JREF

Air Conditioning Units for Close Control Application

Users Manual GB

HF61GD0039F JREF-0-UM-GB_NEUTRALE
HF61GD0039F JREF-0-UM-GB_NEUTRALE 1
Index

Index
1 General Description....................................................................................................... 3
1.1 Structure ................................................................................................................. 4
1.2 Field of application .................................................................................................. 5
1.3 Cooling circuit (DX version) .................................................................................... 5
1.4 Hydraulic section (CW version)............................................................................... 7
1.5 Installation warnings ............................................................................................... 8
2 Inspection / Transport / Positioning ............................................................................... 8
2.1 Inspection on receipt............................................................................................... 8
2.2 Lifting and transport ................................................................................................ 8
2.3 Unpacking ............................................................................................................... 8
2.4 Positioning .............................................................................................................. 8
2.5 Refrigerant connections ........................................................................................ 10
3 Installation ................................................................................................................... 10
4 Evacuation and Charging Operations.......................................................................... 12
4.1 Introductions ......................................................................................................... 12
4.2 Full vacuum and charge of the unit ....................................................................... 13
4.3 Evacuating a circuit “contaminated” with refrigerant ............................................. 13
4.4 Charging positions (single point)........................................................................... 14
5 Electrical Connections ................................................................................................. 14
5.1 Generalities .......................................................................................................... 14
6 Operating Diagrams .................................................................................................... 16
7 Starting Up .................................................................................................................. 16
7.1 Preliminary checks................................................................................................ 16
7.2 Starting operation ................................................................................................. 17
7.3 Checks during operation ....................................................................................... 17
7.4 Checking the refrigerant level (DX version) .......................................................... 17
8 Operating Parameters Setting ..................................................................................... 18
8.1 Generalities .......................................................................................................... 18
8.2 Maximum pressure switch .................................................................................... 19
8.3 Minimum pressure switch ..................................................................................... 19
9 Maintenance ................................................................................................................ 19
9.1 Warnings .............................................................................................................. 19
9.2 Periodical checks .................................................................................................. 20
9.3 Repairing the cooling circuit .................................................................................. 22
9.4 Tightness test ....................................................................................................... 22
9.5 Hard vacuum and drying of cooling circuit ............................................................ 22
9.6 Recharging with refrigerant R407C....................................................................... 22
9.7 Environmental protection ...................................................................................... 23
10 Troubleshooting ....................................................................................................... 23

HF61GD0039F JREF-0-UM-GB_NEUTRALE 2
1 General Description
JREF “CCAC” self-contained units are specially designed for installation in technological environments such as
Computer rooms, laboratories and in general where a high precision in climate control and a 24h/day operation are
requested. JREF units represent the state of the art between technology and design as well as all our products: thanks to
their characteristics, JREF can be installed also in offices where people are working. The depth of 449 mm for ”C”
versions, allows the compatibility with standard offices furniture: furthermore the innovative design and the high tech
selected colours make JREF units complementary to the last generation of IT devices. The internal design of the units in
firstly made looking to efficiency and reliability but don’t loosing accessibility: all components, including e-heaters, fans,
compressors, valve, etc. can be maintained from the front and furthermore the door(s) are dismountable in just a few
seconds thanks to an innovative hinge: this is very important when units are installed in small corridors. The exclusive
use of primary brands components and a fully integrated development process (CAD + CAM, CAE) stands for highest
possible quality level regarding efficiency, reliability, maintenance time, pre and after sales support. All DX units are
available only in single circuit.

Fig. 1 DX version (Down / Up)

JADC unit JAUC unit

(Down-flow) (Up-flow)

6 6

1 7

7 8
2

2 8
1
9 9
3 3
10 10
4 11 4 11

5 5
12 12

1 Filter 8 Centrifugal fan

2 Electrical heaters 9 Thermostatic valve
3 Safety valve 10 Compressor
4 Liquid receiver 11 Sight glass
5 Humidifier 12 Filter dryer
6 Microprocessor control
7 Electrical panel

HF61GD0039F JREF-0-UM-GB_NEUTRALE 3
 Fig. 2 CW version (Down / Up)

JCDC unit JCUC unit

(Down-flow) (Up-flow)

4 4

1
5

6
5 2

2 6 1

7 7

8 8
3 3

1 Filter 5 Electrical panel

2 Electrical heaters 6 Centrifugal fan
3 Humidifier 7 Electrical valve actuator
4 Microprocessor control 8 3-way valve

1.1 Structure
JREF units are designed with a self supporting frame and all components are made inside using sophisticated computer
driven machines and special tools. All sheet metals are galvanized and all external panels are powder coated RAL 7016
giving to the units the image and the quality like last generation of IT devices. Units are completely closed and only
frontal access is requested. Anyway it is also possible to have side access in order to reach the steam piping and the
drain pan, or simply to substitute a damaged side panel: all this problems are very rare, but with JREF units it is possible
to solve them. The shape of the units is characterized with the rounded edges with R = 26,5 mm radium this feature is
obtained using special tools and gives both a good aesthetic and advantages against injuries. The compressor
compartment is separated from the air flow and the special internal design allows the simple dismounting of the upper
part of it ensuring an insuperable accessibility to all refrigerating components.
All fixing elements are made in stainless steel or in non corroding materials. The dray pan is made in stainless steel in
order to ensure long time operation without damages.
All panels are thermally insulated with a polyurethane foam class 1 according UL 94 norms: this material, thanks to the
open cells, gives good performances in sound absorption. As an option, sandwich panels are available: in this case
mineral fibres are closed between the panel and a second sheet of metal giving the maximum in terms of internal
cleaning. Double skin panels are classified between non flammable materials class A1 according DIN 4102 norms : the
sound insulation is better than the standard solution, but the internal reflected sound power will increase the amount in
delivery side (+2dB).

