RHV INSTALLATION AND OPERATION MANUAL. AIR COOLED WATER CHILLER WITH HELICAL FANS kw. imigliori gradi centigradi

Transcription

1 imigliori gradi centigradi RHV AIR COOLED WATER CHILLER WITH HELICAL FANS kw FERROLI adheres to the EUROVENT certification programme. The products concerned appear in the products guide to INSTALLATION AND OPERATION MANUAL

2 Dear Customer, Thank you for having purchased a FERROLI Idustrial coolers. It is the result of many years experience, particular research and has been made with top quality materials and higlly advanced technologies.the CE mark guaranteed thats the appliances meets European Machine Directive requirements regarding safety. The qualitative level is kept under constant surveillance. FERROLI products therefore offer SAFETY, QUALITY and RELIABILITY. Due to the continuous improvements in technologies and materials, the product specification as well as performances are subject to variations without prior notice. Thank you once again for your preference. FERROLI S.p.A GB CE DECLARATION OF CONFORMITY We, the undersigned, hereby declare under our responsibility, that the machine in question complies with the provisions established by Directives : DK CE OVERENSSTEMMELSESERKLERING Underfegnede forsikrer under eget ansvar al den ovennævnte maskine er i overensstemmelse med vilkårene i. direktiveme : DE EG KONFORMITÄTSERKLÄRUNG Wir, die Unterzeichner dies er Erklärung, erklären unter unseren ausschlie ßlichen Verantworfung, daß die genannte Maschine den Bestimmungen der folgenden EG-Richtlinien entspricht : SE FÖRSÄKRAN OM CE ÖVERENSSTÄMMELSE Underfecknade försäkrar under eget ansvar alt ovannämnda maskinskinen er i overensstemmelse med vilkarene i direktivene : FR DECLARATION CE DE CONFORMITE Nous soussignés déclarons, sous notre entière responsabilité, que la machine en objet est conforme aux prescriptions des Directives : NO BEKREFTELSE OM ÆCEØ OVERENSSTEMMELSE Underfegnede forsikrer under eget ansvar al den ovennevnte maskinen er i overensstemmelse med vilkarene i direktivene : IT DICHIARAZIONE CE DI CONFORMITÀ Noi sottoscritti dichiariamo, sotto la nostra responsabilità, che la macchina in questione è conforme alle prescrizioni delle Direttive : FI CE VAATIMUSTENMUKAISUUSVAKUUTUS Allekirjoittaneet vakuutamme omalla vastuullamme että yllämainittu kone noudattaa ehtoja direktiiveissä : ES DECLARACION CE DE CONFORMIDAD Quienes subscribimos la presente declaracion, declaramos, baio nuestra exclusiva responsabilidad, que la maquina en objeto respeta lo prescrito par las Directivas : GR ΔΗΛΩΣΗ ΣΥΜΒΑΤΟΤΗΤΑΣ EE Εμετς που υπογραϕουμε την παρουσα, δηλωνουμε υπο την αποκλειστικη μας ευθυνη, οτι το μηχανημα συμμορϕουται οτα οσ α ορτζουν οι Οδηγιες : PT DECLARAÇÃO CE DE CONFORMIDADE Nós, signatários da presente, declaramos sob a nassa exclusiva responsabilidade, que a má quina em questão está em conformidade com as prescrições das Directrizes : HR IZJAVA O CE SUGLASNOSTI Mi niže potpisani izjavljujemo, pod našom odgovornošu, da ova Mašina odgovara zahtijevima iz Direktiva : NL EG CONFORMITEITSVERKLARING Wij ondergetekenden verklaren hierbij op uitsluitend eigen verantwoording dat de bovengenoemde machine conform de voorschriften is van de Richtlijnen: PL DEKLARACJA ZGODNOŚCI CE My niżej podpisani oświadczamy z pełną odpowiedzialnością, że niżej wymienione urządzenie w pełni odpowiada postanowieniom przyjętym w następujących Dyrektywach: 2006/42/EC 97/23/EC 2004/108/EC 2006/95/EC 3QE22170 rev.03 2

