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Multi-DENCO®

OPERATION MANUAL
Table of Contents Multi-DENCO

1 Overview of Units and Scope of Supply ................................. 13


1.1 Introduction .............................................................................................. 13
1.2 Model number explained .......................................................................... 13
1.3 Product series overview ........................................................................... 14
1.4 DENCO-OfficeCool .................................................................................. 15
1.5 Scope of supply ....................................................................................... 15
1.6 Accessories and special equipment ......................................................... 15
1.7 Directives and regulations ........................................................................ 15
1.8 References within manual ........................................................................ 16

2 Safety and User Information .................................................... 17


2.1 Availability of the operation manual ......................................................... 17
2.2 Scope of the operation manual ................................................................ 17
2.3 Document format ..................................................................................... 18
2.4 Signs used within this manual .................................................................. 19
2.5 Labelling of safety information ................................................................. 21
2.6 Safety-conscious working ........................................................................ 23
2.7 Proper use ............................................................................................... 25
2.8 Modifications and changes ...................................................................... 25
2.9 Spare parts .............................................................................................. 25
2.10 Disposal ................................................................................................... 26
2.11 Personnel selection and qualification ....................................................... 26
2.12 Noise ........................................................................................................ 26
2.13 Environmental considerations .................................................................. 26

3 Technical Description ............................................................... 27


3.1 Unit description ........................................................................................ 27
3.2 Operating limits ........................................................................................ 28
3.3 Operating modes ..................................................................................... 28
3.4 Operating strategies ................................................................................. 29
3.5 Components ............................................................................................. 31
3.6 Heat rejection systems ............................................................................. 33

4 Shipping and Storage ............................................................... 35


4.1 Delivery .................................................................................................... 35
4.2 Handling ................................................................................................... 35
4.3 Storage .................................................................................................... 36

5 Installation ................................................................................. 37
5.1 Requirements and considerations ........................................................... 37
5.2 Substructures ........................................................................................... 39
5.3 Unit placement ......................................................................................... 41
5.4 Clearance and Access ............................................................................. 42
5.5 Installing enclosed accessories ............................................................... 44
5.6 Installation of outdoor units ...................................................................... 47
5.7 Fan touch protection ................................................................................ 50
5.8 EC Declaration of Conformity .................................................................. 50

6 Medium Connections ................................................................ 52


6.1 Requirements ........................................................................................... 52
6.2 Connecting refrigeration pipework ........................................................... 52
6.3 Refrigerant pipework testing procedures ................................................. 60
6.4 Humidifier water connections (optional) ................................................... 62
6.5 Connecting condensate drain .................................................................. 64

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Multi-DENCO Table of Contents

6.6 Connecting water pipework ...................................................................... 65

7 Electrical Connections ............................................................. 70


7.1 Requirements ........................................................................................... 70
7.2 Connecting mains power supply ............................................................... 71
7.3 Connecting outdoor unit ............................................................................ 72
7.4 Connecting signal cabling ......................................................................... 74
7.5 Customer terminals on C5-12 unit controller ............................................ 76

8 Commissioning ......................................................................... 77
8.1 Requirements ........................................................................................... 77
8.2 Pre-commissioning procedure .................................................................. 78
8.3 Commissioning procedure ........................................................................ 83
8.4 Post-commissioning procedure ................................................................ 93

9 Operation ................................................................................... 94
9.1 Requirements ........................................................................................... 94
9.2 General operation ..................................................................................... 94
9.3 Alarms and error messages ...................................................................... 96

10 Servicing and Maintenance ...................................................... 97


10.1 Maintenance access ................................................................................. 98
10.2 Servicing ................................................................................................... 98
10.3 Refrigerant leak testing ........................................................................... 100
10.4 Compressor care .................................................................................... 100
10.5 Humidifier maintenance (if fitted) ............................................................ 100
10.6 Closing down procedure ......................................................................... 101
10.7 Logbook & EU Regulation ...................................................................... 102

11 Fault Finding and Troubleshooting ....................................... 103


11.1 Common Issues ...................................................................................... 104

12 Dismantling and Disposal ...................................................... 106


12.1 Dismantling ............................................................................................. 106
12.2 Disposal .................................................................................................. 107

13 Appendix .................................................................................. 108


13.1 Pre-Commissioning Checklist (DQA 880) ............................................... 109
13.2 Pressure Test Certificate (DQA 653) ...................................................... 112
13.3 Multi-DENCO Commissioning Report (DQA 890) .................................. 113

PROTECTION NOTICES
The reproduction, distribution and utilization of this document as well as the communication of its contents to others without
express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the
event of the grant of a patent, utility model or design.

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Multi-DENCO

The following pages demonstrate the possible type code and options for a
Multi-DENCO unit. The DENCO OfficeCool short type code is listed on page 12.
Please note that the type code is subject to updates and addition due to our continuous
improvement process, therefore for the latest options available please contact your
local office.

Basic Unit

Compressor control
Panel configuration
Air flow direction

Heat exchanger
Cooling system

Power supply
Humidifier
Unit size

Heating
Product

Range

Filter

Fan
D DENCO
M Multi-DENCO
A Air cooled
C Chilled Water
X Split System
010 Size 010
018 Size 018
030 Size 030
045 Size 045
065 Size 065*
092 Size 092*
130 Size 130*
D Downflow
U Upflow
P Front full height panel
F Front air inlet grille panel
L Front low level air discharge panel
S Standard heat exchanger
C CombiCool
L Large heat exchanger
I Inverter compressor scroll
F Fixed speed compressor scroll
N Not fitted
S Steam humidifier standard conductivity
L Steam humidifier low conductivity
H Steam humidifier high conductivity
N Not fitted
4 Filter G4
7 Filter F7
P EC plug fan
E Electric heating
T Modulating electric heating
N Not fitted
R Remote signal 0-10 V
1 3~ 400 V, N, PE, 50 Hz
7 3~ 400 V, N, PE, 60 Hz

* Not available for X-Version

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Multi-DENCO

Refrigeration

Refrigerant circuit arrangement

Refrigerant leakage detection


Connection type refrigeration
Shut off valve refrigerant

Compressor soft start


Plate heat exchanger

Service connections
Key Refrigeration

Compressor size

Expansion valve

Liquid receiver
Refrigerant
Product

Range
D DENCO
M Multi-DENCO
RE Refrigeration
D R410A
1 Single circuit
N Small compressor
C Standard compressor
N Not fitted
E Electronic expansion valve
N Not fitted
S Shut off valves compressor and liquid line
L Shut off valve liquid line
S Solder connections
T Twin solder connections
L Refrigerant leakage detection
N Not fitted
N Not fitted
C Commissioning front connection points
N Not fitted

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Multi-DENCO

Water

Water temperature monitoring


Connection type water
Shut off valve water

Valve actuator
Valve type
Key Water

Valve kv
Product

Range
D Denco
M Multi-DENCO

WA Water
S Shut off valves chilled water

N Not fitted
B Threaded pipework connections (BSPT)
G Flange pipework connections PN06

F Flange pipework connections PN16


S Solder connections
N Not fitted
T Temperature monitoring probes
N Not fitted
2 2-way water valve
P 2-way water valve, pressure independent
3 3-way water valve with bypass

B 3-way water valve with bypass & regulating valve


N Not fitted

D DODC actuator
0 0-10 V actuator, drive open, spring return
N Not fitted
C kv = 1.0

D kv = 1.6
E kv = 2.5
F kv = 4.0

G kv = 6.3
H kv = 10

I kv = 16
J kv = 25

K kv = 40
L kv = 63
M kv = 100
X Small

Y Standard
N Not fitted

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Multi-DENCO

CombiCool

Connection type water


Shut off valve water

Water temperature
Key CombiCool

Valve actuator
monitoring

Valve type

Valve kv
Product

Range
D Denco
M Multi-DENCO
CC CombiCool
S Shut off valves chilled water
N Not fitted
B BSP pipework connections
G Flange pipework connections PN06
F Flange pipework connections PN16
S Solder connections
N Not fitted
T Temperature monitoring probes
N Not fitted
2 2-way water valve
P 2-way water valve, pressure independent
3 3-way water valve
B 3-way water valve with bypass & regulating valve
N Not fitted
D DODC actuator
0 0-10 V actuator, drive open, spring return
N Not fitted
C kv = 1.0
D kv = 1.6
E kv = 2.5
F kv = 4.0
G kv = 6.3
H kv = 10
I kv = 16
J kv = 25
K kv = 40
L kv = 63
M kv = 100
X Small
Y Standard
N Not fitted

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Multi-DENCO

Controls

Smoke detection
Ambient tempe-
Water detection

DENCO-Office-
Air volume flow
Interface BMS

control indoor

Uninterrupted
rature control

power supply

power supply
Key Controls

Pump signal

Accessories
Main switch
Run status

Fan speed

monitoring

monitoring
Air sensor
Language
Controls
Product

Display

Energy
Range

Cool
D DENCO
M Multi-DENCO
CO Controls
C C5-12 controller
N Not fitted
L LonWorks interface
B BACnet MS/TP interface
E BACnet I/P, SNMP, Webpage interface
N Not fitted
T Touch screen display
N Not fitted
R Run status unit
N Not fitted
W Water detection, sensor tape and drain pan sensor
1 Water detection, 1 spot sensor and drain pan sensor
2 Water detection, 2 spot sensors and drain pan sensor
4 Water detection, 4 spot sensors and drain pan sensor
6 Water detection, 6 spot sensors and drain pan sensor
N Not fitted
1 Return Air T&H sensor
2 Return Air T&H sensor, 10 m cable
7 Return Air T&H + Supply Air Temp sensors
8 Return Air T&H + Supply Air T&H sensors, 10 m cable
9 Return Air T&H + Supply Air Temp sensors, 10 m cable
A Return Air T&H, 10 m cable + Supply Air Temp sensors
B Return Air T&H, 10 m cable + Supply Air T&H sensors, 10 m cable
N Not fitted
S Standard languages
O Other language (special)
N Not fitted
P Floor void air pressure control (APS)
S Fan speed control cooling demand
N Not fitted
V Air volume flow monitoring
N Not fitted
E Energy monitoring
N Not fitted
S Pump signal CombiCool free-cooling
N Not fitted
A Ambient temperature control CombiCool free-cooling
N Not fitted
M Main switch
D Dual power supply (ATS), inbuilt
S Smoke detection
N Not fitted
P Condensate pump
T Trend BMS interface
1 Condensate pump and Trend BMS interface
L LECU Interface
N Not fitted
U Uninterrupted power supply controls
N Not fitted

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Multi-DENCO

Casing

Connection position

Installation wheels
Air grille unit top
Display position

Filter gauge
Key Casing

Unit colour

Packaging
Product

Range

Panel
D DENCO

M Multi-DENCO

CA Casing

B Pipework bottom entry

S Standard display position

L Lower display position

N Not fitted

R White

O Other unit colour (special)

G Filter differential pressure gauge

N Not fitted

1 Top air discharge protection grille (Eyelash)


2 Top air inlet protection grille (Eggcrate)

D Air damper

P Prepared for loose air damper


N Not fitted

S Standard panels

A Acoustic insulation panels

N Not fitted
S Standard packaging (Domestic)

E Wooden crate packaging (Export)

P Standard packaging (Domestic) with unit protection sheet


F Wooden crate packaging (Export) with unit protections sheets

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Multi-DENCO

Outdoor Unit *

Key Outdoor unit

Outdoor system

Heat exchanger

Airflow direction

Deliver external
Refrigerant cir-

Liquid receiver

Liquid receiver
Power supply

outdoor units
arrangement
Compressor

Compressor

Unit colour

Packaging

Number of
Winter kit

soft start
Unit size
Product

Coolant

coating
Range

size

size
Fan

unit
cuit
D DENCO
M Multi-DENCO
OU Outdoor unit
C Condenser
D R410A
008 008
013 013
021 021
026 026
032 032
050 050
075 075
100 100
E EC fan
A AC fan with fan speed controller
F AC fan
1 Single circuit
N Not fitted
1 3~ 400 V, N, PE, 50 Hz
2 1~230 V, N, PE, 60 Hz
3 1~265 V, N, PE, 60 Hz
5 1~230 V, N, PE, 50 Hz
6 3~460 V, N, PE, 60 Hz
7 3~ 400 V, N, PE, 60 Hz
W Winter kit, -40 °C ambient
D Winter kit with double pressure relief valve, -40°C ambient
N Not fitted
B Blygold heat exchanger coating
E Epoxy heat exchanger coating
N Not fitted
N Not fitted
R Aluzinc
O Other unit colour (special)
S Standard packaging (Domestic)
E Wooden crate packaging (Ex-
port)
H Horizontal airflow
V Vertical airflow
1 1 outdoor unit
2 2 outdoor units
O External unit is included in package
N Deliver without external unit
P Liquid receiver with pressure relief valve
D Liquid receiver with double pressure relief valve
B Liquid receiver with pressure relief valve and pump-down
C Liquid receiver with double pressure relief valve and pump-down
N Not fitted
1 7L
2 12L
3 15L
4 18L
5 21L
6 25L
7 30L
8 36L
A 50L
N Not fitted
* A-Version, X-Version and H-Version

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Multi-DENCO

Accessories

Accessory
cessories

Unit size
Key Ac-
Product

(indoor)
Range
D DENCO
M Multi-DENCO
AC Accessories
010 Size 010
018 Size 018
030 Size 030
045 Size 045
065 Size 065
092 Size 092
130 Size 130
BAS Base stand
PLI Plinth
PLIO Plinth, other colour (special)
TIL Raised floor tile support
PUM Condensate pump
PUH Condensate pump at humidifier
DAM Shut off damper
DAMC Shut off damper
TRA Underfloor unit drip tray
1WA Horizontal 1 way air discharge
1WAO Horizontal 1 way air discharge, other colour (special)
3WA Horizontal 3 way air discharge
3WAO Horizontal 3 way air discharge, other colour (special)
FI4 G4 Spare filter set
FI7 F7 Spare filter set
FI4C G4 Spare filter set
FI7C F7 Spare filter set
REM Remote monitoring touch screen display
TOU Touch up paint kit
D10 Ceiling connection duct 100 mm
D15 Ceiling connection duct 150 mm
D20 Ceiling connection duct 200 mm
D25 Ceiling connection duct 250 mm
D30 Ceiling connection duct 300 mm
D35 Ceiling connection duct 350 mm
D40 Ceiling connection duct 400 mm
D45 Ceiling connection duct 450 mm
D50 Ceiling connection duct 500 mm
D55 Ceiling connection duct 550 mm
D60 Ceiling connection duct 600 mm
D65 Ceiling connection duct 650 mm
D70 Ceiling connection duct 700 mm
D75 Ceiling connection duct 750 mm
D80 Ceiling connection duct 800 mm
D85 Ceiling connection duct 850 mm
D90 Ceiling connection duct 900 mm
D95 Ceiling connection duct 950 mm
D99 Ceiling connection duct 1000 mm
TRE Trend BMS interface
CEC Central Controller
PLV Plant Visor
TSD Top-side-down duct

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Multi-DENCO

DENCO-OfficeCool

Compressor control
Panel configuration

Heat exchanger
Cooling system

Power supply
Air routing

Humidifier
Unit size
Product

Heating
Range

Filter

Fan
D Denco
M Multi-DENCO
O Chilled water OfficeCool
H Split System OfficeCool
010 Size 010
018 Size 018
030 Size 030
045 Size 045
D Downflow
U Upflow
P Front full height panel
S Standard heat exchanger
H Heat pump heat exchanger
N Not fitted
S Steam humidifier standard conductivity
L Steam humidifier low conductivity
H Steam humidifier high conductivity
N Not fitted
4 Filter G4
7 Filter F7
W Filter washable G4
P EC plug fan
N Not fitted
1 3~400 V, N, PE, 50 Hz
6 3~460 V, N, PE, 60 Hz

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Multi-DENCO Overview of Units and Scope of Supply

1 Overview of Units and Scope of Supply

1.1 Introduction
We would like to thank you for purchasing our products.
Multi-DENCO units are intended and designed for indoor installation for cooling, hea-
ting, humidification, dehumidification and filtering of air at atmospheric pressure. The
units are designed as refrigeration systems and/or chilled water systems and it is prohi-
bited to use our units for any other purposes. The equipment has been designed and
manufactured within a 'Quality Assurance System' within a strict quality controlled env-
ironment to ensure that it reaches you in perfect condition.
For help, assistance, spares or your local office, please visit the following website for
contact details in your region:
https://www.flaktgroup.com/en/contact-us/

1.2 Model number explained


Each product carries an 'Identification Plate' (sometimes referred to as 'serial plate')
inside the equipment for indoor units. For outdoor units, this maybe be on the external
casing. This identification plate carries information that is important and unique to the
unit.
Upon receipt of your equipment it is important to check the 'MODEL NUMBER' (a shor-
tened version called 'Model Type Code' is shown on the serial plate) prior to positioning
and installation, to ensure it matches your requirements. Any discrepancies should be
reported immediately to your representative.
Refer to page 4 for the type code of a particular unit. Below shows an example serial
plate for a Multi-DENCO A-Version unit.

FläktGroup Czech Republic a.s.


Slovanská 781, 463 12 Liberec XXV - Vesec, Czech Republic

PRODUCT RANGE / PROJECT TYPE Multi-DENCO® STANDARD


MODEL TYPE CODE / PED DMA030DPSIN4PN1 CAT. 1
SERIAL NUMBER 6WC955
CONTRACT NO. / DATE OF BUILD 110196 02 / 2017
OPERATION MAN. / WIRING DIAGRAM PR-2013-0101 110196-101
VOLTAGE / PROTECTION RATING 400V-3PH-50HZ/60HZ+N IP20
MAX. PRE-FUSE 32 TYPE D
FULL LOAD INPUT 11,4 kW
FULL LOAD CURRENT 29,9 A
COOLING MEDIUM R410A (GWP 2088) & WATER
SOFTWARE VERSION CV3.04.009B/DV4.06.009B
MWP HIGH PRESSURE SIDE 4,32 MPa
MWP LOW PRESSURE SIDE 4,32 MPa
CHILLED WATER 0,70 MPa
EMPTY WEIGHT 330,00 Kg
NOTE

ANY MODIFICATION MAY NOT BE REFLECTED ABOVE

( Field Charge (R410A) / 1000 ) x 2088 = CO2e


CONTAINS
FIELD CHARGE (kg) CO2e GREENHOUSE

=
FLUORINATED
GASES 1015

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Overview of Units and Scope of Supply Multi-DENCO

1.3 Product series overview

There are 3 versions of the Multi-DENCO product: A-Version, C-Version and X-Ver-
sion. These versions have some common elements and also individual characteristics.

Fig. 1-1: A Multi-DENCO Unit

Common features & – 7 standard box sizes (010, 018, 030, 045, 065, 092 and 130)
options – Cooling capacities up to 150 kW
– Available with both upflow or downflow air paths
– Large EC plug fans
– Integrated or remote temperature and humidity sensors
– Large surface area for heat exchanger coil
– Available with full panel doors or with grilles within the doors
– Humidification and heating options available
– Standard control software and hardware that is compatible for all versions
– Building Management System (BMS) interface compatible
A-Version – Refrigeration based cooling
– R410A used as standard
– Inverter compressors as standard (fitted in indoor unit)
– Electronic expansion valve as standard (fitted in indoor unit)
– Typically supplied with an outdoor condenser
C-Version – Water based cooling
– Can operate with Glycol
– A method of heat rejection separate to Multi-DENCO unit (e.g. Chiller)
– Can be provided with 3-way, 2-way or 2-way PICV valves and a variety of actuators
X-Version – Refrigeration based cooling
– R410A used as standard
– Available for sizes 010 to 045
– Inverter compressors as standard (fitted in outdoor unit)
– Electronic expansion valve as standard (fitted in outdoor unit)
– Typically supplied with an outdoor condensing unit

CombiCool Coil (Optional) A and C-Version units can be upgraded to have inbuilt redundancy. A unit with a Com-
biCool coil, consists of a primary and a secondary circuit. The primary circuit will be a
chilled water cooling circuit. When parameters leave the allowable boundaries (e.g.
chilled water inlet temperatures are too high) then the primary circuit will stop and the
secondary circuit will be activated (e.g. the A-Version DX circuit) to continue the coo-
ling process. A CombiCool coil can also be used in a FreeCool strategy.

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Multi-DENCO Overview of Units and Scope of Supply

1.4 DENCO-OfficeCool
DENCO-OfficeCool is a separate version of the Multi-DENCO design and custom-
made for use in an office environment or similar requiring comfort cooling. The units
consist of one Zone unit to many Local Environmental Control Units (LECUs) to give
temperature control through a raised floor.
Typically, DENCO-OfficeCool units are in downflow air configuration, but Upflow units
can be used with a 'top side down duct'. This can be referred to as 'Underfloor Air Con-
ditioning'.
O-Version – Water based cooling
– Can operate with Glycol
– A method of heat rejection separate to Multi-DENCO unit (e.g. Chiller)
– Can be provided with 3-way or 2-way valves and a variety of actuators
– Available for sizes 010 to 045
– Acoustic insulation and slower fan speeds
H-Version – R410A used as standard
– Available for sizes 010 to 045
– Inverter compressors as standard (fitted in outdoor unit)
– Acoustic insulation and slower fan speeds
– Heat pump options available

1.5 Scope of supply


A typical order of a Multi-DENCO unit could consist of (but is not limited to):
– Indoor unit of Multi-DENCO configuration with associated internal options pre-
installed (unless requiring placement external to the unit or further installation, in
which case, hardware is provided loose within the unit)
– Outdoor unit (Optional) a condenser, condensing unit or drycooler to act as a heat
rejection unit for the system
– Unit documentation
– A copy of the current operation manual (indoor and/or outdoor)
– Controller manual
– Wiring diagrams for both indoor and outdoor units
– Dimensional drawing
– Spare part list in the form of a label or a printed sheet
– Accessories (optional) Any other accessories that may be required for the indoor
or outdoor unit, for example; plinths, base stands, ceiling return sections etc. may
be provided in separate packaging

1.6 Accessories and special equipment


Multi-DENCO units can be designed with a vast number of accessories and features.
To determine the scope of options fitted to your unit, compare the supplied unit 'Model
Number' with the unit model number specified in the typecode.

