oxycom IntrCooll Std. Manual
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oxycom IntrCooll Std. Manual

Direct / indirect evaporative cooler
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IntrCooll Std. / Plus
Direct / Indirect evaporative cooler
Version: Version 1.3
Date: 14/12/2021
Manual
Installation

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Summary of Contents for oxycom IntrCooll Std.

  • Page 1 IntrCooll Std. / Plus Direct / Indirect evaporative cooler Manual Installation Version: Version 1.3 Date: 14/12/2021...

  • Page 3: Table Of Contents

    Table of contents Step 7. Finish the installation 48 Preface 5 Warranty 5 Product liability 5 Operation procedures 53 Compliance 6 How to operate the IntrCooll® 53 Contact data 6 System status and settings 58 Update firmware 64 About this manual 7 Scope of this manual 7 Appendices 67 Audience 7...

  • Page 5: Preface

    Product liability Oxycom Fresh Air B.V. or subcontractor is not liable for any claims of third parties caused by inexpert use of the machine and/or for any claims arising from use other than as stated in this manual and in compliance with the terms of delivery.

  • Page 6: Compliance

    Contact data If you have any questions or need further details on specific matters concerning the equipment, do not hesitate to contact us: Oxycom Fresh Air B.V. P.O. Box 212 8100 AE Raalte The Netherlands Tel: +31 (0)572 349 400 E-mail: service@oxy-com.com...

  • Page 7: About This Manual

    About this manual Scope of this manual This manual describes the safety issues, preparation of the installation location and installation of the IntrCooll®. Caution Before installing the IntrCooll®, read this manual closely to get familiar with the functioning and strictly observe the given indications and instructions. If you do not understand any part of the information in this manual, contact your local service department.

  • Page 8: Typographical Conventions

    Intermediate vocational education level. Note In case of doubt, always consult the Oxycom Service Department. For more information on the IntrCooll® and other Oxycom products, please contact Oxycom Fresh Air B.V.. Typographical conventions The following kinds of formatting in the text identify special information:...

  • Page 9: Availability

    Availability Oxycom expects this manual to be available to all installation technicians, users and service engineers of the IntrCooll®. The original hardcopy (paper) version should always be available near the IntrCooll®.

  • Page 11: Safety

    Safety General (safety) Operating and maintenance personnel, as well as anyone who is around this unit should be aware of the possible dangers. This recommendation applies regardless of other regulations that are issued by a higher authority or included in a (safety) standard.
  • Page 12 Sticker manuals inside...

  • Page 13: Handling And Storage

    Handling and storage Arrival of the package The IntrCooll® is always delivered on a wooden pallet. Crate Caution Obey the instructions and icons on the crate. At delivery of the IntrCooll®, make sure that all the components are present and undamaged.

  • Page 14: Preparations

    Always place the IntrCooll® on a stable loading floor with sufficient load-bearing capacity. Caution Oxycom is not responsible for damage resulting from incorrect transport and storage. Warranty rights will not be accepted in the event of incorrect transport and storage.
  • Page 15 Handling and storage Stacking of crates: (see Transport) • IntrCooll Std.: Max. 1 crate is allowed. • IntrCooll Plus: Do not stack the crates. Do not load other items on top of the crates. Keep dry. Handle with care. Caution Never place the IntrCooll®...

  • Page 16: Transport

    Transport 2.4.1 Package dimensions and weight For dimensions and weight information of the unit, refer to the specification sheets. 2.4.2 Forklift instructions The equipment is supplied on a wooden pallet with a cardboard cover. Use a forklift to move the crate. Please note the following: The equipment is heavy.
  • Page 17 Handling and storage Forklift positions 2.4.3 Hoist instructions Danger Always use certified hoisting equipment to hoist the IntrCooll®. Danger To lift, always use all 4 lifting terminals on top of the IntrCooll®. Failure to use all lifting terminals may cause serious injury and/or damage the machine. Danger Always respect the correct length and angle of the ropes when lifting the unit.
  • Page 18 Lifting instructions A Rope length Rope length (A): IntrCooll Std.: 2 m. minimum (4x) IntrCooll Plus: 3.6 m. minimum (4x) Maximum rope angle: 30°...

  • Page 19: Prepare The Location

    Prepare the location Caution Before operation or maintenance be sure to read and understand the safety information and warranty conditions. The safety and warranty information can be found behind the electrical panel on the IntrCooll®. There are several methods/accessories to support the equipment on the roof, each having its own requirements.

