High temperature air-to-water heat pumps

Transcription

1 Designed to replace conventional boilers and produce domestic hot water 4 High temperature hot water (+65 C) 4 Winter operation (-20 C) 4 High energy efficiency (CP) 4 Compact and quiet 4 Scroll compressors 4 Self-adjusting electronic control Water outlet temperature +65 C at -12 C Heating capacity: 25 to 48 kw ENVIRNMENTALLY HFC R407C PRTECTIN DE FRIENDLY L'ENVIRNNEMENT 65 High temperature Heating Hydraulic module Use n The AQUACIAT CALE TDC series of air-to-water packaged hot water producers, using outside air, are hot water production machines specially adapted to heating applications for new or renovated office, healthcare and residential premises. n These packaged units are specifically designed for outdoor installation and require no special protection from adverse weather, apart from frost protection available, if required, as an option. n To operate in HEATING mode, the AQUACIAT CALE uses outside air as the sole thermal energy source for heating during winter. Connected to high temperature static radiators, an underfloor heating system or fan coil units, it produces hot water at +65 C at an outdoor temperature of -12 C which allows existing buildings to be heated with the greatest of ease. Range AQUACIAT CALE TDC series HEATING only model with hydraulic system (circulation pump) Four sizes available: n Connected to a domestic hot water (DHW) production system with buffer tank capacity, it also allows for complete autonomy of the domestic hot water and conventional heating system, whilst guaranteeing comfort and considerable energy savings. n The AQUACIAT CALE can therefore be used to replace a conventional boiler over a large part of the season during which heating is required. n Each machine is fully assembled, electrically wired (control and power), loaded with refrigerant and tested in the factory. n Installation is simple, and all that is required on site is a mixing tank with several nozzles (optional), and the electrical and hydraulic connections. TDC 80Z: 25 kw TDC 100Z: 35 kw TDC 120Z: 43 kw TDC 150Z: 48 kw 1

2 Description High temperature air-to-water heat pumps The AQUACIAT CALE is only available in a HEATING NLY model, and in TDC hydraulic version as standard, with a single pump. The standard equipment includes the following components: - EVI (enhanced vapour injection) scroll compressor - exchanger/evaporator using outside air ventilated by an axial fan motor assembly, - stainless steel condenser for hot water production, - self-contained hydraulic circuit comprising a circulation pump, an expansion vessel and a safety valve, - power control on the hot water via a CIAT MICRCNNECT remote control electronic module, linked by a two-wire connection, - control, start-up and power supply electrics box:. electrical supply: 3 50Hz 400V (+6%/-10%) + earth. control circuit: 1 50 Hz V (400/230V transformer fitted as standard on the machine), - casing for outdoor installation. n Complies with European EC directives - LW VLTAGE directive (LVD), /42/EC machines - EMC 89/336/EEC electromagnetics - PED 97/23/EEC pressure equipment: n Complies with standards - EN , EN and C Description TDC 150Z R407C refrigerant unit size hydraulic version with pump D: AQUACIAT family HEATING only heat pump Sizes 80 to 150 2

