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1. Cooling unit application
The FLY series cooling units described in this manual
are designed and built to cool the air inside electrical
switchboards in order to protect components sensitive
to thermal shock. They also provide IP55 ingress pro-
tection against contaminating and aggressive/corrosive
substances.
1.1 Intended use
The FLY cooling unit must be used:
- For cooling electrical switchboards
- Within the temperature and voltage-supply limits
indicated on the data plate of the cooling unit and
also given in table F.15 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 condensa-
tion build-up may occur. As a consequence, cable en-
try 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 per-
formed regularly.
Incorrect or careless use may cause irreparable da-
mage to the cooling unit and may lead to hazardous
situations.
1.2 Improper use
The FLY cooling unit must NOT be used:
- Under any condition except those described in sec-
tion 1.1
- Outdoors, with excessive concentration of solid
contaminants and/or aggressive chemical contami-
nants
- 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 su-
spended 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 ob-
structed by walls or objects that are too close To this
end, check the minimum distances as regards the
external air flow (figure F.09), and make sure there
are no obstructions caused by the switchboard com-
ponents as regards the internal air flow.
2. Supply
Inside the packaging you will find:
1 Cooling unit
1 Electronic thermostat manual
1 Installation, operation and maintenance manual
1 CE conformity certificate
1 Test certificate
1 A4 drilling template
1 Installation kit containing (F.05 and F.03):
- 8 M6 flanged nuts (F.05, p.6)
- 8 M4X12 screws (F.03, p.3)
2 Connectors, one for the power supply and one
for the signals (F.06 and F.07)
1 Mounting frame with gasket (figure F.05, p.7)
1 Flexible hose for condensate drainage 12x2x100
mm (figure F.14, p.8)
2 Lifting eyebolts (F.02)
1 Earth cable
4 Reinforcement profile sections (figure F.03, p.5)
3. Updates
Pavarini Components 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 ina-
dequate only because they are not subject to the
above-mentioned updates.
4. Technical features
(figures F.15 and F.16)
The unit's technical features and CE marking are gi-
ven on the data plate attached to the cooling unit (figu-
re F.05, p.9). The identification plate (which includes
the serial number) is located on the rear of the cooling
unit. Another plate is located inside the cooling unit,
under the cover.
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. The
packaging must not have been damaged during
transport (no wear and tear, rips, scratches, oil
stains etc.). The package must be checked upon
reception to ensure it is undamaged. Any damage
found must be noted on the delivery note.
To lift the cooling unit in a safe manner the two sup-
plied M6 eyebolts may be used; these should be
fitted into the threaded inserts located on the top of
the cooling unit (figure F.02).
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 movable frame
supplied with the cooling unit allows it to be installed
on the exterior of the electrical switchboard (exter-
nal installation), on the interior (internal installation),
or semi-recessed (semi-recessed installation), as
shown in figures F.05 and F.17. Select the required
frame position (recessed, semi-recessed or exter-
nal) (figure F.03). Fasten the unit's frame using all
the M4 screws: 4 screws are pre-installed, while
8 are found inside the assembly kit. Drill the holes
and make the necessary cuts in the enclosure (fi-
gure F.05) using the drilling template supplied with
the unit. Use appropriate PPE (personal protective
equipment) to avoid personal injury. Loosen the
screws on the cooling unit support brackets (figure
F.04) without removing them. To lift the cooling unit
safely, use the two M6 lifting eyebolts on the up-
per part of the unit (figure F.02). Use only the lifting
accessories supplied with the product. For cooling
units weighing over 15 kg, two people should under-
take any lifting operations. The maximum recom-
mended weight per person is 15 kg max. Fasten
the cover on the front section with the two screws.
Remove the two screws on the rear panel. Keep
the cooling unit balanced during lifting operations.
Avoid knocks and impacts. These could damage
the product. Fasten the reinforcement profile sec-
tions according to the tightening torques given in
figures F.03 and F.05.
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 co-
oling unit.
The cooling unit is equipped with a condensate
evaporation device which uses the hot (delivery)
tube of the compressor (figure F.14), and has an
emergency discharge which can be taken outside
6
the unit.
The transparent plastic hose, supplied with the u-
nit, 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.
If the cooling unit is used with the doors of the enclosu-
re open, excessive quantities of condensate will form
and this is an unauthorised condition of use (figure
F.10). 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 8.4)
8. Electrical connection
8.1 Safety
Warning! Electrical connections must only be per-
formed 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 ap-
propriate time-delay fuses (type T) or circuit breakers
with K-curve, per the indications given in table F.15.
Connect the power-supply cables to the black con-
nector included with the unit, following the indications
given in figure F.06. Disconnect the cooling unit before
performing testing on the enclosure.
8.2 Two-phase models with autotransformer
(FLY11K / FLY15K)
These two-phase models can operate with two dif-
ferent 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.06). 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 Three-phase models
(FLY20H / FLY25H / FLY32H)
Three-phase models with 460V 3~ 60 Hz power
supply can also be powered with a 400V 3~ 50 Hz
supply by modifying the connection of the cables to
the internal terminal block as show in figure F.08.
8.3 Alarm pins
(figure F.07)
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 program-
med 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 ter-
minals 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.01), wait at least 8
hours before switching it on. Otherwise, 30 mi-
nutes is more than enough time for the oil to re-
turn to the compressor, after which the cooling u-
nit can be powered up. The enclosure air intake
fan starts working immediately, making the tempe-
rature inside the enclosure even. If this temperatu-
re exceeds 2K above the set point, both the com-
pressor 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 ther-
mostat is factory-set to 35°C. The set point can be
set to between 20°C and 50°C. In order to save e-
nergy and minimise the production of condensa-
te, it is nevertheless recommended it not be set be-
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