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Summary of Contents for Carel chillBooster AC012D0 Series
- Page 1 chillBooster adiabatic cooling for finned heat exchangers USER MANUAL NO POWER & SIGNAL CABLES TOGETHER READ CAREFULLY IN THE TEXT!
- Page 2 Index 1. Purpose of the manual ..........7 2. How to read the manual .......... 7 3. General safety information and instructions ..8 3.1 Intended use ......................8 3.2 General safety instructions .................8 3.3 Personal protective equipment ...............9 4. Unit overview ............10 4.1 Description of the unit ................
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Page 3: Purpose Of The Manual
Brugine - Padova (Italy) Tel. (+39) 049.9716611 - Fax (+39) 049.9716600 e-mail: carel@carel.com - www.carel.com 2. HOW TO READ THE MANUAL The manual is divided into chapters and paragraphs. Each paragraph is a sub-level of the corresponding chapter. References to headings or paragraphs are indicated by the abbreviation “Chap. -
Page 4: Intended Use
Note: the liability of the manufacturer in relation to its products is specifi ed in the general contract conditions, published on the website www.carel.com and/or by specifi c agreements with customers; specifi cally, to the extent where allowed by ap-... -
Page 5: Personal Protective Equipment
Personal protective equipment DANGER Strictly follow the instructions provided in the manual. Personal protective equipment (PPE) means any equipment intended to be worn and kept by workers in order to protect them- selves against one or more risks likely to threaten their health or safety during work, as well as any device or accessory intended for this purpose. -
Page 6: Unit Overview
4. UNIT OVERVIEW Description of the unit The unit comprises a pumping station and a distribution system to spray fi nely atomised water. The minute droplets of water evaporate spontaneously at the expense of the energy of the air, which is consequently cooled and reaches the fi nned coil at below-ambient temperature. -
Page 7: Packaging Contents
Packaging contents When opening the packaging, make sure that the components illustrated in Fig. 4.a. and the accessories in Fig. 4.b are present and intact: • kit of screws with anchors for wall mounting (inside the cabinet) (a - Fig. 4.c); •... -
Page 8: Description Of The Controls
Description of the controls Ref. Component Function ON/OFF switch Used to switch the unit ON (position I) and OFF (position O). Black button Simulates the remote ON command (closure of contacts 1-2). Used during commissioning if the ON command from the external con- troller is not available. - Page 9 Nonetheless, the recipient must scrupulously check the packages before they are unloaded from the delivery vehicle. Notify the carrier immediately, in writing, of any damage that may be due to improper or negligent transport. Move the unit to the site of installation before removing it from the packaging, grasping the neck from underneath using suit- able lifting equipment.
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Page 10: Installation
6. INSTALLATION Positioning The unit must be positioned so as to allow the following operations: • opening the front panel; • accessibility to the internal parts for checks and maintenance; • connection of the feedwater lines; • connection of the water distribution lines; •... - Page 11 6.2.2 Water connection layout Refer to the following installation layout for the water connections: 2° Key: 2° manual valve upstream of the system to shut off the water line (not supplied by the manufacturer) 10 μm water fi lter (P/N ACKF000000) to remove particles from the feedwater ChillBooster cabinet Hoses complete with adapters (see par.
- Page 12 Feedwater requirements for optimum operation Feedwater requirements: Type / properties Requirement Demineralised water Tap water ok * Softened water ok ** Temperature °C (°F) 5 to 40 (41 to 104) Pressure (MPa/bars) 0.2 to 0.8 (2 to 8) 6.5 to 8.5 Total hardness mg/l CaCO3 (°F) <...
- Page 13 6.3.2 Plugs If the 1/8” NPT holes on the racks need to be closed, stainless steel plugs are available. ACKCAP0000 Fig. 6.g Important: • Max. tightening torque 10 Nm. • Place a suitable layer of Tefl on tape around the thread. 6.3.3 Racks Stainless steel nozzle racks, outside diameter 20 mm, with NPT 1/8”...
- Page 14 Attaching the 20 mm dia. nickel-plated brass push-lock couplings 1. The pipes must be deburred. Insert 3. Tighten to a torque of 15 Nm. the ring nut, the plastic ring and the rubber gasket into the pipe. 2. Insert the pipe into the coupling, as far as it will go.
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Page 15: Electrical Connections
Fittings and gaskets for hoses Part number Fittings Ref. fi gure ACKRR01200 G1/2” - G3/4” M-M adapter a - 6.m ACKRN01000 G1/2” M-M straight adapter b - 6.m ACKRN02000 G3/4” M-M straight adapter b - 6.m ACKRTF1110 G1/2” M - G1/2” M - G1/2” M ‘T’ fi tting c - 6.m ACKRTF1120 G1/2”... -
Page 16: Power Supply
6.4.3 Power supply Depending on the models: • AC***D0*** voltage 230V 1~ 50Hz; • AC***D1*** voltage 230V 1~ 60Hz; Important: Use sheathed power cables with two wires plus earth, minimum cross-section 0.75 mm and minimum outside diameter of 7 mm. Cables must comply with local regulations. Install a power switch outside of the cabinet to isolate it fully from the power supply. - Page 17 6.4.7 Unit status/pump operation Voltage connections (0-230 V). The terminals are powered when the pump starts and change status when it stops. Pump ON N1C N10 Terminal Voltage Terminal N1C 230V Terminal N1O Terminal L1 Pump OFF Terminal Voltage Terminal N1C Fig.