  • Page 20: Location Requirements

    Location requirements The location must be able to provide space for the unit and carry the weight of the unit. 3.1.1 Weight requirements For weight information of the unit, refer to the specification sheets. 3.1.2 Space requirements 3.1.2.1 Equipment dimensions For dimension information of the unit, refer to the specification sheets.
  • Page 21 Prepare the location Electrical compartment Isolator switch Horizontal entry UV-C water sterilizer (optional) Duct IntrCooll® Std.: 600 mm x 600 mm IntrCooll® Plus: 900 mm x 900 mm 20 mm - 30 mm flange Fasten with screws (do not screw in the red zone!) Water supply ¾"...

  • Page 22: Support Frame (Not Provided)

    Refer to the accessories brochure for more information on the optional support frame. If the contractor provides a support frame, Oxycom recommends the use of a support frame with the following specifications: The profile for the welded frame is galvanized steel "L".

  • Page 23: Natural Ventilator

    Plus: 1714 mm x 1714 mm. IntrCooll® on support frame Natural ventilator As an option a natural ventilator can be ordered at Oxycom. Refer to the accessories brochure for more information on the natural ventilator. Flashing kit IntrCooll® (Optional) The IntrCooll® can also be mounted on an optional Flashing kit. This kit and associated installation instructions are available separately from Oxycom.

  • Page 24: Roof Beam Supports

    Roof beam supports Requirements for roof beam supports: Must be calculated, provided and installed by the contractor (unless already present in the construction). Must be positioned under the support feet or the frame to hold the weight of the IntrCooll®, including frame and ducting. Steel support beams (examples) Already present in the construction installed by the contractor...
  • Page 25 Prepare the location Example of a roof curb Wrong installation example (poor accessibility of the drain valve) Version 1.3, 2021-12-14...

  • Page 26: Roof Transit For Ducting

    Roof transit for ducting Roof transit requirements: Must be provided (including materials) by contractor. Must be watertight. Example of a roof transit for ducting Roof transits for cabling / plumbing Caution Prevent rainwater from following the cables: always bend the cable(s) in a V– shape.

  • Page 27: Exhaust Air

    Exhaust air 3.10.1 Exhaust vents As an option exhaust fans can be ordered at Oxycom: Article no. 5301249, exhaust fan for IntrCooll® Std. Article no. 5301250, exhaust fan for IntrCooll® Plus Refer to the accessories brochure for more information on the optional exhaust fans.
  • Page 28 Wall vent (rain repellent or with sensor) 3.10.2 Exhaust fans The supplied air shall be able to smoothly leave the building at ceiling level (as high as possible). When mechanical exhaust fans are used, these can be powered and controlled by the IntrCooll®...

  • Page 29: Water Requirements

    Caution Water quality is of vital importance for the longevity and hygienic functioning of the system. Please consult Oxycom for a tailored advice specific for your situation. The supplied tap water or reversed osmosis water must meet the requirements according to the table below.
  • Page 30 Ryznar Stability Index or RSI. The RSI value must be higher than 6 to prevent issues due to scale. Please contact Oxycom if you have any question concerning your water quality.

  • Page 31: Drain Connection Requirements

    Prepare the location 3.11.2 Supply water flow requirements For flow requirements of the supply water for the unit, refer to the specification sheets. 3.12 Drain connection requirements The drain connection on the IntrCooll® can be set up in two different configurations: The drain valve discharges directly onto the roof top.

  • Page 32: Water Connections

    3.14 Water connections The IntrCooll® needs a connection to the mains water supply. The water supply and drain piping must comply with the requirements as described in this manual. Connection types Water supply hose and drain piping (example) Note Hoses and piping must be provided and installed by the contractor,...
  • Page 33 All necessary piping and installation must be provided and executed by the contractor. Oxycom recommends to: Install a shut-off valve with drain option for each unit for service/maintenance reasons. The drain can be used for emptying the tubing for the winter period in combination the optional freeze protection valve set.
  • Page 34 Alternatively, an automatic aerator can be considered to install for winter draining. Install a maintenance valve and connection near the unit, for service/ maintenance reasons (i.e. water supply for pressure washer). Supply connections schematic overview 1 Shut-off valve 2 Back-flow preventer 3 2-way valve for winter with positions: close - operation / open - winter (drain) 4 2-way valve for winter with positions: open - operation / close - winter 5 Accessory: Freeze protection valve set (art.
  • Page 35 Prepare the location Note The Freeze protection valve set is an optional accessory (art.5301085) Note Oxycom advices not to use copper piping material. Note Insulate the supply line in facilities that produce humidity. 3.14.2 Drain connections Requirements for drain piping...

