IPAC - IOM - Issue 4.0 - Lo-Res Colour

Eaton-Williams
IPAC
IPAC Air Handling Units

INSTALLATION, OPERATION AND MAINTENANCE
IPAC
IPAC
(Invicta Precision Air Control) 15 to 120 kW, Upflow, Downflow, Direct Expansion, Water-Cooled Direct Expansion, Chilled Water
Document 0410536 Issue 4.0 : April 2008
IPAC
ABOUT THIS DOCUMENT

Using This Document
This document has been designed for online viewing as a PDF file and double-sided printing (subject to copyright - see below) for hard copy. Each section has its own contents list, to facilitate ease of use as a standalone document. The online document contains hyperlinks (hotlinks) indicated as such. Please note that when viewing a standalone section online, only those hyperlinks to within the standalone section will function. Only when viewing the entire document will all hyperlinks function. The documents hyperlinked contents can also be displayed by activating the bookmarks function of the PDF viewing application. Copies of this document can be obtained from Eaton-Williams at the address shown below. This is not a controlled document. Distributed copies will not be updated. All specifications are nominal and subject to change without prior notice as design improvements occur.
Copyright Notice
The confidential information contained in this document is provided solely for use by EatonWilliams Group employees and system owners, and is not to be released to, or reproduced for, anyone else. Neither is it to be used for reproduction of this unit or any of its components.
Disclaimer
Eaton-Williams Group shall not be liable for any damages resulting from mis-application or misuse of its products. E & OE
IPAC
BUSINESS SYSTEMS AND STANDARDS GENERAL STATEMENT

Quality Management System
The Eaton-Williams Group are a registered company to BS EN ISO 9002:1994 Quality management standard. This standard covers all manufacturing areas and associated processes. The Group are now currently in the transition process for accreditation to the new standard ISO 9001: 2000. Target date for accreditation is December 2003.
Safety and Environmental Management

In addition to the above, the Group are currently working to implement an environmental management system in line with ISO 14001, which will be integrated with our existing Quality & Safety Management Systems. Target accreditation date is June 2004. As part of the implementation, the Group have already carried out an audit of the business to identify all significant environmental aspects. Targets and KPIs have been set for environmental impact reduction and the Group already complies with all current environmental legislation identified during the environmental audit, and as required by the local authority.
HR Management and Staff Development

The Group was successfully accredited to the Investors in People standard in February 2000.
Product Standards
The air conditioning products marketed and supplied by Eaton-Williams Limited, when installed and operated in accordance with EW information and instructions, conform to the EMC directive and essential Health & Safety requirements of the machinery directive 91/368/EEC-93/ 44/EEC & 93/68/EEC. This includes the EMC compatibility directive 89/336/EEC. As standard, units comply with an IP21 rating. The standards are also met where compliance to TV, UL and CSA are specific market requirements attained for that product.
IPAC
Eaton-Williams
This page is intentionally blank to facilitate double-sided printing.
Eaton-Williams
Station Road, Edenbridge, Kent, TN8 6EG England Telephone +44 (0)1732 866 055 Fax +44 (0)1732 866 053 Email ews.sales@eaton-williams.com Website www.eaton-williams.com Document 0410536 Issue 4.0 : April 2008
IPAC
CONTENTS
SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 SECTION 9 SECTION 10 SECTION 11 SECTION 12 SECTION 13 SECTION 14 SAFETY AND GENERAL INFORMATION TECHNICAL MANUAL INVICTANET CONTROLLER USER MANUAL INVICTANET CONTROLLER TECHNICAL MANUAL INVICTANET CONTROLLER SETTINGS RECORD INSTALLATION - DX UNITS INSTALLATION - CHILLED WATER UNITS COMMISSIONING - DX UNITS COMMISSIONING - CW UNITS PREVENTATIVE AND GENERAL MAINTENANCE SERVICE AND PARTS INFORMATION FAULT FINDING PROCEDURES UNIT MAINTENANCE LOG UNIT MODIFICATION LOG
IPAC
This page is intentionally blank to facilitate double-sided printing.
Eaton-Williams
IPAC
IPAC
IPAC
SECTION 1
SAFETY AND GENERAL INFORMATION

SECTION CONTENTS
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 General Safety Precautions - Refrigerant Prevention of Legionnaires Disease Installation and Handling Application Warranty Electrical Connection Maintenance Service Parts Codes of Practice Drive Guards Waste Disposal 12 12 13 13 13 14 14 14 14 14 14 14
Document 0410536 Issue 4.0 : Aprill 2008
IPAC
IPAC
SAFETY AND GENERAL INFORMATION
Page 1-2
IPAC
SAFETY AND GENERAL INFORMATION General
Air conditioning equipment presents potential mechanical, electrical, noise or vibration hazards. Observe all safety, installation, operation and maintenance instructions. Installation, servicing and operation of the equipment only by fully trained and technically competent personnel. Eaton-Williams air conditioning equipment is designed to minimise mechanical and electrical hazards by fully restricting access through unit casings, doors and covers whilst the equipment is operational. Some installations may require additional protective features to prevent accidental contact with components. Eaton-Williams can provide advice and make recommendations for additional protection to suit the application. All installation work must be completed in accordance with the safety, installation, operation and maintenance instructions, and the unit correctly earthed before it is operated. Prior to any maintenance work being carried out, ensure that: Equipment is switched OFF. Equipment and controls are isolated from the electrical supply. All rotating parts have come to rest. Air conditioning equipment may, in certain operating conditions, generate unacceptable noise and vibration levels. EatonWilliams can advise on relevant sound level data, appropriate action to be taken and supply suitable components to reduce sound and vibration levels. If in any doubt as to the correct interpretation of performing any of the safety, installation, operation and maintenance instructions, it is essential that Eaton-Williams, their agent or appointed distributor, is consulted for advice and clarification. If any of the above initial symptoms are experienced, the affected person should be moved into fresh air and medical attention sought as a precaution. Over-exposure can be fatal.
Cardiac Irregularities
Exposure levels above the recommended exposure limits can lead to cardiac irregularities, such as irregular pulse, palpitations, inadequate circulation and cardiac arrest. The effect level varies from person to person, but is likely to increase if the person is under physical or emotional stress. If any of the above symptoms are experienced, move the affected person to fresh air and seek medical attention as a precaution. Overexposure can be fatal. NOTE: Do not treat affected persons with drugs, such as adrenaline, as this could increase the risk of cardiac problems.
Skin and Eye Contact

Always wear protective clothing when there is a risk of exposure to liquid refrigerant In liquid form, refrigerant can cause severe frostbite and tissue damage. Where there is possible risk of being splashed by liquid refrigerant, always wear eye protection. If skin or eyes are splashed with liquid refrigerant, flush the affected area with lukewarm water, (do not use hot water). If frostbite has occurred, call medical help. If eyes are splashed, immediately flush with plenty of water for at least 15 minutes and call medical help.
Spills or Leaks
Vapour from a spill or leak of R 407C will tend to concentrate near the floor or in low areas, displacing the oxygen available for breathing, which can result in suffocation. Evacuate all personnel. Use blowers or fans to circulate fresh air. Do not re-enter the affected area until it has been thoroughly ventilated, unless wearing appropriate breathing apparatus.
Safety Precautions - Refrigerant

The following information is provide for guidance.
R 407C - COSHH Considerations

The refrigeration system in this equipment contains liquid and vapour refrigerant under pressure. Each system is hermetically sealed and has been leak tested in production to help ensure safe operation for its life cycle. However, in the unlikely event of a leak or maintenance that requires opening the refrigeration system envelope, the following information must be considered.
Non-flammability
Refrigerant R 407C is formulated such that it remains nonflammable during shipping, handling, storage, in use, or if leaked from a unit.
Combustibility
Refrigerant R 407C is not flammable in air at temperatures up to 100 C at atmospheric pressure. However, mixtures of R 407C with high concentrations of air at elevated pressure and/or temperature can become combustible in the presence of a naked flame. R 407C can also become combustible in an oxygen enriched environment. R 407C MUST NOT BE MIXED WITH AIR UNDER PRESSURE FOR LEAK TESTING OR OTHER PURPOSES. Refrigerants should not be exposed to naked flames or electric heating elements. High temperatures and flames can cause the refrigerant to decompose, releasing toxic and irritating fumes. Always recover refrigerants, evacuate equipment, and ventilate work areas properly before using any open flames.
Inhalation Toxicity
Refrigerant R 407C poses no acute or chronic hazard when handled in accordance with the manufacturers recommendations and when exposures are maintained at or below recommended Acceptable Exposure Limits (AEL), of 1000 ppm. Inhalation exposure, above the recommended exposure limit, to the vapours of R 407C refrigerant, may cause physiological effects that can include temporary depression of the nervous system, with effects such as dizziness, headache, confusion, loss of co-ordination and loss of consciousness.
Document 0410536
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Issue 4.0 : Aprill 2008
IPAC
SAFETY AND GENERAL INFORMATION Prevention of Legionnaires Disease
For further information, please refer to "Prevention of Legionnaires Disease on page 3 of Section 10
iii. iv. v. vi. Supply Authorities. Statutory requirements. Manufacturers instructions and recommendations. All other relevant information, regulations and legislation.
Installation and Handling

The installation and operation of the unit should be conducted in accordance with local regulations and accepted codes of good practice. When moving and lifting the unit, caution must be observed at all times to ensure the safety of all personnel. Only appropriate and approved lifting equipment must be used.
Drive Guards
Whenever drive guards are to be removed to facilitate maintenance, the electrical supply to the unit must first be isolated LOCKED OFF and fuses removed and retained by the person carrying out the work. Any guards removed to facilitate maintenance, must be refitted immediately work is completed. Refitting of guards, restoration of power, starting and restoration of plant into service are only to be carried out by properly trained and authorised personnel.
Application
The unit is only to be used in the application for which it was designed. The unit is NOT to be used in a hazardous environment unless it has been specially designed and approved for such application.
Waste Disposal
All refrigerants, oils and other waste materials must be disposed of in a professional and responsible manner and in strict adherence to environmental regulations. For details, consult local environmental agencies.
Warranty
Failure to comply with the manufacturers installation instructions could affect the reliability and performance of the unit and invalidate the warranty. Warranty is also subject to the implementation of a planned service/maintenance agreement as stipulated in the warranty booklet supplied with the unit and/or the sales contract.
Documentation
All documentation must remain with the unit at all times.
Electrical Connection
The unit must be connected to an external isolator if one is not supplied fitted to the unit. Electrical connections should be carried out in accordance with national and local regulations. In the UK, standard BS 7671 applies. Never make any connections in the unit circuits unless the electricity supply has been switched OFF at the isolators.
Maintenance
For further information, please refer to Section 10 - Preventative and General Maintenance.
Service Parts
Service parts must of the same specification as those being renewed and should be obtained from Eaton-Williams Service Department. The use of incorrect service parts can affect unit operation and reliability and invalidate any warranty.
Codes of Practice
It is important that equipment and products which have been installed and commissioned by Eaton-Williams, are maintained by or under supervision of technical competent personnel and that all work is carried out in accordance with good engineering practice and strict adherence to:
i. ii. IEE Regulations. Codes of good engineering practice.
Page 1-4
Eaton-Williams
IPAC
IPAC
IPAC
SECTION 2
TECHNICAL MANUAL
IPAC
IPAC
Technical Manual
SECTION CONTENTS Heading

Introduction Application
Duty Range Temperature Control Humidity Control
Page
24 24
24 24 24
Reliability Serviceability Unit Identification Temperature Control Cooling Process

Air-cooled Direct Expansion (DX) System Water-cooled DX System Chilled Water Cooling System Economy Cooling Options
24 25 25 25 25
2 15 2 16 2 17 2 18
Humidity Control Dehumidification

Hot Gas Reheat
2 18 2 18
2 18
Network Control System Main Components

Unit Casing Finish Supply Air Fan(s) Air Filters Differential Pressure Switches Cooling Coil Condensate Drip Tray Eaton-Williams InvictaNET AHU Controller Electrical connections Volt-free Alarm Contacts Bottom Connections Compressor Filter / Drier Thermostatic Expansion Valve Moisture Indicating Sight Glass Evacuation and Refrigerant Charging Valves Pressure Safety Devices Modulating Flow Control Valve and Actuator Key Operated Cam-lock Removable Doors Airflow Failure Detection Cardboard Sleeve / Pallet Delivery Protection Contactors, MCBs and MPCBs Internal Unit Isolator Interconnecting wiring loom Integrated Water-Cooled Condenser
2 19 2 19
2 21 2 21 2 21 2 21 2 22 2 22 2 22 2 22 2 23 2 23 2 23 2 23 2 23 2 23 2 24 2 24 2 24 2 24 2 24 2 24 2 24 2 24 2 24 2 24 2 25
Features and Options

Phase-failure relay Control panel cover Fresh Air Control Fresh Air Control, Including Smoke Detection Door-interlocked isolator Mains filter kit In-Room Remote Sensors Document 0410536 Issue 4.0 : April 2008
2 25
2 25 2 25 2 25 2 25 2 25 2 25 2 25
Page 2-2
IPAC
Technical Manual
Duct Remote Sensors Water Detection Tape Audible Alarm Alternate Display Languages ModBus Network Interface Trend Controller Trend Network Interface
2 25 2 25 2 25 2 25 2 26 2 26 2 26
Heating Process
Electric Heating Low Pressure Hot Water Heating System LPHW Heating Coil Capacity Control Hot Gas Injection System 2 Way or 3 Way Control Valve Liquid Receiver Oil Separator Compressor Acoustic Jacket Compressor Discharge Non-return Valve Split Coil Rapid Dehumidification Pressure Relief Water System Isolating Gate Valves Commissioning Set Flexible duct connectors (upflow units only) Back-draught dampers (upflow units only) Airflow Options Humidifier 20% - 100% Proportional Output Humidifier Alarm Diagnostics Tools in Controller Different Bottles for Varying Water Qualities Remote Vapac Options Second Unit OEM Option Rear Cosmetic Cover Panel Multi-speed motors Side Gland Plates Stainless Steel Drip Tray 5 to 10 % fresh air intake, including volume damper control Anti-vibration mountings Dual Pulley Drives Low Display Mounting Lifting Channels Condensate Pump Class 1, energy-efficient motors Customised Colours Pipework Flood Detection Electrical Equipment Air Movement Options Emergency Shutdown Fire Shutdown
2 26
2 26 2 26 2 27 2 27 2 27 2 27 2 28 2 28 2 28 2 28 2 28 2 28 2 28 2 28 2 28 2 29 2 29 2 29 2 29 2 29 2 29 2 29 2 29 2 29 2 30 2 30 2 30 2 30 2 30 2 30 2 30 2 30 2 30 2 30 2 30 2 31 2 31 2 32 2 32 2 32
Ancillary Options
Adjustable Feet Floor Support Angles Open frame Open Frame Base and Scoop Enclosed Section (for ducting, etc.) Turning Section (inc. double-deflection grilles) Fresh Air Modulating Section High-efficiency Filter Section
2 32
2 33 2 33 2 33 2 33 2 33 2 34 2 34 2 34
Document 0410536
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Issue 4.0 : April 2008
IPAC
Technical Manual
Page 2-4
IPAC
Technical Manual Introduction
This section provides information about the main components of Invicta Precision Air Control (IPAC) standard range air handling units (AHUs). All dual module interconnecting wiring is made to numbered terminal rails in each unit for easy connection at site. To ease installation, an interconnecting wiring loom is available as an optional extra. IPAC air handling units are designed for indoor installation only. Units can either be mounted within the space to be conditioned, or mounted elsewhere with air ducted to the room. As well as the standard unit configurations, a variety of customising options can be factory-fitted or site-fitted, to provide a system that precisely matches user requirements.
Application
IPAC units are designed as a modular range of both upflow and downflow, floor-standing, air handling units for operation at room temperatures from 18 C to 30 C as standard. Factoryadded options can enable operation outside this range. These units provide highly reliable air handling systems for space-cooling, where the air must be conditioned to be: Temperature controlled (heating is optional) Humidity controlled (optional) Filtered clean of particulates
Temperature Control
Temperature can be precisely controlled, with cooling provided by the cooling coil(s). Where heating is required, mutli-stage electrical heating, or low pressure hot water (LPHW) are available as options. Air temperature is controlled by two PID (Proportional Integral and Derivative) algorithms, one for heating, the other for cooling. Each algorithm includes the same adjustable dead band, which equally spans each side of the room temperature set point. If I (Integral) and D (Derivitive) values are zero, control is proportional only. Proportional units are in C.
Duty Range
Basic duty sizes for standard units in the IPAC range are as shown in Table 2-1, which also identifies which are single or twin module units, together with matching condenser options. Twin module units can be positioned separately, offering flexibility according to installation requirements; refer to Fig. 2-3 for dimensions and weight data.
Table 2-1 : Duty range and matching air-cooled condensers NOMINAL DUTY kW 15 22 30 30 40 45 50 55 60 60 70 80 90 100 110 120 UNIT IPAC 15-1 IPAC 22-1 IPAC 30-1 IPAC 30-2 IPAC 40-1 IPAC 45-2 IPAC 50-1 IPAC 55-2 IPAC 60-1 IPAC 60-2 IPAC 70-2 IPAC 80-2 IPAC 90-2 IPAC 100-2 IPAC 110-2 IPAC 120-2 Matching Air-cooled SINGLE / TWIN Condenser Models MODULE UNIT Primary Secondary Single Single Single Twin Single Twin Single Twin Single Twin Twin Twin Twin Twin Twin Twin ICV1-18P ICV1-40P ICV2-40P ICV1-18P ICV2-70P ICV2-40P
INCO3-2SGA
Humidity Control
Where dehumidification is required, a cooling coil is operated below the dew point of the air to condense and remove water content from the air. To ensure optimum temperature control in conjunction with dehumidification, the options of hot gas or electric reheat are available. Where humidification is required, a factory-fitted Vapac humidifier unit is available as an option. This is a proportionaloutput humidifier that produces clean, sterile steam, that is entrained into the airflow to increase its humidity. The humidifier responds to a changing demand, using the water level (WL) system of modulation. Output is varied by increasing or decreasing the level of water in the cylinder. Air humidity is similarly is controlled by two PID algorithms, one for humidification, the other for dehumidification. Each algorithm includes the same adjustable dead band, which equally spans each side of the room humidity set point. If I (Integral) and D (Derivitive) values are zero, control is proportional only. Proportional units are in % RH.
ICV2-70P
INCO3-2SGA
ICV2-40P ICV2-70P ICV2-70P
ICV1-18P ICV1-18P ICV1-18P ICV2-40P ICV2-40P ICV2-70P
INCO3-2SGA INCO2-2SGA INCO3-2SGA INCO3-2SGA INCO3-2SGA INCO3-2SGA INCO3-2SGA INCO3-2SGA
Reliability
IPAC units are designed for high reliability with a calculated mean-time between failure of not less than four years, provided that routine maintenance procedures are carried out at prescribed intervals.
By offering a selection of various combinations of unit configuration, duty requirements can be matched accurately. The various standard unit configurations available are as illustrated in Fig. 2-3, while airflow path configurations are illustrated in Fig. 2-11. Units are manufactured with either upflow or downflow air direction, to provide optimum comfort levels. For a dual module pair, the electrical section of the larger unit contains the controls and switchgear for control of the other.
Serviceability
The maximum time required replacing Service Items, and returning the unit to operational condition is approximately 1 hour, excluding refrigeration circuit items, provided of course, that recommended service parts are held ready to use.
Document 0410536
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IPAC
Technical Manual
For details of recommended service parts for each unit, together with contact and ordering details, please contact the EatonWilliams Head Office.
Temperature Control
The temperature of supply air passing through the unit is monitored by an Eaton-Williams InvictaNET AHU controller, which applies cooling or heating (optional) control strategy to correct and maintain room air temperature at a predetermined set point. The Cooling Process is described below. The Humidity Control is described on page 2-20. The air passage through the unit is the same, whether in heating or cooling mode.
Unit Identification
Vital data on a unit can be obtained from the serial number plate, which can be found inside the cabinet, just below the electrical chassis on the left hand side.
Fig. 2-1 : Serial No. plate (typical)
Eaton-Williams Group Ltd Edenbridge Kent England TN8 6EG Tel. +44 (0)1732 866055 Fax +44 (0)1732 863461 Serial No. Manufactured to ISO 9000 Quality System
Product
Cooling Process
The cooling process is used for air cooling and/or dehumidification and is achieved by one of three types of cooling process: Air-cooled Direct Expansion (DX) System on page 2-16, using refrigerant, normally R 407C Water-cooled DX System on page 2-17 using water/glycol as a primary refrigerant, normally containing corrosion inhibitor additive (recommended) Chilled Water Cooling System on page 2-18, or other similar cooled medium The type of cooling process required must be specified at the time of ordering.
DM 5001A
Cooling Capacity
AC06483
Short Cct. Cap. kW Max. Start Current
2004 0.0 183.0

kA Amps
40.7
Electrical supply
400
v/
~/
50
Hz Refrigerant
Wiring Diagram
LAD983 0 DM5001A
Power
R407C
Full Load Current kVA
0 34.5
kg
14.4
Amps
Fig. 2-2 : Approximate position of serial No. plate
The following data is normally shown on the serial number plate: Product - EW code number. Cooling Capacity - design cooling capacity in kW. Electrical Supply - for which the unit is rated. Wiring Diagram - relevant to the unit. Power - consumption at maximum load in kVa. Serial Number - of the unit. Short Circuit Capacity - in kA. Maximum Start Current - consumption in Amps. Refrigerant - type and quantity in kg, to be filled when known; i.e on completion of commissioning. Full Load Current - consumption in Amps.
Page 2-6
IPAC
Technical Manual
Fig. 2-3 : IPAC Range unit configurations, dimensions and weights
IPAC Range Unit Configurations, Dimensions and Weights

B B B B B
IPAC 15-1
B
IPAC 22-1 IPAC 30-1

B
IPAC 30-2
B
IPAC 40-1
IPAC 45-2
B
IPAC 50-1 IPAC 60-1

B
IPAC 55-2
B
IPAC 60-2
IPAC 70-2
B
IPAC 80-2
IPAC 90-2
IPAC 100-2 IPAC 110-2 IPAC 120-2
NOTES Dual units are shown with cabinets mated side-by-side; dashed red lines show unit mating positions. Unit mating positions can be left or right handed as required, and cabinets can be positioned separately to suit room layout.
Unit
15-1
22-1
30-1
30-2
40-1
45-2
50-1
55-2
60-1
60-2
70-2
80-2
90-2 100-2 110-2 120-2
Single and dual unit composition (P = Primary, S = Secondary) Unit Composition Module Widths (mm) A - Height mm B - Width mm Depth mm Weight * kg (combined)
NOTE
P S P S
15 800 -
22 1300 -
30 1300 -
15 15 800 800
40 -
30 15
50 -
40 15 1700 800 1950 2500 800 722
60 2050 -
30 30 800 800
40 30
40 40
50 40
50 50 2050 2050 1950 4100 800 1135
60 50
60 60
1700 1300 2050 800 -
1700 1700 2050 1300 1700 1700 1950 1950 1950 3000 3400 3750 800 922 800 916 800 1027
2050 2050 2050 2050 1950 1950 4100 4100 800 800
1950 1950 800 800 270 1300 800 380
1950 1950 1300 1600 800 402 800 520
1950 1950 1950 1700 2100 2050 800 472 800 652 800 580
1950 1950 2050 2600 800 620 800 784
1170 1210
* Weights are estimated, dry and may vary according to unit configuration and options fitted, please contact Eaton-Williams for further assistance if required.
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IPAC
Technical Manual
Table 2-2 : Technical data
Technical Data
IPAC Model DX unit - Total cooling1 DX unit - Gross sensible cooling1 DX unit - Sensible heat ratio DX unit - Net sensible cooling CW unit - Total cooling1 & 2 CW unit - Gross sensible cooling CW unit - Sensible heat ratio CW unit - Net sensible cooling CW unit - Chilled water flow rate CW unit - water pressure drop Airflow Design external pressure Maximum external Air filter quality Compressors - number fitted Refrigerant4 Estimated initial refrigerant charge5 Estimated initial refrigerant charge with Water Cooled Condenser Humidifier output - Vapac 6 Electric heating6 - at 230 V kg kg kg/hr kW 3.5 3.2 5 5 6.5 5.3 9 10 7.0 5.5 9 10 3.5 + 3.5 3.2 + 3.2 5 5 1 1 1 2 R 407C 10.0 7.3 9 15 7.0 + 3.5 5.5 + 3.2 9 10 16.0 9.2 12 22 10.0 + 3.5 7.3 + 3.2 9 15 pressure3 kW l/s kPa m3/s m
3/h
15-1 kW kW 16.0 14.8 0.92 kW kW kW 13.7 23.6 18.5 0.78 17.3 1.12 49 1.25 4,500
22-1 22.0 20.9 0.95 18.5 32.1 24.7 0.77 23.0 1.53 48 1.70 6,120
30-1 30.0 28.1 0.94 25.6 42.5 33.5 0.79 30.9 2.02 84 2.25 8,100
30-2 32.0 29.6 0.92 27.6 47.2 37.0 0.78 34.6 2.24 49 2.50 9,000 70
40-1 40.7 37.4 0.92 33.7 59.8 47.2 0.79 43.5 2.85 67 3.20 11,520
45-2 46.0 42.9 0.93 39.3 66.1 52.0 0.78 48.2 2.65 49 3.50 12,600
50-1 53.0 46.1 0.86 43.7 67.4 53.8 0.81 50.8 3.21 69 3.50 12,600
55-2 56.0 52.2 0.93 47.4 83.4 65.7 0.78 60.8 3.97 67 4.65 16,020
Pa Pa 400 400 400 400
360 G4 1
400
400
360
Standard colour - cabinet and doors Noise level3 & 7 - IPAC unit dB(A) 55 1-18P dB(A) 58 56 1-40P 58 61 2-40P 61
BS 4800 Grey 00A05 58 1-18P + 1-18P 58 68 2-70P 61 63 2-40P + 1-18P 61 65

INCO32SGA
67 2-70P + 1-18P 61
Condenser - matched Model Noise level8 - outdoor condenser

NOTES
1 Unit ratings at 24 C / 50 % RH internal and 35 C external ambient air conditions. 2
Maximum duty rated at 7/12 C water on/off temperatures. For other water on/off temperatures consult Eaton-Williams. specify at time of ordering). This may result in a larger drive motor than standard being required, and increased noise level.
3 Higher external pressures are achievable by altering the supply fan speed by fitting a different ratio drive pulley (client to 4 In compliance with the Montreal Protocol, units are designed for use with refrigerant R 407C. For non-compliant countries,
Eaton-Williams can supply units specially designed for use with R22. Do not mix refrigerants.
5
Based on a pipe run length of 10 metres. Sound pressure level, per cabinet, at a distance of 3 metres from the unit, with floor return and ducted supply (estimated). Sound pressure level, per condenser, at a distance of 3 metres from the unit, free-field conditions.
6 Optional equipment. 7 8
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IPAC
Technical Manual
Table 2-2 : Technical data
Technical Data
IPAC Model DX unit - Total cooling1 DX unit - Gross sensible cooling1 DX unit - Sensible heat ratio DX unit - Net sensible cooling CW unit - Total cooling1 & 2 CW unit - Gross sensible cooling CW unit - Sensible heat ratio CW unit - Net sensible cooling CW unit - Chilled water flow rate CW unit - water pressure drop Airflow Design external pressure Maximum external Air filter quality Compressors - number fitted Refrigerant4 Estimated initial refrigerant charge5 Estimated initial refrigerant charge with Water Cooled Condenser Humidifier output - Vapac 6 Electric heating6 - at 230 V kg kg kg/hour kW 17 9.5 15 22 7 + 7 5.5 + 5.5 12 22 10 + 7 7.3 + 5.5 9 15 10 + 10 7.3 + 7.3 9 15 1 2 2 pressure3 kW l/s kPa m3/s m
3/h
60-1 kW kW 61.7 51.9 0.84 kW kW kW 47.9 74.6 58.9 0.79 54.9 3.56 82 4.0 14,400
60-2 60.0 56.2 0.94 51.2 85.0 67.0 0.79 61.8 4.04 49 4.50 16,200
70-2 70.6 65.5 0.93 59.3 102.0 80.7 0.79 74.4 4.87 67 5.45 19,620
80-2 81.4 74.8 0.92 67.4 119.6 94.4 0.79 87.0 5.70 67 5.70 23,040 70
90-2 93.7 83.5 0.89 76.9 127.1 101.0 0.80 94.3 5.45 69 6.06 24,300
100-2 106.0 92.1 0.86 86.4 134.9 107.6 0.81 101.6 6.42 69 6.42 25,200
110-2 114.7 98.8 0.85 91.1 141.9 112.7 0.80 105.7 6.77 82 6.77 27,000
120-2 123.4 103.8 0.84 95.8 149.2 117.8 0.79 109.8 7.12 82 7.12 28,800
Pa Pa 400 400 360 360
400
400
400
400
G4, cleanable 2 R 407C 16 + 10 9.2 + 7.3 12 22 16 + 16 9.2 + 9.2 12 22 17 + 16 9.5 + 9.2 12 22 17 + 17 9.5 + 9.5 12 22 2 2 2 2
Standard colour - cabinet and doors Noise level3 & 7 - IPAC unit dB(A) 70
INCO32SGA
BS 4800 Grey 00A05 70 2-40P + 2-40P 64 70 2-70P + 2-40P 61 70 2-70P + 2-70P 61 72

INCO32SGA + INCO22SGA
72
72
73
Condenser(s) - matched model Noise level8 - outdoor condenser

NOTES
1 2
dB(A)
64
64
64
64
64
Unit ratings at 24 C / 50 % RH internal and 35 C external ambient air conditions. Maximum duty rated at 7/12 C water on/off temperatures. For other water on/off temperatures consult Eaton-Williams. specify at time of ordering). This may result in a larger drive motor than standard being required, and increased noise level.
3 Higher external pressures are achievable by altering the supply fan speed by fitting a different ratio drive pulley (client to 4 In compliance with the Montreal Protocol, units are designed for use with refrigerant R 407C. For non-compliant countries,
Eaton-Williams can supply units specially designed for use with R22. Do not mix refrigerants.
5 Based on a pipe run length of 10 metres. 6 Optional equipment. 7
Sound pressure level, per cabinet, at a distance of 3 metres from the unit, with floor return and ducted supply (estimated).
8 Sound pressure level, per condenser, at a distance of 3 metres from the unit, free-field conditions.
Document 0410536
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Technical Manual
Table 2-3 : Design conditions - DX units
Design Conditions - DX Units a

with air on at 24 C / 50 % RH R 407C Normal working pressures at 35 C external ambient Normal working pressures at 40 C external ambient HP side: LP side: HP side: LP side: 22.0 bar g (319 psi g) 5.9 bar g (86 psi g) 24.0 bar g (348 psi g) 5.9 bar g (86 psi g) R 22 19.5 bar g (283 psi g) 5.9 bar g (86 psi g) 21.5 bar g (312 psi g) 5.9 bar g (86 psi g)
a. Nominal working pressures are shown averaged across the IPAC range. Actual design values vary according to unit size. Please contact the technical department for specific pressures. Table 2-4 : Safety pressure switch settings - DX units
Safety Pressure Switch Settings - DX Units

Cut-out LP - low pressure safety HP - high pressure safety 0.5 bar g (7 psi g) 28 bar g (400 psi g) Tolerance 5% 5% Cut-in 1.4 bar g (21 psi g) 21 bar g (300 psi g) Tolerance 5% 5%
Page 2-10
IPAC
Technical Manual
Table 2-5 : Current ratings
Current Ratings
in Amps1
IPAC MODEL UNIT TYPE 15-1 Max. running current Cooling-only unit Fuse Rating Max Starting Current Max. running current DX / A-C Temperature unit Fuse Rating Max Starting Current Max. running current Full air conditioning unit Fuse Rating Max Starting Current Max. running current Cooling-only unit Fuse Rating Max Starting Current Max. running current DX / W-C Temperature unit Fuse Rating Max Starting Current Max. running current Full air conditioning unit Fuse Rating Max Starting Current Max. running current Cooling-only unit Fuse Rating Max Starting Current Max. running current CW Temperature unit Fuse Rating Max Starting Current Max. running current Full air conditioning unit Fuse Rating Max Starting Current
NOTE
22-1 20 32 108 25 35 113 37 40 125 18 32 106 25 35 113 37 40 125 6 16 28 25 32 47 35 40 57
30-1 30 35 137 30 35 137 42 50 150 23 35 131 26 335 134 42 50 150 7 16 44 26 32 63 36 40 74
30-2 24 32 83 24 32 83 34 35 93 22 32 80 22 32 80 31 35 89 6 10 18 15 16 27 17 20 29
40-1 35 50 184 35 50 184 55 63 204 29 50 177 29 50 178 49 63 197 9 20 59 29 32 79 40 50 89
45-2 40 50 148 40 50 148 56 63 164 34 50 142 34 50 142 53 63 161 10 16 47 29 32 66 36 40 74
50-1 42 63 217 45 63 220 74 80 249 33 63 208 43 63 217 66 80 241 13 25 82 45 50 114 66 80 135
55-2 45 63 194 45 63 194 65 80 214 39 63 188 39 63 188 59 80 208 12 20 62 32 35 82 40 50 89
14 25 72 14 25 72 24 32 82 12 25 70 13 25 71 21 32 79 4 10 16 13 16 25 17 20 29
All ratings shown are for units having standard configuration and operating at design conditions.
Document 0410536
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Technical Manual
Table 2-5 : Current ratings
Current Ratings
in Amps1
IPAC MODEL UNIT TYPE 60-1 Max. running current Cooling-only unit Fuse Rating Max Starting Current Max. running current DX / A-C Temperature unit Fuse Rating Max Starting Current Max. running current Full air conditioning unit Fuse Rating Max Starting Current Max. running current Cooling-only unit Fuse Rating Max Starting Current Max. running current DX / W-C Temperature unit Fuse Rating Max Starting Current Max. running current Full air conditioning unit Fuse Rating Max Starting Current Max. running current Cooling-only unit Fuse Rating Max Starting Current Max. running current CW Temperature unit Fuse Rating Max Starting Current Max. running current Full air conditioning unit Fuse Rating Max Starting Current
NOTE
60-2 52 63 160 52 63 160 72 63 180 46 63 154 46 63 154 65 63 173 13 20 51 32 35 70 36 40 74
70-2 57 63 206 57 63 206 77 80 226 51 63 200 51 63 200 71 80 220 16 25 65 36 40 85 40 50 89
80-2 62 80 211 62 80 211 82 100 231 56 80 205 56 80 205 76 100 225 18 25 67 38 40 87 40 50 89
90-2 76 100 250 76 100 250 108 125 283 61 100 236 61 100 236 93 125 268 21 25 90 53 50 122 66 80 135
100-2 83 100 258 83 100 258 115 125 290 65 100 240 65 100 240 98 125 273 24 32 93 57 63 126 66 80 135
110-2 90 100 287 90 100 287 133 160 331 73 100 271 73 100 271 117 160 314 24 32 93 67 80 136 77 100 146
120-2 97 100 295 97 100 295 141 160 338 81 100 279 81 100 279 125 160 322 24 32 93 67 80 136 77 100 146
49 80 247 56 80 253 93 100 290 41 80 239 56 80 253 85 100 282 13 25 82 56 63 125 77 80 146
All ratings shown are for units having standard configuration and operating at design conditions.
Page 2-12
IPAC
Technical Manual
Table 2-6 : Pipework connection sizes
Pipework Connection Sizes

IPAC MODEL LINE 15-1 Indoor liquid Outdoor liquid Indoor discharge Outdoor discharge Chilled water Humidifier water Condensate and humidifier drain, tube i/d LINE 60-1 Indoor liquid Outdoor liquid Indoor discharge Outdoor discharge Chilled water Humidifier water Condensate and humidifier drain, tube i/d in. in. in. in. mm mm mm
7/ 3/ 8 4 8 8
22-1
1 1 3
30-1
1 1 3
30-2
3 3 1
40-1
5 5 7
45-2
1 1
50-1
7 3
55-2
5
in. in. in. in. mm mm mm
3 3 1
/8 /8 /2
4
/2 /2 /4
8
/2 /2 /4
8
/8 3/8 /8 3/8 /2 1/2

4 3/ 4
/8 /8 /8
8
/2 3/8 /2 3/8 /4 1 /2
8 3/ 4
/8 /4
/8 3/8 /8 3/8 /8 1/2
5 7
13/8 11/8 42
3/
7/
7/
3/
7/
7/
7/ 3/ 8 4
28
35
35
28 28 15 13
42
35 28
42 28
IPAC MODEL 60-2

1/ 2 1
70-2
5/ 5/ 7/ 7/ 8 8 8 8 1/ 1/ 3/ 7/ 2 2 4 8 5/ 5/ 7/ 7/
80-2
8 8 8 8 5/ 5/ 7/ 7/ 8 8 8 8 7/ 3/
90-2
8 4 5/ 5/ 7/ 8 8 8 8
100-2
5/ 8 5/ 8 5/ 5/ 8 8 8 8 7/ 5/
110-2
8 8 8 8 7/ 5/ 8 8 8 8 7/ 5/
120-2
8 8 8 8 7/ 5/ 8 8
/2
1/ 1/ 2 2 3/ 7/ 4 8 3 3
13/ 11/
/4 /4
13/8 11/8 42 15 13
11/8 11/8 42
11/ 11/
13/ 11/
13 / 11 /
13/ 11/
13/8 11/8 42
11/
42
35 35
42
35
42
42
42
42
42
42
42
NOTES Except for the humidifier water supply and drain lines, all pipe connections are brazed as standard (options are available on request). Humidifier water feed line connection is push-fit for copper pipe. Each module of dual cabinets have independant service connections.
Document 0410536
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IPAC
Technical Manual
Table 2-7 : Discharge line and liquid line sizes guide - DX units
Discharge Line and Liquid Line Sizes Guide - DX Units

PIPE RUN LENGTH IPAC MODEL LINE 15-1 Liquid <10 m Discharge 10 m to 30 m 30 m to 50 m PIPE RUN LENGTH Liquid Discharge Liquid Discharge LINE 60-1 Liquid <10 m Discharge 10 m to 30 m 30 m to 50 m Liquid Discharge Liquid Discharge in. in. in. in. in. in.
7
22-1
1 3 5
30-1
1 3 3
30-2
1 3 5
40-1 /2 /4 /8
8 8 8 5 7 3
45-2
1 3 3
50-1 /2 /4 /8
8 8 8 7
55-2
5 7 3
in. in. in. in. in. in.
1 3 5
/2 /4 /8
8 8 8
/2 /4 /8
/2 /4 /4
/2 /4 /8
1 3 5
/8 /8 /4
/2 /4 /4
1 3 5
/8
/8 /8 /4
1 3 5
/2 /4 /8
8 8 8
1 /8
7
/8
7/ 5/ 7/
11/8
5/ 8 8
11 / 8
3/ 4 8
7/ 8 5/ 8 7/ 8
7/ 5/ 7/
11/8
7/ 8 8
11/8
3/ 4 8
7/ 5/ 7/
13/8
7/ 8 8
11/8
7/ 8 8
7/ 5/ 7/
11/
11 /
13/
11/
13/
13/
IPAC MODEL 60-2