3 Technical data - Heat pumps AQUACIAT CALE TDC 80Z 100Z 120Z 150Z Net heating capacity (1) kw Net power input kw CP performances (3) Heating capacity (2) kw Power input kw CP performances (3) Lw / Lp (4) (HP high performance version) db(a) 77 / 45 Compressor Hermetic scroll (2900 rpm) Start-up mode Direct in line in series Number 1 Power control % Refrigerant oil type PE il capacity l No. of refrigerant circuits 1 Refrigerant (GWP) R407C (1800) Refrigerant load kg Electrical power supply ph/hz/v Three-phase AC - 50 Hz V (+6%/-10%) + Earth Machine protection rating IP 44 Electrics box protection rating IP 22 Control circuit voltage ph/hz/v Single-phase 50 Hz 230 V (+6%/-10%) - transformer fitted Condenser Brazed plate exchanger(s) Water capacity l Hot water outlet temp. (min./max.) C 25/65 C Minimum water flow rate m 3 /h Maximum water flow rate m 3 /h Unit water connections Ø Male 1½ G Minimum system diameter Ø DN 50 Max. pressure, water end bar 4 bar Air type evaporator Finned heat exchanger Fan mm Ø 800 Rotation speed in High Performance (HP) mode rpm 745 No. x Motor output in High Performance (HP) mode no. x kw 1 x 0.72 Air flow, high-performance (HP) version m 3 /h Minimum system water volume l Expansion vessel l 18 l Maximum system capacity in litres (5) max. water 65 C 450 Pure water max. water 80 C 310 Maximum system capacity in litres (5) max. water 65 C 275 Glycol/water mix 40% max. water 80 C 210 Standard pump Qty Nominal pump capacity kw Height (excluding mounts) mm 1423 Length (standard version) mm 1995 Depth mm 1055 Weight (empty) kg Weight in operation kg Max storage temperature C + 50 C HEATING capacities in HIGH PERFRMANCE version at the unit outlet, based on: net conditions, (1) hot water outlet at +35 C and outside air +7 C BS 86%RH (2) hot water outlet at +45 C and outside air +7 C BS 86%RH (3) CP as net values (4) Lw : verall sound power level, as per IS standard 3744 Lp : verall sound pressure levels, measured at 10 metres in a free field, calculated using the formula LP = LW - 10 log S (5) System capacity depending on expansion vessel fitted on unit 3

4 Electrical specifications Standard and ptional Equipment AQUACIAT CALE TDC 80Z 100Z 120Z 150Z Electrical power supply ph/hz/v Three-phase AC - 50 Hz V (+6%/-10%) + Earth Monitor circuit voltage ph/hz/v Single-phase 50 Hz 230 V (+6%/-10%) - transformer fitted Standard version starting current A Starting current, SFT START option A Breaking capacity (TN-TT neutral system) ka 15 Compressor rated current A Pump rated current A Fan current A 1.5 Control circuit current A 0.7 Standard unit rated current (1) A Frost protection option current 3 x 150W A 0.7 Unit current with frost protection option (1) A Thermal-magnetic circuit breaker (not supplied) curve D A Cross section of PVC type cables - Max temp 60 C A Cross section of PVC- V2K type cables (90 core) -Max temp 60 C mm Thermostat connection, pool sensor, n/ff input mm mm2 (1) pump current included Pump specifications SINGLE PUMP N DUBLE PUMP N - - Max. current 50Hz (A) 400V 1,7 1,91 Motor output 400V/50Hz 66,4 % 77,4 % Max. output power (kw) 0,55 0,75 Max. Input power (kw) 0,83 0,97 Min flow rate m 3 /h 1,0 1,9 MAX pressure mce 20,6 20,9 MAX flow rate m 3 /h 8,0 13,0 Min pressure mce 7,3 9,7 Degree of protection IP55 Electrical supply V 3-phase-50Hz 400V (+10%/-10%) + Earth AQUACIAT CALE TDC HEAT PUMP 3-400V 50hz supply without neutral, with 230V control circuit transformer Std utdoor heat exchanger protective grille Std Resilient mounts Std Additional voltage-free contacts board Remote control (movable console) Std Phase monitor (reversal, loss, over- and undervoltage) Soft start Frost protection All-season operation Std Variable-speed fan Std XTRAFAN for available supply air pressure Connection frame for the duct on the XTRAFAN Frame and flexible sleeve for the duct on the XTRAFAN BLYGLD coated coil Polyurethane coated coil fins 800 m water filter Std Hydraulic control kit (pressure gauges, control & shut-off valve) Hydraulic hoses Twin pump - Auxiliary heating management (2-stage) Std 200 litre 8-nozzle mixing tank 400 litre 8-nozzle mixing tank DHW heating kit (2 x 300 litre tanks in parallel) and motorised 3-way valves (80Z and 100Z) Pool heating kit with motorised 3-way valves 9 kw electrical auxiliary kit to be integrated into the 200 or 400 litre 8-nozzle mixing tank Electrical auxiliary unit by 9 kw loop heater supplied separately Electrical auxiliary unit by 15 kw loop heater supplied separately Std Supplied as standard Kit to be fitted on site Factory-fitted option Note: Some technical options not listed above may be added on special request (please contact us). _ Not available 4