1.7 Directives and regulations


We certify that products supplied within the range of Multi-DENCO conform to, meet
and/or exceed the requirements of the following directives and regulations:
– Directive on Machinery 2006/42/EC
– Low Voltage Directive 2014/35/EU
– Electromagnetic Compatibility (EMC) 2014/30/EU
– Pressure Equipment Directive 2014/68/EU

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Overview of Units and Scope of Supply Multi-DENCO

1.8 References within manual


The following references to standards and regulations are made within this manual.
These may be updated or revised by the relevant bodies, after publication of this
manual. In all instances, review the latest versions for any relevant updates.
(EC) No. 842/2006
EN 378
DIN EN ISO 3745
2014/68/EU
2006/42/EC
2014/30/EU
2014/35/EU
EN 12735-1:2010
EN 60204-1:2006+A1:2012
(EU) No. 517/2014
2008/98/EC
2012/19/EU

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Multi-DENCO Safety and User Information

2 Safety and User Information


The Multi-DENCO range is designed in accordance with state-of-the-art technological
and engineering standards as well as in conformity with the recognized safety regula-
tions.
It must be used in an appropriate manner for suitable purposes, following the details
contained within this manual and taking account of safety aspects and potential
hazards.
Failure to follow the instructions in this manual may result in danger to health and
safety, damage to materials and incorrect unit operation. Information within this
document advises on, but is not limited to, potential threats or concerns related to
health and safety. All users must be, or employ, a trained professional to, assess
issues relating to health and safety, before any handling the Multi-DENCO unit.

2.1 Availability of the operation manual


This operation manual contains important information regarding safe and correct ope-
ration of the unit.
This manual must always be available at the site where unit is operating. Every person
working on the equipment must read this manual fully before commencing the work
and take note of all relevant information while performing a task.
The operation manual is intended to be used by fitting and installation companies, buil-
ding services engineers, technical personnel or trained persons as well as electrical
and refrigeration engineering specialists.

2.2 Scope of the operation manual


THIS IS AN ORIGINAL OPERATION MANUAL VERIFIED BY THE MANUFACTURER.
This document has been developed by the manufacturer specifically for details relating
to the Multi-DENCO range. Information within this document may be common to other
designs or products, but the information contained is exclusive to Multi-DENCO and
non-transferable. The information should not be used as a basis for any other pro-
ducts.
Every effort is made to ensure that information contained within this manual is fair and
accurate, but FläktGroup endeavours to continuously update and improve all of our
products for our customers. Due to this continuous development, some information
contained within this manual may become outdated or no longer relevant. If you are in
any doubt regarding any information contained within this document, please contact
your local sales or support representative who will be happy to assist and enquire
further for you.

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Safety and User Information Multi-DENCO

This operation manual covers topics in the following areas:


– Safety and User Information
– Technical Descriptions
– Shipping and Storage
– Installation
– Mechanical and Electrical Connections
– Commissioning
– Operation
– Servicing and Maintenance
– Troubleshooting
– Disassembly

NOTE!
Please refer to Controls Operation Manual for details about software and control
operation of your Multi-DENCO!

NOTE!
This manual is valid only for configurations built from our standard catalogue.
Any units designed or supplied under special configurations (sometimes referred to
as 'Engineering Specials'), may not be covered by previous, existing or future
documentation.
Please refer to your sales/support contact for any information regarding special
designs.

2.3 Document format


Significant information for each chapter will be highlighted in the following format:

NOTE!
Here you will find additional details on using the Multi-DENCO unit.

– This symbol is used to indicate normal lists.


• This symbol indicates instructions to follow.
9 The result of an action is indicated with this symbol.

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Multi-DENCO Safety and User Information

2.4 Signs used within this manual

2.4.1 Mandatory Signs

General Mandatory Sign

Refer to manual or documentation

Wear ear protection

Wear eye protection

Wear safety footwear

Wear protective gloves

Wear protective clothing

Wear a protective mask

Guards must be used during operation

2.4.2 Prohibition Signs

General prohibition sign

No smoking

No open flame, fire, open ignition source

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Safety and User Information Multi-DENCO

2.4.3 Warning Signs

General warning sign

Warning of low temperature

Warning of electricity

Warning of suspended loads

Warning of toxic substances

Warning of hot surfaces

Warning of automatic starting machinery

Warning of sharp elements

Warning of crushing to limbs

Possible damage to machinery

Environmental damage

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Multi-DENCO Safety and User Information

2.5 Labelling of safety information


The following symbols and notices are provided in appropriate places throughout this
document to designate the safety instructions:

2.5.1 DANGER – Death/serious irreversible injury

Indicates an extremely hazardous situation which will result in death or serious irre-
versible injury, if the safety instruction is not followed.
Example:

Electrocution through hazardous voltage will lead to death or serious injury!


• Disconnect all electric power and ensure the power cannot be inadvertently
energized.
• Verify that all circuits are deenergized, earth, short-circuit and block off all
neighbouring live parts.

2.5.2 WARNING – Death/serious injury

Indicates a hazardous situation which can result in death or serious irreversible


injury, if the safety instruction is not followed.
Example:

High concentration of refrigerants in the air can result in death or serious in-
jury!
High concentration of refrigerants in the air may have an anaesthetic effect and
cause unconsciousness. Prolonged exposure may cause irregular heartbeat and
sudden death. Very high concentration of refrigerant may cause suffocation by
reduced oxygen content in the surrounding air.
• You should therefore only work in an adequately ventilated environment, and
exercise due care and attention when carrying out the work.
• Wear protective clothing and, if necessary, an autonomous breathing apparatus.

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Safety and User Information Multi-DENCO

2.5.3 CAUTION – Minor or moderate injury

Indicates a hazardous situation which can result in minor or moderate injury, if the
safety instruction is not followed.
Example:

Injury due to sharp cutting edges!


• While cleaning care should be taken to prevent risk of injury due to thin fins.
• Wear protective gloves

2.5.4 NOTICE – Environmental or material damage

NOTICE

Indicates actions that can result in equipment or property-damage only accidents.


Examples:

NOTICE
Environmental Damage!
• Dispose of all components and materials (such as water-glycol mix) depending
on material type in an environmentally friendly manner and in accordance with
the local codes, practices and environmental regulations.

NOTICE
Damage to the unit!
• Do not mix up cables during connecting.
• Use the unit wiring diagram to check electrical cablings.

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Multi-DENCO Safety and User Information

2.6 Safety-conscious working


The following is initial general advice to consider during various stages of a project.
More specific information can be found in relevant chapters in this manual.

2.6.1 At all times

Filters (especially used or dirty filters) are easily flammable. Leaking refrigerant can
catch fire and emit noxious substances.
– No smoking is allowed in direct proximity of any aspect of the
Multi-DENCO system.
– No open flames near the system.

To comply with EN 378-3 you must wear suitable Personal Protective Equipment
(PPE) at any point working on a Multi-DENCO unit. As a minimum we recommend:
• Wear safety footwear
• Wear eye protection
• Wear protective gloves
• Wear protective clothing

If operating for a prolonged period of time, noise reducing ear protection may be requi-
red.

• Always conduct your own personal risk assessment to evaluate any further
requirements.

2.6.2 During installation & commissioning


At these times there are higher risks involved with the handling and operating around
a Multi-DENCO system. Further information is provided in chapters 4 to 8.
• Always refer to the latest operation manual and support technical documents
provided with the unit.
• Do not make assumptions based on other products design or information.
• If in doubt, contact your local sales office.

• Protect against unauthorised access.


• Do not use or employ un-qualified or inexperienced workers to install or commission
the Multi-DENCO system.

During installation there is a higher chance of leaks of refrigerant or glycols.


Before adding any cooling medium, ensure:
– Any system pipework is thoroughly tested for leaks
– Use non-polluting methods for testing purposes, e.g. Oxygen Free Nitrogen (OFN)

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Safety and User Information Multi-DENCO

2.6.3 When unit is operational

At any time the unit is operational, rotating machinery and electrically charged com-
ponents are present. When the unit is not electrically isolated:
• Ensure all guards and doors are closed.
• Only remove guards or open doors:
– When the unit has been electrically isolated.
– Sufficient time has been allowed for the rotating fan momentum to cease.
– Sufficient time has been allowed for inverter circuits to discharge.

Information regarding 'Fan touch protection' can be found in Chapter 5.7.


Further relevant information is provided in chapters 9 to 11.

2.6.4 R410A systems


EN 378:2008 Part 1 defines R410A refrigerant to group A1. When using refrigerant
consider your usage in accordance to Regulation (EC) No 842/2006.

NOTE!
Refer to 'Field Charge' on the unit serial plate (see chapter 1.2) in regards to system
refrigerant volume.

NOTICE
• Always refer to the Material Safety Data Sheet (MSDS) from the supplier.
– Information relating to hazards, handling and storage, first aid amongst other
information is contained within the MSDS.
• Store these document(s) along with the Multi-DENCO documents.

Features of R410A:
– Non-combustible
– No direct toxic effect
– Colourless and odourless
– Heavier/denser than air
– Contains fluorinated greenhouse gases as defined by the Kyoto Protocol
– Ozone-depleting potential OPD: 0
– Greenhouse potential GWP: 1980
– Water hazard class WGK: 1, with a slight risk to water

Due to the nature of a refrigeration circuit, a Multi-DENCO system can contain dan-
gerously hot and dangerous cold aspects within the same system or circuit. Failure
to wear PPE could result in moderate injury.
• Review the appropriate chapters for further information.
• Never touch any part of the refrigeration circuit with unprotected skin.
• Always conduct your own personal risk assessment to evaluate any further
requirements.

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Multi-DENCO Safety and User Information

2.6.5 Systems containing glycol

NOTICE
Properties of different glycols can vary significantly between different types of glycols
and different manufacturers
• Always refer to manufacturer’s information for usage guidelines
• Always handle and dispose in accordance with local codes, practices and
environmental regulations.

General features of glycols:


– Usually mixed with water.
– Can reduce the freezing temperature point of the mixture.
– Reduces cooling capacity when compared to water-only systems.
Further information can be found in Chapter 6 and Chapter 8 of this manual.

2.7 Proper use


The Multi-DENCO series are designed as indoor units and for connection to a heat
rejection system. They are designed for cooling, heating, humidification, dehumidifica-
tion and filtering of air at atmospheric pressure.
Unless otherwise stated the equipment will not be suitable for use in corrosive atmo-
spheres, for example, areas near large volumes of salt water.
Proper use also requires adherence to the operation manual for the controller and
suitable and regular inspection and maintenance, following guidelines specified by
FläktGroup.
Improper use Any use other than that described above is considered improper. The manufacturer/
supplier is not liable for damage arising from improper use. The user alone bears any
risk or cost that can be attributed to 'improper use'.
It is not allowed to operate units:
– in explosion risk areas;
– in areas with strong electromagnetic fields, (electromagnetic immunity as of EMC
Directive; refer to the Declaration of Conformity in the unit documentation)
– in environment with high levels of air contamination,
– in environments with corrosive and/or aggressive air.

2.8 Modifications and changes


Changes or modifications of any Multi-DENCO units after dispatch from factory shall
only be performed following discussion and approval by the sales office. Any works
planned that are not covered in this manual must be discussed with, and are subject
to approval; non compliance could invalidate the CE conformity and may void the war-
ranty.

2.9 Spare parts


Only original spare parts from our spare parts department are allowed. Use of third
party spare parts are not allowed and are at the user's own risks. A common spare
parts list is enclosed with the unit (either printed or in the form of a sticker). If in any
doubt as to the spare part required, please contact your local sales representative who
will be able to assist.

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Safety and User Information Multi-DENCO

2.10 Disposal
Main and operating supply materials shall be disposed of according to material type in
a safe and environmentally friendly manner – always refer to your local by-laws and
Country specific legislation (also refer to section 12.2 Disposal).

2.11 Personnel selection and qualification


• Any individual working on the unit must read and understand all of this manual
before starting any works.

• Any individual working on this system shall be suitably qualified and licensed for the
region that the system in installed within.
• Within the European Union, refrigeration circuit operators shall be in accordance
with (EC) No 842/2006 Articles 4 & 5.
• All personnel involved with the system must understand and observe any local
legislation regarding safe working practice.

2.12 Noise
The sound power level of the unit can rise up to 98 dB(A) according EN ISO 3745
accuracy class 1.

2.13 Environmental considerations


Some Multi-DENCO versions can use refrigerants, therefore careful and specific atten-
tion is required regarding the handling and storage. Consideration must be given to
minimise or eliminate any discharge of refrigerant (accidental or deliberate). Chilled
water as a cooling medium may contain impurities or chemicals (such as glycol) requi-
ring disposal according to local or regional codes, practices and environmental regula-
tions.
FläktGroup highly advises that at all stages of our product lifestyle (purchase, install,
maintenance and disposal) carefully consideration is given to any decision to ensure
minimal environmental impact.
Further information about our policies and values can be found on our website:
www.flaktgroup.com

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Multi-DENCO Technical Description

3 Technical Description

3.1 Unit description


Multi-DENCO units are designed for indoor installation (no exposure to outdoor
weather) and the system is completed by being connected to an heat rejection system
(for example; condenser, drycooler, chiller etc). Typically the units are designed for
cooling data centres, though they have a large variety of uses, such as (but not limited
to): server rooms, telecom rooms, laboratories, museums, libraries, production env-
ironments etc.
Heat exchange and airflow is performed vertically; with downflow models receiving
warm air from the top of the unit and delivering cold air at the bottom and upflow units
Fig. 3-1: Multi-DENCO Unit, taking warm air from the bottom of the unit and discharging cold air at the top. These
A-Version, Size 092 airflows can be directed at entry and exit of the unit, by using accessories such as: front
door grille, ceiling return section, base stands, horizontal discharge sections and dam-
pers.
Multi-DENCO units are available in 7 sizes ranging from (WxDxH) 600x600x1940 mm
to 3380x880x1968 mm. These units come with a wide variety of accessories and opti-
ons meaning that each Multi-DENCO unit can be tailored to your room's needs.
Once you have received your Multi-DENCO unit, typical onsite tasks include, (but are
not limited to):
– Installation and positioning of units
– Refrigeration/pipework connections between indoor and outdoor unit
– Connection of electrical power supply
– Connection of communication cabling
– Installation of any accessories provide 'loose' (e.g. water detection tape)
– Commissioning of the Multi-DENCO unit
– Configuration of network settings

3.1.1 DENCO-OfficeCool
This is a variation of a Multi-DENCO unit designed specifically to address the needs of
comfort cooling. The design is aimed at reducing fan velocities, reduced sound and
features for integration with Local Environment Control Units (LECUs) allowing for
adjustable environment to suit comfort levels. These are available as direct expansion
or chilled water versions.
DENCO-OfficeCool design are mostly similar to the requirements and design of
Multi-DENCO units. Within this manual, any differences in the design will be explained.

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Technical Description Multi-DENCO

3.2 Operating limits

Multi-DENCO Unit A-Version C-Version X-Version CombiCool Circuit

Indoor Temperature Minimum °C 10 10 10 10

Indoor Temperature Maximum °C 40 40 32 40

Indoor Humidity (Absolute) Minimum g/kg 2 2 2 2

Indoor Humidity (Absolute) Maximum g/kg 18 18 18 18

Outdoor Ambient Air Temperature Minimum (Standard) °C -20 N/A -15 N/A

Outdoor Ambient Air Temperature Minimum (with low ambient kit) °C -40 N/A N/A N/A

Outdoor Ambient Air Temperature Maximum °C 55 N/A 46 N/A

Condensing Temperature Minimum °C 35 N/A 35 N/A

Condensing Temperature Maximum °C 64 N/A 64 N/A

Maximum Operating Pressure (High) MPa 4.32 0.6 2 4.15 0.6 2

Maximum Operating Pressure (Low) MPa 4.32/3.00 1 N/A 4.15 N/A

1 4.32 MPa for unit sizes 010 to 065. 3.00 MPa for unit sizes 092 & 130
2
Default configuration for standard design. 1.00 MPa for certain configurations

DENCO-OfficeCool Unit H-Version O-Version

Indoor Temperature Minimum °C 10 10

Indoor Temperature Maximum °C 32 40

Indoor Humidity (Absolute) Minimum g/kg 2 2

Indoor Humidity (Absolute) Maximum g/kg 18 18

Outdoor Ambient Air Temperature Minimum °C -15 N/A

Outdoor Ambient Air Temperature Maximum °C 46 N/A


Condensing Temperature Minimum °C 35 N/A

Condensing Temperature Maximum °C 64 N/A

Maximum Operating Pressure (High) MPa 4.15 0.6 1

Maximum Operating Pressure (Low) MPa 4.15 N/A

1 Default configuration for standard design. 1.00MPa for certain configurations

3.3 Operating modes


A basic Multi-DENCO unit only has the capacity to perform cooling, therefore only
being able to control the upper limit of the temperature of the room. Heaters and humi-
difiers can be added to the design to allow for control of both the lower limit of tempe-
rature and to control the humidification of the room.
Cooling The main function of a close control unit is to cool the air within a room to a defined set
point.
If using refrigerant (A-Version & X-Version), this is achieved by adjusting compressor
speed, expansion valve opening and indoor and outdoor fan speed.
If using chilled water (C-Version), this is accomplished by adjusting the water valve
opening and adjusting the indoor fan speed.
Both methods use variable technology to match the heat of rejection by the
Multi-DENCO unit to the volume of heat produced within the room.

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Multi-DENCO Technical Description

Heating (if fitted) If the indoor temperatures are too low then the heating function will be activated. There
are several options for this operation allowing the heating to be a start/stop operation
or variable. When heating is required, the fans can increase their speed.
Humidification (if fitted) If the humidity levels are below the requirements then the humidifier will be activated
to add more moisture to the air. The amount of moisture added to the air varies propor-
tionally to the demand, with the humidifier able to operate between 25 - 100% of its
rated capacity.
Dehumidification (if enabled) As a default factory settings, dehumidification is a secondary priority compared to tem-
perature control, therefore it will only become active and maintained if the temperature
limits are met during the whole operation. If at any point, those limits are not met, the
dehumidification operation will be stopped and the unit will operate on a temperature
control basis.
To perform dehumidification, the unit cools at a higher rate (i.e. over-cools the air) to
create condensate on the the heat exchanger coil. Heating options can then be used
to re-heat the air before it leaves the unit.
Software settings can be changed to deactivate the dehumidification modes, even if
components are fitted.
CombiCool (if fitted) The CombiCool options has two separate cooling circuits. CombiCool can be fitted to
A- & C-versions of the Multi-DENCO units.
The CombiCool circuit is the primary circuit and is chilled water. The secondary circuit
relates to the version (e.g. A-Version, C-Version). The unit will only operate one circuit
at a time.
If the CombiCool circuit is unable to meet the cooling requirements of the room then
the unit changes to use the 'secondary' circuit. When possible, the unit will try to switch
back to the 'primary' CombiCool circuit.
This feature is ideal to provide internal redundancy to each unit.
CombiCool FreeCool The unit is fitted with the same CombiCool Coil as above, but can be configured with a
(if fitted) FreeCool strategy. When the Cooling Demand is low, the unit will operate with only the
FreeCool circuit operating. If this demand increases above a certain threshold, the unit
will then activate its secondary circuit (direct expansion or chilled water) and both cir-
cuits to operate at the same time to meet the cooling requirements.
An ambient sensor can be used to measure the outdoor temperatures. If the ambient
temperature is high (above a set value), then the FreeCool circuit will be deactivated
and only the secondary circuit will operate. Once the ambient temperature has reduced
then the FreeCool circuit will become available again.

3.4 Operating strategies


Multi-DENCO's inbuilt advance software combined with the latest EC variable techno-
logy and networking capability, enables the unit to operate with intelligent control stra-
tegies to increase performance or maximise energy savings. In most instances we
would recommend using a Running Redundancy strategy to help maximise the energy
savings possible.
Duty/standby operation Within a room there may be additional units installed as a backup to maintain cooling
performance in case there is an alarm or failure on a unit. A common description is an
'N+1' setup, where N describes the number of units required to cool a room. By using
the network capability of the unit, upon failure, a signal can be sent to start the standby
unit.
The network of units can be configured so that the unit designated as 'standby' is chan-
ged over after a pre-set period to ensure even wear over their lifetimes.

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Technical Description Multi-DENCO

Running redundancy Instead of the standby unit(s) remaining off, running redundancy allows all units to ope-
rate at the same time, reducing their cooling requirements. This is can be referred to
as 'Hot/Cold Standby'.
Each unit will operate on 'part load', reducing the speed of the fans and other variable
components. The network would still have backup capability: if a unit developed a fault
the other units would use their spare capacity to meet the cooling requirements.
By operating in part load, there are significant energy savings when compared to a tra-
ditional 'Duty/Standby' operation. The diagram shows an example of savings available:

Fig. 3-2: Running Redundancy Example

Sensor averaging Sensor averaging can be calculated on temperature, humidity or both, when
Multi-DENCO units are connected in a network. Each unit sends their sensor readings
to every unit in the network. Each unit then takes all the values and calculates the aver-
age independent of the network units.
This gives the advantage of balancing the cooling requirements across all of the units
within a room, rather than on individual airflows. The software has features to allow for
sensor, communication or unit failure, so that the values do no distort the average
value and the unit can change back to 'stand-alone' if necessary.
Automatic Pressurisation APS ensures a constant pressure in the floor plenum by the Multi-DENCO unit. This
System (APS) can help reduce hot spots and allows for fast reaction to changes in airflow.
This also saves energy as the Multi-DENCO fans only supply the same amount of air
to the floor void, as the amount of air being removed by servers.
For datacentres, this feature can be especially efficient when combined with cold-aisle
containment.

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Multi-DENCO Technical Description

3.5 Components

Fig. 3-3: Components


1 Casing
The casing design gives the unit a high level of air tightness. The side and rear panels
are flat and are flush with the edge of the frame. The front doors are curved and are
removable during servicing. All doors use a compression locking mechanism to give a
high quality seal.
The frame members are anodised aluminium and the panels are white PVC coated
steel. Other panel colours are available on request.
2 Touch screen display
A 4.3" colour touch screen display is mounted into one of the front doors of the unit
(standard configuration). Settings are separated into three levels allowing for control of
system settings based on passwords. The display is able to switch between several
languages and alarms are displayed in plain text.
The display has a screen saver function, which changes to signify when there is an
alarm present.
3 Microprocessor control
The microprocessor can control all the functions for cooling, heating, humidifying and
dehumidifying. It can monitor all digital and analogue inputs and outputs and can be
linked in a network between units. The C5-12 controller can output to the BMS stan-
dard RS485, but other BMS interfaces can be installed into the controller.
As an additional option, the C5-12 controller can be fitted with an UPS capacitor to
enabling the powering of the controls for over 1 minute during a power outage. This
feature removals the start-up time of the unit when the power supply is restored.
4 Cooling coil
The cooling coil is inclined within the unit and uses copper tubes and rippled aluminium
fins to give high performance. To prevent condensed water entering the supply air, an
intermediate drip tray collects water that drains to a larger drip tray, which is mounted
to the bottom of the coil.

