Liebert.

CRV Series Air Conditioner

User Manual

Version V1.4
Revision date May 28, 2012
BOM 31011886

Emerson Network Power provides customers with technical support. Users may contact
the nearest Emerson local sales office or service center.

Copyright © 2010 by Emerson Network Power Co., Ltd.

All rights reserved. The contents in this document are subject to change without notice.

Emerson Network Power Co., Ltd.

Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen
China

Homepage: [Link]

E-mail: support@[Link]
Important Safety Instructions

Warning

The manual is retained for the entire service life of the machine.

The user reads the manually carefully before carrying out any operations on the machine.

The machine is a piece of professional equipment for use in industry, trades, and other professions, and it is not
intended for sale to the general public.

The machine is used exclusively for the purpose for which it is intended; incorrect use of the machine shall release the
manufacturer any liability.
This manual has been prepared to enable the end-user to carry out only the operation that can be made with the panels
closed. Any operation that require the opening of doors or equipment panels must be carried out only by qualified personnel.
Each machine is equipped with an Electric Insulation device which allows the operator to work in condition of safety. Switch
off the machine with this electric insulation device before any maintenance operation to eliminate risks remaining (electric
shocks, burns, automatic restarting, moving parts and remote control).
The panel key supplied with the unit must be kept by person responsible for maintenance.
For identification of the unit (model and serial no.) in case of the necessity for assistance or spare parts, locate the
identification label on the outside of the unit.
Potential hazards
The protective covers can be removed only after the electric power has been cut off by opening the main switch.
A warning label on the front and back panels reminds that:

The machine restarts automatically.

The main switch must be opened before opening the internal compartments for any operation.
If the doors are opened immediately after the machine has been switched off, there might be some hazard related to:
Electrical heaters
Components still at high temperature
Compressor, outlet area and outlet piping (about 100°C)
Components still at low temperature Evaporator
Rotating elements Fan impellers, they might continue to rotate for a while by inertia
These residual risks are highlighted by warning labels on the machine.

Warning - Risk of electric shock

Risk of electric shock. Can cause injury or death.
Disconnect local and remote power supplies before working within.
Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be
sure the voltage matches available utility power.
The iCOM microprocessor does not isolate power from the unit, even in the ‘unit off’ mode.
Some internal components require and receive power even during the ‘unit off’ mode of iCOM control.
The factory-supplied optional disconnect switch is inside the unit. The line side of this switch contains live high-voltage.
The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch. Refer to
unit electrical schematic.
Follow all local codes.

Warning - Risk of explosive discharge from high-pressure refrigerant

Risk of explosive discharge from high-pressure refrigerant. Can cause injury or death.
This unit contains fluids and gases under high pressure. Relieve pressure before working with piping.
 Warning - Risk of refrigerant system rupture or explosion from
overpressurization
Risk of refrigerant system rupture or explosion from overpressurization. Can cause equipment damage, injury or death.
If a pressure relief device is not provided with the condenser unit, the system installer must provide and install a discharge
pressure relief valve rated for a maximum of 609 psig (42bar) in the high side refrigerant circuit. Do not install a shutoff valve
between the compressor and the field installed relief valve.
One or more additional pressure relief valves are required downstream of any and all fieldinstalled isolation. Do not isolate
any refrigerant circuits from overpressurization protection.
For systems requiring EU CE compliance (50Hz), the pressure relief valve must be CE certified to the EU Pressure
Equipment Directive by an EU ‘Notified Body’.

Digit Nomenclature

The unit is fully defined by twenty-five digits.

1 21 13 4 5 6 7 8 9 10 11 .. .. 25

C R 0 2 0
Digit 3, 4 and 5: Cooling
Digit 1 and 2: Family Capacity "kW" (approx.)
CR: [Link] Nominal cooling capacity

Digit 6 - Air Discharge Digit 12 – Display

R: Horizontal airflow A: Display - Small Display 1 T+H Sensor
Digit 7 - System Type N: Display - Small Display 1 Temp Sensor Only
A: System Type - Air cooled D: Display - Large Display 1 T+H sensor
W: System Type - Water cooled C: Display - Large Display 1 Temp sensor Only
C: System Type - Chilled Water Digit 13 - Re-Heating
Digit 8 - Airflow 0: None
1: Airflow - EC Plug Fan 1: Electric heating 1 Level
Digit 9 - Power Supply Digit 14 - Air Filter
0: Power Supply - 380V ~ 415V /3ph/50Hz+N 0: G4 (EU4)
C: Power Supply - 208V/3ph/60Hz 1: F5 (EU5)
A: Power Supply - 460V/3ph/60Hz 2: G4 (EU4) + Clogged Filter Alarm
Digit 10 - Cooling System 3: F5 (EU5) + Clogged Filter Alarm
2: Cooling System - CW with two way valve 8: Merv 8 + Clogged Filter Alarm
3: Cooling System - CW with three Way 9: Merv 11 + Clogged Filter Alarm
7: Cooling System - DX with digital scroll single Digit 15 - Coil
circuit R410A 1: Air cooled - water cooled two ways water valve
Digit 11 - Humidification 7: Water cooled 3 ways water valve
0: Humidification - None H: CW Standard coil
S: Humidification - Electrode humidifier
Digit 16 - Enclosure options 3: One IS485 card
1: Color Standard 4: Two IS485 cards
2: Color Special 5: IS web & IS 485 cards
Digit 17 - Condensate pump/crankcase heater Digit 20 - Sensors
A: DX units - crankcase heater 0: Sensors - None
E: DX units - condensate pump & crankcase heater H: Sensors - High Temperature - Firestat
L: CW units - no condensate pump S: Sensors - Smoke Sensor - Smokestat
5: CW units - condensate pump F: Sensors - Smoke & High Temp - Smoke and
Digit 18 - Option Package Firestat
0: None Digit 21 - Packaging
L: Option Package #1 – humidifier and reheat P: PLP and pallet Domestic
lockout & compressor jacket & one additional alarm C: PLP and wooden crate Export
H: Option Package - Reheat & Humidifier Lockout S: Seaworthy
C: Option Package #2 - humidifier and reheat Digit 22 - Special Requirements
lockout & one additional alarm A: SFA - none
D: Option Package #3 – compressor jacket X: SFA included
Digit 19 - Monitoring Digit 23-25 - Order Identifier
N: Without IS housing
0: With IS housing/no card
1: One IS web card
2: Two IS web cards
 Contents

Chapter 1 Preliminary Operations ....................................................................................................................................... 1

1.1 Inspection ............................................................................................................................................................. 1

1.2 Handling ................................................................................................................................................................ 1
1.3 Operating Limits .................................................................................................................................................... 2
1.4 Noise Level Limits ................................................................................................................................................. 4
1.5 Product Description............................................................................................................................................... 4

Chapter 2 Unit Positioning................................................................................................................................................... 8

Chapter 3 Unpacking And Installation ............................................................................................................................... 13

3.1 Reference Guide For Receiving, Unpacking, And Preparing For Installation ...................................................... 13
3.1.1 Equipment Inspection .............................................................................................................................. 13
3.1.2 Packing Material ...................................................................................................................................... 13
3.2 Recommended Unit Handling Equipment ........................................................................................................... 13
3.3 Handling The Unit While Packaged .................................................................................................................... 14
3.4 Unpacking The Unit ............................................................................................................................................ 14
3.5 Installation ........................................................................................................................................................... 16

Chapter 4 Refrigeration Connections ................................................................................................................................ 19

4.1 Refrigeration Pipeline Connections For Air-Cooled (A) Units .............................................................................. 19

4.1.1 General Layout ........................................................................................................................................ 19
4.1.2 Pipe Diameter And Thickness ................................................................................................................. 20
4.1.3 Installing Pipelines ................................................................................................................................... 21
4.2 Vacuum Creation And Refrigerant Charge ......................................................................................................... 22
4.2.1 R410A Precharge For Air-Cooled (A) Units ............................................................................................. 23
4.2.2 Refrigerant Charge For Air-Cooled (A) Units ........................................................................................... 24
4.3 Refrigeration Circuits .......................................................................................................................................... 24

Chapter 5 Water Connections ........................................................................................................................................... 25

5.1 General Warning ................................................................................................................................................. 25

5.2 Water Connections – Supply Humidifier And Drain Water (All Units).................................................................. 26
5.3 Chilled Water Connections For Water/Glycol-Cooled (W) Units ......................................................................... 27
5.3.1 Notes For Open Circuit Applications ........................................................................................................ 27
5.3.2 Notes For Closed Circuit Applications ..................................................................................................... 27
5.4 Chilled Water Connections For Chilled Water (C) Units...................................................................................... 28

Chapter 6 Electrical Connections ...................................................................................................................................... 30

6.1 Cable Entry Ports, Routing Cables And Connection Procedures ........................................................................ 30
6.2 Protective Features Of EC Fans ......................................................................................................................... 31
6.3 Protective Features Of Electrical Heaters ........................................................................................................... 32
6.4 Temperature Probes Placed On Racks .............................................................................................................. 32
Chapter 7 Start-Up ............................................................................................................................................................ 35

7.1 First Start-Up (Or After Long Standstill) .............................................................................................................. 35

7.2 Automatic Restart ............................................................................................................................................... 36
7.3 Checking The Refrigeration Piping Pressure Drops............................................................................................ 36
7.4 Chilled Water Valve Of Chilled Water (C) Units .................................................................................................. 36

Chapter 8 Operation .......................................................................................................................................................... 38

Chapter 9 Calibrations & Regulation (At Start-Up) ............................................................................................................ 39

9.1 Setting Thermostatic Expansion Valve ............................................................................................................... 39

9.2 Water Leakage Sensor ....................................................................................................................................... 39
9.3 Environment Protection....................................................................................................................................... 39

Chapter 10 Maintenance & Spare Parts ............................................................................................................................ 40

10.1 Safety Instructions ............................................................................................................................................ 40

10.2 Spare Parts ....................................................................................................................................................... 40
10.3 Maintenance Schedule ..................................................................................................................................... 40
10.4 Air Filter Check Or Substitution ......................................................................................................................... 41
10.5 Condensate Drain And Condensate Pump Systems ........................................................................................ 43
10.5.1 Condensate Drain .................................................................................................................................. 43
10.5.2 Condensate Pump ................................................................................................................................. 43
10.6 Air-Cooled Condenser And Drycoolers ............................................................................................................. 43
10.7 Electrical Heaters .............................................................................................................................................. 43
10.8 Refrigeration Circuit .......................................................................................................................................... 43
10.8.1 Refrigerant Charge Of The Water-Cooled Units .................................................................................... 44
10.8.2 Oil Charge R410A ................................................................................................................................. 44
10.8.3 Oil Topping-Up Of An Installed Circuit ................................................................................................... 44
10.9 Dismantling The Unit......................................................................................................................................... 44
10.10 Regulation (EC) No. 842/2006 (F-Gas)........................................................................................................... 45
10.11 Unit Diagnostic ................................................................................................................................................ 46

Appendix 1 Humidair Humidifier ........................................................................................................................................ 47

1. Preface ................................................................................................................................................................. 47
2. Installation ............................................................................................................................................................. 47
3. Humidifier Components ........................................................................................................................................ 49
4. Start-Up And Operation ........................................................................................................................................ 49
4.1 Start-Up ...................................................................................................................................................... 49
4.2 Operation .................................................................................................................................................... 49
5. Maintenance ......................................................................................................................................................... 50
5.1 Removing The Steam Cylinder ................................................................................................................... 50
5.2 Replacing The Steam Cylinder ................................................................................................................... 50
5.3 Annual Maintenance ................................................................................................................................... 50
6. Replacing Humidifier Spare Parts ......................................................................................................................... 51
Appendix 2 Technical Data Tables.................................................................................................................................... 52

Appendix 3 Installation Drawing ........................................................................................................................................ 55

Appendix 4 Refrigerant, Hydraulic And Electrical Connections ......................................................................................... 59

Appendix 5 Refrigeration & Hydraulic Circuits................................................................................................................... 64

Appendix 6 Wiring Diagram............................................................................................................................................... 67

 Chapter 1 Preliminary Operations 1

Chapter 1 Preliminary Operations

This chapter introduces the preliminary operations of the [Link] series air conditioner ([Link] for short),
including inspection, handling, operating limits, noise level limits and product description.

Warning - Risk of top-heavy unit falling over

Risk of top-heavy unit falling over. Can cause death, injury and equipment damage. Read all of the following instructions before
attempting to move, lift or remove packaging from the unit.

Caution - Risk of sharp edges, splinters and exposed fasteners

Risk of sharp edges, splinters and exposed fasteners. Can cause personal injury. Only trained personnel wearing appropriate
safety headgear, gloves, shoes and glasses should attempt to move, lift or remove packaging from the unit or prepare the unit for
installation.

Caution - Risk of overhead interference

Risk of overhead interference. Can damage the unit and structure. The unit may be too tall to fit through a doorway while on the
skid. Measure the unit and doorway heights and refer to the installation plans to verify clearances before moving the unit.

Caution - Risk of frozen fluids

Risk of frozen fluids. Can cause equipment damage. Keep the unit upright, indoors and protected from dampness, freezing
temperatures and contact damage.

1.1 Inspection
Upon arrival of the unit, and before unpacking it, verify that the delivered equipment matches the bill of lading.
Examine the packaging for any signs of mishandling or damage. Inspect all items for damage, visible or concealed.
Report any damage immediately to the carrier and file a damage claim. Send a copy to Emerson Corporation or to
your sales representative.

1.2 Handling
Always keep the unit vertically upright and do not leave it out in the open.

If possible, transport the [Link] using a forklift or pallet jack. Otherwise use a crane with belts or cables
and spreader bars to protect the unit’s sides from damage.

If using a forklift or pallet jack, make sure the forks (if adjustable) are spread to the widest distance that fit under
the skid. Also, ensure the fork length is suitable for the unit length.

When moving the packaged unit, do not lift it any higher than 152 mm off the ground. Exercise great care if the
unit must be lifted higher than 152 mm; any personnel not directly involved in lifting the unit must be at least 5m
from the unit.

Take care of the Center of Gravity indicated on the package.

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2 Chapter 1 Preliminary Operations

Table 1-1 Center of gravity

Distance from corner (unit: m)
Model
X (±0.05m) Y (±0.05m) Z (±0.05m) z

CR020 0.52 0.30 0.71

CR035 0.50 0.30 0.80

CR040 0.54 0.30 0.80 y

Note: The center of gravity on the [Link] varies with the options and the model’s size

Moving by a forklift and unit weight

The schematic diagram of moving the unit by a forklift is shown in Figure 1-1. The unit weight is given in Table 1-2.

Figure 1-1 Moving the unit by a forklift

Table 1-2 Unit weight (unit: kg)

Weight (±5%)
Model Power supply
Air-cooled Water/Glycol-cooled Chilled water
CR020 380V ~ 415V/3-phase/50Hz 335 350 -
CR035 380V ~ 415V /3-phase/50Hz 365 385 -
CR040 380V ~ 415V /3-phase/50Hz - - 330
Note: Weights of full version units without packaging

1.3 Operating Limits

The units are designed to operate within working ranges (see Table 1-3 ~ Table 1-7). These limits are referred to new
machines or to those that have been correctly installed and serviced.
The warranty clauses are no longer valid for any possible damage or malfunction that may occur during or due to
operation outside the application values.