1
70-2 /2 /4 /4
1
80-2 /8 /8 /4
5
90-2 /8
8 4 7
100-2 /8
8 3
110-2
7
120-2
7
/8
8
/2
4 4
1 3 3
/2
4 4
5 7 3
/8
/8
8
/4
8
/4
/8
8
/8
8
/8
8
/8
8
13/
7/
3/ 3/
3/ 3/
7/ 8 3/ 4
7/ 3/
13/
7/ 3
11/
7/
11/8
7/ 8
13/
13/
7/
13/
7/
13/
7/
7/ 8
/4
7/ 8
13/8 11/8 15/8
11/8 11/8
3/ 4 3/ 4
11/8 11/8
3/ 4 7/ 8
11/8
7/ 8
11/8
7/ 8
13/8 11/8
7/ 8 7/ 8
13/8
7/ 8
13/8
7/ 8
13/8 11/8 15/8
13/8
7/ 8
13/8 11/8 15/8
13/8 11/8 15/8
11/8 11/8
11/8 13/8
13/8
13/8
13/8 13/8
13/8
13/8
13/8
NOTES: All pipe connections are brazed as standard (options are available on request). Sizes are provided for guidance only. Qualified personnel should specify pipework, subject to site layout and conditions. Each module of dual cabinets have independant service connections.
Page 2-14
IPAC
Technical Manual
Table 2-8 : Water flow rates for integrated plate heat exchanger condensers
Standard Water Flow Rates for Integrated Plate Heat Exchanger Condensers
Water Flow Rates at 35 C Supply and 45 C Return IPAC MODEL Water Flow Rate Pressure Drop Optional Glycol Pressure Drop l/s kPa kPa IPAC MODEL Water Flow Rate Pressure Drop Optional Glycol Pressure Drop l/s kPa kPa 15-1 0.46 52 t.b.a 60-1 1.90 109 t.b.a 22-1 0.69 46 t.b.a 60-2 1.85 63 t.b.a 30-1 0.93 63 t.b.a 70-2 2.18 68 t.b.a 30-2 0.93 52 t.b.a 80-2 2.52 68 t.b.a 40-1 1.26 68 t.b.a 90-2 2.96 97 t.b.a 45-2 1.4 63 t.b.a 100-2 3.39 97 t.b.a 50-1 1.7 97 t.b.a 110-2 3.59 109 t.b.a 55-2 1.12 68 t.b.a 120-2 3.79 109 t.b.a
Optional Water Flow Rates for Integrated Plate Heat Exchanger Condensers
Water Flow Rates at 20 C Supply and 40 C Return IPAC MODEL Water Flow Rate Pressure Drop l/s kPa IPAC MODEL Water Flow Rate Pressure Drop l/s kPa 15-1 0.23 18 60-1 0.95 33 22-1 0.34 13 60-2 0.93 19 30-1 0.46 19 70-2 1.09 20 30-2 0.46 18 80-2 1.26 20 40-1 0.63 20 90-2 1.48 34 45-2 0.69 19 100-2 1.70 34 50-1 0.85 34 110-2 1.80 34 55-2 0.86 20 120-2 1.90 33
Water Flow Rates at 40 C Supply and 50 C Return IPAC MODEL Water Flow Rate Pressure Drop l/s kPa IPAC MODEL Water Flow Rate Pressure Drop l/s kPa 15-1 0.46 52 60-1 1.90 109 22-1 0.69 46 60-2 1.85 63 30-1 0.93 63 70-2 2.18 68 30-2 0.93 52 80-2 2.52 68 40-1 1.26 68 90-2 2.96 97 45-2 1.4 63 100-2 3.39 97 50-1 1.70 97 110-2 3.59 109 55-2 1.72 68 120-2 3.79 109
NOTES Supply temperatures shown are typical for open loop water systems. 40 C is typical for closed-loop water systems. For alternative water temperatures, refer to Eaton-Williams.
Table 2-9 : Service electrical connections - all units
Service Electrical Connections - All Units

Power supply Indoor unit power supply cable Outdoor (condenser) unit power supply cable 400 V, 3 ph, 50 Hz 5 core, 3ph / N / E 3 core, L / N / E
Document 0410536
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IPAC
Technical Manual
Air-cooled Direct Expansion (DX) System
Fig. 2-4 : Air-cooled DX refrigeration system basic circuit diagram
Air-cooled DX Refrigeration System Basic Circuit Diagram

NOTES 1 This diagram illustrates a typical IPAC air-cooled DX refrigeration system, including oil separator and liquid receiver options. 2 Safety pressure relief valves must be sized, rated and fitted according to refrigeration industry safety regulations, legislation and equipment manufacturer's instructions. 3 If an oil separator is required to be fitted, the oil return line (customer supply and fit) must be sized and fitted according to the manufacturer's recommendations.
Condenser
Pressure relief valve2
Liquid line
Airflow
Unit envelope LP HP
Liquid receiver1
Pressure 2 relief valve Expansion line Airflow TEV Sight Filter / glass drier Liquid line
Superheated vapour at discharge pressure Superheated vapour at suction pressure Subcooled liquid at discharge pressure Subcooled liquid / vapour at suction pressure Optional arrangement for fully automatic hot gas injection for evaporator capacity control
Flow Control Evaporator (air cooler)
Pilot line LP HP
Capacity regulator Oil separator

1
Alternative optional arrangement of hot gas injection for capacity reduction control, with manually-set flow control and operation determined by controller strategy
Sensing bulb Suction line
Discharge line Compressor Oil return line3
From the suction line, the compressor draws refrigerant gas (normally R 407C), compresses it and then discharges it into the discharge line. The high pressure, superheated discharge gas flows through the discharge line to the condenser, where the gas is cooled and condensed by relatively cool air flowing on the other side of the heat exchange surface. The resulting liquid, still at high pressure, flows through the liquid line and through a filter/drier before reaching the thermostatic expansion valve. NOTE Depending on system design external to the unit, it may be necessary to fit a liquid receiver in the liquid line, after the condenser; refer to Liquid Receiver on page 6-6 of Section 6. To ensure that only liquid reaches the thermostatic expansion valve, the liquid line continues from the liquid receiver via a dip tube arrangement.
The thermostatic expansion valve meters the flow of refrigerant entering the evaporator in response to the temperature of refrigerant leaving the evaporator. On entering the evaporator, the refrigerant is a saturated vapour and liquid mixture at low pressure. As the refrigerant passes through the evaporator, any liquid present is vaporised by extracting heat from the relatively high temperature supply air flowing on the other side of the heat exchange surface. From the evaporator, the superheated, low pressure gas enters the suction line and flows to the compressor again. The process is continuous while the compressor is operating. To achieve evaporator capacity control, one of two types of Capacity Control Hot Gas Injection System arrangements may be fitted; refer to page 2-29 for more details. Depending on the unit model, there may be two independent refrigeration systems fitted, so that high demand conditions can be met. The controller has been designed to enable refrigeration system operation to be tempered to meet demand without inefficient short-cycling of equipment.
Page 2-16
IPAC
Technical Manual
Water-cooled DX System
Fig. 2-5 : Water-cooled DX refrigeration system basic diagram
Water-cooled DX System Basic Refrigeration Circuit Diagram

1 This diagram illustrates a typical IPAC water-cooled DX refrigeration system, including liquid receiver, water system isolating valves, and commissioning control valve and flow meter. 2 An optional safety pressure relief valve must be sized, rated and fitted according to refrigeration industry safety regulations, legislation and equipment manufacturer's instructions. 3 If an oil separator is required to be fitted, the oil return line (customer suppy and fit) must be sized and fitted according to the manufacturer's recommendations. KEY Superheated vapour at discharge pressure Superheated vapour at suction pressure Subcooled liquid at discharge pressure Subcooled liquid / vapour at suction pressure Optional arrangement for fully automatic hot gas injection for evaporator capacity control
Water return Suction line Compressor Bypass line Flow meter Water flow 3-Way valve
Unit envelope LP HP Pressure 2 relief valve Liquid line TEV Sight Filter / glass drier Liquid receiver1
S
Expansion line Airflow
Flow Control Evaporator (air cooler)
Pilot line LP HP
Capacity regulator
Sensing bulb
Alternative optional arrangement of hot gas injection for capacity reduction control, with manually-set flow control and operation determined by controller strategy Optional commissioning control valve and flow meter Optional water system isolating valves
Sensing bulb
Cooling water (glycol solution or similar primary refrigerant) at a specified rate and temperature (see Table 2-2) is pumpcirculated (by customer system) through the plate heat exchanger. From the suction line, the compressor draws refrigerant gas (normally R 407C), compresses it and then discharges it into the discharge line. The high pressure, superheated discharge gas flows through the discharge line to the plate heat exchanger condenser, where the gas is cooled and condensed by relatively cool water (glycol solution or similar primary refrigerant) flowing on the other side of the heat exchange surface. The resulting liquid, still at high pressure, flows through the liquid line to the liquid receiver (fitted as standard), which is designed to accommodate all excess liquid not required in the evaporator (air cooler) when the unit is operated at below maximum load conditions. To ensure that only liquid reaches the thermostatic expansion valve, the liquid line exits the liquid receiver via a dip tube arrangement. Note that because the liquid receiver cannot be isolated, there is no requirement for a pressure relief valve. However, it is recommended that a suitably sized and rated fire-hazard safety pressure relief valve is fitted as an option. The thermostatic expansion valve meters the flow of refrigerant entering the evaporator in response to the temperature of refrigerant leaving the evaporator.
On entering the evaporator, the refrigerant is a saturated vapour and liquid mixture at low pressure. As the refrigerant passes through the evaporator, any liquid present is vaporised by extracting heat from the relatively high temperature supply air flowing on the other side of the heat exchange surface. From the evaporator, the superheated, low pressure gas enters the suction line and flows to the compressor again. The process is continuous while the compressor is operating. To achieve evaporator capacity control, one of two types of Capacity Control Hot Gas Injection System arrangements may be fitted; refer to page 2-29 for more details. Depending on unit model, there may be two independent refrigeration systems fitted, so that high demand conditions can be met. The controller has been designed to enable refrigeration system operation to be tempered to meet demand without inefficient short-cycling of equipment. Cooling water flow and return connections are on the same face of the plate heat exchanger and are arranged to contraflow the direction of refrigerant flow. Because the DX refrigerant system is close-coupled within the unit and velocities are sufficient to carry oil round the system, an oil separator arrangement is not required.
Document 0410536
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IPAC
Technical Manual
Chilled Water Cooling System
Fig. 2-6 : Chilled water cooling and LPHW heating diagram
Chilled Water Cooling and LPHW Heating Diagram

3-WAY VALVE OPTION2 3-Way Modulating M Valve 2-WAY VALVE OPTION2 2-Way Modulating M Valve Flow meter Flow control valve1
Airflow Flow control Valve Air Cooler (heat exchanger) Bypass line
To cooling plant
This diagram illustrates a typical IPAC chilled water system, including optional 3-way valve, 2-way valve, system isolating valves and commissioning flow control valve and combined flow meter. 1 If the system isolating valves option is fitted, but not the commissioning control valve and flow meter option, an isolating valve will be provided in the return line, to replace the isolating capability that would have been provided by the flow control valve. 2 The 3-way valve and 2-way valve are alternative options.
COOLING
From cooling plant
KEY Chilled water Return water at cooling coil outlet temperature LPHW (Low Pressure Hot Water) supply Return water at heating coil temperature Optional 3-way modulating valve, bypass line and flow control valve for cooling or heating capacity control Alternative optional arrangement of 2-way modulating valve for basic cooling/ heating capacity control Optional commissioning flow control valve and flow meter Optional water system isolating valves
1 1
Isolating 1 valve 3-WAY VALVE OPTION2 3-Way M Modulating Valve Airflow Flow control Valve Air Heater (heat exchanger) Bypass line 2-WAY VALVE OPTION2 2-Way Modulating M Valve Flow meter Flow control valve1
To heating plant
HEATING
From heating plant
Isolating 1 valve
This system is illustrated in Fig. 2-6 - Chilled water cooling and LPHW heating diagram. In response to the temperature of air entering the unit, the InvictaNET controller modulates a flow control valve to meter the flow of chilled water (or other suitable chilled medium) entering the heat exchange coil. NOTE Effective control of air temperature relies upon the supply of low pressure chilled water at a specified constant temperature being available to the unit. As the chilled water passes through the cooling coil, heat is extracted from the relatively high temperature supply air flowing on the other side of the coils heat exchange surface. Having passed through the cooling coil, the water then returns to the water chilling plant for re-cooling, before returning to the unit again. Depending on the unit model, there may be two independent flow control valve / cooling coil systems fitted, so that high demand conditions can be met. As can be seen in Fig. 2-6, there is a choice of two types of optional modulating flow control valve arrangement: 2-way valve 3-way valve For details of the modulating control valve, see page 2-25.
Document 0410536
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IPAC
Technical Manual
Economy Cooling Options
Fig. 2-7 : Glycol Economy Cooling Circuit Diagram
Glycol Economy Cooling Circuit Diagram

Refrigerant return Refrigerant flow
3-Way valve
3-Way Modulating Valve M
Sensing bulb
Flow meter Flow control valve1 Isolating 1 valve
To cooling plant
Airflow
GLYCOL (Heat Exchanger)
Flow control Valve Bypass line
Bypass line
GLYCOL COOLING
Isolating 1 valve From cooling plant
Chilled water Return water at condenser coil outlet temperature Return water at glycol cooling coil temperature
M
3-way valve, bypass line and on/off control for cooling and heating Optional commissioning flow control valve1 and flow meter Optional water system isolating valves
1
3-way modulating valve, bypass line and flow control valve for cooling or heating capacity control
This diagram illustrates a typical IPAC Glycol Economy cooling system, including 3-way valve, 2-way valve, system isolating valves and commissioning flow control valve and combined flow meter. 1 If the system isolating valves option is fitted, but not the commissioning control valve and flow meter option, an isolating valve will be provided in the return line, to replace the isolating capability that would have been provided by the flow control valve.
There are two types of economy cooling option available for the IPAC range of AHUs, Fresh-Air Economy Cooling and Glycol Economy Cooling. Both can be optimised to use the relevant cooling medium, where conditions allow, to achieve the required air condition, whilst minimising the running time of the compressor or cooling plant. The pay-back return period for the initial additional equipment cost is achieved within two to three years typically. Fresh-Air Economy Cooling Option Fresh-air economy cooling can be applied to either DX or chilled water units, where the unit is either installed with its back against an outside wall (louvre required), or fitted with fresh-air duct (room pressure relief required). This system requires a separate modulating damper box fitted in the return air path to the unit, plus an outside air temperature sensor. The modulating damper box comprises a modulating damper plate and an G2 filter on the fresh-air side. The InvictaNET controller modulates the damper to vary the return-air /fresh-air mix to achieve optimum air temperature at a constant airflow volume.
For control details, refer to Fresh-Air Economy Cooling on page 19 of Section 4. Glycol Economy Cooling Option Glycol (cooling by glycol/water solution cooled medium) economy cooling can be applied to water-cooled DX units, where cooling coil heat rejection is capable of returning the cooling medium at a temperature below that of room air. For this system, an additional coil, for the glycol / water cooling medium, is included in the cooling heat exchanger coil block and faces the DX cooling coil.
CAUTION
The cooling medium must contain a suitable antifreeze mix otherwise the DX process may freeze the cooling medium and result in damage to the unit. IPAC units have been designed for an 80%/20% Ethylene Glycol mix by volume. The arrangement is such that the return air passes through the economy cooling coil, where it is pre-cooled, before passing through the DX cooling coil, where the main cooling process, to required temperature, takes place.
Document 0410536
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IPAC
Technical Manual
The chilled glycol / water primary cooling medium, first passes through the economy cooling coil, if the water temperature is lower than the return air temperature, prior to passing through the plate heat exchanger to liquefy the refrigerant. If the water temperature is not lower than the return air temperature, the InvictaNET controller opens a valve to divert the cooling medium straight to the plate heat exchanger. For control details, refer to Glycol Economy Cooling on page 19 of Section 4. In this way, additional cooling by the cooling medium, that has already performed its condensing function, is achieved before returning to the cooling plant. Therefore, depending on unit application, after dehumidification, reheating of the air may be necessary to control air temperature.
Hot Gas Reheat

This option is only applicable for DX units only and provides reheat of the air following dehumidification, when air temperature is reduced to below the required set point. NOTE If primary heating is required (i.e other than for dehumidification reheat, electric heating must be installed in the second module (therefore not available on single module units). When the controller evaluates that, because the air has been cooled to below the set point during dehumidification, reheat is required, a solenoid valve is energised (opened) to admit compressor discharge gas (at high temperature and pressure) to enter the heating coil. In this way, air is reheated after cooling, by reclaiming heat dissipated from the compressor, which also saves energy compared to electrical or LPHW heating.
Humidity Control
Humidity control is an option for all units. The humidity of supply air passing through the unit can also be monitored by the controller, which applies humidity control strategy to correct and maintain air humidity at a predetermined set point. If a humidifier is fitted (see page 2-30), this can be controlled to produce an increase in air humidity by introducing steam into the airstream. Whether in humidifying or dehumidifying mode, the air passage through the unit is the same as for heating or cooling.
Network Control System

In multi-unit applications, where there is a master unit controlling several network slave units, each unit operates independently, but under the central control of the master unit. This ensures optimum performance of the total system and that failure of one unit will not affect the continued operation of other units, provided that the power supply to the master unit controller remains live. To prevent excessive current from being drawn during starting, the controller starts units and their equipment in a staggered, delay-timed sequence. For details of the starting sequence, refer to page 4-15 of the INVICTANET CONTROLLER TECHNICAL MANUAL.
Dehumidification
For environments where high humidity is a problem, the refrigeration system is used to reduce and control air relative humidity (RH %). This is achieved by passing the supply air across the evaporator coil, where moisture condenses onto the relatively cold surface of the heat exchanger. As the condensate accumulates, it forms water droplets, which then fall into the condensate drip tray. All resulting water then drains from the condensate tray and passes, via a trap, to external drains. NOTE Because of the nature of the dehumidification process, unless the heating option is fitted, accurate dehumidification may not achievable without overcooling the supply air.
Table 2-10 : Standard main components
Main Components
Standard Main Components

Standard Main Components and Features Air-cooled DX Water-cooled DX Chilled Water
Unit Casing Finish Supply Air Fan(s) V Belt Drive on Adjustable Slide-Bases Air Filters - G4, cleanable Differential Pressure Switches Cooling Coil (evaporator / heat exchanger) Condensate Drip Tray Eaton-Williams InvictaNET AHU Controller
Page 2-20
IPAC
Technical Manual
Table 2-10 : Standard main components
Standard Main Components

Electrical connections Volt-free Alarm Contacts Bottom Connections Compressor Filter / Drier Thermostatic Expansion Valve Moisture Indicating Sight Glass Evacuation and Refrigerant Charging Valves Pressure Safety Devices Modulating Flow Control Valve and Actuator Key Operated Cam-lock Removable Doors Airflow Failure Detection Cardboard Sleeve / Pallet Delivery Protection Contactors, MCBs and MPCBs Internal Unit Isolator (Handle Optional) Interconnecting wiring loom Integrated Water-Cooled Condenser

Options Air-cooled DX Electrical / Control Options Water-cooled DX Chilled Water
Phase-failure relay Control panel cover Fresh Air Control Fresh Air Control, Including Smoke Detection Door-interlocked isolator Mains filter kit In-Room Remote Sensors Duct Remote Sensors Water Detection Tape Audible Alarm Alternate Display Languages ModBus Network Interface Trend Controller Trend Network Interface
Heating Options
Electric Heating - 5/10/15/22.5/30 kW Electric Finned Element Low Pressure Hot Water Heating System LPHW Heating Coil (heat exchanger) with 0 - 10 V Control Valve
Refrigeration Options
Capacity Control Hot Gas Injection System Liquid Receiver Modulating Flow Control Valve and Actuator
Document 0410536
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IPAC
Technical Manual
Options Air-cooled DX Water-cooled DX Chilled Water
Oil Separator Compressor Acoustic Jacket Compressor Discharge Non-return Valve Split Coil Rapid Dehumidification
Humidifying Options
Humidifier 20% - 100% Proportional Output Humidifier Alarm Diagnostics Tools in Controller Different Bottles for Varying Water Qualities Remote Vapac Options Second Unit OEM Option to increase dual unit options
General Options
Rear Cosmetic Cover Panel Multi-speed motors Side Gland Plates Stainless Steel Drip Tray 5 to 10 % fresh air intake, including volume damper control Anti-vibration mountings Dual Pulley Drives (standard on modules > 40kW) Low Display Mounting Lifting Channels Condensate Pump Class 1, energy-efficient motors Customised colours Pipework
Airflow Options
Upflow - Bottom Return Upflow - Front Return Upflow - Rear Return (Not size 4) Downflow - Top Return Downflow - Front Return Downflow - Rear Return (Not size 4)
Filtration Options
Coil Face Filtration - G4 or F5. F6 or F7 with G4 pre-filter Remote Filtration - F6-H8 Deep Panel Filter in secondary section
Fluid Control Options
2 Way or 3 Way Control Valve Water System Isolating Gate Valves

Upflow Discharge Options
Flexible duct connectors (upflow units only) Non-Return Dampers
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Unit Casing
The IPAC units are constructed using pre-coated outer panels, light grey finish to BS 00A05. Internal metalwork is of galvanised steel construction. External panels are insulated with fire-retardant, vapour-proof, closed-cell, high-density foam, to maximise thermal insulation while minimising noise breakout. NOTE This may increase maximum running currents shown in duty tables and increase noise levels. Multi-speed motors Multi-speed motors are available. Please contact Eaton WIlliams for further information. Class 1, energy-efficient motors As an option, supply fan drive motors are available to Class 1 Energy Efficiency. V Belt Drive Each supply air fan is driven by V belts for increased performance and reduced loss of power.
Finish
External metalwork surfaces are coated in a light-grey (BS 4800 Grey 00A05), durable, protective paint as standard. Internal panels are of galvanised steel. Customised colours If an alternative colour option is required, metalwork is primed with etch primer and then given one coat of finish paint.
Air Filters
As standard, air filters are fitted internal to the unit in the supply air path, prior to the evaporator coil, to filter the air before it is conditioned and then discharged into the room, see Table 2-11 on page 2-23. As an option, filters may be installed externally to the unit, in a High-efficiency Filter Section - see page 2-36 There are various filter grade options, however, it is worth noting that filters above grade F6 would require relatively frequent replacements, as the holding capacity of panel filters at this high efficiency is low. For applications requiring such high-efficiency filtration, the external High-efficiency Filter Section (see page 2-36) should be fitted. NOTE The fitting of panel filters instead of pad filters is easily carried out and requires only a change of retaining clips, with no alteration necessary to the framework.
Supply Air Fan(s)

Each room air supply fan will deliver air against an assumed standard external static resistance pressure of 70 Pa. Alternative external pressure ratings can be achieved by changing the fan drive ratio and, if necessary, the drive motor. IPAC 15-1, 22-1, 30-1 and 40-1 units have a single, forwardcurved, centrifugal fan, coupled, via a wedge belt drive, to a totally enclosed, fan ventilated, IP54 rated, motor. IPAC 50-1 and 60-1 units have a duplex fan (two fans driven from one shaft). Each unit has a single motor mounted on an adjustable base to enable correct tensioning of the wedge drive belts. Each unit has been designed with the recommended number of belts for the shaft motor power. Redundancy in belts is available as an option. Twin module units may have a combination of the above. These drives contain alternative pulleys/taperlocks, belts and fan motors, where required.
Table 2-11 : Alternative air filter options
Alternative Air Filter Options

Panel Description Fitting Notes Cleanable, synthetic, cut pad, fire-rated to DIN 53438 This option initially reduces unit external pressure development by 55 Pa Two spring clips per filter This option initially reduces unit external pressure development by 130 Pa This option initially reduces unit external pressure development by 220 Pa. Where necessary, the reduction in external pressure developed must be compensated by selecting an alternative fan drive to standard.
G4 (Standard) 50 mm thick panel G4 panel filter F5 F6 F7 50 mm thick panel G5 panel filter Cleanable G4 pad pre-filter, with 50 mm thick F6 panel filter Cleanable G4 pad pre-filter, with 50 mm thick F7 panel filter
F8
Cleanable G4 pad pre-filter, with 50 mm thick F8 panel filter
Differential Pressure Switches

Both airflow detection and dirty filter condition are monitored in both cabinets (where applicable). This is achieved by sensing the differential pressure across the filter / coil section of the units.
They are factory set but can be adjusted on site if required.
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Cooling Coil
The standard cooling coil is manufactured from copper tubes with aluminium fins. As an option, the coil can be supplied as copper/copper, or copper/copper-electro-tinned; note that this will increase the weight of the unit. A water-tight drip tray, fitted below the coil, collects the condensate. The cooling coil, condensate drain tray, plastic drain pipework and drain trap are illustrated in Fig. 2-8 and Fig. 2-9 on page 2-24. As it accumulates, water is drained off via two outlets and passes through the internal drain trap, before exiting the unit to the external drain facility (by others). NOTE The unit has an internal drain trap. An external trap should NOT be fitted.
Fig. 2-8 : Drain pipe Layout (DX unit shown)
Eaton-Williams InvictaNET AHU Controller

The InvictaNET AHU controller is a purpose-designed LONWORKS microprocessor, which fully complies with EEC directives for electromagnetic compatibility (EMC). The controller includes the following features as standard: Temperature and humidity set point adjustment Dead band adjustment Proportional band adjustment Alarm band adjustment Fault and service alarm volt-free contacts Winter low pressure switch delay timer adjustment Start delay timers (to minimise starting current demand) Historical alarm logging LONWORKS network communications Stand-alone or Master/Slave control Run/standby and duty rotations The controller is fully described in Section 4 - INVICTANET CONTROLLER TECHNICAL MANUAL.
Electrical connections
All terminals for customer connection of power supply and control circuits are adjacent to the cable entry point, inside the lower left hand side of the unit.
Volt-free Alarm Contacts

As standard, all IPAC units are fitted with 2 sets of terminal connections for urgent and non-urgent (fault and service alarms). When the controller is in an alarm situation the alarm contacts will be held in the unhealthy condition until the alarm is cleared. Remote alarms can either be closed or open circuit healthy.
Fig. 2-9 : Condensate drain trap (DX unit shown)
Bottom Connections
The standard service connections are at the bottom of the IPAC units, with the electrical connections located to the left and the service to the right. Two blind gland plates are provided for site cutting to suit requirements. As an option, side gland plates can be provided.
Compressor
Each units refrigeration system uses a high-efficiency scroll-type compressor, fitted with an internally relieving pressure relief device and integral sump. Crankcase oil heaters are available as an option, for circumstances that necessitate their use; refer to Compressor Crankcase Oil Heater(s) on page 6-7 of Section 6 Compressors are installed on anti-vibration mountings to minimise noise and vibration levels. Capacity control is as described under and Section 4 Compressor Capacity Control .
Condensate Drip Tray

As standard, the condensate tray is manufactured from galvanised steel plate, with stainless steel available as an option.
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Fig. 2-10 : Liquid line components
Moisture Indicating Sight Glass

The sight glass is located between the Filter / Drier and the Thermostatic Expansion Valve, as shown in Fig. 2-10. The sight glass performs two functions: It enables the condition of the refrigerant to monitored and provides visual indication of the presence of any moisture. Bubbles in the sight glass could be due to operating under hot gas injection and may not necessarily mean the system is undercharged.
Evacuation and Refrigerant Charging Valves

To facilitate evacuation and refrigerant charging, and to allow monitoring, two Schraeder type valves are fitted to each refrigeration circuit; one each on the high pressure (HP) and low pressure (LP) sides of the system.
Pressure Safety Devices

In adverse operating conditions, excessively high discharge or low suction pressures can develop, which can reach unacceptable levels. To protect against this and consequential damage it may cause, high and low pressure cut-out safety controls are fitted as standard, as described in Section 4 INVICTANET CONTROLLER TECHNICAL MANUAL. These pressure switches are non-adjustable and self-resetting. However, the system should only restart after the cause of the adverse condition has been rectified and the alarm is cleared at the controller.
1. 2. 3. 4. 5. 6. 7. 8.
Thermostatic expansion valve Equalising line Moisture indicating sight glass Liquid line Filter/drier Suction line Temperature sensing phial location Expansion line to evaporator
Modulating Flow Control Valve and Actuator

This electronic valve and actuator illustrated, is used to control the flow of chilled water or low pressure hot water (LPHW) to the cooling coil or heating coil (if fitted). The InvictaNET AHU Controller uses a Proportion, Integral and Derivative (PID) algorithm to determine control response and provides a 0 to 10 volt signal to modulate the flow control valve according to demand. The 0 to 10 volt signal provided by the controller is directly proportional to the positioning range of the flow control valve. The IPAC range offers a choice of either a two-way (standard) or three-way control valve. Twoway valves can be used on systems that have variable spped pumps to maintain constant pressure drop through the circuit. For constant speed pump systems, the third outlet from the three-way valve is used to bypass the coil. The bypass leg is designed to produce a balanced pressure drop through the system to match the coil, regardless of operating mode.
Filter / Drier
The filter / drier is located before the sight glass and the thermostatic expansion valve, as shown in Fig. 2-10. The filter / drier ensures that any moisture, that may have entered the system during charging, is removed. It is essential to ensure that there is no free moisture circulating round the refrigerant system, otherwise: The moisture may otherwise freeze and cause a blockage, usually at the TEV Or, in the worst case: Moisture may affect the insulation of the compressor drive motor, causing a burn-out
Thermostatic Expansion Valve

The thermostatic expansion valve, which has a fixed orifice and adjustable superheat, maintains the design degree of superheat at the evaporator outlet. Liquid line main components are shown in Fig. 2-10. A remote sensing bulb is securely fixed to the evaporator outlet piping, in a position where the superheat can be correctly sensed. The thermostatic expansion valve incorporates an external equaliser line.
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Key Operated Cam-lock Removable Doors
Each door is secured shut by means of three door-locking mechanisms, which, compresses the door sealing gasket to preventing air and noise leakage. After unit installation, all access for maintenance is via the front of the unit. Each unit is supplied with a door lock key.
Integrated Water-Cooled Condenser

Any IPAC unit can be fitted with an integral, matched, stainless steel brazed plate heat exchanger, complete with pressure sensing diverter valves and associated pipework; see Fig. 2-5 on page 2-17. There are two options for the diverting valve: 3-Way Valve - for constant flow pump systems 2-Way Valve - for variable flow systems A commissioning set comprising a flow measuring variable orifice double regulating valve and shut-off valves is available for either of the units as an option. Due to space limitations some of these components may need to be fitted on site external to the units. Water flow rates for integrated plate heat exchanger condensers are shown in Table 2-8 on page 2-15.

Phase-failure relay Airflow Failure Detection
As standard, each unit module is fitted with an air pressure switch to monitor airflow. This option is recommended for any application where the quality of the electrical supply is not guaranteed. This DIN rail-mounted relay protects units and offers the following features: Monitors the phase-to-phase supply Adjustable under-voltage and over-voltage trip levels Phase sequence and Phase-failure detection Adjustable time delay When the device is triggered, the individual unit enters shutdown mode, allowing other units in a network to operate to compensate for the loss of duty.
Cardboard Sleeve / Pallet Delivery Protection

As standard, units and condensers are packed on pallets and have cardboard protective sleeving and polystyrene corner packing. Export packing is available on request.
Control panel cover Contactors, MCBs and MPCBs

To protect against electrical damage, all unit electrical plant is individually switched by contactors, MCBs and MPCBs. As shown in Fig. 2-12 on page 33, these items are located on a fixed chassis, located directly behind the front access door. The electrical section is accessible behind a key-locked door. However for added protection (for example, to provide increased electrical safety for a Maintenance Engineer during routine servicing), an additional hinged cover can be fitted over the electrical chassis.
Internal Unit Isolator

Positioned within the electrical chassis is a 3 phase isolator for customer connection. A door-interlocked handle is available as an option.
Fresh Air Control

To be used with the 100 % Fresh Air Modulating Section (see page 2-36) or remote dampers (contact Eaton-Williams), this option utilises an additional sensor to control a 0 to 10 V output for a modulating damper. This is used to draw in outside air for cooling / heating and used where energy savings can be made compared to only conditioning the return air. Control set points inhibit use of fresh air in close control applications when either the temperature or humidity are heading out of predetermined limits. If this option is selected, remote room pressure relief is required.
Interconnecting wiring loom

To facilitate interconnecting wiring between twin modules, easily accessible, rail-mounted terminal blocks for all necessary circuits are provided in each cabinet. An optional, factory-made interconnecting wiring loom, suitable for adjacent cabinets, is available as an option.
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Fresh Air Control, Including Smoke Detection
This option is the same as the Fresh Air Control (see page 2-26), but includes a smoke detector on the outside air path, as close as possible to the point of entry. If smoke is detected in the incoming airstream, this control overrides (via hard-wired relays) the unit controller and shuts the fresh air damper to prevent further entry of outside air. An alarm signal is generated by the device, via its own volt-free relay contacts. When the sensor detects that the air is clear of smoke, the device resets and normal operation resumes.
ModBus Network Interface

When interfacing with the InvictaNET Echelon network via a PC based BMS system, a serial interface board is available. This is written using the ModBus protocol and has connectivity for RS232 or RS485 (jumper settable). One interface board is required per network (up to 9 AHUs). The ModBus interrogation software is by others.
Trend Controller
Where required, the IPAC units can be provided with a Trend IQ204 controller with custom designed software to meet the individual site requirements. Please note, if this option is used, separate documentation will be required as this manual is solely based on the InvictaNET controller. Please contact Head Office for further information.
Door-interlocked isolator
For safe electrical isolation of units, Eaton-Williams recommends that an optional, local door-interlocked isolator is fitted. This device will isolate the unit when the door handle is turned to open the unit door panel.
Trend Network Interface Mains filter kit

IPAC units fitted with the InvictaNET controller pass the following EMC tests: Immunity: EN61000-6-2:2001 Emissions: EN61000-6-3:2001 Should an installation have known problems with its electrical supply, then the factory-fitting of an EMC kit is recommended, to minimise any problems with regards to EMC interference. The EMC kit is also available as a site retro-fit kit, should a unit suffer from EMC susceptibility after installation. When interfacing with the InvictaNET Echelon network via Trend BMS system, a combination of the EW Serial Interface Board and a Trend Interface Device is available. Custom designed software makes the InvictaNET network visible on the Trend Network as an IQ Device. Further details and compatibility information is available from Head Office.
Heating Process
Electric Heating
Single or two-stage electrical heating can be provided as an option. As described under Dehumidification on page 2-20, where air temperature and humidity are both critical, it is necessary to reheat the air after dehumidification. In this case, the correct amount of reheat capacity must be available. Heaters can of course be used for heating-only (i.e. no dehumidification) cycles. The design of the electric heating in IPAC units is flexible and comprises multiples of 2.5 kW, finned resistance elements, balanced, where possible, over the three electrical phases. The standard heating option is a single bank of heaters in the first module of a twin unit. However, installed heating can be configured to match demand, with options for two-stage or fourstage heating. For details of capacity and heater bank arrangements, refer to Table 2-13 on page 2-28 For heater control philosophy, refer to Section 4 - Electrical Heating Where the electrical heat load is higher than standard for a particular unit, some of the heating elements may be fitted into the second module. Each applicable module is fitted with two self-resetting, overtemperature thermostats, to ensure safety, should a fault condition arise.
In-Room Remote Sensors

Should the positioning of the IPAC units cause unsuitable room condition readings, a remote room sensor is available to provide accurate location sensing (site fitted and wired).
Duct Remote Sensors

Should the positioning of the IPAC units cause unsuitable room condition readings, a remote duct sensor is available to provide accurate location sensing (site fitted and wired).
Water Detection Tape

water detection tape can be supplied for flood detection which is 5 metres long - one per unit module, plus PCB for the master module.
Audible Alarm
As part of the graphical display assembly, a buzzer can be fitted. This will be activated should the controller be in alarm condition. It can be muted by pressing the OK button (EW Controller only).
Alternate Display Languages

The InvictaNET controller can be configured to display in either English or Chinese. Other languages may be available at a later date, please check with Eaton-Williams Head Office if required.
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Low Pressure Hot Water Heating System
Both upflow and downflow master units can be supplied with an LPHW (Low Pressure Hot Water) coil fitted to the air-off side of the cooling coil. Duties are shown on Table 2-12 on page 2-28. This heating option includes a 2-way or 3-way modulating valve, proportionally controlled to enable the LPHW coil to act as the primary heating source, as well as a re-heat coil during dehumidification duty. The duty of the LPHW coil is rated to match the dehumidification available on the IPAC units. As a special, a larger coil and pipework arrangement could be installed if required; refer to Eaton-Williams for details.
Table 2-12 : LPHW duties
LPHW Duties
Rated at design airflow, with air on at 20 C and water temperatures on/off temperatures of 70/60 C IPAC Model Total Heating Water Flow Rate Hydraulic Pressure Drop IPAC Model Total Heating Water Flow Rate Hydraulic Pressure Drop kW l/s l/hr kPa kW l/s l/hr kPa 15-1 9 0.21 760 14 60-1 42 1.03 3708 40 22-1 13 0.33 1177 9 60-2 31 0.76 2729 14 30-1 16 0.38 1364 22 70-2 37 0.91 3272 30 30-2 17 0.42 1519 14 80-2 44 1.06 3816 30 40-1 22 0.53 1908 30 90-2 57 1.39 5004 30 45-2 24 0.59 2124 22 100-2 71 1.72 6192 30 50-1 35 0.86 3096 30 110-2 78 1.89 6804 40 55-2 30 1 2668 30 120-2 85 2.06 7416 40
Table 2-13 : Capacity and stages of electrical heating
Capacity and Stages of Electrical Heating

All elements are 2.5 kW rating CAPACITY kW 5 7.5 10 15 22.5 30 NUMBER OF ELEMENTS AND CONTROL BANKS SINGLE STAGE 2 elements in a single bank 3 elements in a single bank 4 elements in a single bank 6 elements in a single bank (not applicable to IPAC 15-1 or IPAC 30-2) MULTI-STAGE 1 element in the first bank, 1 element in the second bank 1 element in the first bank, 2 elements in the second bank 1 element in the first bank, 3 elements in the second bank 3 elements in the first bank, 3 elements in the second bank (not applicable to IPAC 15-1) 1 element in the first bank, 6 elements in the second bank (not applicable to units <40 kW) 6 element in the first bank, 6 element in the second bank (not applicable to units <60 kW)
This system is illustrated in Fig. 2-6 - Chilled water cooling and LPHW heating diagram and comprises similar components, arrangement and flow control principles. In response to the temperature of air entering the unit, the InvictaNET controller modulates a flow control valve to meter the flow of LPHW entering the heat exchange coil.
As the hot water passes through the heating coil, heat transfers from the hot water to the relatively low temperature supply air flowing on the other side of the coils heat exchange surface. Having passed through the heating coil, the water then returns to the water heating plant for reheating, before returning to the unit again.
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LPHW Heating Coil
For LPHW heating, the standard heat exchange coil is manufactured from copper tubes with aluminium fins. As an option, the coil can be supplied as copper/copper, or copper/copper-electro-tinned.
Liquid Receiver
A horizontal liquid receiver is recommended for each refrigeration circuit having a pipe run of greater than 30 metres. For further information, refer to: Air-cooled Direct Expansion (DX) System on page 2-16, Water-cooled DX System on page 2-17, and Liquid Receiver on page 6-6 of Section 6. The liquid receiver is a site-fit option, which should be installed at the liquid outlet from the condenser. NOTE It is recommended that a suitable pressure relief device is fitted with this option
Capacity Control Hot Gas Injection System

Either of two types of capacity control hot gas injection arrangements may be fitted as an option. Only operative during cooling demand only, these arrangements are both illustrated in: Fig. 2-4 - Air-cooled DX refrigeration system basic circuit diagram, see page 2-16 Fig. 2-5 - Water-cooled DX refrigeration system basic diagram, see page 2-17 Options are: Fully automatic hot gas injection This system operates independently of the controller and modulates in response to sensed suction pressure, to meter the required volume of hot gas into the expansion line. In this way a false evaporator load is created, which enables the compressor to continue operation at times of low load, when it would otherwise be stopped by the controller because of inadequate demand. When correctly adjusted for optimum performance, this arrangement offers superior control of evaporator capacity and, in turn, closer control of air temperature. Manually preset hot gas injection flow control, with operation determined by the unit controller This system provides master units with two stages of capacity control and master/slave units with four stages; for further control details, refer to .Compressor Capacity Control on page 4-16 of Section 4. The hot gas injection line is fitted with a solenoid valve and a flow control valve, which is set during commissioning to provide the appropriate injection flow, which is adjustable from 0 % (valve shut) to approximately 40 % (valve fully open) of discharge gas flow. At a predetermined low load condition, the controller opens (energises) the solenoid valve to allow discharge gas to enter the expansion line.
Oil Separator
Although not normally required on IPAC units, compressormatched oil separators for long pipe runs are available for site installation. One oil separator would be required for each refrigeration circuit.
Compressor Acoustic Jacket

To minimise noise breakout, an acoustic jacket can be fitted to each compressors as an option. NOTE The fitting of an acoustic jacket is recommended for upflow front return units, where noise breakout may be an issue.
Compressor Discharge Non-return Valve