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Technical Description Multi-DENCO

5 EC fan
All Multi-DENCO units use direct driven, variable speed, high efficiency EC plug back-
ward curved fan with three dimensional profiled blades as standard. The impeller is
optimally balanced according to ISO1940 and fan speed modulates on standard set-
tings.
The fan is made of a composite material and variable speed regulation is performed
using a 0-10 V control signal. An EC drive motor with an internal overload protection is
integrated in the fan. Fan operation is monitored using a current relay. In the event of
a fan failure, all other functions are interlocked, to prevent their operation.
6 Filters
Multi-DENCO units are provided with G4 class filters as standard, with high efficiency
G7 filters or G4 washable filters (limited regions) available. The filters are positioned
directly in front of the coil and are replaceable from the front of the unit. Other filters
can be supplied upon request.
7 Humidifier
An electrode boiler humidifier can be installed into the unit to allow humidity to be con-
trolled. The humidifier generates steam using proportional regulation of untreated
mains cold water. Electrode boiler humidifiers generate sterile, odourless steam free
of mineral deposits. The humidifier has an inlet hose connection and a water drain
connection to remove any remaining water.
8 Electric heater
Units with electrical heating are equipped with sturdy sheathed elements with stainless
steel finning and rated to operate at black heat in order to prevent annealing conditions
and sparking. Overheat protection is provided through a thermostat (Klixon). The
available heating duty is sufficient to prevent low supply temperatures in the dehumi-
dification mode.
Electric heating can also have an integrated thyristor control to provide variable heating
loads and closer control.
Low-pressure, hot water options are also available as an alternative heating method.
9 Electronic Expansion Valve (EEV)
The electronic expansion valve is an efficient, service friendly, refrigerant metering
device that accurately controls the superheat of the refrigerant within the cooling coil.
It is controlled through set parameters in the C5-12 controller and software and requi-
res no external adjustment throughout its working life.
The EEV has the ability to close itself in the event of a power failure by using a power
supply stored within the C5-12 controller.
10 and 11 Compressor and inverter
Multi-DENCO units use variable speed inverter compressors. These operate using
R410A and have a high efficiency using a permanent magnet and brushless DC
Motors.
Within the unit, the configuration can be; single compressor, in tandem with a fixed
speed compressor or in tandem with another inverter compressor.
The compressors are provided with Neoprene anti-vibrational mounts, motor protec-
tion against overcurrent and thermal overload and are able to perform periodical oil
reclaim on a cyclical basis.
Units using only fixed speed compressors are only available for size 010 and 018.

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Multi-DENCO Technical Description

12 Chilled water valve & actuator


A variety of modulating ball valves are available with the Multi-DENCO units:
– 3-port valve
– 3-port valve with double regulating valve (DRV) in bypass
– 2-port valves
– 2-port pressure independent control (PIC) valves
All valves are fully modulating and are placed within the return water pipework. The ac-
tuators available come in 2 varieties:
– Drive Open Drive Close (DODC)
– 0-10 V control
These options, combined with the variety of valves, ensure that you have a valve and
actuator combination that meets your needs.
The same valves and actuators are used for both the chilled water units (C-Version)
and the CombiCool circuits.

3.6 Heat rejection systems


A Multi-DENCO unit needs to be part of a system which includes heat rejection. There
are several different methods for heat rejection (depending on your Multi-DENCO unit)
and your local sales office can help you decide the best for your requirements.

3.6.1 Condensers
A-Version units typically use condensers to reject the heat that the Multi-DENCO unit
has absorbed from the room. They consist of a large coil and a fan to condense the
R410A gas into a liquid form. Condensers can be supplied with AC or EC fans and can
be installed with vertical or horizontal airflow.
Nominal duties for condensers range from 5kW to 100kW when using a 15°C tempe-
rature differential. The refrigerant gas inlet and liquid outlet pipes are terminated as
stub connections, sealed to contain a low-pressure nitrogen holding charge (5 psig/
0.35 bar).
Condensers can be installed either with a direct 1 to 1 relationship with the indoor unit
or 2 condensers can be used with a single Multi-DENCO unit as part of 1 single circuit.
This arrangement is refer to as 'twin condensers'.

3.6.2 Chillers
C-Version units are typically used with chillers (usually several are connected to the
same chiller). The water inlet temperature and the room set point can determine the
capacity of the unit when using chilled water from a chiller.
Chillers can bring benefits of several economies of scale for larger operations and
allow for multiple functions to source the same chiller for heat rejection. We are able to
offer freecooling chillers that can use low ambient temperatures to minimise energy
usage.
Separate operating manuals are supplied.

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Technical Description Multi-DENCO

3.6.3 Condensing units


Condensing units perform the same functions as condensers, but they also contain the
compressor. Used for the X-Version of Multi-DENCO and H-Version of DENCO-Office-
Cool, usually the indoor unit would be used with 1 condensing unit, but for certain unit
sizes, 2 condensing units can be used. 2 circuits are used and the indoor unit has a
'split coil', half the coil operates with 1 condensing unit, the other half of the coil with
the other condensing unit.
Separate operating manuals are supplied with the outdoor units for this configuration.

3.6.4 Dry coolers


Typically used in CombiCool configurations, our drycoolers are designed exactly the
same as our condensers (dimension and build design) but are used to cool water or
glycol based fluids. These units can be used for FreeCool strategies also.

3.6.5 Plate heat exchangers


Where installation of A-Version units requires a large distance between the indoor unit
and any heat rejection location, a plate heat exchanger can be used to interface bet-
ween the refrigerant system and a chilled water system. The plate heat exchanger can
use the chilled water to condense the refrigerant into liquid form, thereby transferring
the heat to the chilled water circuit, which can then be transported to a chiller or similar.
We have a vast catalogue and plate heat exchangers available and your local sales
office will be able to help you with your options. Separate operating manuals will be
supplied.

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Multi-DENCO Shipping and Storage

4 Shipping and Storage

4.1 Delivery
On receipt, the equipment should be carefully checked against the despatch note and
examined for completeness and damage.
It is necessary to take photographs of all visible transit damage.

NOTE!
Missing parts or claims of shipping damage shall only be reported to the transport
insurance, if the damage has been confirmed by the delivering carrier.

NOTE!
We recommend to keep the equipment in the original packaging for protection, ease
of handling, shipping and storage. Remove the original packaging only before instal-
lation.
If the unit is stored for a period of time before installation or commissioning, it must
be protected from the elements, build-up of dust and dirt!

4.2 Handling

Multi-DENCO units are heavy and can have a high centre of gravity. Failure to
safely secure the equipment may result in death or serious injury.
• See unit's serial plate or documents for weight information.
• Always use proper and suitable lifting equipment for each movement.
• When moving using a fork lift truck or a stack-a-truck – secure the unit against
tilting.
• Never stand beneath suspended loads.

As a minimum for handling and shipping, we recommend wearing:


– Safety footwear
– Protective gloves
• Conduct your own risk assessment to evaluate the need for any additional PPE.

When handling a Multi-DENCO unit:


• Only use the designated lifting points.
• Never attach lifting hooks or similar gear directly to the unit construction.
• Use proper and appropriate lifting gear.
• When handling and shipping, do not tilt the unit by more than 15°.
• With the packing pallet and slinging the unit; use spreader bars to prevent damage.

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Shipping and Storage Multi-DENCO

• Before lifting or shipping the unit, make sure that all mountings are fixed and
secured.
• Only use lifting gear with sufficient load carrying capacity.
• Never use damaged lifting equipment.
• Ropes/chains shall not be knotted or be exposed to sharp edges.
• Only use ropes/chains of the same length.
• Move the unit carefully without fast irregular movements.
• Always set the unit down gently, without a large impact.
• Take steps to avoid twisting the cabinet during positioning.
• If necessary, use a specialist company to transport the unit.

Use slings to secure the unit against tilting!

Fig. 4-1: Handling of unit in export packing and wooden crate

NOTE!
The only valid dimensional drawing is enclosed with the unit documentation.

Placement at the installation site is covered by chapter 5.3.

4.3 Storage
Storage conditions for uninstalled units
Air temperature: -20 °C to +50 °C
Air humidity: up to 90 % (relative humidity with no condensation)
During storage, the unit and packaging must be in a protected environment and not
exposed to the outdoor environment.

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5 Installation
Note on unit assembly and installation!
Placement, installation and assembly should only be carried out by qualified person-
nel and must observe relevant accident prevention regulations, as well as other
recognized health and safety codes of practice.
Information on moving the unit!
If the units have been moved from one plant/location to another, they will need to be
re-commissioned even if the new room layout is similar.

As a minimum for handling and positioning, we recommend wearing:


– Safety footwear
– Protective gloves
• Conduct your own risk assessment to evaluate the need for any additional PPE.

5.1 Requirements and considerations

Refer to the unit's dimensional drawing for weights and dimensions.

5.1.1 General requirements


The unit must be installed at a location that fulfils the following requirements:

NOTICE
Dusty environments can damage electronic printed circuit boards.
• Ensure the Multi-DENCO unit is protected from dust during installation
• Clean unit before first use
Humidity sensors can be damaged by aggressive vapours (e.g. chlorine
or acetone)
• Ensure possible vapours are removed from the local environment before
installation
• Ensure the room has a good 'air tightness' to prevent any entry of vapours.

– Ensure that the site is level and that it can support the weight of the equipment, so
that no vibrations or operating noise occurs when the unit is operating.
– The unit should be set in an upright position - level in both directions. Failure to carry
out levelling correctly may cause operational problems; particularly to the drainage.
Possible misalignment of panels will indicate that the unit is not level.
– The unit should be installed so that it is only accessible to trained and authorised
personnel.
– Sufficient clearance in front of the unit must be ensured for maintenance and
service jobs.
– (If applicable to local regulation) Check installation site fulfill requirements as defined
in EN 378-3:2008+A1:2012.
– It is recommended that once the the Multi-DENCO unit is located, then it is fixed in
placed (e.g. bolted, bracketed etc) to prevent unwanted movement or vibrations.

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Installation Multi-DENCO

5.1.2 Noise consideration at installation site


It is important noise has been considered before the installation. Options are available
to equip your Multi-DENCO unit with sound reduction features. Noise is usually a high
consideration of DENCO-OfficeCool installations therefore. Ask your local sales repre-
sentative for details.
When planning or installing units, consider:
– The acoustic properties of the room – soft furnishings, curtains and carpets tend to
reduce sound reflections. Bare walls and vertical surfaces tend to produce larger
sound reflections which result in higher noise levels.
– Equipment placed alongside a solid wall can transmit noise through and along the
wall into adjacent areas.
– Floors with high deflections e.g. wooden floors, can amplify the noise produced by
the unit.
To reduce these problems, the following are suggestions, dependent upon site condi-
tions:
– Ensure that any vertical planes directly in front of the unit are acoustically insulated.
– Where units are situated in equipment rooms, acoustic treatment of the walls of the
equipment room should be considered.
– Acoustic pads may be placed behind equipment to reduce wall transmissions.
– Panels and cables in the air flow direction can cause vibrations and produce noise.
Rigidly support these components to a solid structure to reduce this effect.
– Positioning close control air handling units on building columns or supporting ele-
ments of the building to try to minimise noise transmission on the building. Steel floor
framing for unit equipment may be used for this purpose.
– Acoustic rubber pads for vibration insulation may be used beneath the equipment.
– Abrupt bends in pipework should be avoided by fitting long turn elbows or forming
long radius bends.
– Where pipes pass through walls or partitions, an oversize sleeve to be packed with
suitable insulation material is recommended.
– Insulate pipes and rigidly support to a solid structure of a building.

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5.2 Substructures

5.2.1 Under unit drip tray


To protect the floor underneath a unit from any condensation, a drip tray can be moun-
ted underneath.
The drip tray can be used in a raised floor (underneath a base frame) or with a plinth.
It is design to hold a small volume of water and should be used along with water detec-
tion tape or spot sensor to prevent any significant build-up of water.

Fig. 5-1

5.2.2 Base stand


For units to be used with a raised floor (upflow and downflow), a base stand should be
used underneath the close control unit. The height of the base stand can be from a
minimum of 300 mm.
The base stand comes complete with adjustable feet (+/- 25 mm available). The sur-
face between the base stand and the unit should be lined with a 3 mm semi-hard gas-
ket. For more details or specification please contact your local sales representative.

Fig. 5-2

5.2.3 Support plinth


For units installed without a raised floor, a plinth should be used to allow for service
connections to the unit. The standard plinth is 200 mm tall and uses the same frame
and materials as the unit for a consistent look. Panels are removable with a cross-head
screwdriver, the same as the unit's panels.

Fig. 5-3

5.2.4 Shut off damper


Dampers can be provided loose for further installation on site. The control of the dam-
per is linked to the unit's C5-12 controller and can be made to open/close depending
on the unit's operation. It can also close if a critical alarm in generated or linked to fire
alarm shutdown routines to protect your units.
Dampers should not be directly mounted to the air discharge of a fan. At least a
600 mm duct should be in between the damper and the fan.

Fig. 5-4

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Installation Multi-DENCO

5.2.5 Ceiling connection duct


For units that wish to connect with a suspended ceiling, a connection duct can be used
to create an air path.
The ceiling connection duct is made of the same material as the unit's panels. The
height of ceiling connection ducts are made to specification and they can bolt onto the
top of the close control unit through a service panel on either side.

Fig. 5-5

5.2.6 Horizontal air discharge


For upflow units that do not have ceiling voids, a horizontal air discharge section can
be used to change the airflow direction.
The design can have a grille on the front panel only (1 way blow) or grilles on the front
and sides (3 way blow).
The assembly is bolted onto the top of the unit through the frame. This can be acces-
sed via the service panels on either side of the unit (for 3 way blow, remove the grille
for access).
Fig. 5-6

5.2.7 Protection grille


This is the standard grille that is placed directly on top of the unit to protect individuals
from the rotating fan blades during operation. The grille design is different for upflow
and downflow units.

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5.3 Unit placement


It is easier for unit placement can be carried out prior to the installation of a raised floor.
It is recommended not to remove the transport packing to provide sufficient protection
for the unit during placement.

Multi-DENCO units are heavy and can have a high centre of gravity. Failure to
safely secure the equipment may result in death or serious injury.
• Never stand beneath suspended loads.

Multi-DENCO units are heavy and can have a high centre of gravity. The unit, or
parts of the unit can, tip and fall. Failure to safely install the equipment may result
in death or serious injury.
• Secure the unit against tipping before removing the unit from the pallet.
• Do not lean against or lean objects against the unit.
• Do not expose any part of your body, limbs or hands to the space between the
unit and any substructures (see chapter 5.2) or between the unit and the ground.

NOTICE
During installation and placement, weight loads may be increased or concentra-
ted. Failure to account for this can cause damage to the floor or the unit.
• Ensure the floor can withstand the weight and forces of the unit, lifting equipment
and operators.
• For installation on a raised floor, ensure flooring can support increased point
loads.

NOTE!
We recommend using two heavy-duty jacks. Always refer to the manu-
facturer's instructions when operating the heavy-duty jacks. For further
advice, consult your local office.

Fig. 5-7: Heavy-duty jack

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Installation Multi-DENCO

5.3.1 Placement without raised floor


The unit could be placed on a lift truck or two to six-wheeled platform and manoeuvred
to its installation site. Once in position, check and adjust levelling will need to be con-
ducted.
• Care should be taken to prevent damage from contacting the unit by the lifting gear/
slings or fork lift truck etc.
• Lift the unit from the pallet and take care to manoeuvre it.
• The unit should be lifted from the base frame only with suitable measures to prevent
tipping or rolling.

NOTE!
We strongly recommend using a third party, specialist lifting company to offload and
position all Multi-DENCO equipment.

5.3.2 Placement on raised floor


• Perform the levelling of the unit at the installation site.
• Take good care when manoeuvring the unit during placement using wheeled
platform.
• At the same time secure the unit against tipping.

5.4 Clearance and Access

5.4.1 Clearance

Size Unit Nominal Clearance Floor Service Ac- Distance to


Width Airflow above unit (A) Void (B) cess (C) first floor grille (D)
mm m3/s mm mm mm mm
010 600 0.83 300 300 600 2000
018 800 1.43 300 300 600 2000
030 1180 2.40 400 400 600 2000
045 1670 2.53 400 400 600 2000
065 1992 5.09 500 500 600 2000
092 2500 6.59 500 500 880 2000
130 3380 9.19 500 500 880 2000

Tab. 5-1:
Fig. 5-8
Columns A, B and D are recommended minimum values to ensure satisfactory
operation by your Multi-DENCO unit.
Column C is the mandatory minimum values to ensure serviceability for your
Multi-DENCO unit.

Note!
Column C is ONLY the minimum service requirements and does not reflect any
safety requirements that may affect your local region. Refer to your local Health and
Safety regulation for aisle clearances and free space requirements to ensure a safe
working environment.

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5.4.2 Access
Multi-DENCO has been designed to be serviceable exclusively through the front doors
of the unit (the curved panels). Access to the right hand side panel (as you face the
unit) can increase the speed of service, but is not mandatory.
Multi-DENCO units are compact and efficient design, therefore the larger the clearance
all around the unit, the easier service and repair work can be conducted.
The doors are hinged and removable. Some frame mullions are removable for assi-
sting in removing larger components.

5.4.3 Removing doors and panels


All unit components are accessible through front doors and panels.
s

Doors and panels can weigh up to 11kg and easily tip and fall.
• Ensure panels are held in place when fixings are being removed.
• Ensure doors are properly attended when being removed.
• Use access platforms for units that are installed above floor height.

• To open the front doors, use the key supplied with the unit to release the 1/2 turn
locks.
• Before removing a door with an integrated display remove the cable between the
C5-12 controller and the display module.
• Release the upper hinge retainer and remove panel.
• To reinstall the doors, first lift the panel and clip into the bottom retainer. Release the
top retainer, shift the panel upwards to the unit and clip into the top retainer.
• The rear and side panels can be removed by unscrewing six screws (per panel). It
is recommended to, use a vacuum lifting tool for holding panels.

5.4.4 Ductwork
On units where ductwork is to be fitted, ductwork connections must be completed
before any pipework and electrical connections are made.

Note!
Care must be taken when fixing ductwork to the unit that all panels and metal plates
can be removed and are not impeded by rivets, 'tec-screws' and other fixings!

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Installation Multi-DENCO

5.5 Installing enclosed accessories


Below is a list of items or options that could be supplied with your Multi-DENCO unit.
The accessories could be inside of the unit on delivery or as a separate package. The
below items will need further installation once the unit is in place.

5.5.1 Interface cards


• There are several versions of the interface cards available, these all install directly
into the controller within the unit. Installation and configuration of these cards must
only be conducted by a suitably qualified person.

Fig. 5-9

5.5.2 Air sensor


• If a temperature and humidity sensor is supplied as an remote accessory item, it
must be positioned in the reference air flow and must not be subjected to direct
sunlight.
• The sensor cable is already connected to the unit and can be extended to a
maximum of 30 m by using a cable of the same specification.

Fig. 5-10

Note!
Take care when locating the remote air sensor as the unit will attempt to control the
conditions of the room based on the sensor location. Do not place the sensor in
areas of draft or anywhere near a heat source that could provide a 'false reading'!

5.5.3 Floor void air pressure control (APS)


• The air differential pressure sensor is mounted within the unit. But the two hoses
must be connected to the sensor during installation to enable the sensor to read the
air pressures.
• Two hose ports are available: '+' (high pressure), which needs the hose to be
positioned within the floor void. The other hose, '-' (low pressure) which needs to be
installed within the room space.
• Air hose opening in the raised floor must be positioned at the right angle to air flow,
in order to prevent measurement of dynamic pressure.This can also be achieved if
the hoses are enclosed in perforated boxes.
Fig. 5-11
• The pressure test point must be placed at least 2 m away from the unit.
• It is optimal to run multiple pressure test points in one closed circular line, shown in
figure Fig. 5-12.
• APS can also be used to monitor pressure difference between a hot and cold aisle.
• If multiple units used within a room, use a BMS system must be used to calculate an
average value and then use the BMS to adjust the fan speed.

Fig. 5-12: Showing multiple


pressure test points
in a floor void.

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5.5.4 Water detection

Important Note!
The water detection tape should be installed prior to commissioning and the end
user should be made aware that, upon contact with water, an alarm is generated by
the controller as an indication of the presence of water. This alarm is not critical to
the unit's operation, therefore the unit will continue to operate. The alarm does not
protect the unit from water build up, it simply highlights the issue, therefore at every
occurrence of the alarm it should be investigated to find the cause and rectify the
issue. If an under unit drip tray is supplied it is ideal to mount the sensors within the
drip tray (see Fig. 5-1 on page 39).

Water detection tape


• The water detection tape will be delivered connected to the unit's controller. The
tape will be collected together and should be unwound once the unit is in it's final
position (see Fig. 5-13).

Fig. 5-13
• The sensor tape should be routed on the floor where it is likely to come into contact
with any leaking water.
• If possible, run the tape around the perimeter of the unit around the base stand feet
(if fitted).
• The water sensor needs to be fitted to the floor in such a way that it maintains a
contact with the surface at all times but will not come into contact with any vibrating
parts that could cause damage to the sensor. A quick curing, non-conductive epoxy
resin or silicone sealant is an effective way to keep the water sensor in its correct
location.
Fig. 5-14

Water detection spot • Spot sensors are also available for water detection.
sensors • These should also be installed in the under unit drip tray (if included).
• Distribute the sensors evenly to help ensure all areas under the unit can detect a
water build up.

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Installation Multi-DENCO

5.5.5 Condensate pump

When a humidifier is fitted, condensate collected in drip trays and condensate


pumps can be at near boiling temperatures. This condensate, or surfaces that it
has been in contact with, can cause scalding or burns.
• The installer must install condensate tubing suitable for these temperatures.
• The installer must ensure individuals cannot come in contact with this fluid, tubing
or affected regions.

When installing a condensate pump:


• Never run power supply cables for the condensate pump together with control
cabling
• Position the condensate pump carefully and secure it against slipping
• Where ever possible consider future servicing needs where this pump may have to
be removed and cleaned as part of a maintenance program
• Fitting the condensate pump outside of the unit casing offers the best access
• Care must be taken that condensate inlet and outlet are not placed beneath the fan
• Ensure that no power or water hoses can contact the fan, if necessary, suitable
condensate hose bracketing should be installed
For cold water condensate pumps (units without a humidifier):
Pump Capacity: 0.85 litres
Max. Discharge Height: 9 metres
Max. Flow Rate: 40 litres per hour for 1 metre discharge height
28 litres per hour for 9 metre discharge height
For hot water condensate pumps (units with a humidifier):
Pump Capacity: 5 litres
Max. Discharge Height: 6 metres
Max. Flow Rate: 480 litres per hour for 1 metre discharge height
120 litres per hour for 6 metre discharge height

5.5.6 Remote monitoring touch screen display


• The display can be mounted up to 50 m away from the C5-12 controller within the
Multi-DENCO unit.
• A 24 VAC supply is required, local, to power the display, together with a two
core screened data cable that networks the display to the pLAN connection on
the C5-12 controller. For further details refer to the wiring diagram.