4 HF61GD0039F JREF-0-UM-GB_NEUTRALE
1.2 Field of application
All JREF units are to be used within the operating limits stated in this manual; failure to comply with said limits will
invalidate the warranties provided in the contract of sale (see Tab. 1, Tab. 2 and Fig. 3).
Tab. 1 Operating limits “DX version”
Power supply limits and storage conditions for “DX” version
Model JA . . . C
Power supply 230 Vac ±10 %
-10 °C / 90 % R.H.
Storage conditions
+55 °C / 90 % R.H.

Tab. 2 Operating limits “CW version”

Power supply limits and storage conditions for “CW” version
Model JC . . . C
Power supply 230 Vac ±10 %
-10 °C / 90 % R.H.
Storage conditions
+60 °C / 90 % R.H.

Fig. 3 Application limits

F
i JA . . . C JW . . . C JC . . . C
Air condensed versions Water condensed versions Chilled water versions
g
. R.H. ≤ 65% R.H. ≤ 65% R.H. ≤ 65%
°C °C °C
Indoor air temperature

Indoor air temperature

Indoor air temperature

3
32 32 32
28 28 27

18 18 20

20 40 45 °C 25 40 43 °C 5 7 16 °C
Condenser air temperature Condenser water temperature Chilled water temperature

1.3 Cooling circuit (DX version)

The entire refrigerating circuit is assembled in our warehouse including all pipe work and using only primary brand for
components. The workers involved in the welding and pipe work process are qualified by a third part according CEE
97/23 PED directive: it is worth to be underlined that this qualification for workers were not request, but it is our own
decision taking care of the quality and/or in general to the customer satisfaction. All DX unit (“A“, “W“, “F“, “D“, “Q“
versions) are in single circuit execution and are prechargerd with dry nitrogen for “A“, “D“ or with R407C refrigerant for
“W“, “F“, “Q“ versions.
Refrigerant different from R407C, like R22, R134a, R410A are available on request and previous check for local rules.
Compressors
On JREF units are installed only primary brand scroll compressors. Scroll compressor represent for CCAC units the best
solution in terms of efficiency and reliability. The internal compression ratio is very close to the typical operating condition
of CCAC giving the maximum in terms of COPs and the perfect balanced pressures at start up gives big advantages to
the e-motor in terms of reliability, mainly in this filed where frequent start up may be possible.
All motors are thermally protected with an internal sensors chain: in case of overload this sensor opens without giving
contacts to the connection box.
Cooling components
D Molecular mesh activated-alumina filter dryer.
D Flow indicator with humidity indicator. Indications are provided directly on the sight glass.
D Thermostatic valve with external equalization and integrated MOP function.
D High and low pressure switches.
D Schrader valves for checks and/or maintenance.

HF61GD0039F JREF-0-UM-GB_NEUTRALE 5
 Electric control board
The electric control board is constructed and wired in accordance with Directives 73/23/EEC and 89/336/EEC and
related standards. The board may be accessed through a door after the main switch has been put-off. All the remote
controls use 24 V signals powered by an insulating transformer situated on the electric control board.
Note: The mechanical safety devices such as the high pressure switch are of the kind that trigger directly; their
efficiency will not be affected by any faults occurring in the microprocessor control circuit, in compliance with
97/23 PED.
Microprocessor control
The microprocessor built into the unit allows the different operating parameters to be controlled from a set of push-
buttons situated on the electric control board:
D Switching On / Off of compressor to maintain the temperature set point T inside the shelter.
D Alarm management: - High / Low pressure;
- Dirty filters alarm;
- Air flow alarm.
D Alarm signalling.
D Display of operating parameters.
D RS232 or RS485 serial output management (optional).
D Phase sequence error (not displayed only by the mP, but prevents the compressor from starting up).

See microprocessor control manual for further details, also in relation to particular customer specifications.