  • Page 36: Electrical Requirements

    3.14.4 Valves For a proper connection to the mains water supply Oxycom advises the contractor to use the following valves in the installation: An additional shut-off valve to isolate the IntrCooll® from the water supply, i.e. during maintenance activities or when taking the system (temporary) out of service.

  • Page 37: Communication Requirements

    An external automated circuit breaker is not included in the package and must be provided and installed by the contractor. 3.15.4 Mains power outlet Oxycom recommends to install a mains power outlet near the IntrCooll®. This can be used by the service technician for maintenance equipment. 3.16 Communication requirements There are several possibilities to control the IntrCooll®.
  • Page 38 2 Types of thermostats are available: Temperature Humidity limit Time schedule control sensor Non-programmable Thermostat Programmable Thermostat Example of a programmable thermostat and of a non-programmable thermostat Each thermostat has 3 operation modes with manual or automatic switch over: Heat reclaim (only applicable/used when a Heat Reclaim module is ordered). Free cooling (fan only).
  • Page 39 The contractor must take care of the control system that regulates the temperature control, fan speed and operation mode. The Modbus interface information is available in a separate document. This can be requested at Oxycom. 3.16.4 Control by an air handling unit For pre-cooling purposes, the IntrCooll®...
  • Page 40 J12: 0 (no circuit) = Free Cooling / 1 (circuit) = Cooling. J23: Alarm signal (collective) feedback to AHU.

  • Page 41: Install The Intrcooll

    Always place the IntrCooll® on a stable loading floor with sufficient load-bearing capacity. Note Oxycom is not responsible for damage resulting from incorrect transport and storage. Warranty rights will not be accepted in the event of incorrect transport and storage.

  • Page 42: Step 1. Positioning And Leveling

    Step 2. Duct connection to the IntrCooll The design of the IntrCooll® facilitates to connect the unit directly to the duct via the duct connection unit. There are different ways to connect the IntrCooll® to the roof opening: Oxycom recommends to use a flexible duct connector.

  • Page 43: Step 3. Drain Valve Installation

    Install the IntrCooll® Duct connection requirements: In case of an elevated setup, the ducting must be insulated and the duct transit must be finished waterproof. In case of an elevated setup, the drainage pipe can be connected to the sewer, or the wastewater can be discharged onto the roof. The overflow connection may be combined with the drain.
  • Page 44 2. The drain valve is packed in the pump compartment during transport. Remove the corner cover and take out the drain valve package. Install the panel back in its original position afterwards. 3. Mount the drain valve to the 1 "...

  • Page 45: Step 4. Flow Regulator Cap

    Install the IntrCooll® 5. Connect the power supply connector for the drain valve to the drain valve. 6. Lock the connector in place with the pre-mounted screw. Step 4. Flow regulator cap The ring tube assembly is linked to the pump. There is a difference between the amount of water the pump delivers at 50 Hz or 60 Hz.

  • Page 46: Step 5. Making Connections

    Step 5. Making connections Connections on the IntrCooll® Note Install vents in the drain line to prevent from vacuum. 4.6.1 Water connections Make sure that all water system components comply to the requirements as described in the section Water supply and discharge on page 29. Mains water supply: 1.

  • Page 47: Step 6. Check Installation And Settings

    Connect the new cable to the internal switch and to earth (screwed terminal connector). Oxycom recommends the use of a cable according to the following specifications: Type H07RN-F or equal. Note Calculate the correct diameter of the power supply cable based on the factors that are of influence (length, bundled, temperature, etc.).

  • Page 48: Step 7. Finish The Installation

    4.7.1 Connect the thermostat When the IntrCooll® is controlled by a thermostat follow the documentation of the thermostat for a correct installation. Before installation see the communication requirements on page 37 for more information. IntrCooll® connector for communication (RS485) with thermostat is J17: 2 wires used for RS485 communication.
  • Page 49 Install the IntrCooll® Delivery of the crate and transport to the installation site Reference Is there a place indoor where the crated equipment can be stored Handling and storage temporarily? Is there a fork-lift truck or any other lifting device available with Transport proper lifting gear/ropes according to manual? Remarks:...
  • Page 50 Minimum free space for 3 or more sides of 1000mm? Space requirements on page 20 Modulating exhaust air vents/fans including cabling are accounted Exhaust air on page 27 for? (might require roof support beams as well) Remarks: Electrical specifications Electrical supply phases/voltage/frequency meets equipment Electrical requirements? requirements on page 36...
  • Page 51 Install the IntrCooll® Thermostat connected with correct cable, to specified connection Thermostat control on page 37 in IntrCooll®? If Oxyconnect gateway is ordered, are necessary preparations Oxyconnect gateway done? control on page 38 If Building Management System will control the unit, is contractor Control by a Building informed to take care of installation? Management...