Fig. 5-15

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5.6 Installation of outdoor units


Note!
It is mandatory to connect the Multi-DENCO indoor unit to a heat rejection unit.
This is achieved typically in five different forms, depending on the version used:
– Condensers (DMOUCD)
– Condensing units (DMOUUD) (including heat pumps)
– Chiller
– Drycoolers
– Plate heat exchangers
This chapter covers only the condensers (DMOUCD). Condensing units
(DMOUUD) has a separate installation manual that can be provided on request and
is provided with the delivery of the equipment. For all other varieties or equipment
not purchased with a Multi-DENCO unit, please refer to their independent manuals.

Outdoor condensers use exposed heat exchanger coils, which have thin metallic
fins. These fins can cause cuts to limbs.
• Ensure cut protective PPE is worn.
• Do not handle the condenser in the region where the coil is exposed.

• All warnings found in chapter 5.3 Unit placement also apply.

5.6.1 Requirements
– Condensers are design for outdoor installation
– As standard, condensers can operate in temperatures as low as -20 °C
– Winter kits are available for very low ambient conditions (down to -40 °C)
– For condensers to be installed in a coastal region or an area of high corrosion,
ensure:
– The unit is supplied with epoxy or Blygold® coated coil
– The outdoor unit has sufficient housing and protection from the elements of the
local environment
– All pipework and interconnecting electrical cables are insulated and protected
from the environment

5.6.2 Separation
The separation between the indoor Multi-DENCO unit and the outdoor condenser
must be within the following limits for the interconnecting pipework requirements:
– No more than 35 m above the height of the indoor unit
– No more than 10 m below the height of the indoor unit
– The interconnecting pipework between the indoor and the condenser must be less
than 100 m
For more details about interconnecting pipes, please see chapter 6.

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5.6.3 Positioning
The condenser must be installed on a level surface that can support the weight of the
equipment and allowing for access from all sides. If multiple condensers are used for
1 indoor unit, the condensers must be installed on the same level and the same
distance to the indoor unit.
Whenever possible, shelter condensers from winds and avoid prevailing winds blowing
directly onto the fan(s) or the heat exchanger. Always bolt down units to ensure secure
fixing to location.
Consideration should also be given to minimising the noise created by the condenser.
Pipework and cabling running underneath the unit should be configured so as not to
obstruct airflow.
Pipework and cabling underneath the unit can cause a reduction in airflow as well as
an increase in noise as air passes around the obstruction.
All outdoor units should be fixed to a rigid structure using the holes provided (wherever
possible). If the units are in an exposed situation and normal bolting is not practical,
then alternative brackets, fixings or adhesive should be used.
Condensers are delivered with the mounting legs loose, allowing for installation on site
to decide the orientation of the unit (vertical or horizontal). The legs have been desi-
gned to maximise the clearances onto the coil, so it is essential they are installed cor-
rectly.
The hot gas discharge line MUST be positioned at the top of the condenser for hori-
zontal airflow (labelled as 1 on the diagrams below). Therefore, the liquid line (labelled
as 2) will be at the bottom of the unit.
Vertical airflow condensers must not be installed upside down.

Horizontal Airflow Vertical Airflow

Fig. 5-16

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5.6.4 Clearances
Condensers must be located in an unobstructed position to ensure adequate air circu-
lation through the cooling coil. Care must be taken to avoid air recirculation from one
unit to another.
Clearances around the condensers must be in accordance with condenser specific
drawings supplied in the unit documentation.
Horizontal airflow

Fig. 5-17

Vertical airflow

Definition of 'L' and 'W' Y must be greater than 2X Requirements if more Solid obstructions along any
than one unit is installed two walls.
by a solid wall.

When multiple units are located When multiple units are located alongside When multiple units are located alongside
with solid obstructions along any two solid obstructions and two louvered sec- one solid obstruction and three louvered
three sides, the open side must tions: C + D > L sections: B + C + D > L
give free air to each of the units. The total free area of the louvres should not The total free area of the louvres should
be less than 70%. Fan discharge should be not be less than 70%. Fan discharge
level with the top of the louvres. should be level with the top of the louvres.

Fig. 5-18

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Installation Multi-DENCO

5.7 Fan touch protection


It is extremely important that no one can come into contact with the fans within the
Multi-DENCO units during operation or immediately after operation. Users must wait 5
minutes after turning off a Multi-DENCO unit before removing any safety guard, to
ensure fans have come to a complete stop.
On Downflow units: Full Height Panels – these units are typically used with a raised floor. The floor tiles
must be unremovable without the use of tools for sufficient protection. If this is not the
case, then the installer must install additional fan protection grille below the unit to pre-
vent access to the fans.
Low Level Discharge Grille – these units are typically used with a plinth. The plinth's
design means that the panels are unremovable without the use of tools. If the unit used
with a raised floor then the same conditions apply as for Full Height Panels.
On Upflow units: If the unit isn't supplied with one of the following accessories then the installer must
build a touch protection device on the top of the unit.
The accessories are:
– Top air outlet protection grille (Eyelash)
– Ceiling connection duct
– Horizontal 1 way air discharge
– Horizontal 3 way air discharge

5.8 EC Declaration of Conformity


Note!
ANY installation of a unit that is labelled as CAT II under the Pressure Equipment
Directive 2014/68/EU (see serial label on unit), within the EU, MUST be completed
by an installer that is certified with a notified regulatory body.
Outside of the EU installers must comply with local legislation and regulations.
We strongly recommend that anyone involved with any installation of
Multi-DENCO units reviews and understands all the necessary legislation, in parti-
cular, the Pressure Equipment Directive 2014/68/EU.

For any installation of Multi-DENCO equipment that requires interconnecting pipework,


it is the responsibility of the installer to produce an EC Declaration of Conformity, if
installed within the European Economic Area (EEA). Outside of the EEA there may be
similar, separate requirements by different nations.
To assist with these requirements, we have prepared a short guide. This guide is NOT
exhaustive and care should be taken by the installer that the EC Declaration of Con-
formity that is produced, conforms to the necessary requirements.

Guidelines on producing a Declaration of Conformity


Since the installation is the concept/design of the installer, the EC Declaration of Con-
formity of the whole system needs to be prepared and completed by the installer. This
will require the creation of a technical file along with suitable documentation of safety
and design to meet the legal requirements.

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It is the responsibility of the installer to carry out the assessment and to prepare the EC
Declaration of Conformity. For the installation of the interconnecting pipework and
electrical cabling, the declaration must then be signed by your legally responsible
representative (which may be the Managing Director of the Company).
The installer will need to consider some or all of the following:
1. Machinery Directive 2006/42/EC
2. EMC Directive 2014/30/EU
3. Low Voltage Directive 2014/35/EU
4. Pressure Equipment Directive 2014/68/EU
5. EC type examination certificate:
6. Applied Harmonised Standards:
7. Safety of machinery: Electrical equipment:
8. Safety of machinery: Basic design, concept and technical principle:
9. EMC emissions for residential, commercial and light industrial environments:
10. EMC immunity for industrial environments:
11. Refrigerating Systems:
12. Pressure equipment for refrigerating systems and heat pumps (General piping)
13. Applied National Standards/Technical Specifications:

This assessment will need to include creating a technical file including:


1. Description of the equipment, accompanied by block diagram.
2. Wiring, circuit diagrams, and cable sizing information.
3. Pipework layout drawing.
4. List of standards applied. (See above).
5. Records of risk assessments and assessments to standard's
6. Description of control philosophy/logic. (Controls Manual)
7. Materials list including source traceability on pressure related components
e.g. pipework, fittings, and brazing materials etc.
8. Copies of any markings and labels.
9. Copy of this manual.
10. Test reports e.g. pressure test certificates, wiring test certificates.
11. Commissioning records.
12. Declaration of Conformity.

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Medium Connections Multi-DENCO

6 Medium Connections
NOTE!
When routing pipework, take due care that air flow is not obstructed as this may
reduce the efficiency of the system.

6.1 Requirements
– (For refrigeration circuits) Only pipe sizes recommended by FläktGroup are allowed.
Incorrect pipe sizing can cause compressor damage and void the warranty.
– Every part of all circuit(s) (cooling and heating) must be designed and installed to
national and local standards and regulations.
– Piping must be properly sized to meet the design requirements.
– Mechanical connections shall only be carried out by qualified licensed staff or other
individuals with proper professional training and experience in the relevant accident
prevention regulations, as well as other generally recognized safety and occupatio-
nal health codes.
Only copper refrigerant lines meeting EN 12735-1:2010 standards shall be used for
refrigeration pipework installation. R410A is the standard refrigerant used within
Multi-DENCO units, ensure that pipework used is suitable for the higher pressures
used with this refrigerant.
The relevant requirements of the standard, especially apply to:
– Quality of internal surfaces
– Sealed pipe ends
– Pipe labelling
– Testing
– Pressure resistance
Short line lengths Keep the pipe length as short as possible. The greater the distance between the air
handling unit and the outdoor heat rejection unit, the greater the pressure drops in
connected pipes, resulting in reduced energy efficiency of the unit.
Liquid receivers Installing a refrigerant receiver is not mandatory. With long pipe runs and low ambient
temperature operation of the unit it is, however, recommended to install a refrigerant
receiver. If a receiver is not installed, the refrigerant should be selected and charged
with extreme care. When charging the unit with refrigerant at low ambient temperature,
ensure that the system is not overfilled and the unit can be trouble-free operated at high
ambient temperature as well. Consider the manufacturer's instructions on layout of a
refrigerant receiver and installation manual on mounting a receiver.

6.2 Connecting refrigeration pipework

6.2.1 Pipework
All pipework must be installed in accordance with EN 378-4 and with recognised good
refrigeration practices in a tidy manner. Any further local legislation may vary, but must
be observed.
Within the EU, certain systems may be subject to mandatory requirements of the Pres-
sure Equipment Directive 2014/68/EU. To know the classification of your equipment,
refer to the serial plate on each unit.
Details of the maximum lengths of interconnecting pipework are in chapter 5.6.2.

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6.2.2 Material quality


For refrigeration pipework:
– Copper tube quality must be the equivalent of EN 12735-1
– Refrigeration grade copper must be used
– Pipework must be cleaned and dehydrated
– Use of joints, bends or sets must be kept to a minimum
– Bends or sets are to be machine pulled to approved radius at all times
– Only properly swaged joints can be used (butt joints are not allowed)
– Manufactured bends are not recommended
– It is recommended to use half-hard straight lengths of copper instead of coils.

6.2.3 Sizing
NOTE!
Prior to installation it is particularly important to check the correct size refrigeration
pipework is being installed. Contact your local representative if you are unsure.

NOTE!
Only the pipe sizes listed below are ALLOWABLE for each size. ONLY these sizes
MUST be used for both horizontal and vertical risers. This table is for REFERENCE
ONLY.

NOTE!
FINAL and ULTIMATE responsibility for pipe sizing is of the contractor or installer.
The below table is for GUIDANCE ONLY to specify the range of sizes applicable. It
is necessary that suitably qualified engineers conduct their own, separate calculati-
ons to determine the sizing suitable for the application.

Pipe sizing When sizing pipework, consideration should be given with regards to adequate oil
return during all conditions.
It is also important that the pressure drops in pipework are minimised to avoid unneces-
sary decreases in capacity. Larger pipe sizes reduce gas velocity and make oil return
more difficult to accomplish. Smaller pipe diameters increase oil velocity, but will be
more susceptible to high pressure drops.
A-Version
Metric (mm) 10 12 16 18 22 28 35 42 2 x 22 2 x 28
Imperial (Inch) 3/8 1/2 5/8 3/4 7/8 1-1/8 1-3/8 1-5/8 2 x 7/8 2 x 1-1/8
Liquid z z z z
010
Discharge z z z
Liquid z z z
018
Discharge z z
Liquid z z z
030
Discharge z z z
Liquid z z z
045
Discharge z z z
Liquid z z
065
Discharge z z
Liquid z z
092
Discharge z z z
Liquid z z
130
Discharge z z z
Tab. 6-1
Discharge Line: Recommended pressure drop = 1.0K, Max pressure drop = 2.5K
Liquid Line: Max pressure drop = 1.5K

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X-Version & H-Version (DENCO-OfficeCool)


Metric (mm) 10 12 16 18 22 2 x 12 2 x 22
Imperial (Inch) 3/8 1/2 5/8 3/4 7/8 2 x 1/2 2 x 7/8
010 Expansion z
1 x PUHZ-ZRP100YKA Suction z
018 Expansion z
1 x PUHZ-RP200YKA Suction z
030 Expansion z
1 x PUHZ-RP250YKA Suction z
045 Expansion z
2 x PUHZ-RP250YKA Suction z
Tab. 6-2
Only valid for unit combination listed within table. For any other version please contact your local sales/service support.

6.2.4 Installation with 2 condensers

NOTE!
For condensing units, see separate installation manual.

On Fig. 6-1 and Fig. 6-2 the labels are as follows:


1 Discharge line (hot gas) from the Multi-DENCO indoor unit
2 Branches of discharge line
3 Liquid Line returning to the Multi-DENCO indoor unit
4 Branches of liquid line
For any installation with 2 condenser in tandem configuration:
• Both must be placed on the same level
• If this is not possible, an external liquid receiver must be installed
• Pipes 2 and 4 (pipework after the 'T-Joint') should be 1 pipe diameter size smaller
than pipes 1 and 3 respectively (see tab 6.1 and 6.2)
• Ensure that A = A and B = B
• For Horizontal Airflow: A + B < 5 metres
• For Vertical Airflow: A < 5 metres and B < 5 metres

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Horizontal airflow

Isometric View

Top View

Fig. 6-1

Vertical airflow

Isometric View Side View

Fig. 6-2

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6.2.5 Thermal expansion


All pipework, which is subject to changes in temperature, expands and contracts. The
routing and joining of the pipework must be capable of absorbing this movement. An
example of the rate of expansion on a Multi-DENCO unit is as follows:

Pipe Pipe Operating Expansion in 0 °C Expansion in 21 °C


Temperature Temperature Temperature
°C mm/m mm/m
Hot Gas Line 80 1.35 1.00

Liquid Line 45 0.76 0.41

Suction Line 12 0.20 0.15


Tab. 6-3
Pipework with multiple bends and where any straight lengths are short prevents issues
with expansion. If long, straight pipework is unavoidable, the following methods can be
used:
– Expansion loops
– Offsets
– Anacondas (see manufacturer's datasheets for details)
If using expansion loops or offsets, the following minimum dimensions must be obser-
ved:

Expansion Loops Offset

Fig. 6-3

Size of expansion movement [mm]:


Tube Outer
Diameter 10 20 30 50 70 100
Length (L) of required loop or offset [mm]:
1/2" or 12 mm 200 275 350 425 500 550
5/8" or 16 mm 200 300 375 450 550 650
3/4" or 18 mm 225 325 400 500 600 700
7/8" or 22 mm 225 350 425 550 650 750
1 1/8" or 28 mm 250 375 450 600 700 850
1 3/8" or 35 mm 250 400 475 650 800 900
1 5/8" or 42 mm 275 425 500 700 850 1000
Tab. 6-4

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6.2.6 Insulation
For insulating pipework:
– All insulation (e.g. Armaflex or equivalent) shall be class O minimum 3/8" wall thick-
ness
– All joints and edge splits must be glued or taped on suction lines
– Vapour sealing is not required on hot gas lines
– Any painting of insulation installed outdoors must be completed in line with manu-
facturer's guidelines
Each site must be individually assessed depending on pipework exposure, position,
length and accessibility to pipework, but for Multi-DENCO units:
A-Version: Discharge lines and liquid lines do not need to be insulated, but may be required due
to site conditions and accessibility to pipework. We recommend insulating the liquid
line in the raised floor to avoid heating the cold air.
X-Version: Both lines (suction and expansion) MUST be insulated.

6.2.7 Cutting tubes


Where appropriate, pipework and cables shall be sleeved when passing through buil-
ding walls or roof structures.
When cutting copper tubing or pipe, care must be exercised to prevent the filings or
cuttings from entering the pipe. Some effective means should be used to clean out the
small particles of copper when they do enter the tube or pipe. When cutting copper
tubing with a wheel cutter, it is extremely important to use sharp wheels. The copper
wears the edge of the wheels more quickly than might be expected; therefore the con-
dition of the wheel must be checked regularly. Always ream the tube ends to remove
burrs.

NOTE!
We recommend using a wheel cutter as the best method for cutting pipework.

6.2.8 Brazing
Brazed joints are to be made with Easy-Flo® or similar copper alloy rod. Flux is not
required for joining copper to copper. When bronze or brass is involved, Silver-Flow®
self-fluxing rod or similar is required.

NOTE – IMPORTANT!
When soldering or brazing, purge a small amount of dry nitrogen through the
pipe to prevent oxidation and scaling internally. Failure to purge nitrogen whilst
brazing will result in scale build up and this WILL block the
Electronic Expansion Valve (EEV).
Any subsequent scale found within the valve body may result in voiding of
warranty!

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It is necessary to create a positive pressure inside the pipe. Before applying heat to
pipes, remove Schraeder valve cores and open any other valves, solenoids etc. which
will cause a build-up of pressure in the line and, therefore, blowholes in the joint. Also,
any valve seats, gaskets, capillaries etc. that may be damaged by heat, flux or dry
nitrogen must be removed or protected, (e.g. wrap in a cold damp cloth.).
When making soldered or brazed joints, it is essential that the surfaces to be joined are
clean. Unclean metals do not take the flux properly, which results in bare spots over
the brazing alloy and will not flow. Thin films of soldering alloy make the strongest
joints. Clearances of between 0.02 mm to 0.07 mm are all that are required. Too much
clearance prevents the proper capillary action, wastes alloy, promotes a weak joint and
allows ingress of soldering material in the lines. After completion of joints ensure that
all surplus flux is thoroughly cleaned off. Flux left on the pipes looks unsightly and can
cause oxidisation, pitting and prematurely age the tubing.

6.2.9 Oil traps

Fig. 6-4: Requirements of discharge lines on Multi-DENCO units

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If the condenser(s) are installed ABOVE the Multi-DENCO unit, for the discharge line:
– The condenser must be NO MORE than 35 m above the Multi-DENCO unit
– 'P' traps must be installed at the bottom of EVERY vertical riser in the discharge line,
including pipework outside of riser cupboards (Detail 1)
– For every max. 5 m of vertical pipework, and 'S' trap must be installed (Detail 2)
– At the top of every riser a bend should be used to prevent oil return (Detail 3)
– Use a 1% slope in the direction of refrigerant flow (Detail 3 & 4)

NOTICE
Failure to install sufficient oil traps can cause a lack of lubrication in a compressor
resulting in poor performance or failure.
The last trap (detail 3 in Fig. 6-4) prevents liquid refrigerant travelling backwards
to the compressor outlet.
• Ensure suitable oil traps are installed as per Fig. 6-4.
When the condenser is located BELOW the Multi-DENCO unit, oil traps are not requi-
red. Consideration must be given to ensure that the liquid line pressure losses are not
excessive (see chapter 6.2.3 'Sizing' for more information).

6.2.10 Tube support (clamping)


It is recommended:
– All tubing should be independently clamped in position using a cushion based
vibration absorption clamps
– Supports should be spaced at no more than 1.5m separation
– A thermal break should be provided between suction pipes and any
support brackets

6.2.11 Fan removal to aid installation


On certain downflow units, access to the refrigeration pipework connections can be dif-
ficult (especially if there is no side access to the unit). Multi-DENCO units are designed
to allow for the removal of fan closest to the pipework to make installation easier.

NOTE – LABELLING OF ELECTRICAL WIRES!


It is very important to observe and label any electrical wires for the fan being remo-
ved to ensure a correct re-installation.

Fig. 6-5

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Each fan assembly is heavy and can weight up to 36 kg (special designs could
weigh more).
• Conduct a risk assessment and plan any manoeuvre before starting any work.
• Ensure a safe lifting procedure is observed.

1 Remove the 2 x 4.8 mm self-tapping screws that connect the mullion to the horizontal
frame.

2 Remove the 2 x 4.8 mm self-tapping screws that connect the mullion to the bracket and
vertical frame

3 Loosen the fan inlet ring (6 x M6x25 bolts) but DO NOT REMOVE THE BOLTS

4 Remove the bolts used to fix the fan assembly to rails. Once unscrewed, remove the
assembly by pulling it towards the front of the unit as far as possible. Then lift the
assembly up and remove it from the unit.

6.3 Refrigerant pipework testing procedures


On completion of the refrigeration pipework the equipment must be pressure tested
with dry nitrogen, at a pressure relevant to the refrigerant used. This should be com-
pleted by a competent person holding the relevant refrigerant handling qualification.

NOTE!
The procedures below are according to EN 378 and are the minimum standards
expected during leak, pressure and strength testing. Always refer to your country/
region specific legislation.

Leak testing A thorough leak test must be performed to ensure that the system is 'leak tight'. It must
be carried out at pressure, using oxygen-free nitrogen. This can be carried out at rela-
tively low pressures (see below) in accordance with safe methods of working and good
refrigeration practice
Certification On all new installations once the system is found to be leak free, a label stating date
and time and final pressure reading is to be attached to the pipework inside the unit.
A pressure test certificate must be signed, witnessed and passed to the commissioning
engineer.

NOTE!
The use of 'tracers' or 'dyes' are not permitted on Multi-DENCO units under any cir-
cumstances.

NOTE!
Depending upon your commercial agreement, you may be required to perform the
vacuuming and oil and refrigerant pre-charging of the system, before the commis-
sioning engineer's arrival.
For details of this 'Pre-Commissioning Procedure' please see chapter 8 'Commis-
sioning' and in particular chapter 8.2.6 'Initial charge for refrigerant circuits'.
Important safety information is listed at the start of chapter 8, therefore read the
whole chapter IN FULL before commencing any work.

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6.3.1 A-Version: Size 010 to 065


For standard units, all devices fitted to the low pressure side of the system are suffi-
ciently pressure rated and can remain connected to the system during pressure
testing.
1: Ensure that the adjacent area is clear of non-essential staff, complete a risk
assessment and establish an exclusion zone for safety purposes.
2: Insert 3.5 bar nitrogen into the unit to identify first fix leaks, if leaks occur, release
the nitrogen, repair the issues and re-insert nitrogen to 3.5 bar.
3: Complete a strength test by pressurising system with dry nitrogen to 47.6 bar and
leave on test for a minimum of 60 minutes.
4: On completion of the strength test drop the pressure down to zero by using the relief
valve on the nitrogen regulator or charging manifold.
5: Repair any leaks found and then repeat steps.
6: If the client or end-user requires witnessing the pressure test, carry out this witness
at this point making notes of dates, times and pressures.
7: At the completion of the pressure test, the Oxygen-Free Nitrogen charge should be
safely purged away leaving a holding charge prior to the evacuation process.
Ensure you have recorded the holding charge in your records at this point.
8: On completion, prepare and sign the 'Pressure Test Certificate' (chapter 13.2).