- Page 18 6.4.10 Electrical panel indicator lights Ref. On Signal White light Indicates that power is connected to the panel. The white light is on when the ON/OFF switch (1a - Fig. 4.c) is in position I. Green light Indicates correct operation of the unit, i.e. that the unit is producing humidity and the pump is running (pump ON).
- Page 19 Factory setting, type B relay T1 full scale 10 sec (reference 1) T1 activation time15 (reference 2-bottom) T2 full scale 30 min (reference 1-top) T2 activation time 15 (reference 1-top) Fig. 6.aa Assuming there is on/off signal to operate the system. Relay RT2 is powered when the LP contact (see the wiring diagram) is in position 2 (this means that the pressure is below the 0.5 bar activation value), i.e.
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Page 20: Preliminary Checks
7. COMMISSIONING Preliminary checks Before starting the unit, check the following: 7.1.1 Cabinet • Cabinet (3 - Fig. 7.a) installed on a level surface • Cabinet (3 - Fig. 7.b) protected against direct sunlight. • Make sure that the cap on the automatic air vent valve (15 - Fig. 7.b) is NOT tightened. •... -
Page 21: Start-Up Procedure
Start-up procedure 1. Open the manual valve (1 - Fig. 7.a) on the feedwater line and power on the unit. 2. Switch the unit on by moving the disconnect switch (1a - Fig. 7.b) to position I. 3. Start the system by closing contacts 1-2 (automatic via external control, manual via black button, 1b - Fig. 7.b) 4. -
Page 22: Unit Operation
8. UNIT OPERATION Normal operation The unit normally operates automatically based on the request from the system it is installed in. Once the disconnect switch (1a - fi g .4.3) has been set to position I (ON) and the circuit breaker has been reset, the unit and its electrical panel will be powered by the power line and, in the versions where featured (AC******1*), the UV lamp electrical panel will also be powered. -
Page 23: Control Panel Components
Switching the lamp on and off The lamp electrical panel (Fig. 9.a) cannot switch on or off independently with respect to the unit, as it does not have its own power button; nonetheless, the lamp can be switched off in one of the ways shown below: •... -
Page 24: Settings Menu
9.3.2 Settings menu Use the arrow buttons to scroll between the screens in the settings menu. The following items have settings that can be changed: ON delay OFF delay Press OK to set the switch-on delay. The value is ex- Press OK to set the remote switch-off de- pressed in seconds. -
Page 25: Maintenance Table
10. MAINTENANCE DANGER: • always wear protective gloves during maintenance operations. • poor maintenance, removal or modifi cation of safety devices and/or the use of non-original spare parts can cause serious or fatal injuries to operators or third parties and unit malfunctions. Carry out systematic preventive maintenance annually or at the start of each season. -
Page 26: Replacing The Uv Lamp
10.5 Checking the UV lamp Check the status of the UV lamp every month on the lamp control panel (Fig. 9.b). Specifi cally, check: • the remaining lamp operating hours (see par. 9.3) shown on the display; • that the alarm LED is not on (see par. 9.3.4). 10.6 Replacing the UV lamp DANGER: Make sure that the unit is not powered and the disconnect switch (1a - Fig. -
Page 27: Replacing The Pump
10.7 Replacing the pump DANGER: Make sure that the unit is not powered and the disconnect switch (1a - Fig. 4.c) is in position O. Every 3 months, visually inspect the pump (9 -Fig. 4.a) and replace it if necessary, proceeding as illustrated below: 1. -
Page 28: Troubleshooting
11. TROUBLESHOOTING Problem Cause Verifi cation Solution The motor does not Power supply Faulty fi ll solenoid valve Check the pressure gauge insi- Replace the faulty solenoid valve start when the unit is de the cabinet when operating switched on (the LP Incorrect LP switch calibration Check that the switch is activa- Replace the LP switch... - Page 29 ANNEX Annex A: Wiring and connection diagrams Version with UV lamp AC**2D**1* (Rev 2.000) Key: 1. racks with nozzles 2. drain valves “chillBooster” +0300076IE - rel. 1.3 - 03.02.2025 Annex...
- Page 30 Version without UV lamp AC**2D**0* (Rev2.00) Key: 1. racks with nozzles 2. drain valves “chillBooster” +0300076IE - rel. 1.3 - 03.02.2025 Troubleshooting...
- Page 31 Annex B: Checklist prior to startingo Checklist prior to starting 1. Cabinet Installed level. Protected against direct sunlight. Automatic air vent valve cap not tightened (15 - Fig. 4.a). Drain solenoid valve outlet runs to an outside drain (8 - Fig. 7.a). 2.
- Page 32 Annex C: Accessories and spare parts kits “chillBooster” +0300076IE - rel. 1.3 - 03.02.2025 Troubleshooting...
- Page 33 Part number Description Ref. fi gure Ref. unit label ACKV1D0010 NO water drain solenoid valve kit IP67 NC water fi ll solenoid valve kit IP65 ACKV1F0000 ACKVENT000 automatic air vent valve kit 1309851AXX 0 to 10 bar glycerine-fi lled pressure gauge 0 to 25 bar glycerine-fi lled pressure gauge 1309852AXX MCKMNFD000...
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