5 Main components n Casing - Removable galvanised metal panels, - RAL 7024 and RAL 7035 lacquer coating High temperature air-to-water heat pumps n Compressor - Hermetic Scroll compressor with enhanced vapour injection - Built-in electric motor cooled by suction gas - Motor protected by internal winding thermostat - Placed on anti-vibration mounts n Hydraulic circuit - single water circulation pump fitted and electrically connected - expansion vessel provided to offset the water circuit corresponding to the heat pump and the mixer tank - safety valve - pressure tappings for water pressure gauges (optional) - drain valve micron water filter, to be connected to the unit, supplied as standard on the TDC (mandatory on all installations) - manual air bleed valve AQUACIAT CALE Version «C» n Hot water exchanger - Brazed plate exchanger operating in condenser mode - End and inside plates in stainless steel - High-performance, optimised plate patterns - Thermal insulation 80 to 150 n Exchanger using outside air - High efficiency air-cooled exchanger, aluminium fins with optimised profiles and grooved copper tubes - perating in evaporator mode on the TDC series heating only heat pump - Variable speed propeller fan with anticorrosive airfoil blades, with a low sound level - Motor with electronic pole switching and brushless type rotor with permanent magnets, in direct current IP54, class F n Control functions and safety devices - Water flow switch, - Thermostatic expansion valve, - Refrigerant HIGH and LW-pressure safety devices, - Safety valves on refrigeration circuit, - Temperature and pressure sensors - Unit start-up sequence - Cycle reversing valve for defrosting, - Liquid tank, - Dryer filter n Electrics box Fully wired and accessible via a lockable door, the electrics box houses the electrical components and the main electronic CPU board for the automatic Microconnect device, controls the entire unit, monitors its operation, adjusts setpoints. The interface with the remote control fitted inside is made via a 2-wire connection. Contents of the electrics box: - Control and power circuits, - Numbered wiring, - Main safety switch with handle on front, - Control circuit transformer, - Circuit breakers on the power and control circuits, - Fan compressor motor and pump switches, - Main earth connection, - Microprocessor-controlled electronic control unit, - Alarm or information signals on free terminals 5

6 Microconnect electronic control module CIAT electronic control module with microprocessor and CPU, with central automatic operation and access to internal operation states. n Features: Control terminal with display supplied separately (for interior wall mounting, protection rating IP30): - Allows the remote control of the unit with: l either regulation based on the ambient temperature if it is placed indoors, l or regulation based on the water temperature if it is placed in a mechanical room, - Digital display with backlit screen CPU electronic control card located inside the electrics box, with additional dry contacts allowing:. load shedding. remote protection from freezing. the authorisation for switching on the boiler or auxiliary heaters. a fault report n Functions: - Start, stop, reset and remote control, - peration information displayed via: l 6-position operation switch with pictograms, l direct reading of temperatures - Daily programming of a «Comfort» or «Economy» profile for use, - Complete management of the compressor and its start-up sequence - Management of the circulation pump with frost protection and anti-seize functions - Pre-emptive function with adjustment of the control stage differential and the compressor running time on the water temperature parameter drift - Staged-start capacity-reduction system based on the controlled heating requirements, either on the ambient temperature (water properties), or on the water temperature - Triggering of the defrosting cycles - Checking the internal operation or fault parameters - Second setpoint management - Direct display of the required temperature and the fault codes - Diagnosis of operation and fault states - Short-cycle protection ptions (kit for installation on site) n Accessories to be fitted on the unit - phase monitor kit: direction of rotation, absence of phase, over and under voltage - SFT START gradual start-up kit - unit frost protection kit - hydraulic hose kit to be connected to the water inlet and outlet - hydraulic control kit including water pressure gauges, control valve and shut-off valve - Pool heating kit (3-way valve with sensor) - Mixed heating kit domestic hot water DHW / SANI 300L (80Z and 100Z sizes) 6

