

1. Plug the sensor cables into the appropriate RJ45 terminals.

2. Position the sensors:

Position the Internal temperature sensor close to the ceiling, in the middle of the equipment room.

The External temperature sensor should already be in position.

Position the Humidity sensor next to the internal temperature sensor. (if installed)

Frost sensors are not used on COOLflow4E Fan and Filter systems.

Internal Temperature

External Temperature

Frost

Humidity


7. Wire the eController to the 48V DC Fan

The eController needs to be wired to the fan so that it can control its speed. The eController will use its internal

logic programs to calculate the appropriate speed for the fan, depending on the temperature in the equipment

room and the temperature outside.

To wire the eController to a 48V DC fan, connect the fan to the eController s terminals as described in the table below.

Fan Cable Colour Controller Terminal Cable

Red (Positive) DC Fan 1 Out + 1.5mm2 core

Blue (Ground/Negative) DC Fan 1 Out - 1.5mm2 core

White (Tacho) TACH1 1.5mm2 core

Yellow (Control) CTRL1 1.5mm2 core


8. Wire the eController to the DC Power Supply

As part of the install process for a COOLflow4E Force 48V DC system, you need to connect the eController to a

DC power supply in the equipment room.

In this section, we explain the basic method of connection, which is connecting an eController directly to a

breaker in the DC power supply. For all installations within the CTIL estate, the COOLflow4E system, must

always be fed from the PRIORITY LOAD of the PSU distribution.

WARNING. Only qualified electricians (Who have undertaken and

passed the PSU training course DELTA and/or ELTEK) should wire the

eController to the power supply. Always follow electrical safety

standards (see Health and Safety on page 6). Failure to follow electrical

safety standards could result in equipment damage, physical injury or

death.

Basic Method of DC Power Supply to eController Connection:

3. Remove the cover to the DC power supply unit s distribution board and ensure that the protective cover

of the bus bar is in place. If the protective cover is missing, live working is required. Take the necessary

precautions for live working (please refer to the relevant Method Statement for live working).

4. Select an appropriately sized MCB in the PSU. If the PSU does not have an appropriate MCB available,

install a new one. The new MCB must always be from the same manufacturer Make and Model as the

other breakers in the DC power supply.

For a direct connection between the eController and DC power supply, a B10 or C10 breaker is required.

(You will need to calculate the appropriate breaker size if wiring via an isolator. The load of the

eController is included in Appendix A.3 eController Specification, on page 36).

5. An un-switched fused spur must be installed adjacent to the eController, to allow local isolation. On all

systems.

If you are installing two COOLflow systems, you need to use a

separate MCB (in the DC Power Supply) for each system.

6. Wire the eController to the 48V DC power supply. You need to use correctly sized cable, according to

country standards.


7. Wire the eController to the DC power supply:

If you are wiring a -48V DC power supply to the eController:

Connect the -48V DC wire to the DC FAN 1 IN- terminal on the eController

Connect the 0V DC wire to the DC FAN 1 IN+ terminal on the eController

Use plastic Copex to keep the cables neat and tidy, terminating around 100mm inside the PSU.

8. All system labelling should be completed according to CTIL document SDN5016.

9. Complete the required documentation (as outlined in the relevant Method Statement).

10. Complete any further testing required for the site (as detailed in the relevant Method Statement).


9. Wire the eController to an Alarm System

The eController can output alarm signals to external alarm systems, such as an alarm system in an equipment

room. Typically, the alarms are monitored remotely, usually from a control center, and if an alarm condition is

detected, operators in the control center can arrange for engineers to investigate.

To wire the eController to an alarm circuit, you will wire to the RL2 relay on the eController. The types of alarm

that the eController can output via RL2 include:

Power failure (supply or internal eController power)

Fan failure

Smoke alarm input (if a smoke alarm signal is received by the eController, it will output an alarm via

RL2).

To wire the eController to an external alarm system:

1. Make sure the eController has power, but is not switched on (see Wire the eController to the DC Power

Supply, on page 24).

2. Open the alarm system connection box in the equipment room.

3. Prepare an appropriate cable for connecting the eController to the alarm connection box.

4. Run the cable from the eController to the alarm box, but do not connect it to any terminals at this stage.

5. Connect the cable to RL2 NO and C on the eController

.

