iTrack EGO Series User manual
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Installation, operation and maintenance manual
Cooling units for door or wall mounting
ATTENTION!
Read carefully and completely before installation. Keep the manual until unit decommissioning.
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1. Cooling unit application 3
1.1 Intended use 3
1.2 Improper use 3
2. Supply 3
3. Updates 3
4. Technical features 4
5. Transport and handling 4
6. Installation 4
7. Condensate discharge hose 4
8. Electrical connection 4
8.1 Safety 4
8.2 Two-phase models with autotransformer 4
8.3 Alarm pins 5
9. First start up and adjustment 5
9.1 Electronic thermostat 5
9.1.1 Setting the set point 5
10. Maintenance 5
11. Technical information 5
11.1 Operating principle 5
11.2 Safety devices 6
11.3 Disposal 6
12. Troubleshooting 6
13. Pictograms 7
14. Technical data 9
15. Performances 10
16. Dimensions 12
17. Spare parts 14
18. Wiring diagram 17
19. Guarantee 18
20. Assistance service 18
ENG
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1. Cooling unit application
The EGO series cooling units described in this manualare designed and built to cool the air inside electrical switchboards
in order to protect components sensitive to thermal sh ock. They also provide IP54 ingress protection against
contaminating and aggressive/corrosive substances.
1.1 Intended use
The EGO cooling unit must be used:
- For cooling electrical switchboards
- Within the temperature and voltage-supply limits indicated on the data plate (F.06, pos. 5) of the cooling unit and also
given in table F.14 of this manual
- Away from any sources of heat or hot air
- In an environment with adequate air exchange
- On switchboards with IP54 rating or higher. If these requirements are not respected, excessive condensation build-up
may occur. As a consequence, cable entry points or any other openings in the cabinet should be well sealed. To ensure
correct operation, the specified scheduled maintenance operations (see section 10) must be performed regularly.
Incorrect or careless use may cause irreparable damage to the cooling unit and may lead to hazardous situations.
1.2 Improper use
The EGO cooling unit must NOT be used:
- Under any condition except those described in section 1.1
- Outdoors, with excessive concentration of solid contaminants and/or aggressive chemical contaminants
- With the doors of the electrical switchboard open, or installed on enclosures without a minimum IP54 rating, due to
excessive condensate formation
- With the temperature set below the dew point of the ambient air
- In explosive atmospheres, or those with aggressive chemicals or high concentrations of dust or oil suspended in the
air
- In potentially inflammable atmospheres
- Exposed to the elements
- With the condensate line closed or blocked off, or in any case in which the condensate is not allowed to run off freely
- Without the front panel
- With the cooling unit intake and outlet air flows obstructed by walls or objects that are too close To this end, check
the minimum distances as regards the external air flow (figure F.02), and make sure there are no obstructions caused
by the switchboard components as regards the internal air flow.
2. Supply
Inside the packaging you will find:
1 Cooling unit
1 Electronic thermostat
1 Installation, operation and maintenance manual
1 CE conformity certificate
1 Test certificate
1 A4 drilling template (F.06, p.4)
1 Installation kit containing (F.06):
- Flanged nuts (p.1)
- Flat washers (p.2)
- Grub screws (p.3)
2 Connectors, one for the power supply and one for the signals (F.5)
1 Self-adhesive sealing strip (F.06, p.4)
1 Flexible hose for condensate drainage 12x2x100 mm (F.10) Lifting eyebolts (F.03)
3. Updates
ITRack S.r.l. reserves the right to update its products and the corresponding manuals based on technical progress
without prior notice. Please note that at the time of sale, this manual and the corresponding product may not be
considered inadequate only because they are not subject to the above-mentioned updates.
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4. Technical features
(figures F. 14 and F. 15)
The unit’s technical features and CE marking are given on the data plate attached to the cooling unit.