For all units

Table 1-3 Operating limits for all units

Item From To
Temperature 18°C 40°C
Room air
Humidity ratio 5.5g/kg 11g/kg
conditions
Relative humidity 20% 60%
Storage
Temperature -20°C 50°C
conditions
Power supply Voltage ±10%
tolerances Frequency ±2Hz

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 Chapter 1 Preliminary Operations 3

For air-cooled (A) units

Table 1-4 Operating limits for air-cooled (A) units

Item Description
To install an air conditioner in places in which external temperature reaches very low values sometime in
the year requires some means of control to maintain adequate condensing pressures to ensure proper
liquid system operation.
With low temperatures the refrigerant condensates in pipeline and the liquid tends to fulfill the
condenser.
It's mandatory to install the following components:
1. Non return valve (liquid line)
Outdoor Install a non-return valve in the liquid line directly out of the condenser. It doesn’t allow the liquid to come
temperature: lower back to the condenser (that means efficiency loss and dangerous stress for the compressor).
limit (-20°C) 2. Variex fan speed control (the CRV standard outdoor unit has been configured with the function)
Use Variex fan speed control to regulate the condensing pressure and have a continuous and better
subcooling control.
It’s suggested to have:
3. Horizontal condenser position
The condenser horizontal disposition (vertical flow) is necessary to reduce subcooling variations due to
direct wind exposure. (very important to have a good subcooling control).
For all exceptions contact the Emerson sales representative
This limit is determined by coupled condenser model. Exceeding of this limit (or a lack of maintenance),
will caused a compressor stop by HP safety thermostat. Reset to normal operation can only be carried
Outdoor
out manually.
temperature: higher
Once the condensing pressure rises at or above the 34bar / 493psi value, the capacity of the
limit
compressor is reduced by 20% compared to the requested capacity. This because iCOM control tries to
maintain the unit's operability reducing the cooling power of digital scroll

Table 1-5 Relative position of room unit and 50Hz remote condenser
Item Description
From unit to condenser max distance equivalent length1 50m
From unit to condenser max geodetic height2 -8m ~ 30m
Pipe diameter See Table 4-2
Requirements Oil traps on vertical line of gas refrigerant Install one every 6m
Extra oil charge See Table 5 and Table 6 in the appendix
Note:
1: If the equivalent length from the indoor unit to the condenser exceeds 50m, please consult with Emerson sales representative;
2: Positive difference in height: condenser above conditioner; Negative difference in height: condenser below conditioner

For water/glycol-cooled (W) units

Table 1-6 Operating limits for water/glycol-cooled (W) units

Item Description
Water or mixture temperature to condenser Min. 5°C
Other information See Chapter 5 Water Conections

For chilled water (C) and water/glycol-cooled (W) units

Table 1-7 Operating limits for chilled water (C) and water/glycol-cooled (W) units
Description
Item
CR020RW CR035RW CR040RC
Max. water pressure (bar) 16 16 16
Max. differential pressure through the
300 300 175
closed valve: Dpcv (kPa)
Max. differential pressure across the
300 300 175
valve for modulating service: Dpms (kPa)

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4 Chapter 1 Preliminary Operations

1.4 Noise Level Limits

The sound pressure level in free field at 1.5m height and 2m in front of the air conditioner, with compressor and fan in
operations, is less than 70dBA for all models (excluding the chilled water unit).

1.5 Product Description

Appearance
The appearance of the air conditioner is shown in Figure 1-2.

Figure 1-2 Appearance of the air conditioner

Example of installation
The [Link] is a range of full-featured compressorized (air, water, glycol cooled) and chilled water cooling units
to be installed within a row of high density computing racks in a ‘hot-aisle-cold-aisle’ configuration.
The example of high density installation with cold aisle and hot aisle alternation is shown in Figure 1-3.

CR Hot
Hot aisle
aisle

CR
CR CR

CR

Coldaisle
Cold aisle
CR
CR

Hot
Hotaisle
aisle

Hot
Hot aisle
aisle CR

Cold
Cold aisle
aisle

Figure 1-3 Example of high density installation with cold aisle and hot aisle alternation

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 Chapter 1 Preliminary Operations 5

Thermal performance
The thermal performance (at 1.1m from floor) of a system with 2 CRV and 20 racks is shown in Figure 1-4.

Figure 1-4 Schematic diagram of thermal performance

Inlet air enters this unit from the hot aisle, is filtered, cooled and conditioned, and is returned to the cold aisle. It
provides all the necessary functions of a standard precision air conditioner, including cooling, heating, humidification,
dehumidification, air filtration, condensate management, temperature control, alarm functions and data
communications. The [Link] is optimized for maximum cooling capacity in minimal footprint.

iCOM display panel

The iCOM display panel is shown in Figure 1-5.

Figure 1-5 iCOM display panel

The iCOM display panel shows: air inlet temperature and humidity, air outlet temperature, fans status, cooling power
status, next service time.

Component locations
The component locations of [Link] air-cooled (A), water/glycol-cooled (W) and chilled water (C) units are
shown in Figure 1-6.

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6 Chapter 1 Preliminary Operations

3 6

1. iCOM control display 2. Electric Box 3. Evaporator / CW Coil 4. Condensate pump 5. Electric heaters
6. Humidifier distributor 7. Top water connections 8. Drain tray 9. EC fans
Figure 1-6 Component locations

The component locations of Liebert CR020 ~ CR035 air-cooled (A) units are shown in Figure 1-7.

8
2
1
10

1. Termostatic expansion valve 2. Solenoid valve 3. Sight glass 4. Filter dryer

5. Liquid receiver 6. Safety valve 7. Humidity/Temp. sensor 8. Humidifier
9. Top refrigerant connections 10. Bottom refrig. connections
Figure 1-7 Component locations of Liebert CR020 ~ CR035 air-cooled (A) units

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 Chapter 1 Preliminary Operations 7

The component locations of Liebert CR020 ~ CR035 water/glycol-cooled (W) units are shown in Figure 1-8.

2 4

1. Top Water connections 2. Compressor 3. Water condenser

4. Bottom water connections 5. Three-way water valve
Figure 1-8 Component locations of Liebert CR020 ~ CR035 water/glycol-cooled (W) units

The component locations of Liebert CR040 chilled water unit are shown in Figure 1-9.

3
4

1. Top CW connections 2. Filters 3. Three-way CW valve 4. Bottom CW connections 5. Humidifier

Figure 1-9 Component locations of Liebert CR040 chilled water unit

[Link] Series Air Conditioner User Manual

8 Chapter 2 Unit Positioning

Chapter 2 Unit Positioning

This chapter provides some ideas of typical installation of the [Link] unit(s), shows several examples of the
server room layouts and applications using [Link] units.
For best performances of [Link] is important to:

Reduce at minimum recirculation from hot aisle around the ends and/or over the top of the racks, prevent gaps
between the racks.

Reduce at minimum recirculation from hot aisle through server racks by using blanking panels.

Ensure cold air is being distributed across the front of all neighboring equipment racks by properly placed
[Link] unit(s).

Distribute load within the rack – it is generally advised to distribute the load as much possible uniformly across
the rack height, except for the rack closest to the [Link] unit, where it is suggested to have the higher
density load in the bottom and central part of the rack.
For more details refer to following details or contact Emerson Sales Representative.
1. Placement in the row of racks
For single row application with one [Link] unit it is not preferred to put the unit in the middle of the row because
of possible hot spots at top part of racks, unless in combination with CoolFlex or in application with more [Link]
units. The best approach is to place the [Link] at the end of the row, resulting into much better air distribution.
Please refer to the sample case study comparing the same server room with different [Link] position. The CFD
(Computational fluid dynamics) analysis results are shown in Figure 2-1 (height 1.8m off the floor for all following
cases).

Good approach:
CRV

End of row is preferred.

Not advised approach:

CRV

Figure 2-1 CFD analysis results of comparing the same server room with different [Link] position

2. Number of racks / length of the row

Standard application with one [Link] unit is with 2 ~ 6 racks. The exact number of racks depends on size of
[Link] unit used and heat load per rack. Whenever applying more than 6 racks for one CRV or heat load more
than 10kW per rack contact Emerson sales representative.
The CFD analysis result of one [Link] unit with 2 ~ 6 racks is shown in Figure 2-2.

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 Chapter 2 Unit Positioning 9

2 ~ 6 racks (0.6m ~ 5m)

CRV

Figure 2-2 CFD analysis result of one [Link] unit with 2 ~ 6 racks

3. Placement in the room

1) Width of hot aisle/cold aisle
For good air distribution it is recommended to keep width of the cold aisle as small as possible for single row server
room. Otherwise the cold air discharged by [Link] unit is being led far from server suction and hot air may
by-passed from hot aisle.
Exceptions where wider cold aisle may be used are: applications with CoolFlex (Cold Aisle Containment) or with two
rows facing each other.
The width of hot aisle/cold aisle is shown in Figure 2-3.

Min. 0.65m
CRV

0.6m ~ 1.2m

Figure 2-3 Width of hot aisle/cold aisle

The CFD analysis result of cold aisle with different width is shown in Figure 2-4.
Good approach:
CRV

< 1.2m

Not advised approach:

CRV

> 1.2m

Note: Please refer to the service area dimensions in Appendix 3.

Figure 2-4 CFD analysis result of cold aisle with different width

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10 Chapter 2 Unit Positioning

2) Distance between the ends of rows and walls

For single row application with one [Link] unit it is not preferred to put the unit at wall because of not proper air
paths and possible hot spots at furthest racks, unless in combination with CoolFlex (cold aisle containment) or in
application with more [Link] units. The best approach is to keep a gap between at least 0.65m or to use more
[Link] units. Good approach is also having wall at the furthest rack.
Please refer to the following sample case study comparing various [Link] positions. The CFD analysis result is
shown in Figure 2-5.

Min. 0.65m Variable

CRV

Example of an application with gaps on both sides

Good approach:
CRV

Not advised approach:

CRV

Figure 2-5 CFD analysis result of [Link] unit in different positions

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 Chapter 2 Unit Positioning 11

As you can see on CFD result above, it is not advised to place [Link] at the wall in single row layout. On the
contrary, it is not an issue in application with two rows and two or more [Link] units, as shown in Figure 2-6.
Good approach:

CRV
0.6m ~ 1.8m

CRV
Min. 0.1m

Note: Please refer to the service area dimensions in Appendix 3.

Figure 2-6 CFD analysis result of two rows and two or more [Link] units

4. Solutions with redundancy

Following an example of more complex applications where N+1 redundancy provided.
Please note the number and size of [Link] units have to be designed in order to achieve required cooling
capacity if any of the units fails. The other option to easily achieve redundancy is CoolFlex (Cold aisle containment),
see point 5 below.
The CFD analysis result of solutions with redundancy is shown in Figure 2-7.
CRV

Off

Example of an application with one row and N+1 redundancy

(right side unit failed).
CRV

CRV
CRV

CRV

Example of an application with two rows and N+1 redundancy

(unit placed right down failed).

Figure 2-7 CFD analysis result of solutions with redundancy

5. Example of applications with CoolFlex

When high density IT equipment is used (typically over 10kW per rack) or load distribution in the row(s) of racks is not
constant and high energy efficiency is required it is strongly recommended to apply CoolFlex (cold aisle containment)
together with [Link].

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12 Chapter 2 Unit Positioning

Other advantage of the CoolFlex application is less limitations, see above points.
The CFD analysis result of applications with CoolFlex is shown in Figure 2-8.

CRV
CoolFlex

CRV
CRV

CoolFlex

Figure 2-8 CFD analysis result of applications with CoolFlex

6. Example of applications with Liebert XD

When high density IT equipment is used (typically over 10kW per rack) with less floor space available especially
when scalable solution is required (starting from less heat load and ready for future grown), the best answer is Liebert
CRV together with Liebert XD system.
Please find following an example layout of typical installation with two rows of racks with [Link] modules. Two
[Link] units are used to support the Liebert XD system and to ensure N+1 redundancy on humidity control. See
also CFD result showing site view of the room, as shown in Figure 2-9.
CRV

XDV

XDV

XDV

XDV

XDV

XDV
XDV

XDV

XDV

XDV

XDV

XDV

CRV

Figure 2-9 CFD analysis result of applications with Liebert XD

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 Chapter 3 Unpacking And Installation 13

Chapter 3 Unpacking And Installation

This chapter introduces unpacking and installation of the [Link] air conditioner, including reference guide for
receiving, unpacking, and preparing for installation, recommended unit handling equipment, handling the unit while
packaged, unpacking the unit and installation.

3.1 Reference Guide For Receiving, Unpacking, And Preparing For Installation

Warning - Risk of top-heavy unit falling over

Risk of top-heavy unit falling over. Improper handling can cause equipment damage, injury or death. Read all of the following
instructions before attempting to move, lift, remove packaging from the unit or prepare unit for installation.

Caution - Risk of sharp edges, splinters and exposed fasteners

Risk of sharp edges, splinters and exposed fasteners. Can cause personal injury. Only trained personnel wearing appropriate
safety headgear, gloves, shoes and glasses should attempt to move, lift or remove packaging from the unit or prepare the unit for
installation.

Notice - Risk of overhead interference

Risk of overhead interference. Can cause unit and/or structure damage. The unit may be too tall to fit through a doorway while on
the pallet. Measure the unit and doorway heights and refer to the installation plans prior to moving the unit to verify clearances.

Notice - Risk of unit damage if improperly stored

Risk of unit damage if improperly stored. Keep the unit vertically upright, indoors and protected from dampness, freezing
temperatures and contact damage.

3.1.1 Equipment Inspection

Upon arrival of the unit, and before unpacking, verify that the labeled equipment matches the Bill of Lading. Carefully
inspect all items for either visible or concealed damage. Damage should be immediately reported to the carrier and a
damage claim filed with a copy sent to Emerson Corporation or to your sales representative.

3.1.2 Packing Material

All material used to package this unit is recyclable. Please save the material for future use, or dispose it appropriately.

3.2 Recommended Unit Handling Equipment

The recommended unit handling equipment is shown in Figure 3-1.

Figure 3-1 Recommended unit handling equipment

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14 Chapter 3 Unpacking And Installation

3.3 Handling The Unit While Packaged

If possible, transport the packaged unit using a fork lift or a pallet jack; otherwise use a crane with slings and
spreader bars.

If using a fork lift or pallet jack, make sure the forks (if adjustable) are spread to the widest allowable distance to
still fit under the pallet. Also, make sure the fork length is suitable for the unit length.

When moving the packaged unit with a fork lift or pallet jack, lift the unit from either end of the pallet.

When handling the packaged unit with a fork lift or pallet jack, the unit shall not be lifted any higher than 51mm ~
102mm) off the ground. All by-standing personnel shall be no closer than 3.7m to the handled packaged unit.

If circumstances require the unit to be lifted higher than 102mm great care shall be exercised and all by-standing
personnel are to be no closer than 5m to the lift point of the unit.

3.4 Unpacking The Unit

Move the product to the place closest to the final installation site before unpacking the unit.
Follow the procedures below to unpack the unit:
1. Removing the side boards and top cover.
1) CRV series air conditioner uses the international packaging. You can use a hammer or straight screwdriver to
straighten the connection hook between the side boards and top cover, as shown in Figure 3-2.

Figure 3-2 Straighten the hook

2) As shown in Figure 3-3, at first, straighten all the hooks that fix the side boards, and remove the four side boards.
At last remove the top cover.

Top cover

Side panel

Figure 3-3 Remove the side boards and top cover

2. Remove the cushion (see Figure 3-4) from the unit, exposing the bag over the unit. The bag may remain in place
for dust and panel protection, or removed for immediate unit installation.

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 Chapter 3 Unpacking And Installation 15

Cushion

Figure 3-4 Remove the cushion

3. CRV series air conditioner is fixed onto the pallet with M8 × 45 bolts, as shown in Figure 3-5. You can use an M10
open-end spanner, a ratchet spanner or a sleeve to remove the screws.

Pallet fixing
bolts (4 pcs)

Figure 3-5 Remove the pallet fixing bolts

4. Using the unit castors, at least two trained persons can move the unit to the site for installation, as shown in
Figure 3-6.

Figure 3-6 Move the unit

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16 Chapter 3 Unpacking And Installation

3.5 Installation
1. Open the unit panel, follow the procedures as below:
1) Opening the front up panel, the serial number of the unit for service is revealed. See ‘a’ in Figure 3-7.

Figure 3-7 Serial number of the unit

2) Using a screwdriver open the electrical panel and the front down panel to prepare installation, as shown in
Figure 3-8.

Open the electrical panel Open the front down panel

Figure 3-8 Open the electrical panel and the front down panel

3) Using the keys (‘b’ in Figure 3-9) open the electrical panel and the down panel on the rear.

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 Chapter 3 Unpacking And Installation 17

Figure 3-9 Open the electrical panel and the down panel on the rear

2. When the unit is on site, to lock it, adjust the four base supports with a ‘24’ key. Turning them the unit will be lift. It’s
very important that unit has to be horizontal, because, in other cases, condensed water is not able to come out
completely (possibility of malfunctions, corrosions and hygienic problems). Finally lock the top bolts (‘c’ in
Figure 3-10).