IMPORTANT. Use a multimeter to test the NO and NC terminals on

the eController PCB before connecting to the relays. Some

eControllers may have their NO and NC terminals labelled incorrectly

on the circuit board.

RL2 for AC

and Alarm


6. Use the multimeter to perform a continuity test on the cable.

i. With the cable connected to the eController (RL2 NO and C), connect a multimeter to the opposite

end of the cable. Take care not to damage the cable. Connect the multimeter s red lead to one conductor (cable) and the black lead to the other conductor.

ii. Keep the eController turned off, and use the multimeter to perform a continuity test. The test

should show that there is an open circuit.

iii. Restore the power supply to the eController so that it turns on. Perform the continuity test again.

The test should show that there is a short circuit (indicating RL2 is energised).

Please refer to the multimeter manufacturer s documentation for details on how to perform a continuity test.

If the cable passes the test, you can proceed to step 7.

If the cable fails the test, replace the cable and then repeat the tests starting from step 4.

7. Connect the other end of the cable to the designated terminals in the alarm box (according to SDN5042)

you need to use an IDC termination tool to connect the cable to the terminals.

For brief details on the terminals that can be used in the alarm equipment, see Appendix A.1 Site Specific

Settings, on page 34.

8. All system labelling should be completed according to SDN5016.

9. Replace the alarm box cover.

Further Information

Wiring diagrams are included in Appendix A.6 Wiring Colour Schemes (see page 42).

For further guidance and detail on alarm connections please refer to document SDN5042 & RICP 004-37.


10. Commission the eController

When you have fitted and wired up the eController to the power supply, fan, and any other systems (heater,

alarm, etc.), you need to set up the eController:

1. Restore the power supply to the equipment room.

2. Perform a Configuration Test (see page 28).

3. If the configuration needs to be changed, Re-Configure the eController (see page 28).

4. Perform a Sensor Test, (see page 31).

5. Perform a Fan Speed Test, (see page 31).

6. Log Out (see page 31).

Configuration Test

The eController is pre-configured with set points and other settings. When you have installed it, you need to

check that the pre-configured settings match the settings that are needed for the site (see Appendix A.1 Site

Specific Settings, see page 34).

To check the settings:

1. Power up the eController. When the LCD shows a series of readings, press the OK button to access the

Main Menu.

2. Use the Keypad to select the Diagnostics option. The pre-configured settings for the eController are

shown in a list. You can use the Keypad to scroll up and down the list. Compare the settings to those

required for the site.

If the settings match, ignore the remaining steps of this section and proceed to: Sensor Test (see page

31).

If the settings do not match, you will need to report this to 4energy. You may need to Re-Configure the

eController (see page 29).


Re-Configure the eController

There are two ways to change the configuration of the eController.

Using the wizard

Using the Advanced Settings.

When you use the wizard , you make a series of choices, based on the type of system you are installing. From

these choices, the eController is able to put preset configuration settings in place. These preset settings are

often, but not always, suitable for the site. You will need to compare the default settings to the settings

required for the site (see Appendix A.1 Site Specific Settings on page 34). If they do not match, you will need to

configure the Advanced Settings separately on the eController.

To use the wizard:

1. Press OK and then press the down key until the cursor is on the Setup option.

2. Press OK and use the keypad to enter the password at the prompt (contact 4energy support if password

required).

3. Select the option for the type of COOLflow4E system you have installed.

Fan Only

Fan and Site A/C

Fan + 4Energy A/C

4. Press OK.

5. Select Target Temperature.

6. Set the temperature you want the COOLflow4E system to try and maintain in the equipment room. Use

the left and right keys to move the cursor between the digits; use the up and down keys to increase and

decrease the values. Press OK when you have entered the value.

7. Select Fan Mode and press OK.

8. Choose Variable Speed Mode or 100% Mode. (Variable Speed Mode allows the eController to manage

the fan speed automatically, whereas 100% Mode sets the fan to run at full speed at all times). Press OK

when you have made your choice.

9. Select START and press OK.

10. Define whether the fan has Tacho Enabled or Tacho Disabled (if the fan has the tacho wire connected

to the eController, choose Tacho Enabled). Press OK.