Fig. 4 Basic cooling circuit (DX version)

1 Compressor
2 HP pressure switch
8 3 Pressure transmitter
4 Ball valve
M 5 Refrigerant filter
6 Sight glass
P 9 7 Thermostatic valve
8 Evaporating coil
7 9 LP pressure switch
6 10 Liquid receiver
1 11 Remote condenser
12 Flooding valve
13 Safety valve
5
14 Check valve
P 2

13
3
10

4 SUPPLY LIMIT 4

13

10

14 M

12
OPTIONAL 11

6 HF61GD0039F JREF-0-UM-GB_NEUTRALE
1.4 Hydraulic section (CW version)
3-way valve
The 3-way valve used on JREF CW version units for inlet water flow regulation allowing a foundamentally maximum
precision’s regulation on CCAC applications.
Tab. 3 Technical characteristics
Frame 1 Frame 2 Frame 3
Brand / valve’s type Controls VMT2 Controls VMT2 Controls VMBT3
Kvs valve (m3/h) 4 4 6.3
PN valve 16 16 16
∆P max. (kPa) 250 250 170
Connections (inch) 1/2” 1/2” 3/4”

All JREF CW units are supplied with 3-way valve setted by 3 points motor. Upon request, is possible to set an advanced
precision control with 0 ÷ 10 V signal regulation.
Air presence on hydraulic circuit
It is necessary to leak air from the hydraulic circuit of unit after the connection to the external circuit. To do this, open the
frontal panels and remove the air filter; after this, open the small valve on the right-top side of the coil’s collector (take the
front side of unit in reference). Use adapted tools for the manual valve’s setting.

Fig. 5 Basic cooling circuit (CW version)

2 1 2 1

4 M 4 M
3 7
6 6

5 5

Standard Opt. 2-way valve

Pos. Description Pos. Description

1 Chilled water inlet 5 Coil heat exchanger
2 Chilled water outlet 6 Breather valve
3 3-way valve 7 2-way valve (Opt.)
4 Plug fan -

HF61GD0039F JREF-0-UM-GB_NEUTRALE 7
1.5 Installation warnings
General rules
D When installing or servicing the unit, you must strictly follow the rules provided in this manual, comply with the
directions on the units themselves and take all such precautions as are necessary.
D The fluids under pressure in the cooling circuit and the presence of electrical components may cause hazardous
situations during installation and maintenance work.

All work on the unit must be carried out by qualified personnel only, trained to do their job in
accordance with current laws and regulations.

D Failure to comply with the rules provided in this manual or any modification made to the unit without prior
authorisation will result in the immediate invalidation of the warranty.

Before performing any kind of work on the unit, make sure it has been disconnected from the
power supply.

2 Inspection / Transport / Positioning

2.1 Inspection on receipt

On receiving the unit, check that it is perfectly intact: the unit left the factory in perfect conditions; immediately report any
signs of damage to the carrier and note them on the Delivery Slip before signing it. The factory or its Agent must be
promptly notified of the entity of the damage. The Customer must submit a written report describing every significant sign
of damage.

2.2 Lifting and transport

While the unit is being unloaded and positioned, utmost care must be taken to avoid abrupt or violent manoeuvres. The
unit must be handled carefully and gently; avoid using machine components as anchorages or holds and always keep it
in an upright position.
The unit should be lifted using the pallet it is packed on; a “transpallet” or similar conveyance means should be used.

Warning: In all lifting operations make sure that the unit is securely anchored in order to prevent
accidental falling or overturning.

2.3 Unpacking
The packing must be carefully removed to avoid the risk of damaging the unit. Different packing materials are used:
wood, cardboard, nylon etc.
It is recommended to keep them separately and deliver them to suitable waste disposal or recycling facilities in order to
minimise their environmental impact.

2.4 Positioning
Bear in mind the following aspects when choosing the best site for installing the unit and the relative connections:
D positioning and dimensions of the coupling flanges;
D location of power supply;
D solidity of the supporting floor.
It is recommended to first prepare holes in the floor/wall for passing through the power cables and for the air outlet (down
flow units).

The dimensions of the air outlet and the positions of the holes for the screw anchors and power cables are shown below.

8 HF61GD0039F JREF-0-UM-GB_NEUTRALE
 Fig. 6 Dimensions

1875

Front view Lateral view

B
A

Bottom view

Model A (mm) B (mm)

DX version
JADC0060 - JAUC0060
600 449
JADC0080 - JAUC0080

JADC0100 - JAUC0100
JADC0110 - JAUC0110 900 449
JADC0130 - JAUC0130

JADC0160 - JAUC0160
JADC0190 - JAUC0190 1200 449
JADC0205 - JAUC0205

JADC0132 - JAUC0132 900 449

JADC0162 - JAUC0162
1200 449
JADC0212 - JAUC0212
CW version
JCDC0080 - JCUC0080
600 449
JCDC0110 - JCUC0110
JCDC0140 - JCUC0140
900 449
JCDC0160 - JCUC0160

JCDC0200 - JCUC0200
1200 449
JCDC0230 - JCUC0230

HF61GD0039F JREF-0-UM-GB_NEUTRALE 9
2.5 Refrigerant connections
To connect angle valves with ODS connection to the piping,
you must use pipe belling and brazing, with a maximum
melting temperature of 750° C and a brazing alloy that is at
least 5% silver.
Before installation, make sure the valve is in the open position
and that plastic caps, if any, have been removed. During
soldering, protect the valve from being overheated by the
flame with a wet cloth or guard.