Figure 3-10 Lock the top bolts

3. Connect the unit as described in below paragraphs: refer to Chapter 4 Refrigeration Connections for units’ type A
and W; refer to Chapter 5 Water Connections for all units; refer to Chapter 6 Electrical Connections for all units.
4. Before start-up, adjust the frontal panel baffles to give right air flow direction, as shown in Figure 3-11. This
operation is very important to obtain the maximum efficiency from [Link] unit and to prevent rack’s overheating
in the system. For any doubt contact Emerson service people.

Figure 3-11 Adjust the frontal panel baffles

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18 Chapter 3 Unpacking And Installation

1) Baffles have always to direct air flow up, as shown in Figure 3-12.

Figure 3-12 Direct air flow up

2) Turn the baffles (if necessary) to direct right or left the air flow, in Figure 3-13.

1. Remove the screws (one on left and one on right) 2. Disassemble only the wrong baffles

3. Rotate around a horizontal axle to adjust direction 4. Reassemble and lock the screws
Figure 3-13 Turn the baffles

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 Chapter 4 Refrigeration Connections 19

Chapter 4 Refrigeration Connections

This chapter introduces refrigeration connections of the [Link] air conditioner, including refrigeration pipeline
connections for air-cooled (A) units, vacuum creation and refrigerant charge, and refrigeration circuits.

Warning
Use only condenser unit design for R410A refrigerant.
The unit is designed both from top and bottom side.

4.1 Refrigeration Pipeline Connections For Air-Cooled (A) Units

The refrigeration pipeline connections on unit top and bottom are shown in Figure 4-1.

Bottom refrigeration pipeline connections

Top refrigeration pipeline connections (If you are using bottom ones, de-braze pipes across square dot line and
remove pipes to the top of the unit. Then braze new pipes to bottom.)
Figure 4-1 Refrigeration pipeline connections

The air condensing units are delivered with nitrogen pressurized at 2bar.

Warning
The discharge operation of the room unit pressurized with nitrogen (at 2bar) and the de-brazing of the bottoms from the
connections must be carried out as last operations, immediately followed by the connection and emptying of the whole system.

4.1.1 General Layout

The recommended pipe layout is shown in Figure 4-2, and the No. descriptions are as follows:
①: In soft or hard copper. The diameter required is stated in Table 4-2. If the installer intends to use pipes of a larger
diameter (e.g. for long winding runs) then consult Emerson services. Use refrigeration pipelines which are as short as
possible to minimize the total charge of refrigerant and the pressure drops. Lay the horizontal gas pipes with 1%
downward gradient towards the refrigerant flow.
②: Reduce the number of bends, which must be of large radius, to a minimum.
③: Insulate the piping as specified in Table 4-1. If the pipes are put next to electrical cables it is advised to insulate
them to avoid damage to cable insulation.
④: There must be a minimum separation of 20mm between the gas and liquid pipelines. If this is not possible insulate
both lines.
⑤: Support both horizontal and vertical pipes with vibration-damping clamps (which include rubber gaskets). Place
these every 1.5m ~ 2m.

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20 Chapter 4 Refrigeration Connections

4
2

Figure 4-2 Recommended pipe layout

The condenser positioning is given in Table 4-1.

Table 4-1 Condenser positioning
Condenser positioning
Item Condenser and indoor unit at Condenser below indoor unit
Condenser above indoor unit
the same level (not recommended)
Gas inlet Necessary Necessary Necessary
Insulation

Gas outlet Only for aesthetic reasons Only for aesthetic reasons Only for aesthetic reasons
Liquid inlet Absolutely not Not necessary No (expose to cold underfloor air)
Liquid outlet Only for aesthetic reasons Only if exposed to sun Only if exposed to sun
Liquid
Gas

Indoor unit Indoor unit

(See Table 1-5)

Indoor unit (See Table 1-5)

Gas
Layout
Liquid
Gas
6m*

Liquid
Note*: Oil traps every 6m of
vertical piping.

4.1.2 Pipe Diameter And Thickness

Warning
The diameters and thickness of the connecting pipes between the conditioner and the condensing unit listed in Table 4-2 must
be respected for safety reasons (we are managing the R410A refrigerant) and otherwise the guarantee becomes invalid.

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 Chapter 4 Refrigeration Connections 21

Table 4-2 Pipe diameters (Indoor unit to condenser)

External diameter x minimum thickness (mm)
Model
Gas Liquid
CR020RA 19 × 1.2 16 × 1
CR035RA 22 × 1.2 19 × 1.2
Note: the diameters in the table is standard pipe dismeters (invalid for equivalent lengths up to 50m)

4.1.3 Installing Pipelines

The following operations must be carried out by an experienced refrigeration technician.

Warning
The discharge operation of the room unit pressurized with nitrogen (at 2bar) and the de-brazing of the bottoms from the
connections must be carried out as last operations, immediately followed by the connection and emptying of the whole system.

1. Lay the piping, taking note of the following:

1) Brazing:

All joints must be braze-brazed.

Avoid butt brazes by using sleeves or enlarging one of the pipes using a pipe opener.

Use silver-based solders and the correct apparatus.

Guarantee a correct braze as a refrigerant leak, or a faulty braze which leads to a leak later on, can seriously
damage the air conditioner.
2) Always use large-radius curves (bending radius at least equal to pipe diameter). Bend the pipes as follows:

Soft copper: by hand or bending device.

Hard copper: use preformed curves. Do not overheat the pipes when brazing so as to minimize oxidation.
2. Connect the pipes to the condenser:
1) Condensers with butt-brazed pipe connections: cut the pipe, enlarge it and braze it to the pipeline.
2) Condensers with threaded tap connections: flange the pipes and connect.
Note: respect the direction of refrigerant flow (see labels on refrigerant connections).
3. Wash out the pipelines as follows:
1) Plug up the free ends of the pipes.
2) Connect a helium or nitrogen cylinder, fitted with a reducer (max. pressure 10bar), to the ¼" SAE Schrader cock of
the condenser.
3) Pressurize the pipes with helium or nitrogen.
4) Unplug the pipes instantaneously.
5) Repeat 1) - 4) several times.
Note: This operation is especially important when hard copper piping is used.
4. Open all the room unit shut-off valves.
5. Discharge the room unit pressurized with nitrogen (at 2bar) opening the charge cocks so that all the branches of
the circuit are discharged (e.g. on the receiver, on the low pressure side and on the compressor delivery).
6. De-braze the bottoms from the connections of the room unit.
7. Fix (braze) the pipes to the connections on the air conditioner.
8. Connect the refrigerant safety valve to the outdoor with a 16mm copper pipe.

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22 Chapter 4 Refrigeration Connections

The equivalent lengths of curves, shut-off valves and check valves are listed in Table 4-3.

Table 4-3 Equivalent lengths of curves, shut-off valves and check valves

Equivalent lengths
90° curve 45° curve 180° curve 90° shut-off valve Check valve

Nominal
diameter

12mm 0.50m 0.25m 0.75m 2.10m 1.90m

14mm 0.53m 0.26m 0.80m 2.20m 2.00m
16mm 0.55m 0.27m 0.85m 2.40m 2.10m
18mm 0.60m 0.30m 0.95m 2.70m 2.40m
22mm 0.70m 0.35m 1.10m 3.20m 2.80m

4.2 Vacuum Creation And Refrigerant Charge

Warning
1. Check the refrigerant type to be used on the data plate of the air conditioner and on the refrigerating compressor.
2. Poor quality or counterfeit refrigerant will damage the system seriously. For the system abnormality, fault or damage caused
by using poor quality or counterfeit refrigerant, Emerson Network Power Co., Ltd. will not assume the warranty responsibility.

Pump and refrigerant charging cylinder connection for vacuum creation and refrigerant charge is shown in Figure 4-3.

11a

14

11

R.L.

12

10a

10b

10

Figure 4-3 Pump and refrigerant charging cylinder connection

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 Chapter 4 Refrigeration Connections 23

Suction and supply line connection for vacuum creation is shown in Figure 4-4.

Figure 4-4 Suction and supply line connection for vacuum creation

Liquid line connection for vacuum creation is shown in Figure 4-5.

Figure 4-5 Liquid line connection for vacuum creation

Connection after thermostatic valve for vacuum creation and refrigerant charge is shown in Figure 4-6.

Figure 4-6 Connection after thermostatic valve

4.2.1 R410A Precharge For Air-Cooled (A) Units

1. Open all cocks of the system including those used for pressurizing (ambient unit and condensing unit).
By this operation all the components of the refrigerating circuit must be subject to vacuum.
2. Connect a proper, high efficiency vacuum pump (10) suitable for polyester oils to the couplings:

Compressor intake and delivery using, if available, the three-way Rotalock cocks, coupling 1/4” SAE (make sure
that all three ways are open), otherwise the Schrader valves brazed on the pipings.

Coupling 1/4” SAE of the liquid receiver (12).

Coupling 1/4” SAE of the evaporator coil (14).
3. Provide for a connection with refrigerant cylinder before making vacuum.

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24 Chapter 4 Refrigeration Connections

4. Make the system vacuum up to 0.3mbar (absolute) and after 3 hours check if 1.3mbar (absolute) have not been
exceeded. This condition warrants the humidity lower than 50ppm inside the system. If the complete vacuum is not
possible, this means that there are some leaks (to be removed according to the instructions in 6 below).
Never use the compressor to create a vacuum (this invalidates its guarantee).
5. Break the vacuum as follows:
1) Close the cock (10a) for the vacuum pump (10).
2) Open the cock of the refrigerant cylinder (11a) until the system reaches a pressure value of about 1 bar. Repeat
this procedure using a Schrader valve on high pressure side near liquid receiver.

Warning
The refrigerant must be introduced and charged by taking only liquid fluid from the cylinder.

3) At this point both the vacuum pump and the refrigerant cylinder can be disconnected as follows:

Close the cylinder cock (11a).

Close the way 1/4" SAE of the Rotalock cocks and of the connected Schrader valves.
6. Inspect all connections/joints using a leak detector. If a leak is found, empty the pipes and the condenser, seal the
leak and repeat the instructions in 3 ~ 6.
7. Now the machine is ready for completing the charge and the start-up.
8. Charge the refrigerant (only liquid) by means of the charge valve placed at the evaporator inlet.

4.2.2 Refrigerant Charge For Air-Cooled (A) Units

1. Start the unit as described in 7.1 First Start-up (Or After Long Standstill).
2. Manually start the compressor at 100% modulation (ensure the unit is not in the dehumidification phase).
3. Guarantee a constant condensation temperature (preferably 45°C); if necessary, partially obstruct the condenser
coil surface or limit its ventilating power to obtain these conditions.
4. Charge the unit until the working conditions of the entire refrigeration circuit have become normal.
5. Using a manometer to measure the suction pressure and calculate the evaporating temperature, check that the
evaporating temperature is above 0°C.
6. Verify that the superheat is 5K ~ 8K (refer to 9.1 Setting Thermostatic Expansion Valve).

4.3 Refrigeration Circuits

Refer to Appendix 5 Refrigeration & Hydraulic Circuit.

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 Chapter 5 Water Connections 25

Chapter 5 Water Connections

This chapter introduces water connections of the [Link] air conditioner, including general warning, water
connections, chilled water connections for water/glycol-cooled (W) units and chilled water (C) units.
The options for water connections are listed in Table 5-1.
Table 5-1 Options for water connections
Options Top connections Down connections
Condensate pump Available choice Available choice
Nothing (drain only) No Single choice

Condensate pump must be selected and used for top connection of water pipes of the unit. Top connections: ‘e’ in
Figure 5-1 is the position of supply and drain water connection for all types unit. ‘f’ is the position of supply and drain
water connection for the chilled water (C unit) or cooling water (W unit).

e f

Figure 5-1 Supply and drain water connection

5.1 General Warning

If the tubing is to run outdoors, add glycol to the circuit as described in Table 5-2.
Table 5-2 Glycol to be added to water
Percentage in weight of total mixture added to water
Item
0% 10% 20% 30% 40%
Freezing Glycol* 0°C -5°C -11°C -18°C -27°C
temperature Propylene glycol 0°C -3°C -7°C -14°C -
Note*:
Values are for Shell antifreeze 402. For different brands check manufacturer’s data

Notes:

To avoid stratification run the circulation pump for at least 30min. after adding any glycol.

After adding water to the water circuit, disconnect the unit from the sanitary water piping system; in this way the
water mixed with glycol won’t return into the same piping system.

After any topping-up of water check the glycol concentration and add any glycol if necessary.

The hydraulic features of the system vary by adding glycol. Therefore check the head and the flow rate of the
pump to be used.

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26 Chapter 5 Water Connections

5.2 Water Connections – Supply Humidifier And Drain Water (All Units)
Units with condensate pump are pre-set to be connected from the top. If it’s to use floor connections the water lines
can be intercepted in the points shown in Figure 5-2.

Figure 5-2 Points for intercepting water lines

The schematic diagram of condensate drain without pump is shown in Figure 5-3, take the following procedures:

Use galvanized steel, PVC or flexible polythene tubing.

Allow a 2% gradient towards the drain.

There must be a drain trap ① placed at least 20 cm/8” below the drain tray ②. The drain trap must be placed
under the unit, in the false floor.

Fill the drain trap with water ③.

1 Min. 20cm

Bracket Min. 10cm

(2 pcs)

Note:
1. Do not cut the bracket of this drain trap or
the draining of the condenser will be affected.
2. Fill the drain trap with water before startup
To be connected to avoid spraying condensate.
by user 3. To avoid water leakages, use teflon tape
between flexible tube and connections.
Figure 5-3 Condensate drain

For humidifier (optional), refer to Appendix 1 Humidair Humidifier.

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 Chapter 5 Water Connections 27

5.3 Chilled Water Connections For Water/Glycol-Cooled (W) Units

For rear bottom cooled water condensed connections, see Figure 5-4.

Figure 5-4 Rear bottom cooled water condensed connections

The unit must receive cooling water as follows:

1. From an external cooling water source, in open circuit (see Figure 5-6).
2. Using a Dry cooler, in closed circuit (see Figure 5-7).

Connect the piping by reference to Appendix 4 Refrigerant, Hydraulic And Electrical Connections.

It is advisable to use hoses to be connected, with 3-piece joints, to the condenser water inlet and outlet
couplings.

Install a 16 ~ 20 mesh strainer on the chilled water supply to the [Link]. The strainer is needed to prevent
particles in the chilled water from entering the heat exchanger of the [Link].

Place shut-off ball valves at the conditioner inlet and outlet to allow easy maintenance.

It is advisable to install a water drain system at the lowest point in the circuit.

Fully drain the piping before connecting it to the air conditioner.

5.3.1 Notes For Open Circuit Applications

Use the unit with mains or well water. Do not use water from an evaporative cooling tower unless the filling water
hardness is controlled.

The water pressure must be 2bar ~ 10bar (if this is not so, contact the technical support department).

The required water flow at different temperatures is given in our catalogues or on request.

If necessary (very low water temperature) insulate both pipes using Armaflex insulation.

5.3.2 Notes For Closed Circuit Applications

The installation in Figure 1-8 is indicative only; for individual installations follow the project diagram.

Install a pump system calculated on the basis of the flow and total head of the system (see project data), and
controlled by the compressor running.

Insulate both pipes using Armaflex insulation.

Very important: Add water and ethylene glycol to the circuit, when the ambient temperature is below zero. Do not
exceed the nominal operating pressure of the circuit components.

Bleed air out of the circuit.

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28 Chapter 5 Water Connections

5.4 Chilled Water Connections For Chilled Water (C) Units

The positions for chilled water connections are shown in Figure 5-5.

Top chilled water connections Rear bottom chilled water connections

Figure 5-5 Positions for chilled water connections

The chilled water circuit is shown in Figure 5-6, as described below:

Use copper or steel (Mannesmann) tubing.

Place the tubing on supporting saddles ①.

Insulate both tubes using Armaflex insulation ②.

Place shut-off ball valves ③ at the conditioner inlet and outlet to allow easy maintenance.

It is useful to install a thermometer ④ and a manometer ⑤ at the conditioner inlet and outlet.