7 n Multi-nozzle mixing tanks This hydraulic device is indispensable when installing an AQUACIAT CALE. Working as boiler back up, the tank allows the circuit for the heat pump and its accelerator pump to be uncoupled from that of the existing boiler, which generally has a different flow rate and water temperature regime. A sufficient water flow rate is ensured on the heat pump, whilst avoiding an excessive flow rate in the radiators (source of noise). The mixing tank also ensures the minimum volume for an installation, and avoids short cycle operations, whilst facilitating the defrosting of the heat pump. Two vertical mixing tank models are available as an option for ground mounting on 3 adjustable feet: model with 8 nozzles model with 8 nozzles Each tank is supplied with 8 cast iron plugs, which are not fitted, to allow the inlets and outlets to be used (or not) for each circuit to be configured during installation on site. A 9 kw backup electrical heater with 2 power stages (3 kw + 6 kw), and with a safety thermostat, is available as an option to be fitted directly on the tank. The switches and electrical protective devices for the heating elements are not supplied. Notes - the water temperature at the mixing tank outlet during use will be hotter the closer the heating accelerator pump flow rate is to that of the unit. At the tank outlet, obtaining a hot water temperature as close as possible to that at the heat pump outlet will therefore be conditioned by having the lowest possible difference between these two flow rates, - the bleed and drain valves are not provided by CIAT. Mixing tank Height (mm) Width (mm) Volume (litres) Weight without load (kg) Number of nozzles 8 8 Max service pressure 7 bars Max temperature ( C) +90 C Thermal insulation Polyurethane 50 mm Backup electrical heater (optional) 9 kw (3 + 6) Diameter of connections G 1 1/2 F n Loop heaters The loop heaters available as an option provide extra heating during periods of low outdoor temperatures, and guarantee a minimum level of heating in the event of a fault. Depending on the region and the climate, they also allow the outdoor heat exchanger s defrosting cycles to be carried out correctly. They are supplied separately for inside installation in a mechanical room, and must be fitted as standard downstream of the heat pump. An electrics box contains the switches, electrical protective devices and a safety thermostat. A bypass valve must be provided on site for adjusting the water flow rate in the heater. Two heater capacities are available: 9kW model (vertical assembly) Loop heater Height (mm) 9 kw kw 252 Width (mm) Depth (mm) Weight (kg) 13 kg MAX temperature setpoint +60 C No. of stages Recommended MAX water flow rate 2 m3/h 4 m3/h Electrical power supply 400 V three-phase 50 Hz + Earth Control circuit voltage 230V single-phase 50 Hz 15kW model (horizontal assembly) Machine protection rating Ambient temperature -> IP Qv 44A water A-10 C (m 3 /h) at +40 C Max. rated current 13A 24A Max service pressure 5 bar Diameter of connections G 1 1/4 7

8 n Domestic hot water DHW production (TDC 80Z and 100Z sizes) In addition to the main HEATING function, the AQUACIAT CALE allows domestic hot water (DHW) to be produced, for a programmed time, and for a total volume of 600 litres (2 x 300 litres). The automatic MICRCNNECT device authorises a boost of the DHW, during thermodynamic production, twice a day. This operation is limited to a few hours, according to a factory setting, with the heat pump automatically restarting its heating mode at the end of this maximum predefined time. Supplied separately in kit form, the DHW option comprises 2 identical 300 litre tanks for preparing domestic hot water, the SANI- 300 model with integrated coil heat exchanger, which must each be installed in parallel with a 3-way valve. Each SANI 300l kit is made up of the following elements: - a cased tank with polyurethane insulation, - interior enamelled coating - 3-way valve with servomotor (G 1»1/4) - magnesium anode (corrosion-resistant) - coil type hot water heat exchanger - built-in 3 kw back-up heater, supplied in three-phase or single-phase current (switches a n d electrical protective devices not supplied). To be provided onsite: - the electrical supply and the fuses, - the supply of drinking water, - the shut-off valves or bleed valves, - the valves and bleed devices, - the DHW circulation pump. Cold water Precautions: - domestic hot water must be installed in strict compliance with the regulations in force where the installation is taking place, particularly as concerns the prevention of health risks linked to legionellas - the SANI 300 tanks must be installed in premises which are sheltered from frost - a base is provided to facilitate cleaning of the premises - the extraction points must be as close as possible so as to minimise power losses via the pipes - a free space of 500 mm is required around and on top of the tanks - a safety valve plumbed at 7 bar (safety unit) must be provided on the DHW inlet Hot water tank SANI 300 (x 2) Max service temperature ( C) 110 C Max service pressure 12 bar Coil water volume 16.5 l Max water flow rate 4 m3/h (x2) Diameter of exchanger connections 1 GAS Max temperature ( C) 90 C DHW max service pressure 7 bars Volume (litres) 300 (x2) Diameter of DHW connections 1 GAS Circulation connection 3/4 GAS Height (mm) 1779 Diameter (mm) 600 Weight without load (kg) 168 (x2) Heat exchanger capacity 20 kw (x2) Extra heaters 3 kw (x2) Use the diameters given in the heat pump operating instructions Mandatory valve HEAT PUMP Heater (optional) Pool heating (optional) Towards the underfloor heating system, radiators, fan coil units Flexible connections Filter 8