Diameters used:
• ANGLE VALVE ODS 12 mm
• ANGLE VALVE ODS 16 mm
• ANGLE VALVE ODS 18 mm
• ANGLE VALVE ODS 22 mm
• ANGLE VALVE ODS 28 mm

Please refer to the unit’s dimension drawings for connection

dimensions.

10 HF61GD0039F JREF-0-UM-GB_NEUTRALE
3 Installation
The JREF package air-conditioning unit is suitable for all environments except aggressive ones. Do not place any
obstacles near the units and make sure that the air flow is not impeded by obstacles and/or situations causing back
suction.

Fig. 7 Service area

MODEL A (mm) B (mm) C (mm) D (mm) E (mm)

DX version
JADC0060 - JAUC0060 600 650 449 30 1875
JADC0080 - JAUC0080 600 650 449 30 1875
JADC0100 - JAUC0100 900 650 449 30 1875
JADC0110 - JAUC0110 900 650 449 30 1875
JADC0130 - JAUC0130 900 650 449 30 1875
JADC0160 - JAUC0160 1200 650 449 30 1875
JADC0190 - JAUC0190 1200 650 449 30 1875
JADC0205 - JAUC0205 1200 650 449 30 1875
CW version
JCDC0080 - JCUC0080 600 650 449 30 1875
JCDC0110 - JCUC0110 600 650 449 30 1875
JCDC0140 - JCUC0140 900 650 449 30 1875
JCDC0160 - JCUC0160 900 650 449 30 1875
JCDC0200 - JCUC0200 1200 650 449 30 1875
JCDC0230 - JCUC0230 1200 650 449 30 1875

HF61GD0039F JREF-0-UM-GB_NEUTRALE 11
 The following steps should be carried out to ensure proper installation:
D Apply a anti-vibration rubber lining between the unit and the bottom.
D Positioning the unit on the floor / base frame.
D Further info to be added.
The recommended sizes for the power cables and emergency line are shown in the tables below:
Tab. 4 Electrical connections (JREF “CW”)
R (Radial) C (Centrifugal)
Model Power supply Cable type (*) Power supply Cable type (*)
JCDC0080
4 x 6 mm2 + T 6 mm2
JCDC0110 4 x 6 mm2 + T 6 mm2
JCDC0140
230V / 1Ph / 50Hz 230V / 1Ph / 50Hz
JCDC0160
2 2 4 x 10 mm2 + T 6 mm2
JCDC0200 4 x 10 mm + T 6 mm
JCDC0230

Tab. 5 Electrical connections (JREF “DX”)

R (Radial) C (Centrifugal)
Model Power supply Cable type (*) Power supply Cable type (*)
JADC0060
4 x 6 mm2 + T 6 mm2 4 x 6 mm2 + T 6 mm2
JADC0080
JADC0100
JADC0110 4 x 10 mm2 + T 6 mm2 4 x 10 mm2 + T 6 mm2
400V / 3Ph + N / 50Hz 400V / 3Ph + N / 50Hz
JADC0130
JADC0160
JADC0190 4 x 16 mm2 + T 6 mm2 4 x 16 mm2 + T 6 mm2
JADC0205

(*) Sections dimensioned for using cables made with PVC, line max. lenght = 100m

4 Evacuation and Charging Operations

This type of work must be carried out by qualified personnel only trained to do their job in accordance
with current laws and regulations.

4.1 Introductions
The contemporaneous presence of liquid and vapour requires for both to be in a state of saturation (Gibb’s law), as
shown in Fig. 8. In thermal equilibrated conditions, the pressure in the tank corresponds to the ambient temperature.
Withdrawal of refrigerant from the tank has following effects:
D .. withdrawal of refrigerant charge: .... ..... ..... pressure drop inside the tank;
D .. pressure drop inside the tank: ... .... ..... ..... T drop & change of status;
D .. T drop & change of status: .. ..... .... ..... ..... evaporation of part of the liquid, causing a cooling down of the liquid;
D cooling of liquid: thermal exchange with ambient air, further evaporation of remaining
liquid; the original pressure in the tank will be restored after a certain
period of time.
Fig. 8 Gibb’s law diagram

12 HF61GD0039F JREF-0-UM-GB_NEUTRALE
 T
P tank/ambient

Saturated gas

Saturated liquid

Enthalpy h

4.2 Full vacuum and charge of the unit

Vacuum cycle
In general it is better to apply a “long” rather than a “hard” vacuum: reaching a low pressure too abruptly may in fact
cause that any remaining humidity evaporates instantaneously, thus freezing part of it.
Fig. 9 Vacuum cycle diagram

P
[Pa]

150

200 s
Time

The Fig. 9 represents a vacuum cycle and an optimal subsequent pressure rise for the refrigeration devices we
manufacture. Generally in bigger refrigeration systems or if there is a suspicion of an extensive quantity of humidity in the
refrigeration circuit, the vacuum needs to be “broken” by using anhydrous nitrogen. Then the steps of evacuation need to
be repeated as described before. This operation facilitates the removal of remaining and/or frozen humidity during the
evacuation process.