6.3.2 A-Version: Size 092 & 130


NOTICE
During the pressure test, system pressures exceed the maximum values specified
by the supplier. Exceeding these pressures could damage the sensors resulting
in incorrect operation by the unit.
• Ensure low pressure switches are disconnected before pressure testing.
1: Ensure that the adjacent area is clear of non-essential staff, complete a risk
assessment and establish an exclusion zone for safety purposes.
2: Low side strength test; Complete a strength test on the whole system by
pressurising with dry nitrogen to a maximum of 33.0 bar and leave on test for a
minimum of 30 minutes.
3: High side strength test; On completion of step 2, CLOSE THE SUCTION LINE
SHUT OFF VALVE, and increase the dry nitrogen pressure to 47.6 bar and leave
on test for a minimum of 30 minutes.
4: Decrease the pressure to 17.2 bar by using the relief valve on the pressure
regulator or manifold. Re-fit the LP switches, open the suction line valve and
complete a bubble test on the LP switch joints.
5: On completion of step 4, reduce the pressure to zero by using the relief valve on the
nitrogen regulator or charging manifold.
6: Repair any leaks that are found and then repeat steps 1 to 5.
7: If the client or end-user requires witnessing the pressure test, carry out this witness
at this point making notes of dates, times and pressures.
8: At the completion of the pressure test, the Oxygen-Free Nitrogen charge should be
safely purged away leaving a holding charge prior to the Evacuation process.
Ensure you have recorded the holding charge in your records at this point.
9: On completion, prepare and sign the 'Pressure Test Certificate' (chapter 13.2).

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6.3.3 X-Versions and DENCO-OfficeCool H-Versions


For guidelines on how to perform pressure testing for these installations, please refer
to the separate installation manual.
Some condensing units may be delivered with a 'pre-charge' of refrigerant: ensure this
is not released during pressure testing.

6.4 Humidifier water connections (optional)


The humidifier unit must be connected to a standard piped cold water supply. All mains
water pipework to humidifiers must be installed to national and local standards, in par-
ticular, local water authorities' regulations and requirements.
• Connect the humidifier using a fitted flexible hose and a compression fitting.
• The water supply should have a stop cock adjacent to the unit.
• The earth bonding (supplied) must be connected to the incoming water supply and
also to the drain line if electrically conducting tubing is used for instance copper pipe.
Supply water quality In general the water supply feed to the humidifier must be normal quality drinking water
but must comply with the following parameters:
– Water feed pressure between 0.1 and 0.8 MPa (1 and 8 bar)
– Temperature between 1 and 40 °C
– Hardness not exceeding 400 ppm equalling CaCO3 (40 °fH)
– Conductivity 125 to 1250 µS/cm (microSiemens/cm) (depending on bottle used)
– No organic substances

In operation, the humidifier can produce hot water vapour. The vapour, tubing that
it is directed through and areas that it has been in contact with can be hot and will
cause scalding or burns.
• Always allow time for the humidifier and affected regions to cool sufficiently before
starting any work
• Do not touch affected regions with unprotected skin.

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NOTICE ON WATER USE!


– Under no circumstances should the water supply be fed from a water softening
system.
– Do not add disinfectants or anti-corrosive substances (irritants).
– It is not recommended to use industrial water or chemically and bacteriologically
polluted water for cooling circuits.
– Do not use demineralised water (e.g. osmosis/purified water)
– Where a salt exchange plant is in use at a site, the feed water to the unit should
by-pass this.

Water feed quality Unit Normal Water with low salt


tap water content
Min. Max. Min. Max.
Activity of hydrogen ions (pH) – 7 8,5 7 8,5
Specific conductivity 20 °C (σR,20 °C) μS/cm 350 1250 75 350
Dissolved solid materials (cR) mg/l (1) (1) (1) (1)
Solid residue at 180 °C (R180) mg/l (1) (1) (1) (1)
Total hardness (TH) mg/l CaCO3 100 (2) 400 50 (2) 160
Temporary hardness mg/l CaCO3 60 (3) 300 30 (3) 100
Iron + manganese mg/l Fe+Mn = 0,2 = 0,2
Chlorides mg/l Cl- = 30 = 20
Silica mg/l SiO2 = 20 = 20
Residual chlorine mg/l Cl2 = 0,2 = 0,2
Calcium sulphate mg/l CaSO4 = 100 = 60
Metal contamination mg/l 0 0 0 0
Dissolvents, thinners, detergents, lubricants mg/l 0 0 0 0
(1) = General values, depending on specific conductivity: CR≅0,65 x σR,20 °C; R180≅ σR,20 °C
(2) = Not below 200 % of chloride content in mg/l Cl
(3) = Not below 300 % of chloride content in mg/l Cl
Tab. 6-5

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6.5 Connecting condensate drain


Air handling unit The following should be considered during installation:
– Drainpipe runs shall be 22 mm OD or larger of water carrying quality of either copper
or high temperature rigid plastic and should be adequately supported at regular
intervals and have a slope of at least 2 % to ensure drainage.
– If the run is long and has a number of bends, the tube should be adequately sized
Drainage and suitable cleaning (rodding) eyes installed at bends.
stack
– If an air handling unit is fitted with a humidifier, drain pipework must be designed as
Drip tray temperature-proof to withstand up to 100 °C.
– Upon completion of the installation, drain pipework should be leak tested.
– Depending on unit type, condensate traps may be in-built into the unit or the pipe-
work may be provided loose - review unit design before completing installation.
Condensate
humidifer drain – Condensate trap must be filled with water prior to commissioning and after long inac-
Air break
tive periods.
– Electrically conductive drain pipework should be earthed at a point adjacent to the
unit.
Fig. 6-6: Condensate drain

NOTE!
Some units will have two separate drains to connect (humidifier/condensate).

NOTICE
Local and regional legislation will require a minimum quality standard for drainage.
• Ensure the drainage system is reviewed during installation and assessed for
possible issues, such as, blockage, overflow, contamination and Legionella.

NOTE!
Direct connection to a waste network is not allowed. Ensure drain has an air break
fitted as shown in Fig. 6-6.

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6.6 Connecting water pipework


Mechanical connections shall only be carried out by qualified licensed staff or other
individuals with professional training and experience in the relevant accident preven-
tion regulations.
Chilled water pipework connections are placed at the bottom of the Multi-DENCO unit
and are terminated with flanges, BSP connectors or just copper tubes (solder connec-
tion). Please refer to the unit dimensional drawing.
When connecting:
– Entire chilled water circuit must be designed and installed to national and local stan-
dards and regulations.
– Piping and pump must be properly sized to meet the design volume flow. Non-com-
pliance can cause operational malfunctions.
– All chilled water and dry-cooler water pipework must be vapour sealed and insulated
to avoid condensation and capacity losses. The exterior surface of steel piping must
be protected against corrosion using protective paint.
– Hydraulic devices such as solenoid valves, modulating valves or hand shut off val-
ves may cause hydraulic hammer. This condition should be avoided.
– Beware of any residual glycol solution that may be left in the hydraulic circuit follo-
wing testing. Residual glycol solution must be disposed of in an environmentally-fri-
endly manner.
– Whenever possible it is recommended that "reverse return" piping (Tichelmann
system) be used for multiple installations to ensure an easily balanced system.
– Regulating valves (preferably with pressure test points for measurement of volume
flow) should be used before each unit to enable balancing of water flow rates. This
regulating valve should be installed before each unit.

NOTICE
The chilled water circuit must be protected from fouling, freezing or solid materi-
als. Failure to do so may result in poor performance or system failure.
• Install at least 1 water strainer per hydraulic circuit
• Provide frost protection though glycol or trace heating on external pipework
• Chemically treat condenser water served by an open evaporative cooling tower.
• Ensure filtration of solid materials within the circuit
We recommend using a plate heat exchanger for system separation.

– Separate isolating valves should be provided at all equipment to enable servicing to


be carried out without draining the water circuit system.
– Thermometers and pressure gauge test points should be located in supply and
return lines of air handling units, heat rejection unit or chillers for commissioning and
normal service checks.
– All high points and coils of the water circuit must be provided with vent cocks to
enable system venting to prevent air locks. Your Multi-DENCO unit is already provi-
ded with a vent at the top of the coil.
– All coils and low points of the water circuit must be provided with drain cocks to
enable complete draining.
– Pipe expansion and contraction should be allowed for by the installation of expansi-
on bellows and loops (where necessary).
– A closed type expansion tank must be provided for the hydraulic system.
– Pipework must be properly cleaned and flushed.
– Pressurisation may be required to ensure a static head pressure is always available
to protect the circulation pump from cavitation.

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AIR HANDLING UNIT


CASING
CHILLED WATER RETURN TO
RECOMMENDED CHILLED WATER MAIN/CHILLER

EXPANSION
TANK

RECOMMENDED WATER FILL


HUM

CONDENSATE
TRAY/DRAIN

CHILLED WATER SUPPLY FROM


CHILLED WATER MAIN/CHILLER

LINE TYPES:
HUMIDIFIER
CONDENSATE / WATER SUPPLY
HUMIDIFIER DRAIN (IF FITTED) CHILLED WATER SUPPLY
CHILLED WATER RETURN
CONDENSATE / HUMIDIFIER DRAIN
P/W TO EXPANSION VESSEL

UNIT ON SITE

Fig. 6-7: Hydraulic circuit example

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6.6.1 Water quality


Recommendation on water quality for chilled, warm and condensing water circuits/heat
exchanger:

Parameter Unit Value


pH-value (at 20 °C) 7.5 - 9
Conductivity (at 20 °C) μS/cm < 700
Dissolved solid materials (cR) O2 mg/l < 0.1
Total hardness (TH) °dH 1 - 15
Dissolved sulphur S not detectable
Sodium Na+ mg/l < 100
Iron Fe2+, Fe3+ mg/l < 0.1
Manganese Mn2+ mg/l < 0.05
Ammonium content NH4+ mg/l < 0.1
Chloride Cl- mg/l < 100
Sulphate SO42- mg/l < 50
Nitrite NO2- mg/l < 50
Nitrate NO3- mg/l < 50
Tab. 6-6

A good water quality – e.g. salt and lime free drinking water – considerably increases
the service life and efficiency of the unit and the connected secondary system.
• Check the limit values in the table once a year to avoid damage to the hydraulic
system components.

6.6.2 Glycols

Glycols and other anti-freeze materials can be harmful for humans and animals.
• Prior to use, refer to the supplier's Material Safety Data Sheet (MSDS).
• If ingested, seek urgent medical help.

NOTE!
The following recommendations are based on using the brands Antifrogen® N for
ethylene glycol and Antifrogen® L for propylene glycol. Other suppliers and variety
may have different properties or hazard warnings.
• Always refer to the supplier's information and the MSDS.

Water-glycol mixtures have different thermodynamic and physical properties to water-


only chilled water systems. If glycol is mixed with a medium, the resultant mixture has:
– Lower specific heat capacity
– Higher viscosity
– Increase flow rate
– Increased pressure drops
– Increased power and current consumption of a pump
– Lower cooling capacity
– Larger thermal expansion when compared with water-only

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When using glycol:


• Water-glycol mixture does not have a burst effect starting from frost resistance of -
20°C, as slush ice forms when the mixture is cooled below the freezing point.
• Use only one type of glycol, do not mix different types.
• Only charge the system with a prepared water-glycol mixture.
• Do not use Teflon seals if using water-glycol mixtures.
• Add glycol concentration to match the ambient temperatures to ensure energy
consumption of the pump is not excessively increased.
• Once a system is filled, always double check the water-glycol concentrations.
Minimum concentrations to prevent corrosion:
– Ethylene glycol = 20% by volume
– Propylene glycol = 25% by volume.

NOTICE
Excessive volumes of glycol within a chilled water system can result in poor heat
transfer, increased viscosity and possible damage to pumps and valves.
• Glycol content must be less than 50% of total system content.

6.6.3 Connecting chilled water pipework

NOTICE
Incorrect fitting of water inlet and outlet connections can result in leaks and cooling
capacity reduction.
• Counter hold connection fittings to prevent damage.
– We recommend using a pipe wrench.

Access to water pipe connections can sometimes be difficult if there is no side access.
The procedure to remove indoor fans to allow easier access to the connections is in
chapter 6.2.11.

NOTE!
There are three different available connections depending on the size of the equip-
ment (see unit type code)
– 'BSP pipework connections'
– 'Flange pipework connections'
– 'Solder connections'

• Connect the piping system, to the chilled water inlet/outlet in accordance with best
practice and conforming to and local and national regulations.

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6.6.4 Hot water heating (optional)


The L.P.H.W. (low pressure hot water) coil is fitted with a modulating three port valve,
which is wired and fitted within the unit casing.
It is important to consider the fitting of commissioning sets in the supply/return pipe-
work to allow accurate water measurements and flow adjustments. These should be
supplied and fitted in accordance with the manufacturer's recommendations.
The installation of the hot water pipework is similar to that of the chilled water pipework
(chapter 6.6.3).

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7 Electrical Connections
When making an electrical installation, the installer must:
• be qualified and licensed according to local and regional regulation.
• Observe regulation relating to electrical power supply for the installation region
• Observe the Low Voltage Directive 2014/35/EU
• Provide potential equalisation
• Equipped, and any connected component, must be wired with an earth
connection.

Unmade or partly made electrical connections have a high hazard of creating an


electrical potential on other materials. This can lead to death or serious injury.
When installing electrical connections:
• Ensure all power supplies are disconnected including existing connections and
power to new connections to be made
• Ensure any power supply cannot be inadvertently energised by 'locking' the
power supply.

NOTICE
The electrical wiring must be installed fully and correctly.
Failure to do so may result in damage to components and failure to operate.
• Always refer to the 'unit-specific' wiring diagram.
• Never connect multiple units to the same mains power supply.
Failure to follow these instructions can invalidate warranty.

7.1 Requirements
Before making electrical connections, check the following:
– The mains power supply properties comply with EN 60204-1:2006+A1:2009 and the
power requirements of the unit.
– Mains power supply voltage tolerance should not exceed ± 10% with a maximum
phase difference of 3%.

NOTE!
We recommend installing power surge protection devices in areas of poor quality
electrical supply.

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7.2 Connecting mains power supply

7.2.1 Cable requirements


A suitable 3-phase mains supply (with earth and neutral) shall be available to connect
the unit (voltage and frequency must be according to the unit identification plate). The
power supply line must be equipped with necessary protective devices; in particular,
fuses must be of type D.

7.2.2 Electrical protection requirements


The pre-fuse size should be determined on the basis of the wiring diagram or unit iden-
tification plate and must not exceed the size specified in the above-mentioned docu-
ments. For further information contact your local sales office.

7.2.3 Cable connection


Connect the main power supply cable to the isolator provided within the unit. ALWAYS
refer to electric wiring diagram supplied with the unit.

NOTE!
When connecting the supply voltage, make sure to observe the clockwise rotating
direction! If the rotation direction is incorrect, an adjustment shall be performed by
changing the phases using the main connection of the unit. Change the phase
sequence of the power supply lines through other.
Never change the wiring in the unit control cabinet.

NOTE!
If NO door interlocked isolator is fitted to the unit, a multi-core cable must be used
for unit power (to avoid cable breaks by the hinged cabinets) and a means of isola-
tion must be provided meet country specific regulations. Always refer to local and
country specific electrical regulations when installing power supplies. A maximum
distance of 1m from the unit is recommended.

If the unit is supplied with an "Automatic Transfer Switch (Dual Power Supply)", this will
be in a different location to the isolator.

7.2.4 Cable routing inside unit


– Multi-DENCO units are designed for cable entry from the BOTTOM of the unit.
– Secure any interconnecting cables within the unit and ensure that the cables cannot
make contact with the fan or any hot components.
– Do not remove any unused rubber glands or blanking plugs.
– Do NOT drill any holes in the top panels of ANY electrical cabinets.
– Cable routing must consider that some electrical panels can pivot on hinges.

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7.3 Connecting outdoor unit


NOTE!
We STRONGLY recommend that the outdoor unit should be connected to the
indoor unit for its power supply.

7.3.1 A-Version
Condensers (DMOUCD) that are supplied with A-Version Multi-DENCO units are pro-
vided with their OWN SEPARATE ISOLATOR.
For condensers, the following power and controls layouts are possible:

Fig. 7-1: EC fan installation

1 Condenser 2 Condenser

Control Power Control Power


2 Core + Earth
AC Fans Not Required 2 Core + Earth Not Required Separate Power**

AC fans with Winter Kit Not Required 3 Core + Earth Not Required 3 Core + Earth
Separate Power**

EC Fans* 2 Core Screened 3 Core + Earth 2 Core Screened 3 Core + Earth

EC Fans with Winter Kit* 2 Core Screened 4 Core + Earth 2 Core Screened 4 Core + Earth

* Not available in size 008


** For AC units, Fig. 7-1 does not apply. Power cables must be installed for each condenser and connected to the indoor unit separately.

We recommend any 2 core screened data cable for control wiring, for example:
– Beldon 8761
– Alpha 2401C
– BICCH8082

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7.3.2 X-Version & DENCO-OfficeCool H-Version

Fig. 7-2: Note 1: External isolator provided by others.

Power Control (24 VDC)

1 Phase Power Supply 2 Core + Earth 3 Core + Earth

3 Phase Power Supply 4 Core + Earth 3 Core + Earth

Tab. 7-1

NOTE!
Power supply is dependent on outdoor unit's size. See electrical drawing for details.

Multi-DENCO X-Version and DENCO-OfficeCool units are provided with PAC interface
control boards to allow for control of condensing units. If 2 outdoor units are required,
2 boards will be provided.
Designated terminal blocks are available within the controls cabinet for connecting of
the outdoor condensing unit for power supply.
For further details please see the unit specific electrical contract drawing.

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Electrical Connections Multi-DENCO

7.4 Connecting signal cabling

NOTE!
This chapter is for C5-12 controls only.

NOTE!
For all electric connections ensure that control and safety signals (24V AC) are run
in a separate cable to the mains power cable (e.g. 400V AC/230V AC). Where
power and signal/control cables have to run together, then a minimum gap of 30 mm
between each category is to be maintained. Ideally, power and signal/control cables
should never cross, but if unavoidable, ensure that they cross at 90°.

7.4.1 Signal cable installation


Maximum cable length: 100 m
Minimum cable 1.5 mm2
cross-section:
– Multi-DENCO units are designed for cable entry from the BOTTOM of the unit.
– Secure any interconnecting cables within the unit and ensure that the cables cannot
make contact with the fan or any hot components.
– Do not remove any unused rubber glands or blanking plugs.
– Do NOT drill any holes in the top panels of ANY electrical cabinets.
– Cable routing must consider that some electrical panels can rotate on hinges.
– Signal cables must enter the controls cabinet at the side of the cabinet, through the
rubber grommets provided

7.4.2 Remote display


For a remote/dual display, provided with a Multi-DENCO unit, the electrical require-
ments are:
– 2 core screen cable for data signal to the unit's C5-12 controller
– A 24V AC power source (this can be from the Multi-DENCO unit)
The remote display can be installed up to 50m away from the Multi-DENCO unit. In all
installations, consider the effect of signal attenuation and voltage drop.

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7.4.3 Unit networking


When multiple Multi-DENCO are located within the same cold space, it is best practice
to set them up in a network. Creating a network has the advantages of being able to
perform sensor averaging or rotating standby units.
Details of how to network your units are available in the electrical drawing provided with
the unit and also within the Controls Manual.

NOTE!
If networking multiple Multi-DENCO units together it is strongly recommended that
this is carried out by an experienced FläktGroup engineer due to its complex nature.
Your local office can help you arrange this.

7.4.4 Network wiring

Up to a maximum of
15 units on the network

Unit 1 Unit 2 Unit 8

Fig. 7-3

A recommended cable specification to use for the network wiring is 22 AWG


(0.326 mm²) stranded conductors, polyethylene insulation, twisted pair with 22 AWG
(0.326 mm²) drain wire and aluminium foil outer shield, covered in a PVC jacket.
Examples of this style of cable are:
– Beldon 8761
– Alpha 2401C
– BICC H8082

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7.5 Customer terminals on C5-12 unit controller


Unit Network/Remote Display/Unit Display Air intake sensor Air discharge sensor

C5-12 CONTROLLER TERMINALS

Serial Card

Interface Card
(Optional)

CUSTOMER TERMINAL BLOCKS

Remote contact Emergency off Critical Maintenance Condensate Run status #


on/off * (Fire Alarm) * Alarm # Alarm # Pump * (Optional) (Optional)

Terminals Notes
6–5 Remote On/Off for activating and deactivating the unit via a normally open volt free contact by others.
3–5 Emergency Off, a volt free contact (supplied by others) opening, deactivates the unit (e.g. used in a fire alarm system)
10 – 11 The unit's critical alarm indication e.g. HP/LP, Airflow, High Temperature.
12 – 13 The unit's maintenance alarm indication e.g. Dirty Filter, humidifier.
17 – 5 Alarm contact of condensate pump (optional accessory)
100 – 101 Indication of unit’s operation (i.e. fans enabled)
+VDC – GND – U1 – U2 Air intake sensor
+VDC – GND – U3 – U8 Air discharge sensor (optional, only if the item is fitted).
Serial Card Interface cards for building management (optional).
Rx-/Tx- - Rx+/Tx+ - GND Unit’s network terminals for connecting multiple units. Displays already connected to these terminals.
-------- Cabling provided by others.
# Volt free contacts (voltage or signal to be provided by others).
* On-site volt free contacts must be provided (if function is required remove jumper).
Tab. 7-2

NOTICE
Wiring that is not isolated from active (live) components of non-SELV or non-
PELV circuits may induce power than can cause damage to control boards.
This may cause poor operation or system failure.
• Use double or reinforce insulation on electrical wiring external to the unit.

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8 Commissioning
8.1 Requirements
NOTICE
READ ALL OF THIS CHAPTER BEFORE STARTING ANY WORK.
– Different options can require different commissioning procedures (e.g. winter kit).
– This chapter applies to initial commissioning as well as re-commissioning due to
extended shut down periods or relocation.
– Only R410A can be used in Multi-DENCO systems.

Refrigerants poses hazardous risks:


– Refrigerant cylinders can be heavy.
– Refrigerant cylinders can have unstable centres of gravity.
– Refrigerants are stored or used at high pressures.
– Systems using refrigerants can be operating with very high and very
low temperatures.
– Refrigerant released into an enclosed space could cause asphyxiation and death.
During commissioning:
• Ensure a full risk assessment has been conducted.
• Ensure only qualified individuals conduct work on the system.
• Establish an exclusion zone from the system for non-essential individuals.
• Ensure that the room is well ventilated.