On installations where there is risk of liquid (resulting from condenser low temperature) migrating to the compressor during an off-cycle, the optional discharge non-return valve should be fitted.
Split Coil Rapid Dehumidification

Split coil rapid dehumidification is available. Please contact Eaton WIlliams for further information.
Pressure Relief
Eaton-Williams recommends that a pressure relief kit option is fitted to each refrigeration circuit.
WARNING
Depending on system design and/or total charge weight, pressure relief may be mandatory according to safety legislation. Pressure relief devices must be sized, rated and installed according to industry safe practice and legislation. The pressure relief kit comprises a pressure relief device, bursting disc and rupture indicator. If system pressure rises to a predetermined value, the pressure relief device will open, exposing the bursting disc to system pressure.
2 Way or 3 Way Control Valve

The IPAC range offers a choice of either a two-way (standard) or three-way control valve. Two-way valves can be used on systems that have variable spped pumps to maintain constant pressure drop through the circuit. For constant speed pump systems, the third outlet from the three-way valve is used to bypass the coil. The bypass leg is designed to produce a balanced pressure drop through the system to match the coil, regardless of operating mode.
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If the bursting disc ruptures (at a predetermined pressure), excess pressure will be relieved to atmosphere until system pressure returns to a safe level. The pressure relief valve will then close so that further loss of refrigerant to atmosphere is avoided. The rupture indicator provides a visual signal that pressure relieving has occurred and that a new kit is required to be fitted (after rectifying the cause of the excessively high pressure condition).
Back-draught dampers (upflow units only)

For applications where units discharge into common ducting, if there is the possibility of air recirculation while any unit is in standby or shut-down mode, it is recommended that optional back-draught dampers are fitted at the fan discharge.
Airflow Options
Fig. 2-11 : Airflow path configurations
Water System Isolating Gate Valves

To enable the unit to be isolated from the water system, gate valves can be provided as an option; for water chilled or chilled water units only; refer to Fig. 2-5 and Fig. 2-6, as applicable.
Airflow Path Configurations

Upflow Configurations
Discharge Air Discharge Air Discharge Air
Commissioning Set
This option can be used to set the design flow rate through the unit during commissioning of water chilled or chilled water units only; refer to Fig. 2-5 and Fig. 2-6, as applicable Comprising water system isolating gate valves and a D931 flowmeasuring double-regulating balancing valve, complete with fixed orifice flow measurement tappings on the return leg.
Flexible duct connectors (upflow units only)

For applications where an upflow unit is ducted straight from the fan outlet, optional flexible duct connectors are available, which reduce vibration transmission through the ductwork and also simplify installation. The ductwork connection is a 30mm Doby 'slide-on' flange system, which conforms fully to HVCA specification DW142 for rectangular duct connections.
Table 2-14 : Flexible duct connection sizes
Front Return Bottom Return Back Return
Downflow Configurations
Top Return
Back Return
Flexible Duct Connection Sizes in mm

DUCT DIMENSION Height Unit IPAC MODEL 15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2 150 420 667 670 670 420 670 457 670 420 670 1335 720 667 670 420 670
Discharge Air Discharge Air Discharge Air Back Return Front Return
Width 420 457 457 Module Depth 670 670 670 Unit Width Module Depth DUCT DIMENSION Unit
IPAC MODEL
Humidifier
60-1 60-2 70-2 80-2 90-2 100-2 110-2 120-2 150 Height Width 1335 457 667 667 1335 1335 1335 1335
Module Depth 670 670 670 670 670 670 670 670 - 457 457 667 667 1335 1335 1335 Unit Width Module Depth - 670 670 670 670 670 670 670
The optional Vapac humidifier is a fully integrated system for maintaining and controlling air humidity. The humidifier comprises a cylinder, in which electrodes are inserted. When electrical power is applied to the electrodes, energy passes between them, causing the water to boil and vaporise, producing steam. The steam leaves the cylinder from the top and is released, via a manifold, into the air stream passing through the unit.
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For high humidification demand applications, the second module of a twin unit can also be fitted with a humidifier, as an option.
Table 2-15 : Humidification capacities
Rear Cosmetic Cover Panel

Where the units are to be installed in the centre of a room, cosmetic cover panels to match the overall unit finish can be factory fitted.
Humidification Capacities
CAPACITY kg/hr <5 NUMBER OF ELECTRODES 3-electrode Vapac cylinder Can be fitted to all models 3-electrode Vapac cylinder Not applicable to single module units <30 kW Not applicable to dual module units <45 kW 3-electrode Vapac cylinder Not applicable to single module units <60 kW Not applicable to dual module units <100 kW
Multi-speed motors
Multi-speed motors are available. Please contact Eaton WIlliams for further information.
Side Gland Plates

As service connections may be required to pass through enclosed sections, each section can be supplied with a gland plate on either side, for ease of site service connection. This design reduces the discharge pressure drop and under-floor noise levels. It can be used to discharge air to the rear of the units, as an alternative to the normal front-supply arrangement. * Not available on water cooled condenser versions
<9
< 15
20% - 100% Proportional Output Humidifier

The InvictaNET Controller will attempt to balance the required humidification demand by varying the output of the steam humidifier from 20% to 100% of the available capacity. This is achieved by varying the water quantity and quality within the cylinder.
Stainless Steel Drip Tray

As an option, the drip tray is available manufactured from stainless steel.
5 to 10 % fresh air intake, including volume damper control

An IPAC unit can have a 200 mm x 200 mm volume-controlled damper fitted to either the rear or the side of the unit. Once balanced, the unit will draw approximately 5 % fresh air to the unit, to help attain the recommended air changes per hour for a given room environment. The fresh air inlet is supplied complete with a replaceable prefilter; for details of the exact location of the fresh air entry points, contact Eaton Williams or their authorised agents.
Alarm Diagnostics Tools in Controller

By analysing feedback from the cylinder, the controller recognises various alarm states possible with the humidifier and displays them on the screen and extending remote alarms when necessary.
Different Bottles for Varying Water Qualities

A medium conductivity cylinder is provided with the humidifier option as standard. To suit particular site water qualities, alternastive cylinders can be provided. If the requirements are known prior to manaufacture, the unit can be supplied with the most appropriate cylinder at this stage. Using the correct cylinder will both extend the life of the cylinder and provide better control of the environment. Please contact Head Office for further information.
Anti-vibration mountings
As an option, for applications where vibration transmission to surroundings must be kept to a minimum, anti-vibration mountings (AVMs) can be fitted to fan drive assemblies.
Dual Pulley Drives

For cabinets of duties less than 40kw, the fan drives are selected as single belts, these can be replaced by dual belt drives where specified.
Remote Vapac Options

Where the limited capacity of internal humidifier is insufficient for the system design, a range of options are available. A selection of Vapac standalone humidifiers can be networked to the InvictaNET Controller and can discharge steam either directly to the room (room distribution unit, RDU) or injected into the supply duct of a system. Control and alarms from the remote humidifer are shared with the AHU display.
Low Display Mounting

Where the units are positioned above floor level, the display can be lowered 600mm to compensate.
Lifting Channels
A set of galvanised steel lifting channels is available to lift the units off of their pallets without damaging the units. Please refer to the Installation Section for correct use.
Second Unit OEM Option

In dual cabinet units a second OEM humidifier can be factory fitted into the second cabinet to increase the units output.
Condensate Pump
Two types of optional condensate pump are available: Hot condensate pump Cold condensate pump
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Application and suitability are dependent on whether drainage by gravity can be achieved and whether a humidifier is fitted. This pump is capable of holding 2 litres of water and can pump against a nominal head of 4 metres.
Class 1, energy-efficient motors

As an option, supply fan drive motors are available to Class 1 Energy Efficiency.
Flood Detection
If required, an optional condensate flood detection device can be fitted. This could be from either an optional water detection tape (5 metres long - one per unit module, plus PCB for the master module), or, an alarm signal from a condensate pump (optional). NOTE If supplied by a third party, the device must provide a volt-free digital input, where: Open circuit = healthy Closed circuit = fault If a flood is detected, the cooling process and humidifier (if fitted) stop, so that further flooding is avoided (configurable). For details on connection and operation, refer to Section 4 - INVICTANET CONTROLLER TECHNICAL MANUAL and the unit wiring diagram.
Customised Colours
The standard pre-coated steel used in the cabinet construction can be oversprayed with any RAL or BS colour at additional cost.
Pipework
Pipework is manufactured from refrigeration quality copper tube. Connections are hermetically sealed by solder/brazed joints. After pipework assembly, the system is pressure tested. Suction lines are insulated with a closed-cell, synthetic rubber insulation material, which is jointed and vapour-sealed. Auxiliary Humidification On twin module units, if humidification demand is greater than the standard output, a second humidifier can be fitted to the secondary module. The secondary humidifier contains its own Echelon controller works in tandem with the InvictaNET controller to meet demand. The size of the secondary humidifier is limited by module cabinet size into which it is being installed. Where the installation would benefit from steam being injected directly into a duct, an additional (or alternative) humidifier, controlled by the InvictaNET controller, can be supplied; for details, refer to Eaton-Williams. Hot condensate pump For use in full air-conditioning units, where the internally trapped condensate pipe and Vapac humidifier outlet cannot be gravity fed to a suitable drain point. Pump component materials are suitable for water high temperatures that can be produced by the humidifier. Although this is a site-fit option, terminals are fitted to the IPAC unit for the power supply, and connection for the fault relay, into the water detection input of the controller This pump is capable of holding 4 litres of water and can pump against a nominal head of 6 metres. NOTE Please note that a non-return valve may need to be fitted in the external pipework on site (by others) as this is not supplied with this pump. Cold condensate pump For use in non-humidifying units, where the internally trapped condensate pipe cannot be gravity fed to a suitable drain point a cold water condensate pump is supplied.
Electrical Equipment
Electrical equipment, specifications and options are as follows: External electrical connections are: 380 to 415 volt, 5-wire, 3-phase, neutral and earth mains supply Remote alarm monitoring. Remote start/stop control functions. Emergency and fire shutdown functions. IPAC units are all designed for minimum power input. The control panel is wired via clearly labelled terminal blocks, enabling easy modification / replacement of control system components. All components are internally wired to terminals. Any external interconnecting wiring must be made, by customer, to local regulations. In a twin module unit, interconnecting wiring is terminated, in both modules, to a numbered terminal rail, for customer interconnection at site. All controls are operated from a 24 V ac transformer supply. The equipment will, under all conditions, function within the limits required by Electromagnetic Compatibility Standards BSEH50081-1 and BSEH50081-2. Wiring cable is PVC insulated to BS 623 or BS 6004, as appropriate, and installed in accordance with BS 7671. Conductors for auxiliary purposes have a minimum cross section of 0.5 mm2. Except for the 3-phase supply, conductors are identified by colour coded cables or by numbered ferrules, enabling easy identification and reference to the circuit diagram.
CAUTION
A cold condensate pump is not suitable for use in units fitted with a humidifier, where water high temperatures can damage pump components. Although this is a site-fit option, terminals are fitted to the IPAC unit for the power supply, and connection for the fault relay, into the water detection input of the controller.
Page 2-32
IPAC
Technical Manual
Fig. 2-12 : Electrical chassis general arrangement
13
12 4
11
10
1. Internal wiring and fuses. 2. MPCB's for: Fan 1 & 2 Compressor 1 & 2 Heater stages 1 & 2 Humidifier Condenser 3. Internal wiring terminals. 4. Earth Terminal Bar. 5. Contactors for: Condensers 1 & 2 Humidifier Heater stage 1 & 2 Compressor 1 & 2 Fans 1 & 2
6. Power out for: Sump pump Module 2 Fan 2 (if fitted) Module 2 Compressor 2 (if fitted) Module 2 CGH 2 (if fitted) Condensers 7. Incoming power supply to Isolator. 8. Transformer 0 to 480/9/24 V ac. 9. Flow & Filter Air Differential Pressure switches. 10. Internal wiring for Module 2. 11. Wiring for Alarms, Shutdown and Water Detect. 12. InvictaNET controller daughter board. 13. InvictaNET controller mother board.
Where cables are grouped together in runs and subject to movement, they are suitably secured and protected from mechanical abrasion by a PVC sheath. Supply to the compressor(s), fans, heaters and Vapac unit is via approved protective devices. All terminal blocks are mounted on rails, clamped tightly together using intermediate end-brackets, where required. Terminals are designed to accommodate oversized cables, to ensure that voltage drops can be kept to a minimum. The standard service connections are through the base plinth. Where this is not convenient (i.e. an upflow front-return unit), as an option, side panels of the unit can have gland plates fitted for side service entry.
Air Movement Options

Front / Rear Return Front return air entry is available as an option on the majority of the range of IPAC units, however this option is not available on the following small units: IPAC 15-1, 30-2, 45-2, 55-2 For units with the front return option, rounded slots are punched into the front panels, to maximise return air area. Low PPI filter media is fitted behind these holes to enhance the appearance. It is recommended that the Compressor Discharge Non-return Valve option (see page 2-29) is fitted to units having upflow front return, to minimise compressor breakout noise. Rear return air entry is available on the majority of the range of IPAC units, however this option is not available on the following: Units fitted with a water cooled condenser, IPAC 50-1, 60-1, 90-2, 100-2, 110-2 or 120-2 units. For these, the turning section should be used instead.
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Technical Manual
On downflow units, the change from top to rear return is via a moveable plate. Configuration of upflow units must be specified at the time of ordering. Typically front return units will have a greater noise level than figures generally given for the rear return units.
Table 2-16 : Front / rear return availability
WARNING
In an emergency, do NOT attempt to use controller functions to shutdown equipment, as this will initiate a controlled shutdown that is unlikely to be effective immediately. It is recommended that an optional external Emergency Stop button is fitted, which when pressed will interrupt the power supply, shutting down the unit(s).
Front / Rear Return Availability

RETURN ARRANGEMENT Vertical Front - Upflow Front - Downflow Rear - Upflow* Rear - Downflow RETURN ARRANGEMENT Vertical Front - Upflow Front - Downflow Rear - Upflow* Rear - Downflow* IPAC MODEL 60-1 60-2 70-2 80-2 90-2 100- 110- 120IPAC MODEL 15-1 22-1 30-1 30-2 40-1 45-2 50-1 55-2
Fire Shutdown
An optional fire shut down facility may be fitted at the site and wired into unit terminals If a fire is detected and triggers the system, it will interrupt the power supply to the controller, shutting down the unit and any network slaves. For details on connection and operation of both, refer toSection 4 - INVICTANET CONTROLLER TECHNICAL MANUAL and the unit wiring diagram.
Ancillary Options
A range of ancillaries is available for each of IPAC unit and the most suitable choice is dependent on the particular application and installation. Eaton-Williams Engineers will be pleased to offer advice as to the most suitable selections. If a twin module unit is selected, the base is supplied in two sections, allowing for unit modules to be installed in separate positions. All ancillaries are despatched with two locating pins, which fit into corresponding holes in the IPAC unit frame, to locate the extra sections. NOTE The supplied gasket seal must be used between any mating sections to eliminate air by-pass noise. As standard, unit module sections are not bolted together.
* Not available on water cooled condenser versions
Emergency Shutdown
In an emergency, the unit must be shutdown by using the quickest means possible.
Table 2-17 : Available ancillaries and Section Heights
Standard available Ancillaries and Section Heights

Dimensions in mm Open Frame 350 350 1000 50 Open Frame with Adj. Feet 450 450 1100 50 Frame + Scoop 350 350 1000 50 Frame + Scoop with Adj. Feet 450 450 1100 50 Enclosed Sections 600 500 1100 100 Turning Sections 600 500 1100 100 Fresh Air High-Efficiency Sections 600 600 1100 100 Filter Sections 700 700 800 100
Dimension Nominal Height Minimum Height Maximum Height In Increments of
Adjustable Feet Floor Support Angles Side Gland Plates
Page 2-34
IPAC
Technical Manual
Adjustable Feet
The adjustable feet option is recommended for all under-floor base plinth options. Providing 25 mm adjustability in corner jacking height, adjustable feet make levelling of base plinth sections quick and easy, before fitting a unit into position.
Enclosed Section (for ducting, etc.)

An enclosed section can be used on either the supply or return air path. A typical example of use would be to duct from an upflow unit into a vented ceiling. Front panels are removable, should access be required.
CAUTION
It is essential that units are level when installed, otherwise unit operation may be adversely affected and can result in damage to the unit.
Floor Support Angles

Where any of the above sections are used under a false floor, the plinth can be supplied with suitably sized angles, which can support the floor local to the plinth.
Open frame
The Open Frame illustrated (shown with adjustable feet), is recommended for floor return systems. This is the simplest base option and is designed to match each unit of the IPAC range.
Turning Section (inc. double-deflection grilles)

Either used as a header or a base plinth, the turning section contains a scoop to aid airflow. This section is fully enclosed to match the unit design, with egg-crate return air grilles, or double-deflection supply grilles of satin anodised finish.
Open Frame Base and Scoop

This base is of the same construction as the Open Frame, but with the addition of side enclosure panels and a discharge scoop, to guide the air into a floor void from downflow units.
This design reduces the discharge pressure drop and under-floor noise levels. It can be used to discharge air to the rear of the units, as an alternative to the normal front-supply arrangement.
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Technical Manual
Fresh Air Modulating Section
This is a 0 to 100% modulating fresh air mixing section. Either as a header (downflow) or a base plinth (upflow), the section utilises outside air, where possible, to condition the room. This optimises unit efficiency, reducing compressor loads by up to 60 % over a year. The fresh-air control facility (refer to Economy Cooling Options on page 2-19 and Economy Cooling Options on page 4-19 of Section 4) senses outside air temperature and internal temperature / humidity levels and responds by modulating the fresh air damper to keep the room air at the required condition.
When room air is evaluated as heading away from being at the required condition, the fresh air facility is inhibited by closure of the inlet damper. Each section is supplied complete with coarse grade, F2 pre-filters.
High-efficiency Filter Section

The high-efficiency filter section, which should be connected to the outlet section IPAC unit, contains standard size, 300 mm deep pleated front withdrawal panel filters to F5, F6, F7 or F8 specification. The high-efficiency filter section is made from a 450 mm filter section and a 250 mm spacer plenum section.
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Eaton-Williams
IPAC
IPAC
IPAC
SECTION 3
INVICTANET CONTROLLER USER MANUAL

Introduction Description Graphical Display and Keypad
Screen Navigation System Screen (default) Status Screen Alarm Screen Graphical Display Symbols and Icons Status Indicator LEDs
Page
33 33 34
34 35 36 37 38 39
Text Screens
Setup Menu Logon Status Menu (for information-only) Parameters (for settings adjustment) Historic Log
3 10
3 10 3 10 3 10 3 10 3 10
Using Text Screens

Controller Settings Differential Settings Historic Log
3 10
3 11 3 12 3 12
Alarms
Urgent alarm Non-urgent alarm Alarms remote monitoring
3 15
3 15 3 15 3 15
Identifying and Clearing Alarms Emergency Shutdown Fire Shutdown Troubleshooting
3 15 3 15 3 15 3 17
IPAC
IPAC
INVICTANET Controller User Manual
Page 3-2
IPAC
INVICTANET Controller User Manual Introduction
The purpose of this document is to describe functionality and adjustments that are available to a user of an Eaton-Williams InvictaNET air handling unit controller. Information provided here is intended for guidance only and is not exhaustive. Full details of the controller can be found in the Section 4 - INVICTANET CONTROLLER TECHNICAL MANUAL. Any queries or points of uncertainty should be referred to EatonWilliams or their representative.
Description
The Eaton-Williams AHU controller has been specifically designed to operate IPAC range units to provide air conditioning of rooms/areas of a building where a precision air-controlled environment is required. Depending on the unit(s) and options installed, the following control functions may be available: Cooling only Temperature control (heating option must be installed) Air Condition (heating and humidifier options must be installed) The user interface is described under: Graphical Display and Keypad on page 4 Text Screens on page 10 Using Text Screens on page 10 On powering-up the controller, the display appears similar to as shown in Fig. 3-1.
CAUTION
Only authorised personnel should be permitted to operate the controller. Do not attempt to operate the controller unless it has been commissioned fully, otherwise damage may result. Before operating the controller, the information provided here must be read fully and clearly understood. Failure to operate the controller properly can affect plant performance and may result in damage to any equipment that relies on unit operation. The information provided assumes that the display / keypad option has been fitted and that the air conditioning system and controller(s) have been fully commissioned and is either ready for operation or already operating.
Fig. 3-1 : Graphical display and keypad
Graphical Display and Keypad
POWER ON
Status Indicator LEDs Graphical Display Area Colours and state (flashing or steady) indicate overall system status
AHU STATUS
HUM STATUS
ESC Button
OK
ESC
To return to the System (default) screen
Arrow Buttons For navigation and value adjustment
OK Button To enter or accept the displayed value or command. To make audible alarm.
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IPAC
INVICTANET Controller User Manual Graphical Display and Keypad
The combined display and keypad, illustrated in Fig. 3-1, is used for adjustment of settings and interrogation of the controller. The EW logo (or optional customised logo) is displayed briefly during initialisation and whenever the unit is in standby mode.
Screen Navigation
Navigation of display screens is as shown in Fig. 3-2. By pressing the appropriate arrow buttons on the keypad, the required screen can be displayed. Note that by pressing and arrow buttons simultaneously, at any time, the Setup / Logon / Status screen and subsequent text-only screens can be accessed.
Fig. 3-2 : Graphical display screen navigation
Graphical Display Screen Navigation

scroll to Status Screen
a l a r m :1 2 3 1 2 1. 2.
Alarm Screen
ahu 5 . 4
20.6C 41 % 23.5C
Logo Screen shown during initialisation or when in standby mode System Screen
setup logon status

Main Menu Screen to logon or
status 1 2 3 :1. 2. 1 2 1. 2.
to scroll menu
Status Screen
scroll to Alarm Screen
Press
ESC at any time to return to the System Screen and to log off as a user.
Page 3-4
IPAC
System Screen (default)
The System Screen screen provides an overview of system status and is always displayed (after the EW logo screen) following power-up and initialisation of the controller / network.
Fig. 3-3 : System screen (default - typical shown)
The System Screen is the default screen display and can be accessed at any time, by pressing the ESC escape button. Note that, for quick reference, pressing and holding down the OK OK button will display the set point temperature and humidity values in place of sensed actual values.
System Screen (default - typical)
Alarm indicator (shown only when active) - urgent alarm shown A non-urgent alarm appears as System operational
invictanet
Demand percentage indicators Room / space temperature and relative humidity
20.6C 41 %
Auxiliary temperature indicator *
23.5C
Temperature demand Humidity demand
NOTE: Auxiliary temperature indicator is only shown when an economy cooling option is used. For glycol economy cooling, the glycol / water temperature is shown. For fresh-air cooling, outside ambient temperature is shown.
Document 0410536
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IPAC
Status Screen
Each unit in a network has its own Status screen. By default, the Status screen for the unit to which the controller is fitted is displayed first; i.e. if the controller is fitted to network unit No. 3, the status screen for unit 3 is displayed. The exception to the above is in the case of an alarm, when the controller behaves intuitively: If an alarm is present, the Status screen for the unit having the alarm will be displayed first. If there is an alarm on more than one unit, the Status screen for the unit having the first alarm is displayed first. The system number is reversed-out (green on black) to indicate which units Status screen is currently being displayed. To navigate to the Status screen of any other unit on the network, press either the or arrow button, as appropriate. Plant items are represented by icons, which animate to indicate operation. The full range of icons is detailed under . For units fitted with two of the same type of plant (e.g. two compressors), these are identified by numbers; i.e. 1 or 2.
Fig. 3-4 : Status screen (typical)
Status Screen (typical)
Special information displayed for network units only

System numbers of all other AHUs (up to 9) connected in the network. The number which flashes identifies the unit you are in front of.
Reversed-out (green on black) number identifies the unit to which the currently displayed Status screen refers.
123
Dot identifies the Master unit of a network.
Underline identifies any other units which are operating in the network.
Status screen identifier
status -1 2 3 :
1. 2. 1 2 1. 2.
Heater status (when operating, flame icons flash)
Plant item identification numbers (within a unit)
1.
Humidifier status shown here operating (vapour rising) Flow control valve or damper status shown here as closed
Fan status shown here as operating (animated rotation)
Compressor status shown here as not operating (no animated flow arrow)
Page 3-6
IPAC
Alarm Screen
If an alarm is present, the appropriate plant icon is reversed-out as illustrated in Fig. 3-5, which shows a compressor 1 alarm on the Alarm Screen for AHU 1. If there is an alarm present on any other unit, the number of the affected unit(s) will be underlined to indicate this, as shown under unit number 3 in Fig. 3-5. To navigate to the status screen of any other unit on a network, press either the or arrow button, as appropriate. Note that if a standby unit is not powered-up, this is considered to be a fault condition (because it is unavailable for operation) and the alarm screen will display a question mark, ? in the centre of the alarm screen for that unit.
Fig. 3-5 : Alarm screen showing a compressor alarm condition (typical)
Alarm Screen Showing a Compressor Alarm Condition (Typical)
Special information displayed for network units only

System numbers of all other AHUs (up to 9) connected in the network. The number which flashes identifies the unit you are in front of.
Reversed-out (green on black) number identifies the unit to which the currently displayed Alarm screen refers.
123
Dot identifies the Master unit of a network.
Underline identifies any other units which are operating in the network.
Alarm screen identifier
alarm:- 2 3 1
1 2 1. 2.
Plant item identification numbers (within a unit)
Compressor 1 shown in alarm icon reversed-out (green on black)
Document 0410536
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IPAC
Graphical Display Symbols and Icons
Symbols that may appear in the graphical display are shown in Table 3-1, together with names and definitions.
Table 3-1 : Graphical display icons and symbols
Graphical Display Icons and Symbols

Icon Name Demand Percentage Indicator Cooling Demand N/A Icon animates to show growth from the centre of the snowflake. N/A Icon animates to show the percentage bar fill rising or falling according to demand. Symbol Animated Alarm Comments
Heating Demand
N/A
Icon animates to show radiant lines from the sun.
Dehum. Demand Humidification Demand Fan

1. 1.
N/A
Icon animates to show droplets falling from the bottom of the half-snowflake. Icon animates to show steam rising from the surface of the liquid. Fan icon rotates to indicate running status. On status or alarm screens, the number, 1 or 2, identifies the fan within the unit. Arrow animates to indicate running status. On status or alarm screens, the number, 1 or 2, identifies the compressor within the unit. Icon animates to show flames rising. On the unit status screen, the number, 1 or 2, identifies the heater within the unit. Alarm icon indicates that the water detection device is in the tripped state. Alarm icon indicates that air filters are clogged and require servicing. Displayed whenever an urgent alarm is present. Icon animates to show the bell ringing. Displayed whenever a non-urgent alarm is present. This icon does not animate. Shows the state of the flow control valve or mixing damper closed, modulating or open. On the unit status screen, the number, 1 or 2, identifies the valve or damper within the unit. Shows detected room air temperature and relative humidity. Icon flash reverses-out during temperature or humidity alarm. May also show outside ambient air temperature (outside the building icon), if option is utilised.
1.
Compressor
1 1 1
Heater Demand Flood Alarm

1. 1. 1.
N/A
Air Filter
N/A
Urgent Alarm
Non-urgent Alarm Flow Control Valve or Mixing Damper Room temp., RH and outside ambient temperature
N/A
N/A
1.
1.
1.
closed
modulating
open
20.6C 41 %
23.5C
27.4C 54%
Page 3-8
IPAC
Status Indicator LEDs
Three keypad-mounted LEDs provide indication of the condition of the unit. Table 3-2 shows the meaning of each LED state.
Table 3-2 : Status indicator LED definitions
Status Indicator LED Definitions

LED State Power Status LED Off Red continuously Power supply is not live to the controller. Power supply is live to the controller. AHU and Humidifier Status LEDs Both Together Red/Amber flashing for 1 second periods Red/Amber/Green flashing for 1 second periods Controller has entered site setup mode, which must be completed before the unit can be operated. Controller is unconfigured - Engineer required. AHU Status LED Off Red continuously Red flashing for 1 second periods Amber continuously Amber flashing for 1 second periods Amber flashing for 2 second periods Green continuously Green flashing for 1 second periods Green flashing for 2 second periods Amber/Green flashing for 1 second periods Amber/Green flashing for 2 second periods Red/Amber flashing for 1 second periods AHU is inoperative: Load shed input active, no 24 V ac supply, or humidifier control switch in OFF position. AHU running under normal control to meet demand. AHU idle (no demand) or in standby mode. HT cut-out tripped alarm on master or slave AHU. Compressor 1 fault alarm: HP cut-out, LP cut-out, or motor overload tripped. Compressor 2 fault alarm: HP cut-out, LP cut-out, or motor overload tripped. Condensate flood alarm. Air filter blocked alarm on master unit 1. Air filter blocked alarm on master unit 2. Supply airflow fault alarm on master unit 1. Supply airflow fault alarm on master unit 2. AHU operating at full output on manual override. Humidifier Status LED Off Red continuously Red flashing for 1 second periods Amber continuously Amber flashing for 1 second periods Amber flashing for 2 second periods Green flashing for 1 second periods Green flashing for 2 second periods Green continuously Red/Amber flashing for 1 second periods Humidifier is inoperative: Load shed input active, no 24 V ac supply, or humidifier control switch is in the OFF position. Humidifier operating under normal control to meet demand. Humidifier idle (no demand) or in standby mode. Condensate flood alarm. Water supply fault to humidifier fault alarm. Over-current high fault alarm. Humidifier operation stopped. Service interval expired alarm. Automatic service routine in progress. Automatic service routine completed. Humidifier operating at full output on manual override. Definition
Document 0410536
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IPAC
INVICTANET Controller User Manual Text Screens
For users, the following menu levels are accessible: Setup (set-up level) Logon (password logon level) Status (information-only level) Parameters (setting adjustment and historic log level) The menu tree structure of text screens is outlined in Fig. 3-9 on page 11, while the purpose of each level is described below.
Historic Log
This menu level enables a user to view the alarm history of a unit. The history log shows date, time and type-of-event information; for details see . A password is required to view this menu item.
Using Text Screens

The basic principles of accessing and using the text features of the graphical display are described below. By following these principles, a user will quickly become familiar with operating the keypad to access required menus, information and settings. Fig. 3-9 on page 11 shows the Text-only screens tree structure outline. 1. At any time, press the and arrow buttons simultaneously to display the Main Menu screen.
Fig. 3-6 : Main menu screen
Setup Menu
This menu level should not be adjusted by users, as it is used to attach slave modules to the system, configure a network, initiate run/standby group control and enter fundamental configuration settings.
CAUTION
Use of the Setup menu is a commissioning and servicing function and is not be altered by users. Unauthorised alterations made under the Setup menu can severely disrupt plant operation. Use of the Setup level, by authorised personnel, is described in the INVICTANET CONTROLLER TECHNICAL MANUAL.
ahu 5 . 4
setup logon status

View-only data can now be accessed by using the arrow buttons to select Status or Parameters and to navigate. Alternatively, to change a setting value, view the historic log, or accept and clear an alarm, proceed as follows. 2. With logon selected, press OK to enter the logon password screen, as shown in Fig. 3-7.
Fig. 3-7 : Logon password screen
Logon
This is used to logon for access to password-protected controller functions, settings adjustment and the historic log. The user level password is 4602 The logon procedure is described under - Using Text Screens on page 10. Non-user levels of access and adjustment, such as those at Service level, are also password-protected and are described in the INVICTANET Controller User Manual.
Status Menu (for information-only)

This information-only menu level provides the user with information about prevailing conditions and enables viewingonly of certain control settings and the historical data log, as listed in Table 3-3 on page 13.
Parameters (for settings adjustment)

This menu level enables changes to be made to controller settings.
logon password 0000

3. Key in user level password 4602 by using the and
CAUTION
Applying inappropriate setting values for prolonged periods can adversely affect room air condition and may result in damage to any environment-sensitive equipment that relies on unit operation. Access to this menu level should only be entrusted to personnel who are competent in process control of air handling units. Settings are listed in Table 3-4 on page 14.
arrow buttons to adjust the value of each digit; see Fig. 3-8 on page 11. The currently adjustable digit is reversed-out (green on black). Enter the completed password by pressing
OK
OK.
Page 3-10
IPAC
Fig. 3-8 : Keying in the password
logon password 4602

Fig. 3-9 : Text-only screens tree structure outline
Provided that the password entered is correct, the Main Menu screen will be displayed again (with user level password permissions enabled), otherwise, the Invalid Password message will be displayed. 4. 5. Use the required. arrow buttons to navigate as
To terminate a logon session, press the ESC escape button to return to the System screen. Once the System screen has been returned to, it is necessary to logon again before settings can be adjusted,
Text-only Screens Tree Structure Outline
Press + to enter text screens at any time after powering-up and initialisation
Colour Key to Password-based Access User level Service level Engineering (E-W authorised)
1 Setup 2 Logon 3 Status (4) Service Sub-menu 4 (5) Parameters (6) Engineering 5 (7) Historic Log AHU1 4-2 AHU2 4-3 AHU3 Low Temp Diff 4-0-5 High RH Diff Etc. for up to ten AHU's High Temp Diff 4-0-4 System 4-1 RH Setpoint 4-0-3 4-0 Sub-sub-menu 4-0-1 Temp Setpoint 4-0-2 Enter Password
User = 4602
NOTE: Screen numbers in brackets are applied under Service and Engineering password access Tree structure shown down to Setting level
Setting
4-0-6 etc.
Controller Settings
Controller settings are configured during commissioning, to obtain optimum performance. NOTE There are two types of settings - System and AHU:
System settings apply to all AHUs in a network AHU settings apply only to individual AHUs
Document 0410536
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IPAC
This means that networked AHUs are able to run independently, as required; for example, if the Master unit controller is off-line for any reason, or if zone control is required. Any adjustment to setting values should be recorded, together with the date changed. It is recommended that a copy of each appropriate settings record is kept with the plant log book. Having this information to hand will keep any down time period to a minimum, should controller settings need to be input again. Always keep the settings record up to date and in a safe place, preferably with the unit log record. For a complete listing of adjustable settings available at user level, refer to Table 3-4 on page 14. Note that settings cannot be adjusted at Status menu level, which is view-only for information. Differential Settings While the majority settings are self-explanatory, it is worth detailing how differential setting values are determined. The following examples are provided for guidance. Example 1: This example is for the Room High Temperature Alarm setting, which determines at which temperature the high temperature alarm is generated. If the Room Temperature set point value is 20 C and the HT alarm is required to be set at 25 C, the calculation to determine the setting value is: 25 C minus 20 C = 5 C Therefore: Room High Temperature Alarm setting value = 5.00 Example 2: This example is for the Room Low Temperature Alarm setting, which determines at which temperature the low temperature alarm is generated. If the Room Temperature set point value is 20 C and the LT alarm is required to be set at 17 C, the calculation to determine the setting value is: 20 C minus 17 C = 3 C Therefore: Room Low Temperature Alarm setting value = 3.00 By using this method, positive and negative value offsets from set points can be determined for any differential setting. Each event is allocated a number and this, together with the total number of events logged, is shown to the right in the first line of text. Therefore, in the example screens shown in Fig. 3-10 and Fig. 3-11 on page 12, the number 11-11 indicates that this is alarm event eleven of eleven events (i.e. the most recent event in the history log). The first line shows that the screen information relates to either when the alarm was active (first generated), as in Fig. 3-10, or was cleared, as in Fig. 3-11. NOTE The term activated does not mean that the alarm event still exists, but only that it was originally generated at the date and time shown. If a particular alarm has been cleared, as described under , there will be a corresponding cleared event screen of a later date for the same alarm condition. The second line, shows the date DD-MM-YY and time, hour : minute : second. The third line identifies the AHU number. The fourth line identifies the plant item and the nature of the alarm (e.g. high temperature) indicates that air handling unit No. 1 has an air high temperature condition (i.e. air temperature is excessive and has reached or exceeded the Room High Temperature Alarm set point.
Fig. 3-10 : Historic log of an activated alarm
active ahu 1 high temp
11-11
22-09-03 17:50:21
Fig. 3-11 : Historic log of a cleared alarm
cleared ahu 1 high temp
11-11
22-09-03 17:55:31
Historic Log
The log provides a list of up to approximately forty alarm events (determined by available memory). To view the historic log, it is necessary to logon as described under . The historic log is then shown in the Main Menu. On entering the history alarm log, the latest occurring event is shown first. Use the arrow button to scroll the display to earlier events in descending chronological order.
Page 3-12
IPAC
Table 3-3 : Status menu points list
Status Menu Points List

SYSTEM POINTS Point No. (Screen) 3-0-1 3-0-2 3-0-3 3-0-4 Screen Text temperature rel humidity temp demand rh demand Room temperature (sensed actual) Room relative humidity (sensed actual) Cooling or heating demand (where = cooling, + = heating) Humidification or dehum. demand ( = dehum, + = hum ) AHU NOS. 1 TO 10 POINTS Point No. 3-x-1 3-x-2 3-x-3 3-x-4 3-x-5 3-x-6 3-x-7 3-x-8 3-x-9 3-x-10 3-x-11 3-x-12 3-x-13 3-x-13-1 3-x-13-2 3-x-13-3 3-x-13-4 3-x-13-5 3-x-13-6 3-x-13-7 3-x-13-8 3-x-13-9 3-x-13-10 3-x-14 3-x-15a 3-x-16a 3-x-17a 3-x-18a 3-x-19
NOTE a.
Description
Units C % RH % %
Screen Text ahu mode vap mode temperature rel humidity temp demand rh demand free cool temp air on-coil temp free cool demand unit run hours vapac run hours comp run hours factory setup ahu config index free cooling led operation heater control vapac fitted max current cylinder o/p num electrodes num of turns cylinder size sw version digital io analogue ips resistive ips analogue ops current
Description AHU operating mode (online or standby) Humidifier operating mode (online or standby) Room temperature (sensed actual) Room relative humidity (sensed actual) Cooling or heating demand (where = cooling, + = heating) Humidification or dehum. demand ( = dehum, + = hum ) Temperature of economy cooling medium Temperature of air sensed before entering the coil Economy cooling demand Accumulated hours run of each unit module Accumulated hours run of the Vapac unit Accumulated hours run of each compressor in a unit Factory set-up sub-menu (comprising points 3-x-13-1 to 3-x-13-8) Configuration index number (two digits) of the unit Whether economy cooling function is implemented LED regional operating mode; e.g. eu for European mode Heating control mode Whether a Vapac unit is fitted Maximum operating current configuration of the Vapac unit Rated output of the Vapac cylinder Number of heating electrodes fitted to the Vapac unit Number of turns of the torod sensor winding Humidifier cylinder size (rated 5, 9, or 18) Software version current installed in the controller Digital Input (0 = Open, 1 = Closed) DI1 - DI9 24v Digital Output (0 = Inactive, 1 = Active) DO1 - DO10 Daughter Board Digital IO (as above) DI11 - DI15 DO11 - DO15 Analogue Inputs Resistive Inputs Analogue Outputs AI1 - AI4 AI5 - AI8 AO1 - AO4 Amps number yes / no Amps kg/hr number number number xx active / C % RH % % C C % hrs hrs hrs
Measured current being drawn by the humidifier
x shown in a point / screen number represents the designated number of an AHU on a network. For further information, please seeInput
/ Output Schedule on page 4-29 of Section 4
Document 0410536
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IPAC
Table 3-4 : Settings list (user level)
Settings List (User Level)