Install a water drain tap ⑥ at the lowest point in the circuit.

Fill the circuit with water/glycol.

Air
conditioner

④ ⑤
②

③
① ⑥
Figure 5-6 Chilled water circuit

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 Chapter 5 Water Connections 29

It is advised to install the dry cooler following Figure 5-7.

Filling
water

HTC TS
Disconnect after charge

Pressure-operated
by-pass
Stand-by pump Air
conditioner
(Option)

Shut-off valve TS Thermostat Air separator

Pump HTC Variex (option)
Charge group (filter, reducer, check valve)
Check valve Safety valve
Filling meter
Manometer Expansion tank
Drain (at lowest point)

Figure 5-7 Schematic diagram of installing dry cooler

For detailed parameters, refer to Appendix 4 Refrigerant, Hydraulic And Electrical Connections.

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30 Chapter 6 Electrical Connections

Chapter 6 Electrical Connections

This chapter introduces electrical connections of the [Link] air conditioner, including cable entry ports, routing
cables, connection procedures, protective features of EC fans and electrical heaters, and placement of the
temperature probes.

6.1 Cable Entry Ports, Routing Cables And Connection Procedures

The cable entry ports of [Link] are shown in Figure 6-1, in which ‘g’ is the cable entry port for low voltage signal
cable, ‘h’ is the cable entry port for power supply cable.

h
h
g
g

Bottom cable entry ports Top cable entry ports

Figure 6-1 Cable entry ports of [Link]

Use cable ties to fix high and low voltage wires to plastic clamps, and route cables following the arrow direction
shown in Figure 6-2.

Route cables from the bottom Route cables from the top
Figure 6-2 Route cables

The procedures of electrical connections are as follows:

1. Before proceeding with the electrical connections, ensure that:
1) All electrical components are undamaged;
2) All terminal screws are tight;
3) The supply voltage and frequency are as indicated on the unit.

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 Chapter 6 Electrical Connections 31

2. Power supply cable connections:

1) Connect the cable to the Line inlet terminal board;
2) Use the cable size defined according to the flow, the supply voltage and the installation type;
3) Protect the supply using a back-up fuse;
4) Do not fit the supply cable in the raceways inside the machine electric board;
5) Use multipolar cables with sheath (CEI20-22) only.
3. Wiring connections:
1) Connections for remote on-off must be done by the installer;
2) The General Alarm terminals allow remote alarm signaling.
4. In case of short circuit, check the sticking of the involved switch and possibly replace it.
5. During start-up and maintenance, it is possible to connect a remote display on the rear side of the unit. Inside the
compressor/chilled water valve compartment, there are two cables (supply and Ethernet) available for connecting, so
to manage all the parameters like front iCom display. For part numbers and specification, refer to Appendix 6 Wiring
Diagram.
For electrical data, refer to Appendix 2 Technical Data Tables.

6.2 Protective Features Of EC Fans

The locations of the EC fans are shown in Figure 6-3.

Figure 6-3 EC fans

The EC fans have been provided with the following protective features:

Over temperature of electronics

Over temperature of motor

Locked rotor protection

Short circuit at the motor output
With any of these failures, the motor stops (electronically-no potential separation), the status relay is released. NO
automatic restart. To reset the alarm, power supply has to be switched off for min. 20s once motor is at standstill.

Mains under-voltage detection
If mains voltage falls below 3ph/290Vac (typical value) for 5s minimum, motor will be switched off (only by electronics,
no potential separation), status relay is released.
If mains voltage returns to correct values, the motor will restart automatically.

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32 Chapter 6 Electrical Connections

Phase failure recognition

If one phase failes for 5s minimum, motor will be switched off (only by electronics, no potential separation), status
relay is released. If all 3 phases return to correct values, the motor will restart automatically within 10s ~ 40s.
The power supply for an external speed setting potentiometer is short-circuit protected.
Motor is overload-protected via motor current limitation.
Warning: Leakage current of the motor is 7mA roughly.

6.3 Protective Features Of Electrical Heaters

The electrical heaters with temperature sensor protection are shown in Figure 6-4.

Figure 6-4 Electrical heaters with temperature sensor protection

In case of over temperature of electrical heating, the temperature sensor checks it and the thermal protection turns off
the current. To reset the thermal protection push the bottom in front of the unit as indicated in Figure 6-5.

Figure 6-5 Resetting button

6.4 Temperature Probes Placed On Racks

Each unit is provided with at minimum three temperature probes (standard feature) and they can be up to ten. They
are located inside the unit, behind rear door (access to the fans panel rotating the three locks with the black key).
The sensors may be placed where desired or left coiled inside the unit. It is recommended that the sensor be routed
to the front of the heat load for the most accurate temperature reading. If the sensor is left inside the unit, ensure the
sensor and cable do not rest against the compressor or refrigerant lines. Doing so may damage the sensor. In sensor
chain configuration (see Figure 6-6), each temperature sensor monitors the temperature of the air entering the rack
equipment. The reading is used to control the operation of the unit. A standard position is at 1.5m in height, so the
sensor must be placed as shown in Figure 6-6, or the equipment will not operate properly.

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 Chapter 6 Electrical Connections 33

SENSOR CHAIN

1.5m(59 in)

(59 in)
1500

1.5m

(59 in)
1500

1.5m
1 500
Figure 6-6 Sensor chain configuration

Insert the rack temperature sensor connector in the temperature sensor port (CAN port as shown in Figure 6-7) at the
iCom interface. After cabling like shown in pictures to exit from the top or from the bottom of the unit, connect to first
probe, then from first to second one, from second to third one and so on, like a chain. Secure the temperature sensor
in front of the warmest heat source in the enclosure. Do not secure in front of a blanking panel. For this operation use
the support provided for each probe (see Figure 6-8). The sensors must be installed where lack of sufficient cooling
air is most likely. Due to air flow behavior (see Chapter 2 Unit Positioning), sometimes it would be better to
reconsider the layout, or particular attention must be taken positioning the sensors.

Cable connection of first sensor

TOP
TopINLET
inlet

FRONT VIEW
Front view
Amplified

CAN port

BOTTOM
Bottom inletINLET
(possible
(possible with raised floor)
with raised floor)

Figure 6-7 Connection of temperature sensor

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34 Chapter 6 Electrical Connections

Figure 6-8 Use provided support to fix each probe

Sensor chain–CAN termination

The CAN Bus of sensor chain needs to be terminated. If a CAN device is the last component in the CAN Bus, the
termination jumper has to be set to pin 2 and pin 3. If a CAN device is in the middle between other CAN devices, no
termination has to be set, the jumper remains on pin 1 and pin 2.
To connect the temperature probes to use only cable with these characteristics:

6 wires, 3 couples, shielded twisted pair

Termination: RJ12
2

3 × 2 × 0.14mm (min), twisted pairs, shielded

Plenum rated

300V

-5°C ~ +70°C

Flexible

Characteristic impedance of between 108Ohm and 132Ohm@50kHz

Conductor resistance < 150Ohm/km

Flame retardant

Black jacketing

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 Chapter 7 Start-Up 35

Chapter 7 Start-Up

This chapter introduces start-up of the [Link] air conditioner, including first start-up (or after long standstill),
automatic restart, checking the refrigeration piping pressure drops, and chilled water valve of chilled water (C) units.

7.1 First Start-Up (Or After Long Standstill)

Warning
To prevent compressor damage, the crankcase(s) must be preheated for at least 4 houes before conditioner start-up (failure to
do so invalidates the guarantee).

Start the air conditioner as follows:

1. Open all valves in the refrigeration circuit according to the instruction label attached to the valve.
2. Water-cooled unit only: Open all valves in the water circuit according to the instruction label attached to the valve.
3. Ensure that the refrigerant charge is correct (see Chapter 4 Refrigeration Connections).
4. Using a leak detector, verify that there are no refrigerant leaks. If there are any, then repair the leak and recharge
as described in Chapter 4 Refrigeration Connections.
5. At least 4 hours before start-up, close the main switch and the compressor switch on the electrical panel.
In the ‘iCom’ control system factory setting the stand alone mode is standard. The stand alone mode gives the
possibility of turning on the unit simply rotating the main switch on the electric panel. The yellow LED on the iCom
case will light after turning on the unit, because of the presence of electric power.
If the LED does not light up:

Check the electric panel power supply;

Check the protection devices (e.g.: thermal switches);

Check the fuses.
6. Verify the operation of the crankcase heater.
7. Check that there are no water leakages.
8. If an external condenser or Dry cooler is installed, start it by supplying power to it.
9. Close all MCBs on the electrical panel.
10. Check the supply voltage on all phases.
11. Check the supply voltage on all phases for the external condenser or Dry cooler, if fitted.
12. Ensure that the compressor has been preheated for at least 4 hours before starting the unit.
13. Start the unit by pressing ON/OFF.
14. Check the electrical absorption of all components (see Chapter 6 Electrical Connections).
15. Check the electrical absorption of the external condenser/Dry cooler, if fitted.
16. Important: If the compressor makes a loud and unusual noise, it is necessary to invert the electrical connections
of the phases supplying the corresponding scroll compressor, which accepts only one direction of rotation.
17. Ensure that the fans rotate in the correct direction (see arrow on fan).
Caution: risk of contact with rotating devices.
18. Ensure that all control system settings are correct and that there are no alarms.
19. Water-cooled unit only: Verify the water flow.
20. Water-cooled unit only: For closed circuit units ensure that the water pump starts when the compressor starts.
21. Once the system is operating under load, check the various components, as follows:

Verify that the fans are operating properly.

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36 Chapter 7 Start-Up

Ensure that the temperature and relative humidity are being controlled, and that the humidifier and heating steps
operate when required.

Ensure that the compressor operates when required.

Ensure that the fan operation controller on the external condenser/Dry cooler (if fitted) is calibrated correctly, and
that it controls the fan operation.

7.2 Automatic Restart

If desired, the unit will automatically restart on the return of power after a supply interruption. If the power interruption
is expected to be of several hours, to avoid an automatic cold restart of the compressor stop the unit before the
black-out and, on the return of power, allow the compressor to preheat before restarting the unit.

7.3 Checking The Refrigeration Piping Pressure Drops

[Link] is equipped with connections to check the refrigeration piping pressure drops: room unit → condenser
→ room unit.
To carry out this operation it is necessary to use two calibrated manometers and connect them as follows:
M1 is connected to the compressor delivery valve; M2 is connected to the Schrader valve (2) in Figure 7-1.

6 4
5 3

1. Liquid receiver valve 2. Filter dryer inlet Schrader valve 3. Filter dryer
4. Sight glass 5. Solenoid valve 6. Thermostatic expansion valve
Figure 7-1 Components of refrigeration pipeline

When the compressor is running, you should check M1 and M2.

Note: Repeat this test, inverting the manometers to calculate the correct pressure drops, consider the average value
of the two readings.
At 45°C, the refrigeration pipeline pressure drops (Dp bar) are as follows:

At the same geodetic level: Dp (bar) = M1 - M2

When condenser is above the room unit: Dp (bar) = M1 - M2 + geodetic difference (m x 1.1:10.2)

When condenser is below the room unit: Dp (bar) = M1 - M2 - geodetic difference (m x 1.1:10.2)

7.4 Chilled Water Valve Of Chilled Water (C) Units

The three-way valve controls the chilled water flow and operates as follows (Figure 7-2):

When the valve is fully open (i.e. max. chilled water flow), the actuator slot is set to ‘1’.

When the valve is closed (i.e. no chilled water flow), the actuator slot is set to ‘0’.

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 Chapter 7 Start-Up 37

0
1

Position indicatorindicator
Position on on 0: Position indicator
Position on
indicator on 1:
0 = CLOSED valve 1 = OPEN valve
closed valve (three-way
(3-way valve: by-pass open)
open valve
(3-way valve: by-pass (three-way
closed)
valve: by-pass open) valve: by-pass closed)

1 0

Figure 7-2 Position of the chilled water valve actuator (for two-way or three-way valve)

Note:
1. In the unlikely event of control system failure, the valve can be manually controlled by means of the rotary knob. It
can be used to drive the actuator into any position between 0 and 1.
2: When actuator stem is completely down, the valve is open and chilled water coil is supplied.

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38 Chapter 8 Operation

Chapter 8 Operation

Unit operation is completely automatic. This chapter explains how the unit operates.
1. The air, sucked in by the fans, which operate continuously, enters the unit.
2. The air is immediately filtered.
3. The temperature sensor or temperature & rel. humidity sensor (check type installed, see Figure 8-1 for its position),
verifies the state of the inlet air, and relays this information to the control system.

Figure 8-1 Sensor position

4. The treated air is then dispersed out of the unit.

5. The control system compares the relayed information to the set point and proportional band values programmed
into its memory: it then commands the air conditioner to treat the air as follows:

Cooling

Direct expansion mode (DX)
The compressor is started and the cold refrigerant flows through the evaporator, thus cooling the air passing over it.

Chilled water mode (CW)
The three-ways valve is opened and the chilled water flows through the coil, thus cooling the air passing over it.

Heating
Electrical heating (optional): the heating elements heat the air passing over them. There is one heating steps activate
in case of dehumidification if supply air temperature is too low.

Dehumidification
Under the DX mode, the compressor starts and the air flow on the evaporator surface is reduced (increasing
modulation capacity of compressor), thereby causing dehumidification.
Note: If, during dehumidification, the ambient temperature drops below a specified level, dehumidification will be
stopped if necessary.
In dehumidification mode, the air after passing over the coil it’s reheated (if needed) by electrical heater to re-stabilize
the initial temperature.

Humidification
The humidifier creates steam, which is distributed into the air stream via the steam distribution pipe, refer to
Appendix 1 Humidair Humidifier.

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 Chapter 9 Calibrations & Regulation (At Start-Up) 39

Chapter 9 Calibrations & Regulation (At Start-Up)

The air conditioner has already been tested and calibrated in factory, but it is very important to check, at start-up, the
superheating of thermostatic valve (A/W versions).

The air conditioner has already been tested in factory.

For calibrations of instruments installed on the external condensers/dry coolers refer to the relevant manual.

For control system calibrations refer to Control manual (to prevent erratic operations do not use temperature and
rel. humidity set points/proportional bands which differ excessively from the standard settings).

9.1 Setting Thermostatic Expansion Valve

This operation must be performed by an experienced refrigeration technician.
The valve has been factory preset and, if necessary, should be reset as follows:
1. Important: ensure that the instructions in Chapter 4 have been carried out.
2. Allow the compressor to operate for 15 minutes.
3. Measure the superheat as follows:
1) Place a contact thermometer on the tube exiting the evaporator.
2) Connect a manometer to the compressor suction valve.
3) The overheating is the difference between the refrigerant saturation temperature corresponding to the pressure
read on the manometer and the real temperature read on the thermometer.
4. The superheat must be 5K ~ 8K; if not, set the expansion valve as follows:
1) Remove the protective cover.
2) Turn the adjustment screw by 1/4 turn only.
3) Wait 10 minutes.
4) Measure the superheat and repeat the operation if necessary.
Note: If the superheat is too low, the screw must be turned in a clockwise direction. If the superheat is too high, the
screw must be turned in a counterclockwise direction.

9.2 Water Leakage Sensor

Due to high flooding alarm device sensitivity, to the end to avoid undesirable alarm signal because of few sporadic
water drops, place the sensors at a minimum distance of 50cm from the unit base perimeter.
This solution assures alarm intervention for real flooding risk only.

9.3 Environment Protection

A misuse or an incorrect calibration of the unit leads to increased energy consumption, resulting in an economic and
environmental damage.

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40 Chapter 10 Maintenance & Spare Parts

Chapter 10 Maintenance & Spare Parts

This chapter introduces maintenance & spare parts of the [Link] air conditioner, including safety instructions,
spare parts, maintenance schedule, air filter check or substitution, condensate drain and condensate pump systems,
air-cooled condenser and drycoolers, electrical heaters, refrigeration circuit, dismantling the unit, regulation (EC) No.
842/2006 (F-gas), and unit diagnostic.