8.1.1 Commissioning report


– A sample of the Commissioning Report is available in this manual (chapter 13.3)
– An electronic version can be provided upon request
– The report must be completed, during commissioning, by a Service representative
or an appointed contractor
– Once completed, the report MUST be sent to your sales/service representative
– Failure to send the completed report, may invalidate warranty

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8.1.2 Suggested equipment


It is important that all equipment is safe to use, is calibrated and is portable appliance
tested (PAT) where appropriate. Below is a list of recommended equipment to be able
to fully commission a unit:
– Electrical test meter
– Phase rotation meter
– Current measuring device
– Airflow measuring device
– Digital thermometer
– (If humidifier is fitted) water conductivity meter
– Suitable R410A refrigerant gauge manifolds and gauge lines
– Oil pump
– Vacuum pump (must be able to achieve 2.66 mBar)
– Fresh vacuum pump oil
– Digital refrigerant cylinder weighing scales

8.2 Pre-commissioning procedure


For all checks, we recommend following EN 378-3:2008+A1:2012. Ensure all
protective clothing and equipment is worn. In particular:
– Suitable eye protection
– Suitable hand/finger protection
– Protective cloths for entire body including safety footwear

8.2.1 Pre-commissioning checklist


We recommend that the "Pre-Commissioning Checklist" is completed, by the instal-
ler/contractor, prior to the commissioning engineer attending site. A copy of this chec-
klist can be found in chapter 13.1. Please present this completed checklist to the
commissioning engineer on or before their arrival.
If the site does not meet the requirements or information required in the checklist, the
engineer may be unable to conduct the commissioning and may abort the commissio-
ning.

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8.2.2 General checks


AFTER all installation work has been completed and the pre-commissioning checklist
has been completed, the following checks should be completed BEFORE mains
electrical supply power is applied to the unit:

Documentation
• Check that the unit configuration (listed on the serial plate) matches what has been
ordered
• Check the "Pre-Commissioning Checklist" (chapter 13.1) has been completed and
has been filed appropriately
• Check that a copy of this manual is available
• Check a copy of the electrical drawings/wiring diagrams are available

Multi-DENCO unit
• Check the unit internally and externally for any damage
• Photograph and record any damage (including shipping damage) and inform the
end user
• Check the unit has the minimum clearances available (chapter 5.1)
• Check that the fans inside the unit can rotate freely
• Check the unit is mounted suitably within the room (e.g. if on a base frame)
• Check that the entire heat exchanger is protected by the air filter(s)
• (If fitted) check the humidifier is supplied with water and that the earth bonding
device is secured to the incoming pipework
• Check that the condensate drain is connected correctly and water can drain freely,
for both coil condensate and humidifier (if fitted)

Room
• Check interconnecting services, Mechanical and Electrical, have been installed as
per requirements in chapter 6 & 7 respectively
• Check the dimensions of raised floor is sufficient for airflow (if used)
• Check floor tiles do not prevent the opening of panels and doors
• (If used) check all dampers (including fire protection) are fully open
• (For humidity control) check the control space/installation room is vapour sealed and
fresh air is not supplied excessively

Outdoor unit
• Check the unit is installed with appropriate clearances and the fans and coils are
free to operate (chapter 5.6.4)
• (If powered from indoor unit) check the unit's isolator is set to the 'ON' position
• If separates power supply, leave isolator in the OFF position

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8.2.3 Checking refrigerant circuits (A-Version, X-Version & H-Version)


• Check the oil traps are installed and to specifications (chapter 6.2.9)
• Check that pipework is sized correctly and within the limits (e.g. length
between indoor and outdoor unit) (chapter 5.6.2)
• Check appropriate insulation has been added to pipework
• Check pipework for cleanliness and tidiness

8.2.4 Checking water circuits (C-Version, O-Version, CombiCool, Hot Water Heating)
• Check the hydraulic connections have been made correctly
• Check the hydraulic circuit is fitted with a water filter
• Check the water pipework is clean and has been flushed
• Check all shut off valves within the unit are open
• Check all filling valves and vent cocks are closed
• Check any water circuit safety devices for proper function

8.2.5 Checking electrical connections

Untested or unused electrical systems poses higher risks of faults.


Unsafe operation on these systems can lead to death or serious injury.
Before conducting the following checks:
• Ensure all electrical connections are isolated and interlocked to prevent
accidental activation
• Check the unit is voltage free
• Switch off all circuit breakers (MCBs)

NOTE!
When commissioning a unit with the option: "Automatic Transfer Switch (Dual
Power Supply)" it is important to check the electrical supply of BOTH the incoming
supplies. Both electrical supplies must match the requirements of the unit name-
plate. Also the phase rotation of both incoming supplies must be checked.
Select a primary supply using the supplied key and test that the dual power supply
changes over when the primary supply is lost. Then select the other supply to be the
primary power supply and carry out the test again.

• Check any electrical installation has been conducted as per the unit specific contract
electrical drawing
• Check all electrical connections are tight
• Check earth conductors are connected correctly and the earth terminals are secured
tightly
• Check any signal and mains power cables are segregated
• Check inside of the control cabinet for loose connections or damaged components
• Tighten all supply terminals in the motor terminal clamps
• Ensure temperature and humidity sensors are adequately protected by their
enclosures
ONLY when all the above checks been completed can the unit's circuit breakers
(MCBs) can be set to the ON position.

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8.2.6 Initial charge for refrigerant circuits


NOTE!
It is recommended a triple evacuation is thoroughly conducted. If the system cannot
be evacuated to the levels defined below, you must NOT add any refrigerant and
the system installation must be checked and corrected. Once completed, re-con-
duct the procedure and ensure requirements are achieved. Incorrect or inadequate
evacuation resulting in moisture or contamination within the system will void war-
ranty.

NOTE!
No refrigerant commissioning can commence until the commissioning engineer has
reviewed the 'Pressure Test Certificate' (chapter 13.1) and ascertained what gas
and pressure the system is at.

NOTE!
Any work on the refrigerant system must only be carried out by suitably trained and
qualified personnel. Refer to local and national regulations and guidelines.

The recommended procedure requires a triple evacuation, whilst adding any addition
oil before adding the initial charge. It is as follows:

Initial evacuation
• Connect the service manifolds to the Multi-DENCO system in an appropriate and
safe manner.
• Make sure that all system valves are open (i.e. shut off valves)
• If the system contains Oxygen-Free Nitrogen (OFN), carefully purge the gas to
atmosphere in accordance with safe working practices
• Connect the vacuum pump to the service manifolds
• Achieve a vacuum of at least two Torr (2.6 mBar)
Adding oil
If the interconnecting pipe length (one-way) is greater than 20 metres, it is likely that
more oil would be required for the system. Your local representative can advise on the
amount of oil required (if supplied with the required information).
• Add the required oil to the system (under vacuum) via the discharge line.
NOTICE
Excessive oil added to a stationary compressor may cause a hydraulic lock and
damage the unit during start up. This will void warranty.
• During evacuation, oil must be added into the discharge line.
Non-return valves are installed in the compressor discharge line to prevent
the oil travelling against the flow direction (into the compressor).

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Commissioning Multi-DENCO

NOTE!
Multi-DENCO units can contain two different types of compressors – each with their
own oil type. Please follow the below recommendations:
A-Version - Size 010 - 065 A-Version - Size 092 - 130
FV50S POE 160SZ
Emkarate RL68H Emkarate RL32H
Mobil Arctic EAL68
Alternative oils are compatible with the original oil type used, therefore these can
be mixed and alternatives can be used as "top up".
For X-Version & H-Version units, refer to the separate condensing unit installation
manual for compatible oil types.

Emkarate Typical Properties


Property and Procedure RL32H RL68H
Viscosity @ 40°C (cSt), ASTM D-445 33.7 72.3
Viscosity @ 100°C (cSt), ASTM D-445 5.9 9.8
Typical SUS Viscosity @ 100°F 150 300
Viscosity Index, ASTM D-2270 110 120
Pour Point (°C), ASTM D-97 -46 -39
Density @ 20°C (g/ml), ASTM D-1298 0.977 0.977
Flash Point (COC) (°C), ASTM D-92 270 270
Acid Value (mgKOH/g), ASTM D-974 modified 0.02 <0.02
Water Content (ppm), ASTM E 1064-85 <50 <50
Refractive Index @ 28°C 1.4530 1.4557

Tab. 8-1

2nd and 3rd vacuum


• Shut off the vacuum pump and add oxygen free nitrogen to a system pressure of
1 bar.
• Safely release the gas to just above atmospheric pressure
• Evacuate the system to at least 2 Torr (2.6 mbar)
• Again, shut off the vacuum pump and add oxygen free nitrogen to a system pressure
of 1 bar
• Safely release the gas to just above atmospheric pressure and once again evacuate
the system to at least 2 Torr (2.6 mbar)
• Once achieved, turn the vacuum pump off and observe that the system maintains a
vacuum for at least 30 minutes to prove the tightness of the circuit.
• On completion of evacuation, the gauge manifold should be closed off and isolated
from the vacuum pump, then connected to a refrigerant cylinder, the gauge lines
should be carefully purged of any air.

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Adding refrigerant
The initial 'charge' of refrigerant that is added to the system is not an exact measure,
but a volume of refrigerant to enable the system to start initially. This first charge should
always go into the liquid line of the unit and be approximately 75% of the planned
charge amount.
Your sales/support representative should be able to give you an estimate of total
system charge (if supplied with the required information).
• Add an 'inital-charge' of refrigerant R410A until 'high' and 'low' side pressures are
equal. Be careful that no liquid refrigerant is injected into the compressors.
• Close off the manifold valves and record the quantity of refrigerant added.
NOTE!
It is important that the volume of refrigerant added during the initial charge is recor-
ded accurately. When commissioning it is a LEGAL REQUIREMENT for the total
refrigerant weight to be added to the unit's nameplate. Ensure the pre-charge mea-
surement is accurate and this information is provided to the commissioning
engineer.

8.3 Commissioning procedure


NOTE!
Due to the complex nature of the Multi-DENCO product, we strongly recommend
that a FläktGroup commissioning engineer is employed to carry out the commissio-
ning procedure. Contact your local representative for assistance with this.

8.3.1 Room considerations


During commissioning, it is important to understand the heat load and the ambient tem-
perature in relation to:
– Initial design conditions
– Current conditions (during commissioning)
– (Possible) future conditions
For example, attempting to commission a Multi-DENCO A-Version unit in a room with
no heat source is difficult, as you would not be able to give a consistent operation to
observe refrigerant charge. Alternatively, commissioning a unit on a cold day could
result in lower condensing temperatures, which may cause over-charging of a unit.
Wherever possible, attempt to recreate the required conditions needed by the end
user, so that the unit is configured for the appropriate operating range. Always consider
that the ambient temperature on initial design conditions, may only be 'peak' tempera-
ture and that the unit will probably be operating at lower temperatures for a significant
percentage of operation.

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8.3.2 Calibration of refrigeration devices


Before finishing commissioning, but after the initial charge has been added, various
refrigeration devices/sensors must be calibrated to ensure accurate operations. This
will require the controller/display to be enabled, but the cooling circuit must remain
disabled (i.e. compressors are off). This can be achieved by the controller or through
disabling MCBs.
These devices and the suitable commissioning devices are as follows:
– Suction transducer(s) with a refrigeration gauge
– Suction pipe temperature probe(s) with a temperature touch probe
– Discharge transducer with a refrigeration gauge
– Discharge pipe temperature probe with a temperature touch probe

NOTICE
Refrigeration devices that are not calibrated can result in safety and
protection features being disabled. Failure to calibrate during commissioning
will void the warranty.

8.3.3 Enabling the unit

NOTE!
For chilled water units, review and complete requirements of chapter 8.3.6 before
enabling the unit.

Once the electric power supply is connected and energised, there is a risk of
electric shock during commissioning. Also inverter circuits may store electrical
energy for some time after isolation.
• Once isolated, allow time for stored energy to fully decay before operating on
inverter based circuits.

With the initial charge added and the devices calibrated the unit can be enabled by the
following order:
• Enable any isolator or circuit breakers in the main power distribution board (both
boards for units with dual power supply)
• Ensure the outdoor unit's isolator is set to 'ON' (if applicable)
• Enable any 'in-line' isolation for the Multi-DENCO unit
• Set the door interlock isolator (if fitted) to the 'ON' position
• Wait 1 - 2 minutes for the unit to start up
• When display is active, press the 'Enable' button in the bottom left corner of the
display
9 The unit will now being to operate and control to the default settings in the
C5-12 controller.

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8.3.4 Calibration of control sensors


Recommendation: If suitable cooling demand can be provided to the unit from within the controlled space
during commissioning, then at this point in the procedure would be appropriate to
change the set-point and other variables to the requirements of the end-user. Details
of how to change values in the C5-12 controller are available in the Multi-DENCO con-
trols manual.
Once the unit is enabled and operating, calibration of control sensors is vital to ensu-
ring an accurate and efficient operation of your Multi-DENCO unit. These sensors in-
clude (but are not limited to):
– Control temperature and humidity sensors – all fitted within the unit
and/or remotely
– Pipework pressure and temperature sensors
– Floor void air pressure control (APS) sensors
– Ambient temperature sensor
These sensors must be calibrated accurately to allow for a successful commission to
be completed. Failure to calibrate these sensors may lead to inefficient operation or
possibly alarms and non-operation.

8.3.5 Commissioning refrigerant circuits

NOTE!
When commissioning a refrigerant circuit for a Multi-DENCO unit it is important that
the compressors are operating at a high speed. Once the high speed is achieved,
time should be allowed for the system to stabilise.

Consideration and Targets


Below are the commissioning targets for an optimum system charge:
Superheat: 7 - 9 K (Default set point = 8 K)
Sub-cooling: 5-8K
Discharge superheat: Compressor(s) at Low Speeds (< 50 RPS) = 15 - 25K
Compressor(s) at High Speeds (> 50 RPS) = 25 - 35K

NOTE!
If fitted, it is important to consider the state of BOTH compressor speeds to under-
stand the unit's operating level. For example, an inverter compressor may be ope-
rating at low speeds (< 50 RPS), but if the other compressor is active then the unit
will be operating at above 50% capacity. Compressor speeds can be viewed in the
'Engineering level' of the C5-12 controller display.

All 3 of these variables must be considered together for a successful commissioning.


You must also consider/witness what these variables will be at different operating con-
ditions (e.g. low demand vs high demand).

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Procedure
With a stable system, additional refrigerant can be progressively added to the circuit to
bring the system to the required charge. When adding refrigerant, the following proce-
dure and advice applies:
• Refrigerant should be added to the suction line as liquid
• A metering valve on a set of manifold gauges should be used
• Any refrigerant should be added as lightly/slowly as possible
NOTICE
Large concentration of liquid refrigerant entering the compressor can cause
'hydraulic lock' and permanently damage the compressor.
• Add refrigerant in no more than 0.5 kg additions.
• Allow the system to stabilise after each addition.
– It may take several minutes for the system to stabilise.
– Adding refrigerant too quickly can cause an 'over-charged' condition.

• To stop the charging, close the LP manifold valve


• Observe the state of the liquid in the Electronic Expansion Valve (EEV) sight
glass
• Wait several minutes for the system to settle before proceeding further
• Observe the system to see if the unit charge is suitable and effective
• Observe superheat, sub-cooling and discharge superheat against targets listed
earlier in this chapter
• If fitted/required, adjust the fan speed controller settings to modify the sub cooling
settings
• If overcharge, remove refrigerant from system

NOTICE
Refrigerant is damaging to the environment.
• Never discharge refrigerant to the atmosphere.
• Recover any refrigerant and dispose of according to national/regional
requirements.

• If refrigerant circuit charge is to your satisfaction, re-perform the 'Calibration of


refrigeration devices' (chapter 8.3.2) to ensure proper operation of control devices.
• If good operation is observed, record the total charge of the system, check the oil
and perform the safety procedure as detailed in the next sections.

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Oil level check


Before the system can be left as fully charged, the oil level within the system must be
checked a final time. There are 2 different procedures depending upon your size of
unit:
Size 010 - 065 For these sized units there is no oil level sight glass available, therefore the tempera-
ture of the oil reservoir within the compressor must be taken.
With stable running conditions, the reservoir temperature must be 10 K more than the
running evaporating temperature for example:
If evaporating temperature equals 10 °C then the oil reservoir temperature must be
greater than 20 °C.
Size 092 - 130 In these units, an oil balance sight glass is fitted, allowing for visual inspection of the
system. There are also sight glasses on each compressor which should be reviewed.
The below table describes what should be observed in the sight glass when at optimum
conditions:

Unit stopped Both compressors operating


Size 092 ½ to ¾ full ¼ to ½ full
Size 130 0 to ¼ full ½ full *
Tab. 8-2

* For this scenario, this must be observed in the sight glass for the fixed speed compressor.

If either scenario requires additional 'top-up' of oil, ensure this is conducted whilst the
unit is off and deactivated.

Function Test of Safety Device(s)


Multi-DENCO units are fitted with High Pressure (HP) switch(s) to mechanically protect
the refrigeration circuit. After charging, these MUST BE TESTED. For details of the
procedure, please refer to the controls manual.

This test requires system pressure to be continually increased to check safety


devices of the system. If the devices fail the test and appropriate actions are not
taken to stop further pressure increases, there is danger of pipework ruptures and
catastrophic failures. Failure to follow recommendations may lead to death or
serious injury.
• Do not allow the system pressures to rise above the Maximum Operating
Pressure (MOP) stated on the unit's nameplate.
• If the High Pressure (HP) switch fails to deactivate the compressors and the
pressure continues to rise; DEACTIVATE THE UNIT IMMEDIATELY (for
example, isolate the power supply).
Before re-enabling the unit;
• Mechanically measure the pressure within the system
• Wait until the pressures have reduced to normal standby conditions
• Ensure the condenser fan MCB(s) have been re-enabled.

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8.3.6 Commissioning chilled water circuits


The following procedure applies to any water circuit used within a Multi-DENCO
system (C-Version, CombiCool circuit, O-Version etc).

Procedure
• Check for an established water flow
• Check that any temperature sensors are securely fastened to the correct pipework
• Take readings of water temperature sensors and compare these values with the
values displayed on the C5-12 controller: all probes and sensors MUST be
calibrated
• Check for correct rotation in the water pump and any air within the water system is
being removed by the pump or by air purge valves
• (If applicable) add, as required, pressure to any expansion vessels
• (If applicable) sample and check Glycol concentration (more details below)
• Record all details to the commissioning report

Glycol and corrosion inhibitors


We recommend using a hand held refractometer (for example Kittiwake, RHA-21ATC)
for measuring glycol concentrations. It is able to give accurate readings from a very
small sample of fluid and covers both Ethylene Glycol and Propylene Glycol.
It is important to ascertain the quality and quantity of any glycol and corrosion inhibitors
(see chapter 6.6.2 'Glycols' on page 67). Pumps must never have a negative pressure
or vacuum on their inlet.
Automotive inhibitors and anti-freeze MUST NOT BE USED as nearly all automotive
anti-freeze contains silicate-based inhibitors, which gel and foul, coating heat exchan-
ger surfaces and reducing energy efficiency. These silicates have also been shown to
significantly reduce the lifespan of pump seals.

NOTICE
Low levels of glycol or inhibitors can cause corrosion of steel or iron
components.
• Ensure minimum concentration of inhibitor is above 20%.
Coolant concentrations are determined by first deciding what freeze and/or burst pro-
tection is appropriate for the application, based on operating temperatures or ambient
temperatures.
Fig. 8-1: Kittiwake hand held
refractometer

Freeze protection This is imperative when a system requires pumping. It is achieved when glycol concen-
trations in a system are sufficient to prevent ice crystals from forming when the fluid
experiences the lowest temperature for its application.
Burst protection This is achieved when the concentration of glycol in a system is high enough to prevent
the fluid from freezing solid. The glycol concentration will be lower than that of a 'Freeze
Protected' system, therefore it can form ice crystals at low temperatures (being a semi-
fluid state) and will no longer be pump-able. When ice crystals being to form the solu-
tion will expand.

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The table refers to general percentage concentration of Ethylene Glycol. Always con-
tact the manufacturer for specific values for their variant of Glycol:

Temperature Percentage concentration needed for (%):


°C Freeze Protection Burst Protection

-7 16 11

-12 25 16

-18 32 21

-23 39 26

-28 44 31

-34 48 36

-40 52 37

-46 55 38

Tab. 8-3

Ethylene glycol gives added protection against system damage from bursting:
– On freezing water expands about 9%
– This volume change may rupture piping and cause catastrophic system failure
– Adding ethylene glycol significantly reduces the expansion the solution upon free-
zing, thus reducing the likelihood of system pipes bursting
– The higher the ethylene glycol concentration, the less the expansion
– Pure ethylene glycol does not expand at all upon freezing
Refer to the Tab. 8-3 for freeze and burst protection. In a system not operational in win-
ter, it may be sufficient to choose a lower fluid concentration, one that merely protects
against bursting, since some crystal formation in the fluid will not be harmful.

8.3.7 Water balancing


3 & 2-port Drive Open Drive Close Valves (DODC)
• Ensure the valve is '100% open' during water balancing; failure to follow this may
result limited capacity of the unit
• To force the valve to be 100% open, use the controls to modify the set-point
temperature (supply or return) so that it is below the water temperatures within the
chilled water circuit

2-port Pressure Independent Control Valves (PICV)

NOTE!
The following instructions are for 2-port PICV valves used with C5-12 controllers in
Multi-DENCO units. For all other configurations or equipment please see separate
manuals or contact your local office.

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To set up the maximum design chilled water flow rate, on site:


• The unit must be powered on, pre-commissioned and running under automatic
control
• The chilled water pump must be operating to provide pressure differential across the
unit of 100 kPa (minimum 50 kPa, maximum 350 kPa)
• Force the chilled water valve to 100% open by reducing the set-point temperature
(supply or return) to below the water temperatures within the chilled water circuit
• Measure the chilled water flow rate using a hydronic manometer with the hoses
connected to the local orifice plate in the external chilled water pipework supplying
the unit (supplied/fitted by others)
• To adjust the maximum chilled water flow rate to design conditions, adjust the
setting PIC Valve Max Value % to achieve the design maximum flow rate (see the
C5-12 controller manual for instructions on how to do this)
• Record the maximum flow rate and PIC Valve Max Value %

8.3.8 Variances for winter kit


Units operating in low ambient temperatures may be fitted with a winter kit. The system
operates as a 'liquid backup'. At high ambient temperatures, the system regulates so
that liquid refrigerant is stored in the liquid receiver. At low ambient temperatures liquid
refrigerant is stored/backed-up in the condenser coil instead.
The components of the winter kit are:
– Electronic Regulation Valves (ERV)
– Condenser fans
– Liquid receiver with trace heating
– Control circuit transformer for controlling the ERVs (Evolution Driver)
– Control panel heater
– Mains Circuit Breaker (MCB) in the indoor units electrical panel (power supply to the
winter kit)
Commissioning engineers must observe the good practices with the following additio-
nal requirements for winter kits.

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Procedure
1. Calculate the 'system refrigerant'.
– This is the refrigerant required to charge a standard system without a winter kit
option (indoor/outdoor unit and interconnecting pipework).
2. Calculate the refrigerant required to fill the liquid receiver to 80% (see Tab. 8-4).

NOTICE
Overfilling of liquid receivers can result in poor system performance or failure.
• The liquid receiver should never exceed 80% full.