User password = 4602 SYSTEM SETTINGS Setting (Screen) 4-0-1 4-0-2 4-0-3 4-0-4 4-0-5 4-0-6 Screen Text temp setpoint rh setpoint high temp diff low temp diff high rh diff low rh diff Setting Room temperature set point Room humidity set point Room high temperature alarm differential from room temperature set point 4-0-1 Room low temperature alarm differential from room temperature set point 4-0-1 Room high humidity alarm differential from room humidity set point 4-0-2 Room low humidity alarm differential from room humidity set point 4-0-2 Date and time real-time clock setting adjustment DD-MM-YY HH:MM:SS Dehumidification override control enables/disables implementation of Dehum. override temperature differential setting 4-0-9 Dehumidification override temperature differential differential from room temperature setting 4-0-1 Inhibits dehumidification if temperature is low, to prevent overcooling. AHU SETTINGS Setting (Screen) 4-x-1 4-x-2 4-x-3 4-x-4 4-x-5 4-x-6 4-x-7 4-x-8
NOTE
Range Min. 0 5 0 0 0 0 Max. 39 95 10 10 10 10
Default 22 50 10 10 10 10
Units C % RH C C % RH % RH
4-0-7
date . time
4-0-8
dehum o/r
enable
disable
enable
4-0-9
dehum o/r
40
Screen Text temp setpoint rh setpoint high temp diff low temp diff high rh diff low rh diff man o/r reset input voltage
Setting Room temperature set point Room humidity set point Room high temperature alarm differential from room temperature set point 4-0-1 Room low temperature alarm differential from room temperature set point 4-0-1 Room high humidity alarm differential from room humidity set point 4-0-2 Room low humidity alarm differential from room humidity set point 4-0-2 Manual override reset control AHU manual override reset control setting enable or disable Specified input voltage to the AHU i.e. 380 V ac, 415 V ac, or 440 V ac
Range Min. 0 5 0 0 0 0 enable 380 Max. 39 95 10 10 10 10 disable 440
Default 22 50 10 10 10 10 enable 440
Units C % RH C C % RH % RH Volts
x shown in a point / screen number represents the designated number of an AHU on a network.
Page 3-14
IPAC
INVICTANET Controller User Manual Alarms
The controller monitors for various fault conditions according to configuration and signal inputs. In response to a detected fault condition, controller generates one of two types of alarm, namely, an urgent alarm, or a nonurgent alarm. These are defined as follows:
Alarms remote monitoring

Urgent and non-urgent alarm conditions may be monitored remotely; refer to the INVICTANET CONTROLLER TECHNICAL MANUAL .
Identifying and Clearing Alarms

Assuming that a fault condition has arisen, adopt the procedure described in Fig. 3-14 to identify and then, after the cause has been corrected, clear the alarm.
Urgent alarm
(animated bell icon) An urgent alarm (see Fig. 3-12) is generated in response to a fault condition which prevents unit operation; e.g. Airflow Failure alarm.
CAUTION
Some fault conditions, such as temperature or pressure trips, will seem to rectify themselves as conditions return to normal when the unit stops operating. DO NOT reset the controls and restart the unit without first identifying and rectifying the cause of the fault. Repeatedly resetting and restarting can damage the unit and may invalidate any warranty.
Fig. 3-12 : System screen urgent alarm
invictanet
20.6C 41 %
WARNING
23.5C
The cause of an urgent alarm requires immediate action to correct the fault condition before the unit can restart. Any control function that is unaffected by the fault will continue to be operative. (static icon, reversed-out icon) A non-urgent alarm (see Fig. 3-13) is generated in response to a fault condition, which requires attention, but does not immediately prevent a unit from operating. Note that if the building icon is flashing reversed-out (Fig. 3-13), the alarm relates to air temperature, humidity, or both.
Fig. 3-13 : System screen non-urgent alarm
Non-urgent alarm
Fault investigations, diagnosis and remedial actions that necessitate opening up the unit cabinet can involve potentially hazardous procedures and must only be undertaken by properly trained and authorised personnel. When all alarms have been cleared, the controller will resume normal operation and restart the unit, provided that no faults exists. Note that compressor restarting may be subject to its Starts Per Hour Limiting Time setting; refer to the INVICTANET CONTROLLER TECHNICAL MANUAL for details. If the fault condition still exists, the controller will detect this during its next data scan cycle and will indicate the same fault again.
invictanet
Emergency Shutdown
CAUTION
27.4C 54%
24C
The cause of a non-urgent alarm should be attended to at the earliest opportunity, otherwise, if ignored, a more serious fault can develop, resulting in an urgent alarm, which prevents unit operation. Example: If a blocked filter alarm is ignored and the filter continues to clog-up, an airflow failure fault will ultimately stop the plant and generate an urgent alarm, perhaps at critical moment.
In an emergency, do NOT attempt to use controller functions to shutdown equipment, as this will initiate a controlled shutdown that is unlikely to be effective immediately. If an external Emergency Stop button is fitted (as recommended), pressing this will interrupt the power supply to the controller and stop the plant (including paired slave, if fitted) immediately
Fire Shutdown
If a fire shutdown remote switching device is fitted (and interlocked as recommended), when triggered, it will interrupt the power supply to the controller and stop the plant (including paired module, if fitted) immediately.
Document 0410536
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IPAC
Fig. 3-14 : Identifying and clearing alarms
Identifying and Clearing Alarms

invictanet
Alarm condition reported on the System screen.
20.6C 41 %
23.5C
IDENTIFY AND CORRECT THE CAUSE
1 2
Press to view the Alarm screen and identify affected plant item. In this case - compressor 1 of unit 1.
alarm:- 1 2 3
1 2 1. 2.
Press + to enter the Main Menu screen.
ahu 5 . 4
setup logon status !! alarm !!

ahu 1 compressor hp module 1
Alarm Detail screen is shown automatically when data next refreshes (a few seconds). Press OK to return to the Main Menu.
3
CLEAR THE ALARM
Investigate and rectify the cause of the reported fault condition before proceeding to clear the alarm.
4 5
If necessary, repeat step 2 to view the Main Menu screen. Press OK to view the Logon screen.
logon password 0000 logon password 4602

!! alarm !!
ahu 1 compressor hp module 1
invictanet
Press password 4602.
to key in user
Press OK to enter the password. The Main Menu screen is displayed again during a data refresh period (a few seconds). The Alarm Detail screen is then displayed automatically.
6 7
Press OK to clear the alarm. Press ESC to return to the System Screen. Normal operation should now resume.
20.6C 41 %
23.5C
NOTE If the cause of the alarm has not been eliminated, the alarm condition will be reported again, when data next refreshes.
Page 3-16
IPAC
INVICTANET Controller User Manual Troubleshooting
Table 3-5 : Troubleshooting guide
Troubleshooting Guide
DISPLAY PROBLEM Condition Reason / Remedial Action The controller has been designed to be robust and reliable in operation. However, communications faults or interruptions can, in certain circumstances, corrupt the display. If the display is suspected of not functioning normally, power to the affected unit(s) should be switched OFF to power-down the controller for a period of 30 seconds, before switching it back ON. On restoration of power, the controller and display should re-initialise and operate normally. If the problem recurs and causes a nuisance, the communications wiring and connections should be checked for integrity by and Engineer. AHU NOT OPERATING Condition / Consideration Reason / Remedial Action Check that any external interlocks, (such as Fire Shutdown and Emergency Shutdown on page 15, are in a healthy state. Note that if the fire shutdown facility is utilised, the display will continue to function after the fire shutdown device is triggered. Therefore the display being live does not mean that the controller power supply is healthy. Check that the unit operating mode is healthy. Do this by interrogating the controller: Is power available to the controller? Unhealthy = Healthy = AHU online - see Status | AHU x | Ahu mode AHU standby - see Status | AHU x | Ahu mode an alarm exists; e.g. Comp 1 HP Shutdown, where either the Remote Start/Stop or the Fire Shutdown are OFF - see Status | AHU x | Ahu mode Not configured - this message means an engineer is required to re-configure the unit/network setup
Display corruption
Is there a demand?
Check that there is truly a demand. For example, if demand has been satisfied, the controller will not initiate the unit process (cooling, heating, humidification or dehumidification) to operate. Check that demand exists by viewing the Status screen (see Status Screen on page 6), which shows demand and percentage indicators, and by interrogating System Status points 3-1-4 or 3-1-5 as appropriate; see Table 3-3 on page 13.
If demand is present (see above), but the appropriate process is not operating, a normal delay time may be in effect. If system status points 3-0-3 and 3-0-4 show no demand and this is unexpected, check temperature set point 4-0-1 or 4-0-2 (humidity) and compare this to the actual measured value shown for status point 3-0-1 (temperature) or 3-0-2 (humidity), as appropriate. Demand exists, Remember to take into account: Dead band control settings but the unit is Override controls idle Compressor starts per hour limiting External interlocks (if fitted) are in a healthy state; such as Fire Shutdown on page 15 and Emergency Shutdown on page 15. Refer to the INVICTANET CONTROLLER TECHNICAL MANUAL for details. AHU NOT OPERATING Condition / Consideration Reason / Remedial Action
A unit in standby mode will only operate to take over the duty of another unit that becomes unavailable, or when due to take over Is the AHU idle according to run/standby rotation control settings. in standby On the Status > AHU menu, check AHU operating mode point 3-x-1, or humidifier operating mode point 3-x-2 for the humidifier mode? (where x is the AHUs system number on the network), as appropriate; see Table 3-3. The unit process will only be operative if status is shown as online.
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IPAC
Page 3-18
Eaton-Williams
IPAC
IPAC
SECTION 4
INVICTANET CONTROLLER TECHNICAL MANUAL
IPAC

Introduction Description
User Interface Passwords Servicing and Maintenance Facility Engineering Level Information Setup
Page
44 45
45 45 45 45 4 12
Control Functions
Power-up condition Starting and operation - basic overview Temperature and Humidity PID control Humidity PID control
4 13
4 14 4 14 4 14 4 14
Compressor and Condenser - Starting Operation

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

Built-in Hysteresis
4 16
4 16
Chilled Water Unit Cooling Duty Control Economy Cooling Options

Fresh-Air Economy Cooling GlyCool Economy Cooling
4 18 4 19
4 19 4 19
Electrical Heating
Heating capacity control
4 19
4 20
Humidifier Control Dehumidification Control

Cooling control override
4 20 4 21
4 21
Commissioning Network Master / Slave Control

Duty Rotation
4 21 4 21
4 21
Local Networking System Networking

External Interface Protocol
4 21 4 22
4 22
Page 4-2
IPAC
ModBus Network Interface Trend Controller Trend Network Interface ( <5 Units ) Alternative Language (ASCII)
4 22 4 22 4 22 4 22
Fault Conditions, Alarms and Response

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

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

Display Corruption AHU Not Operating
4 25 4 25 4 25
4 25 4 25
AHU Configuration Index Configuration Plug (early units) Input / Output Schedule External Interface Protocol
4 27 4 29 4 29 4 32
Document 0410536
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IPAC
INVICTANET CONTROLLER TECHNICAL MANUAL Introduction
The purpose of this section is to provide technical and commissioning information for an Eaton-Williams InvictaNET Controller for AHU (air handling units). Information provided here is intended for guidance only and is not exhaustive. This section should be read in conjunction with Section 3 - INVICTANET Controller User Manual and Section 5 INVICTANET Controller Settings Record. This section has been written assuming that the principles of using the controller, as described in the INVICTANET Controller User Manual, are understood.
Fig. 4-1 : Graphical display and keypad
Please note that this section here contains information appertaining to the Engineering level menu, which is only accessible by, or with permission of, Eaton-Williams personnel. This menu level enables access to and adjustment of low level settings, which are determined and configured by EatonWilliams prior to despatch. Information about the Engineering level is provided for reference only. Any queries or points of uncertainty should be referred to EatonWilliams or their representative.
Graphical Display and Keypad
POWER ON
Status Indicator LEDs Graphical Display Area Colours and state (flashing or steady) indicate overall system status
AHU STATUS
HUM STATUS
ESC Button
OK
ESC
To return to the System (default) screen
Arrow Buttons For navigation and value adjustment
OK Button To enter or accept the displayed value or command. To make audible alarm.
Page 4-4
IPAC
INVICTANET CONTROLLER TECHNICAL MANUAL Description
The Eaton-Williams AHU controller has been specifically designed to operate IPAC range units to provide air conditioning of room/areas of a building that require a precision air-controlled environment. Depending on the unit(s) and options installed, the following control functions may be available: Cooling only Temperature control (heating option must be installed) Air Condition (heating and humidifier options must be installed) Factory-set configuration modes of the controller allow the same hardware and software to be used throughout the IPAC range, whilst allowing each variation of combination of internal components to be optimally controlled for efficiency and close control. When on site, controllers can either be configured as stand-alone units, or be networked into a system of up to ten units, by using the units LONWORKS open protocol networking capabilities. For clarity, the following terminology and definitions are used: Network Master A unit/controller, either stand-alone, or in a system and configured (during commissioning) to be the Network Controller. Network Slave A unit/controller, in a system and configured (during commissioning) to be a slave of the Network Master; i.e. the unit receives its control from the Network Master, to ensure optimal control of a networked area. Should the network control signal fail, a Network Slave will return to stand-alone control, thereby ensuring that operation continues. Master Module / Primary Module Either a Network Master or any Network Slave unit, fitted with an InvictaNET controller. Slave Module / Secondary Module A unit containing mechanical components and local controls, but no InvictaNET controller. All components are controlled by the unit's matching Master Module. Therefore, a slave module is not seen by the LON Network.
Passwords
Passwords are provided for two menu levels: User level password = 4602 To enable adjustment of user level settings, viewing of the history log, and clearing of alarms; see Section 3 INVICTANET Controller User Manual. Service menu level password = 5699 For manual control and service functions; see Servicing and Maintenance Facility below. Site Setup menu level password = 1111 To access site network setup functions; see Setup on page 4-12.
CAUTION
Use of passwords must only be entrusted to authorised personnel. Eaton-Williams cannot be held responsible for any consequence of unauthorised use of passwords.
Servicing and Maintenance Facility

The Service level menu, accessed via password 5699, enables manual control and override functions to be implemented so that scheduled maintenance and servicing tasks can be carried out without needing to adjust and then restore user-defined and engineering-defined settings. Service level menu system settings are listed in Table 4-1.
Engineering Level Information

The Engineering level menu is only accessible by, or with permission of, Eaton-Williams personnel. This menu level enables access to and adjustment of low level settings, which are determined and configured by Eaton-Williams prior to despatch. To enable the controllers full functionality and control philosophy to be understood, all Engineering menu settings are shown in Table 4-2.
User Interface
The InvictaNET combined display and keypad, illustrated in Fig. 4-1, is fitted to all IPAC units. The display uses a backlit LCD screen and provides information and control facilities. The display offers a user-friendly interface, with the benefits of animation and icon representations of plant items, plus features such as historical alarm logging. For general information on using the graphical display / keypad, together with user-specific information refer to Section 3 INVICTANET Controller User Manual .
Document 0410536
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IPAC
Table 4-1 : Service level menu system settings
Service Level Menu Settings

Maintenance password* = 5699 AHU No. 1 (Master) through AHU Nos. 2 to 10 (Slaves) Setting (Screen) Maint. E-W Screen Text Setting AHU control selection Options are: Auto control Override ON - forces AHU to start Override OFF- forces AHU to stop / prevents starting Airflow failure override Options are: Auto control Override ON - inhibits shutdown caused by an airflow switch trip. Compressor 1 manual control selection Options are: Auto control Override ON - operates compressor continuously Compressor 1 hot gas injection selection Options are: Auto control Override ON - operates the hot gas valve to implement minimum capacity Compressor 2 manual control selection Options are: Auto control Override ON - operates compressor continuously Compressor 3 manual control selection Options are: Auto control Override ON - operates compressor continuously Heating stage 1 manual control selection Options are: Auto control Override ON - operates stage 1 heating continuously Heating stage 2 manual control selection Options are: Auto control Override ON - operates stage 1 heating continuously Heating stage 3 manual control selection Options are: Auto control Override ON - operates stage 1 heating continuously Heating stage 4 manual control selection Options are: Auto control* Override ON - operates stage 1 heating continuously Range Min. Max. Default
4-x-1
5-x-1
ahu manual
override off
override on
auto
4-x-2
5-x-2
air flow o/r
auto
override on
auto
4-x-3
5-x-3
compressor 1
auto
override on
auto
4-x-4
5-x-4
hot gas
auto
override on
auto
4-x-5
5-x-5
compressor 2
auto
override on
auto
4-x-6
5-x-6
compressor 3
auto
override on
auto
4-x-7
5-x-7
heater stage 1
auto
override on
auto
4-x-8
5-x-8
heater stage 2
auto
override on
auto
4-x-9
5-x-9
heater stage 3
auto
override on
auto
4-x-10
5-x-10
heater stage 4
auto
override on
auto
Page 4-6
IPAC
Table 4-1 : Service level menu system settings
Service Level Menu Settings

Maintenance password* = 5699 AHU No. 1 (Master) through AHU Nos. 2 to 10 (Slaves) Setting (Screen) Maint. E-W Screen Text Setting Economy cooling valve control Options are: 0 % - override OFF range from 1 % (minimum open) to 100 % (fully open) for minimum to maximum opening of the valve 101 % - operates forces the valve closed Humidifier control Options are: 0 % - override OFF range from 1 % (minimum output), to 100 % (maximum output) - for humidifier output control 101 % - operates the humidifier at maximum output continuously Humidifier manual drain2 Implements a manual drain cycle for the humidifier cylinder. Note that the humidifier status LED illuminates green continuously to indicate that the cycle is complete. Humidifier auto-flush2 Initiates a single automatic flush of the humidifier cylinder and its associated system pipework. Note that the humidifier status LED illuminates green continuously to indicate that the cycle is complete. Force unit run rotation Increments run / standby duty rotation of all units on a network. This function is only applicable to a network. Note that the final run / standby state will continue after completion of servicing. Range Min. Max. Default
4-x-11
5-x-11
free cool valve
0%
101 %
0%
4-x-12
5-x-12
vapac
0%
101 %
0%
4-x-13
5-x-13
manual drain
No (ESC)
Yes (OK)
4-x-14
5-x-14
auto flush
No (ESC)
Yes (OK)
4-x-15
5-x-15
force rotation
No (ESC)
Yes (OK)
NOTES
E-W settings are only to be accessed and adjusted by Eaton-Williams personnel or their authorised agents. User level password does not provide access to the Service level menu. x shown in a setting (screen) number represents the AHUs designated number on the system network. * Maintenance password also permits access to a limited number of Engineering menu settings; see Table 4-2.
Document 0410536
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IPAC
Table 4-2 : Engineering menu settings
Engineering Menu Settings

E-W password full access and Maintenance password 5699 part access (indicated by asterisk) only SYSTEM SETTINGS Setting (Screen) Screen Text Setting Sensor operation Specifies temperature / humidity sensor / data handling - options are: Average - for averaging of data from several sensors Individual - for individual sensor From master - for using only the Master units sensor data Number of run units Specifies the number of units allowed to run in the network at any time Duty rotation cycle period Hours between each rotation of duty for pairs of units Duty rotation time Time of day that duty rotation is executed for pairs of units; inhibit setting = 00:00 Run-on time at changeover Specifies the period that a unit due to go on standby unit is permitted to keep running, to eliminate any issues caused by start delays of the starting unit. Temperature deviation required to start standby unit Offset from the temperature set point that will initiate starting of the standby unit Standby run period The period that the standby unit is required to run after being started in response to setting 6-0-6 Urgent alarm output type Specifies the type of alarm signal - pulsed or continuous Non-urgent alarm output type Specifies the type of alarm signal - pulsed or continuous 0 10 00000 99999 00000 hours hours / mins. Range Min. Max. Default Units
*6-0-1
sensor operation
*6-0-2
num run units
*6-0-3
rotation period
*6-0-4
rotation time
00:00
24:00
00:00
*6-0-5
run on period
mins.
*6-0-6
standby temp
10
*6-0-7
standby period
240
mins.
*6-0-8 *6-0-9
level 1 alarm level 2 alarm
pulse pulse
cont. cont.
cont. cont.
*6-0-10
temp alarms
Temperature alarms display Specifies whether temperature alarms are shown automatically on dis-abled en-abled the display shown = enabled not shown = disabled Relative humidity alarms display Specifies whether RH alarms are shown automatically on the display shown = enabled not shown = disabled
en-abled
*6-0-11
rh alarms
dis-abled en-abled
en-abled
Page 4-8
IPAC

E-W password full access and Maintenance password 5699 part access (indicated by asterisk) only AHU SETTINGS Setting (Screen) 6-1-1 Screen Text Setting Manual override run period Duration of manual override (for service) before unit reverts to normal operation Set point source Specifies whether each unit controls to the system setpoint, or individual AHU values. - options are: System AHU Fan start delay time Delay period before fan starting is permitted, following unit start initialisation Temperature deadband value No PID control is applied while the temperature is within the deadband, which is an offset value from the temperature set point. Heating control loop menu Enters the heating PID control loop menu comprising the next three settings Heating proportional band value For PID control Heating integral time value For PID control Heating derivative time value For PID control Cooling control loop menu Enters the heating PID control loop menu comprising the next three settings Cooling proportional band value For PID control Cooling integral time value For PID control Cooling derivative time value For PID control Humidity deadband value No PID control is applied while RH is within the deadband, which is an offset value from the RH set point Humidification control loop menu Enters the humidification PID control loop menu comprising the next three settings Humidification proportional band value For PID control Humidification integral time value For PID control Range Min. 0 Max. 120 Default Units
man o/r period
60
mins.
6-1-2
setpoint source
AHU
6-1-3
fan start delay
300
secs.
6-1-4
temp d/b
10
6-1-5
heating loop
6-1-5-1 6-1-5-2 6-1-5-3
proportional i action i response
1 0 0
10 250 250
2 0 0
C mins. mins.
6-1-6
cooling loop
6-1-6-1 6-1-6-2 6-1-6-3
1 0 0
10 250 250
2 0 0
C mins. mins.
6-1-7
rh d/b
10
%RH
6-1-8
hum loop
6-1-8-1 6-1-8-2
proportional i action
1 0
10 250
3 0
% RH mins.
Document 0410536
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IPAC

E-W password full access and Maintenance password 5699 part access (indicated by asterisk) only AHU SETTINGS (continuation) Setting (Screen) 6-1-8-3 Screen Text i response Setting Humidification derivative time value For PID control Dehumidification control loop menu Enters the dehumidification PID control loop menu comprising the next three settings Dehumidification proportional band value For PID control Dehumidification integral time value For PID control Dehumidification derivative time value For PID control Compressor 1 control settings menu Enters the compressor control menu comprising the next five settings Compressor 1 start delay time Delay period, following start initiation, before the compressor is permitted to start Compressor 1 winter start delay time For problem-free starting during winter, when ambient temperature is low Compressor 1 starts per hour limiting Ensures that compressor starts per hour are limited to manufacturers recommendations Compressor 1 hot gas start delay time Delays hot gas implementation following compressor starting Compressor 2 control settings menu Enters the compressor control menu comprising the next five settings Compressor 2 start delay time Compressor 2 winter start delay time Compressor 2 starts per hour limiting Compressor 2 hot gas start delay time Compressor 3 control settings menu Enters the compressor control menu comprising the next five settings Compressor 3 start delay time Compressor 3 winter start delay time Compressor 3 starts per hour limiting Compressor 3 hot gas start delay time Compressor rotation period For equalisation of hours run between compressors Range Min. 0 Max. 250 Default 0 Units mins.
6-1-9
dehum loop
6-1-9-1 6-1-9-2 6-1-9-3
1 0 0
10 250 250
2 0 0
% RH mins. mins.
6-1-10
compressor 1
6-1-10-1
start delay
300
15
secs.
6-1-10-2
winter start dly
300
180
secs.
6-1-10-3
start to start
500
300
secs.
6-1-10-4
hot gas st dly
120
45
secs.
6-1-11 6-1-11-1 6-1-11-2 6-1-11-3 6-1-11-4 6-1-12 6-1-12-1 6-1-12-2 6-1-12-3 6-1-12-4 6-1-13
compressor 2 start delay winter start dly start to start hot gas st dly compressor 2 start delay winter start dly start to start hot gas st dly comp rotation
0 0 0 0 0 0 0 0 0
300 300 300 120 300 300 300 120 60100
15 180 180 45 15 180 180 45 -
secs. secs. secs. secs. secs. secs. secs. secs. hours
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IPAC

E-W password full access and Maintenance password 5699 part access (indicated by asterisk) only AHU SETTINGS (continuation) Setting (Screen) Screen Text Setting Economy cooling deadband value No PID control is applied while economy cooling medium temperature is within the deadband, which is an offset value from the room temperature set point Economy cooling proportional band value For proportional control Economy cooling inhibit %RH value For economy cooling override in favour of minimising the need to control humidity Heater start delay period Ensures that excessive temperature is avoided, by delaying heater operation until the airflow switch is deemed to be made (healthy) Humidifier start delay period Delays humidifier operation until the airflow switch is deemed to be made (healthy) Filter blocked alarm delay period Delays the filter blocked alarm from being reported Airflow failure alarm delay period Delays the airflow failure alarm from being reported Hours run counters reset Resets all counters to zero Range Min. Max. Default Units
6-1-14
free cool d/b
6-1-15
free cool prop
20
6-1-16
free cool inhibit
50
100
%RH
6-1-17
heater start dly
300
90
secs
6-1-18
vapac start dly
900
60
secs
6-1-19 6-1-20 6-1-21
filter block dy airflow period reset hours
240
mins. mins. -
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Setup
Setup menu settings, shown in Table 4-3, are normally factoryset and should not be adjusted at site unless a network configuration is being set up. Setup is carried out during installation and not normally altered thereafter. However, use of certain setup functions is occasionally necessary, to enable the following to actions be carried out: Run any units of a network as standalone units
Table 4-3 : Setup menu settings
Adding or removing units from a network Assign an alternative unit to be the Master in a network Assign or change run / standby arrangements Attach or unattach units of a network Breaking down a network to create zones of control, by creating additional Master units and assigning slave units to those zone Masters Reassigning slave units to alternative zones
Setup Menu Settings

Password not required Setting No. (Screen) 1-1 1-2 1-3 1-3-1 N/A Screen Text languages attach to unit site setup no. run units rotation period Description Languages - enables selection of the native language for text display Unit attachment - attaches the display to the controller motherboard; this requires the service pin on the motherboard PCB to be pressed. Setup unit - enables the next three items to be configured Number of run units - used to specify the number of units allowed to run in the network at any time, under normal conditions Run rotation period - used to specify the number of hours (up to 99999) before duty changeover, to equalise hours run between units Sensor operation - used to specify temperature / humidity sensor / data handling - options are: Average - for averaging of data from several sensors Individual - for individual sensor in each of all AHUs in the network From master - for using only the Master units sensor data AHU service message - executes the service message required to attach to the Master unit Network setup - enables attachment of units to make up a network Display reset - enables the display screen to be reset or refreshed Display type - used to specify whether the display is either local or remote (special option) Restores the controller to factory installed default settings System resynchronisation - enables resynchronisation of a slave units settings Enables logo selection for display splash screen during initialisation; i.e. InvictaNET or EW
N/A
sensor operation
1-4 1-5 1-6 1-7 (1-10) (1-7) (1-8) (1-9)

NOTE
ahu serv. msg network setup reset display display type factory defaults resync system select logo
Setting numbers in brackets are accessed by using the E-W password and are provided here for information only.
The setup procedure descriptions which follow are provided for information: To prevent inadvertent changes from being made, the message are you sure? is displayed whenever appropriate. Only clear this message by pressing OK if certain that changes being made are correct, otherwise press ESC .
CAUTION
Whenever making any changes under the Setup menu, always continue through to the finish; i.e. do not attempt to backtrack or press ESC (except in response to are you sure), otherwise corruption can result. For the same reason, do not interrupt power to the controller while making changes under the Setup menu.
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If ESC is pressed inadvertently, or power is interrupted, to rectify any corruption, it may be necessary to setup the controller / network from first principles. After making any changes under the Setup menu, always complete the process by executing the Reset Display command from the Setup Menu, for each unit in the network. This synchronises displays with controllers. Displays that are not synchronised do not show up-to-date information and can cause confusion. Note that interrupting power to a controller will not reset or synchronise the display after changes have been made under the Setup menu. Setting 1-1 Languages This is used to select the native language for the text-only display, as follows: 1. 2. Select the required language (e.g.) and then press Press
ESC OK
Setting 1-4 AHU service message With this selected, press OK .to provide the service message required to attach the unit to a network Master unit. Setting 1-5 Network setup When executed by pressing OK , this command instructs the controller to expect a service message (see ) from a slave unit, to create, or add to, a network. Setting 1-6 Reset display With this selected, press OK .to refresh the display. NOTE After carrying out any operations under the Setup menu, it is important to reset the display of each unit in a network, otherwise, the display may not reflect changes made. The Reset Display function is also useful to refresh the display in the unlikely event that it has become corrupted for any reason. Setting 1-7 Display type This is used to specify the type of display, according to installation preference. Options are: Local - for unit-based display (standard) Remote - for off-unit display, enabling remote monitoring Note that via the E-W password logon, the screen number for this setting is 1-10. Setting 1-7 Factory defaults Executing this command restores the controller to factory default setting values. Note that this setting is only available via the E-W password logon. Setting 1-8 Resync system This is command is used to synchronise a network slave unit to the system settings configured on the Master unit. Note that this setting is only available via the E-W password logon. Setting 1-9 Select logo This setting enables the logo to be specified for the splash screen displayed during initialisation; i.e. InvictaNET or EW. Note that this setting is only available via the E-W password logon.
to implement the choice and exit the menu.
Setting 1-2 Attach to unit This is used to attach, in software, the display to the mother board, as follows: 1. 2. 3. Select attach to unit and then press
OK
The Waiting for service message is now displayed. Press the <Service> pin button on the motherboard PCB. Press
ESC
to exit the menu.
Setting 1-3 Site Setup This enables three sequenced setting configurations to be specified: NOTE Configuration settings made under setting 1-3 are applied to all units in a network Number of run units - to specify the number of units that are allowed to run in the network at any time, under normal conditions. Rotation period - to specify the number of whole hours before running duty changeover takes place, to equalise hours run between units. Sensor operation - to specify temperature / humidity sensor / data handling - options are: Average - which controls from an average value calculated from all operating unit sensor readings Individual - for control in response to an individual sensor From Master - for control in response to the Master units sensor only Input voltage - set the main incoming voltage to the unit. There are various options - typically: 380 V ac, 415 V ac, 440 V ac Set this to the most appropriate value for the site.
Control Functions
A controller start-up timing diagram is shown in Fig. 4-2 and it will be found helpful to refer to this while reading the following control descriptions.
Power-up condition
Assuming that the controller has already been commissioned, on powering-up, the controller is in a reset state, ready for normal operation. Operational status following power-up depends on whether an external start/stop control is fitted: No external start/stop.
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If an external start/stop control is not fitted, plant equipment will be operational, subject to controller starting strategy. External start/stop or optional door switch. If an external start/stop control is fitted, plant equipment will remain idle on standby until the start signal is provided. Upon receipt of the start signal, plant equipment will be operational, subject to controller starting strategy.
Compressor and Condenser - Starting Operation

Compressor starting and condenser enablement are initiated simultaneously in response to a demand for cooling and/or dehumidification. Starting is only permitted when: Supply fan has been running for the Compressor Start Delay Time period of 60 seconds (default) and the airflow switch is made (healthy). Condensate drain sensor (if fitted) signals that the drain is not blocked. High pressure HP cut-out is made (safe). And: Low pressure LP cut-out is made (safe). And: Compressor drive motor overload is made (healthy). If any of these are control circuits are not made, the appropriate urgent alarm is generated and starting is aborted. Assuming that all the above conditions are met, compressor and condenser starting is initiated and the following control strategies implemented during the start period.
Starting and operation - basic overview

Each AHU starts operation subject to control as follows: 1. Master unit control power ON, or network slave unit signal to RUN received. Network units are started in sequence according to preselected order. 2. 3. The supply fan starts when the Fan Start Delay Time setting of 30 seconds (default) expires. Airflow failure alarm is inhibited for a further 20 seconds (non-adjustable default), to enable airflow to established and make the airflow switch. Provided that airflow is correct on expiry of the alarm inhibit period, normal operational control is enabled. If the airflow switch fails to make, an Airflow Failure urgent alarm is generated and starting is aborted. 4. Sensed air temperature is compared to the room temperature set point, to establish whether cooling or heating is required. Heating or cooling is then initiated as appropriate, according to PID control; for details refer to . Sensed air humidity is compared to the room humidity set point, to establish whether humidification or dehumidification is required. Humidification or dehumidification is then initiated as appropriate, according to PID control; for details refer to .
Condenser operation
Apart from start/stop signals provided by the controller, condenser operation is wholly subject to control by its own controller and starter panel. Condenser control enablement and stopping is simultaneous with compressor starting and stopping.
Low pressure (LP) cut-out inhibit

During compressor starting, the LP cut-out is effectively bypassed for the Winter Start Delay Time setting period of 150 seconds (default). This period enables normal operational suction pressure to be established during periods of low ambient temperature, when the LP cut-out might otherwise trip and prevent compressor starting. If normal operational suction pressure is not achieved by the time the setting period expires, an LP cut-out tripped urgent alarm is generated and starting is aborted.
Temperature and Humidity PID control

Air temperature is controlled by two PID (Proportional Integral and Derivative) algorithms, one for heating, the other for cooling. Each algorithm includes the same adjustable dead band, which equally spans each side of the room temperature set point. If I (Integral) and D (Derivative) values are zero, control is proportional only. Proportional units are in C.
Hot gas injection system

The hot gas injection system (if fitted) is only operative for cooling demand. When the master compressor is required to operate at part load because there is only a small demand for cooling, the hot gas injection system is used to create a false load. In this way, as illustrated in Fig. 4-3, the minimum stage of capacity control is achieved. However, during the start period, hot gas injection is undesirable because of the possibility of high discharge pressure being generated quickly and tripping the HP cut-out. Therefore, during the start period, hot gas injection is inhibited for the Hot Gas Start Override Time setting period of 30 seconds (default).
Humidity PID control

Air humidity is similarly is controlled by two PID algorithms, one for humidification, the other for dehumidification. Each algorithm includes the same adjustable dead band, which equally spans each side of the room humidity set point. If I and D values are zero, control is proportional only. Proportional units are in % RH.
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Fig. 4-2 : Controller start-up timing diagram
Controller Start-up Timing Diagram

Supply ON, controller initialised and operative. Control enabled for cooling, heating, humidification and dehumidification (master unit only). Supply Fan Start Delay Time of 30 seconds expires - supply fan starts. Airflow Failure Alarm Inhibit Time of 20 seconds starts. Airflow Failure Alarm Inhibit Time of 20 seconds expires. Provided airflow switch is made (healthy), starting control is enabled. If airflow switch is not made (healthy), controller generates an Airflow Failure prompt alarm and starting is aborted.
If cooling or dehumidification is required, Compressor Start Delay Time of 60 seconds starts. If heating is required, Heating Start Delay Time of 90 seconds starts. If humidification is required, Humidifier Start Delay Time of 300 seconds starts. Compressor Start Delay Time of 60 seconds expires. Provided that HP and LP cut-outs, compressor drive motor overload and airflow switch are made (healthy), compressor starts and condenser is enabled. If HP cut-out, LP cut-out, compressor drive motor overload, or airflow switch are not made (healthy), the corresponding prompt alarm is generated and starting is aborted.
First stage capacity Hot Gas Bypass1 Start Override Time of 30 seconds starts. Winter Start Delay Time2 of 150 seconds starts. If compressor 21 is also required to start, the Compressor 2 Start Delay Time of 60 seconds starts. Heating start delay time of 90 seconds expires heating control enabled. First stage capacity Hot Gas Bypass1 Start Override Time of 30 seconds expires - hot gas bypass solenoid valve energises (opens). Winter Start Delay Time2 of 150 seconds expires LP cut-out control no longer inhibited. If LP cut-out is not made (healthy), compressor stops and a prompt alarm is generated. Humidifier Start Delay Time of 300 seconds expires humidifier control enabled.
60
120
180
240
300
WinterStart Delay Time2 of 150 seconds expires LP cut-out control no longer inhibited. If LP cut-out is not made (healthy), compressor 2 stops and a prompt alarm is generated.
360
TIME IN SECONDS
NOTES: Values shown for timed events are controller default settings. 1 If fitted. 2If utilised (default is utilised). COLOUR KEY:
Normal events. Compressor start event. Fault conditions and response. Timed event path from source.
Compressor 21 Start Delay Time of 60 seconds expires. Provided that HP and LP cut-outs, compressor drive motor overload and airflow switch made (healthy), compressor starts and condenser is enabled. If HP cut-out, LP cut-out, compressor drive motor overload, or airflow switch are not made (healthy), the corresponding prompt alarm is generated and starting of compressor 2 is aborted.
Winter Start Delay Time2 (compressor 2) of 150 seconds starts.
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On expiry of this period, the hot gas injection solenoid valve is energised (opened) to bring the system into operation. The hot gas injection system is not implemented for dehumidification demand.
Fig. 4-3 : Compressor capacity stage control diagram
Compressor Capacity Stage Control Diagram

SINGLE COMPRESSOR CONTROL
m De ng 50 a % nd
100
Compressor 2 starting
For units fitted with dual refrigeration circuits, compressor 2 is only started when required to meet cooling demand and can only start if: Compressor 1 has been running for the Compressor 2 Start Delay Time of 60 seconds (default). Or: It is required to run in place of compressor 1, which is not running because of a fault condition (e.g. overload tripped). Or: Humidity override is set to <ON>. All pre-start control conditions described under Compressor and Condenser - Starting Operation on page 4-14 must be met. Control strategies described under Low pressure (LP) cut-out inhibit and Hot gas injection system on page 4-14 are applied as appropriate.
TWO COMPRESSOR CONTROL
Co
70 % - Stage2 Comp. (no hot gas)
oli
Stage 4 - 95%
Comps.1 + 2 (no hot gas) Stage 3 - 70% Comp.1 + hot gas + comp. 2 (no hot gas Stage 2 - 50% Comp.1 (no hot gas) Stage 1 - 30% Comp.1 + hot gas
0
30 % - Stage1 Comp + hot gas 20 21 Set point Dead band 22 23 24 25 26 27
Air Temperature C Proportional band
NOTES: The example shown here is for information only and assumes that a Room Temperature Set Point of 21C is required, with a Dead Band of 2C and a cooling Proportional Band of 5C. Values shown here have been selected for clarity. The default value for the Dead Band is 2C. The default value for the Proportional Band is 3C. Because Dead Band and Proportional Band setting values are both offsets from the Set Point, their true value is adjusted automatically to follow any adjustment made to the Set Point value.
Formula for calculation of cooling demand:

RT [ SP + ( 0.5 DB ) ] CD = ------------------------------------------------------------- 100 PB
Compressor starts per hour limiting

Once a compressor has been started and then stopped (by a fault or temporary drop in demand), it cannot restart for the Starts Per Hour Limiting Time setting of 360 seconds (default). This delay period prevents short-cycling, which could otherwise cause the compressor drive motor to burn out.
Where: CD = Cooling Demand % RT = Return/room air Temperature C SP = Set Point = 21 C DB = Dead Band = 2 C PB = Proportional Band = 5 C Therefore, if return air temperature = 25 C:
25 [ 21 + ( 0.5 2 ) ]CD = --------------------------------------------------- 100 5 3 CD = -- 100 = 60 % 5
CAUTION
Failure to observe the compressor manufacturers recommendations for starts per hour limiting may result in the drive motor burning out and consequential contamination of the entire refrigeration system. The Starts Per Hour Limiting Time default setting(s) should not be adjusted without permission from Eaton-Williams.
Compressor Capacity Control

Fig. 4-3 illustrates how stages of compressor capacity are controlled, for two compressors, in response to an increasing cooling demand, from zero to maximum. Table 4-4 shows control response for units fitted with one, two, or three compressors, with or without hot gas injection compressor capacity reduction. Fig. 4-3 and Table 4-4 show how a closer match to cooling demand can achieved by using more than one compressor, and that capacity can be matched even more closely by using a hot gas injection system on one compressor.
By referring to Fig. 4-3 and applying this example to a single compressor unit, it can be seen that 60 % capacity equates to the compressor running + hot gas. Whereas, applying the example to a two compressor unit, 60 % capacity equates to compressor 1 running (no hot gas).
Built-in Hysteresis
On reduction of cooling demand, control OFF signals will lag ON signals by approximately 20 to 30 % of cooling demand as follows: Example:
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Table 4-4 : Cooling Duty Control Response - DX units
Cooling Duty Control Response - DX Units