3 TABLE OF CONTENTS GENERAL SPECIFICATIONS...4 PRESENTATION OF THE UNIT...4 GENERAL SPECIFICATIONS...4 EUROPEAN DIRECTIVES...4 IDENTIFICATIONPLATEOFTHEUNIT...5 IDENTIFICATIONCODEOFTHEUNIT...5 DESCRIPTION OF THE COMPONENTS...6 ACCESSORIES AND OPTIONAL EQUIPMENT...9 AVAILABLE ACCESSORIES...9 MECHANICAL OPTIONS...11 ELECTRICAL OPTIONS...11 GENERAL SPEC - IR UNIT FOR COOLING MODE ONLY...12 GENERAL TECHNICAL SPECIFICATIONS BASIC VERSION UNIT..12 ACOUSTIC VERSION: AB (BASIC VERSION)...12 STANDARD PERFORMANCES - BASIC VERSION VB...13 ACOUSTICVERSION:AS(LOWNOISEVERSION)...14 STANDARDPERFORMANCES-LOWNOISEVERSIONAS...15 ACOUSTIC VERSION: ASS (EXTRA LOW NOISE VERSION)..16 STANDARD PERFORMANCES - EXTRA LOW NOISE VERSION ASS..17 GENERAL SPEC - BRINEVERSION(VI)...18 TECHNICAL SPECIFICATIONS FOR RECOVERY VERSION IR UNITS FOR COOLING ONLY...19 VERSIONWITHDESUPERHEATER(VD)...19 RECOVERY HEAT. CAP. IN VERS WITH DESUPERHEATER (VD).20 VERSION WITH TOTAL RECOVERY ON ALL CIRCUITS (VR)...21 RECOVERED HEATING CAPACITY IN TOT REC VERS (VR)...21 NOISE LEVEL...22 AB BASIC VERSION...22 ASLOWNOISEVERSION...22 ASS EXTRALOWNOISEVERSION...22 OPERATING RANGE...23 OPERATING RANGE BASIC VERSION...23 OPERATINGRANGEFORRECOVERYVERSION...23 OPERATINGRANGEFORBRINEVERSION(VI)...23 WATERPRESSUREDROPEVAPORATOR...24 OPERATINGRANGE...24 WORKINGHEAD2PSTD...25 OPERATINGRANGE...25 WORKINGHEAD2PHP OPERATINGRANGE...26 WORKINGHEAD2PHP OPERATINGRANGE...27 WORKINGHEAD4PSTD...28 OPERATINGRANGE...28 WATER PRESSUR DROP DESUPERHEATER VERSION...29 OPERATINGRANGE...29 WATERPRESSUREDROPRECOVERYVERSION...30 OPERATINGRANGE...30 WATERFILTERPRESSUREDROP...31 OPERATINGRANGE...31 MAXIMUMVOLUMEOFWATER...32 MAXIMUM VOLUME OF WATER OF THE SYSTEM WITH MODULE PUMPING...32 ARRIVAL...33 INSPECTIONS ON ARRIVAL...33 SAFETYREGULATIONS...33 HANDLING...33 STORAGE...33 DIMENSIONALANDPHISICALDATA...34 MOD AB / AS / ASS...34 MOD AB / AS / ASS...34 MOD AB / AS / ASS...35 MOD AB / AS / ASS...36 MOD AB / AS / ASS...37 MOD AB / AS / ASS...38 MOD AB / AS...39 MOD ASS...40 MOD AB / AS...41 MOD ASS...42 MOD AB / AS...43 MOD ASS...44 MOD AB / AS...45 MOD ASS...46 MOD AB / AS...47 MOD ASS...48 MOD AB / AS...49 MOD ASS...50 COILSANDANTINTRUSIONGUARDPROTECTION...51 REMOVETHELIFTPLATES...51 VIBRATION-DAMPER INSTALLATION...51 VICTAULIC CONNECTIONS AND WATER FLOW SWITCH.51 LAYOUTOFTHEMAINCOMPONENTOFTHEUNIT...52 ELECTRICALCONNECTIONS...53 GENERAL RULES...53 STRUCTURE OF THE ELECTRIC PANEL...53 COMPOSITION OF THE SYSTEM...53 ELECTRICALCONNECTIONS...53 WETCONNECTIONS...56 GENERAL RULES...56 HYDRAULIC LAYOUT OF THE SYSTEM...56 PRECAUTIONSFORTHEWINTER...56 BASIC DIAGRAM FOR UNITS WITH HEAT RECOVERY [HOT WATER CIRCUIT]...57 BASIC DIAGRAM BASIC VERSION VB [COOL WATER CIRCUIT]...57 VALVE REGULATING DIAGRAM THREE-WAY DRIVEN VALVE..58 PROTECTIONDEVICES...58 REFRIGERANT FLOW DIAGRAM...59 REFRIGERANT FLOW DIAGRAM BASIC VERSION...59 REFRIGERANT FLOW DIAGRAM BASIC VERSION WITHECONOMIZER...60 MONITORING SYSTEM BASIC VERSION...61 USERINTERFACE...61 USERSETTING...64 ALARM...70 DESCRPTIONS OF ALARM TYPES...70 USERALARMSTABLES...71 AUTOMATICALARMS...72 ALARMSLOG...73 MONITORING SYSTEM RECOVERY VERSION...74 USERINTERFACE...74 USERSETTINGS...77 SETTING THE UNIT OPERATING PARAMETERS IN REC. MODE..79 ALARMS...86 DESCRIPTIONS OF ALARM TYPES...86 USERALARMSTABLE...87 AUTOMATICALARMS...88 ALARMSLOG...89 SETTINGATWORK...90 GENERAL RULES...90 MANTENANCE...90 GENERAL RULES...90 ROUTINEMAINTENANCE...90 SAFETY AND PULLOTION...91 GENERALCONSIDERATIONS...91 GENERAL RECOMMENDATIONS ABOUT THE REFRIGERANT USED..92 FIRSTAID...95