  • Page 53: Operation Procedures

    Operation procedures How to operate the IntrCooll® 5.1.1 Checks before starting Before starting make sure that: All panels and covers of the IntrCooll® are installed. There is no marking on the IntrCooll® ‘DO NOT START’ . There are no loose or strange parts within the IntrCooll®. The water supply to the IntrCooll®...
  • Page 54 5.1.3 Power-up unit and final checks and settings Main switch 1. Main switch 1. Check if water and electricity are connected. 2. Remove the cover from the electric component section. Danger Electric shock hazard while working on electric components. 3. Power up the unit by turning the main switch (1) on. The OxyLogic display will light up and the unit will start-up.
  • Page 55 Operation procedures 5.1.4 How to switch the IntrCooll® off There are several situations from which the IntrCooll® can be switched off. To switch the IntrCooll® off: If the unit is on 'stand by' , the main switch (1) can be switched off immediately.
  • Page 56 Dry the IntrCooll® using the ventilation mode for 10 to 15 minutes. Switch off the IntrCooll®. See Switch off for maintenance. Note If the system is not in use for a longer period of time or if there is no cooling demand, the water supply line is automatically emptied by the automatic drain valves.
  • Page 57 Operation procedures 5.1.6 Fan settings During commisioning the nominal airflow must be checked and the correct fan speed must be set. 1. Make sure that all ductwork is installed. 2. To expose the OxyLogic LCD display, remove the cover. 3. See which software version is installed on the Oxylogic (Status value: W33). This is important to know for the next steps.

  • Page 58: System Status And Settings

    System status and settings 5.2.1 System characteristics The system goes into adiabatic cooling mode when the following two conditions are met: Thermostat/Modbus Master/Pre-cooling input must be in cooling mode. The outdoor temperature is above the cooling release temperature. When the system is in cooling mode: Tank fill: The drain valve closes and the water supply solenoid opens.
  • Page 59 Operation procedures 5.2.2 Using the LCD The OxyLogic LCD on the PCB of the IntrCooll® can show: System status: During normal operation, by default the OxyLogic LCD shows which processes are currently active in the IntrCooll®. Display menu: The actual state of various components inside the unit. These values have the prefix "W".
  • Page 60 5.2.3 Display menu Navigation: Open display menu: From the system status menu, press navigation button [2]. Scroll through the menu: Press navigation button [1] and [2]. Display menu Status value Reading Unit Brief description W01:Model name Model name and type. W02:SerialNumber Unit serial number.
  • Page 61 Operation procedures Status value Reading Unit Brief description Output value for building exhaust output (optional damper, fan or W27:A-ExhaustAir Status Natural Ventilator box) (0% to 100% = 0 V to 10 V). Output value for outdoor air/ventilation output (optional damper) (0% to 100% = 0 V to 10 V) W28:A-OutdoorAir Status...
  • Page 62 / do not forget to switch back to automatic and save again). S12: Min Fan Heating Setting Minimum fan speed for Heat Reclaim (only change when approved by Oxycom or representative). S13: Max Fan Heating Setting Maximum fan speed for Heat Reclaim...
  • Page 63 Operation procedures S15: Max Fan Free Setting Maximum fan speed for free-cooling Cooling S16: Min Fan Cooling Setting Minimum fan speed for cooling S17: Max Fan Cooling Setting Maximum fan speed for cooling S18: Cooling release Setting °C Minimum outdoor temperature for cooling.

  • Page 64: Update Firmware

    Error codes on the OxyLogic LCD Error code Error type Description Error 01 01(A) Tank fill takes too long; check water pressure or replace supply/drain valve (Port: 20/21). Error 02 02(A) Measured flow while supply solenoid was closed; check or replace supply solenoid (Port: 20). Error 03 03(B) Tank drain takes too long;...
  • Page 65 Operation procedures * Available as download on https://www.oxy-com.com/manuals. No password yet? Please email your contact person at Oxycom® and ask for login details) Accessibility: See section Remove panels: Remove corner cover (1) on the electrical connections side of the IntrCooll®.
  • Page 66 6. When the "bootloader" is ready (see OxyLogic LCD), press the reset button [3] on the OxyLogic. OxyLogic will now restart and the system is ready. 7. Disconnect the USB. Set the language: 1. Enter the Settings menu by pressing buttons [1] and [2] simultaneously on OxyLogic for 2 seconds.

  • Page 67: Appendices

    Appendices Version 1.3, 2021-12-14...

This manual is also suitable for:

Intrcooll plus3800oxystd380oxyplus

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