DEMAND COOLING DEMAND % UNIT OPERATING STATE 5 Hot gas injection 1 COMPRESSOR UNIT Rise Compressor Output % - with HGI Output % - no HGI Compressor Fall Hot gas injection Output % - with HGI Output % - no HGI Hot gas injection Compressor 1 2 COMPRESSOR UNIT Rise Compressor 2 Output % - with HGI Output % - no HGI Compressor 2 Compressor 1 Fall Hot gas injection Output % - with HGI Output % - no HGI Hot gas injection Compressor 1 Rise Compressor 2 Compressor 3 Output % - with HGI Output % - no HGI Hot gas injection Compressor 3 Fall Compressor 2 Compressor 1 Output % - with HGI Output % - no HGI 5 20 33 10 20 33 15 20 33 20 33 33 25 33 33 30 33 33 35 53 67 40 53 67 45 53 67 50 67 67 55 67 67 60 67 87 87 87 87 100 100 100 67 100 100 100 100 100 100 100 65 70 75 80 85 90 95 100 20 33 20 33 20 33 33 33 33 33 33 33 53 67 53 67 53 67 67 67 67 67 67 87 87 87 87 100 100 67 100 100 100 100 100 100 30 50 30 50 30 50 30 50 30 50 50 50 50 50 50 50 50 80 80 80 80 80 80 100 100 100 100 50 100 100 100 100 100 100 100 100 100 100 30 50 30 50 30 50 30 50 50 50 50 50 50 50 50 80 80 80 80 80 100 100 50 100 100 100 100 100 100 100 60 60 60 60 60 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 60 60 60 60 60 60 60 60 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
3 COMPRESSOR UNIT
NOTES HGI = Hot Gas Injection for capacity reduction. Tick denotes that the function is operating. Output % values shown in columns are percentage values of whole unit capacity.
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INVICTANET CONTROLLER TECHNICAL MANUAL Chilled Water Unit Cooling Duty Control
For chilled water units, the cooling duty control response is directly proportional to the demand. The controller uses the cooling Proportion, Integral and Derivative (PID) algorithm to determine control response and provides a 0 to 10 volt signal to modulate the flow control valve according to demand. The 0 to 10 volt signal provided by the controller is directly proportional to the positioning range of the flow control valve, where: 0 volts = valve fully closed 100 volts = valve fully open
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INVICTANET CONTROLLER TECHNICAL MANUAL Economy Cooling Options
There are two types of economy cooling control option available for the IPAC range of AHUs. Fresh-Air Economy Cooling Glycol Economy Cooling Both systems can be optimised to use the relevant cooling medium, where conditions allow, to achieve the required air condition, whilst minimising the running time of the compressor or cooling plant. Basic control of fresh-air economy cooling adopts a simple strategy, which is subject to both cooling and humidity control algorithms and defined by the following settings in the Engineering AHU Menu: Economy cooling deadband value setting 6-x-14 Economy cooling proportional band value setting 6x-15 Economy cooling inhibit %RH value setting 6-x-16 Where x = the AHU number. Refer to Section 5 - INVICTANET Controller Settings Record GlyCool economy cooling (cooling air by using glycol and water cooling medium) control requires that the following items of optional equipment are installed: A modified air cooling coil block, which has an airflow-facing economy cooling coil, before the DX main cooling coil. A 3-way modulating valve A modulating valve actuator, 0 to 10 V dc A temperature sensor strapped to the cooling medium pipe Standard control philosophy operates at all times, unless: The temperature of the cooling medium entering the unit is at a predetermined value (derived from the Room Temperature Set Point) or lower. In this case, control response is to permit modulation of the 3way valve to meet GlyCool economy cooling demand (if required). The required volume of cooling medium is diverted through the economy cooling coil of the coil block, before returning to the cooled medium circuit. In this way, whenever favourable conditions exist, compressor duty is supplemented by the surplus duty performed by the dry cooler. When optimum conditions exist and all air-cooling duty can be met by the dry cooler, the controller stops the compressor. This is when GlyCool economy cooling is at its most energy-efficient. The controller will then not restart the compressor until the dry cooler is no longer able to meet the increase in cooling demand.
Fresh-Air Economy Cooling

Fresh-air economy cooling control requires that the following items of optional equipment are installed: A mixing box with modulating damper, in the return air path A modulating damper actuator, 0 to 10 V dc An outside air temperature sensor Although energy-efficiency is the reason for utilising this option, control of air condition is the primary concern. Therefore, various control features will override fresh-air cooling, when appropriate, to ensure that air is maintained in a satisfactory condition. If air humidity reaches a predetermined limit, defined by the Economy Cooling Inhibit %RH Value setting, demand for economy cooling is overridden until the controller deems that economy cooling can resume without adversely affecting the air condition. Standard control philosophy operates at all times, unless the any of the following events occur. Temperature differential between outside ambient air and return air is 13 C or greater. In this case, control response is to permit damper modulation to meet economy fresh-air cooling demand (if required) Fire shutdown In this case, control response is to shut down the unit and force the fresh-air inlet damper to the maximum closed position. Smoke extract In this case, control response is to force the fresh-air inlet damper to the maximum open position.
Electrical Heating
Electrical heater operation is only permitted when: The supply fan has been running for the Heating Start Delay Time period of 90 seconds (default). The relevant airflow switch is made (healthy). The relevant high temperature (HT) cut-out monitoring circuit is made (healthy). Up to six stages of heating can then be bought into operation and controlled according to the temperature PID algorithm; see . The controller considers the heater elements as being in two banks and controls heater contactors to give stages of zero, one third and two thirds of the full heating demand. Where a single heater bank is fitted, this is bought into operation at two-thirds of the full demand. Where two heater banks are fitted, on a rising demand, the first bank is bought into operation at one-third of the full demand. At two-thirds of full demand, the first bank is switched OFF and the second bank is bought into operation. At a full-demand condition, the first bank is bought into operation is also bought into operation. In this way, near proportional control of the heater banks is achieved. If a high temperature condition causes the HT cut-out to trip, heaters are de-energised and an urgent alarm is generated at the customer terminals and on the unit display (if fitted).
Glycol Economy Cooling

This option is applicable to water-cooled DX units only.
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Heating capacity control
Heating capacity control is as shown in Table 4-5 or Table 4-6, depending on whether a hot gas reheat system is fitted. Note that for only one stage of electrical heating, control for this is to be connected to the second stage (heater 2) output.
Table 4-5 : Heating capacity control strategy - without hot gas reheat On rising demand from 0 to 100 % Capacity Master unit heater 1 Master unit heater 2 Slave unit heater 1 Slave unit heater 2 0% Off Off Off Off 20 % On Off Off Off 35 % On Off On Off 50 % Off On On Off 65 % Off On Off On 80 % On On Off On 95 % On On On On 100 % On On On On
On falling demand from 100 to 0 % Capacity Master unit heater 1 Master unit heater 2 Slave unit heater 1 Slave unit heater 2 100 % On On On On 80 % On On Off On 65 % Off On Off On 50 % Off On On Off 35 % On Off On Off 20 % On Off Off Off 5% Off Off Off Off 0% Off Off Off Off
Table 4-6 : Heating capacity control strategy - with hot gas reheat On rising demand from 0 to 100 % Capacity Master unit heater 1 Master unit heater 2 Slave unit heater 1 Slave unit heater 2 0% Off Off Off Off 20 % Off Off Off On 45 % On Off Off On 50 % Off On On Off 60 % Off On Off On 75 % Off On On On 95 % On On On On
On falling demand from 100 to 0 % Capacity Master unit heater 1 Master unit heater 2 Slave unit heater 1 Slave unit heater 2 100 % On On On On 80 % Off On On On 65 % Off On Off On 50 % Off On On Off 35 % On Off Off On 20 % Off Off Off On 5% Off Off Off Off
Humidifier Control
Humidifier operation is only permitted when: The supply fan has been running for the Humidifier Start Delay Time period of 300 seconds (default). The airflow switch is made (healthy). For a Vapac WL humidifier, control is as follows: Note that in addition to the following description, humidification is subject to control according to the humidity PID algorithm; refer to for details. If air humidity falls below the Room Humidity Set Point of 50 % RH (default) and is below the PID dead band lower limit, the humidifier is bought into operation, initially at 20 % of its capacity. The humidifier is then capacity-modulated (range 0 to 100 % capacity), to meet humidity demand.
If humidity increases to within the PID dead band, modulation of humidifier capacity ceases. On increasing humidity, capacity is modulated downwards until it is reduced to 19 %, at which point, humidifier operation ceases. Note that if demand current is lower than running current by 10 %, the humidifier will switch off until demand is 5 % higher than the demand current was at switch-off; this is part of the Vapac WL humidifier control strategy. For a combined master/slave AHU, if humidity demand is greater than 80 % of capacity and only the master unit compressor is operating on cooling demand, control will be overridden to stop master unit compressor 1 and start slave unit compressor 2 to meet cooling demand. This is done to maximise absorption of steam generated by the humidifier in the master section of the unit.
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IPAC
If cooling demand then increases, requiring both compressors to run stage 3 cooling, then compressor 1 will be started to meet stage 3 duty. If humidity demand reduces to 30 %, the cooling resets to standard operation. In this way, the AHU of a master unit does not have to be the first to be installed. To avoid unacceptable surges in electrical demand during start periods, each unit follows the same sequence of equipment start delay times (e.g. supply fan, compressor, condenser, heating and humidifier) as illustrated in Fig. 4-2. Therefore, using Engineering menu level default settings, starting of units is sequential and staggered, so that simultaneous starting of units and their equipment is avoided. For standby units, starting is as described under .
Dehumidification Control
On rising humidity, where a demand for dehumidification rises from 0 to 100 %, dehumidification is bought into operation at full capacity and then modulated down to zero to match falling demand and according to the dehumidification PID control algorithm.
Automatic starting of standby units in response to a fault condition

Once running, if a unit develops a type of fault that generates an urgent alarm and there are standby units available to run, the unit will be switched <OFF>. This event will be detected by the master units, as the units running count will be less than the required number. In this case, the first-in-sequence standby unit will start, regardless of its position in the normal start sequence. In this way, the duty of the stopped unit is replaced at the next shortest start delay
Cooling control override

At times when compressor 1 + hot gas is operating (i.e. at minimum capacity) to meet cooling demand, if demand for dehumidification rises to 80 %, then cooling demand is overridden and the hot gas solenoid valve is de-energised (closed). Compressor 1 is now operating at maximum capacity to meet dehumidification demand. When demand for dehumidification falls to 20 %, the hot gas solenoid valve is permitted to energise (open) to allow compressor 1 to return to minimum capacity cooling duty (if required). To prevent the air from being overcooled unacceptably during a period of cooling override, if air temperature falls to the value determined by the Dehumidification Override Temperature Differential setting, cooling control override ceases. This allows air temperature to rise toward the Room Air Temperature Set Point. When air temperature has risen to halfway between the value determined by the Dehumidification Override Temperature Differential setting, Room Air Temperature Set Point and the Room Air Temperature Set Point, cooling control override is again permitted (if required), so that maximum dehumidification can be resumed.
Automatic starting of standby units in response to an air high temperature condition

If air temperature rises to the extent that the Standby Override on Temperature Rise setting is reached, this causes the number of each unit required to run on the zone to be increased automatically by 1, resulting in the next standby unit being started. This standby unit is then run for 2 hours and then switched off until the next high temperature condition arises (should one do so), whereupon the override strategy is repeated.
Duty Rotation
Where two units operate as run / standby, to equalise run times, automatic rotation of units is available.
Commissioning
Commissioning must only be carried out by Eaton-Williams authorised personnel. All commissioning is carried out at Setup and Service level menus.
Local Networking
If a group of up to ten AHUs (comprising a master and up to nine network slave AHUs) are to be locally networked, each controller must be connected to at least one other controller on the network, in any desired configuration. Connections between controllers are made using twin-core communications cable, which can be either screened or unscreened. Two terminals, Net A and Net B, are provided on each controller for making these network connections. NOTE To minimise the risk of poor connection, network cabling is to be connected direct to the controller terminals provided, not via customer terminal rails.
Network Master / Slave Control

Up to ten AHUs can be networked together as an overall system. For connection details, refer to wiring diagrams for the installation and to . For network control to function, supply must be live to the unit controller(s). Each unit will start operation in the same order of sequence as it was attached to the master unit during commissioning. Future modifications to overall network operation can be achieved by nulling controllers to stand-alone and then reattaching them in the preferred order, including extra units (if applicable).
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INVICTANET CONTROLLER TECHNICAL MANUAL System Networking
Multiple network zones, each comprising a master and up to nine network slave AHUs, may be monitored and controlled from a control centre. The control centre can be either local or remote and may be networked to each zone via telecommunications links, which can be either hard-wired or wireless, depending on requirements, location, etc. Unattended control centres can also incorporate remote alarm reporting. Such a system typically includes an automatic voicedialler, which can be configured to ring a sequence of predetermined telephone contact numbers in turn, until answered. A PC fitted with a modem can then be connected to the system, which, after correct password entry, can be interrogated to evaluate the alarm and how it should be responded to. For further information on system networking, requirements and protocols for single or multiple network zones and/or remote alarm reporting, please contact Eaton-Williams. Vapac is LONMARK PARTNER and LonMark compliant. For details of external interface protocol, refer to Table 4-11. All Eaton-Williams coding is fully LON Interruptible compliant to the LONWORKS Echelon Local Operating Network (LON) standard and therefore meets registered requirements.
Trend Network Interface ( <5 Units )

This option is a network add-on to the InvictaNET system. Consisting of the Modbus Network Interface, as well as a Trend XNC device, with custom written software (I/O available from Eaton-Williams). The XNC device can sit directly on a Trend IQ network and can be directly seen by a Trend 945 or 962 Supervisor.
Alternative Language (ASCII)

The InvictaNET graphical user interface can be supplied with all text screens switchable between two languages, with English always residing on the display for E-W Engineer access. When exported, the display can be changed to display one other European language by default. Non-ASCII character languages can be supported, but may require additional programming.
Fault Conditions, Alarms and Response

The controller monitors for various fault conditions according to configuration and signal inputs. In response to a detected fault condition, controller generates one of two types of alarm, namely: These are defined as follows; also refer to Alarms on page 315 of Section 3. Urgent Alarm Indicated by an animated bell icon being automatically displayed on the System screen. An urgent alarm is generated in response to a fault condition which prevents unit operation; e.g. Airflow Failure alarm. The cause of an urgent alarm requires immediate action to correct the fault condition before the unit can restart. Any control function that is unaffected by the fault will continue to be operative. Non-urgent Alarm Indicated by a static bell icon, reversed-out, being automatically displayed on the System screen. A non-urgent alarm is generated in response to a fault condition, which requires attention, but does not immediately prevent a unit from operating. Both types of alarm can be monitored remotely; see Alarm remote monitoring on page 4-23 for details. Controller Response to an Alarm
External Interface Protocol
ModBus Network Interface

This gateway allows proprietary control and monitoring systems to interface to E-W LonWorks AHU network. The gateway provides a EIA-232 serial port, which can be used to communicate at the application layer via the MODBUS protocol. Acting as a MODBUS slave, it will respond to queries from a master device. The gateway utilises ASCII serial transmission mode. Full exception processing is implemented One gateway is required for up to nine units in a network
Trend Controller
For units that are fitted into an area controlled by a Trend BMS system, a Trend Network Interface is available. Should this be unsuitable, a Trend IQ204 controller can be fitted instead. By default, such units are fitted with a Trend FPK display. NOTE Certain IPAC range options may not be available with the Trend control option. Please contact Eaton-WIlliams for further details.
Urgent alarm
This is indicated by an animated bell icon being displayed on the System screen. An urgent alarm (see Fig. 4-4) is generated in response to a fault condition which prevents unit operation; e.g. Airflow Failure alarm.
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IPAC
Fig. 4-4 : System screen urgent alarm
Fault Conditions, Alarms and Reset

The controller monitors for various fault conditions, according to configuration and signal inputs. On detection of a fault condition, the controller responds by: Stopping items of plant equipment, such as the compressor, as appropriate. Initiating urgent or non-urgent alarms as appropriate; described under Fault Conditions, Alarms and Response on page 4-22. Automatically changing the display to indicate the fault; for details refer to Alarms on page 3-15 of Section 3. For details of the Alarm Screen, refer to .Alarm Screen on page 3-7 of Section 3. After correction of a fault condition, the fault must be cleared by pressing OK on the keypad; refer to Fig. 4-1. Text menu levels must be accessed to view and clear alarms; refer to Identifying and Clearing Alarms on page 3-15 of Section 3. If the fault no longer exists, the controller will resume normal operation. Note that compressor restarting may be subject to the Start Per Hour Limiting Time setting, as described under . If the fault condition still exists, the controller will detect this during its next scan cycle and will indicate the same fault again. The controller monitors for the following fault conditions:
invictanet
20.6C 41 %
23.5C
The cause of an urgent alarm requires immediate action to correct the fault condition before the unit can restart. Any control function that is unaffected by the fault will continue to be operative.
Non-urgent alarm
This is indicated by a static bell icon, reversed-out, being displayed on the System screen) A non-urgent alarm (see Fig. 4-5) is generated in response to a fault condition, which requires attention, but does not immediately prevent a unit from operating. Note that if the building icon is flashing reversed-out (as shown in Fig. 4-5), the alarm relates to air temperature, humidity, or both
Fig. 4-5 : System screen non-urgent alarm
Air temperature alarms

Should air temperature rise to the Room High Temperature Alarm setting, a non-urgent alarm is generated at the customer terminals and on the unit display (if fitted). Should air temperature fall to the Room Low Temperature Alarm setting, a non-urgent alarm is generated at the customer terminals and on the unit display (if fitted). Note that this alarm is inhibited for two hours following starting and for five minutes after the alarm has been accepted.
invictanet
27.4C 54%
24C
Alarm remote monitoring

Both urgent and non-urgent alarm conditions can be remotely monitored, via volt-free contacts, by making appropriate wiring connections to the customer terminals provided. Refer to the unit wiring diagram for details.
Air humidity alarms

Should air temperature rise to the Room High Humidity Alarm setting, a non-urgent alarm is generated at the customer terminals and on the unit display (if fitted). Should air temperature fall to the Room Low Humidity Alarm setting, a non-urgent alarm is generated at the customer terminals and on the unit display (if fitted). Note that this alarm is inhibited for two hours following starting and for five minutes after the alarm has been accepted.
CAUTION
The low voltage alarm circuit from the controller MUST be isolated from high voltage, otherwise the controller may be damaged. Urgent and non-urgent alarms can each be configured to provide either pulsed or continuous signals.
High pressure (HP) cut-out tripped

If discharge pressure rises to the extent that the high pressure HP cut-out trips, the compressor stops and an urgent alarm is generated at the customer terminals and on the unit display (if fitted).
Fault Conditions
The controller monitors for fault conditions and responds as detailed in Table 4-7. Urgent and non-urgent alarm types are described under Alarms on page 3-15 of Section 3.
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IPAC
Table 4-7 : Fault conditions and response
Fault Conditions and Response

Fault Air high temperature Air low temperature High humidity Low humidity High pressure (HP) cut-out trip Low pressure (LP) cut-out trip Description Air temperature rises to the Room High Temperature Alarm setting. Air temperature falls to the Room Low Temperature Alarm setting. Air temperature rises to the Room High Humidity Alarm setting. Air temperature falls to the Room Low Humidity Alarm setting. Excessive discharge pressure trips the high pressure HP cut-out. Compressor stops. Urgent alarm. Compressor stops. Urgent alarm. Alarm is inhibited for two hours after starting and for five minutes after clearing the alarm. Response and Alarm Type Notes
Non-urgent alarm.
Excessively low suction pressure trips the low pressure LP cut-out.
Air filter blocked
Air filter choked to the extent that the air differential pressure switch trips.
Display changes to indicate that the filter is blocked. The Filter Blocked Alarm Delay setting period of 60 minutes (default) is initiated. Failure to rectify the condition within delay period results in a non-urgent alarm.
Display identifies affected filter bank(s).
Airflow failure
Airflow reduces to the extent that the airflow switch trips
Unit stops operating. Urgent alarm. Respective compressor is switched OFF. Urgent alarm.
Compressor overload trip
Compressor overload trips, stopping the compressor.
Refrigeration system and humidifier stop. Condensate flood Condensate flood is detected. Urgent alarm.
Supply fan continues to operate.
Low pressure (LP) cut-out tripped

If suction pressure falls to the extent that the low pressure LP cut-out trips, the compressor stops and an urgent alarm is generated at the customer terminals and on the unit display (if fitted).
Air filter blocked

If the air filter becomes choked to the extent that the air differential pressure switch trips, the display changes to indicate that the filter is blocked.
For units fitted with multiple filter banks, each bank is separately monitored by a differential pressure switch. A blocked filter condition initiates the Filter Blocked Alarm Delay setting period of 60 minutes (default). If the blocked filter condition is not rectified within the delay period, a non-urgent alarm is generated at the customer terminals. The display (if fitted) will indicate which filter bank(s) are affected. The unit continues to operate.
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IPAC
Airflow failure
If supply airflow reduces to the extent that the airflow switch trips, the unit stops operating and an urgent alarm is generated at the customer terminals and on the unit display (if fitted). If the fire detection system is triggered, it will interrupt the power supply to the controller and stop the plant (including paired slave, if fitted) immediately. The display will continue to function. Note that because the signal circuit is low voltage, line losses must be allowed for, do not exceed 20 metres length of 0.5 mm2 core wiring. For longer distances, install a suitable relay device.
Compressor drive motor overload tripped

If a compressor overload trips, stopping the compressor, the respective compressor is switched <OFF> and an urgent alarm generated.
CAUTION
The low voltage circuit from the controller MUST be isolated from high voltage, otherwise the controller may be damaged.
Condensate flood alarm

If required, an optional condensate flood detection device can be fitted. This could be, for example, a water detection sensor, or an alarm signal from a condensate pump. Signal contact function is: Open circuit (contact breaks) = Healthy Closed circuit (contact makes) = Alarm If a condensate flood is detected, the refrigeration system and humidifier stop and an urgent alarm is generated at the customer terminals and on the unit display (if fitted). The supply fan continues to operate.
Troubleshooting
The following information is provided for guidance should a problem arise relating to the controller or display.
Display Corruption
The Eaton-Williams AHU controller has been designed to be robust and reliable in operation. However, communications faults or interruptions can, in certain circumstances, corrupt the display. If the display is suspected of not functioning normally, power to the affected unit(s) should be switched OFF to power-down the controller for 30 seconds, before switching it back ON. On restoration of power, the controller and display should re-initialise and operate normally. If the problem recurs and causes a nuisance, the communications wiring and connections should be checked for continuity.
Emergency Shutdown
CAUTION
In an emergency, do NOT attempt to use controller functions to shutdown equipment, as this will initiate a controlled shutdown that is unlikely to be effective immediately. It is recommended that an optional external Emergency Stop button is fitted and connected into the master AHU controller power supply interlock; for details, refer to the unit wiring diagram. NOTE Each network slave AHU controller must be individually connected to an Emergency Stop button, which may be a common device. When the Emergency Stop button is pressed, it will interrupt the power supply to the controller and stop the plant (including paired slave, if fitted) immediately.
CAUTION
Do not apply high voltage to any circuit connected to the controller.
AHU Not Operating

Before assuming that a fault exists and attempting to locate the cause, the following possibilities should be eliminated: Is power supply available to the controller? Check that any external interlocks, such as Fire Shutdown on page 4-25, are in a healthy state. Note that if the fire shutdown facility is utilised, the display will continue to function after the fire shutdown device is triggered. Therefore the display being live does not mean that the controller power supply is healthy. Is there a demand? Check that there is truly a demand. For example, if demand has been satisfied, the controller will not initiate the unit process (cooling, heating, humidification or dehumidification) to operate. Check that demand exists by viewing the Status screen (see Status screen (typical) on page 3-6 of Section 3), which shows demand and percentage indicators, and by interrogating System Status points 3-0-3 or 3-0-4 as appropriate; see Status menu points list on page 3-13 of Section 3.
Fire Shutdown
If required, a fire shutdown remote switching device (by customer) can be connected into the master AHU controller power supply interlock; for details, refer to the unit wiring diagram. The switching device may be, for example, a function of the buildings fire alarm system controller. NOTE Each network slave AHU controller must be individually connected to the fire shutdown switching device.
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IPAC
Demand exists, but the unit is idle If demand is present (see Is there a demand? on page 4-25), but the appropriate process is not operating, a normal delay time may be in effect; see Fig. 4-2. If system status points 3-0-3 and 3-0-4 show no demand and this is unexpected, check the set point, 4-0-1 (temperature) or 4-0-2 (humidity) and compare this to the actual measured value shown for status point 3-0-1 (temperature) or 3-0-2 (humidity), as appropriate. Remember to take into account: Dead band control settings; see Control Functions on page 413 Override controls; see Control Functions on page 4-13 Compressor starts per hour limiting on page 4-16 Are external interlocks (if fitted) in a healthy state; e.g. Fire Shutdown on page 4-25 Is the AHU idle in standby mode? A unit in standby mode will only operate to take over the duty of another unit that becomes unavailable, or when due to take over according to run/standby rotation control settings. On the Status > AHU menu, check AHU operating mode point 3x-1, or humidifier operating mode point 3-x-2 for the humidifier (where x is the AHUs system number on the network), as appropriate; see Status menu points list on page 3-13 of Section 3. The unit process will only be operative if status is shown as online.
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IPAC
INVICTANET CONTROLLER TECHNICAL MANUAL AHU Configuration Index
Table 4-8 shows controller configurations that are available, together with the Eaton-Williams part number. Basic configuration for the system is automatically implemented in the controller by fitting the appropriate UCP (Unit Configuration Plug).
Table 4-8 : AHU configuration index
CAUTION
The configuration index must only be altered by Eaton-Williams approved personnel. Incorrect configuration may damage the controller or implement inappropriate control strategy
AHU Configuration Index

Cooling Type Heating Type Reheat Valve Fitted Dehumidification Control Number of Modules Configuration Index 1 No No Yes Electric No Yes Yes DX Refrigerant No No Yes LPHW No Yes Yes 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
NOTES The appropriate configuration index for the application is input during factory setup. prior to despatch. Fresh air and glycol cooling are also factory setup options, which are set independently of the configuration index.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
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IPAC
Table 4-8 : AHU configuration index
AHU Configuration Index

Cooling Type Heating Type Reheat Valve Fitted Dehumidification Control Number of Modules Configuration Index 1 No No Yes Electric No Yes Yes Chilled Water Cooling No No Yes LPHW No Yes Yes 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
NOTES The appropriate configuration index for the application is input during factory setup. prior to despatch. Fresh air and glycol cooling are also factory setup options, which are set independently of the configuration index.
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
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IPAC
INVICTANET CONTROLLER TECHNICAL MANUAL Configuration Plug (early units)
Table 4-9 shows controller configurations that are available for early units, together with the Eaton-Williams part number. Basic configuration for is automatically implemented in the controller by fitting the appropriate UCP (Unit Configuration Plug).
Table 4-9 : Unit configuration plug identification
CAUTION
Configuration plugs must only be fitted by EatonWilliams approved personnel. Incorrect fitting may damage the controller or implement inappropriate control strategy.
Unit Configuration Plug Identification

UCP x Ref. ID* A B C D E F G H I J K L
NOTE
UCP Part No. 1160457 1160458 1160459 1160460 1160461 1160462 1160463 1160464 1160465 1160466 1160467 1160468
No. of Modules 1 2 1 2 1 2 1 2 1 2 N/A N/A
Cooling System DX DX DX DX DX DX Chilled water Chilled water Chilled water Chilled water Chilled water Chilled water
Heating System Electric or LPHW Electric or LPHW Electric or LPHW Electric or LPHW Electric or LPHW Electric or LPHW Electric Electric Electric Electric LPHW LPHW
Reheat Valve Fitted No No No No Yes Yes N/A N/A N/A N/A No No
Dehum. Control No No Yes Yes Yes Yes No No Yes Yes No Yes
* UCP Cross Reference ID provided for cross-referencing to Table 4-10.
Input / Output Schedule

All analogue and digital I/Os (Inputs and Outputs) that may (dependent on unit configuration) be connected to terminals on the controller mother board and daughter board are listed in Table 4-10. NOTE The I/O schedule shown in Table 4-10 is exhaustive. Which I/Os are permitted to be used for a particular unit is determined by the configuration index - see Table 4-8. For early units, I/Os are determined by the UCP (Unit Configuration Plug) - see Table 4-9. For alternative, non-standard application configurations, consult Eaton-Williams. Any unused I/Os that must be linked out can be identified on the wiring diagram for the unit.
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IPAC
Table 4-10 : Input / output schedule

Function Description DX Cooling With Electrical Heating UCP x Ref. IDa A, B, C, D, E, F CW Cooling With Electrical Heating UCP x Ref. IDa G, H, I, J MOTHER BOARD ANALOGUE INPUTS AI 1 AI 2 AI 3 AI 4 AI 5 AI 6 AI 7 AI 8 CR2/13 CR4/1 - 2 CR4/3 - 4 CR4/5 - 6 CR4/7 - 8 Condensate flood sensor / alarm Room air temp. Air filter(s) blocked Outside air temp. CR3/3 CR3/1 Humidity sensor Current input from humidifier Humidity sensor Current input from humidifier Not for use Condensate flood sensor / alarm Room air temp. Air filter(s) blocked Outside air temp. Glycol temp. MOTHER BOARD DIGITAL INPUTS DI 1 DI 2 DI 3 DI 4 DI 5 DI 6 DI 7 DI 8 DI 9 CR1/16 CR2/1 CR2/2 CR2/1 CR2/3 - 4 CR2/5 - 4 CR2/6 - 7 CR2/8 - 7 CR2/9 - 10 CR2/11 - 10 CR2/12 - 10 Airflow switch - fan 1b Airflow switch - fan 2b Airflow switch - fan 1b Airflow switch - fan 2b Airflow switch - fan 1b Airflow switch - fan 2b Volt-free / 9 to 24 V ac or dc Volt-free / 9 to 24 V ac or dc Volt-free / 9 to 24 V ac or dc Volt-free / 9 to 24 V ac or dc Volt-free / 9 to 24 V ac or dc Volt-free / 9 to 24 V ac or dc Volt-free / 9 to 24 V ac or dc volt-free volt-free External interlock for remote Start/Stop or Fire Shutdown External interlock for remote Start/Stop or Fire Shutdown Condensate flood sensor / alarm Room air temp. Air filter(s) blocked Outside air temp. Glycol temp. 0 to 18 V dc, 0 to 20 mA 2K2 to 180K Ohm resistive 2K2 to 180K Ohm resistive 2K2 to 180K Ohm resistive 2K2 to 180K Ohm resistive Humidity sensor Current input from humidifier 0 to 18 V dc, 0 to 20 mA 0 to 18 V dc, 0 to 20 mA CW Cooling + LPHW Heating / Fresh Air Inlet Damper UCP x Ref. IDa K, L Input / Output Device Properties
Ident
Terminals
Heating HT cut-out 1b tripped Heating HT cut-out 1b tripped Heating HT cut-out 1b tripped Heating HT cut-out 2b tripped Heating HT cut-out 2b tripped Heating HT cut-out 2b tripped HP cut-out / O/L tripped compressor 1b LP cut-out tripped - compressor 1b HP cut-out / O/L tripped compressor 2b Humidifier water cylinder full Humidifier water cylinder full Humidifier water cylinder full LP cut-out tripped - compressor 2b External interlock for remote Start/Stop or Fire Shutdown
CR1/13 - 14
volt-free
NOTES a UCP x Ref. IDs provided for cross-referencing to Table 4-9. b 1 refers to the master module equipment, while 2 refers to the slave module equipment.
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IPAC
Table 4-10 : Input / output schedule

Function Description DX Cooling With Electrical Heating UCP x Ref. IDa A, B, C, D, E, F CW Cooling With Electrical Heating UCP x Ref. IDa G, H, I, J MOTHER BOARD DIGITAL OUTPUTS DO 1 DO 2 DO 3 CR1/4 - 3 CR1/6 - 5 CR1/8 - 7 Humidifier contactor Humidifier water feed valve Compressor 1b and condenser 1b run Compressor 1b hot gas valve open Module 1b heating first stage (for twostage heating only) Module 1b heating second stage or single stage only Urgent alarm fault relay Non-urgent alarm fault relay Humidifier pump run Fan 1b run Module 1b dehum. override Urgent alarm fault relay Non-urgent alarm fault relay Humidifier pump run Fan 1b run DAUGHTER BOARD ANALOGUE OUTPUTS Module 1b AO 1 CR11/1 - 2 CR11/3 CR11/4 LPHW valve, fresh air inlet damper,or glycol valve position Module 2b LPHW valve position Module 1b CW valve position Module 2b CW valve position Module 1b LPHW valve, or fresh air inlet damper position Modules 1b and 2b CW valve position 0 to 10 V dc Humidifier contactor Humidifier water feed valve Module 1b heating stage 1 Module 1b heating stage 2 Humidifier contactor Humidifier water feed valve Module 1b heating stage 1 Module 1b heating stage 2 Module 1b cooling inhibit Module 1b dehum. override Urgent alarm fault relay Non-urgent alarm fault relay Humidifier pump run Fan 1b run 24 V ac, 30 VA 24 V ac, 30 VA 24 V ac, 30 VA CW Cooling + LPHW Heating / Fresh Air Inlet Damper UCP x Ref. IDa K, L Input / Output Device Properties
Ident
Terminals
DO 4
CR1/10 - 9
24 V ac, 30 VA
DO 5
CR3/7 - 8
9 V dc, 150 mA
DO 6
CR3/9 - 10 CR6/6 - 4 (no) CR6/6 - 5 (nc) CR6/3 - 1 (no) CR6/3 - 2 (nc) CR5/6 - 4 (no) CR5/6 - 5 (nc) CR5/3 - 1 (no) CR5/3 - 2 (nc)
9 V dc, 150 mA Volt-free c/o, 7 A, com/no/nc Volt-free c/o, 7 A, com/no/nc Volt-free c/o, 7 A, com/no/nc Volt-free c/o, 7 A, com/no/nc
DO 7 DO 8 DO 9 DO 10
AO 2
0 to 10 V dc
DAUGHTER BOARD DIGITAL OUTPUTS DO 11 DO 12 DO 13 DO 14 DO 15 CR4/1 - 3 (no) CR4/1 - 2 (nc) CR4/4 - 6 (no) CR4/4 - 5 (nc) Module 2 heating first stage on
b
CR2/1 - 3 (no) CR2/1 - 2 (nc) CR2/4 - 6 (no) CR2/4 - 5 (nc)
Fan 2b run Compressor 2b and condenser 2b run
Fan 2b run
Fan 2b run Module 2b cooling inhibit
Volt-free c/o, 7 A, com/no/nc Volt-free c/o, 7 A, com/no/nc
Not for use Module 2b heating first stage on Module 1b heating inhibit Module 2b heating inhibit Volt-free c/o, 7 A, com/no/nc Volt-free c/o, 7 A, com/no/nc
Module 2b heating 2nd stage Module 2b heating 2nd stage on, or unit 1b reheat on on, or unit 1b reheat on
NOTES: a UCP x Ref. IDs provided for cross-referencing to Table 4-9. b 1 refers to the master module equipment, while 2 refers to the slave module equipment.
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INVICTANET CONTROLLER TECHNICAL MANUAL External Interface Protocol
Table 4-11 : External interface protocol
External interface protocol

Network Variable nviRequest nvoStatus Nvo00FileDir NviSysEnable NviInterlock NviEnergyHoldOff NviHVACTemp NviHVACRH NvoSysStatus NvoHVACTemp NvoHVACRH NvoTempDemand NvoHumDemand NvoUnitEnable[10] NviTempDemand NviHumDemand NvoCylDemand NvoHoursRun NvoCurrent NvoPower NvoDuty NvoAIs NvoRIs NvoDIOStatus NviMORComp1 NviMORHotGas NviMORComp2 NviMORHeater1 NviMORHeater2 NviMORHeater3 NviMORHeater4 NviMORVapac NviMORAHU Format SNVT_obj_request SNVT_obj_status SNVT_address SNVT_switch SNVT_switch SNVT_switch SNVT_temp_p SNVT_lev_percent SNVT_switch SNVT_temp_p SNVT_lev_percent SNVT_lev_percent SNVT_lev_percent SNVT_switch SNVT_lev_percent SNVT_lev_percent SNVT_lev_percent SNVT_count SNVT_amp SNVT_power_kilo SNVT_elec_kwh SNVT_analogue SNVT_analogue SNVT_state_64 SNVT_count SNVT_count SNVT_count SNVT_count SNVT_count SNVT_count SNVT_count SNVT_count SNVT_count Vapac demand manual override 0 to 100 %. AHU manual override 0 to 100 %. Manual override inputs; used for commissioning. 0 = auto control. non-zero = manual override ON. Description Node object request; see LONMARK application guidelines for details. Node object request; see LONMARK application guidelines for details. File description; see LONMARK application guidelines for details. System enable via network. System interlock via network. Energy hold-off. Input provides current temperature, when a network sensor is used. Input provides current humidity, when a network sensor is used. AHU status. Current temperature. Current humidity. Temperature demand; +ve heating, -ve cooling. Humidity demand; +ve humidification, -ve dehumidification. Slave enable signals; used in network systems. Temperature demand input; used by slaves. Humidity demand; used by slaves. Vapac Cylinder demand Vapac hours run. Vapac current. Vapac instantaneous power. Vapac power used. 4 * analogue inputs, 0 to 4096. 4 * resistance inputs, 0 to 2096. Bits 0 to 9 digital inputs. Bits 10 to 23 digital inputs.
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IPAC
IPAC
SECTION 5
INVICTANET CONTROLLER SETTINGS RECORD

5.1 Table 5-1 : Table 5-2 : Table 5-3 : Table 5-4 : Introduction User-adjustable system settings User-Adjustable AHU settings Engineering menu system settings Engineering menu AHU settings
Page
53 54 55 5 10 5 11
IPAC
INVICTANET Controller Settings Record
Page 5-2
IPAC
INVICTANET Controller Settings Record Introduction
The controller is fully described in Section 4 - INVICTANET CONTROLLER TECHNICAL MANUAL. Controller settings are configured during commissioning, to obtain optimum performance. On completion of commissioning, the controller settings record is to be completed for each unit before handover. Any setting that are adjusted from default values are to be recorded in the Input Value column. Any adjustment to User level setting values should be recorded, together with the date changed. Always keep the settings record up to date. Always keep the settings record in a safe place, preferably with the unit log record.
Table 5-1 : User-adjustable system settings
Note that adjustment to Engineering level settings must only be carried out by personnel who are competent in refrigeration control system configuration.
WARNING
Inappropriate setting values can adversely affect plant performance and/or operation and may result in damage to the unit or any environmentsensitive equipment that relies on unit operation. It is recommended that a copy of each appropriate settings record is kept with the plant log book. Having this information to hand will keep any down time period to a minimum, should controller settings need to be input again.
User-Adjustable System Settings

User password = 4602 MASTER UNIT Setting No. (Screen) User 4-0-1 4-0-2 4-0-3 Maint. 5-0-1 5-0-2 5-0-3 E-W 5-0-1 5-0-2 5-0-3 Serial No. __________________ Site Unit No. / Location __________________ Screen Text temp setpoint rh setpoint high temp diff Setting Room temperature set point Room humidity set point Room high temperature alarm (differential from room temperature set point 4-0-1) Room low temperature alarm (differential from room temperature set point 4-0-1) Room high humidity alarm (differential from room humidity set point 4-0-2) Room low humidity alarm (differential from room humidity set point 4-0-2) Date and time (real-time clock setting adjustment) DD-MM-YY HH:MM:SS Dehumidification override control en-able dis-able en-able (enables/disables implementation of Dehum. override temperature differential setting 4-0-9) Dehumidification override temperature differential (differential from room temperature setting 4-0-1) Inhibits dehumidification if temperature is low, to prevent overcooling. Range Min. 0 5 0 Max. 39 95 10 Fact. Set 22 50 10 Units C % RH C Input Value
4-0-4
5-0-4
5-0-4
low temp diff
10
10
4-0-5 4-0-6
5-0-5 5-0-6
5-0-5 5-0-6
high rh diff low rh diff
0 0
10 10
10 10
% RH % RH
4-0-7
5-0-7
5-0-7
date . time
4-0-8
5-0-8
5-0-8
dehum o/r
4-0-9
5-0-9
5-0-9
dehum o/r
40
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Table 5-2 : User-Adjustable AHU settings
User-Adjustable AHU Settings