4 GENERAL SPECIFICATIONS Presentation of the Unit This new series of air-cooled water chillers with helical fans is suitable for outdoor installation: the bearing structure and panelling are made of adequately thick, coated and galvanized sheet metal. All the fastening components are made of stainless and/or galvanized steel. The cabinet that houses the electrical components and all the parts exposed to outdoor weather conditions (fans, pressure switches, valves, etc.) have a protection degree of at least IP54. When the units were designed, particular attention was also paid to sound emission in our endeavour to comply with the increasingly more restrictive laws governing acoustic pollution: all the units can be supplied in standard, silenced or supersilenced versions, according to the required noise level. The units produce cold water from 6 to 12 C through to the maximum air temperature of 45/46 C. If equipped with the accessory head pressure control the units can operate at low outdoor temperatures down to about -10 C. They are equipped with 2 independent refrigerant circuits, each of which has a semi-hermetic TWIN- SCREW compressor featuring a 25 to 100% control capacity device. As part of the standard outfit, the units are also equipped with a shell and tube heat exchanger evaporator optimized for use with R134a, featuring high-efficiency grooved pipes and thermally insulated and protected by means of a differential water pressure switch and electrical antifreeze heater that enables the exchanger to be protected against winter freezing down to a min. air temperature = -10 C, coils with extended surfaces and extensive heat exchanging areas formed by copper pipes and louvered aluminium fins, electric fans with scythe-shaped blades to reduce the sound emission, electric panel for setting and controls with a door-locking main circuit-breaker, controller with microprocessor plus display with 4 lines of 20 characters, R134a environment-friently refrigerant gas. The evaporator is feeded by an electronic expansion valve that allows the exploitation of the evaporator surface thus increasing the efficiency of the system in all working conditions (25 to 100%) so achieving the optimal seasonal energy efficiency. The range is completed with numerous options and accessories, including the possibility of having units equipped with pumping modules with 2 pumps 2 poles (Standard Version) and 4 poles (for Silenced and Super Silenced Versions). All the units are accurately built and tested individually, thus only the electrical and wet connections need be made for installation. General specifications This manual and the wiring diagram supplied with the unit must be kept in a dry place and ready to hand for future consultation when required. This manual has been compiled to ensure that the unit is installed in the correct way and to supply comprehensive information about how to correctly use and service the appliance. Before proceeding with the installation phase, please carefully read all the information in this manual, which describes the procedures required to correctly install and use the unit. Strictly comply with the instructions in this manual and conform to the current safety standards. The appliance must be installed in accordance with the laws in force in the country in which the unit is installed. Unauthorized tampering with the electrical and mechanical equipment will VOID THE WARRANTY. Check the electrical specifications on the identification plate before making the electrical connections. Read the instructions in the specific section where the electrical connections are described. If the unit must be repaired for any reason, this must only be done by a specialized service center recognized by the manufacturer and using genuine spare parts. The manufacturer also declines all liability for any damage to persons or property deriving from failure of the information in this manual to correspond to the actual machine in your possession. Proper uses: this series of chillers is designed to produce cold or hot water for use in hydronic systems for conditioning/heating purposes. The units are not suitable for the production of domestic hot water. Any use differing from this proper use or beyond the operating limits indicated in this manual is forbidden unless previously agreed with the manufacturer. The prevention of the risk of fire at the installation site is the responsiblity of the end user. European Directives The company hereby declares that the machine in question complies with the matters prescribed by the following Directives: Machinery directive 2006/42/EC Pressurised equipment directive (PED) 97/23/EC Electromagnetic compatibility directive (EMC) 2004/108/EC Low voltage directive (LVD) 2006/95/EC 4