4.3 Evacuating a circuit “contaminated” with refrigerant

The first step is to remove the refrigerant from the circuit. To do this a specific machine is necessary with a drying
compressor in order to recover the refrigerant.
Refrigerants all tend to dissolve in oil (compressor sump). The Fig. 10 illustrates a specific property (Charles’ Law) of
gases, which are more soluble in liquids as the pressure increases but less soluble as the temperature increases.
Fig. 10 Charles’ law diagram

T oil
Pressure T3

T2

HF61GD0039F JREF-0-UM-GB_NEUTRALE 13
 If the oil in the sump is held at a constant pressure, an increase in temperature will significantly reduce the amount of
refrigerant dissolved in it, thus ensuring that the lubricating function desired is maintained. The problem of inadequate
lubrication occurs if the crankcase is not duly heated, above all after seasonal interruptions when, due to the suction
effect of the compressor, there is an abrupt drop in pressure inside the sump, which results in considerable evaporation
of the refrigerant previously dissolved in the oil. If heating elements were not installed, this phenomenon would cause two
problems:
T1
1) The release of refrigerant from the cooling circuit tends to cool
down the oil and thus actually creates the opposite effect by keeping

more refrigerant dissolved in the oil: for this reason, it is advisable to switch
% di Refrigerant in oil
on -if available- the crankcase heater during the evacuation process.
2) If a high % of refrigerant gets in contact with the Pirani gauge (vacuum sensor), it may “mislead” this sensitive
sensor and misinterpret the value for a certain period of time. For this reason, if no machine for recovering
refrigerant is available, it is nonetheless advisable to switch on the crankcase heater and to avoid full vacuum
before the circuit has been adequately purged of refrigerant. The refrigerant may in fact dissolve in the oil of the
vacuum pump, reducing its performance for a long time (hours).

4.4 Charging positions (single point)

The best position to charge the unit is the section between the thermostatic valve and the evaporator. Take care to avoid
the fixing of the thermostat bulb until the operation is completed. It is important to ensure that the valve orifice remains
open in order to allow the passage of refrigerant also towards the condenser / liquid receiver.
If possible, avoid the charge of refrigerant into the suction line of the compressor as this may cause excessive dilution of
the lubricant. In any case verify first the necessary volume of the crankcase and compare it with the required charge
volumes.

5 Electrical Connections

5.1 Generalities

Before carrying out any job on electrical parts, make sure the power supply is disconnected.

Check that the mains electricity supply is compatible with the specifications (voltage, number of phases, frequency)
shown on the unit rating plate.
The power connection for single-phase loads is to be made with a three-pole cable and “N” wire at the centre of the star
(optional: power supply w/o neutral).

The size of the cable and line protections must conform to the specifications provided in the wiring
diagram.

The supply voltage may not undergo fluctuations exceeding ±10% and the unbalance between phases must always be
below 2%.

The above operating conditions must always be complied with: failure to ensure said conditions will
result in the immediate invalidation of the warranty.

The electrical connections must be made in accordance with the information shown in the wiring diagram provided with
the unit and with current and local regulations. An earth connection is mandatory. The installer must connect the
earthing wire using the earthing terminal situated on the electric control board (yellow and green wire).
The power supply to the control circuit is taken from the power line through an insulating transformer situated on the
electric control board.
The control circuit is protected by suitable fuses or automatic breakers depending on the unit size.

14 HF61GD0039F JREF-0-UM-GB_NEUTRALE
 When the motor runs independently due to air flowing through or if it continues to run down after
being turned off, dangerous voltages of over 50V can arise on the motor internal connections
through operation of the generator.

Even after disconnecting the mains voltage, life-threating charges can appear between the protective
ground “PE” and the mains connection. The protective earth is conducting high discharge currents
(dependent on the switching frequency, current source voltage and motor capacity). Earthing in
compliance with EN specifications shall therefore be observed even for testing and trial conditions
(EN 50 178, Art.5.2.11).

Regarding the differential protection that needs to be installed upstream, it is necessary to use a type A switch that is
sensitive to direct currents. It is mandatory for it to have the following features:

1. Calibratable operation threshold

2. Calibratable operation delay

HF61GD0039F JREF-0-UM-GB_NEUTRALE 15
6 Operating Diagrams
Fig. 11 Operating diagrams

JREF “DX" direct expansion unit

Mod. JADC Mod. JAUC Mod. JAXC

Downflow version Upflow version Displacement version

Return air
Conditioned air

7 Starting Up

7.1 Preliminary checks

D Check that the electrical connections have been made properly and that all the terminals are securely tightened. This
check should also be included in a periodic six-month inspection.
D Check that the voltage at the RST terminals is 400 V ± 5% and make sure the yellow indicator light of the phase
sequence relay is on. The phase sequence relay is positioned on the electric control board; if the sequence is not
duly observed, it will not enable the machine to start.
D Make sure there are no refrigerant leaks that may have been caused by accidental impacts during transport and/or
installation.
D Check the power supply to the crankcase heating elements, where present.

16 HF61GD0039F JREF-0-UM-GB_NEUTRALE
 The heating elements must be turned on at least 12 hours before the unit is started.
They are automatically activated when the main switch is put on. Their function is to raise the T of the
oil in the sump and limit the quantity of refrigerant dissolved in it.