9 Pressure drop (kpa) 40 High temperature air-to-water heat pumps DHW heater heat exchanger Water flow rate (m 3 /h n Pool heater kits (TDC 80Z-150Z) Pressure drop The AQUACIAT CALE also allows a swimming pool to be heated, replacing the main HEATING mode. As this additional operation is generally used outside of the normal heating season, the PL mode cannot therefore be programmed and, as a consequence, must be manually controlled with the remote control. As the selection of PL heating then becomes the main mode of use, the option remains to use the DHW heating function on a programmed basis. The kit includes a 3-way valve, equipped with a servomotor with a sensor designed to be connected to an intermediate exchanger. Specifications recommended for selecting the exchanger: - TITANIUM plates - NITRILE gaskets - STAINLESS STEEL nipple connections on the heat pump side - MPLEN nipple connections on the swimming pool side - mounting brackets way valve N.B.: the system schematics are provided as a guide; under no circumstances do they constitute a model for installation. Pressure drop (kpa) Water flow rate (m 3 /h 6 perating range n perating limits Variable speed of the fan utdoor temperature ( C) Temperature operating range in C HEATING mode Water outlet ( C) n Hot water production Minimum water return temperature for warm-up: +5 C Minimum water return temperature during operation (in pure water): é + 20 C (underfloor heating system) é + 25 C (TU or radiators) maximum water return temperature in the unit: +60 C 9

10 Noise levels The distinguishing feature of the AQUACIAT CALE range is its rigourous design incorporating «noiseless» assembly techniques: 4 Scroll compressor placed outside of the air stream and fitted on anti-vibration mounts 4 Pipes separate from the body of the unit 4 Variable speed fan with low sound level 4 Automatic air flow adjustment 4 Anti-vibration mounts underneath the units, supplied as standard n Ref. sound power levels 2x10-12 Pa ± 3 db (Lw) AQUACIAT CALE SUND PRESSURE SPECTRUM (db) verall level (Lp) 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz db(a) n Ref. sound pressure levels 2x10-5 Pa ± 3 db (Lp) Measurement conditions: free field, 10 metres from the machine microphone at 1.50 metres from the ground, directivity 2 AQUACIAT CALE SUND PRESSURE SPECTRUM (db) verall level (Lp) 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz db(a) N.B.: Sound pressure levels depend on the installation conditions of each system. As such, the levels listed above are given for information only. We remind you that only sound power levels are comparable and certified. 10

11 Heating capacities R407C TDC 80Z 100Z 120Z utdoor air temperature in C DB (1) High temperature air-to-water heat pumps HT WATER UTLET TEMPERATURE ( C) HT WATER UTLET TEMPERATURE AT THE CNDENSER ( C) Hc Pi Hc Pi Hc Pi Hc Pi Hc Pi Hc Pi Hc Pi Hc Pi Hc Pi kw kw kw kw kw kw kw kw kw kw kw kw kw kw kw kw kw kw Hc = Heating capacity Power consumption level calculations include defrosting cycles 150Z Pi = Power input for compressor control fan(s) Hc: Gross acceptable heating capacity for delta T, based on operating limits Pi: Gross power input (compressor + fan) pump not included Power consumption level calculations include defrosting cycles The water temperatures are measured directly at the terminals on the unit Calculated fouling m2 C/W (1) Relative humidity variation for calculations: -20 C 95%RH / +7 C 85%RH / +27 C 50%RH 11