5 GENERAL SPECIFICATIONS Identification plate of the Unit The figure on the left depicts the identification plate of the unit, affixed to the outer left-hand side of the Electric Panel. A description of the data is given below: Basic versions A- Trademark B-Model C-Serial number D-Cooling Capacity E-Heating Capacity F-Power input in COOLING mode G-Power input in HEATING mode H-Reference standard I - Electric power supply I - Electric power supply L-Maximum current absorption M- Type of refrigerant and weight of charge N-Shipping weight of the unit O-Sound pressure level P-IP Level Protection Q-Maximum pressure - High Side R-Maximum pressure - Low Side S-PED certification authority Special versions A - Trademark B - Model C - Serial number D - Useful cooling output (same as Standard Version of the unit) E - Useful heating output for IR unit, VD and VR version, same as the recovered Heat rating for IP unit, VD version, same as the Heat rating / recovered Heat rating F - Electric power draw in the COOLING mode (same as Standard version of the unit) G- Electric power draw in the HEATING mode H-Reference standard L-Maximum current absorption M- Type of refrigerant and weight of charge N-Shipping weight of the unit O-Sound pressure level P-IP Level Protection Q-Maximum pressure - High Side R-Maximum pressure - Low Side S-PED certification authority NOTES: The identification plate of the Brine Version (VI) is filled out as shown in the diagram for the Basic Version of the unit (VB). Identification code of the unit The codes that identify the units are listed below and include the sequences of letters that determine the meanings for the various versions and set-ups. Unit type IR- Unit for installation in an Hydronic system with operation as a Chiller. IR VR - AS - 4 -M-5 Type of Power supply 5-400V-3ph~50Hz Operating climates Model of unit N compressors= 2 Version VB - Basic Version VD - Version with Desuperheater VR - Version with Total heat recovery VI - Brine Version Acoustic Version AB - Basic Version AS - Low noise Version ASS - Extra low noise Version M-Medium Climates 4 - R134a Refrigerant type Acustic versions The available unit versions are described below: AB: Basic Version. The compressors in these units are installed without a soundproofed cabinet and with axial fans operating at 900 rpm. AS: Low Noise Version. The units are as standard equipped with head pressure control, made with compressors installed inside a soundproofed cabinet, helical fans working at low speed rotation at nominal condition. The unit can work with low noise emission up to an external air temperature of 40 C. Compared with the Basic Version the noise level is reduced of 5/6 db. ASS:Extra Low Noise Version. The units are as standard equipped with head pressure control, made with compressors installed inside a soundproofed cabinet, helical fans working at very low speed rotation at nominal condition and coils with increased surface. The unit can work with low noise emission up to an external air temperature of 38 C. Compared with the Basic Version the noise level is reduced of 10/11 db. 5