10.1 Safety Instructions

All maintenance operations must be carried out strictly observing the European and national accident prevention
regulations. We refer especially to the accident prevention regulations concerning electrical systems, refrigerators,
and manufacturing resources. Maintenance may be done to air conditioning equipment only by authorized and
qualified technicians.
To keep all warrantees valid, the maintenance must adhere to the manufacturer's regulations.

Warning
The work should be done in the system only when it is at standstill. Do this by switching off the air conditioner at the controller
and the main switch. Post a warning sign saying: ‘Do not switch on.’ Electrical components of device have to be switched off and
be checked that they are not under voltage.

Ignoring the safety instructions can be dangerous to persons as well as to the environment.
Soiled parts always cause a loss of performance and for switch or control devices can lead to the break-down of a
plant.

10.2 Spare Parts

Only original spare parts made by Emerson Network Power may be used. Using third-party material can invalidate
the warrantee.
Note:
1. When a faulty component is replaced, follow the relevant manufacturer instructions.
2. When the spare parts must be brazed, be carefully do not damage the internal parts (gaskets, seals, o-rings, etc.).

10.3 Maintenance Schedule

Monthly, quarterly, biannual and annual checks must be conducted according to the following guidelines.
All tasks and periods listed in Table 10-1 are regulations from the manufacturer and need to be documented in an
inspection report.

Warning
All these tasks should be carried out only by an authorized and trained technician. We recommend the Emerson Network Power
Customer Service.

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 Chapter 10 Maintenance & Spare Parts 41

Table 10-1 Maintenance schedule

Maintenance period
Components
Monthly quarterly biannual annual
Check unit display for clogged-filter warning ×
Check for irregular noise from unit fans ×
General Check for irregular noise from compressor ×
Check for irregular noise from remote condenser fan/s (if
×
applicable)
Check state of filters ×
Filters Replace air filter whether necessary ×
Filter switch functionality check ×
Verify impellers move freely ×
Check bearings ×
Blowers
Check motor mounts for tightness ×
Check fan safety switch ×
Check condition of contactors ×
Check electrical connections ×
Electrics/electronics
Check operation of controller ×
Check unit operation sequence ×
Check cylinder & pan ×
Steam generating
Check steam hoses conditions ×
humidifier
Verify filling solenoid valve proper operation ×
Circuit leakage/general condition check ×
Check water(-glycol) inlet temperature ×
Cooling water circuit
Check water regulating valve operation ×
(W and C units)
Check in/out water(-glycol) t ×
Check mixture glycol level (if applicable) ×
Check compressor noise/vibrations ×
Check oil level through compressor sight glass ×
Adjust/tighten compressor/functional elements ×
Check sight glass for problem detection ×
Refrigerating circuit Check starting/running amps ×
Check refrigerating circuit main pressures ×
Check compressor suction superheat ×
Check discharge temperature ×
Check sub cooling ×
Check fan/s bearings ×
Air cooled Check fan/s motor mounts for tightness ×
condenser/dry cooler Check coil condition ×
(if applicable) Check pipelines supports ×
Check fan/s speed controller operation ×
Water/glycol pump
See relevant manual
(if applicable)

10.4 Air Filter Check Or Substitution

Every month it’s important to check the state of air filter to maintain a good efficiency of air distribution throw the
evaporator coil.
First switch off the CRV, then open the rear panel with the key, access to the fan panel rotating the three locks with
the black key. Wait until fans are stopped (when you open the first lock, you also open a security switch that cut the
current, see Figure 10-1).

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42 Chapter 10 Maintenance & Spare Parts

Figure 10-1 Security switches of the fans

To extract the filters, push up the upper one and rotate it. Then move the other one up and repeat as before, as
shown in Figure 10-2.

Figure 10-2 Extract the filters

After cleaning or replacing the filter, before reassembly, check that the position of air differential pressure switch pipes
(clogged filter alarm) would be in right position and in right order.
Check also that the drain trays would be clean and the pipe fix. The air differential pressure switch pipes and
condensate drain pipe are shown in Figure 10-3.

Figure 10-3 Air differential pressure switch pipes and condensate drain pipe

Before re-start the unit, be sure that micro-switches are properly closed. Otherwise the unit maintains a safety status.

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 Chapter 10 Maintenance & Spare Parts 43

10.5 Condensate Drain And Condensate Pump Systems

10.5.1 Condensate Drain

Check and clear obstructions in tubing during routine maintenance.

10.5.2 Condensate Pump

The position of the condensate pump is shown in Figure 10-4.

Figure 10-4 Condensate pump

Clean the condensate pump following the procedures below:

1. Disconnect power to unit using disconnect switch.
2. Check and clear obstructions in gravity lines leading to condensate pump.
3. Remove sump and clean with a stiff nylon brush and flush with water.
4. Inspect and clear clogs in discharge check valve and float mechanism.
5. Reassemble and check for leaks.

10.6 Air-Cooled Condenser And Drycoolers

The cleaning procedures are as follows:
1. Clear coil surface of all debris that will inhibit airflow.
2. Check for bent or damaged coil fins and correct.
3. Do not permit snow to accumulate around or under outdoor unit.
4. Periodically consider commercial cleaning of coil surface.
5. Inspect fans, motors and controls for proper operation.
6. Check all piping and capillaries for proper support.
7. Inspect for leaks.

10.7 Electrical Heaters

The cleaning procedures are as follows:
1. Inspect and clean reheat elements.
2. Inspect and tighten support hardware.

10.8 Refrigeration Circuit

When repairing the refrigeration circuit, collect all refrigerant in a conditioner, do not allow it to escape.
When either removing (for repairs) or charging refrigerant this must always be done on both the high and low
pressure sides of the compressor simultaneously.

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44 Chapter 10 Maintenance & Spare Parts

The compressor copper plated steel connections should be brazed with a silfos material containing a minimum of 5%
silver.

10.8.1 Refrigerant Charge Of The Water-Cooled Units

1. Start the unit as described in 7.1 First Start-Up (Or After Long Standstill).
2. Manually start the compressor (ensure the unit is not in dehumidification).
3. Wait a few minutes to allow conditions to stabilize.
4. Check the refrigerant circuit using a leak detector. If there is a leak, recharge the unit until the working conditions of
the entire refrigeration circuit have become normal.
5. Using a manometer, check that the evaporating temperature is above 0°C.
6. Verify the water pressostatic valve (WV) setting (refer to Chapter 7 Start-Up).
7. Verify that the superheat is 5K ~ 8K, refer to Chapter 9 Calibrations & Regulation (At Start-Up).

10.8.2 Oil Charge R410A

The oil to be used when topping up (only if there are any leaks) is EMKARATE RL 32-3MA or Mobil EAL Arctic 22CC
(see Table 10-2 and Table 10-3).
Table 10-2 EMKARATE RL 32-3MA oil
Item Description
Viscosity at 40°C 31.2cSt
Viscosity at 100°C 5.6cSt
Viscosity index (ISO Grade) 32

Table 10-3 Mobil EAL Arctic 22CC oil

Item Description
Density (at 15 °C) 0.967kg/l
Flash point (C.O.C.) 245°C
Pour point < -54°C
Viscosity at 40°C 23.6cSt
Viscosity at 100°C 4.7cSt
Viscosity index (ASTM D2270) 130

These oils rapidly absorb the humidity present in the air when they are exposed to the atmosphere.
If the oil absorbs humidity, the ester molecules can break down, forming acidity.
We therefore recommend exposing the oil for as short a time as possible (no more than a few minutes) and, in case
of topping up, using exclusively the oil indicated on the refrigerating compressor.
Normally 1-litre or 2-litre cans are available for this purpose; once they are opened, they must be completely used up.
They must not be used after a long period, as they absorb humidity.
It is therefore obvious that the taps of the compressor must only be turned after the whole plant has been subjected
to a vacuum and partial filling.

10.8.3 Oil Topping-Up Of An Installed Circuit

If oil leakages occur, the topping-up operation is necessary. Contact the local service before intervention.

10.9 Dismantling The Unit

The machine has been designed and built to ensure continuous operation.
The working life of some of the main components, such as the fan and the compressor, depends on the maintenance
that they receive.

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 Chapter 10 Maintenance & Spare Parts 45

Warning
The unit contains substances and components hazardous for the environment (electronic components, refrigerating gases and
oils). At the end of the useful life, when the unit is dismantled, the operation must be carried out by specialized refrigerating
technicians. The unit must be delivered to suitable centers specialized for the collection and disposal of equipment containing
hazardous substances.

The refrigerating fluid and the lubricating oil inside the circuit must be recovered according to the laws in force in the
relevant country.
To recover the gas, use all the connections described in 4.2 Vacuum Creation And Refrigerant Charge.

10.10 Regulation (EC) No. 842/2006 (F-Gas)

Stationary air conditioning placed into the European Community market and operating with fluorinated greenhouse
gases (f-gas), such as R410A, R134a, R410A, they have to comply with the F-gas Regulation (applied since 04 July
2007).
Be aware that refrigerants as R22 are not f-gas and their relevant regulation is Reg. (EC) no. 2037/2000.
Following notes have to be considered when operating with the above mentioned equipments.
1. Fluorinated greenhouse gases are covered by the Kyoto Protocol.
2. The fluorinated greenhouse gases in this equipment should not be vented to the atmosphere.
3. Referring to the value noted in Annex I of Regulation (EC) No 842/2006. Here below the global warming potential
(GWP) of some major f-gases: R-134a: 1300; R-407C: 1610; R-410A: 1890.
4. Operators of the above mentioned applications, which contain fluorinated greenhouse gases, shall, using all
measures which are technically feasible and do not entail disproportionate cost:
1) Prevent leakage of these gases and as soon as possible repair any detected leakage.
2) Ensure that they are checked for leakage by certified personnel.
3) Ensure for putting in place arrangements for the proper recovery by certified personnel.
4) In case of applications containing 3 kg (6kg in case of hermetically sealed system) or more of f-gases: certified
personnel and companies (according to Reg. 303/2008) provides regular leak testing (according to Reg. 1516/2007
and Reg. 1497/2007) and maintain records of maintenance activities in a dedicated log book.
5) Recovery for the purpose of recycling, reclamation or destruction of the fluorinated greenhouse gases, pursuant to
Art.4 (Recovery) of Reg.842/2006, shall take place before the final disposal of that equipment and, when appropriate,
during its servicing and maintenance.
5. Operator, according to Reg. 842/2006, Article 2, point 6, means the natural or legal person exercising actual power
over the technical functioning of the equipment and system covered by the Regulation. The State may, in defined,
specific situations, designate the owner as being responsible for the operator's obligations.
6. Direct methods of leakage checking approved by the manufacturer (Reg. 1516/2007 and Reg. 1497/2007).
1) Gas detection device adapted to the refrigerant in the system; the sensitive of portable gas detection devices (as a
direct test method) shall be at least five grams per year.
2) Proprietary bubble solutions/soapsuds.
7. Additional information located into a dedicated label of unit (Reg. 1494/2007).
1) Where fluorinated greenhouse gas is foreseen to be added to the equipment outside of the manufacturing site at
the point of installation, a dedicated label accommodates notation of both the quantity (kg) pre-charged in the
manufacturing plant and of the quantity charged at the installation site as well as the resulting total quantity of f-gas
as a combination of the above mentioned quantities, in a manner which conforms to the legibility and indelibility. Our
split units are usually not pre-charged on factory, in this case the total quantity of refrigerant charged in the unit has to
be written in the relevant label, during the commissioning operation at the installation site.
2) Our packaged units (not split) operating with f-gas are usually full charged on factory and the total amount of
refrigerant charge is already reported on the label. In this case, the label has no need of further written information.
3) In generally, the above mentioned information has been located in the main nameplate of relevant unit.

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46 Chapter 10 Maintenance & Spare Parts

4) For equipment with double refrigeration circuits, in regards to differentiates requirements on the basis of the
quantity of f-gas contained, the required information about refrigerant charge quantities has to be listed separately for
each individual circuit.
5) For equipments with separate indoor and outdoor sections connected by refrigerant piping, the label information
will be on that part of the equipment which is initially charged with the refrigerant. In case of a split system (separate
indoor and outdoor sections) without a factory pre-charge of refrigerant, the mandatory label information will be on
that part of the product or equipment which contains the most suitable service points for charging or recovering the
fluorinated greenhouse gas(es).
8. Safety data sheets of f-gases used into the products are available on demand.

10.11 Unit Diagnostic

The possible cause and corrective action of the unit problem are listed in Table 10-4.
Table 10-4 Unit diagnostic
Problem Possible cause Corrective action
Dirty filters Replace filters
False filter clogs Call Emerson services
Incorrect positioning of remote Verify remote temperature sensors correct
temperature sensor(s) positioning
Remote temperature sensor(s) issue Call Emerson services
(A units) verify remote condenser fans are
running
Too high condensation pressure (W units) check cooling water supply
(W units) check cooling water temperature
Racks temperature is too high
Call Emerson services
(C unit) inlet water temperature is too high Check cooling water temperature
Refrigerating circuit charge issue Call Emerson services
Verify unit positioning/room configuration
Cold air short-circuiting issues Verify unit air-baffles set-up
Verify cold aisle containment seals (if applicable)
Insufficient room cooling capacity Reduce racks heat load or add cooling units
(C unit) water regulating valve issue Call Emerson services
Unit safety devices intervention Call Emerson services
Unit fan fail to start The fan is faulty Call Emerson services
Room humidity is over acceptable limit Check room condition
Water drops carried by airflow Condensate pan drain is clogged Call Emerson services
Problem to humidifier control Call Emerson services
Unit is not properly levelled Adjust the levelling feets
Unit condensate drain pipe is clogged Remove pipe obstruction
(C and W units) leak in the water circuit Locate the leak and fix it
Water on the floor around the
Piping insulation broken/damaged Restore insulation integrity
unit
Leak in the draining circuit Call Emerson services
Condensate pump is faulty Call Emerson services
Leak in the humidifier filling hose Call Emerson services
Incorrect positioning of remote
Verify temperature sensors correct positioning
Cooling unit noise level is too temperature sensors
high than expected Unbalanced heat load distribution Enhance racks heat load distribution
Remote temperature sensor(s) issue Call Emerson services
Unsteady air delivery Faulty temperature sensor Call Emerson services
temperature Unit controller issue Call Emerson services
Local display cable disconnected Connect the cable
Local display not operational
Local display cable damaged Replace cable
but unit operates
Local display configuration lost Call Emerson services
Unit electrical supply is off Restore electrical supply
Local display not operational Unit main switch is off Switch on the unit
and unit does not operate Control board supply issue Call Emerson services
Control board issue Call Emerson services

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 Appendix 1 Humidair Humidifier 47

Appendix 1 Humidair Humidifier

1. Preface
The unit adopts humidair humidifier technology, guaranteeing the steam as clean as possible together with simple
maintenance.
In order to obtain optimum performance from the humidair it is advisable to read this manual carefully.
The specifications of the humidair humidifier are listed in Table 1.
Table 1 Specifications of the humidair humidifier
Max. cylinder Max. supply Max. drain
Air conditioner Humidair Main power Setting Absorbed Power
water water quantity water quantity
model model supply (±10%) (kg/h)* current (A) (kW)
volume (L) (L/min) (L/min)
CR020RA/W
CR035RA/W KUECLA 230V/1ph/50Hz 0.6 ~ 2.0 6.5 1.5 1.7 0.6 4.0
CR040RC
Note*: Unit is factory-set to produce about 70% of the maximum value

2. Installation
The humidifier is supplied already mounted within the air conditioner. The only necessary operations are the
connections for the supply water (see Figure 1) and drain water (see Figure 2).

Supply water features:

The supply water temperature must never exceed 40 C.
The supply water pressure must be between 0.3bar ~ 6bar.
If greater, use a pressure reducing valve set to 3bar ~ 4bar.
Sanitary water should be used. Do not use demineralized
water or water containing impurities.
Conductivity range: 125μS/cm ~ 1250μS/cm.
B

Supplying limit
Water supply A

Alternative supply water

tubing
Cut-off tap Supply water tubing Unscrew the ring nut A and
Must be included in the It is supplied a 1.5m long connect a tube straight to
supply water tubing. plastic tube, with 1/2"Gm the 3/4" male connection B
connections. on the humidifier.