Condenser Liquid Receiver – 100% Capacity 100% Filled – R410A 80% Filled – R410A
Size Litres kg kg

DMOUCD008 7 7 5.6

DMOUCD013 7 7 5.6

DMOUCD021 12 12 9.6

DMOUCD026 15 15 12.0

DMOUCD032 18 18 14.4

DMOUCD050 21 21 16.8

DMOUCD075 21 21 16.8
Tab. 8-4
At average condensing temperatures of 41 °C with 6 K sub-cooling; 35 °C liquid temperatures. Density = 1 kg/L3.

3. Before adding refrigerant, set the condenser fans to minimum speed and lowest
pressure setting.
– This is to allow the liquid receiver to be assessed whilst the fans are operating.
NOTICE
To change the required settings for C5-12 controls, you must use the display of the
unit, which requires the unit to be enabled. To perform safely you must observe the
following:
• Enable power to the unit and set the local isolator to the 'ON' position
• Wait for the unit to finish its start-up procedure
• DO NOT press the 'Enable' button on the home screen (bottom left hand corner)
• Navigate to the condenser settings (Advanced Level)
• Modify settings as advised
• Navigate to the home screen
• Set the local isolator to the 'OFF' position and remove power from the main
power distribution board
9 The unit is now ready for charging

4. Add the initial refrigerant.


• ONLY add 75% of the 'system refrigerant' (excluding the liquid receiver
refrigerant) should be added initially (see 'Initial charge for refrigerant circuits'
chapter 8.2.6).
• Enable the unit and set the compressors to operating at high speed (chapter
8.3.5)
• Add refrigerant in amounts no larger than 0.5kg into the suction line: using the
metering valve on appropriate service gauges.
• After each addition, allow the system to stabilise and check conditions before
adding any more.
• Monitor the sight glass throughout the process - when flashes of liquid are ob-
served – stop adding refrigerant

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5. When liquid is observed, you will find that you have not use all of the estimated
refrigerant (system and liquid receiver)
– You will have only filled the liquid receiver to its minimum level (Fig. 8-2)

Required level

Level when 'liquid flashes' are


observed.

Fig. 8-2

• Add ALL the remaining estimated refrigerant to the system to fill the liquid
receiver further.

6. Once all the refrigerant has been added, the liquid receiver needs to be checked.
• Measure the ambient temperature on the face of the condenser coil.
• Take several measurements at different positions and calculate an
average value.
• Using the average temperature, the level of the liquid receiver should match
Tab. 8-5
• For example; if the temperature is above 20°C, the liquid receiver should only be
80 % full (no liquid refrigerant in the condenser coil)
• Otherwise; if ambient temperature is 0°C on the day of commissioning, then the
liquid receiver should be about 30 % full (lots of liquid refrigerant in the condenser
coil)

Ambient Temperature Liquid Receiver Fill Level


°C %
30 80
20 80
10 50
0 30
-10 20
-20 15
-30 10
Tab. 8-5
• Using a touch probe on the receiver shell (under the insulation) measure every
5 to 10 mm to determine the liquid receiver fill level.
• If the level does not match, add/remove refrigerant to meet the values in
the table.

7. Once the refrigerant level is correct, perform standard calibration checking (chapter
8.3.4).

8. The condenser fan settings should then be restored to 24 Bar and left on 'Minimum
Speed' control.

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8.3.9 Common commissioning issues


• If the discharge pressure is unstable, adjust the set-points and proportional bands
of the condenser until the discharge pressure stabilises. The condenser(s) should
be left on 'Minimum cut-off' wherever possible.
• If the electronic expansion valve(s) (EEV) do not open during start-up, and no alarm
or status message is shown, check the EEV transducers and the temperature probe
for functionality.
• (Size 010 to 065 units) if during charging there is an 'Overcurrent' alarm from the
inverter drive, potentially too much liquid is entering the compressor. Throttle back
the manifold gauge to reduce liquid entering the system.

8.4 Post-commissioning procedure

8.4.1 Nameplate
Once the commission has been successfully completed, it is a LEGAL REQUIRE-
MENT that the total refrigerant charge for the whole system is written onto the unit's
nameplate.
You will see space for this to be written on the bottom left corner of the serial plate.

8.4.2 Saving controller settings


After commissioning, we recommend that your service technician saves the unit confi-
gurations to the controller. This can allow for the system settings to be restored, back
to the configuration made during commissioning. More details of this feature are availa-
ble in the controller manual.

8.4.3 Commissioning report


As mentioned previously, it is very important that you submit a copy of the
'Multi-DENCO Commissioning Report' (chapter 13.3) to your local sales/service repre-
sentative, so that this can be retained against the project. Failure to do so may invali-
date warranty.

8.4.4 Configuration of accessories


Depending upon what design options have been selected, you may be required to con-
tinue with configuration of specific accessories (for example, humidifier or condensate
pump).
Refer to initial design selection or the serial plate within the unit to establish if all neces-
sary parts have been commissioned and configured.

NOTE!
For filter switches, we recommend the following settings:
– G4 = 0.7mbar (70 Pa)
– G7 = 1.2 mbar (120 Pa)
These values are based on standard pressure drops when fans operating at max
velocity. Different values may be required if fans are operating at lower speeds (as
alarm may not occur until fan increases speed to compensate for dirty filters).

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9 Operation
More comprehensive details and explanation on the control and regulation of the
Multi-DENCO units are available in Controller Manual.
This manual does not cover control of units that have been provided "without controls".

9.1 Requirements
Prior to using a Multi-DENCO unit, a full and safe installation and commission must
have been conducted by a suitably qualified personnel and a record of both processes
must be stored. The commissioning report (chapter 13.3) must have been sent to your
local sales office to validate warranty during operation.
Before use all operators MUST be familiar with the following:
– The contents of this manual
– Safety assessment for the location where the Multi-DENCO unit is situated
– Location of the associated outdoor unit (if applicable)
– Location of power distribution board isolator
– Location of the mains isolator
– Either fitted within the door of the Multi-DENCO unit or within 1m of the unit
– Location of circuit breakers (MCBs) inside the Multi-DENCO unit
– Shut off (isolation) valves for the Multi-DENCO unit including (if applicable):
– Refrigerant circuit
– Chilled Water Circuit
– Hot Water Circuit
– Humidifier Circuit

9.2 General operation


Close control units, like Multi-DENCO, are designed for continuous operation to cover
the 8760 hours in a year, thus allowing constant indoor temperatures to be maintained.

9.2.1 Enabling the unit


To enable the unit to operate, you must:
• Switch the isolator to the 'ON' position at the mains distribution board
• Switch the isolator to the 'ON' position on isolator fitted to the unit (or within 1 m)
• Switch the isolator to the 'ON' position for the outdoor unit (if applicable)
• Wait for the unit to begin its start-up procedure (approximately 45 seconds)
• Enable the unit by keyboard (see the next chapter for details)

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9.2.2 The home screen (C5-12)

1: Unit ON/OFF (by keyboard) 9: Unit Number (for networking)


2: Unit Status 10: Model Reference
3: Alarms Page 11: Icon if any alarms are active
4: Unit Graphs 12: Date
5: Login 13: Unit function Icons
6: Status Information 14: Network Status
7: Current Temperature 15: Time
(depending on control sensor)
8: Current Humidity 16: Help/additional information
(depending on control sensor)

9.2.3 Screen saver


If you do not use the touch screen for 15 minutes, a screen saver is displayed. To turn
off the screen saver simply touch the display. The screen will show a bright red alarm
symbol, if the unit has an active alarm during screen saver mode.

9.2.4 Physical operation and access

NOTICE
During operation:
• Do not open any doors.
• Do not remove any panels of an operating unit.
• Do not remove any floor tiles near to the unit.
• Do not conduct any work above or below the unit.
• Do not insert any tools through any of the grilles of the unit.

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9.2.5 Stopping the unit

Multi-DENCO units use fans which are regulated independently by the main control
board. Removing guards whilst unit is operational risks death or serious injury.
Inverters also store energy for a period of time after isolation.
• Disable the unit.
• Electrically isolate the unit.
• Wait AT LEAST 5 minutes.
9 Once fan momentum has ceased and the inverter energy discharged, you can
open the doors and conduct work.

• To stop the Multi-DENCO unit, simply press the ON/OFF button on the home
screen.
9 The screen will display 'UNIT OFF BY KEYBOARD' if successful.

9.2.6 Disconnecting from power supply

Multi-DENCO units use fans which are regulated independently by the main control
board. Removing guards whilst unit is operational risks death or serious injury.
Inverters also store energy for a period of time after isolation.
• Disable the unit.
• Electrically isolate the unit.
• Wait AT LEAST 5 minutes.
9 Once fan momentum has ceased and the inverter energy discharged, you can
open the doors and conduct work.

Having deactivated the unit (chapter 9.2.5) and waiting AT LEAST 5 MINUTES, you
can disconnect the unit by:
• Switch the isolator to the 'OFF' position for the outdoor unit (if applicable)
• Switch the isolator to the 'OFF' position on isolator fitted to the unit (or within 1m)
• Switch the isolator to the 'OFF' position at the mains distribution board

When the isolator fitted to the unit (or within 1 m) is in the OFF position, the first half
of the isolator could still be live (with electrical power).
• To ensure safe operations, ensure that the circuit has been isolated in the OFF
position at the mains distribution board and suitably locked to prevent inadvertent
re-connection of electrical power.

9.3 Alarms and error messages


Details and explanation of the alarms by Multi-DENCO units are available in controller
manual.
Chapter 11 'Fault Finding and Troubleshooting' has details of typical issues than can
be encountered.

NOTICE
Resetting of alarms without rectifying the cause can lead to extended unit damage,
which may result in the voiding of the warranty.

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10 Servicing and Maintenance


Regular preventative maintenance of your equipment is strongly recommended to
ensure that it is kept in excellent operating condition.
Along with equipment recommended in Chapter 2, we recommend that a protective
mask is worn during service and maintenance.
• Review your cleaning equipment's guidelines for the required properties of your
protective mask.
• Ensure your working area is well ventilated.
• Conduct your own personal risk assessment to evaluate any further requirements.
NOTE!
We recommend a maintenance contract with FläktGroup or an approved service
company. Maintenance shall only be undertaken by authorized and fully qualified
staff with the required Country specific qualifications in refrigerant handling and a
sound knowledge of the operation and the dangers involved with inverter techno-
logy and other electrical services.

• Ensure all incoming electrical connections are isolated and cannot be


inadvertently energised.
• Inverter technology and rotating fans required at least 5 minutes from
electrically isolating the unit before any doors or panels can be removed.
– Units fitted with and humidifier may have hot water condensate and hot
pipework/metal work
– Refrigeration circuits may have both very hot and very cold sections within
the same system.

Whilst cleaning, thin fins present a risk of cutting. Panels and doors can be heavy
and present a crushing risk when being removed.
• Do not touch the coil with unprotected skin.
• Ensure doors are properly attended when being removed.
• Use access platforms for units that are installed above floor height.

NOTICE
Damaging fins or louvres during the cleaning process will reduce the
unit's cooling capacity.

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10.1 Maintenance access


All panels can be removed to perform maintenance.
However, all main components are accessible from the front.

10.2 Servicing
Routine, planned maintenance visits will be required throughout the year to
maintain efficiency and may also be a legal requirement depending on Country spe-
cific legislation.
The intervals of service will depend entirely on the operating conditions of your room.
This can be as often as once per month for critical, production essential equipment.
Your FläktGroup representative will be able to assist you with arranging a maintenance
contract that will suit your needs.

During maintenance and servicing:


• Do not allow the system pressures to rise above the Maximum Operating
Pressure (MOP) stated on the unit's nameplate.
• If the High Pressure (HP) switch fails to deactivate the compressors and the
pressure continues to rise; DEACTIVATE THE UNIT IMMEDIATELY (for
example, isolate the power supply).
Before re-enabling the unit:
• Mechanically measure the pressure within the system
• Wait until the pressures have reduced to normal standby conditions
• Ensure the condenser fan MCB(s) have been re-enabled.

NOTE!
Items of equipment attached to the refrigerant circuit, for instance the H.P.
switch (Fig. 10-1), are often protected by a schrader core. If this is the case the
connecting nut is painted red. If the connecting nut has no red paint then you
must assume that no Schraeder core is present and therefore the whole
system refrigerant charge will have to be recovered before the component
can be removed

Fig. 10-1

10.2.1 Example Maintenance schedule


Below show an example maintenance schedule for a Multi-DENCO unit. We advised
the below is the minimum requirements. Most situations will require further actions and
a shorter time interval to ensure good operating conditions.
After every inspection, any relevant information must be recorded into the logbook.
Certain countries have specific legislation regarding record keeping (e.g. Fluorinated
Greenhouse Gases Regulation (EU) No 517/2014). Please refer to chapter 10.7 'Log-
book & EU Regulation' for more details.

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Interval Action

Daily 1: Check for any outstanding alarms.


2: Check display for good operation.
3: Visual inspection of exterior condition of the unit.
4: Visual inspection in and around the unit for the presence of refrigerant oils, which may show signs of a leak.

Weekly 1: Inspect outdoor heat exchanger for freedom of airflow.


2: Inspect gaskets, leaks, insulation, fan bearings and water drain of the unit, pay attention for any unusual noises.

Monthly 1: Check cleanliness of filters – inspect for break up and suitable sealing. Replace if necessary.
2: (If fitted) check cleanliness of grilles.
3: Check cleanliness both inside and outside of the unit.

Every 1: Check that the evaporating and condensing pressures are acceptable.
Three 2: Check safety protection features, such as low pressure and temperature alarms, operate correctly.
Months 3: Check capacity control for correct operation and configuration.
4: Check electrical connections for tightness. Repair or replace all damaged terminals.
5: Check all component electrical currents are within acceptable limits.
6: Check refrigerant sight glass.
7: Check condensate drain for free flow and drainage.
8: Check for refrigerant leaks 1: Inspect all accessible refrigeration pipework with an electronic leak detector paying
particular attention to flexible tubes, capillary tubes etc. Check all accessible pipework fixings for tightness and
security.
9: Inspect oil charges and levels to identify any loss since last inspection – rectify as necessary.
10: Inspect fan touch protection devices for compliance and functionality.
11: Check operation of on-board electrode steam boiler humidifier (if fitted): Check drain down and fill function,
disposal pumps and bottle current. Replace any expired bottles.

Every Six 1: Check contactors for damage or eroding.


Months 2: Check that the electrical contactor overloads functions are set correctly.
3: Check any crankcase heaters (if fitted) for correct operation.
4: Check the evaporator fans can rotate freely.
5: Check conditions of evaporator coils and clean as required. Inspect heat exchangers for free airflow, cleaned
and combed where necessary.
6: If not conducted within the last 6 months; change air filters.
7: Check colour code of sight glass moisture indicator.
8: Check compressors for smooth operation.
9: Check anti-vibration mountings (outdoor unit) for damage.
10: Check pipework and insulation for damage (indoor, outdoor and interconnecting pipework).
11: The glycol content should be checked (if applicable) then adjusted and recorded as necessary (water-based
circuits).
12: Check the condition of the water pipework, water volume flow, valve operation, and the cleanliness of all the
strainers (water-based circuits).
13: Check the calibration and functionality of the unit controller.
14: Check casing and connected ducting for any air leakage – repair where required.
15: Check room conditions required and adjust unit settings as necessary.
16: Clean unit inside and out with vacuum cleaner and wipe down with moist cloth.
17: Check proper function of the refrigerant leakage detection system (if fitted) either through use of a service tool
or use of testing refrigerant.

Yearly 1: Test the high pressure safety switch cut out and adjust/replace as necessary (see chapter 8.3.5 'Commissioning
refrigerant circuits' on page 84).

After 5 1: (If fitted) it is recommended that the pressure relief valve is replaced.
years of
operation

Tab. 10-1
1The equipment should be thoroughly tested to ensure there are no refrigerant leaks to comply with EN 378-4:2008+A1:2012
Associated equipment should also be service in accordance with manufacturer's specifications.

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10.3 Refrigerant leak testing


Leak testing on the equipment is required:
– After any strength affecting work (e.g. Brazing)
– If the unit has not operated for longer than two years
– Changes or extensions to the system
– Suspicions of refrigerant leakage
– On Multi-DENCO systems with a R410A refrigerant charge of 2.4 - 23.9 kg (equiva-
lent 5 - 50 tonnes CO2) a yearly leak test is mandatory.
– On systems with charges of 24 - 239 kg (equivalent 50 - 500 tonnes CO2) then it is
mandatory to perform a leak test twice a year.
– Within one month of fixing a refrigerant leak

10.4 Compressor care


NOTICE
Following advice received directly from the manufacturers of compressors, we DO
NOT allow the use of additives (for example Quickshot®) with ANY Multi-DENCO
system. ANY USE WILL INVALIDATE WARRANTY.

On new Multi-DENCO systems, if installed and commissioned correctly, no acids are


present. Multi-DENCO units are fitted with molecular sieve type of drier to help
moisture content be at an extremely low level.
If the system has operated under adverse conditions for some time, weak acids may
appear from the oil and refrigerant by system heat and electrical arcing. This acid will
remain INERT until moisture is added to the system, for example, via air ingress into
the system during service work.

NOTE!
During any service or at any time that the refrigeration system is opened, a replace-
ment filter drier (molecular sieve type) should be fitted. These can contain a propor-
tion of activated oxides that absorb weak acids and remove them from the system.

10.5 Humidifier maintenance (if fitted)


As the humidifier usually operates in automatic mode and the relevant wear of the
device is displayed, a standard maintenance interval is usually sufficient. Cylinder life
will be dependent on the quality of the water supplied and the length of time the cylinder
will be active.
Each cylinder is equipped with an integrated filter in the drain pipe. With every cylinder
replacement this filter must be changed also.

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10.6 Closing down procedure


It is essential for starting, closing down, emergency operation and fault finding to know
the location of the following components:
– Location of isolator for power distribution to the unit
– Main Isolator (integral to unit or local position)
– ON/OFF icon on the display of the unit
– All valves likely to affect water supply to humidifier (when fitted)

NOTE!
The units are designed for continuous operation and it is recommended that the
system is kept running overnight and at weekends to maintain stable room conditi-
ons.

Short periods Should you require the equipment to be closed down for the weekend or Bank Holi-
days, no special precautions are required.
Each unit may simply be turned off by pressing the On/Off icon.
Alternatively, the "On/Off Times" can be configured in the controller software.

Long periods If the plant is to be shut down for longer periods (up to a month) this can be done by
switching off at the on/off icon, then opening the Main Isolator, and closing the local
mains water supply to the humidifier. When re-starting the plant, follow the same
instructions but in the reverse order.

Indefinitely When the equipment is to be taken out of service for an indefinite period we recom-
mend a qualified air conditioning engineer. An engineer will also be required for the
restarting of the equipment.
For units fitted with chilled water cooling and/or hot water heating, the mains power
should remain "ON" for at least the stroke time of the valve actuator to ensure that the
valve closes fully.

10.6.1 Freeze prevention of water pipework


If water piping is installed where the temperature may drop below freezing, it must be
completely drained. Water coils are difficult to drain therefore it is advisable to remove
any remaining water by using compressed air.
If systems are to remain out of operation for long periods, this can result in corrosion
of the inner surfaces of the piping and coils. Therefore we recommend that the hydrau-
lic system be refilled with an anti-freeze solution. The anti-freeze solution should con-
tain inhibitors. Refer to chapter 6.6.2 and ask your anti-freeze supplier for advice.
On re-commissioning the equipment, the anti-freeze solution must be drained and pro-
perly recycled.

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10.7 Logbook & EU Regulation


A logbook should be available throughout the working life of the equipment. In the EU
this is a legal requirement if the system charge is 2.3 kg or above.
The logbook needs to be updated after each maintenance to comply with
EN 378-4:2008+A1:2012 and should include the following information:
– Initial refrigerant charge following commissioning
– Details of any maintenance or repair work
– Quantities of new, re-used or recycled refrigerant additions or removals
– If there is details of re-used refrigerant, the results should be kept in the
logbook also
– The refrigerant source should also be recorded
– Changes and replacements of any components of the refrigeration system
– Results of all periodic, routine tests
– The periods of any significant non-use
Members of the EU must also comply with the Fluorinated Greenhouse Gases Regu-
lation (EU) No 517/2014, alongside any further country specific legislation. This regu-
lation places responsibility for record keeping and leak detection on the owner/operator
of the equipment and the company that services it.
Information required for this regulation is more comprehensive than a simple logbook
and a required period for record keeping, therefore all parties involved should have an
understanding of the regulations implications. Furthermore, individual countries can
impose stricter rules than those set within the regulation.

102 FläktGroup DC-2013-0101-GB • Subject to modifications • R4-05/2018


Multi-DENCO Fault Finding and Troubleshooting

11 Fault Finding and Troubleshooting


The Multi-DENCO range is designed to perform its primary function: cooling of the con-
trolled space, for as long as possible. As long as a consistent and suitable power sup-
ply is given to the unit, only 'Critical' alarms will stop the unit performing its primary
function. Other alarms or faults may deactivate additional features of the unit (e.g. turn
off the humidifier etc).
This chapter provides information on fault finding and remedies to problems found with
your unit. Fault finding shall only be carried out by qualified licensed staff or other indi-
viduals with proper professional training and experience in the relevant accident pre-
vention regulations, as well as other generally recognized safety and occupational
health codes.
Provided that a high quality, thorough and planned maintenance program is maintai-
ned, a Multi-DENCO unit should provide years of smooth and problem-free operation.

NOTE!
A quality, routine, planned maintenance program should be implemented from com-
missioning. Failure to have a maintenance program in place during the warranty
period may invalidate the warranty.

NOTE!
In the event of persistent faults, room conditions going out of specification or pos-
sible refrigerant leaks you must contact competent maintenance & service technici-
ans to rectify your problems. Your local representative should be able to help you
with this.

If you find that your room conditions are outside of design specifications, there are
some simple areas that you can check to gather valuable information:
– Have conditions within the room changed?
– Has the equipment been recently moved?
– Has the airtightness of the room been compromised (e.g. door/window open)?
– Is there new equipment with higher/lower heat load?
– Is the air path temporarily blocked?
– Has additional cooling equipment been added to the room?
– Have the grille tiles been moved?
– Observing the unit status:
– Has the unit got power from the main distribution board?
– Is the unit isolator in the ON position?
– Is the unit display working?
– What does the unit status description say?
– Is the unit controlled via BMS? What are the current commands?
– Is the unit a part of a network – is it currently in duty or standby mode?
– Can you hear the fans operating?
– Observe what previous alarms have been made (and dismissed)
– Have the set-points been modified?
– When was the last service?

FläktGroup DC-2013-0101-GB • Subject to modifications • R4-05/2018 103


Fault Finding and Troubleshooting Multi-DENCO

These simple questions and observations give important information to an engineer to


be able to appreciate a situation before attending site. The more information you can
provide, the more likely the issue will be solved in a fast and timely manner.