12 Hydraulic specifications Condenser (do not extrapolate the curves) The available static pressure values include the manometric head of the pump fitted to each unit, from which the pressure drop in the exchanger and in the water filter (supplied separately) are calculated. Comment: - the pressure drop generated by the hydraulic flexible connections must be calculated from the values read on the curves. AQUACIAT CALE TDC Available static pressure at the unit outlet with filter (municipal water): +20 C 200 TDC 80 TDC 100 TDC 120 TDC > Available static pressure (KPa) > Qv water (m 3 /h) n Unit conversion formulae kpa = bar x 100 bar = mh2 x kg/cm2 = bar x Pi (lbf/in2) = bar x Inches (in) = mm x Feet (ft) = mm x Pounds (lb) = kg x Cubic feet mn (cfm) = m 3 /h x US Gallons = m 3 x UK Gallons = m 3 x

13 Dimensions AQUACIAT CALE TDC models 80 to 150 INSET Lifting 2090 overall 1145 overall 1: Condenser hot water inlet 2: Condenser hot water outlet 7: Lifting points 8: Wooden blocks for handling 9: Electrical panel access 10: Hydraulic module access E: Electrical power supply utdoor air discharge utdoor air intake AQUACIAT CALE 80 Positions of anti-vibration mounts Weight (kg) A B C D E empty in operation P25 50x100 P25 50x P25 50x120 P25 50x n Positioning of the mounts on the ground AQUACIAT CALE L1 316 L2 316 L L The chassis may be affixed to the ground. (Mounts with bolts NT supplied by CIAT). Hardness to be defined depending on the unit s weight and centre of gravity 13

14 Schematic installation diagrams Less heat is produced by the AQUACIAT CALE as the outdoor temperature drops, whereas the heating needs inside a home increase when this outdoor temperature is lower. For this reason, when operating as boiler backup, the heat pump needs a boiler to compensate for this heat loss when the outdoor temperature is low. Existing installations These are existing heating installations to which the AQUACIAT CALE can be added without any major modification to the distribution system. The boiler will therefore generally use a «standard» mounting and will extract into the mixing tank before distributing hot water to the radiators. n Installation with a boiler and 3-way control valve DHW tank with Boiler Radiators Boiler HEAT PUMP Swimming pool heating 200L or 400L mixing tank Flexible connections Loading MDULE Underfloor heating Filter n Installation with a boiler and 4-way control valve DHW tank with Boiler Radiators Boiler HEAT PUMP Pool heating (optional) 200L or 400L mixing tank Flexible connections Loading MDULE Underfloor heating Filter N.B.: the system schematics are provided as a guide; under no circumstances do they constitute a model for installation 14

15 New installations These are new installations to which the AQUACIAT CALE could be either installed alone, provided that the sizing takes into account the heating requirements for low outdoor temperatures, or installed at the same time as a boiler with a distribution system created for this purpose. The boiler and the AQUACIAT CALE may also be mounted in «parallel» on the mixing tank, with the distribution circuits then extracting directly into this multi-nozzle mixing tank. It is prohibited for the heat pump and boiler to operate at the same time. n Installation with a new boiler HEAT PUMP Pool heating (optional) DHW heating (optional) Radiators Flexible connections Filter Loading 200 L or 400 L mixing tank Underfloor heating Boiler n Installation as heat pump only HEAT PUMP Pool heating (optional) DHW heating (optional) Radiators Flexible connections Filter Loading 200 L or 400 L mixing tank Underfloor heating Diagram key: Control valve Shut-off valve 3-way valve Circulating pump Check valve 4-way valve 15