To verify whether the heating elements are working properly, check the lower part of the compressors: it should be warm
or in any case at a temperature 10 - 15 °C higher than the ambient temperature.

Fig. 12 Charles’ law diagram

Pressure
T
Oil T3

T2

T1

% R407C in oil

The diagram above illustrates a specific property of gases (Charles’ Law), which are more soluble in liquids as the
pressure increases but less soluble as the temperature increases: if the oil in the sump is held at a constant pressure, an
increase in temperature will significantly reduce the amount of refrigerant dissolved in it, thus ensuring that the desired
lubricating function is maintained.

7.2 Starting operation

Before starting the unit, turn the main switch on, select the operating mode desired from the control panel and press the
”On” button on the control panel.
If the unit fails to start up, check if the service thermostat has been set according to the nominal values
provided.

You should not disconnect the unit from the power supply during periods when it is inoperative but
only when it is to be taken out of service for a prolonged period (e.g. at the end of the season).

7.3 Checks during operation

D Check the phase sequence relay on the control board to verify whether the phases occur in the correct sequence: if
they do not, disconnect the unit from power supply and invert two phases of the incoming three-pole cable.
Never attempt to modify internal electrical connections: any undue modifications will immediately invalidate the
warranty.

7.4 Checking the refrigerant level (DX version)

D After a few hours of operation, check whether the liquid level indicator has a green ring: a yellow colour indicates the
presence of humidity in the circuit. In such a case the circuit must be dehumidified by qualified personnel.
D Large quantities of bubbles should not appear through the liquid level indicator. A constant passage of numerous
bubbles may indicate that the refrigerant level is low and needs to be topped up. The presence of a few bubbles is
however allowed, especially in the case of high-glide ternary mixtures such as HFC R407C.
D Make sure the overheating of the cooling fluid is limited to between 5 and 8 °C: to this end:
1 ) read the temperature indicated by a contact thermometer placed on the compressor intake pipe;
2) read the temperature indicated on the scale of a pressure gauge likewise connected to the intake side; refer to
the pressure gauge scale for the refrigerant R407C, marked with the initials D.P. (Dew Point).
The degree of overheating is given by the difference between the temperatures thus determined.
D Make sure that the Sub-cooling of the cooling fluid is limited to between 3 and 5°C: to this end:

HF61GD0039F JREF-0-UM-GB_NEUTRALE 17
 1) read the temperature indicated by a contact thermometer placed on the condenser outlet pipe;
2) read the temperature indicated on the scale of a pressure gauge connected to the liquid inlet at the condenser
outlet; refer to the pressure gauge scale for the refrigerant R407C, marked with the initials B.P. (Bubble Point).
The degree of Sub-cooling is given by the difference between the temperatures thus determined.

Warning: All JREF units are charged with dry nitrogen and you must empty them before charging
with refrigerant.

Warning: Any top-ups must be made using R407C only. This operation is to be considered
extraordinary maintenance work and must be performed by qualified personnel only.

Warning: The refrigerant R407C requires “POE“ polyolester oil of the type and viscosity indicated
on the compressor rating plate.
For no reason should oil of a different type be introduced into the oil circuit.

Real P
compressor Average T
outlet (T1+T2)/2
P

T1 (start of
condensation)
T2 (end of condensation)
BUBBLE POINT
R407C

Heat content h

The difference between the “Dew Point” and “Bubble Point” is known as “GLIDE” and this is a characteristic property of
refrigerant mixtures. If pure fluids are used, the phase change occurs at a constant T and thus the glide is equal to zero.

8 Operating Parameters Setting

8.1 Generalities
All the control devices are set and tested in the factory before the unit is dispatched. However, after the unit has been in
service for a reasonable period of time you can perform a check on the operating and safety devices.
The settings are shown in Tab. 6 and Tab. 7.

All servicing of the equipment is to be considered extraordinary maintenance and may be carried out
BY QUALIFIED TECHNICIANS ONLY: incorrect settings may cause serious damage to the unit and
injuries to persons.

18 HF61GD0039F JREF-0-UM-GB_NEUTRALE
 The operating parameters and control system settings configurable by means of the microprocessor control are
password protected if they have a potential impact on the integrity of the unit.
Tab. 6 Setting of control devices
Control device Set point Differential
Differential air pressure switch (outlet air flow) Pa 50 30
Differential air pressure switch (dirty filter) Pa 50 20
Values to be calibrated depending on the application.

Tab. 7 Setting of safety-control devices

Control device Activation Differential Resetting
Maximum pressure switch Bar 28.0 4.0 Manual
Minimum pressure switch Bar 2.0 1.5 Automatic
Modulating condensation control device Bar 14.0 7.0 -
Time lapse between two compressor starts s 480 - -

8.2 Maximum pressure switch

The high pressure switch stops the compressor when the outlet pressure exceeds the set value.

Warning: Do not attempt to change the setting of the maximum pressure switch: Should the latter
fail to trip in the event of a pressure increase, the pressure relief valve will open.

The high pressure switch must be manually reset; this is possible only when the pressure falls below the set differential
(see Tab. 7).