User password = 4602 Setting No. (Screen) User Maint. E-W Screen Text Setting Range Min. Max. Def. Units Input Value
AHU No. 1 - MASTER 4-1-1 4-1-2 4-1-3 5-1-1 5-1-2 5-1-3 5-1-1 5-1-2 5-1-3
Serial No. __________________ Site Unit No. / Location __________________ Room temperature set point Room humidity set point Room high temperature alarm (differential from room temperature set point 4-0-1) Room low temperature alarm (differential from room temperature set point 4-0-1) Room high humidity alarm (differential from room humidity set point 4-0-2) Room low humidity alarm (differential from room humidity set point 4-0-2) Manual override reset control AHU manual override reset control setting enable or disable Specified supply voltage to AHU 0 5 0 39 95 10 22 50 10 C % RH C
temp setpoint rh setpoint high temp diff
4-1-4
5-1-4
5-1-4
low temp diff
10
10
4-1-5 4-1-6
5-1-5 5-1-6
5-1-5 5-1-6
0 0
10 10
10 10
% RH % RH
4-1-7 4-1-8
5-1-7 5-1-8
5-1-7 5-1-8
man o/r reset input voltage
en-able dis-able en-able 380 440 440
Volts
AHU No. 2a - SLAVE 4-2-1 4-2-2 4-2-3 5-2-1 5-2-2 5-2-3 5-2-1 5-2-2 5-2-3
Serial No. __________________ Site Unit No. / Location __________________ Room temperature set point Room humidity set point Room high temperature alarm (differential from room temperature set point 4-0-1) Room low temperature alarm (differential from room temperature set point 4-0-1) Room high humidity alarm (differential from room humidity set point 4-0-2) Room low humidity alarm (differential from room humidity set point 4-0-2) Manual override reset control AHU manual override reset control setting enable or disable Specified supply voltage to AHU 0 5 0 39 95 10 22 50 10 C % RH C
temp setpoint rh setpoint high temp diff
4-2-4
5-2-4
5-2-4
low temp diff
10
10
4-2-5 4-2-6
5-2-5 5-2-6
5-2-5 5-2-6
0 0
10 10
10 10
% RH % RH
4-2-7 4-2-8
5-2-7 5-2-8
5-2-7 5-2-8
man o/r reset input voltage
en-able dis-able en-able 380 440 440
Volts
a. The AHU number will correspond to the setting number at each level, ie. AHU 5 Room Temp Set Point will be under setting No. 4-5-1.
Page 5-4
IPAC
Table 5-3 : Engineering menu system settings
Engineering Menu SYSTEM Settings

E-W password access and Maintenance password access only Setting No. (Screen) Screen Text MASTER UNIT Setting Range Min. Max. Def. Units Input Value
Serial No. __________________ Site Unit No. / Location __________________ Sensor operation Specifies temperature / humidity sensor / data handling options are: Average - for averaging of data from several sensors Individual - for individual sensor From master - for using only the Master units sensor data Number of run units Specifies the number of units allowed to run in the network at any time Duty rotation cycle period Hours between each rotation of duty for pairs of units 00000 99999 00000 hours hours / mins.
6-0-1
sensor operation
6-0-2
num run units
6-0-3
rotation period
6-0-4
rotation time
Duty rotation time Time of day that duty rotation is executed for pairs of units; 00:00 inhibit setting = 00:00 Run-on time at changeover Specifies the period that a unit due to go on standby unit is permitted to keep running, to eliminate any issues caused by start delays of the starting unit. Temperature deviation required to start standby unit Offset from the temperature set point that will initiate starting of the standby unit Standby run period The period that the standby unit is required to run after being started in response to setting 6-0-6 Urgent alarm output type Specifies the type of alarm signal - pulsed or continuous Non-urgent alarm output type Specifies the type of alarm signal - pulsed or continuous Temperature alarms display Specifies whether temperature alarms are shown automatically on the display shown = enabled not shown = disabled Relative humidity alarms display Specifies whether RH alarms are shown automatically on the display shown = enabled not shown = disabled
24:00
00:00
6-0-5
run on period
mins.
6-0-6
standby temp
10
10
6-0-7
standby period
240
mins.
6-0-8 6-0-9
level 1 alarm level 2 alarm
pulse pulse
cont. cont.
cont. cont.
6-0-10
temp alarms
dis-abled en-abled en-abled
6-0-11
rh alarms
dis-abled en-abled en-abled
Document 0410536
Page 5-5
IPAC
Table 5-4 : Engineering menu AHU settings
Engineering Menu AHU Settings

E-W password full access and Maintenance password 5699 limited access (indicated by asterisk) only Setting No. (Screen) Screen Text AHU No. 1 - MASTER *6-1-1 man o/r period Setting Range Min. Max. Def. Units Input Value
Serial No. __________________ Site Unit No. / Location__________________ Manual override run period Duration of manual override (for service) before unit reverts to normal operation Set point source Specifies the control sensor to which the set point is applied - options are: AHU System Fan start delay time Delay period before fan starting is permitted, following unit start initialisation Temperature deadband value No PID control is applied while the temperature is within the deadband, which is an offset value from the temperature set point. Heating control loop menu Enters the heating PID control loop menu comprising the next three settings Heating proportional band value For PID control Heating integral time value For PID control Heating derivative time value For PID control Cooling control loop menu Enters the heating PID control loop menu comprising the next three settings Cooling proportional band value For PID control Cooling integral time value For PID control Cooling derivative time value For PID control Humidity deadband value No PID control is applied while RH is within the deadband, which is an offset value from the RH set point Humidification control loop menu Enters the humidification PID control loop menu comprising the next three settings Humidification proportional band value For PID control Humidification integral time value For PID control 0 120 60 mins.
*6-1-2
setpoint source
6-1-3
fan start delay
300
secs.
6-1-4
temp d/b
10
6-1-5
heating loop
6-1-5-1 6-1-5-2 6-1-5-3
1 0 0
10 250 250
2 0 0
C mins. mins.
6-1-6
cooling loop
6-1-6-1 6-1-6-2 6-1-6-3
1 0 0
10 250 250
2 0 0
C mins. mins.
6-1-7
rh d/b
10
%RH
6-1-8
hum loop
6-1-8-1 6-1-8-2
proportional i action
1 0
10 250
3 0
% RH mins.
Page 5-6
IPAC

E-W password full access and Maintenance password 5699 limited access (indicated by asterisk) only Setting No. (Screen) Screen Text AHU No. 1 - MASTER 6-1-8-3 i response Setting Range Min. Max. Def. Units Input Value
Serial No. __________________ Site Unit No. / Location__________________ Humidification derivative time value For PID control Dehumidification control loop menu Enters the dehumidification PID control loop menu comprising the next three settings Dehumidification proportional band value For PID control Dehumidification integral time value For PID control Dehumidification derivative time value For PID control Compressor 1 control settings menu Enters the compressor control menu comprising the next five settings Compressor 1 start delay time Delay period, following start initiation, before the compressor is permitted to start Compressor 1 winter start delay time For problem-free starting during winter, when ambient temperature is low Compressor 1 starts per hour limiting Ensures that compressor starts per hour are limited to manufacturers recommendations Compressor 1 hot gas start delay time Delays hot gas implementation following compressor starting Compressor 2 control settings menu Enters the compressor control menu comprising the next five settings Compressor 2 start delay time Compressor 2 winter start delay time Compressor 2 starts per hour limiting Compressor 2 hot gas start delay time Compressor 3 control settings menu Enters the compressor control menu comprising the next five settings Compressor 3 start delay time Compressor 3 winter start delay time Compressor 3 starts per hour limiting Compressor 3 hot gas start delay time Compressor rotation period For equalisation of hours run between compressors 0 250 0 mins.
6-1-9
dehum loop
6-1-9-1 6-1-9-2 6-1-9-3
1 0 0
10 250 250
2 0 0
% RH mins. mins.
6-1-10
compressor 1
6-1-10-1
start delay
300
15
secs.
6-1-10-2
winter start dly
300
180
secs.
6-1-10-3
start to start
300
180
secs.
6-1-10-4
hot gas st dly
120
45
secs.
6-1-11 6-1-11-1 6-1-11-2 6-1-11-3 6-1-11-4 6-1-12 6-1-12-1 6-1-12-2 6-1-12-3 6-1-12-4 6-1-13
compressor 2 start delay winter start dly start to start hot gas st dly compressor 2 start delay winter start dly start to start hot gas st dly comp rotation
0 0 0 0 0 0 0 0 0
300 300 300 120 300 300 300 120 60100
15 180 180 45 15 180 180 45 -
secs. secs. secs. secs. secs. secs. secs. secs. hours
Document 0410536
Page 5-7
IPAC

E-W password full access and Maintenance password 5699 limited access (indicated by asterisk) only Setting No. (Screen) Screen Text AHU No. 1a - MASTER Setting Range Min. Max. Def. Units Input Value
Serial No. __________________ Site Unit No. / Location__________________ Economy cooling deadband value No PID control is applied while economy cooling medium temperature is within the deadband, which is an offset value from the room temperature set point Economy cooling proportional band value For proportional control Economy cooling inhibit %RH value For economy cooling override in favour of minimising the need to control humidity Heater start delay period Ensures that excessive temperature is avoided, by delaying heater operation until the airflow switch is deemed to be made (healthy) Humidifier start delay period Delays humidifier operation until the airflow switch is deemed to be made (healthy) Filter blocked alarm delay period Delays the filter blocked alarm from being reported Airflow failure alarm delay period Delays the airflow failure alarm from being reported Hours run counters reset Resets all counters to zero -
6-1-14
free cool d/b
6-1-15
free cool prop
20
6-1-16
free cool inhibit
50
100
%RH
6-1-17
heater start dly
300
90
secs
6-1-18
vapac start dly
900
60
secs
6-1-19 6-1-20 6-1-21
filter block dy airflow period reset hours
240
mins. mins. -
a. The AHU number will correspond to the setting number at each level, ie. AHU 5 Economy cooling deadband value will be under setting No. 6-5-14.
Page 5-8
Eaton-Williams
IPAC
IPAC
IPAC
SECTION 6
INSTALLATION - DX UNITS
Introduction Persons Permitted to Carry Out Installation
Arrival at Site Off-loading and Handling Off-loading by Crane Off-loading by Forklift Moving a Unit
Page
64 64
64 64 64 64 64
Storage Installation Obstructions

Noise Condensate Drain
64 65
65 66
Positioning
Floor Mounting Base Plinth Mounting
66
66 66
Installation Clearances Piping up the System Refrigerant Pipework and System Components Interconnecting Refrigerant Pipework Liquid Receiver Pressure Relief Valve Humidifier Mains Water Supply Condensate Drain Power Supply Emergency Stop Electrical Connections
Air-cooled Condenser Remote Start / Stop Signal Fire Shutdown Signal Compressor Crankcase Oil Heater(s) Combined Strength and Leak Pressure Test
66 66 66 67 67 67 67 67 68 68 68
68 68 68 69 69
Evacuation and Dehydration Initial Charging With Refrigerant
6 10 6 11
IPAC
IPAC
Installation - DX Units
Page 6-2
IPAC
Installation - DX Units Introduction
The purpose of this section is to provide an overall guide for the installation of IPAC range AHUs and is not an exhaustive stepby-step installation guide. Each site will vary in requirements regarding layout and obstacles to overcome. If there are queries or points of uncertainty, refer to EatonWilliams for clarification. Also refer to any special instructions issued by Eaton-Williams, or their appointed distributor, for a specific project.
Fig. 6-1 : Unit lifting brackets
Persons Permitted to Carry Out Installation

Only personnel who have been properly trained in the installation of refrigeration equipment should be permitted to carry out installation of the equipment covered by this manual.
Arrival at Site
If any damage is found, this must be reported to Eaton-Williams, or their appointed distributor, immediately. Units are normally despatched enclosed in suitable packaging for protection during transit. The arrangement and type of packaging will vary according to the method of transportation, site location, unit type and quantity, etc. Before Acceptance: Before unpacking, check all packaging for any evidence of damage that could indicate possible damage to a unit within. Carefully remove all packaging and then thoroughly check each unit for damage. Do not allow the unit to become wet. Each unit is supplied containing a holding charge of dry nitrogen, nominal pressure 3.4 Bar g (50 psi g). Fit a calibrated test pressure gauge and check that the holding charge is intact. Report any damage or escape of holding charge to the carrier and to Eaton-Williams immediately. Eaton-Williams cannot be held responsible for any damage occurring during transit. To avoid damage to the unit or injury to personnel, observe the following points: Ensure that all lifting and handling gear, including any slings, etc., are of adequate specification and have relevant safety certificates. If the unit is to be lifted by crane or hoist, correctly sized load spreaders must be used. Ensure that the lift is vertical. Do not allow the unit to drop.
Off-loading by Crane
CAUTION
To avoid damage, load spreaders must always be used when lifting the unit by hoist or crane. Always use the specially designed lifting brackets provided by Eaton-Williams; refer to Fig. 6-1.
Off-loading by Forklift
CAUTION
The unit can be off-loaded and moved using a forklift, provided that the lift is from under the pallet; refer to
Off-loading and Handling

Before moving units, check the weight by referring to IPAC Range unit configurations, dimensions and weights on page 27 of Section 2. Add an adequate allowance for any significant packaging, such as wooden crating.
CAUTION
At NO time is the unit to be laid on its back, side or front. Doing this will cause irreparable damage. To facilitate lifting by crane or hoist, Eaton-Williams can provide specially designed lifting brackets on request. These brackets are to be fitted to the top of the unit, one at each end, as shown in Fig. 6-1.
Fig. 6-2. Lifting directly against the unit bottom will cause irreparable damage.
Moving a Unit
The unit can be moved around using appropriate equipment as illustrated in Fig. 6-2 and Fig. 6-3.
Storage
Units that are not installed directly following arrival at site must be stored in a weatherproof, dry, well-ventilated and vermin-free area.
WARNING
Lifting eyes must not be used, otherwise they may strip-out during the lift and the unit may fall.
Document 0410536
Page 6-3
IPAC
Fig. 6-2 : Off-loading by crane (generic unit shown) and Off-loading by forklift (generic unit shown)
Fig. 6-3 : Using pallet trucks (generic unit shown)
Installation Obstructions
A number of factors must be assessed regarding the installation of air handling units. Hot water pipework - must be properly lagged to minimise heat transfer. Radiators or night storage heaters positioning. Electrical fittings and installations. Telecommunications equipment positioning. Cable tray and busbar support drop rod positioning. Cable tray and busbar distribution systems. The proximity of these items must be taken into consideration, especially in respect of any adverse affect they may have on the flow of return air.
To prevent Brinelling of bearings, units must be stored in a vibration-free area, otherwise adequate steps must be taken to prevent such damage.
Noise
The installation must be checked regarding noise levels generated during operation, to ensure that local requirements and limitations are adhered to.
CAUTION
Any leakage of holding charge must be rectified immediately. Failure to maintain the holding charge will invalidate the warranty for the unit. After rectifying the cause of any leakage, the unit must be evacuated and a holding charge of industrial grade dry nitrogen then installed to a nominal pressure of 3.4 Bar g (50 psi g).
Condensate Drain
Condensate must be arranged to discharge directly into a properly designed drain, which should be lagged. Refer to Condensate Drain on page 6 for further details.
Positioning
IPAC units are designed for indoor use only, and to locate either directly on to raised floor jacks, or onto a base plenum.
Page 6-4
IPAC
CAUTION
For downflow units with top or back return, BEFORE positioning the unit, ensure that the aperture blanking plate is correctly positioned for airflow direction. Site refrigerant system connections (discharge line and liquid line) are terminated and capped off in the base of the unit. Each unit is despatched containing a holding charge of nitrogen. If a matched air-cooled condenser is supplied by Eaton-Williams, this is also despatched with site connections capped off and a holding charge of nitrogen. For further details, refer to the separate instruction publication for the condenser. After units have been correctly positioned and installed, interconnecting pipework can be installed between the unit and the condenser.
Multiple Section Assembly

To provide an air seal, use a layer of gasket above and below the plinth.
CAUTION
It is essential that all appropriate gaps are sealed to prevent bypassing, otherwise unit performance will be impaired. Before assembling multiple sections, ensure that the lower section is perfectly level in both planes and will remain so when the unit is mounted. Mount additional sections using the two locating pins provided. Fit the pins in opposite corners of the mating section.
Refrigerant Pipework and System Components

Throughout connecting up the system and components, observe the following practices.
WARNING
Ensure that all pipework, connections and system components are suitably pressure rated. Each refrigerant system within a unit is capped and filled with a holding charge of nitrogen, at a nominal pressure of 3.4 Bar g, before despatch from the factory. The holding charge must be vented to atmosphere immediately before opening the system envelope.
Base Plinth Mounting

If the floor is uneven, it is recommended that a suitable flooringlevelling screed is applied. To provide an air seal, use a layer of gasket above and below the plinth.
WARNING
The holding charge represents a pressure hazard. Therefore, before breaking into the system envelope, ensure that the holding charge has been vented and that the system is at atmospheric pressure. Do not leave any part of the system exposed to atmosphere any longer than is strictly necessary. When routing the pipework through the base into the unit, ensure that pipework does not obstruct airflow unnecessarily. Use only clean, hard drawn, refrigeration quality copper tubing, with wrought copper fittings. Route pipework to produce the minimum length refrigerant circuit, with swept bends. Gradient lines and install traps as shown on the pipework diagram for the site. When brazing, ensure that flux does not get inside the tubing. To prevent oxidation of the copper, a constant stream of dry nitrogen should be passed through the pipework during brazing. When installing pipework, allowance must be made for thermal movement. Piping must be arranged so that connections are not stressed. To eliminate vibration transfer, flexible connections must be used at the compressor discharge. Piping runs should be supported at 1.5 m intervals by suitable hangers or brackets. Ensure that pipework is isolated from supports by using foam insulation or similar. This will also be necessary where pipework passes through floors or walls. Where refrigerant lines are run in close proximity, they must be insulated from each other.
Floor Mounting
Front-return units can be located directly onto the floor. Before locating the unit in place, remove any flooring material. To provide an air seal, use a layer of gasket between the floor and the unit.
CAUTION
It is essential that all appropriate gaps are sealed to prevent bypassing, otherwise unit performance will be impaired. If it is suspected that the installation will be susceptible to vibration, it is recommended that the unit is seated on a 15 x 30 mm continuous strip of Tico anti-vibration packing. This will also provide a good seal.
Installation Clearances
Because the full-height doors provide full access for maintenance purpose, a unit can be installed against a wall at the back and sides as required. A clear distance of 800 mm must be allowed at the front for maintenance access. To ensure unobstructed flow of return air to the unit, a minimum distance of 300 mm must be allowed between the top of unit and the ceiling.
Piping up the System

IPAC range units are despatched complete with expansion valve(s), moisture indicating sight glass(es), filter/drier(s) and evacuation/charging connection points.
Document 0410536
Page 6-5
IPAC
Installation - DX Units Interconnecting Refrigerant Pipework
Pipework connection sizes are shown inPipework connection sizes on page 2-13 of Section 2. Discharge line and liquid line sizes are as shown inDischarge line and liquid line sizes guide - DX units on page 2-14 of Section 2 , which is provided for guidance only. Observe the following points: Where vertical lift between compressor and condenser exceeds 3 metres, traps are to be fitted to return oil to the compressor. Where horizontal runs exceed 25 metres, traps should be fitted to prevent excessive oil hold-up in the system. Thereafter, U bend traps should be formed in the vertical riser at 4 metre intervals. On shutdown, these traps will retain oil and prevent it from reentering the compressor. For excessive pipe lengths, the diameter of pipes should be calculated using accepted refrigeration practice. The following information is provided as a guide: Velocities in horizontal discharge lines should be 2.6 to 12.0 m/sec. Velocity in vertical lines should be 5.0 to 15.0 m/sec. Pressure drops between compressor and condenser must not exceed 41 kPa (6 psi).
WARNING
Do NOT attempt to test relief valve opening pressure while fitted to the system. Pressure relief valves must not be isolated. Do NOT fit isolating valves. As pressure relief valves must be arranged to relieve safely to atmosphere, it is recommended that at least one is fitted in the discharge line, near the condenser and in a safe area. If a relief valve is fitted inside the building, pipework must be installed to vent to a safe area. This pipework must be adequately sized for relief purposes, according to industry safe practice.
Humidifier Mains Water Supply
Liquid Receiver
If pipe runs are excessively long, a liquid receiver may be required. This is to ensure that only liquid refrigerant is supplied to the thermostatic expansion valve.
WARNING
The liquid receiver must be designed to accommodate all excess liquid not required in the evaporator (air cooler) when the unit is operating at below maximum load conditions. Depending on the design and installation of the liquid receiver, it may be necessary to fit a suitably sized and rated safety pressure relief valve. This must be installed according to refrigeration industry safety regulations, legislation and equipment manufacturers instructions. On a system having long enough runs of pipework to warrant the fitting of a liquid receiver, an additional volume of oil may need to be added to the compressor to allow for wetting of the system. If there is any doubt regarding the fitting of a liquid receiver, consult Eaton-Williams, or their appointed distributor for advice.
The Vapac humidifier is an electrode boiler operating at atmospheric pressure and is designed for connection to standard mains water supply, provided local regulations for this type of equipment are observed. To eliminate possible contamination of the water supply, the humidifier has a tundish which incorporates a 25 mm vertical gap over the maximum overflow level of the fill cup and below the end of the feed pipe. Subject to local regulations, this arrangement should eliminate the need for a static tank in the supply water feed. A Water Authority approved stop cock and strainer must be fitted in the supply from the water main; use 15 mm diameter copper tube or approved equivalent material. Pre-treatment of the feed water is unnecessary, as Vapac humidifiers are designed to operate on a wide range of water qualities. The standard Vapac humidifier is not suitable for connection to a fully demineralised water supply. The water quality range of the Vapac humidifier is: Hardness 50 to 500 ppm (mg/l) Conductivity 80 to 1000 microsiemens Water Pressure 0.30 to 8.00 bar g
Condensate Drain
The condensate drain runs from the condensate tray to the base of the unit in 13 mm internal diameter clear, flexible hose, which is looped within the unit to from a trap. If a humidifier is fitted, the condensate and humidifier drain lines are commoned-up, before the trap, using an equal tee piece to provide a single 13 mm internal diameter drain connection. The external drain line must be connected to the drain line hose and should provide a continuous fall to an open drain.
CAUTION
The unit is fitted with an internal condensate trap, do not fit an external trap. If a Vapac humidifier is installed, any plastic piping and fittings must be rated for use at 100 C.
Pressure Relief Valve

To protect against system pressure rising to a level that could be hazardous, it is recommended that a pressure relief valve, venting to a safe area, is fitted in the discharge line.
Page 6-6
IPAC
Installation - DX Units Power Supply
Units must be provided with a reliable power supply of 380/415 Vac, 3 ph, 50 Hz. Ensure that the supply is adequately rated to meet maximum demand; for details refer to unit wiring diagrams. It is recommended that an external local isolator is fitted, preferably one that incorporates an Emergency Stop button.
Fig. 6-4 : Electrical connection points
Emergency Stop
To enable the unit to be shutdown quickly in an emergency, it is recommended that an Emergency Stop button is fitted, either as part of an external isolator or as a separate control.
Electrical Connections
All IPAC units have bottom left hand cable entry as standard. Connection points are shown in Fig. 6-4 and Fig. 6-5. Main incoming power supply is connected to a main isolator, fitted master units only. Slave units are powered via controls in the master unit. All terminals for customer connection of power supply and control circuits are adjacent to the cable entry point, inside the lower left hand side of the unit. Note the following points: Do not run power and signal wiring close together. If it is necessary for signal wiring to cross power cables, ensure that they cross at right angles to each other. For details of mains power supply and control circuits, refer to specific unit wiring diagrams.
Fig. 6-5 : Interconnecting wiring connection points
WARNING
The unit isolator must remain in the OFF position until pre-commissioning checks have been carried out, which are part of the commissioning procedure.
Air-cooled Condenser
The power supply (normally single phase) to the condenser is taken from the dedicated terminal in the unit (master).
WARNING
If a voltage hazardous to life is connected to the volt-free contacts of the fault relay at the motherboard, this voltage may be present even when the unit isolator is switched OFF. Appropriate notices must be fixed to the unit to warn of this hazard.
Fire Shutdown Signal

This optional facility is linked out as standard. If this function is required, a volt-free contact of the Fire Shutdown control device should be connected to the customer terminals specified on the schematic wiring diagram for the unit. Contact function is: Closed circuit (contact makes) = Normal Open circuit (contact breaks) = Shutdown
Remote Start / Stop Signal

This optional facility is linked out as standard. If this function is required, a volt-free contact of the Start / Stop control device should be connected to the customer terminals specified on the schematic wiring diagram for the unit. Contact function is: Closed circuit (contact makes) = Unit Run Open circuit (contact breaks) = Unit Stop
Compressor Crankcase Oil Heater(s)

Compressor crankcase oil heaters are normally required to drive liquid refrigerant out of the oil if:
Document 0410536
Page 6-7
IPAC
Table 6-1 : Crankcase oil heater requirement criteria
Compressor Crankcase Oil Heater Requirement Criteria

Compressor Maximum permitted refrigerant charge without crankcase heaters Heater Part Number Electrical Rating
NOTE Identify the compressor by referring to the data plate on the compressor.
ZR61 ZR61/90 4.5 kg (9.9 lb) 2050050
ZR11 ZR12 10 kg (22 lb) 2050049
ZR16 7.7 kg (17 lb) 2050049
ZR19/250 11.3 kg (25 lb) 2050049x
220/240 Vac, 1 ph, 50 Hz, 59/70 W
The system has been inoperative for a period of time, or: During an off-cycle, when refrigerant can migrate back to the crankcase due to prevailing system temperatures; e.g. if the compressor is cooler than the condenser or evaporator. Because compressors fitted to IPAC units are able to cope with limited quantities of liquid refrigerant in flooded conditions, no crankcase oil heater is required when the system charge does not exceed the appropriate value in Table 6-1. Provided that there is no down time (i.e. normal operation is continuous throughout the year) and the system charge does not exceed the appropriate value in the table above, then crankcase oil heating is not a requirement. When installing heaters, follow the manufacturers instructions. Make electrical connections to the existing sleeved-off wiring in the unit. Refer to the electrical schematic wiring diagram for each unit, including slave units (where applicable).
Before carrying out the procedure, ensure that all personnel not essential for testing are at a safe distance. Place warning notices wherever appropriate around the site, advising of the hazard. 1. To avoid the need to open up the system later, first check the compressor oil level sight-glass to ensure that the oil level is correct. 2. Remove the system HP and LP (suction) pressure switches and in their place fit calibrated test pressure gauges. For details, refer to the system piping and instrument schematic diagram for the unit. 3. Connect a cylinder of test gas, such as Protec 5 (for an R22 system, use industrial grade dry nitrogen), to the charging point in the discharge line.
WARNING
Combined Strength and Leak Pressure Test

The following procedure must be carried out in turn for each refrigeration circuit of the unit. Because the system comprises components, such as interconnecting pipework, that are made up and fitted at site, these must be strength and leak pressure tested. As it is not practical to test such assembled components separately, the pressure test must be applied to the whole system.
Do NOT use any gas other than either a proprietary test gas, such as Protec 5 or dry nitrogen (as appropriate). Do NOT use oxygen or acetylene. Ensure that the charging line is adequately pressure rated and designed for use with refrigerant. Purge the charging line of air and then initially charge the system to a gauge pressure of 1.4 bar g (20 psig). Over a period of 15 minutes, monitor pressure gauges for indication of any leakage. Use leak disclosing fluid to locate the source of any leakage.
WARNING
Before carrying out the combined strength and leak test, consideration must be given to the relieving pressure of any additional pressure relief devices, such as bursting discs, that may be fitted by a third party, etc. The combined strength and leak test requires the system to be pressurised to 31.0 bar g (440 psi g). Carry out a combined strength and leak pressure test on each refrigeration system as follows:
WARNING
Do NOT attempt to carry out repairs or rectify leaks while the system is under pressure. In the case of any leakage, the test charge must be removed, the cause of leakage rectified and then steps 2 and 3 repeated. 4. Provided that there has been no leakage, continue to charge the system, gradually and in stages, until a test gauge pressure of 31.0 bar g (440 psi g) is reached.
CAUTION
Pressure testing is a potentially hazardous procedure and involves applying high pressure to the system.
Page 6-8
IPAC
WARNING
Do NOT raise system pressure straight up to test pressure. Raise the pressure gradually and in stages, allowing pressure to stabilise at each stage. At each stage of pressurisation, monitor pressure gauges for any indication of leakage. When the test pressure is reached, disconnect and remove the test charge cylinder. Note the pressure and ambient temperature. Leave the system to stand and over a period of 24 hours, monitor pressure gauges, from a safe distance, for indication of any leakage. 5. Start the vacuum pump and evacuate the system down to 0.5 Torr. Note that for dehydration to be effective, an ambient temperature of at least 7 C is required. If necessary, use heaters to warm the surroundings. 6. Leave the unit to stand for approximately 4 hours. Any rise in pressure during this period indicates that there is either moisture in the system, or a leak. Repeat the evacuation at intervals until the system can stand for 4 hours without pressure rising by more than 0.25 Torr. Failure to maintain a vacuum without pressure rising by more than 0.25 Torr indicates that there is a leak, which must be rectified and then the pressure and leak testing procedure repeated. 7. Switch off and disconnect the vacuum pump and vacuum test pressure gauge. 8. Refit the system HP and LP pressure switches. Provided that the evacuation has been successful, the system is now ready for Initial Charging With Refrigerant.
WARNING
Do NOT approach any part of the system while it is undergoing pressure testing. At the end of 24 hours check that pressure has been held, taking into account any variations caused by changes in ambient conditions. In the case of any leakage, at any time during pressurisation or while standing under test pressure, the test charge must be removed, the cause of leakage rectified and then steps 2 to 4 repeated. 5. On satisfactory completion of the pressure and leak test, vent the system down to a pressure just above atmospheric, ready for evacuation prior to charging. If the system is not to be evacuated and then charged with refrigerant immediately following strength and leak pressure testing, only reduce system pressure to a holding charge pressure of 3.4 bar g (50 psi g). On completion of the combined strength and leak pressure test, each refrigeration circuit must undergo Evacuation and Dehydration on page 9.
Initial Charging With Refrigerant

Throughout the charging procedure, observe the following points: Only use the correct refrigerant for the system. Never mix refrigerants. Only use fresh refrigerant. NEVER use reclaimed or contaminated refrigerant. Accurately weigh cylinders of refrigerant, before and after charging, to establish how much charge has been installed. Record the volume of refrigerant charged into the system. This is essential information for future reference. The charging line must be fitted with a non-return valve. A pressure gauge must be fitted to the charging cylinder, so that its condition can be monitored. To prevent moisture or other contaminants from entering the system, the charging line must be fitted with a new filter/ drier. Refrigerant R 407C, which is a blend, must be added as liquid only, otherwise characteristics of the refrigerant will be altered by fractional evaporation of its components in the cylinder. Therefore, ensure that the cylinder is arranged to charge liquid only. The following procedure must be carried out in turn for each refrigeration circuit of the unit. 1. Ensuring that the charging line is fully purged of air, connect a cylinder of the correct refrigerant to the charging point in the discharge line. For details, refer to the schematic diagram for the system. 2. SLOWLY open the liquid charging valve to break the vacuum and admit refrigerant into the system.
Evacuation and Dehydration

The following procedure must be carried out in turn for each refrigeration circuit of the unit. Prior to charging, the system must be evacuated and dehydrated as follows:
WARNING
Do NOT operate the compressor while the system is under vacuum. Do NOT use the compressor to evacuate the system. 1. If the system still contains a holding charge, vent the system down to a pressure just above atmospheric. 2. Remove the HP and LP pressure gauges. 3. Fit a barometrically compensated vacuum test gauge to the system. 4. Connect a suitable vacuum pump to the HP and LP sides of the system.
Document 0410536
Page 6-9
IPAC
CAUTION
Until system pressure has been raised above atmospheric, only admit small quantities of refrigerant, otherwise violent cooling may cause thermal shock to system components. The system needs to be charged on the HP AND LP sides of the compressor. Add the charge gradually and in stages, until as much as possible of the estimated charge has been added to the system. For the estimated weight of initial charge, refer to Technical data on page 2-8 of Section 2. During charging, if system and cylinder pressures equalise, the flow of refrigerant into the system will cease. To encourage further charge to enter the system, place the cylinder in a bucket of warm water to increase cylinder pressure.
Fresh air intake

Suitable for 250 ducting, drill and fix to suit. Recommend filtration.
Condensate pumps
Cold water Position underneath outlet. Site fit. Hot water As above but non-return valve needs to be fitted after discharge pump. All materials used must be suitable for use up to 100C.
Oil separators
Site fitted, follow manufacturers installation instructions.
Fresh air control

If the fresh air is ducted, then the outside air sensors are to be moved from their standard position and wiring extended to a location as close as possible to the outside air source. As the IPAC unit will draw the design quantity of fresh air into the system, the overall design should inhibit water ingress into the building. For optimum system performance the fresh air pressure drop should be kept to a minimum.
WARNING
Do NOT use a flame or heat gun to warm the cylinder, otherwise it may rupture. When as much as possible of the estimated weight of charge has been added, stop charging, isolate the cylinder of refrigerant at the cylinder and disconnect the cylinder.
Mains filter kit

See Alan!!!
WARNING
The charging line contains liquid refrigerant under high pressure. Adequate precautions must be taken to avoid freeze burns to the face, eyes and skin. 3. Record the weight of refrigerant charged into the unit. Any final charging must be carried out (by customer) during commissioning. 4. When pressure has stabilised throughout the system, record HP and LP pressure gauge readings; these should be equal. At regular intervals, monitor pressure gauges for any indication of leakage. 5. Disconnect and remove the cylinder of refrigerant. Initial charging is now complete and this also completes the installation procedure. If necessary, any final charging is carried out during commissioning. The unit is now ready for commissioning as described in Section 8 - Commissioning - DX Units.
Remote sensors
See Alan!!!
Water Detection tape

Terminals are provided within the electrical chassis for connection of the water detection tape. The sensing length of the tape should be positioned in the unit or underfloor where water may collect. In multi-module units a tape should be fitted to each section.
ICV Condensor Interlock

Please see wiring diagram for additional control wiring to be fitted for this option.
Flexible duct connection

The ductwork connection is a 30mm Doby 'slide-on' flange system, which conforms fully to HVCA specification DW142 for rectangular duct connections.
Floor support angles

These are supplied loose with certain base plinth options. The base plinth should be drilled to suit exact floor height allowing for anti-vibration gasket to be installed between the angles and the floor tiles.
Installation of optional accessories

High efficiency filter housing
Actual fitting of filters.
Side service entry

Removal of gland plates, drill to suit.
Page 6-10
Eaton-Williams
IPAC
IPAC
IPAC
SECTION 7
INSTALLATION - CHILLED WATER UNITS

Introduction Persons Permitted to Carry Out Installation Arrival at Site Off-loading and Handling
Off-loading by Crane Off-loading by Forklift Moving a Unit
Page
74 74 74 74
74 74 74
Storage Installation Obstructions

Noise Condensate Drain
74 75
75 75
Positioning
Floor Mounting Base Plinth Mounting
75
75 76
Installation Clearances Piping up the System Filling the System Humidifier Mains Water Supply Condensate Drain Power Supply Emergency Stop Electrical Connections
Remote Start / Stop Signal Fire Shutdown Signal
76 76 76 76 77 77 77 77
77 77
Completion of Installation
77
IPAC
IPAC
Installation - Chilled Water Units
Page 7-2
IPAC
Installation - Chilled Water Units Introduction
The purpose of this section is to provide an overall guide for the installation of IPAC range AHUs and is not an exhaustive stepby-step installation guide. Each site will vary in requirements regarding layout and obstacles to overcome. If there are queries or points of uncertainty, refer to EatonWilliams for clarification. Also refer to any special instructions issued by Eaton-Williams, or their appointed distributor, for a specific project.
Fig. 7-1 : Unit lifting brackets
Persons Permitted to Carry Out Installation

Only personnel who have been properly trained in the installation of refrigeration equipment should be permitted to carry out installation of the equipment covered by this manual.
Arrival at Site
If any damage is found, this must be reported to Eaton-Williams, or their appointed distributor, immediately. Units are normally despatched enclosed in suitable packaging for protection during transit. The arrangement and type of packaging will vary according to the method of transportation, site location, unit type and quantity, etc. Before Acceptance: Before unpacking, check all packaging for any evidence of damage that could indicate possible damage to a unit within. Carefully remove all packaging and then thoroughly check each unit for damage. Do not allow the unit to become wet. Each unit is supplied containing a holding charge of dry nitrogen, nominal pressure 3.4 bar g (50 psi g). Fit a calibrated test pressure gauge and check that the holding charge is intact. Report any damage or escape of holding charge to the carrier and to Eaton-Williams immediately. Eaton-Williams cannot be held responsible for any damage occurring during transit. To avoid damage to the unit or injury to personnel, observe the following points: Ensure that all lifting and handling gear, including any slings, etc., are of adequate specification. If the unit is to be lifted by crane or hoist, correctly sized load spreaders must be used. Ensure that the lift is vertical. Do not allow the unit to drop.
Off-loading by Crane
CAUTION
To avoid damage, load spreaders must always be used when lifting the unit by hoist or crane. Always use the specially designed lifting brackets provided by Eaton-Williams; refer to Fig. 7-1.
Off-loading by Forklift
CAUTION
The unit can be off-loaded and moved using a forklift, provided that the lift is from under the pallet; refer to Fig. 7-2. Lifting directly against the unit bottom will cause irreparable damage.
Off-loading and Handling

Before moving units, check the weight by referring to IPAC Range unit configurations, dimensions and weights on page 27 of Section 2. Add an adequate allowance for any significant packaging, such as wooden crating.
CAUTION
At NO time is the unit to be laid on its back, side or front. Doing this will cause irreparable damage. To facilitate lifting by crane or hoist, Eaton-Williams can provide specially designed lifting brackets on request. These brackets are to be fitted to the top of the unit, one at each end, as shown in Fig. 7-1.
Moving a Unit
The unit can be moved around using appropriate equipment as illustrated in Fig. 7-2 and Fig. 7-3.
Storage
Units that are not installed directly following arrival at site must be stored in a weatherproof, dry, well-ventilated and vermin-free area. To prevent Brinelling of bearings, units must be stored in a vibration-free area, otherwise adequate steps must be taken to prevent such damage.
WARNING
Lifting eyes must not be used, otherwise they may strip-out during the lift.
Document 0410536
Page 7-3
IPAC
Fig. 7-2 : Off-loading by forklift (generic unit shown) and Off-loading by crane (generic unit shown)
Fig. 7-3 : Using pallet trucks (generic unit shown)
The proximity of these items must be taken into consideration, especially in respect of any adverse affect they may have on the flow of return air.
Noise
The installation must be checked regarding noise levels generated during operation, to ensure that local requirements and limitations are adhered to.
Condensate Drain
Condensate must be arranged to discharge directly into a properly designed drain. Refer to for further details.
Positioning Installation Obstructions

A number of factors must be assessed regarding the installation of air handling units. Hot water pipework - must be properly lagged to minimise heat transfer. Radiators or night storage heaters positioning. Electrical fittings and installations. Telecommunications equipment positioning. Cable tray and busbar support drop rod positioning. Cable tray and busbar distribution systems IPAC units are designed to locate either directly on to raised floor jacks, or onto a base plenum.
CAUTION
IPAC range AHUs are designed for indoor use only. For downflow units with top or back return, BEFORE positioning the unit, ensure that the aperture blanking plate is correctly positioned for airflow direction.
Page 7-4
IPAC
Floor Mounting
Front-return units can be located directly onto the floor. To provide an air seal, use a layer of gasket between the floor and the unit. If it is suspected that the installation will be susceptible to vibration, it is recommended that the unit is seated on a 15 x 30 mm continuous strip of Tico anti-vibration packing. This will also provide a good seal. Piping runs should be supported at 1.5 m intervals by suitable hangers or brackets. Ensure that pipework is isolated from supports by using foam insulation or similar. This will also be necessary where pipework passes through floors or walls. Where lines are run together, they must be insulated from each other. When installing pipework, allowance must be made for thermal movement. Piping must be arranged so that connections are not stressed.
Base Plinth Mounting