5. Transport and handling
During transport and storage the cooling unit must be kept in a vertical position, as indicated on the packaging (figure
F.01), and must not be exposed to temperatures above 70°C or below -20°C. Upon receipt, check that the packaging has
not been damaged during shipping. To lift the cooling unit in a safe manner the two supplied M6 eyebolts may be used;
these should be fitted into the threaded inserts located on the top of the cooling unit (figure F.03).
6. Installation
Installation of the unit should only be performed by qualified and authorised personnel. The cooling unit must be
installed with the enclosure air intake hole in the highest possible point. Ensure the fixing elements and couplings will
not interfere with the equipment inside the enclosure itself. If the cooling unit is to be installed on a door, make sure
the door can take the weight. The unit must be installed in the vertical position indicated. Maximum permitted deviation
from the vertical is 2°. Disconnect power before starting any work inside the switchboard. The cooling unit must be
installed on the outside of the electrical switchboard. If semi-recessed installation is required (fig. F.06), the
corresponding accessory must be used. This is available upon request as an optional extra. Depending on the installation
option, drill the holes and make the necessary cuts in the switchboard (figure F.06) using the drilling template supplied
with the unit. Fit the sealing strip on the cooling unit on the side connected to the enclosure and follow the assembly
diagram (figure F.06).
7. Condensate discharge hose
The condensate which, depending on the ambient temperature and humidity conditions, forms on the heat exchanger
which cools the enclosure air, is not a malfunction but a normal phenomenon of the cooling unit. In models EGO04-
EGO06, this condensate is taken outside through a hose at the bottom of the cooling unit. The transparent plastic hose,
supplied with the unit, must be connected to this outlet (figure F.10). This plastic hose can be connected to another one
with the same diameter to carry the condensate to another point, allowing it to be discharged where there can be no
slipping hazard for personnel. In this case, make sure the condensate flows without any hindrance. Avoid horizontal
lengths of more than 0.5 metres, uphill sections and the accidental formation of traps (figure F.07). The end of the
condensate discharge hose must always be free and not underwater, so never place the end of the discharge hose inside
a condensate collection container (figure F.08). Models EGO08 to EGO40 are fitted with a condensate evaporation
device which operates via the hot (outlet) tube of the compressor (Fig. F.13). These models nevertheless have an
emergency condensate outlet which can be carried outside as described above. If the cooling unit is used with the doors
of the enclosure open, excessive quantities of condensate will form and this is an unauthorised condition of use (figure
F.09). We suggest using a position switch on the door connected to the cooling unit’s digital input to stop the unit if the
door is opened. (See section 8.3)
8. Electrical connection
8.1 Safety
Warning! Electrical connections must only be performed by specialised and authorised personnel. Switch power off
to the enclosure before making the connection. Check that there is no power to the switchboard and that the supply
voltage corresponds to the characteristics given on the cooling unit’s data plate. The power supply must be protected
using appropriate time-delay fuses (type T) or circuit breakers with K-curve, per the indications given in table F.14.
Connect the power-supply cables to the black connector included with the unit, following the indications given in figure
F.04. Disconnect the cooling unit before performing testing on the enclosure.
8.2 Two-phase models with autotransformer
(EGO06G / EGO08G / EGO10G / EGO12G /EGO16G)
These two-phase models can operate with two different supply voltages: 440V 2~50-60Hz and 400V 2~50-60Hz. If the
available power supply is 440V 2~50-60Hz, connect terminals L1(0) and L3(440) on the terminal board (figure F. 04). If,
on the other hand, the available supply voltage is 400V 2~50-60Hz, connect terminals L1(0) and L2(400) on the same
terminal board.
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(EGO10K / EGO16K)
These two-phase models can operate with two different supply voltages: 460V 2~50-60Hz and 400V 2~50-60Hz. If the
available power supply is 460V 2~50-60Hz, connect terminals L1(0) and L3(460) on the terminal board (figure F. 04). If,
on the other hand, the available supply voltage is 400V 2~50-60Hz, connect terminals L1(0) and L2(400) on the same
terminal board.