The eController now runs with the default settings for your choices in place. You will need to compare

the settings to those required for the site (see Appendix A.1 Site Specific Settings, on page 34). You can

view the default settings by pressing OK on the Home page and then selecting the Diagnostics option.

If you need to adjust the settings so that they match the site requirements, you will need to use the

Advanced Settings.


To use the Advanced Settings:

1. Display the Home page, and then press the OK button to display the Main Menu.

2. Select the Advanced Settings option and then log on. If you do not have a password, contact your local

technical support.

3. Use the options in the Advanced Settings menu to apply the required configuration.

For more details on the options, see the eController manual.

4. Repeat the Configuration Test (see page 28).


Sensor Test

You need to complete the sensor test to make sure that the sensors are working correctly (and are being read

correctly by the eController).

1. Use a thermometer to take the temperature at a position close to the internal sensor and a position

close to the external sensor. Write down your measurements as you will need them in the next step.

2. Compare the temperature measurements you took in step 1 to the Internal Temperature and External

Temperature readings shown on the Home page of the LCD display (you can display the Home page by

pressing the Home button).

If the temperatures are within 4°C of the measurements you took, the sensors are working correctly.

If there is a significant difference between the measurements you took and the temperatures shown,

there may be a fault. There are usually differences between the measurements of different sensors, but

they should only differ by 1-4 degrees.

If the temperatures are not within 4°C of your measurements, replace the sensor(s) and repeat the

sensor test. If the new sensors also result in large differences, the eController may be faulty. Try using

new sensors again, but if this fails, replace the eController and then repeat the commissioning process

after install.

Fan Speed Test

The fan speed should increase when the temperature rises and decrease when the temperature falls. To test

the fan speeds up and slows down correctly:

1. Heat the internal sensor with a heating device, such as a hairdryer. Care should be taken not to burn the

sensor or yourself.

2. Observe the fan speed. As the temperature of the sensor increases, the fan should spin faster.

3. Cool the internal sensor with a freeze spray.

4. Observe the fan speed. As the temperature of the sensor decreases, the fan should slow down.

If the sensors passed the Sensor Test (see page 31) and the fan speed did not increase/decrease as expected,

the eController may be faulty. Replace the eController and contact 4energy to arrange the return of the faulty

eController.

If the fan increased speed and decreased speed as expected, the eController fan speed test process is

complete.

Log Out

When you have configured the eController to meet the requirements for the site, you need to log out. This

helps to prevent unauthorised users from gaining access to the configuration options.


1. Press the Home button to return to the home page and then press OK.

2. Select the Log Out option. You are now logged out and will need to enter your password again if you

wish to change any configuration settings.

The eController s configuration can now only be altered by someone who logs on and enters the

appropriate password.

The installation of the eController is now complete.


Appendices

The following appendices contain supplementary information about the wiring and operation of the

eController.

A.1 Site Specific Settings (see page 34)

A.2 Site-Specific Documentation Requirements (see page 35)

A.3 eController Specification (see page 36)

A.4 Connections on the eController (see page 37)

A.5 COOLflow4E Force Drawings (see page 39)

A.6 Wiring Colour Schemes (see page 42)

A.7 Wiring Diagrams (see page 42).


A.1 Site Specific Settings

CTIL Sites

eController Set Points and Configuration

Enter the following values in the eController configuration:

eController Setting Required Value

Windmill T 18

Windmill S 22%

Ramp Start 22

Pid Offset 2

AC On 35

AC Speed 0%

Panic Temp 35

Alarm System Wiring

eController Terminal Alarm Box Terminal

RL2 NO (Normally Open) K2-9a or K2-9b

RL2 C (Common) K2-9a or K2-9b (do not use the same K terminal that you used for the Normally Open

connection).


A.2 Site-Specific Documentation Requirements

CTIL Sites

The following documentation is required when installing on a CTIL site:

Document Stage of Installation Process

Booking In (VF Site Diary) When you arrive on site, you need to book in via text message.

Please contact 4energy if you need more information.

Hazardous Waste Regulations 2005:

Consignment Note – Mirror Note

To be completed for each site where refrigerant is removed. This has to be completed

before transportation of the refrigerant.