8.3 Minimum pressure switch

The low pressure switch stops the compressor when the inlet pressure falls below the set value for more than 180
seconds. The switch is automatically reset when the pressure rises above the set differential (see Tab. 7).

9 Maintenance
The only operations to be performed by the user are to switch the unit On and Off.
All other operations are to be considered maintenance work and must thus be carried out by qualified personnel trained
to do their job in accordance with current laws and regulations.

9.1 Warnings

All the operations described in this chapter MUST ALWAYS BE PERFORMED BY QUALIFIED
PERSONNEL ONLY.

Before carrying out any work on the unit or accessing internal parts, make sure you have
disconnected it from the mains electricity supply.

The upper part and the outlet pipe of the compressor reach high temperatures. Be especially careful
when working in the surrounding area with the panels off.

Be especially careful when working in proximity to finned coils since the 0.11 mm thick aluminium fins
can cause superficial injuries due to cuts.

After completing maintenance jobs, always replace the panels enclosing the units and secure them
with the fastening screws provided.

HF61GD0039F JREF-0-UM-GB_NEUTRALE 19
9.2 Periodical checks
To guarantee a constantly satisfactory performance over time, it is advisable to carry out routine maintenance and
checks as described below. The indications below are related to standard tear and wear.
Tab. 8 Periodical checks
Operation Frequency
Check the efficiency of all the control and safety devices. Once a year
Check the terminals on the electric control board and compressor terminal boards to ensure that they are
securely tightened. The movable and fixed contacts of the circuit breakers must be periodically cleaned and Once a year
replaced whenever they show signs of deterioration.
Check the refrigerant level by means of the liquid level indicator. Every 6 mos.
Check the efficiency of the differential air pressure switch and dirty filter differential pressure switch. Every 6 mos.
Check the condition of the air filter and replace it if necessary. Every 6 mos.
Check the humidity indicator (green = dry, yellow = humid) on the liquid level indicator; if the indicator is not
Every 6 mos.
green as shown on the indicator sticker, replace the filter.

20 HF61GD0039F JREF-0-UM-GB_NEUTRALE
 Fig. 13 Inspecting the air filter

“Down-Flow" version

Air filter

“Up-Flow" version

Air filter

Remove the panel above the evaporator fan to access the damper and air filter compartment.
Pull out the air filter.
Check the condition of the filter and replace it if necessary.

HF61GD0039F JREF-0-UM-GB_NEUTRALE 21
9.3 Repairing the cooling circuit

Warning: While performing repairs on the cooling circuit or maintenance work on the
compressors, make sure the circuit is left open for as little time as possible. Even if
briefly exposed to air, ester oils tend to absorb large amounts of
humidity, which results in the formation of weak acids.

If the cooling circuit has undergone any repairs, the following operations must be carried out:
D tightness test;
D evacuation and drying of the cooling circuit;
D charging with refrigerant.

If the system has to be drained, always recover the refrigerant present in the circuit using suitable
equipment; the refrigerant should be handled exclusively in the liquid phase.

9.4 Tightness test

Fill the circuit with anhydrous nitrogen supplied from a tank with a pressure-reducing valve until the pressure rises to 22
bars.

During the pressurisation phase, do not exceed a pressure of 22 bars on the compressor low pressure
side.

The presence of any leaks must be determined using special leak detectors. Should any leaks be detected during the
test, empty out the circuit before repairing the leaks with suitable alloys.

Do not use oxygen in the place of nitrogen as a test agent, since this would cause a risk of explosion.

9.5 Hard vacuum and drying of cooling circuit

To achieve a hard vacuum in the cooling circuit it is necessary to use a pump capable of generating a high degree of
3
vacuum, i.e. 150 Pa of absolute pressure with a capacity of approximately 10 m /h. If such a pump is available, one
evacuation will normally suffice to achieve an absolute pressure of 150 Pa.
If there is no such vacuum pump available, or whenever the circuit has remained open for long periods of time, you are
strongly recommended to adopt the triple evacuation method. This method is also recommended when there is a
presence of humidity within the circuit. The vacuum pump should be connected to the inlets.
The procedure to be carried out is as follows:
D Evacuate the circuit until you reach an absolute pressure of at least 350 Pa: at this point inject nitrogen into the circuit
until you reach a relative pressure of about 1 bar.
D Repeat the step described above.
D Carry out the step described above for the third time, but in this case attempting to reach the hardest vacuum
possible.
Using this procedure you can easily remove up to 99% of pollutants.

9.6 Recharging with refrigerant R407C

D Connect the tank of refrigerant gas to the male 1/4 SAE inlet situated on the liquid line after discharging a little gas to
eliminate air in the connection pipe.
D Fill with refrigerant in liquid form until you reach 75% of the total charge.
D Then connect to the inlet on the pipe between the thermostatic valve and evaporator and complete the charging
process with the refrigerant in liquid form until no more bubbles can be seen on the liquid level indicator and the
operating parameters specified in section 8 have been reached.