Figure 1 Supply water connection

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48 Appendix 1 Humidair Humidifier

K Water drain tubing

It is supplied a hose with an integral drain trap.
Do not dismantle the drain trap.
The hose is already fitted onto the humifier
drain outlet (K).
L Fill the drain trap with water (L).
Drain water device The drain pipe is made of plastic material
Dispose the drain water into an which does not conduct electricity.
ordinary drainage network, using
a funnel (the drainage network
must be able to withstand water Note:
temperatures up to 100℃). 1. Do not cut the bracket of this drain trap or
the draining of the condenser will be affected.
2. Fill the drain trap with water before startup
to avoid spraying condensate.
3. To avoid water leakages, use teflon tape
between flexible tube and connections.

Figure 2 Drain water connection

Notes:
1. Allow a 2% gradient towards the drain outlet.
2. Avoid back pressures in the drain piping.

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 Appendix 1 Humidair Humidifier 49

3. Humidifier Components
The components of the humidair humidifiers are shown in Figure 3.

From humidifier
power electrodes
Steam outlet to electrical supply
Drain valve assembly (D) Y
S
Z
A From level sensor
U to interface
P

L
O Filling
H cup Level electrode

R
Overflow
tube
Power electrodes
C
Supply valve (F)
Steam cylinder

Drain valve
G
Supply valve V V
D From supply
F
valve to interface

Water drain
Water supply outlet
Drain tank T E
N
From supply
valve to interface
Figure 3 Humidifier and its connections

4. Start-Up And Operation

4.1 Start-Up

Before using the humidifier, check the following:

Supply and drain connections.

That the cut-off tap is open.

All wiring.

Earthing.

Steam hose connection between steam cylinder and distributor.
To start the humidifier simply switch on the air conditioner, which will in turn automatically start and stop the humidifier
as required. The (adjustable) parameters which determine humidifier operation have already been factory-preset (see
iCom manual).

4.2 Operation

Water, provided it contains even a small quantity of salts in solution, is a conductor of electricity. Therefore, if the
steam cylinder is filled with water and a potential difference is applied between the electrodes, the water behaves like
an ordinary electrical resistance and becomes hot, thus creating steam. The steam production rate can be controlled

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50 Appendix 1 Humidair Humidifier

by varying the water level in the cylinder; the higher the water level, the deeper the electrodes are immersed into it
and the greater the steam production.
Note:
1. In case of low water conductivity, consult Emerson services.
2. When starting with an empty cylinder, the water conductivity is normally insufficient for the humidifier steam output
to be reached immediately. Therefore the humidifier produces as much steam as possible to fill the cylinder
completely. Any evaporation water is immediately refilled. The drain valve is kept shut and therefore, as the steam
does not contain any salts, the conductivity of the water within the cylinder slowly increases until the humidifier steam
output is obtained. The length of the start-up period depends upon the water conductivity. For very conductive water it
may occur that the humidifier steam output is obtained immediately.

5. Maintenance

5.1 Removing The Steam Cylinder

To remove the steam cylinder, proceed as follows (see Figure 3):

1. Open the general switch relative to the humidifier.
2. Drain all the water from the cylinder by activating ‘HUM. DRAIN’ in the control service menu several times.
3. Disconnect the steam hose (S) (made of non-conductive rubber).
4. Disconnect the power electrode wires (P) and level sensor wire (L).
5. Undo the clip (R).
6. Pull the cylinder (C) out of its gland at the bottom (G).

5.2 Replacing The Steam Cylinder

When the steam cylinder is approaching the stage where it needs to be replaced, warning A25 is generated to advise
the user that the cylinder must be replaced. To replace the cylinder, proceed as follows (see Figure 3):
1. Carry out the instructions in 5.1 Removing The Steam Cylinder.
2. Using the new cylinder, carry out procedures 4 ~ 6 in 5.1 Removing The Steam Cylinder in reverse order.
3. Connect the steam hose (S); the clip on the hose needs to be tightened only slightly.
4. Manually switch the humidifier on for 2 ~ 3 minutes (in the iCom service menu). Then switch it off.
5. Drain the water as for procedure 2 in 5.1 Removing The Steam Cylinder.
6. If the air conditioner features an iCom CDL with Graphic display, reset the humidifier working hours (window no. 1
of parameter menu) to zero.
7. Close the general switch relative to the humidifier.

5.3 Annual Maintenance

Annually carry out the following service on the humidifier (see Figure 3):
1. Carry out the instructions in 5.1 Removing The Steam Cylinder.
2. Disconnect the supply (F) and drain (D) valve wires.
3. Unscrew and remove the drain tank (T).
4. Unscrew the drain valve assembly screws (V).
5. Remove the drain valve assembly.
6. Unscrew and remove the drain valve solenoid (O).
7. Unscrew and remove the drain valve armature (D).
8. Clean all parts of the drain valve using a commercially available descaling agent (to remove any incrustations).
9. Detach the hose from the supply valve.
10. Remove the supply valve connection (N).

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 Appendix 1 Humidair Humidifier 51

11. Unscrew the supply valve (F) and remove it.

12. Clean the supply valve using a jet of water.
13. Replace any hose which has become hard and brittle.
14. Thoroughly flush the drain line (E).
15. Reassemble the humidifier by carrying out the above instructions in reverse order.
Attention: always empty the cylinder completely before any close-down period.

6. Replacing Humidifier Spare Parts

When replacing the humidifier spare parts, it is recommended the use of original spare parts. When placing an order,
please contact Emerson services.

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52 Appendix 2 Technical Data Tables

Appendix 2 Technical Data Tables

Table 2 Electrical data of the unit (compliant with CE)

Residual current
Configuration Model Power supply FLA (A) LRA (A) circuit breakers
I△n = 0.3A (400V)
Cooling CR020 22.3 107 40A Curve C
380V ~ 415V/3N/50Hz
Fan + compressor CR035 28.0 121 50A Curve C
Cooling + electrical heating
CR020 31.0 116 50A Curve C
(dehumidification)
380V ~ 415V/3N/50Hz
Fan + compressor +
CR035 36.7 130 63A Curve C
electrical heaters
Cooling + humidification CR020 31.0 116 50A Curve C
Fan + compressor + 380V ~ 415V/3N/50Hz
humidifier CR035 36.7 130 63A Curve C
Cooling
CR040 380V ~ 415V/3N/50Hz 3 3 10A Curve C
Fan
Cooling + electrical heating
CR040 380V ~ 415V/3N/50Hz 11.7 11.7 20A Curve C
Fan + electrical heaters
Cooling + Humidification
CR040 380V ~ 415V/3N/50Hz 9.5 9.5 20A Curve C
Fan + humidifier
Note:
1. Without condensate pump option.
2. The cables have to be sized in compliance with local standards and according to the type and characteristics (e.g. Amperes)
of installation

Table 3 Electrical data of components (compliant with CE)

Nominal
Component Unit power supply Model OA1 (A) FLA2 (A) LRA2 (A)
power (kW)
CR020 2 × 1.95 2 × 3.1 2 × 0.1 2 × 0.30
Fan 380V ~ 415V/3N/50Hz CR035 2 × 0.85 2 × 1.5 2 × 0.1 2 × 0.53
CR040 2×1 2 × 1.5 2 × 0.1 2 × 0.63
CR020 11.13 16.1 101 5.99
Compressor 380V ~ 415V/3N/50Hz
CR035 16.70 25.0 118 9.34
CR020 6.5 6.5 - 1.50
Humidifier 380V ~ 415V/3N/50Hz CR035 6.5 6.5 - 1.50
CR040 6.5 6.5 - 1.50
CR020 8.7 8.7 - 6
Electrical
380V ~ 415V/3N/50Hz CR035 8.7 8.7 - 6
heater
CR040 8.7 8.7 - 6
CR020 - 1.2 - -
Condensate
380V ~ 415V/3N/50Hz CR035 - 1.2 - -
pump
CR040 - 1.2 - -
Note*:
1: At nominal operating condition: condensing temperature is 48.9°C, inlet air temperature is 37.8°C, inlet air relative humidity is
20%RH.
2: FLA: Max operating current; LRA: locked rotor Amps

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 Appendix 2 Technical Data Tables 53

Table 4 Calibrations of electrical components

No. Component Setting Notes Contact

Range: 0 ~ 45barg
1 High pressure transducer -
Output: 0 ~ 5V

See iCom manual

Range: 0 ~ 17.3barg
2 Low pressure transducer -
Output: 0 ~ 5V

See iCom manual

Stop: 37.0 ± 1barg

3 High pressure switch (HP) Start: 30.0 ± 1.5barg Normally closed
(Fixed setting – manual reset)
Reset

Set point range: 0.5mbar ~

Clogged filter differential
4 4mbar Normally closed
pressure switch (CF)
Filter G4 = 2mbar Setting
ring

Table 5 R410A refrigerant and oil charge for air cooled models (A type)
Base Base oil charge* Max. system refrigerant Weight of oil to add for every
Model refrigerant (oil within compressor, kg) charge before oil 4.5kg of refrigerant over Max.
charge (kg) Initial oil charge Max. topping up addition (kg) system charge (g)
CR020RA 5.9 1.68 1.57 17.1 44.8
CR035RA 10 3.08 2.97 12.6 112.0
Note*:
The recommended oil is EMKARATE RL 32-3MA

Table 6 Refrigerant charge of pipeline for air cooled models

External pipe diameter At different condensing temperatures, R410A liquid* (kg/m)
R410A gas（kg/m）
(mm) 35°C 46°C 57°C
12 × 1 - 0.08 0.07 0.07
16 × 1 0.0169 0.16 0.14 0.13
19 × 1.2 0.0221 0.20 0.19 0.17
22 × 1.2 0.0346 - - -
28 × 1.2 0.0584 - - -
Note*:
Liquid pressure and density varies according to condensing temperature

The distance of pipeline for air cooled models is shown in Figure 4.

Pipeline from conditioner to air condenser

Condenser c

Air conditioner
b

Distance (D) = a + b + c
a

Figure 4 Distance of pipeline

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54 Appendix 2 Technical Data Tables

Table 7 Refrigerant and oil charge for water cooled models (W type)
Model R410A refrigerant charge (kg) Initial oil charge* (kg)
CR020RW 6.5 1.68
CR035RW 11 3.08
Note*:
The recommended oil is EMKARATE RL 32-3MA

Note: The air conditioner is supplied complete with refrigerant and oil.
The detailed sound data of the [Link] are listed in Table 8.
Table 8 Sound data of [Link]
Unit SPL
Airflow Octave band frequency(Hz) Sound
Fan speed suction
level
(%) (2m from
SCFM m3/h Level 31.5 63 125 250 500 1000 2000 4000 8000 (dBA)
front, dBA）
CR020 air cooled models
100 2454 4170 PWL 73.8 69.4 71 77.3 75.9 74.2 73.5 68.2 59.2 79.6 69.2
75 2166 3680 PWL 71.2 66.8 68.4 74.7 73.3 71.6 70.9 65.6 56.6 77 66.9
55 1780 3025 PWL 67.6 63.2 64.8 71.1 69.7 68 67.3 62 53 73.4 63.9
CR035 air cooled models
100 3260 5540 PWL 76 76.2 80.5 82.7 77.3 73.1 74.5 69 61.9 80.9 70.0
75 2708 4600 PWL 71.3 71.5 75.8 78 72.6 68.4 69.8 64.3 57.2 76.2 65.7
55 2048 3480 PWL 66.3 66.5 70.8 73 67.6 63.4 64.8 59.3 52.2 71.2 61.9
CR040 water cooled models
100 3325 5650 PWL 86.4 78.1 82.4 84.6 79.2 75 76.4 70.9 63.8 82.8 71.6
75 2708 4600 PWL 80.8 72.5 76.8 79 73.6 69.4 70.8 65.3 58.2 77.2 66.0
55 1972 3350 PWL 75.1 66.8 71.1 73.3 67.9 63.7 65.1 59.6 52.5 71.5 60.3
Note: PWL is sound power level; SPL is sound pressure level

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 Appendix 3 Installation Drawing 55

Appendix 3 Installation Drawing

2000

75
600 75 11

Front view

Figure 5 Dimensions of the air conditioner (unit: mm)

45
12

4 5
12

Figure 6 Front and back service area (unit: mm)

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56 Appendix 3 Installation Drawing

Service area is S + B or S + A
650 700

350
A

650
S

100
2725

1175
550

600
100

700

Figure 7 Service area (top view, unit: mm)

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 Appendix 3 Installation Drawing 57

Front view

11
75
0
60
Unit area

600
80

195.5 324.5
44
130
1175

31.5 154.5 414

90
52

234

55
55.5
544.5
Dimensions of the unit area
Figure 8 Dimensions of the raised floor for piping and electrical connections (unit: mm)

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58 Appendix 3 Installation Drawing

Air bleeding valve

A

A amplified

Figure 9 Position of the air bleeding valve for chilled water models (rear view)

Top inlet

Front view

Amplified figure

Bottom inlet (possible with raised floor)

Figure 10 Cable inlet for electrical connections

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 Appendix 4 Refrigerant, Hydraulic And Electrical Connections 59

Appendix 4 Refrigerant, Hydraulic And Electrical Connections

Rear view

28
Top connections 247.5 324.5
83 440 77
225.5

44
OG

74
237

130
242

69
HF OG
IL
HF/HD

DP IL
69
69
1175

76.5
98
CD or DP
EC-HV
97

EC-HV EC-LV
45

35

EC-LV
199
127

55.5
56 54
83 600
Bottom connections (possible with raised floor)
Figure 11 CR020RA, CR035RA connections (unit: mm)

Table 9 Refrigerant and hydraulic connections for air cooled units

Unit connection CR020RA CR035RA
IL Refrigerant liquid line inlet OD 12.7mm CU sweat OD 16 mm CU sweat
OG Refrigerant gas line outlet OD 16mm CU sweat OD 22mm CU sweat
Condensate drain
CD ID 20mm
Attention: with pump, CD is connected with HD, see DP
12.7mm GAS-F for top connections,
HF Humidifier feed
19mm GAS F for bottom connections
Humidifier drain
HD ID 22mm
Attention: with pump, CD is connected with HD, see DP
DP Pump drain 12.7mm GAS F
EC-HV Electrical supply – high voltage Hole, Φ63mm
EC-LV Electrical supply – low voltage Hole, Φ28mm

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60 Appendix 4 Refrigerant, Hydraulic And Electrical Connections

Rear
view

105
155
28
Top connections 247.5 324.5
83 440 77 225.5 OWC

44
74
HF/HD

130
242

237

69
HF OWC
IWC

DP IWC
69

69
1175

76.5
98 CD or
EC-HV
DP
97

EC-HV
45

EC-LV
35

EC-LV
199
127

56 54 55.5

83 Bottom connections (possible with raised floor)

600

Figure 12 CR020RW, CR035RW connections (unit: mm)

Table 10 Refrigerant and hydraulic connections for water cooled units

Unit connection CR020RW CR035RW
IWC Water to condenser inlet 32mm GAS F 32mm GAS F
OWC Water from condenser outlet 32mm GAS F 32mm GAS F
Condensate drain
CD ID 20mm
Attention: with pump, CD is connected with HD, see DP
12.7mm GAS-F for top connections,
HF Humidifier feed
19mm GAS F for bottom connections
Humidifier drain
HD ID 22mm
Attention: with pump, CD is connected with HD, see DP
DP Pump drain 12.7mm GAS F
EC-HV Electrical supply – high voltage Hole, Φ63mm
EC-LV Electrical supply – low voltage Hole, Φ28mm

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 Appendix 4 Refrigerant, Hydraulic And Electrical Connections 61

155 105

Rear view
Top connections 247.5 28
83 440 77 324.5

44
74
225.5
OCW
242

237
HF OCW HF/HD

130
ICW

69
DP ICW
69

69
1175

76.5
98
CD or DP
EC-HV
35
45

97 EC-LV
EC-LV
127

199

56 54 55.5
83
Bottom connections (possible with raised floor)
600

Figure 13 CR040RC connections (unit: mm)

Table 11 Refrigerant and hydraulic connections for chilled water units

Unit connection CR040RC
ICW Chilled water inlet 32mm GAS F
OCW Chilled water outlet 32mm GAS F
Condensate drain
CD ID 20mm
Attention: with pump, CD is connected with HD, see DP
12.7mm GAS-F for top connections,
HF Humidifier feed
19mm GAS F for bottom connections
Humidifier drain
HD ID 22mm
Attention: with pump, CD is connected with HD, see DP
DP Pump drain 12.7mm GAS F
EC-HV Electrical supply – high voltage Hole, Φ63mm
EC-LV Electrical supply – low voltage Hole, Φ28mm

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62 Appendix 4 Refrigerant, Hydraulic And Electrical Connections

2 4

16

1 3

15 8 9
X1

105
106
121
121
121
125
127
126
128
400
401
402
300
301
302
29

24
24
24
24
24

19
50
0
0
0
0
0

Wire bridge
X1.1
29

054

710
710

395
G0
Y2
51
51
52
53
53
54
55
61
61
62
63
81
82
83
84

70
71
72
73
22

13 6 12 7 11 10

Figure 14 Electrical board layout (50Hz)

Electrical field connecions descriptions (50Hz)

1. Standard electrical connections
1) Primary high voltage entrance - 64mm; 44mm; 35mm diameter concentric knockouts located in bottom of the box.
2) Secondary high voltage entrance - 64mm; 44mm; 35mm diameter concentric knockouts located in top of the box.
3) Primary low voltage entrance - Quantity: 3, 28mm diameter knockouts located in bottom of the unit.
4) Secondary low voltage entrance - Quantity: 3, 28mm diameter knockouts located in top of the box.
5) Earth ground - Terminal for field supplied earth grounding wire.
6) Remote unit shutdown - Replace existing jumper between terminals 52 & 53 with field supplied normally closed
switch having a minimum 75VA, 24Vac rating. Use field supplied Class 1 wiring.