The original mirror note is to be kept with the commissioning documents and

returned to 4energy as part of the commissioning documents for the site.

A photocopy of the mirror note is to be kept with the reclaim cylinder (used for the

removal of the refrigerant from the site).

Hazardous Waste Regulations 2005:

Consignment Note

To be completed for each reclaim cylinder, when full.

Attach the two copies of the consignment note to the photocopy of the mirror notes

for the full reclaim cylinder.

Duty of Care: Waste Transfer Note To be completed before the air conditioning is removed from site.

Booking Out (VF Site Diary) When you leave site, you need to book out via text message.

Please contact 4energy if you need more information.


A.3 eController Specification

Physical Properties of eController

Length/Width/Depth (mm) 233/255/47

Net Weight Less than 1kg

Power Usage (W) 19V to 72V (6W)


A.4 Connections on the eController

The eController s terminals are located behind the top cover panel and the bottom cover panel. The

connections on the top side of the eController are as follows:

Board ID Purpose

COMM The COMM connection allows add-in cards to be fitted to the eController. The eController supports RS 485 and RS

232 add-in cards (the RS 485 card can also be used for RS 422). These connections are intended for use when

debugging the eController. In future, COMM will also be used for communications with devices that use the Modbus

protocol.

RJ45 The RJ45 ports are for connecting internal temperature, external temperature, frost temperature, and humidity

sensors.

Digital

Inputs

The digital inputs are for connecting the eController to alarm-capable devices, such as a smoke alarm. Aux is for

connecting the eController to an actuator which is used with a damper.

GND is a common ground for all of the digital inputs.

RL3/RL4 RL3 is for outputting a high temperature alarm. COM and NO are most commonly used for these connections.

RL4 is for outputting a low temperature alarm to another device, such as an RTU or PLC. It is also used for

connecting an external heater to the eController.

COMM is for connecting add-in cards

that support RS 485 or RS 232

communications.

RJ45 Ports for connecting sensors to the

eController

Digital inputs for smoke alarm,

actuator, etc. Relays for high temperature and low

temperature alarm outputs to RTUs/PLCs. Also

used for connecting an external heater.


Board ID Purpose

RL1 Use for connecting an air conditioning unit (A/C) to the eController. COM and NO are most commonly used for this

connection.

RL2 Use for a general signal alarm. Typically, the COM and NO are wired to an A/C alarm.

DC Fan 2 Use for connecting a secondary DC fan (via the OUT+ and OUT- terminals)

AC Fan 2 Use for connecting a secondary AC fan (via the LOUT, E, and N terminals).

AC IN Use for connecting an AC power supply (via the N, E and LIN terminals).

AC Fan 1 Use for connecting a primary AC fan (via LOUT, E, N, TACH1, and CTRL).

DC Fan 1 Use for connecting a primary DC fan (OUT+, OUT-) and DC power supply (IN+, IN-).

RL1 for ACU RL2 for AC

and Alarm

DC Fan 2

for

secondary

DC fan

DC Fan 1 for DC

power supply and

DC primary fan

AC FAN 2 for

secondary AC fan AC IN for AC

Power Supply

AC FAN 1 for

primary AC fan


A.5 COOLflow4E Force Drawings

This section contains the drawings for the COOLflow4E Force unit. They are shown on separate pages

(landscape orientation).


A.6 Wiring Colour Schemes

In this appendix, we provide information about the wiring colour schemes that are relevant to COOLflow4E

products, within the CTIL estate. Using SDN5016 as a guide.

DC Wiring Colour Schemes (2-Wire Earthed)

Purpose IEC Wiring Colour

Positive of positive

earthed circuit (M)

Blue

Negative of positive

earthed circuit (L-)

Grey

A.7 Wiring Diagrams

This section contains the wiring diagram for the COOLflow4E Force eController when used with a 48V DC fan.

It is shown on a separate page (landscape orientation).

4energy ltd • Debdale Lane Industrial Estate • Debdale Lane, Keyworth • Nottinghamshire • NG12 5HN

Tel: +44(0)115 9372700 – Fax: +44(0)115 9372747 – www.4energy.co.uk

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