16 n Pre-heating of domestic hot water (DHW) only (hotel type) N.B.: the system schematics are provided as a guide; under no circumstances do they constitute a model for installation. FS Flow rate controller bm Mixing tank vr Control valve bt Buffer tank rb Loop heater ve Balancing valve s Safety valve rb Loop heater DHW Domestic hot water rt Thermostatically controlled valve v3v 3-way valve e Expansion vessel m Pressure gauge v Drain valve AQUACIAT CALE Installation recommendations n Water quality criteria to be respected The quality of the water used has a direct impact on the correct and compliant operation of the AQUACIAT CALE hot water production unit and its service life. This is particularly true if the water used clogs or corrodes components or promotes the growth of algae or microorganisms. The water must be tested to determine whether it is suitable for the unit and whether chemical treatment will suffice to make it of acceptable quality and if a water softening/demineralising system should be installed. The results of the analysis must confirm whether the site s water is compatible with the various materials used on the CIAT unit s circuit: % copper tubes brazed with copper and silver, - threaded bronze couplings or flat steel flanges, depending on the unit model, - plate heat exchangers and connections made of AISI 316/ DIN stainless steel brazed with copper and silver. Use of toxic frost protection agents such as monoethylene glycol is prohibited. N.B.: - the unit s guarantee shall be void if these instructions are not followed. - it is essential to install an 800 micron water filter on the unit s water inlet, whether this is supplied as standard by CIAT, or available as an option. n Lifting and handling The utmost safety precautions must be taken when lifting and handling the unit. Always follow the lifting diagram affixed to the unit and the installation, operation, commissioning and maintenance manual. Before attempting to lift the unit, make sure the path leading to its intended location is free from obstacles. Always keep the unit vertical when moving it. Never tip it or lie it on its side. n Choosing a location for the unit The standard version of AQUACIAT CALE is designed for outdoor installation. Precautions should be taken to protect it from freezing temperatures. The unit must be placed on a perfectly level, fireproof surface strong enough to support it once charged. For acoustic reasons, ensure respect for neighbours when the unit is installed outside: - ensure the equipment is placed as far away from your neighbours as possible, by using any natural screens, - avoid placing the equipment adjacent to walls as they can considerably increase the noise level by reflecting and changing the directivity of the sound. Noise pollution from auxiliary equipment such as pumps should also be studied thoroughly. Potential noise transmission routes should be studied, with assistance from an acoustical engineer if necessary, before installing the unit. Flexible couplings must be placed over pipes (available as options). Special attention should be paid to ensure sufficient free space (including at the top) to allow maintenance. Units installed in areas prone to snowfall or heavy frost should be raised approximately 300 mm off the floor or ground. - According to the regulations in force in the place in which the machine is to be stored and installed certain precautions must be taken, especially when installed on a roof, to ensure the unit is fully stable (violent wind, earthquake, etc.); this may require that it is mounted on the ground. - For winds over 120 km/h, the unit must be secured to the ground As the unit is not fitted with a condensate drain pan, the condensation generated on the air-cooled exchanger and the water resulting from the defrosting cycles must be correctly evacuated and drained. Water vapour may be created at the fan discharge during the defrosting cycles; it is recommended that its evacuation is not impeded. 16