If the floor is uneven, it is recommended that a suitable flooringlevelling screed is applied. To provide an air seal, use a layer of gasket above and below the plinth. Before mounting the unit, ensure that the plinth is perfectly level in both planes and will remain so when the unit is mounted. Mount the unit onto the plinth, using the two locating pins provided. Fit the pins in opposite corners of the base plinth; the unit has matching clearance holes for location. Use screw fixings to secure the unit to the wall.
Filling the System

After all pipework has been installed, the system can be filled. Only potable water should be used to fill the system. To prevent sludging, it is recommended that a corrosion inhibitor / anti-sludging agent is used in the chilled water system. NOTE Any antifreeze or corrosion inhibitor must be suitable for system materials. During and after filling the system, check thoroughly for leaks, paying particular attention to all connections and unions. Leakage at a compression fitting can sometimes be remedied by tightening the fitting. To repair leakage at a soldered or brazed connection, the system must be drained to empty the section of pipework before carrying out the repair. The system can then be re-filled and then re-checked for leaks.
Installation Clearances
Because the full-height doors provide full access for maintenance purpose, a unit can be installed against a wall at the back and sides as required. A clear distance of 800 mm must be allowed at the front for maintenance access. To ensure unobstructed flow of return air to the unit, a minimum distance of 300 mm must be allowed between the top of unit and the ceiling.
Humidifier Mains Water Supply
Piping up the System

Site chilled water system connections (flow and return) are terminated and capped off in the base of the unit. After units have been correctly positioned and installed, interconnecting pipework can be installed between the unit and the chilled water system. Throughout connecting up the system, observe the following practices. To protect the modulating flow control valve from being affected by sludge or debris, a fine mesh strainer should be installed before the flow connection to the unit. NOTE Failure to protect the flow control valve from system sludge and debris can adversely affect plant performance. The ideal arrangement is for two full-capacity strainers to be fitted in parallel, with isolating valves, so that unit operation will not be interrupted during strainer maintenance. When routing the pipework through the base into the unit, ensure that pipework does not obstruct airflow unnecessarily. Use only clean, hard drawn, refrigeration quality copper tubing, with wrought copper fittings. Route pipework to produce the minimum length circuit, with swept bends.
The Vapac humidifier is an electrode boiler operating at atmospheric pressure and is designed for connection to standard mains water supply, provided local regulations for this type of equipment are observed. To eliminate possible contamination of the water supply, the humidifier has a tundish which incorporates a 25 mm vertical gap over the maximum overflow level of the fill cup and below the end of the feed pipe. Subject to local regulations, this arrangement should eliminate the need for a static tank in the supply water feed. A Water Authority approved stop cock and strainer must be fitted in the supply from the water main; use 15 mm diameter copper tube or approved equivalent material. Pre-treatment of the feed water is unnecessary, as Vapac humidifiers are designed to operate on a wide range of water qualities. The standard Vapac humidifier is not suitable for connection to a fully demineralised water supply. The Vapac humidifier water quality range is: Hardness 50 to 500 ppm (mg/l) Conductivity 80 to 1000 microsiemens Water Pressure 0.30 to 8.00 bar g After connecting the water supply to the humidifier, fill the pipework and check for leaks; repair as necessary, adopting the procedure described under .
Document 0410536
Page 7-5
IPAC
Installation - Chilled Water Units Condensate Drain
The condensate drain runs from the condensate tray to the base of the unit in 13 mm internal diameter clear, flexible hose, which is looped within the unit to from a trap. If a humidifier is fitted, the condensate and humidifier drain lines are commoned-up, before the trap, using an equal tee piece to provide a single 13 mm internal diameter drain connection. The external drain line must be connected to the drain line hose and should provide a continuous fall to an open drain.
Fig. 7-4 : Electrical connection points
CAUTION
The unit is fitted with an internal condensate trap, do not fit an external trap. If a Vapac humidifier is installed, any plastic piping and fittings must be rated for use at 100 C.
Power Supply
Units must be provided with a reliable power supply of 380/415 Vac, 3 ph, 50 Hz. Ensure that the supply is adequately rated to meet maximum demand; for details refer to unit wiring diagrams. It is recommended that an external isolator is fitted, preferably one that incorporates an Emergency Stop button.
Emergency Stop
To enable the unit to be shutdown quickly in an emergency, it is recommended that an Emergency Stop button is fitted, either as part of an external isolator or as a separate control.
Fig. 7-5 : Interconnecting wiring connection points
Electrical Connections
All IPAC units have bottom left hand cable entry as standard. Connection points are shown in Fig. 7-4 and Fig. 7-5. Main incoming power supply is connected to a main isolator, fitted master units only. Slave units are powered via controls in the master unit. All terminals for customer connection of power supply and control circuits are adjacent to the cable entry point, inside the lower left hand side of the unit. Note the following points: Do not run power and signal wiring close together. If it is necessary for signal wiring to cross power cables, ensure that they cross at right angles to each other. For details of mains power supply and control circuits, refer to specific unit wiring diagrams.
Contact function is: Closed circuit (contact makes) = Unit Run Open circuit (contact breaks) = Unit Stop
Fire Shutdown Signal

This optional facility is linked out as standard. If this function is required, a volt-free contact of the Fire Shutdown control device should be connected to the customer terminals specified on the schematic wiring diagram for the unit. Contact function is: Closed circuit (contact makes) = Normal Open circuit (contact breaks) = Shutdown
WARNING
The unit isolator must remain in the OFF position until pre-commissioning checks have been carried out, which are part of the commissioning procedure.
Remote Start / Stop Signal

This optional facility is linked out as standard. If this function is required, a volt-free contact of the Start / Stop control device should be connected to the customer terminals specified on the schematic wiring diagram for the unit.
Completion of Installation
On completion of installation, the unit is now ready for commissioning as described in Section 9 - Commissioning - CW Units.
Page 7-6
Eaton-Williams
IPAC
IPAC
IPAC
SECTION 8
COMMISSIONING - DX UNITS
Introduction Persons Permitted to Carry Out Commissioning Pre-commissioning Checks - Unit Non-operational Unit Operational Checks
Electrical Fan(s) and Airflow Air Filter Blocked Function Fault Detection and Control Functions Condenser Start-up Control High Pressure Cut-out Final Charging System Checks Smoke alarm test (if applicable) Test of Vapac humidifier operation (if applicable) Finalising operational tests
Page
84 84 84 85
85 85 85 85 86 86 86 86 87 87 87 87
Room Balancing Leaving Site
87 87
IPAC
IPAC
Commissioning - DX Units Introduction
The purpose of this section is to describe pre-commissioning, checking and final commissioning for a typical installation equipped with IPAC air handling units fitted with DX cooling. Information provided in this section is intended for guidance only and is not an exhaustive step-by-step commissioning guide. Although similar in function, each installation will have characteristics peculiar to it. Any queries or points of uncertainty should be discussed with the Eaton-Williams Commissioning Supervisor for clarification. All results and readings, observed or calculated, should be recorded in a logbook. For multiple installations, these instructions are to be carried out for each separate unit and (where applicable) for each refrigeration circuit of the unit. For each test that generates an alarm, restore normal conditions and then clear the alarm before moving on to next step. 5. Check that the main isolator and all circuit breakers in the unit are in the OFF position. 6. Check the unit casing for damage and check that all doors and covers seal correctly against mating surfaces. 7. Unlock and open front access doors. 8. Check all items within unit to ensure that they have not become loose, dislodged, or damaged in transit. 9. Check that the earth connection is correctly made to both the isolator and the unit. 10. Check that the earth connection is made correctly to any metal drain and water supply pipes for the Vapac humidifier, (if fitted). 11. Check that all mains electrical connections are tight and secure. 12. Check for free rotation of fans. Inspect for damage and remove any debris.
WARNING
Although a fan may be OFF, its impeller may still be induced to rotate at considerable speed, driven by inlet/outlet pressure differences caused by other equipment or local conditions. Beware of this potential hazard and take precautions to avoid injury - DO NOT use fingers to check for free rotation, instead, use a piece of stiff card. Do not use a material that may damage the impeller or break up. 13. If ductwork is fitted to supply or discharge, check that mating surfaces are sealed. 14. Check that insulation is securely fastened to panels. 15. Check the external drain connection by pouring water into the condensate tray to prime the trap. Check for leaks and that the water drains correctly. NOTE The unit is fitted with an internal condensate trap, do not fit an external trap. 16. Check water supply and drain connections for the Vapac humidifier (if fitted). 17. Check the steam line and its connections (units fitted with a Vapac humidifier). 18. Check the unit log record for the pressure and charge weight that was recorded during the last stages of installation. If there any is indication of leakage, this must be rectified (by customer) before commissioning can proceed further. 19. Check that air filters are fitted correctly. 20. Check that refrigeration system pressure switches and their connections are secure. 21. Inspect all internal electrical wiring and terminations. 22. Check for free operation of all contactors. 23. Check that fuses are in position and correctly rated according to the wiring diagram.
Persons Permitted to Carry Out Commissioning

Only personnel who have been properly trained in the commissioning of refrigeration equipment should be permitted to carry out commissioning of the equipment covered by this manual.
Pre-commissioning Checks - Unit Non-operational

During this procedure, note the following points: Ensure that the area around the air handling unit, including grilles, is clear of any obstruction, e.g. builders rubbish, packing material or other debris. The area must be swept of light litter, such as sawdust or paper particles, that may become airborne, enter the unit and foul air filters. Removal of any obstruction from the area around the unit must be done in co-operation with the Site Manager. Carry out the following procedure steps in order of sequence: 1. Remove any remaining packing material from the outside of the unit. 2. Ensure that the power supply is of the correct voltage and that all electrical connections made at site are correct. 3. Ensure that external controls, such as Fire Shutdown, and Smoke Detection (if fitted) are in the MADE (closed circuit) state. If these functions are not installed, ensure that the appropriate terminals are linked-out in accordance with the wiring diagram. 4. Check that the power supply to the unit is switched OFF at the external isolator or distribution board. For increased safety, remove any fuses in the power supply to the unit.
WARNING
To prevent personnel from restoring power to the unit, place warning notices where applicable.
Page 8-2
IPAC
Commissioning - DX Units
24. For ducted systems, check that any manually operated dampers are correctly positioned to achieve design operation. 25. Close all windows and doors to the equipment room. 8. If airflow is incorrect, check possible causes. If incorrect airflow is due to non-standard external resistance, check whether this is acceptable, or whether the fan drive ratio needs to be modified to obtain design airflow. 9. Using a clip-on ammeter, measure fan operating currents and record readings in the commissioning log. 10. Switch all circuit breakers to ON. 11. Check the Airflow Failure control function: 12. Adjust the air switch up to 5.0 mbar. A prompt alarm is generated at the customer terminals and the unit display (if fitted). 13. After testing, re-adjust the airflow switch setting to 0.5 mbar.
Unit Operational Checks

Carry out the following checks in order of sequence:
Electrical
1. Check that the main isolator and all circuit breakers in the unit are in the OFF position 2. Disable compressor starting by disconnecting compressor(s) supply from the contactor(s). 3. At the external isolator or distribution board, switch ON the power supply to the unit. 4. Check that the mains supply voltage at the unit input terminals is correct: 5. Phase to Phase = 380 to 415 V ac 6. Phase to Neutral = 220 to 240 V ac 7. Check that connections to the transformer are correct for the supply to the unit according to the wiring diagram.
Air Filter Blocked Function

To check the Filter Blocked control function: 1. Cover air filters with suitable material to simulate a choked filter. With 75 % (approx.) of filter covered, the airflow switch should trip. A deferred alarm is generated at the customer terminals and on the unit display (if fitted). 2. Remove the blockage after testing.
WARNING
Incorrect connection to the transformer may result in damage to the control system. 8. Check the function of each EMERGENCY SHUTDOWN facility (where fitted). 9. Check for correct operation of the controller display on the front of the unit; refer to Section 4 - INVICTANET CONTROLLER TECHNICAL MANUAL for details.
Fault Detection and Control Functions

To check the Flood Detection control function: Flood detection 1. Simulate a water flood by operating the flood detection sensor (if fitted), or connect a link across the water detection terminals. A prompt alarm is generated at the customer terminals and on the unit display (if fitted). 2. After testing remove the link (if one was fitted) Supply fan failure In turn, manually trip each supply fan MPCB. A prompt alarm is generated at the customer terminals and on the unit display (if fitted). Also check each overload setting. Compressor failure In turn, manually trip each compressor MPCB. A prompt alarm is generated at the customer terminals and on the unit display (if fitted). Also check each overload setting.
Fan(s) and Airflow

1. Switch ON unit at external isolator switch or distribution board.
WARNING
Remember that the unit is now live - extreme caution must be exercised at all times. Switch ON fan MPCBs in the control section. This enables fan(s) operation on automatic control. Switch ON control circuit MCBs. Unit is now under automatic control. After a period of 30 seconds (nominal), fan(s) will start. Airflow failure monitoring alarm is delayed for a further 20 seconds. Check for direction of fan rotation and listen for any adverse noises. Using an anemometer, check supply fan airflow at the return air grille/opening. Check that airflow is within 10 % of design; refer to Technical data on page 2-8 of Section 2. If airflow is correct, record the reading in the unit commissioning log.
2. 3. 4.
5. 6. 7.
Document 0410536
Page 8-3
IPAC
Fig. 8-1 : Temperature controls and heating
45 40 35 30 Temperature 25 20 15 10 5 0 3000 8000 13000 18000 OHMS 23000 28000
1. Check the high pressure trip and control function:
WARNING
During this procedure, do NOT permit pressure to rise above the leak test pressure of 31.0 bar g (440 psi g). If necessary, stop the unit immediately. With the unit running in cooling mode, partly cover the condenser coil, or switch OFF the condenser fan. 2. Check that check that HP pressure switch operates at the correct pressure and shuts down the relevant compressor. A Prompt alarm is generated at the customer terminals and on the unit display (if fitted). 3. After testing, restore condenser cooling. 4. Disconnect and remove the temperature simulation resistance that was installed at step 1 of 8-1.
1. So that changes in air temperature can be simulated for testing, connect a variable resistance box, or 0 to 20 k ohm potentiometer, to the return air sensor connection on the unit controller; refer to the unit wiring diagram. 2. Heater check (if applicable): 3. Adjust temperature simulation resistance to 5.5 C, at which point the heating is brought into operation. This is checked using a clip-on ammeter and the reading then recorded. 4. Check that the overheating cut-out functions correctly by setting the temperature simulation resistance to 24 C. 5. Adjust temperature simulation resistance to: 40 C - check high temperature alarm. 05 C - check low temperature alarm. 6. Switch OFF the main isolator. Reconnect compressor wiring to the contactor.
Final Charging
For this type of DX system, the maximum volume of refrigerant charge is required when the unit is running at design load conditions. The system is fully charged when the point is reached that there are no bubbles visible in the moisture indicating sight glass in the liquid line. Top-up the system charge as follows: 1. Arrange a cylinder of the correct refrigerant for the unit so that only liquid will be charged. NOTE The weight of charge added to the unit must be recorded. 2. Operate the unit at design load conditions. 3. Add liquid-only refrigerant via manifold into the suction line, gradually and in stages, allowing system operating conditions to stabilise each time after adding liquid.
Condenser
Switch the condenser isolator ON and then carry out commissioning checks according to the condenser instruction manual.
WARNING
Do not overcharge the system. Do not add any more refrigerant than is necessary to produce a bubble-free moisture indicating sight glass, otherwise the system will be overcharged and likely to result in high pressure cut-out trips when the unit is run at maximum load. 4. Update the unit log record to show the charge weight and pressure.
Start-up Control
1. Switch the main isolator ON. 2. Adjust temperature simulation resistance to 35 C - to generate a cooling required / start refrigeration condition. Check that start delays are correct for the controller.
System Checks High Pressure Cut-out

The following procedure must be carried out in turn for each refrigeration circuit of the unit. NOTE If the unit is undercharged and therefore low overall system pressures exist, it may not be possible to check the HP cut-out trip function until Final Charging has first been carried out as described under . 1. Allow system to operate normally for at least ten minutes to stabilise. Ideally, with room air temperature at design, record the following data: 2. Evaporating pressure. Condensing pressure. Compressor operating current. For 2 compressor control, adjust temperature simulation resistance to stage-out each compressor and observe damper operation.
Page 8-4
IPAC
3. Disconnect the temperature simulation resistance and reconnect the temperature sensor. Ensure that any witness signatures are obtained before handover. Keys should be handed over to the Officer or Site Manager in charge.
Smoke alarm test (if applicable)

Check smoke alarm function as specified by the manufacturer.
Test of Vapac humidifier operation (if applicable)

1. Check the MPCB overload setting. 2. 3. 4. 5. Set humidity demand. Check that the cylinder fills and there are no leaks. Check and record the operating current. Reduce humidity demand and check that the humidifier cuts-out correctly.
Finalising operational tests

1. Reset the unit to automatic control. 2. Reset all default settings, unless specifically requested otherwise. 3. If any controller settings have been changed from default values, record these values in the appropriate table(s) provided under Section 5 - INVICTANET Controller Settings Record. 4. Check operation of the display screen by scrolling through all screens and levels. 5. Observe and record: Return air temperature Outside ambient air temperature Unit run time Relative humidity (if applicable) 6. The function of all alarms should be checked at the: Unit Remote display (if applicable) Remote Monitoring Centre (if applicable) 7. Record any alteration to default settings.
Room Balancing
It is recommended that the entire environmental control installation is fully commissioned (by customer) before being brought into service.
Leaving Site
Before leaving site: Ensure that all covers are located and fitted correctly, are airtight and locked. Finally check that unit(s) are left in good order and (if required) switch OFF the supply at the external isolator or distribution board. Ensure that all tools and test instruments are removed from site. Finally check through the documentation to ensure that all aspects have been covered.
Document 0410536
Page 8-5
IPAC
Page 8-6
Eaton-Williams
IPAC
IPAC
IPAC
SECTION 9
COMMISSIONING - CW UNITS

Introduction Persons Permitted to Carry Out Commissioning Pre-commissioning Checks - Unit Non-operational Unit Operational Checks Finalising operational tests Room Balancing Leaving Site
Page
94 94 94 95 96 96 96
IPAC
IPAC
Commissioning - CW Units Introduction
The purpose of this section is to describe pre-commissioning, checking and final commissioning for a typical installation equipped with IPAC air handling units. Information provided in this section is intended for guidance only and is not an exhaustive step-by-step commissioning guide. Although similar in function, each installation will have characteristics peculiar to it. Any queries or points of uncertainty should be discussed with the Eaton-Williams Commissioning Supervisor for clarification. All results and readings, observed or calculated, should be recorded in a logbook. For multiple installations, these instructions are to be carried out for each separate unit and (where applicable) for each system circuit of the unit. For each test that generates an alarm, restore normal conditions and then clear the alarm before moving on to next step. 5. Check that each cooling and heating pipework circuit has been connected correctly and that flow and return connections are correct. This may seem obvious, but it is surprisingly easy for system pipework to be inadvertently cross-connected during installation. 6. Check that all pipework is insulated correctly, including any through-wall pipework. 7. Check that all unit coil vent and drain valves are closed. 8. Fill the cooling system circuit by opening appropriate isolating valves. Purge as much air as possible from the system by using the highest of any manually operated external vent valves. Check the system for leaks and make any repairs as necessary. 9. After allowing the system to fill as much as possible, start the cooling system circulating pump. Continue to purge as much air as possible from the system. 10. Purge air from the coil by partially opening the cooling coil vent valve. When all air has been purged from the coil, close the vent valve. For multiple installations, purge all air from the unit closest to the pump in the system circuit flow first. Then proceed to the next closest and so on round the system circuit until each unit has been purged of air. NOTE Failure to purge all air from the system and coil block will result in poor performance from the unit. 11. Repeat steps 8 to 10 for the heating system and each unit heating coil (if fitted). 12. Ensure that the power supply is of the correct voltage and that all electrical connections made at site are correct. 13. Ensure that external controls, such as Fire Shutdown, and Smoke Detection (if fitted) are in the MADE (closed circuit) state. If these functions are not installed, ensure that the appropriate terminals are linked-out in accordance with the wiring diagram. 14. Check that the power supply to the unit is switched OFF at the external isolator or distribution board. For increased safety, remove any fuses in the power supply to the unit. 15. Check that the main isolator and all circuit breakers in the unit are in the OFF position. 16. Check the unit casing for damage and check that all doors and covers seal correctly against mating surfaces. 17. Unlock and open front access doors. 18. Check all items within unit to ensure that they have not become loose, dislodged, or damaged in transit. 19. Check that the earth connection is correctly made to both the isolator and the unit.
Persons Permitted to Carry Out Commissioning

Only personnel who have been properly trained in the commissioning of refrigeration equipment should be permitted to carry out commissioning of the equipment covered by this manual.
Pre-commissioning Checks - Unit Nonoperational

Ensure that the area around the air handling unit, including grilles, is clear of any obstruction, e.g. builders rubbish, packing material or other debris. The area must be swept of light litter, such as sawdust or paper particles, that may become airborne, enter the unit and foul air filters. Removal of any obstruction from the area around the unit must be done in co-operation with the Site Manager. This part of the commissioning procedure is carried out with the unit(s) non-operational and before the power supply is turned on.
WARNING
Do NOT supply power to the unit while carrying out this part of the commissioning procedure. Carry out the following in order of sequence. 1. Remove any remaining packing material from the outside of the unit. 2. Check that the earth connection is correctly made to the unit. 3. Check that the earth connection is correctly made to flow and return pipework and any metal condensate drain pipes (where fitted). 4. Ensure that all units, duct work and louvres are clean and free of any installation debris. The area must be made clean of light litter, such as sawdust or paper particles, that may become airborne and clog the air filter(s).
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IPAC
Commissioning - CW Units
20. Check that the earth connection is made correctly to any metal drain and water supply pipes for the Vapac humidifier, (if fitted). 21. Check that all mains electrical connections are tight and secure. 22. Check for free rotation of fans. Inspect for damage and remove any debris. 23. If ductwork is fitted to supply or discharge, check that mating surfaces are sealed. 24. Check that insulation is securely fastened to panels. 25. Check the external drain connection by pouring water into the condensate tray to prime the trap. Check for leaks and that the water drains correctly.
WARNING
Remember that the unit is now live - extreme caution must be exercised at all times. 6. Switch ON fan MPCBs in the control section. This enables fan(s) operation on automatic control. 7. Switch ON control circuit MCBs. Unit is now under automatic control. 8. After a period of 30 seconds (nominal), fan(s) will start. Airflow failure monitoring alarm is delayed for a further 20 seconds. 9. Check for direction of fan rotation and listen for any adverse noises. 10. Using an anemometer, check supply fan airflow at the return air grille/opening. 11. Check that airflow is within 10 % of design; refer to Technical data on page 2-8 of Section 2. If airflow is correct, record the airflow reading in the commissioning log. 12. If airflow is incorrect, check possible causes. If incorrect airflow is due to non-standard external resistance, check whether this is acceptable, or whether the fan drive ratio needs to be modified to obtain design airflow. 13. Using a clip-on ammeter, measure fan operating currents and record readings in the commissioning log. 14. Check the function of each EMERGENCY SHUTDOWN facility (where fitted). 15. Switch all circuit breakers to ON. 16. Check for correct operation of the controller display on the front of the unit; refer to Section 4 - INVICTANET CONTROLLER TECHNICAL MANUAL for details. 17. Check the Airflow Failure control function: 18. Adjust the air switch up to 5.0 mbar. A prompt alarm is generated at the customer terminals and the unit display (if fitted). 19. After testing, re-adjust the airflow switch setting to 0.5 mbar. 20. Check the Filter Blocked control function: 21. Cover air filters with suitable material to simulate a choked filter. With 75 % (approx.) of filter covered, the airflow switch should trip. A deferred alarm is generated at the customer terminals and on the unit display (if fitted). 22. Remove the blockage after testing. 23. Check the Flood Detection control function: 24. Simulate a water flood by operating the flood detection sensor (if fitted), or connect a link across the water detection terminals. A prompt alarm is generated at the customer terminals and on the unit display (if fitted). 25. After testing remove the link (if one was fitted) 26. Check Supply Fan Failure control function: 27. In turn, manually trip each supply fan MPCB. A prompt alarm is generated at the customer terminals and on the unit display (if fitted). Also check each overload setting.
CAUTION
The unit is fitted with an internal condensate trap, do not fit an external trap. 26. Check water supply and drain connections for the Vapac humidifier (if fitted). 27. Check steam line and connections (units fitted with a Vapac humidifier). 28. If there any is indication of leakage, this must be rectified (by customer) before commissioning can proceed further. 29. Check that air filters are fitted correctly. 30. Inspect all internal electrical wiring and terminations. 31. Check for free operation of all contactors. 32. Check that fuses are in position and correctly rated according to the wiring diagram. 33. For ducted systems, check that any manually operated dampers are correctly positioned to achieve design operation. 34. Close all windows and doors to the equipment room.

1. Check that the main isolator and all circuit breakers in the unit are in the OFF position. 2. At the external isolator or distribution board, switch ON the power supply to the unit. 3. Check that the mains supply voltage at the unit input terminals is correct: Phase to Phase = 380 to 415 V ac Phase to Neutral = 220 to 240 V ac 4. Check that connections to the transformer are correct for the supply to the unit according to the wiring diagram.
CAUTION
Incorrect connection to the transformer may result in damage to the control system. 5. Switch ON unit at external isolator switch or distribution board.
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Commissioning - CW Units
28. So that changes in air temperature can be simulated for testing, connect a variable resistance box, or 0 to 20 k ohm potentiometer, to the return air sensor connection on the unit controller; refer to the unit wiring diagram. 29. Heater check (if applicable): 30. Adjust temperature simulation resistance to 5.5 C, at which point the heating element is brought into operation. This is checked using a clip-on ammeter and the reading then recorded. 31. Check that the overheating cut-out functions correctly by setting the temperature simulation resistance to 24 C. 32. Adjust temperature simulation resistance to: 40 C - check high temperature alarm. 5 C - check low temperature alarm. 33. Adjust temperature simulation resistance to: 35 C - to generate a cooling required condition. 34. Check that start delays are correct for the controller. 35. Record unit operating current(s) in cooling mode. 36. Record unit operating current(s) in heating mode (if applicable). 37. Switch OFF the unit at the isolator and then disconnect the temperature simulation resistance and reconnect the temperature sensor. Smoke alarm test (if applicable) Check smoke alarm function as specified by the manufacturer. Test of Vapac humidifier operation (if applicable) 1. Check the MPCB overload setting. 2. 3. 4. 5. Set humidity demand. Check that the cylinder fills and that there are no leaks. Check and record the operating current. Reduce humidity demand and check that the humidifier cuts-out correctly. Remote Monitoring Centre (if applicable) 7. Record any alteration to default settings.
Room Balancing
It is recommended that the entire environmental control installation is fully commissioned (by customer) before being brought into service.
Leaving Site
Before leaving site: Ensure that all covers are located and fitted correctly, are airtight and locked. Finally check that unit(s) are left in good order and (if required) switch OFF the supply at the external isolator or distribution board. Ensure that all tools and test instruments are removed from site. Finally check through the documentation to ensure that all aspects have been covered. Ensure that any witness signatures are obtained before handover. Keys should be handed over to the Officer or Site Manager in charge.
Finalising operational tests

1. Reset the unit to automatic control. 2. Reset all default settings, unless specifically requested otherwise. 3. If any controller settings have been changed from default values, record these values in the appropriate table(s) provided underSection 5 - INVICTANET Controller Settings Record. 4. Check operation of the display screen by scrolling through all screens and levels. 5. Observe and record: Return air temperature. Outside ambient air temperature. Unit run time. Relative humidity (if applicable). 6. The function of all alarms should be checked at the: Unit Remote display (if applicable)
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Eaton-Williams
IPAC
IPAC
IPAC
SECTION 10
PREVENTATIVE AND GENERAL MAINTENANCE

Includes Decommissioning and Disposal Procedure SECTION CONTENTS Heading
Introduction Persons Permitted to Carry Out maintenance Preventive Maintenance Objectives Tools and Consumables Alarm Monitoring Centres Prevention of Legionnaires Disease Maintenance Checklist Preventive Maintenance Tasks
Pressure Relief Valve(s) (if fitted) - DX Units Air Filters Unit Cabinet and Components Vapac Humidifier (if fitted) System Strainers - Chilled Water Units Water Quality - Chilled Water Units Chilled Water System Circuits - Chilled Water Units
Page
10 4 10 4 10 4 10 4 10 4 10 4 10 4 10 9
10 9 10 9 10 9 10 10 10 10 10 10 10 11

Air Supply Fan(s) Airflow Failure Test Filter Blocked Test Flood Detector Test (if fitted) and Condensate Pump (if fitted) HP Cut-out Test - DX Units LP Cut-out Test - DX Units Compressor Fail Test - DX Units Heater (if fitted) Temperature Controls Controller Functions Emergency and Fire Shutdown Controls (if fitted) Vapac Humidifier (if fitted) Refrigeration System - DX Units Earth Wiring and Connections Door Panel Locks and Seals Finalising Preventive Maintenance Checks
10 11
10 11 10 11 10 11 10 11 10 11 10 12 10 12 10 12 10 12 10 13 10 13 10 13 10 13 10 13 10 13 10 13
Documentation Before Leaving Site Renewing a Vapac Steam Cylinder

Decommissioning Procedure Disposal Document 0410536 Issue 4.0 : April 2008
10 13 10 13 10 13
10 16 10 16
IPAC
IPAC
Preventative and General Maintenance
Page 10-2
IPAC
Preventative and General Maintenance Introduction
The purpose of this section is to provide an overall guide for first line preventive maintenance tasks for standard IPAC range units and is not an exhaustive step-by-step maintenance guide.
Prevention of Legionnaires Disease

For any system that uses an evaporative condenser or cooling tower, it is essential that maintenance is carried out rigorously and at intervals specified by the equipment manufacturer.
WARNING
Failure to carry out maintenance can result in component failure. Eaton-Williams cannot be held responsible for damage, injury or death resulting from failure to carry out maintenance and testing procedures correctly at specified or recommended intervals. If there are any points of uncertainty, refer to Eaton-Williams for clarification. Also refer to any special instructions issued by Eaton-Williams for a specific project. Maintenance Checklists are provided under and should also be completed by the Service Engineer, following routine maintenance.
WARNING
Failure to carry out correct maintenance of any evaporative condenser or cooling tower can result in an outbreak of Legionnaires Disease, which causes serious illness and death. Eaton-Williams cannot be held responsible for consequences arising from failure of the owner/ user to carry out maintenance correctly and at specified intervals according to the manufacturers instructions and current legislation covering this type of plant. Before carrying out any maintenance, always check to establish the type of primary cooling system. Wherever an evaporative condenser/cooling tower is used, establish the maintenance status. If it is suspected that maintenance of an evaporative condenser or cooling tower has lapsed, DO NOT carry out any work until maintenance has been carried out on the evaporative condenser/cooling tower according to the manufacturers instructions and current legislation covering this type of plant. NEVER operate a unit if it is suspected that there is risk of air contaminated with Legionnella bacteria being produced or drawn into the building. For information on the prevention of Legionnaires disease, consult the local water authority or appropriate government department.
Persons Permitted to Carry Out maintenance

Only personnel who have been properly trained in the maintenance of refrigeration equipment should be permitted to carry out maintenance of the equipment covered by this manual. Tasks should be programmed initially to take place at quarterly intervals. However, the frequency with which louvres, air filters and Vapac steam cylinders require attention will vary, depending on site location, height above ground, air and water quality, humidity demand, etc. The frequency of preventive maintenance checks and tasks should therefore be adjusted upwards or downwards according to local conditions and based on practical experience.
Preventive Maintenance Objectives

Performing the tasks in this section will ensure that: Air filters are changed before contamination restricts airflow. Vapac steam cylinders are cleaned/renewed before they scale up (only units fitted with this option).
Maintenance Checklist
The following Maintenance Checklists are provided: DX units - see Table 10-1 on page 4 Chilled water units - see Table 10-2 on page 6 These are designed for quick reference and contain all relevant items detailed in the above procedures. Cross references are provided for each topic. Checkboxes are provided so that each item can be ticked on completion. It is recommended that a copy of the appropriate checklist is made so that checkboxes can be ticked against each item as it is completed. The checklist should then be signed and dated. A copy of each completed checklist should be kept with the logbook for the unit.
Tools and Consumables

The following items are required: Standard tool set. Socket key to open unit door panels. Polythene dustbin liner for disposal of old filters. Adhesive tape or string to seal the dustbin liner and prevent dust escaping. New panel filters. For details, refer to General Parts List on page 11-4 of Section 11. Vacuum cleaner.
Alarm Monitoring Centres

If alarms are extended beyond the unit, the Alarm Monitoring Centre should be informed that maintenance work is being carried out.
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IPAC
Table 10-1 : Maintenance checklist - DX units
Maintenance Checklist - DX Units

Refer to Page Task Description
page 10-8
Air Filters - clean or renew Unit Cabinet and Components

Vacuum and clean internally Condensate tray - clean and check drainage
page 10-8
Inspect fan impeller(s), bearings and belts for wear and movement Check heater element electrical connections for tightness Check all wiring for insulation damage and tightness of connections Inspect compressor anti-vibration mountings for wear
Vapac Humidifier (if fitted) page 10-9

Clean or renew strainer in the water supply solenoid valve Drain pump - clean and inspect Steam cylinder - inspect and renew if necessary
Air Supply Fan(s) page 10-10

Check for noise or vibration Check operating current(s) Check fan overload setting(s) value value
page 10-10 page 10-10 page 10-10 page 10-10 page 10-10
Airflow Failure Test Filter Blocked Test Flood Detector Test (if fitted) and Condensate Pump (if fitted) HP Cut-out Test - DX Units LP Cut-out Test - DX Units Compressor Fail Test - DX Units
page 10-11
MPCB trip and alarm Overload setting value
Heater (if fitted) page 10-11

MPCB trip and alarm Overload setting value
Temperature Controls
Heater ON temperature control value value value value value
page 10-11
Heater OFF temperature control High temperature cut-out function High temperature alarm function Low temperature alarm function
Page 10-4
IPAC
Table 10-1 : Maintenance checklist - DX units
Maintenance Checklist - DX Units

Controller Functions
Supply air fan(s) start delay time Compressor(s) start delay time value value value value
page 10-11
Heater(s) (if fitted) start delay time Humidifier (if fitted) start delay time Compressor stage-in (two compressor unit only) Compressor stage-out (two compressor unit only) Re-connect air temperature sensor
Emergency and Fire Shutdown Controls (if fitted) page 10-11

Emergency shutdown function (if fitted) Fire shutdown function (if fitted)
page 10-11
Earth Wiring and Connections Refrigeration System - DX Units

Evaporating pressure value value value
page 10-11
Condensing pressure Compressor operating current Check for refrigerant leaks and oil leaks
page 10-11
Door Panel Locks and Seals Finalising Preventive Maintenance Checks

Return the unit to normal operation Record return air temperature value value value value value
page 10-11
Record unit run time Record relative humidity (if applicable) Record room temperature set point Record relative humidity set point Update the settings record to reflect any changes made
Maintenance carried out by: Printed Name Organisation Signature Date
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IPAC
Table 10-2 : Maintenance checklist - chilled water units
Maintenance Checklist - Chilled Water Units

page 10-8
Air Filters - clean or renew Unit Cabinet and Components

Vacuum and clean internally
page 10-8
Condensate tray - clean and check drainage Inspect fan impeller(s), bearings and belts for wear and movement Check heater element electrical connections for tightness Check all wiring for insulation damage and tightness of connections
Vapac Humidifier (if fitted) page 10-9

Clean or renew strainer in the water supply solenoid valve Drain pump - clean and inspect Steam cylinder - inspect and renew if necessary
page 10-9 page 10-9
Water Quality - Chilled Water Units Chilled Water System Circuits - Chilled Water Units Air Supply Fan(s)
page 10-10
Check for noise or vibration Check operating current(s) Check fan overload setting(s) value value
page 10-10 page 10-10 page 10-10
Airflow Failure Test Filter Blocked Test Flood Detector Test (if fitted) and Condensate Pump (if fitted) Heater (if fitted)
page 10-11
MPCB trip Overload setting value
Heater ON temperature control value value value value value
page 10-11
Heater OFF temperature control High temperature cut-out function High temperature alarm function Low temperature alarm function
Page 10-6
IPAC
Table 10-2 : Maintenance checklist - chilled water units
Maintenance Checklist - Chilled Water Units

Supply air fan(s) start delay timevalue Heater(s) (if fitted) start delay time value value value
page 10-11
Humidifier (if fitted) start delay time Cooling stage-in (two-circuit unit only) Cooling stage-out (two-circuit unit only) Re-connect air temperature sensor
Emergency and Fire Shutdown Controls (if fitted) page 10-11

Emergency shutdown function (if fitted) Fire shutdown function (if fitted)
Earth Wiring and Connections page 10-11

Check wiring and connections Shut and lock the unit door(s) and return the unit to normal operation
page 10-11
Door Panel Locks and Seals Finalising Preventive Maintenance Checks

Return the unit to normal operation Record return air temperature value value value value value
page 10-11
Record unit run time Record relative humidity (if applicable) Record room temperature set point Record relative humidity set point Update the settings record to reflect any changes made
Maintenance carried out by: Printed Name Organisation Signature Date
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IPAC
Preventative and General Maintenance Preventive Maintenance Tasks
Carry out preventive maintenance by adhering to the following procedures: NOTE If the installation comprises a master with network slave units, when the master unit power supply is isolated, all slave units will continue to operate under their own default control. Where possible, avoid switching OFF more than one air handling unit at a time. One at a time, carefully remove each filter panel from the framework, taking care not to release any dust. See Figs. 10-1 to 10-3. Ideally, bag-up filters and take them to a suitable area where cleaning can take place. 5. Use a vacuum cleaner to clean each filter in turn. If necessary, loosen particles by gently rapping the filter against a wall; ensure that a mask is worn while doing this. NOTE Cleaning will not remove all discolouration from the filter surface. Standard filters are not washable. 6. If filters are to be renewed instead of cleaned, seal them in a dustbin liner for disposal. 7. Install cleaned or new filter panels by placing them into the unit frame and fitting the retaining bar. NOTE Ensure that air filter surfaces are fitted in the correct orientation for the airflow, otherwise, when the unit next starts, residual dust particles will be driven from filter surfaces and enter the supply airflow to the room. The plain (or dirty) surface of the filter must face into the airflow.
Fig. 10-1 : Filter arrangement
Pressure Relief Valve(s) (if fitted) - DX Units

Eaton-Williams recommend that, to protect the system and components against unacceptably high pressure, a suitably rated pressure relief valve is fitted in the discharge line and close to the condenser. Where these are fitted, it is the responsibility of the user to ensure that all pressure relief valves are periodically tested in accordance with local and national regulations.
WARNING
You should NEVER attempt to test a pressure relief device.
Air Filters
All air filters in a unit should be cleaned or renewed at the same time and at a frequency that, from experience of operating the unit, is known to just precede a FILTER BLOCKED alarm. NOTE Discolouring is not a cause for changing the filters, as filter efficiency increases as they become slightly dirty. Not until airflow is restricted, should filters be changed. A FILTER BLOCKED alarm is indicated when airflow becomes too restricted. If it is necessary to renew any air filter, all other air filters of a unit should also be renewed at the same time, otherwise airflow through unit will be imbalanced and could adversely affect unit performance. Clean or renew air filters as follows: 1. Switch OFF the unit external isolator (if fitted).
WARNING
Lock the isolator in the OFF position. If this cannot be done, place a suitable notice to prevent the isolator from being inadvertently switched ON by other personnel. 2. Open the unit door panel(s). 3. Switch OFF the internal isolator (if fitted). 4. Filters are released for removal by sliding the retaining bar upwards until it can pass outwards through the slot in the framework and be removed.
Unit Cabinet and Components

Carry out the following cleaning and inspection procedures:
WARNING
The unit must remain electrically isolated while carrying out these procedures. 1. Vacuum and clean out the inside of the cabinet, paying particular attention to all surfaces.
Page 10-8
IPAC
Fig. 10-2 : Removing a filter retaining bar
5. Check the condition of electrical connections to heater elements (if fitted). 6. Check all wiring for damage to insulation and tightness of electrical connections. 7. For DX units, closely inspect compressor anti-vibration mountings for signs of wear or failure.
Vapac Humidifier (if fitted)

Carry out the following cleaning and inspection procedure
WARNING
The unit must remain electrically isolated while carrying out this procedure. NOTE In units fitted with a Vapac humidifier option, water condition and humidity demands determine the effective life of the steam cylinder. For example, areas with soft water will have longer service life from a steam cylinder than areas with hard water. 1. Remove and clean the strainer in the water supply solenoid valve; renew if necessary. 2. Clean and inspect the drain pump. 3. Inspect the Vapac steam cylinder; renew if necessary. 4. Restore the unit to operational condition.
Fig. 10-3 : Removing a filter panel from the frame
Water Quality - Chilled Water Units

Obtain a sample of water from the chilled water system and check that it is not contaminated with sludge. NOTE Sludge in the chilled water system can adversely affect the flow control valve and performance of the unit. If in doubt, consult Eaton-Williams for advice. 2. Clean out the condensate tray and check for blockages. Pour 1.5 litres of disinfected water into the tray and check that the water flows to drain. 3. On larger units, condensate trays are fitted with two drain outlets, one at each end. Ensure that each outlet drains correctly. 4. Inspect impellers and bearings of the air supply fan(s), and drive belts, for wear and mechanical movement.
Chilled Water System Circuits - Chilled Water Units

Thoroughly check the units chilled water circuit(s) for evidence of leakage. Any leaks must be repaired by adopting the following procedure: 1. Isolate the unit from the chilled water system by closing the units flow and return isolating valves. 2. Drain all water from the affected section of pipework by opening vent and drain cocks provided on the unit. 3. Repair or renew the leaking component(s), resoldering or rebrazing, where necessary. 4. Shut the vent and drain cocks. 5. Open the flow isolating valve. Do not open the return isolating valve, otherwise air will be driven into the chilled water system. 6. Purge air from the units pipework by opening the vent cock SLOWLY until air can pass out. When all air has been purged and water begins to appear, shut the vent cock.
WARNING
Although a fan may be OFF, its impeller may still be induced to rotate at considerable speed, driven by inlet/outlet pressure differences caused by other equipment or local conditions. Beware of this potential hazard and take precautions to avoid injury - DO NOT use fingers to check for free rotation, instead, use a piece of stiff card. Do not use a material that may damage the impeller or break up.
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Page 10-9
IPAC
7. Open the return isolating valve to re-unite the unit with the chilled water system. 8. Recheck for leaks and, if necessary, repeat the procedure until satisfied that the unit is free of leaks. DO NOT permit pressure to rise above the pressure switch setting. 1. Stop the unit and switch OFF the unit isolator.
WARNING
Lock the isolator in the OFF position. If this cannot be done, place a suitable notice to prevent the isolator from being inadvertently switched ON by other personnel. Disconnect and remove the HP high pressure cut-out from the unit. Connect the HP cut-out, via a pressure regulator that incorporates a test pressure gauge, to a cylinder of nitrogen. Connect a meter or test lamp to the cut-out terminals, so that cut-out function can be monitored. While monitoring the gauge pressure, gradually increase pressure to the HP cut-out until the trip setting of 28 bar g (400 psi g) is reached and the cut-out contacts break circuit.