11.1 Common Issues


NOTE!
The advice in the following section assumes the unit has been operating consi-
stently for a significant amount of time with appropriate design conditions, applica-
tion and all necessary resources are supplied to the unit (electrical power, water,
free airflow etc.).

Multi-DENCO units use fans which are regulated independently by the main control
board. Removing guards whilst unit is operational risks death or serious injury.
Inverters also store energy for a period of time after isolation.
• Disable the unit.
• Electrically isolate the unit.
• Wait AT LEAST 5 minutes
9 Once fan momentum has ceased and the inverter energy discharged, you can
open the doors and conduct work.

Below is a list of conventional alarms or issues that, if initially installed and commissio-
ned properly, have a small chance of occurring. Before addressing the fault and pos-
sible remedy, please observe the following:
• Always refer to the correct electrical drawing for the equipment.
• Regular maintenance is the most effective measure to preventing any issues.
• Refrigerant leak testing must only be conducted by suitably qualified engineers
• If troubleshooting requires adjustments to the controller's settings, please refer to
the separate controller manual before proceeding.
• All person(s) must know the location of protection features for the unit (e.g. isolation
points) before conducting any work
• For water based circuits; plant hydraulic settings should not be altered as this may
affect the balance of the complete system. Rebalancing of a system can be a costly
operation, therefore any adjustments must be conducted by qualified individuals
with full knowledge of the system design and requirements.
The following table contains a sample list of mechanical issues and possible remedies
to fix them. A list of common control issues can be found in the separate controller
manual.

NOTE!
Due to the relationship between temperature and humidity, high temperature and
low humidity or alternatively low temperature and high humidity can occur at the
same time. To resolve such situations, always address the temperature first, before
taking measures to resolve humidity.

Fault Possible Reason Possible Remedy

Low pressure in refrigeration sy- Possible leak in pipework Investigate location of leak and repair. Once repair perform
stem (low pressure alarm) pressure tests and re-commission

Tab. 11-1

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Multi-DENCO Fault Finding and Troubleshooting

Fault Possible Reason Possible Remedy

High pressure in refrigeration sy- Too much refrigerant within Refer to commissioning report and compare current conditi-
stem system ons with conditions during commissioning. If significant
changes then perform re-commission the unit.

Outdoor fans may not See ‘Fault’ below


be operating

Fuse or relay fault Review the unit to check for damage to any fuse or relay that
is part of the refrigeration circuit operation

Outdoor heat exchanger is Clean heat exchanger fins and clear debris in and around
blocked/dirty unit

Indoor fans not operating Blocked filter alarm Check the coil filters for cleanliness, clean or replace as
appropriate

Fan motor failure The fan and the motor are a dynamic pair, therefore the fan
assembly must be replaced

Fan relay not activating Check the fan relays (1 relay per fan)

Unit off by… Check the controller display to see if the unit has been
disabled by; BMS, Time or Keyboard. If the unit is also part
of a network, it could be on a ‘Stand-by’ status.

Outdoor fans not operating Outdoor unit isolated Check the isolator on the unit is set to the ON position

Condensing pressures below If the refrigerant circuit pressure is below the condenser’s
the minimum requirements set-point the fans will not activate – observe the pressure in-
creasing in the unit controller and check fans start when
pressure increases sufficiently

Outdoor unit not receiving con- Compare terminals at outdoor and indoor units to check ca-
trol signal from indoor unit ble integrity

No image on the display No power to the unit Check the power supply at the mains power distribution
board and at the local isolator.

Display unit cable disconnected Deactivate the unit and open the door with the display. In-
spect the connection and cable at the display and the con-
troller.

Unit not cooling/heating/ Airflow failure alarm Check fan operation and suitable clearances in and around
humidifying/dehumidifying the fan. Check output of the controller to the fan and each
fan relay is energised.
Heater over-temperature alarm Check the heater thermostat for functionality, replace if
(heating only) necessary and check function of heaters.

Water detection alarm Standard configuration disables the humidifier only. Settings
available in the controller allow for whole unit operation to be
stopped. Inspect underneath the unit for presence of water
and check coil condensate tray.
Sensor failure Certain temperature and pressure sensors, upon failure, will
disable functions of the unit. Refer to the controls manual to
see what function is affected by each sensor.
Low oil level (functions disabled Check for possible leaks and the recent operations of the
by compressor alarms) unit (to ensure suitable functionality). Add oil as necessary
and re-commission the unit.
Tab. 11-1

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Dismantling and Disposal Multi-DENCO

12 Dismantling and Disposal

12.1 Dismantling
To dismantle a Multi-DENCO unit, proceed as follows:

• Ensure all incoming electrical connections are isolated and cannot be


inadvertently energised.
• Inverter technology and rotating fans required at least 5 minutes from electrically
isolating the unit before any doors or panels can be removed.
• Use earth and short-circuit and cover or isolate any neighbouring live parts.
• Recover all refrigerant or cooling medium and use inert medium (e.g. Oxygen
Free Nitrogen) to equalise the system pressure to meet ambient air pressure.

• Stop the unit as per chapter 9.2.5


• Disable electrical power to the unit as per chapter 9.2.6
• Ensure that the power supply cannot be 're-activated' by interlocking the supply/
supplies at the main power board and removing any fuses
• Humidifier
• Turn off the water feed to the humidifier (if fitted)
• Remove the humidifier connection to the condensate drain
• Ensure the humidifier bottle is suitably sealed or appropriately drained
• Water Circuits
• Close off/shut the valve on any water circuits, hot or cold (if fitted)
• Drain the water/water mixture from the circuit
• Disconnect the water connections and ensure no further fluid is leaking

106 FläktGroup DC-2013-0101-GB • Subject to modifications • R4-05/2018


Multi-DENCO Dismantling and Disposal

• Refrigeration circuits
• A specialist refrigeration engineer should be employed to recover and safely
dispose of the refrigerant gas and any associated oils and glycols prior to cutting
and capping off the refrigerant pipework
• A qualified electrical contractor should be employed to remove/recover the
main(s) and any interconnecting cabling
• Once mechanically and electrically separated from the system, attend to releasing
the Multi-DENCO unit from any fixings to the floor or other sub-structures
• Prepare the unit for handling and transportation as per chapter 4

12.2 Disposal
NOTICE
• Dispose of all components and materials in accordance with local codes,
practices and environmental regulations.

An authorized appointed contractor specializing in waste processing shall dispose


of the unit or its individual components. This appointed contractor shall ensure that:
– the components are separated according to material types
– the used operating materials are sorted and separated according to their respective
properties
– fluorinated greenhouse gases are properly recycled or disposed of by a suitable
qualified and certificated refrigerant handler
– they observe all local, national and international legislation and regulation regarding
the disposal of materials. For example, within Europe, they may refer to (amongst
others):
– Waste Electrical & Electronic Equipment (WEEE) 2012/19/EU
– Waste Framework Directive 2008/98/EC

FläktGroup DC-2013-0101-GB • Subject to modifications • R4-05/2018 107


Appendix Multi-DENCO

13 Appendix
NOTE!
Please note that these documents are samples from the time of publishing and may
not be the latest revision. For copies of the latest versions, please contact your local
sales office who will be able to provide them in either electronic or printed form.

13.1 Pre-Commissioning Checklist (DQA 880)


This document is to be completed before the commissioning engineer arrives to ensure
all requirements have been conducted and checked. The commissioning engineer will
ask you to present this document before they can proceed.

13.2 Pressure Test Certificate (DQA 653)


This is the template for recording the system pressure test conducted on the
Multi-DENCO circuit, once the mechanical installation has been completed.

13.3 Multi-DENCO Commissioning Report (DQA 890)


This is the template for the commissioning report of Multi-DENCO units.

108 FläktGroup DC-2013-0101-GB • Subject to modifications • R4-05/2018


Multi-DENCO Appendix

13.1 Pre-Commissioning Checklist (DQA 880)

Pre
e – Co
ommiission
ning Check
C klist
As a pre
e-requisite to accepting a firm boo oking for co
ommissionin ng we need clarification
n that all
aspectss of the insttallation are
e ready for u eed without delay whenn we arrive on site.
us to proce
Will you
u please the erefore com mplete all re
elevant secttions of this
s form and ee-mail backk to your
designaated FläktGroup contac ct.

End Ussers – Site Name:


N
Installers Name:
Full Site
e Address:

Site Post Code:


FläktGrroup Contra act No
FläktGrroup Contra acts
Enginee er.
FläktGrroup Contra acts
Enginee ers E-Mail
Addresss.

Tick Boxes
Checklist Item Commentss
Yes No
N N/A
Is equip pment in correct positio ons,
mounte ed on floor stands
s (if required) and d
levelledd up.
Is work area clean, tidy, safe, and
accessiible? If areaa has raised d floor is it
complete and free from hazarrds.
Are all ggrilles and ductwork
d co
omplete and d
ready fo or use?
Has reffrigeration pipework
p beeen pressure e
tested a and test cerrtificates ava ailable for
our insp pection and retention?
Is all refrigeration pipework
p installed,
connected, evacua ated, and le eft with a
holding charge of refrigerant.
r
Is mains cold wate er supply pip pework
connected and pre essure available
(equipm ment with hu umidifiers only)
Is chille
ed water or condenser
c water
pipeworrk installed,, fitted with auto air
vents, sstrainers, annd dosing pots,
p tested
and sysstems filled and vented d?

F
Failure to compplete this form or failure to haave all required items ready for
f commissio oning may resuult
in an aborttive visit by ou
ur commissioniing engineer, Your
Y signature on page 2 autthorises the
acceptance
a of a
any abortive co osts according
gly

Page 1 of 3 DQ
QA880 – Re
ev DH1

FläktGroup DC-2013-0101-GB • Subject to modifications • R4-05/2018 109


Appendix Multi-DENCO

Tick Boxes
Checklist Item Comments
s
Yes No
N N/A
If chilledd water or condenser
c water
w
system is to be fille ed with a gly
ycol mix haas
this bee en done and d accurate
concentration read dings available for our
retentioon.
Is drainage pipewo ork connected and
tested.
Are con ndensate pu umps fitted and tested
with ele ectrical suppply and pipe
ework and
has inte ernal packinng been rem moved.
Has ma ains power supply
s beenn installed,
connected, phase rotation che ecked, and
power a available at isolators.
Has inte erconnectinng electrical wiring bee n
installed d and conne ected as peer wiring
diagram ms.
Have firre shutdown n connectioons been
installed d and verifie
ed as operaating
correctly.
Have ex xternal stop
p – start con
nnections (iff
required d) been insttalled and te
ested.
Have in nterconnection cables (Denconet)
(
been installed utilis sing correctt Belden
type cable and leftt for our con nnection.
Do main ns power su upplies – ca
ables have
source isolation tha at compliess with the
current electrical re egulations.
Is secure on-site parking
p available for ou
ur
commis ssioning eng gineer’s vehhicle?
Is an H & S inductiion required d before ourr
commis ssioning eng gineer can commence
c
work?
Spare
Spare
Spare
Spare

Notes:
1. To comply with F-Gas regulationss where the e system ha
as refrigerannt charge (s
supply &
commission n projects) clients musst have their own engin
neer on site
e for the duration of
the works to add refrig
gerant to sysstems and create the relevant
r sta
atutory recorrds.

2. On chilled water or condenser


c ccooling watter systemss (e.g. Ambbicool) clien
nts must
have their own
o engine
eer on site ffor the dura
ation of the works to m
measure and d set up
the flow rattes.

3. If the equip
pment is to
o be conneccted to a BMS
B system
m then clien
nts must ha
ave their
own BMS engineer
e onn site.

F
Failure to compplete this form or failure to haave all required items ready for
f commissio oning may resuult
in an aborttive visit by ou
ur commissioniing engineer, Your
Y signature on page 2 autthorises the
acceptance
a of a
any abortive co osts according
gly

Page 2 of 3 DQ
QA880 – Re
ev DH1

110 FläktGroup DC-2013-0101-GB • Subject to modifications • R4-05/2018


Multi-DENCO Appendix

ents:
Comme

Comple
eted By:

Signatu
ure:

On Beh
half Of:

Date:

F
Failure to compplete this form or failure to haave all required items ready for
f commissio oning may resuult
in an aborttive visit by ou
ur commissioniing engineer, Your
Y signature on page 2 autthorises the
acceptance
a of a
any abortive co osts according
gly

Page 3 of 3 DQ
QA880 – Re
ev DH1

FläktGroup DC-2013-0101-GB • Subject to modifications • R4-05/2018 111


Appendix Multi-DENCO

13.2 Pressure Test Certificate (DQA 653)

Pressure Test Certificate


GEA Heat Exchangers Limited
Dolphin House - Moreton Business Park
Moreton on Lugg - Hereford - HR4 8DS
Telephone: +44 (0) 1432 277277
Fax: +44 (0) 1432 268005

Customer
Site Address

Contract Number
Air Handling Unit Reference
Air Handling Unit Type
Condenser Unit Type

We certify that the following pressure tests have been completed with dry nitrogen

Circuit Pressure Duration of Test Date

Test Carried out by : Test Witnessed by :


Name (Block Capitals)
Company
Signature

Remarks

DQA653 Rev DH1

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Multi-DENCO Appendix

13.3 Multi-DENCO Commissioning Report (DQA 890)

Multi Denco Commissioning Record Book

Before working on this equipment, ensure that all incoming electrical connections are isolated and
checked as voltage free by a competent person.
FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH
Refer to appropriate electrical wiring schematic for all external wiring

Section A: 1 copy for completion by contracts engineer in respect of each model or variant on site.
All boxes in section A to be completed before handing - sending to commissioning engineer.
Contract's Engs Name Date Required & Agreed
End User's Name
Induction Required If Yes State Time Of Start
Client's Name
Installer's Name
Site Address
Site Contact's name Contract Number
Site Contact's Tel No Quantity of this model
Air Balance Yes / No Supply Only Yes / No
Water Balance Yes / No Supply & Install Yes / No
Design RA Condition Temperature c Design RA Condition Humidity % RH
Design Total Cooling Kilowatts Design Sensible Cooling Kilowatts
AHU Model No Heat Rejection Model No
PPE Requirements
Parking on Site Do Site Specific RAM's apply
Special Instructions

Section B: For completion by commissioning engineer for each unit on site before starting commissioning. MANDATORY
AHU Serial No. Heat Rejection Serial Nos
AHU Location AHU Site Reference No.
Heat Load Available During Commissioning Process
Check piping installation complies with O&M manual & Approved Code of Practice-DX Installations Initial Box =
Check & confirm interconnecting wiring and unit mains power supply matches contract wiring diagram Initial Box =
Work may not proceed until the above checks have been completed and the initial box filled in and the contract technical data has
been added. All instrumentation must be covered by a current calibration certificate including pressure gauges, vacuum gauges,
thermometers, airflow meters, ammeter, multimeter, etc.

Electrical Power Supply Units


L1 Mains Supply Voltage V L3 Mains Supply Voltage V
L2 Mains Supply Voltage V Control Circuit Voltage V
Fan Motor Currents
Amps Phase 1 Phase 2 Phase 3
Fan Motor 1 Current Min A
Fan Motor 1 Current Max A Measurement of air volumes and the amperages
of all fans in both minimum speed and maximum
Fan Motor 2 Current Min A
speed is mandatory - no exceptions are
Fan Motor 2 Current Max A permitted.
Fan Motor 3 Current Min A
Fan Motor 3 Current Max A

SUPERSEDES ALL PREVIOUS VERSIONS WITHOUT EXCEPTION Form DQA890 DH1


Page 1 of 4 NO MODIFICATIONS TO FORMAT ALLOWED Effective From August 2015

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Appendix Multi-DENCO

Multi Denco Commissioning Record Book

Air Volume Checks


Measured Air Volume m3/s Air On Temperature °C
Max Fan Speed Setting % or V Air Off Temperature °C
Min Fan Speed Setting % or V Air Flow Fail Setting Check Yes/No
Dehum Fan Speed % or V
Room Distribution Checked Yes/No Filter Change Mbar/Pa
Glycol Circuit (if option fitted) Option Fitted to Machine Yes/No
Pump Make Pump Model
Pump Suction Pressure Bar Pump Delivery Pressure Bar
Design Flowrate Lps Actual Flowrate Lps
Design Exp Vessel Pressure Bar Actual Exp Vessel Pressure Bar
Drycooler Target Setting °C Local Isolators Fitted Yes / No
Fluid Inlet Temperature °C Fluid Outlet Temperature °C
Auto Air Vents Fitted Yes / No Air Vents Checked Yes / No
Glycol Concentration % Double Reg Valve Setting No / kpa
Glycol Type Volume Glycol Added Litres
Dry Cooler Motor Amps A State average amps across all phases & motors if even
Glycol Pump Amps A State average amps across all phases & pumps if even
Controls
Temperature Set Point °C Humidity Set Point %RH
Dead Zone T °C Dead Zone RH %RH
Proportional Band T °C Proportional Band RH %RH
Oil Recovery Time (SIAM only) Seconds Controller Software Vers Number
Sensor Calibration T °C Sensor Calibration RH %RH
Strategy Selected P or PI Type of control selected T or TH
Software Settings Entered Yes / No Network Number of Unit Number
Network Connected Yes / No Type of Comm's Card
Comms Card Fitted Yes / No Hum and RH Control Enabled Yes / No
Discharge Transducer Reading Bar Discharge Transducer Calibration Bar

Suction Transducer Reading Bar Suction Transducer Calibration Bar


Suction Sensor Reading °C Suction Sensor Calibration °C
Refrigeration Circuit (if option fitted) Option Fitted to Machine Yes/No
Pressure Test Level Bar Vacuum Achieved Torr
Circuit Pipe Length M Total Pipework Rise M
Compressor Model 1 Oil Added To Circuit Ltrs
Compressor Model 2 Weight of Refrigerant R401A Kg
Full Load Suction Pressure Bar Full Load Superheat Temp °K
Liquid Line Temperature °C Part Load Superheat Temp °K
Stable Discharge Pressure Bar Sub Cooling Temperature °K
Full Load Discharge Temp °C Full Load Discharge S / heat °K
Part Load Discharge Temp °C Part Load Discharge S / heat °K
Compressor 1 Current A Design Compressor 1 Current A
Compressor 2 Current A Design Compressor 2 Current A
Condenser Motor Current A Software H.P Switch Setting Bar
L.P. Envelope Threshold Bar Mech H.P Switch Setting Bar
L.P. Alarm Threshold Bar EEV Sight Glass Condition

SUPERSEDES ALL PREVIOUS VERSIONS WITHOUT EXCEPTION Form DQA890 DH1


Page 2 of 4 NO MODIFICATIONS TO FORMAT ALLOWED Effective From August 2015

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Multi-DENCO Appendix

Multi Denco Commissioning Record Book

Chilled Water (if option fitted) Option Fitted to Machine Yes/No


CW Flowrate Lps Double Reg Valve Setting No / kpa
CW Water Inlet Temp. °C CW Water Outlet Temp °C
Electric Heating (if option fitted) Option Fitted to Machine Yes/No
Thyristor Control Fitted Yes/No Heater 2 Current A
Heater 1 Current A Heater 3 Current A
Humidifier (if option fitted) Option Fitted to Machine Yes/No
L1 Humidifier Current A Water Supply Conductivity Ms
L2 Humidifier Current A Bottle Type kg
L3 Humidifier Current A % Output Set %
Bottle Conductivity Range Ms Bottle Part Number Number
Condensate Pump Drain (if option fitted)
Gravity or Pumped N/A Pump Model
System Lift Function Test Pass / Fail
Please initial box below to certify and confirm that the listed functional tests have been carried out on the equipment

Low pressure transducer set correctly & functions Head pressure control function & setting correct
High pressure transducer set correctly & functions High temperature alarm set and function operating
High pressure switch set correctly & functions Low temperature alarm set and function operating
Airflow failure transducer set correctly & functions Filter blocked transducer set correctly & functions
Water detection operates ( if fitted & laid out) Alarm output relays set up and operating correctly
Layout of the suction lines has been checked Superheat stable and correctly set as TI & OEM
Discharge line temperature sensor fixing checked System correctly evacuated before charging
Discharge line traps fitted if required Any additional oil added taken from new can
Requirement for crankcase heating checked System fully leak tested after commissioning
Fans free from vibration at all speeds Condensers correctly installed
Discharge pressure is at least 1.8 times suction pressure Pressure transducer readings checked
DQA892 Multi Denco Charging procedure followed Spare
You are verifying that key issues - functions have been checked and conform to the requirements- settings in the O & M manual

Please Detail Any Checks - Measurements Not Completed And Reasons Why

Please detail all site related issues (not equipment) found during commissioning that might affect performance and reliability

Please detail any issues or site related problems (not equipment) with air distribution in the conditioned space

Additionally Complete And Sign Page 4 for DX Units Charged In The Field

SUPERSEDES ALL PREVIOUS VERSIONS WITHOUT EXCEPTION Form DQA890 DH1


Page 3 of 4 NO MODIFICATIONS TO FORMAT ALLOWED Effective From August 2015

FläktGroup DC-2013-0101-GB • Subject to modifications • R4-05/2018 115


Appendix Multi-DENCO

Multi Denco Commissioning Record Book

F-Gas regulation No 842/2006 Record Log Sheet Information For Owners Use - Answer All Questions
Plant Name Reference Number
Location of Plant Serial Number
Plant Operator Plant Operator
Operator Contact
Cooling Loads Served
Refrigerant Type Quantity Installed
Plant Manufacturer Year of Installation
Refrigerant Additions (If none state none)
Date Engineer Amount Added in KG Reason for Addition

Refrigerant Removals (If none state none)

Reason For Removal & What Was Done With Recovered


Date Engineer Amount Removed in KG
Refrigerant

Leak Tests (State Method Used - Mandatory)


Date Engineer Test Result Follow Up Actions Required

Leak Detector Details Model Number Serial Number


Follow Up Action (If none state none)
Date Engineer Related To Test On Actions Taken

Testing Of Automatic Leak Detector (State none if not fitted)


Date Engineer Test Result Comments

Notes:
Notes:
Engineers Full Name Date
Engineers Signature

SUPERSEDES ALL PREVIOUS VERSIONS WITHOUT EXCEPTION Form DQA890 DH1


Page 4 of 4 NO MODIFICATIONS TO FORMAT ALLOWED Effective From August 2015

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Multi-DENCO

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Multi-DENCO

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Multi-DENCO

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FG_DC-2013-0101-GB_Multi-DENCO_OM_R4-2018-05_150dpi © Copyright 2018 FläktGroup
WWW.FLAKTGROUP.COM MULTI-DENCO

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and Critical Air solutions to support every application area. We offer our customers
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than a century of accumulated industry experience. The widest product range in the
market, and strong market presence in 65 countries worldwide, guarantee that we
are always by your side, ready to deliver Excellence in Solutions.

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