17 n Installation in a machine room Installation in a machine room, if required, gives rise to special technical precautions, such as: - the draining of defrosted water, including during periods of very low outdoor temperatures, - the management of water vapour created at the fan discharge during defrosting, - ground which can support the weight of the unit and which must be perfectly watertight and capable of collecting and draining the defrosted water, including during freezing periods, - under no circumstances should the weight of an air discharge sleeve be supported by the roof of the unit. According to the regulations in force in the place in which the machine is to be installed, installation within a machine room must comply with certain ventilation rules for fresh air to ensure there is no risk of discomfort or hazard in the event of a refrigerant leak. n Assembly of separately supplied accessories: A number of optional accessories may be delivered separately and installed on the unit on site. These must be installed before filling and starting the installation. Always follow the instructions in the installation, operation, commissioning and maintenance manual n Electrical connections: Always follow the instructions in the installation, operation, commissioning and maintenance manual. All information concerning electrical connections is stated on the wiring diagrams provided with the unit. Always follow this information to the letter. Electrical connections must be made in accordance with best current practices and applicable standards and regulations. Electrical connections to be made on site:. unit s electrical supply,. outdoor operation authorisation (optional). information feedback (option) It should be noted that the unit s electrical system is not protected against lightning strikes. Therefore components to protect against transient voltage surges must be installed on the system and inside the electrical supply unit. n Pipe connections: Always follow the instructions in the installation, operation, commissioning and maintenance manual. All pipes must be correctly aligned and slope toward the system s drain valve. Pipes must be installed to allow sufficient access to the panels and fitted with heat insulation. The total volume of the hydraulic circuit must be sufficient to ensure operation without short-cycles, and to provide a minimum heat capacity during the defrosting phases of reversible units. n existing installations to which the AQUACIAT CALE is going to be added, it is recommended that the capacity of the expansion vessel is checked to ensure it covers the entire water volume. When using a heat pump as boiler back up, it is imperative that the unit s circuit is uncoupled from the heating network via a mixing tank with a minimum of 4 connections, which will also act as a buffer tank. Pipe mountings and clamps must be separate to avoid vibrations and placing pressure on the unit. Water shut-off and control valves must be fitted when the unit is installed. - Pipe connections to be made on site: water supply for the installation with pressure-reducing valve, and hydraulic check valve to protect the drinking water network and expansion vessel, condenser and drain inlet and outlet. - Accessories essential to any hydraulic system must also be installed, such as: a thermostatically controlled valve for controlling the water flow rate placed at the condenser water outlet, a «zero water» pressure switch to protect the circulation pump, water expansion vessel, connections at the pipe low points to allow draining, exchanger shut-off valves equipped with filters, air vents at pipe high points, check the system s water content (install a buffer water tank if necessary), flexible connection sleeves at exchanger inlets and outlets, if necessary, manual water flow rate control valves, thermometers on each water inlet and outlet to allow all the necessary checks during start-up and maintenance. - Make sure the pressure of the water drawn in by the circulation pumps is greater than or equal to the required minimum NPSH, particularly if the water circuits are open. - Test the water quality in accordance with the relevant technical requirements. - Take the necessary precautions to protect the unit and hydraulic system from freezing temperatures (e.g. allow for the possibility of draining the unit). If glycol is added to prevent freezing, check its type and concentration before commissioning. - Before making any final hydraulic connections, flush the pipes with clean water to remove any debris. N.B.: - Pressure in the water circuits below 4.0 bar - Place the expansion vessel before the pump - Do not place any valves on the expansion vessel - Make sure the water circulation pumps are placed directly at the exchanger inlets 17

18 n Heat pump for boiler backup: High temperature air-to-water heat pumps It is strongly recommended that a mixing tank is installed on the hydraulic circuit between the heat pump and the boiler. Check the compatibility of the boiler against the heat pump control. n boilers with a steel heating surface, the heat pump must not operate at the same time as the boiler if the conditions require a water regulation setpoint below +40 C. In this case, the heat pump must be forced to operate alternately and the boiler must have anticorrosion protection which requires that the accelerator pump is only started up when the burner has brought the water temperature back to above approximately +40 C. n Commissioning AQUACIAT CALE units must be commissioned by CIAT or a CIAT-approved firm. Always follow the instructions in the installation, operation, commissioning and maintenance manual. n Maintenance operations Specific preventive maintenance operations are required at regular intervals and should be performed by CIAT-approved contractors. The operating parameters are read and noted on a «CHECK LIST» form to be returned to CIAT. For this, it is essential to comply with the Instructions, Installation, peration, Commissioning and Maintenance Manual. You must take out a maintenance contract with a CIATapproved refrigeration equipment specialist. Such a contract is required even during the warranty period. Partial list of precommissioning checks: - Correct positioning of unit, - Power supply protections, - Phases and direction of rotation, - Wiring connections on unit, - Direction of water flow in unit, - Cleanliness of water circuit, - Adjusting water flow rate to specified value, - Pressure in the refrigeration circuit, - Direction of rotation of compressors, - Water pressure drops and flow rates, - perating readings. This document is non-contractual. As part of its policy of continual product improvement, CIAT reserves the right to make any technical modification it feels appropriate without prior notification. Head office Avenue Jean Falconnier - B.P Culoz - France Tel.: +33 (0) Fax: +33 (0) info@ciat.fr - CIAT Service Tel. : (0,15 / mn) Fax : (0,15 / mn) Compagnie Industrielle d Applications Thermiques - S.A. with a registered capital of R.C.S. Bourg-en-Bresse B