First, prepare the unit for operation by switching ON the unit external isolator (if fitted) and the internal isolator (if fitted). After allowing the unit controller to initialise and stabilise, carry out unit operational checks as described under each heading following:
2. 3. 4. 5.
WARNING
The following procedures are carried out while the unit power supply is live. Beware of electrical hazards and rotating machinery. Adopt safe working procedures at all times.
Air Supply Fan(s)

1. With the air supply fan(s) operating, listen for any adverse noises or vibrations. If necessary, use controller override settings to force the fan(s) to start. 2. Check each fan overload setting.
WARNING
DO NOT permit pressure to rise above the pressure switch setting If the cut-out fails to trip at the correct setting, it must be replaced by one that does.
WARNING
NEVER allow the unit to operate with a faulty HP pressure switch or one that is not set correctly. 6. Provided that the HP cut-out trips at the correct setting, refit it to the unit and ensure that electrical connections are remade correctly. 7. Start the unit and check that when the HP pressure switch circuit trips, the control system shuts down the relevant compressor. A Prompt alarm is generated at the customer terminals and on the unit display (if fitted).
Airflow Failure Test

Check airflow by gradually opening the unit door. A Prompt alarm is generated at the customer terminals and on the unit display (if fitted).
Filter Blocked Test

Simulate a choked air filter condition by using a suitable sheet material to cover the air filter. A Prompt alarm is generated at the customer terminals and on the unit display (if fitted). Remove the sheet material used for simulation.
WARNING
DO NOT permit pressure to rise above the pressure switch setting. If necessary, shut down the plant immediately. 8. Repeat the above procedure for each HP switch fitted.
Flood Detector Test (if fitted) and Condensate Pump (if fitted)
Manually trip the flood detection circuit by linking it out. A Prompt alarm is generated at the customer terminals and on the unit display (if fitted). Check and operate the condensate pump.
LP Cut-out Test - DX Units

Check the LP low pressure switch trip and control function for each refrigeration circuit of the unit: NOTE It is not possible to check the LP cut-out while it is fitted to the unit. However, the trip setting and control function can be checked as follows: 1. With the unit stopped, switch OFF the unit isolator. 2. Disconnect and remove the LP cut-out from the unit. 3. Connect the LP cut-out, via a pressure regulator that incorporates a test pressure gauge, to a cylinder of nitrogen.
HP Cut-out Test - DX Units

Check the HP high pressure switch trip and control function for each refrigeration circuit of the unit:
WARNING
The following procedure is potentially hazardous. Adequate safety precautions must be taken to guard against damage or injury being caused by component failure at high pressure. Steps 3, 4 and 5 must be carried out in a safe area.
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IPAC
4. Connect a meter or test lamp to the cut-out terminals, so that cut-out function can be monitored. 5. While monitoring the gauge pressure, gradually increase pressure to the LP cut-out until just above the trip setting of 0.5 bar g (7 psi g) and the cut-out contacts make circuit. 4. Check that the high temperature cut-out functions correctly by setting the temperature simulation resistance accordingly. 5. Adjust temperature simulation resistance to: 40 C - check high temperature alarm. 05 C - check low temperature alarm.
WARNING
DO NOT permit pressure to rise above the pressure switch setting. 6. Turn on the unit isolator and allow the unit to start.
1. Adjust temperature simulation resistance to 35 C and check start delay times for: 2. Supply air fan(s) - all units Compressor(s) and condenser(s) - DX units Heater(s) (if fitted) Humidifier (if fitted) For two-circuit chilled water units, check that cooling circuits stage-in and stage-out correctly by adjusting temperature simulation resistance accordingly. 3. For two-compressor DX units, check that compressors stagein and stage-out correctly by adjusting temperature simulation resistance accordingly. 4. Disconnect the temperature simulation resistance and then re-connect the air temperature sensor.
WARNING
The unit is now operating without the protection of the LP cut-out. Do not allow the unit to operate like this any longer than absolutely necessary. 7. Gradually reduce pressure to the LP cut-out setting. Verify that the control system shuts down the relevant compressor. A Prompt alarm is generated at the customer terminals and on the unit display (if fitted). If the cut-out fails to trip at the correct setting, it must be replaced by one that does.
WARNING
NEVER allow the unit to operate with a faulty LP pressure switch or one that is not set correctly. 8. Provided that the LP cut-out trips at the correct setting, refit it to the unit and ensure that electrical connections are remade correctly.
Emergency and Fire Shutdown Controls (if fitted)

In turn, check that emergency and fire shutdown controls stop the unit correctly.
Vapac Humidifier (if fitted)

1. Check function of the Vapac drain and condensate pump. 2. Check function of the Vapac humidifier.
Compressor Fail Test - DX Units

In turn, manually trip each compressor MPCB. A Prompt alarm is generated at the customer terminals and on the unit display (if fitted). Check each compressor overload setting.
Refrigeration System - DX Units

Allow system to operate normally for ten minutes to settle down. Then, carry out the following: 1. With room temperature at nominal 24 C, check the following values for each refrigeration circuit in turn: 2. Evaporating pressure Condensing pressure Compressor operating current Check the system for refrigerant leaks and oil leaks.
Heater (if fitted)

1. In turn, manually trip each heater MPCB to check operation. 2. Check each heater overload setting.
1. So that changes in air temperature can be simulated for testing, connect a variable resistance box, (or 0 to 20 k ohm potentiometer) to the return air sensor connection on the unit controller; refer to the unit wiring diagram. 2. Adjust temperature simulation resistance to reflect a low temperature to bring the heating element (if fitted) into operation. 3. Adjust temperature simulation resistance to reflect a rising temperature and note at which point the heating element (if fitted) ceases operation. This is checked using a clip-on ammeter.
Earth Wiring and Connections

Check the integrity of all earth connections, including external connections.
Door Panel Locks and Seals

1. Shut and lock the unit door(s), checking that door lock(s) operate correctly. 2. Start the unit and check that door seals are effective.
Finalising Preventive Maintenance Checks

1. Return the unit to normal operation.
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2. 3. 4. Observe and record: Return air temperature. Unit run time. Relative humidity %, (units fitted with the Vapac humidifier option). Check and adjust as required: Temperature set point Relative humidity % (units fitted with a with Vapac humidifier option) Update the unit settings record to reflect any changes made; refer to Section 13 - Unit Maintenance Log.
Fig. 10-4 : Vapac cylinder with connections
Documentation
Any necessary documentation should be completed; e.g. Logbook, etc. An example maintenance log record is provided in Section 13 Unit Maintenance Log. The Maintenance Checklist provided under should also be completed.
Before Leaving Site

Ensure that: All air handling unit access panels are properly closed and secured. Mains power has been restored to all air handling units. No alarm is showing on any unit or remote display. Any necessary documentation is handed over to the appropriate person. The Alarm Monitoring Centre is advised of completion of maintenance and departure from site. 9. Check and clean drain pump. After placing drain pump back in position, insert the steam cylinder and press firmly into position. 10. Re-connect electrode caps in accordance with the details on the collar supplied with the new cylinder; see Fig. 10-5. 11. Close and secure access doors. 12. Restore power to unit. 13. Test the function of the Vapac humidifier. 14. Return the unit to normal service.
Fig. 10-5 : Sequence of connection
Renewing a Vapac Steam Cylinder

To renew a Vapac humidifier, referring to Fig. 10-4 carry out the following procedure: 1. Turn OFF the water supply to the unit. 2. With power still connected to the unit, use the Humidifier Manual Drain setting of the unit controller Service level settings to initiate a the manual drain (setting 4-x-13) to empty the steam cylinder. Refer to Service level menu system settings on page 4-6 of Section 4. 3. Switch OFF the unit external isolator (if fitted).
WARNING
Place a suitable notice to prevent the isolator from being inadvertently switched ON by other personnel. Open the unit door panel(s). Switch OFF the unit internal isolator Carefully ease off the red electrode caps and the white cap off the level switch. With a twisting movement, lift and remove the cylinder clear of the feed/drain manifold. Clean feed/drain manifold of sediment and scale.
4. 5. 6. 7. 8.
Cleanable Vapac Cylinders Vapac steam cylinders are available in cleanable versions. These are similar in design to standard Vapac units, but the cylinder comprises two halves that can be separated to enable the removal of loose scale deposits.
Page 10-12
IPAC
WARNING
NEVER touch an operating cylinder, as any leak water will be at mains voltage. The two halves are sealed buy an O-ring and are held together by two clamping rings and quick-release fasteners; see Fig. 10-6. A cleanable cylinder can be ordered by quoting same order code as standard cylinders, but with letters CC instead of CM or CD. When cleaning out loose deposit, make sure to clean any buildup on the level switch. 10. Restore mains power to the unit. 11. Test the function of the Vapac humidifier. 12. Close and lock unit panel doors. 13. Return unit to normal service.
Fig. 10-7 : Vapac water connection
WARNING
Do not disturb the electrodes. If they are badly eroded and/or the internal positioning ring is free, the cylinder must be replaced. During assembly, always use a new seal and ensure that mating surfaces are clean and from scars that will prevent proper sealing.
Fig. 10-6 : Cleanable Vapac cylinder
Fig. 10-8 : Strainer removal
Vapac Drain Pump Vapac Feed Solenoid Valve and Strainer

1. Turn OFF the water supply to the unit. 2. With power still connected to the unit, use the Humidifier Manual Drain setting 4-x-13 of the unit controller Service level settings to initiate a the manual drain to empty the steam cylinder; refer to Service level menu system settings on page 4-6 of Section 4. 3. Switch OFF the unit external isolator (if fitted). 4. Open the unit door panel(s). 5. Switch OFF the unit internal isolator. 6. Unscrew the hose connection to the water supply; refer to Fig. 10-7. 7. Using long-nosed pliers, pull out the push-fit strainer and clean; refer to Fig. 10-8. 8. Re-assemble in reverse order of the above steps. 9. Turn ON the water supply to the unit. The drain pump should be inspected at regular intervals and at least at each change of steam cylinder. 1. Turn OFF the water supply to the unit. 2. With power still connected to the unit, use the Humidifier Manual Drain setting 4-x-13, of the unit controller Service level settings to initiate a the manual drain to empty the steam cylinder; refer to Service level menu system settings on page 4-6 of Section 4. 3. Switch OFF the unit external isolator (if fitted).
WARNING
Place a suitable notice to prevent the isolator from being inadvertently switched ON by other personnel. 4. Open the unit door panel(s). 5. Carefully ease off the red electrode caps and the white cap off the level switch. 6. With a twisting movement, lift and remove the cylinder clear of the feed/drain manifold.
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IPAC
7. Clean feed/drain manifold of sediment and scale.
Fig. 10-9 : Pump and manifold Fig. 10-11 : Dismantled pump
13. Turn ON the water supply to the unit. 14. Restore mains power to the unit. 15. Test the function of the Vapac humidifier. 16. Close and lock unit panel doors. 17. Return unit to normal service.
Decommissioning and Disposal Procedure

Decommissioning, dismantling and disposal of air handling units should be undertaken only by experienced personnel and in full adherence to all safety rules, in particular, with respect to protection of lungs, eyes and skin from refrigerant, dust etc. Only approved lifting gear and power tools should be used and access to the work area restricted to authorised personnel only.
Decommissioning Procedure
8. Remove the pump by pushing it back until it clears the manifold. 9. Remove the water hose and twist the top of the pump body to access the impeller; refer to Fig. 10-10.
Fig. 10-10 : Opening pump
All refrigerant, oil and other waste materials must be disposed off in a professional and responsible manner in strict adherence to legislation and environmental regulations. Greatest possible care should be taken at all times to avoid the release of refrigerant into the atmosphere. 1. 2. Disconnect the unit from the electrical supply. A chilled water unit must be drained of all water, which may contain additives, such as glycol and corrosion inhibitors. This water must be contained and disposed of safely, with strict regard to the environment and in accordance with additive manufacturers instructions and current legislation/regulations. For a DX unit, reclaim ALL refrigerant from the unit by using approved reclaiming equipment in accordance with the manufacturers instructions. Recovery of refrigerant must be carried out only by personnel registered for refrigerant safe handling.
3.
10. Check that the impeller is clean and rotates freely. De-scale and clean as required; refer to Fig. 10-11. 11. Ensuring that the O-ring is correctly seated, re-assemble the pump by following the above steps in reverse order. 12. Following re-assembly of the pump, ensure that the pump coil is dry before reinstating the electrical supply.
Disposal
1. 2. Dispose of reclaimed refrigerant and oil through an approved recycling facility. Separate unit sections (where applicable) and remove to approved recycling facilities.
Page 10-14
Eaton-Williams
IPAC
IPAC
IPAC
SECTION 11
SERVICE AND PARTS INFORMATION

11.1 11.2 11.3 11.4 11.5 General Contact Details for Service and Parts Ordering Spares Recommended Spares Service Parts
Page
11 4 11 4 11 5 11 5 11 5
IPAC
IPAC
Service and Parts Information
Page 11-2
IPAC
Service and Parts Information General
It is essential that service and maintenance parts are of the same specification as those they replace and should be obtained from Eaton-Williams, or their appointed distributor. Where applicable, suitable alternatives will provided to replace obsolete parts. Parts fitted to a refrigeration system must be suitable for such use. Items such as gaskets and O' rings must be compatible with the system refrigerant, lubricating oil, pressure and temperature. Parts must comply with design specifications, current regulations and legislation. Maintenance / Service Contracts Contact Tel. No. 1: Contact Tel. No. 2: Fax No: E-mail General Service and Repair Contact Tel. No. 1: Contact Tel. No. 2: Fax No.: Emergency Service Freephone number, available to clients with a service contract. Service Parts Contact Tel No.: Fax No.: Website http:\\www.eaton-williams.com 01732 869 614 01732 865 709 International: International: +44 1732 869 614 +44 1732 865 709 01732 869 605 01732 869 615 01732 869 630 International: International: International: +44 1732 869 605 +44 1732 869 615 +44 1732 869 630 01732 869 600 01732 869 601 01732 869 630 ews.sales@eaton-williams.com International: International: International: +44 1732 869 600 +44 1732 869 601 +44 1732 869 630
WARNING
Never fit inferior or unsuitable parts. The fitting of incorrect parts can adversely affect plant performance and/or operation and may result in damage to the unit and could cause injury or death of personnel.
Contact Details for Service and Parts
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IPAC
Service and Parts Information Ordering Spares
When ordering spares, always provide the unit serial number as it appears on the serial No. plate; refer to Unit Identification on page 2-6 of Section 2 for location.
Recommended Spares
Table 11-1 lists the site recommended minimum holding of consumable service parts. The number of spares held is dependent on the unit type and number of units installed. NOTE Always quote the unit serial number to identify parts correctly.
Table 11-1 : Site stock recommended spares list
Site Stock Recommended Spares List

COMPONENT Air filter Belt Fuse Fuse - controller mother board PCB Fuse - controller mother PCB Fuse - controller daughter PCB, rating 1 A Humidifier cylinder*
NOTE
*
DESCRIPTION G4 as standard. Optional alternatives are available Fan drive, wedge type 3.15 A, anti-surge, 20 x 5 mm 2 A rating 1 A rating
Vapac, size 2
If fitted.
Service Parts
Service parts must be to the same specification as those they replace and should be obtained from Eaton-Williams, or an appointed distributor. Where applicable, obsolete parts will be replaced by suitable alternatives.
NOTE Table 11-2 is not exhaustive and does not include all option equipment. Always quote the unit serial number to identify parts correctly
Table 11-2 : General parts list
General Parts List

COMPONENT Compressor Air filter Fan - air circulating Belt - fan drive Pulley - motor Bush - motor pulley Pulley - fan Bush - fan pulley Taperlock Taperlock Forward curved, centrifugal Wedge type Scroll type DESCRIPTION / NOTES
Page 11-4
IPAC
General Parts List

COMPONENT Evaporator Thermostatic expansion valve Filter/drier Moisture indicating sight glass Pressure switch - HP Pressure switch - LP Air differential pressure switch Room air temperature sensor Room air temperature and humidity sensor Valve - evacuation / charging Humidifier Humidifier cylinder Lifting bracket Key - cabinet door ELECTRICAL / ELECTRONIC COMPONENTS (master units only) Main, 30 A, 3 pole Isolator Main, 55 A, 3 pole Main, 125 A, 3 pole Isolator cover Level sensor PCB - Vapac humidifier Controller mother board Echelon, E/Boil For each isolator Schraeder type, 0.25 in. flare Vapac OEM assembly Vapac, Size 2 For hoisting the unit 8 mm triangular recess Range 0.5 to 4.0 mbar Cooling coil block To suit refrigerant To suit refrigerant Solder fitting DESCRIPTION / NOTES
ELECTRICAL / ELECTRONIC COMPONENTS (master units only) continuation Controller daughter board Graphical display board Keypad label Keypad label Text-only 10 k ohm, 0.25 W, +/- 1 % Filter resistor 15 k ohm, 0.25 W, +/- 1 % 20 k ohm, 0.25 W, +/- 1 % Echelon Echelon Graphical display
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IPAC
General Parts List

COMPONENT 8 A, 24 Vac, N/O aux. Contactor 12 A, 24 Vac, N/O aux. 22.5 A, 24 Vac, 50/60 Hz, N/O aux. Fuse Fuse - controller mother board PCB 1A Fuse - controller daughter board PCB 1A 4 A, DP 6 A, SP 10 A, SP MCB 2.5 - 4 A 6.3 - 10 A 10 - 16 A 16 - 20 A MPCB 20 - 25 A Link Terminal shroud Auxiliary contacts SPDT, 9 V dc Relay 4PDT, 5 A, 24 V ac, 50/60 Hz 5 pin Relay Base 14 pin ELECTRICAL / ELECTRONIC COMPONENTS (master units only) continuation 200 - 440 V power, 9-24 V supply Transformer Current, 200T, torod Current set plug Heater electric element Thermostat Pump Solenoid valve Manifold - feed/drain 2.5 kW, finned Rod type, max. 80 C, 178 mm lg 24 V ac 24 V ac, 1.2 l/min 3-phase 3.15 A, anti-surge, 20 x 5 mm 2A DESCRIPTION / NOTES
Page 11-6
IPAC
General Parts List

COMPONENT Strainer - water feed O-Ring 4.5 x 1.75 mm cross section, nominal DESCRIPTION / NOTES
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Eaton-Williams
IPAC
IPAC
IPAC
SECTION 12
FAULT FINDING PROCEDURES

Introduction Fault Finding Procedure Is Power Available?
Should the Unit Process be Operating? Is the Unit Idle in Standby Mode? Is the Unit Being Operated Within Design Conditions
Page
12 4 12 4 12 4
12 4 12 4 12 4
Fault Finding Tables

Correcting Fault Conditions That Involve Opening a DX Refrigerant System
12 4
12 5
IPAC
IPAC
Fault Finding Procedures
Page 12-2
IPAC
Fault Finding Procedures Introduction
This section provides basic information on fault diagnosis for various types of air handling units in the IPAC range. If the controller display is blank, see Display Corruption on page 4-25 of Section 4. If the controller display is functioning and not showing a fault alarm, but the unit is not operating when it is suspected that it ought to, see and . If the unit is a network slave and not fitted with a controller display, check the units status on the network master. Depending on the units status, see , and , as appropriate. Before moving to more in-depth fault finding, it is always worth checking the following points:
WARNING
Before carrying out any work on the unit, ensure that it is electrically isolated. Lock the isolator in the OFF position. If this cannot be done, place a suitable notice to prevent the isolator from being inadvertently switched ON by other personnel. The information provided here is not exhaustive, but is designed to assist and minimise the effort required to identify a fault condition, should one arise. Carrying out fault diagnosis requires a thorough understanding of the operation and requirements of the plant.
Is Power Available?
If the unit is apparently dead, eliminate these obvious possibilities: Check that the unit isolator is switched ON. Check that the power supply is live to the unit. Check external and internal circuit breakers and external interlocks; e.g. Fire Shutdown on page 4-25 of Section 4 If the unit is a network slave, visually check that controller communications cable has not been damaged or disconnected. Check door interlocked isolators (if fitted).
CAUTION
Some fault conditions, such as temperature or pressure trips, will seem to rectify themselves as conditions return to normal when the unit stops operating. DO NOT reset the controls and restart the unit without first identifying and rectifying the cause of the fault. Repeatedly resetting and restarting can damage the unit and may invalidate any warranty.
Should the Unit Process be Operating?

Check that there is truly a demand. For example, if demand has been satisfied, the unit process should not be expected to operate; for further details, see AHU Not Operating on page 425 of Section 4.
Fault Finding Procedure

Fault diagnosis is made considerably easier for a unit or a network of units that is fitted with an Eaton-Williams AHU controller/display, as it has been specially designed to indicate the existence of a fault and identifies the affected item; for example, a low airflow rate caused by a blocked filter.
Is the Unit Idle in Standby Mode?

A unit in standby mode will only operate to take over the duty of another unit that becomes unavailable, or when due to take over according to run/standby rotation control settings.
WARNING
Never allow or risk the possibility of mains voltage reaching any controller connection. For this reason, be especially careful if using low impedance instruments for checking voltage etc. No field repairs to the controller /display should be attempted. If an Eaton-Williams AHU controller/display is not fitted, identifying the cause of a fault may involve a lengthy and painstaking process of elimination. Fault finding procedures described in this section assumes that an Eaton-Williams AHU controller is fitted and can be interrogated to identify the affected item of plant and prevailing conditions, such as air temperature and humidity. When this has been done, the Fault Finding Tables shown under may be used to assist in fault diagnosis, identification of possible causes and suggested remedial action. If the controller is displaying a fault condition, each affected item is identified; refer to Section 4 - INVICTANET CONTROLLER TECHNICAL MANUAL for details.
Is the Unit Being Operated Within Design Conditions

IPAC AHUs are designed for operation within certain design conditions (dependent on unit model) and must not be operated outside these conditions. Attempting to operate a unit outside its design conditions will result in fault conditions arising.
Fault Finding Tables

The following fault finding tables are provided for assistance and guidance in fault diagnosis, identification of possible causes and suggested remedial action. The information provided here is not exhaustive, but is designed to assist and minimise the effort required to identify a fault condition, should one arise. Once the controller has been interrogated and the process type affected by the fault condition identified, the fault finding tables can be used to make informed decisions as to what action is required. For clarity and ease of use, information is grouped by topic: Airflow - fault finding - Table 12-1
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Heating systems - fault finding - Table 12-2 DX cooling / dehumidification - fault finding - Table 12-3 Chilled water cooling / dehumidification - fault finding Table 12-4 Humidification system - fault finding - Table 12-5 After repairs have been carried out, the following procedures must be adopted: Combined Strength and Leak Pressure Test on page 6-8 of Section 6 Evacuation and Dehydration on page 6-9 of Section 6 Initial Charging With Refrigerant on page 6-9 of Section 6 Final Charging on page 8-4 of Section 8 DO NOT forego these procedures, otherwise extensive damage to the unit will result.
Correcting Fault Conditions That Involve Opening a DX Refrigerant System

Observe the following caution:
CAUTION
For a DX system, whenever it is necessary to break into the system envelope, the refrigerant charge must first be recovered by using proprietary recovery equipment.
Table 12-1 : Airflow - fault finding
AIRFLOW - FAULT FINDING

Symptom Possible Cause a. MPCB tripped. Action / Remedy a. Check fan bearings, casing clearances and general integrity. Check fan resistance in ducts etc. Check windings for insulation and continuity. If fan can be run, check its running current. b. Check for poor connections and controller output. c. Check power feed to motor. c. No line supply. d. Contactor fault. a. Clogged air filter(s). b. Distribution grilles closed or not open enough. c. Blockage or partial blockage in ducting. d. Airflow switch fault. Supply fan airflow alarm e. Pressure sensor tubing trapped, damaged or missing. f. Fan impeller loose on drive shaft. g. Slack belt drive(s). h. Fan drive motor fault. i. Unit door panel not closed properly, or inadequate sealing of mating surfaces. d. Check wiring, continuity and airflow switch function - repair or renew as necessary. e. Re-route tubing or renew as necessary. f. Tighten the impeller on its drive shaft. a. Clean or renew filter(s). b. Open grilles further to allow more air volume to pass. c. Clear any blockage. d. Check for correct operation.
Supply fan not running
b. No control signal.
g. Tighten drive belt(s), or renew if worn. Never over-tighten, otherwise bearing damage is likely to result. h. Renew the fan drive motor. i. Close the door panel properly. Ensure that mating surfaces are sealed properly and that air escape is not occurring.
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IPAC
Table 12-2 : Heating systems - fault finding
HEATING SYSTEMS - FAULT FINDING

Symptom Electrical heating output low Possible Cause a. Air temperature sensor fault. b. Line switching relay(s) faulty. a. Air temperature sensor fault. b. Faulty heating element(s). Electrical heating non-operational c. Heater over-temperature safety thermostat(s) tripped due to excessive local heat. d. No control signal. e. No power. f. Contactor fault. LPHW flow rate low due to: a. Air temperature sensor fault. b. LPHW temperature lower than design. c. Stop valve partly closed in the LPHW circuit. LPHW heating output low d. Clogged strainer(s). e. Circulating pump fault. f. Flow control valve partly blocked with debris / scale. a. Check operation and wiring continuity - renew if necessary. b. Check LPHW heating system temperature control - adjust as necessary. c. Check that stop valves throughout the LPHW circuit are open. d. Clean strainer(s). e. Refer to pump manufacturers instructions. f. Remove the valve, clear the blockage. Check the flow line strainer mesh for damage - renew if necessary. a. Check operation and wiring continuity - renew if necessary. b. Check operation and wiring continuity - renew if necessary. c. Check airflow; refer to Table 12-1. Note that thermostat(s) will auto-reset on returning to normal temperature. d. Check for poor connection. e. Check MPCB(s) and correct the cause of any trip. f. Check for correct operation - renew if necessary. Action / Remedy a. Check operation and wiring continuity - renew if necessary. b. Check for correct operation.
g. Flow control valve seizing. h. Poor signal to the flow control valve actuator. Zero flow of LPHW due to: a. Air temperature sensor fault. b. LPHW heating system boiler or circulating pump not operating. c. Stop valve closed in the LPHW circuit. d. Clogged strainer(s). LPHW heating non-operational e. No signal to the flow control valve actuator. f. No power feed to the flow control valve actuator.
g. Repair / renew the flow control valve. h. Check the valve actuator control circuit for continuity and resistance correct the cause of any poor continuity / high resistance.
a. Check operation and wiring continuity - renew if necessary. b. Refer to LPHW heating system / pump instruction manual for fault diagnosis and remedial action. c. Check that stop valves throughout the LPHW circuit are open. d. Clean strainer(s). e. Check the valve control circuit for continuity and resistance - correct the cause of any poor continuity / high resistance. f. Check power supply and wiring for continuity - correct as necessary. g. Remove the valve, clear the blockage. Check the flow line strainer mesh for damage - renew if necessary. h. Check actuator operation - renew if necessary. i. Check operation - renew if necessary.
g. Flow control valve blocked with debris / scale. h. Flow control valve actuator faulty. i. Flow control valve seized.
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Table 12-3 : DX cooling / dehumidification - fault finding
DX COOLING / DEHUMIDIFICATION - FAULT FINDING

Symptom Possible Cause HP switch tripped due to: a. Inadequate flow of condenser cooling air a. Refer to the condenser manufacturers instructions for diagnosis and / water. remedial action. Rectify cause before resetting the unit controller. b. Condenser not operating. b. Refer to the condenser manufacturers instructions for diagnosis and remedial action. Rectify cause before resetting the unit controller. c. Air-cooled condenser - clean the heat exchange coil; refer to the manufacturers instructions. Water-cooled condenser - remove scaling / debris and then flush according to manufacturers instructions. a. Check for leaks, repair any leakage point, then carry out all procedures necessary to re-charge the system; see Correcting Fault Conditions That Involve Opening a DX Refrigerant System on page 4. b. Renew the filter / drier; see Correcting Fault Conditions That Involve Opening a DX Refrigerant System on page 4. c. Renew the TEV; see Correcting Fault Conditions That Involve Opening a DX Refrigerant System on page 4. Pressure switches in healthy (normal) condition: a. Compressor MPCB tripped due to motor overload. a. Investigate and rectify the cause before resetting the MPCB. Check the overload setting. Action / Remedy
c. Condenser efficiency impaired.
LP switch tripped due to: a. Low refrigerant charge - inadequately charged or partial loss of charge. b. Filter / drier clogged. c. TEV fault.
Compressor will not run
b. Compressor motor HT thermistor tripped. b. Investigate and correct the cause of the trip - HT thermistor device is autoresetting when it has cooled sufficiently; allow up to one hour. Motor will then restart automatically. c. No control signal. d. Contactor fault. a. Low airflow due to dirty filter. b. Low airflow. c. Cooling coil / fins dirty. d. Filter / drier partially clogged. e. Thermostatic expansion valve (TEV) strainer blocked. Cooling coil (evaporator) loss of capacity f. Cooling coil iced up. a. Clean or renew air filters. b. Refer to Table 12-1 - see Supply fan airflow alarm on page 4. c. Clean the heat exchange coil. d. Renew the filter / drier; see page 12-4 e. Remove and clean; see page 12-4 f. Ensure that the TEV sensing bulb is fitted correctly and in good physical / thermal contact with the compressor suction line at the refrigerant outlet from the cooling coil. c. Check for poor connections and/or replace controller card. d. Check for correct operation.
g. Thermostatic expansion valve (TEV) incorrectly adjusted / faulty. h. Hot gas injection (HGI) valve fault. i. Low refrigerant charge.
g. Check that the TEV is adjusted to give the correct amount of superheat. If adjustment does not remedy the condition, repair or renew the TEV, as appropriate; see page 12-4 h. Check that the HGI valve (if fitted) is able to close properly - renew if necessary; see page 12-4 i. Check the moisture indicating sight glass in the liquid line. If bubbles are visible, indicating loss of charge, check for leaks, reclaim the refrigerant charge, repair any leakage point, then carry out all procedures necessary to re-charge the system; see page 12-4
Page 12-6
IPAC
Table 12-4 : Chilled water cooling / dehumidification - fault finding
CHILLED WATER COOLING / DEHUMIDIFICATION - FAULT FINDING

Symptom Possible Cause a. Low demand. b. CW temperature higher than design. CW cooling output low Action / Remedy a. Check demand status; refer to Is there a demand? on page 4-25 of Section 4.
c. Stop valve partly closed in the circuit, reducing b. Refer to the cooling system manufacturers instruction manual for diagnosis and remedial action. flow to or from the unit. c. Check all stop valves throughout the circuit are open. d. Clogged filter before the water flow control valve. e. Poor signal to the flow control valve actuator. a. No demand signal to the flow control valve actuator. d. Clean filter(s). e. Check valve actuator control circuit for continuity and resistance correct the cause of any poor continuity /high resistance. a. Check: Demand status; refer to Is there a demand? on page 4-25 of Section 4 Valve control circuit for continuity and resistance; correct the cause of any poor continuity / high resistance Strainer is not choked - remove, clean and check strainer mesh renew if necessary b. Refer to the cooling system / pump manufacturers instruction manual for diagnosis and remedial action. c. Check that all stop valves in the circuit are open. d. Check power supply and wiring for continuity - correct as necessary. e. Remove the valve, clear the blockage. Check the flow line strainer mesh for damage - renew if necessary. f. Check actuator operation - renew if necessary. g. Repair or fit new flow control valve.
CW cooling b. CW cooling plant or circulating pump not non-operational operating. c. Stop valve closed in the CW circuit. d. No power feed to the flow control valve actuator. e. Flow control valve blocked with debris / scale. f. Flow control valve actuator faulty. g. Flow control valve seized. Table 12-5 : Humidification system - fault finding
HUMIDIFICATION SYSTEM - FAULT FINDING

Symptom Possible Cause a. Loss of water supply. Humidity low no water b. Solenoid valve malfunction. Humidity low water supply correct Humidifier not operating Humidifier draining does not operate manually or automatically Humidifier steam supply low Humidifier water in duct a. Lack of maintenance - internal arcing. a. No control signal. b. No power supply. c. Contactor faulty. a. No 240 volt supply to pump. b. Drain pump seized. a. Faulty electrodes. b. Poor steam supply. a. Faulty supply. Action / Remedy a. Check that water supply: shut-off valve is open pressure is adequate (i.e. positive); refer to the manufacturers instructions for the humidifier. strainer is not clogged - remove and clean b. Check 24 volt supply, renew the solenoid. a. Renew steam cylinder. a. Check connections and control voltage. If necessary, renew controller. b. Check power supply, MPCB and settings. c. Check for correct operation. a. Check and repair supply. b. Dismantle and clean or renew the drain pump - see Vapac Drain Pump on page 10-13 of Section 10. a. Renew cylinder. b. Check steam pipe and installation. a. Check installation.
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Eaton-Williams
IPAC
IPAC
IPAC
SECTION 13
UNIT MAINTENANCE LOG

Unit Serial No. ____________ Site Unit No. / Location ___________
IPAC
IPAC
Unit Maintenance Log
Table 13-1 : Unit maintenance log ORGANISATION, DATE DESCRIPTION OF WORK CARRIED OUT SIGNATURE AND PRINTED NAME
Page 13-2
IPAC
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IPAC
IPAC
IPAC
SECTION 14
UNIT MODIFICATION LOG

Unit Serial No. ____________ Site Unit No. / Location ___________
User Notes
IPAC
IPAC
Unit Modification Log
Page 14-2
IPAC
Table 14-1 : Unit modification log ORGANISATION, DATE DESCRIPTION OF WORK CARRIED OUT SIGNATURE AND PRINTED NAME
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IPAC
Table 14-1 : Unit modification log ORGANISATION, DATE DESCRIPTION OF WORK CARRIED OUT SIGNATURE AND PRINTED NAME
Page 14-4
IPAC
PRODUCT RANGES
Air-cooled & Water-cooled Liquid Chillers Packaged Roof-Top Units Full Range of Air Handling Units Fan Coil Units Package Telecommunications Units Fresh Air Units Condensing Units Air Cooled Condensers Low temperature Cassettes Cellar & Storage Low Temperature Cooling Units Packaged In-Wall Units Stand-alone Humidifiers OEM Process Cooling Control Units Custom Designed Packages Constant & Variable Air Volume Units
Eaton-Williams
Eaton-Williams Air Conditioning Station Road, Edenbridge, Kent, TN8 6EG England Telephone +44 (0)1732 866 055 Fax +44 (0)1732 866 053 Email ews.sales@eaton-williams.com Website www.eaton-williams.com
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Eaton-Williams

IPAC Air Handling Units

Document 0410536 Issue 4.0 : April 2008

ABOUT THIS DOCUMENT

Document 0410536 Issue 4.0 : April 2008

BUSINESS SYSTEMS AND STANDARDS GENERAL STATEMENT

Safety and Environmental Management

HR Management and Staff Development

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This page is intentionally blank to facilitate double-sided printing.

Document 0410536 Issue 4.0 : April 2008

This page is intentionally blank to facilitate double-sided printing.

Document 0410536 Issue 4.0 : April 2008

SAFETY AND GENERAL INFORMATION

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Skin and Eye Contact

Safety Precautions - Refrigerant

R 407C - COSHH Considerations

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Installation and Handling

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SECTION CONTENTS Heading

Reliability Serviceability Unit Identification Temperature Control Cooling Process

Humidity Control Dehumidification

Network Control System Main Components

Features and Options

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ICV2-40P ICV2-70P ICV2-70P

ICV1-18P ICV1-18P ICV1-18P ICV2-40P ICV2-40P ICV2-70P

INCO3-2SGA INCO2-2SGA INCO3-2SGA INCO3-2SGA INCO3-2SGA INCO3-2SGA INCO3-2SGA INCO3-2SGA

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2004 0.0 183.0

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

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IPAC Range Unit Configurations, Dimensions and Weights

IPAC 22-1 IPAC 30-1

IPAC 50-1 IPAC 60-1

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

90-2 100-2 110-2 120-2

40 15 1700 800 1950 2500 800 722

50 50 2050 2050 1950 4100 800 1135

1700 1300 2050 800 -

1950 1950 800 800 270 1300 800 380

1950 1950 1300 1600 800 402 800 520

1950 1950 2050 2600 800 620 800 784

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Pa Pa 400 400 400 400

BS 4800 Grey 00A05 58 1-18P + 1-18P 58 68 2-70P 61 63 2-40P + 1-18P 61 65

Condenser - matched Model Noise level8 - outdoor condenser

1 Unit ratings at 24 C / 50 % RH internal and 35 C external ambient air conditions. 2

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Pa Pa 400 400 360 360

BS 4800 Grey 00A05 70 2-40P + 2-40P 64 70 2-70P + 2-40P 61 70 2-70P + 2-70P 61 72

Condenser(s) - matched model Noise level8 - outdoor condenser

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Design Conditions - DX Units a

Safety Pressure Switch Settings - DX Units

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22-1 20 32 108 25 35 113 37 40 125 18 32 106 25 35 113 37 40 125 6 16 28 25 32 47 35 40 57