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 Appendix 4 Refrigerant, Hydraulic And Electrical Connections 63

7) Customer alarm inputs - Terminals for field supplied, normally closed contacts, having a minimum 75VA, 24VAC
rating, between terminals 61 & 63. Use field supplied Class 1 wiring.
8) General alarm - On any alarm, normally open dry contact is closed across terminals 400, 401 for remote indication.
2A, 24Vac Max. load. Use Class 1 field supplied wiring.
9) Warning alarm - On any alarm, normally open dry contact is closed across terminals 300,301 for remote indication.
2A, 24Vac Max. load. Use Class 1 field supplied wiring.
10) Compressor motor on - On any call for compressor operation, normally open dry contact is closed across
terminals 72 & 73, 2A, 24Vac Max. load. Use Class 1 field supplied wiring.
11) Fan motor on - On any call for fans operation, normally open dry contact is closed across terminals 70 & 71. 2A,
24Vac Max. load. Use Class 1 field supplied wiring.
2. Optional electrical connections
12) Smoke sensor alarm (with smoke sensor option) – The smoke sensor is factory installed, and senses the delivery
air; it is connected across terminals 61 & 62 and send a visual and an audible alarm. This smoke sensor is not
intended to function as, or replace, any room smoke detection system that may be required by local or national codes.
1A, 24Vac Max. load. Use Class 1 field supplied wiring.
14) Condensate alarm (with condensate pump option) - On pump high water indication, normally open dry contact is
closed across purple wire for remote indication install inside the box near the pump. 1A, 24Vac Max. load. Use Class
1 field supplied wiring.
3. Optional low voltage terminal package connections
15) Flooding alarm (liquistat) – The flooding alarm detects the presence of water and activate an alarm. The sensor is
connected across terminals 105 & 106 and up to five sensors can be connected to the same flooding alarm device to
control many points in the bottom of the unit.
4. Electrical connections for maintenance
16) Switch mode power supply – 220Vac input, 12Vdc output. It can supply power for remote large display panel. The
switch is off by default, and can only be used during maintenance. When maintaining the unit, the maintenance
personnel can connect a large display panel to the unit rear part. Through the display panel, all functions of the
controller can be used, facilitating maintenance. After the maintenance, please switch off the switch mode power
supply.

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64 Appendix 5 Refrigeration & Hydraulic Circuits

Appendix 5 Refrigeration & Hydraulic Circuits

(On CR035 only)

18 13
3
6 2 1
10
14 12
MC
12 16
7
17
9
18
External on CR020 15
8
5 6
11 6

6 12
Area limit for CRV unit

19 19

To disconnect for bottom connections

11
4

1. Compressor 2. Crankcase heater 3. High pressure switch (HP)

4. Air cooled condenser 5. Liquid receiver 6. Access valve
7. Safety relief valve 8. Filter dryer 9. Sight glass
10. Thermostatic expansion valve 11. Check valve 12. Shut-off valve
13. Evaporating coil 14. Low pressure transducer 15. Capacity modulation solenoid valve
16. Shut-off solenoid valve 17. High pressure transducer 18. Vibration absorber
19. Cup and fitting (sweat) joint
Figure 15 CR020RA, CR035RA air conditioner

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 Appendix 5 Refrigeration & Hydraulic Circuits 65

6
(On CR035 only)

18 13
3
6 2 1
10
14
12
12 MC
16
7

18 9
17
15 21
(External on CR020) 8
11 11 5
6
(On CR020 only)
6 6

Water/Glycol outlet
(top connections) 19

AB A
Water/Glycol outlet
(bottom connections) 20 B

22
Water/Glycol inlet 4
(Only with
(top connections) optional
2-way
valve)
Water/Glycol inlet
(bottom connections)

1. Compressor 2. Crankcase heater 3. High pressure switch

4. Water cooled condenser 5. Liquid receiver 6. Access valve
7. Safety relief valve 8. Filter dryer 9. Sight glass
10. Thermostatic expansion valve 11. Check valve 12. Rotalock shut-off valve
13. Evaporating coil 14. Low pressure transducer 15. Capacity modulation solenoid valve
16. Shut-off solenoid valve 17. Head pressure transducer 18. Vibration absorber
19. Head pressure control valve 20. Valve fittings 21. Check valve (10bar)
22. Blind disk - only with optional two-way valve
Figure 16 CR020RW, CR035RW air conditioner

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66 Appendix 5 Refrigeration & Hydraulic Circuits

(Only with
5 optional
2-way
A valve)

AB B
2 4
Chilled water outlet
(top connections)

Chilled water outlet

(bottom connections)
Chilled water inlet
(top connections)

Chilled water inlet

(bottom connections)

1. Chilled water cooling coil 2. Three-port water valve 3. Air bleeding valve
4. Valve fittings 5. Blind disk - only with optional two-way valve
Figure 17 CR040RC air conditioner

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 Appendix 6 Wiring Diagram 67

Appendix 6 Wiring Diagram

P1 1 2 3 4 5
Transformer T2 XP
A1-P1-1
A1-P1-2
A1-P1-3
A1-P1-4

Connection bars 2 1
XP-1
4 T2-6 XP-3
BK P3 1 2
3 4 3
XP-5
A1-P3-1
A1-P3-2

BK 2 6 5
T2-5 BK
BK T2-1
Transformer 1 3

Transformer TC breaker 1 3 5
QF8 2 4 Heater breaker
BK 4 TC-6 TB-24 BK QF5 2 4 6
QF8-2
QF8-4

BK 3 24
Compressor 1

BK
BK
BK
BK QF5-2
BK QF5-4
BK QF3-6
2 TC-5 Humidifier 1 3 1 3
3 5

BK BK TC-1 0
TB-0 BK
breaker Fan breaker AC/DC Supply unit breaker 2

QS-1
QS-3
QS-5
QS-7
4 6

PE1
2 4
QF1 2 4 QF3
BK
BK

QF7 AL

QF3-2
QF3-4
QF3-6
BK

QF1-2
QF1-4
QF7-2
QF7-4
BK N L + - PE 1 3 5 7

KM6-1
KM6-3
KM6-5
Main switch PE1
TB-R8
TB-S8

KM6-A1

AL-PE
PE

ALL+
AL-N
AL-L

AL-L-
A1-P16-1 BK TB-400 QS 2 4 6 8
Etherent switch

BK
BK
1 400

BK
BK
1 3 5
Heat contactor1
BK
BK

A1-P16-2 BK TB-401 R8 S8 PE9 A1

V1-
A3-V1- P16 2 401
A1-P16-3 BK TB-402 A2
A3 V1+ A3-V1+ 3 402 2 4 6 KM6 L1 L2 L3 N PE

XPE
KM5-A1 KM6-A2
KM5-1 KM6-2
KM5-3 KM6-4
KM5-5 KM6-6
TB-PE9

V2- U01U02
TB-R8
TB-S8

V2+
TB-U01 TB-U02 380V～415V/50Hz 3N～

i-COM
A3-PE XPE 0 XPE

KM5-13
PE XPE A1-P15-1 BK TB-300 Y/GN
1 300
A1-P15-2
P15 2 A1-P15-3
BK TB-301
301 Heat

KM7-A1
KM7-1

KM7-5
BK TB-302 302 1 3 5 13
3 contactor2
A1 A1 Remote-DIS

XPE
A2
1 3 5
Humidifier 2 4 6 14 KM5

KM5-A2
A3 A3 A3 A1

KM5-14
XPE XPE
BR
BR

P P
contactor

KM5-2
KM5-4
KM5-6
XPEXPEXPEXPEXPEXPEXPEXPE XPEXPEXPE
A2 2 4 6 Remote display cable supply
KM7-A2

KM1-13
KM7-6 KM7
KM7-2

XPE
XPE
XPE
KM1-1

KM1-5
BK KM1-A1
A1-P4-2 TB-55 Y1 Y1 TB-0 BK BK
A1-P64 P4 2 55 0 Condensate

TB-0
P64 3 pump BK BK
～ 1
1 3 5
A1 3
Freon solenoid valve Optional
0
1 Fan contactor
HUM-SL

A2 2 4 6
HUM-D
HUM-A

KM1
Remote-DIS

BK 4

KM1-A2

KM1-14
EH-1
EH-3
EH-5
EH-2
EH-4
EH-6

KM1-2

KM1-6
BK

KM3-13
SL A D

KM3-1
KM3-3
KM3-5
KM3-A1

KM3-21
KM3-61
0

KM3-71
Humidifier

XPE
Compressor 1 3 5 13 21 61 71

EH-N1
EH-N3
EH-N5
EH-N2
EH-N4
EH-N6
A1
P2
Thermostat XPE contactor
1 2 3 4 24 A2
Remote large Manual Thermostat ST13-C ST13-NC KM3 2 4 6 14 22 62 72

KM3-A2

KM3-62
A1-P2-4 BK BL

KM3-14
display
A6-P3
A6-P4

KM3-2
KM3-4
KM3-6
FAN1-N

FAN2-N
ST12-C ST12-NC

FAN1-L

FAN2-L
BK
BK BK
Door switch1 BK BK
A1-P2-3 BK TB-19
Door switch2 Door switch3 TB-50

TB-0
19 50 BK BK BK
TAM P3 P4 MP1-NO MP1-C MP2-NO MP2-C MP3-NO MP3-C
A1-P2-2 BK TB-22 Y3 Y3 TB-0
22 0 0

Iniection solenoid valve

CP-L1
CP-L2
CP-L3
Isolation board

BK

BK
BL

BL
A6 Remote ON/OFF
P1 6 5 P5 A1-P5-1 BK TB-51 FAN1-COM WH YE WH YE
4 3 2 1 1 51
FAN1-NC WH Fan1 BL Fan2 BL Compressor
2 A1-P5-2 BK TB-52 WH

FAN2-COM
Fire sensor
A6-P1-6
A6-P1-5
A6-P1-4
A6-P1-3
A6-P1-2
A6-P1-1

52 ～ ～ 1

FAN1-YE
FAN1-BL

FAN2-NC
A1-P5-3 BK TB-53

FAN2-YE
FAN2-BL
3 53
A1-P5-4 BK TB-54

CP-PE
4 54 Y/GN Y/GN Y/GN
BK
BK
BK
BK
BK
BK

Y/GN
A1-P7-1 BK
No signal input, with a short connection cable TB-710 FAN1-PE FAN2-PE Y/GN
P7 1 710
A5-P1-1
A5-P1-2
A5-P1-3
A5-P1-4
A5-P1-5
A5-P1-6

A1-P7-2 BK TB-054
2 054
A1-P7-3
3
A1-P7-4 BK
P1 1 2 3 4 5 6 4
A5-P67 A5-P66 A1-P67
P67 P66 P67

Humidification control board P14 1

A1-P14-1 BK
Y1
TB-Y1
A5 2
A1-P14-2 BK
00
TB-00
A1-P14-3 BK TB-Y2
P2 1 2 3 4 5 6 7 8 9 10 3 Y2
A1-P14-4 BK TB-G0
A5-P2-1
A5-P2-2

A5-P2-10

CWV-G0

4 G0
A5-P2-9
A5-P2-5
A5-P2-6
A5-P2-7
A5-P2-8

CWV-G

CWV-Y

TB-24
24
A1-P12-1 BK TB-121
P12 1 121 +5V
2
A1-P12-2
sig
High pressure G G0 Y Condensing water valve
TB-24 BK
TB-0 BK

BK
BK
BK
BK
BK
BK

3 GND sensor
4 A1-P12-4
5 A1-P12-5 BK TB-125 Only for unit CR020RW
125
24 0 6 A1-P12-6 BK TB-126
126 +5V
Low pressure
YV07-2

7 A1-P12-7 BK TB-127 TB-70 BK

YV7-2

127 sig 70
Drain 8
A1-P12-8 BK TB-128
128 GND sensor 71
TB-71 BK
TB-72 BK
Charge solenoid 72
TB-73 BK
73
solenoid valve valve
XPE

High pressure switch

YV07-1

A1-P17-1 TB-24
YV7-1

P17 1 24
HP-1 HP-2 BK
XPE 2 A1-P17-2
No signal input, with a short
THB
BK TB-61 BK
connection cable BK
1 A1-P6-1 61
A1-P6-2 BK TB-62 BK
THB P6
2
A1-P6-3 BK TB-63
62
BK Smoke sensor
3 63
THB A1-P6-4 BK BK BK
4

RT2
A1-P8-1 BK TB-81
INTELLISLOT1 P63 1 81 Optional
2
A1-P8-2 BK TB-82
82 Delivery air probe
P8 A1-P8-3 BK TB-83
3 83
A1-P8-4 BK TB-84 84
4
P65
INTELLISLOT2
395
User input
14 12
Local-DIS

1
A1-P10-1 BK
TSC A1
A2
Terminal block
Network Communication 2
A1-P10-2 BK [Link] safety-sta 11
Interface
3
A1-P10-3 BK CF-COM COM NO

4
A1-P10-4 BK NC CF-NC Clogged filter alarm
P10 A1-P10-5 BK TB-105 1 LWD 2
5
A1-P10-6 BK TB-106
105
Water under floor switch 0 0 0 0 0 24 24 24 24 2410510612112112112512712612612840040140230030130219
Local display 6 106
Local-DIS

2 U0100 00 S8
0
4
U02
Heat and humidification
Y1 Y1 R8
lockout relay
50 51 51 52 53 53 54 05455 61 61 62 63 81 82 83 84 710710Y2 G0 70 71 72 73 22 395
Local display K1
Only for large display
Notes:
Factory supplied line voltage wiring Wire color code：
Ethernet or CAN wiring BK-Black P-Purple
Factory supplied 24 volt wiring BL-Blue R-Red
Device own line BR-Brown YE-Yellow
Inline quick disconnect WH-White
Y/GN-Yellow green
Terminal block connector
Naked crimping connector

Figure 18 CR020 air conditioner

[Link] Series Air Conditioner User Manual

68 Appendix 6 Wiring Diagram

P1 1 2 3 4 5
XP
A1-P1-1
A1-P1-2
A1-P1-3
A1-P1-4

Transformer T2 Connection bars XP-1

2 1
4 T2-6 BK P3 1 2 XP-3
3 4 3
XP-5
A1-P3-1
A1-P3-2

6 5
BK 2 T2-5 BK
BK T2-1
Transformer 1 3

Transformer TC breaker 2 4 Heater breaker 1 3 5

BK 4 QF8
TC-6 2 4 6
BK TB-24 BK
QF5
QF8-2
QF8-4
BK 3 24

QF5-2
QF5-4
QF3-6

BK
BK
BK
1 3
2 TC-5 BK TB-0 BK Humidifier Fan breaker1 3 5 1 3 5
BK BK TC-1 0
QF1 AC/DC Supply unit