8.3 Alarm pins
(figure F.05)
All input/output signals from the electronic control unit are managed via the grey pin:
- Alarm signals from the electronic control unit can be taken from terminals 1 and 2
- A digital input for voltage free contacts is available on terminals 3 and 4
The cooling unit’s electronic control unit is programmed to generate an alarm when the digital input is open. When the
digital input is not being used, it is therefore necessary to bridge it by connecting terminals 3 and 4 of the grey pin
together with a cable.
9. First start up and adjustment
If, prior to installation, the cooling unit was left in an incorrect position (figure F.1), wait at least 8 hours before switching
it on. Otherwise, 30 minutes is more than enough time for the oil to return to the compressor, after which the cooling
unit can be powered up. The enclosure air intake fan starts working immediately, making the temperature inside the
enclosure even. If this temperature exceeds 2K above the set point, both the compressor and external air fan will turn
on, causing the cooling cycle to start. This then stops when the inside temperature reaches the set point. The thermostat
is factory-set to 35°C. The set point can be set to between 20°C and 50°C. In order to save energy and minimise the
production of condensate, it is nevertheless recommended it not be set below 30 °C.
9.1 Electronic thermostat
9.1.1 Setting the set point
The cooling unit is fitted with a TX050 electronic thermostat. See the specific manual C17000199 included with the unit
for the functions of this thermostat and how to program it. ITRack S.r.l. shall be in no way heldliable for any alterations
the customer may make to the default parameters if they have not received authorisation to do so.
10. Maintenance
Warning! Caution! Before embarking on any maintenance work, cut the current to the enclosure.
Job
Frequency
Check the external air heat exchanger and clean if necessary.
Every 3 months
Check effectiveness of the condensate discharge.
Every 3 months
Check the fans for any overheating or excessive vibrations.
Every 6 months
The cooling unit is the low maintenance type, sono filter change is required. The only maintenance required is for the
internal components, which should be checked regularly, as indicated in the table given in this section, and cleaned with
compressed air at a maximum pressure of 4 bar (figure F.11). Any repairs that may need doing must only be performed
by specialised and authorized personnel.
11. Technical information
11.1 Operating principle
The cooling unit for electrical switchboard enclosures works on the basis of a refrigeration circuit consisting of four main
components: compressor, evaporator, condenser and expansion device (figure F.12). The circuit is hermetically sealed
and the refrigerant circulates inside it. The refrigerant used is R134a, chlorine free and harmless for the ozone layer.
The unit is divided into two hermetically separated sections where the ambient air and enclosure air do not come into
contact with one another and are treated separately. The compressor (CP) compresses the refrigerant, taking it to a
high pressure and high temperature. The compressor then pushes the refrigerant through a heat-exchanger coil, called
the condenser (C), where it is cooled by ambient air, thus passing from the gas to the liquid state. In the liquid state it
then passes through the expansion valve (EXP), vaporising at the outlet as it is now at a much lower pressure. It is then
received by the heat exchanger coil, called the evaporator (E), by means of which it absorbs heat from the enclosure air
and passes from a liquid state to gas. The enclosure is cooled down in this manner. The gaseous refrigerant is then
drawn back into the compressor and this cycle is repeated.
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11.2 Safety devices.
The refrigeration circuit is fitted with a high-pressure safety switch P (figure F.12) set to the maximum working pressure
of the cooling unit. If this threshold is exceeded, the pressure switch stops the compressor working. It resets
automatically. The fans and compressor have an (internal or external) thermal cut-out switch that stops them in the
case of overheating.
11.3 Disposal
Caution! The cooling unit contains R134a refrigerant and small quantities of lubricating oil. These are polluting
substances and must not be dumped. Replacement, repairs and final disposal must be performed by experts.
NOTE
Keep the unit’s documentation in a safe, dry place.
12. Troubleshooting
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13. Pictograms
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13. Pictograms
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14. Technical data F.14
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15. Performances F.15
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