Since R407C is a ternary mixture, charging must take place exclusively with liquid refrigerant to
ensure the correct percentages of the three constituents. Introduce refrigerant through the inlet in the
liquid line.

22 HF61GD0039F JREF-0-UM-GB_NEUTRALE
 A unit that was originally charged with R407C in the factory must not be charged with R22 or other
refrigerants without the written authorisation of factory.

9.7 Environmental protection

The law implementing the regulations (reg. EEC 2037/00) which govern the use of ozone-depleting substances and
greenhouse gases bans the dispersal of refrigerant gases in the environment and requires whoever is in their possession
to recover them and, at the end of their useful life, either to return them to the dealer or take them to a suitable waste
disposal facility.
The refrigerant HFC R407C is not harmful to the ozone layer but is included among the substances responsible for the
greenhouse effect and thus falls within the scope of the aforesaid regulations.

Therefore, special care should be taken when carrying out maintenance work to minimise refrigerant
leaks.

10 Troubleshooting
On this pages you will find a list of the most common reasons that may cause the package unit to fail or any malfunction.
This causes are broken down according to easily identifiable symptoms.

You should be extremely careful when attempting to implement any of the possible remedies
suggested: overconfidence can result in injuries, even serious ones, to inexpert individuals.
Therefore, once the cause has been identified, you are advised to contact the manufacturer or a
qualified technician for help.

Tab. 9 Fault-Causes-Corrections
FAULT POSSIBLE CAUSES CORRECTIVE ACTIONS
Check if power is being supplied both to the primary and auxiliary
No power supply.
circuits.
The electronic card is cut off from the
Check the fuses.
power supply.
The unit does not start
Check whether any alarms are signalled on the microprocessor
Alarms have been released.
control panel, eliminate the causes and restart the unit.
Invert two phases in the primary power line after disconnecting them
The phase sequence is wrong.
upstream from the unit.
The compressor is The compressor is rotating in the Check the phase sequence relay. Invert the phases on the terminal
noisy wrong direction. board after disconnecting the unit and contact the manufacturer.
Check for the presence of obstructions in the condenser section
Insufficient airflow through the ventilation circuit.
condenser. Check whether the condenser coil surface is obstructed.
Check the condensation control device (optional).
Presence of air in the refrigerant
Drain and pressurise the circuit and check for leaks. Evacuate
circuit, as revealed by the presence of
Presence of abnormally slowly (for more than 3 hours) until reaching a pressure of 0.1 Pa
bubbles in the flow indicator also with
high pressure and then recharge in the liquid phase.
sub-cooling values exceeding 5 °C.
Unit overcharged, as revealed by a
Drain the circuit.
Sub-cooling of more than 8 °C.
Thermostatic valve and/or filter
obstructed. These symptoms may Check the temperatures upstream and downstream from the valve
also occur in the presence of an and filter and replace them if necessary.
abnormally low pressure.
Low condensation
Transducer fault. Check the efficiency of the condensation control device (optional).
pressure
Warming the bulb with your hand, check whether the valve opens
Malfunctioning of thermostatic valve.
and adjust it if necessary. If it does not respond, replace it.
Pressure drops upstream and downstream from the filter should not
Filter dryer clogged.
Low evaporation exceed 2°C. If they do, replace the filter.
pressure Check the efficiency of the condensation control device (where
Low condensation temperature.
present).
Check the refrigerant level by measuring the degree of Sub-cooling;
Low level of refrigerant.
if it is below 2°C replenish the charge.

HF61GD0039F JREF-0-UM-GB_NEUTRALE 23
 The internal thermal protection device In the case of compressors equipped with a protection module,
has tripped. check the thermal contact. Identify the causes after restarting.
The circuit breakers or line fuses have Pinpoint the cause by measuring the resistance of the individual
The compressor been tripped by a short circuit. windings and the insulation from the casing before restoring power.
does not start One of the HP or LP pressure
Check on the microprocessor, eliminate the causes.
switches has tripped.
The phases have been inverted in the
Check the phase sequence relay.
distribution compartment.
Air in the cooling circuit During external connections. Open the valve positioned on the right side over the top of the coil.
Open the front panels, remove the sheet metal just below the e-
The drain pan hole is closed.
panel (down flow units) and clean it.
Water out from the unit
The siphon is missing. Check for the presence and provide for a new one.
The air flow is too high. Reduce the fan speed up to reaching the nominal air flow.

24 HF61GD0039F JREF-0-UM-GB_NEUTRALE
HF61GD0039F JREF-0-UM-GB_NEUTRALE 25
26 HF61GD0039F JREF-0-UM-GB_NEUTRALE
 MANUFACTURED BY

All rights reserved. No part of this publication may be reproduced without prior written permission from HiRef S.p.A.HiRef
S.p.A. reserves the right to make changes in specifications and other information contained in this manual without prior notice.
In no event shall HiRef S.p.A be liable for any incidental, special, indirect, or consequential damages whatsoever, including but
no limited to lost profits, arising out of or related to this manual or the information contained herein, even if Hiref S.p.A.has
been advised of, known, or should have known, the possibility of such damages.

HF61GD0039F JREF-0-UM-GB_NEUTRALE 27