QS-1
QS-3
QS-5
QS-7
breaker Compressor 2

PE1
2 4 2 4 6 4 6
BK
BK BK BK BK AL
QF7 breaker

QF1-2
QF1-4
QF1-6
QF7-2
QF7-4

QF3-2
QF3-4
QF3-6
BK
BK N L + - PE
QF3 Main switch 1 3 5 7

KM6-1
KM6-3
KM6-5
PE1
QS PE
TB-R8
TB-S8

KM6-A1

AL-PE
AL-L+
2 4 6 8

AL-L-
AL-N
AL-L
TB-400
Etherent switch 1
A1-P16-1 BK
400

BK
BK

BK
BK
BK
1 3 5
BK
BK

A1-P16-2 BK TB-401 A1
V1-
A3-V1- P16 2
A1-P16-3 BK TB-402
401 R8 S8 PE9 Heat contactor1
402 A2
A3 V1+ A3-V1+ 3 2 4 6
TB-PE9

L1 L2 L3 N PE
TB-R8
TB-S8

KM5-A1 KM6-A2

XPE
KM6

KM5-1 KM6-2
KM5-3 KM6-4
KM5-5 KM6-6
V2- U01U02
TB-U01 TB-U02 380V～415V/50Hz 3N～
V2+

i-COM
A3-PE XPE 0 XPE
PE XPE BK Y/GN

KM5-13
1 A1-P15-1 TB-300 300

BK
BK
BK
A1-P15-2 BK TB-301
P15 2 301

KM7-A1
KM7-1

KM7-5
3
A1-P15-3 BK TB-302
302 A1 1 3 5 13 Heat
A1
Remote-DIS

XPE
1 3 5 Humidifier A2 2 4 6 14 contactor2
A3 A3 A3 A1

KM5-A2
XPE
XPE
BR BR P P
contactor KM5 Remote display cable supply XPEXPEXPEXPEXPEXPEXPEXPEXPEXPEXPE

KM5-14
A2

KM7-A2

KM5-2
KM5-4
KM5-6
2 4 6
KM7

XPE
XPE
XPE
KM1-13
1

KM1-1
KM1-3
KM1-5
KM7-2

KM7-6
A1-P4-2 TB-55 Y1 Y1 TB-0 BK KM1-A1
A1-P64 P4 2 55 0 BK BK
Condensate

TB-0
P64 3 pump BK BK
Freon solenoid valve ～ 1 3 5 13
Optional
HUM-SL 0 A1 Fan contactor
A2

HUM-D
HUM-A 2 4 6 14
KM1
Remote-DIS

BK

KM1-A2

KM1-2
KM1-4
KM1-6
KM1-14
EH-1
EH-3
EH-5
EH-2
EH-4
EH-6
BK

SL A D

KM3-13
KM3-21
KM3-61
KM3-1
KM3-3
KM3-5
0 KM3-A1
Humidifier

KM3-71
XPE

EH-N3
EH-N5

EH-N4
EH-N6
1 3 5 13 21 61 71

EH-N1

EH-N2
Thermostat XPE Compressor
A1
P2 1 2 3 4 24
Remote large Manual Thermostat ST13-C ST13-NC
contactor
A2 2 4 6 14 22 62 72

KM3-A2

KM3-14

KM3-62
A1-P2-4 BK BL
display KM3
A6-P3
A6-P4

KM3-2
KM3-4
KM3-6
BK
BK
BK
BK

BK

ST12-C ST12-NC
Door switch2 BK BK
A1-P2-3 BK TB-19 Door switch1 Door switch3 TB-50
19 50 BK BK BK

TB-0
TAM P3 P4 MP1-NO MP1-C MP2-NO MP2-C MP3-NO MP3-C
A1-P2-2 BK TB-22 Y3 Y3 TB-0
22 0
0

FAN1-L1
FAN1-L2
FAN1-L3

FAN2-L1
FAN2-L2
FAN2-L3
Isolation board Iniection solenoid valve

CP-L1
CP-L2
CP-L3
A6
A1-P5-1 BK TB-51
Remote ON/OFF FAN1-COM 0-10(3) FAN2-COM 0-10(3)
P1 6 5 4 3 2 1 P5 1 51 风机1 风机2

FAN1-GND(2)
TB-52 Compressor1

FAN2-GND(2)
A1-P5-2 BK FAN1-NC
A6-P1-6
A6-P1-5
A6-P1-4
A6-P1-3
A6-P1-2
A6-P1-1

2 52 Fire sensor Fan1 Fan2

FAN2-NC
A1-P5-3 BK TB-53 3～ 3～ 3～
3 53
A1-P5-4 BK TB-54 54
4

CP-PE
Y/GN Y/GN Y/GN
BK
BK
BK
BK
BK
BK

Y/GN
No signal input, with a short connection cable Y/GN
P7 A1-P7-1 BK TB-710
1 710
A5-P1-1
A5-P1-2
A5-P1-3
A5-P1-4
A5-P1-5
A5-P1-6

A1-P7-2 BK TB-054
2 054
A1-P7-3
3
A1-P7-4 BK
P1 1 2 3 4 5 6 4
A5-P67 A5-P66 A1-P67
P67 P66 P67

Humidification control board P14 1

A1-P14-1 BK
Y1
TB-Y1
A5 2 A1-P14-2 BK
00
TB-00
P2 1 2 3 4 5 6 7 8 9 10 A1-P14-3 BK TB-Y2 CWV-Y
3 Y2
A1-P14-4 BK TB-G0 CWV-G0
A5-P2-10
A5-P2-1
A5-P2-2

4 G0
A5-P2-5
A5-P2-6
A5-P2-7
A5-P2-8
A5-P2-9

TB-24 CWV-G
24
A1-P12-1 BK TB-121
1 121 +5V
P12
2
A1-P12-2
sig
High pressure Condensing
TB-24 BK
TB-0 BK

G G0 Y
BK
BK
BK
BK
BK
BK

3
A1-P12-4
GND sensor water valve
4
5
A1-P12-5 BK TB-125
125
Only for unit CR035RW
A1-P12-6 BK TB-126 TB-70 BK
24 0 70
6
A1-P12-7 BK TB-127
126 +5V Low pressure 71
TB-71 BK
YV07-2

7 127 sig
Drain sensor TB-72 BK
YV7-2

A1-P12-8 BK TB-128 72
8 128 GND
TB-73 BK
solenoid valve 73
Charge
High pressure switch
XPE
YV07-1

A1-P17-1
YV7-1

solenoid valve P17 1

A1-P17-2
TB-24 24
HP-1 HP-2
2 BK
XPE
No signal input, with a short
THB connection cable
A1-P6-1 BK TB-61 BK BK
1 61
A1-P6-2 BK TB-62 BK BK
THB P6
2
A1-P6-3 BK
62
TB-63 63 BK BK Smoke sensor
3
THB A1-P6-4 BK BK BK
4

RT2
A1-P8-1 BK TB-81
INTELLISLOT1 P63 1 81 Optional
2
A1-P8-2 BK TB-82
82 Delivery air probe
P8 A1-P8-3 BK TB-83
3 83
A1-P8-4 BK TB-84
4 84
P65 395
INTELLISLOT2 User input
TSC 14 12
A1
Terminal block
A1-P101 BK
Local-DIS

1 A2
Network Communication 2
A1-P102 BK [Link] safety-sta 11
A1-P103 BK CF-COM COM NO
3
4
A1-P104 BK NC CF-NC Clogged filter alarm optional 0 0 0 0 0 24 24 24 24 24 105106 121121 121125127 126126128 400401402 300301302 19
P10 A1-P105 BK TB-105 1 LWD 2
5 105
A1-P106 BK
Local display 6
TB-106
106 W ater under floor switch U01 00 00 S8
U02
Local-DIS

0 24
Y1 Y1 R8
Heat and humidification
50 51 51 52 53 53 54 054 55 61 61 62 63 81 82 83 84 710710 Y2 G0 70 71 72 73 22 395
lockout relay
Local display K1
Only for large display

Notes:
Factory supplied line voltage wiring Wire color code：
Ethernet or CAN wiring BK-Black P-Purple
Factory supplied 24 volt wiring BL-Blue R-Red
Device own line BR-Brown YE-Yellow
Inline quick disconnect WH-White
Y/GN-Yellow green
Terminal block connector
Naked crimping connector

Figure 19 CR035 air conditioner

[Link] Series Air Conditioner User Manual

 Appendix 6 Wiring Diagram 69

P1 1 2 3 4 5
XP
A1-P1-1

Transformer T2 Connection bars

A1-P1-2
A1-P1-3
A1-P1-4

XP-1
4 T2-6 2 1
XP-3
BK P3 1 2 4 3
3 XP-5
A1-P3-1

A1-P3-2

6 5
BK 2 T2-5 BK
BK T2-1
1 3

Transformer TC Transformer 1 3 5
breaker 2 4 Heater breaker
BK 4 TC-6 QF5 2

QF8-2
QF8-4
BK TB-24 BK 4 6
BK 3 24 QF8

BK
BK
BK
BK QF5-2
BK QF5-4
BK QF3-6
2 1 3 1 3 5
TC-5 BK TB-0 BK Humidifier
BK BK TC-1 0
AC/DC Supply unit

QS-1
QS-3
QS-5
QS-7
BK breaker Fan breaker 2
BK

PE1
2 4 4 6
AL

QF1-4
QF1-6
QF1

QF1-2
BK

QF7-2
QF7-4
QF7 1 3 5 7
BK N L + - PE

KM6-1
KM6-3
KM6-5
PE1
TB-R8
TB-S8

PE

KM6-A1
Main switch

AL-PE
AL-L-
ALL+
AL-N
2 4 6 8

AL-L
Etherent switch 1
A1-P161 BK TB-400
400 Heat QS

BK
BK
BK
BK
BK
1 3 5
BK
BK

A1-P162 BK TB-401 401 A1

A3-V1-
V1-
A3-V1+
P16 2
A1-P163 BK TB-402 402
R8 S8PE9
A2
contactor1

KM6-A2
2 4 6 L1 L2 L3 N PE
TB-PE9

A3 3
TB-R8
TB-S8

V1+
KM6

XPE
KM5-3 KM6-4
KM5-5 KM6-6
KM5-1 KM6-2
V2- U01U02
TB-U01 TB-U02 380V～415V/50Hz 3N～
V2+
A3-PE XPE XPE
PE XPE
i-COM Y/GN 0

KM5-13
A1-P151 BK TB-300 300
1

KM5-A1
A1-P152 BK TB-301
P15 2 301

KM7-A1

KM7-1

KM7-5
A1-P153 BK TB-302
3 302 A1 1 3 5 13
Heat Remote-DIS

A1

XPE
A2
A3 A3 A3 A1
1 3 5 2 4 6 14
contactor2

KM5-A2
Humidifier
BR
BR

KM5-14
Remote display cable supply

KM5-2
KM5-4
KM5-6
P P XPEXPEXPEXPEXPEXPEXPEXPEXPEXPEXPE
A2 2 4 6
contactor KM5

KM1-13
KM7-A2

XPE
XPE
XPE
1

KM1-1
KM1-3
KM1-5
KM7-2

KM7-6
KM1-A1
A1-P64
P4 2
Condensate
KM7 BK BK BK

TB-0
P64 3 BK BK
pump
～ 1 3 5 13
0 A1
Optional Fan contactor
HUM-SL
A2 2 4 6 14

HUM-D
HUM-A
KM1
Remote-DIS

BK

KM1-A2

KM1-2
KM1-4
KM1-6
EH-1
EH-3
EH-5
EH-2
EH-4
EH-6

KM1-14
BK
SL A D
0
Humidifier

XPE

EH-N1
EH-N3
EH-N5
EH-N2
EH-N4
EH-N6
Thermostat
XPE
P2 1 2 3 4 24
Remote large Manual Thermostat
ST13-C ST13-NC
A1-P2-4 BK BL
display
A6-P3
A6-P4

BK
BK
ST12-C ST12-NC BK
BK

BK

Door switch1 Door switch2 Door switch3

A1-P2-3 BK TB-19 TB-50
19 50
TAM P3 P4 MP1-NO MP1-C MP2-NO MP2-C MP3-NO MP3-C

FAN1-L1
FAN1-L2
FAN1-L3

FAN2-L1
FAN2-L2
FAN2-L3
Isolation board
A6 Remote ON/OFF
P5 A1-P5-1 BK TB-51 FAN1-COM 0-10(3) FAN2-COM 0-10(3)
P1 6 5 4 3 2 1 1 51

FAN1-GND(2)

FAN2-GND(2)
2 A1-P5-2 BK TB-52 FAN1-NC Fan1 Fan2
A6-P1-6
A6-P1-5
A6-P1-4
A6-P1-3
A6-P1-2
A6-P1-1

A1-P5-3 BK TB-53
52 Fire sensor

FAN2-NC
3～ 3～
3 53
A1-P5-4 BK TB-54
4 54 Y/GN Y/GN
BK
BK
BK
BK
BK
BK

Y/GN

P7 A1-P7-1 BK No signal input, with a short connection cable TB-710 Y/GN

1 710
A5-P1-1
A5-P1-2
A5-P1-3
A5-P1-4
A5-P1-5
A5-P1-6

A1-P7-2 BK TB-054
2 054
A1-P7-3
3
A1-P7-4 BK
P1 1 2 3 4 5 6 4
A5-P67 A5-P66 A1-P67
P67 P66 P67

Humidification control board P14 1

A1-P14-1 BK
Y1
TB-Y1

A5 2
A1-P14-2
A1-P14-3
BK
BK
00
TB-00

P2 1 2 3 4 5 6 7 8 9 10 3 Y2 TB-Y2
BK
A5-P2-1
A5-P2-2

A1-P14-4 TB-G0
BK A5-P2-10
A5-P2-5
A5-P2-6
A5-P2-7
BK A5-P2-8
BK A5-P2-9

CWV-G0

4 G0
CWV-G

CWV-Y

TB-24
24
P12 1
2
TB-24 BK
BK

G G0 Y
Chilled water valve
BK
BK
BK

3
4
TB-0

5
24 0 6
YV07-2

Drain 7
YV7-2

8
solenoid 70
TB-70 BK
Charge valve 71
TB-71 BK
XPE

solenoid
YV07-1
YV7-1

P17 1
valve XPE 2
No signal input, with a short
THB
A1-P6-1 BK TB-61 61 BK
connection cable
1
A1-P6-2 BK TB-62 62 BK
THB P6
2
A1-P6-3 BK TB-63 BK
Smoke sensor
3 63
THB A1-P6-4 BK BK
4

RT2
A1-P8-1 BK TB-81
1 81 Optional
INTELLISLOT1 P63
2
A1-P8-2 BK TB-82
82 Delivery air probe
P8 A1-P8-3 BK TB-83
3 83
A1-P8-4 BK TB-84 84
4
395
P65 User input
INTELLISLOT2
TSC 14 12 A1
Terminal block
Local-DIS

1
2
Cold water temperature sensor 11 A2
Network Communication A1-P10-3 BK CF-COM COM NO
Interface 3
4
A1-P10-4 BK NC CF-NC Clogged filter alarm 0 0 0 0 0 24 24 24 24 24 105106 400401402 300301302 19 50
P10 A1-P10-5 BK TB-105 1 LWD 2
5 105
Local display 6
A1-P10-6 BK TB-106
106 Water under floor switch U01 00 00 S8
Local-DIS

0 24 U02
Y1 Y1 R8
51 51 52 53 53 54 054 61 61 62 63 81 82 83 84 710710 Y2 G0 70 71 395
Heat and humidification
Local display lockout relay
Only for large display K1

Notes:
Factory supplied line voltage wiring Wire color code：
Ethernet or CAN wiring BK-Black P-Purple
Factory supplied 24 volt wiring BL-Blue R-Red
Device own line BR-Brown YE-Yellow
Inline quick disconnect WH-White
Naked crimping connector Y/GN-Yellow green

Figure 20 CR040 air conditioner

[Link] Series Air Conditioner User Manual