6 GENERAL SPECIFICATIONS Versions The available special versions are described below: VB: Basic version. The unit can produce cold water at a temperature of 6 to 12 C. VD: Version with Desuperheater. Produces cold water as in the standard version plus hot water at a temperature from 40 to 50 C at the same time. This is achieved thanks to a water-refrigerant gas heat exchanger between the compressors and condensing coils that recovers part of the thermal power that would otherwise be dispersed in the air. VR:Version with Total/Partial heat Recovery. Produces cold water as in the standard version plus hot water at a temperature from 35 to 50 C at the same time. This is achieved thanks to a water-refrigerant gas heat exchanger that totally recovers the thermal power that would otherwise be dispersed in the air. The total heat recovery function is enabled and disabled by means of a valve on the compressor discarge of each circuit: when the temperature of the water that enters the recuperator drops, the valve switches the hot gas flow from the condensing coils to the recovery heat exchanger. On the other hand, when the temperature of the water reaches the set-point, the valve shuts off the heat recuperator and switches the hot gas flow to the condensing coils. VI: Version that produces water at a low temperature (BRINE) The unit can produce cold water with brine at a temperature of -8 to 4 C. Description of the components 1. Fans. These are the helical type with scythe-shaped blades to increase efficiency and reduce the sound emissions. The fans are directly coupled to the threephase motor by means of an external rotor. Thermal protection against operating faults is installed inside the winding. 2. Electric control and monitoring panel. It is housed in a cabinet made of adequately thick painted sheet metal suitable for outdoor installation (protection degree IP 54). The panel comprises the following main components: - Main door-locking circuit-breaker. - Contactors to control and manage the part-winding or star-delta starting mechanism of each compressor. - Fuse holders with protection fuses for each compressor. - Fuse holders with protection fuses for the oil heaters of the compressors. - Fuse holders with protection fuses for the antifreeze heater. - Fuse holders and protection fuses for the fans. - Fan control contactors. - Insulating and safety transformer to power the auxiliaries, protected with fuses. - Basic monitoring board with microprocessor: - Electronic expansion valve controller The main functions of the monitoring system are: Temperature regulation of the water produced by the unit, operating hour counting for compressors and pump/s, operating hour balancing for compressors and pumps, start-up timing, parameter entry digitized via the keyboard, alarm diagnosis. Functions associated with the digital inputs: high pressure, high discharge temperature, correct electric power phase presence-sequence, thermal protection for compressors, thermal protection for fans, thermal protection for pump, differential water pressure switch, remote controlled ON/OFF commands, recovery enabling (only for the VR Version), recovery Pump Thermal Protective (only for the VR Version). Functions associated with the digital outputs: compressor control, solenoid valves for compressor control capacity, liquid injection or economizer solenoid valve control, water pump/s control, electric antifreeze heater,fans control, general alarm (can be remote controlled), recovery valve management (only for the VR Version), recovery pump (only for the VR Version). Functions associated with the analog inputs: water inlet and outlet temperatures, discharge temperature. Suction and discharge pressure, discharge temperature probe, recovery water inlet and outlet probes (only for the VR Version). Suction temperature. Functions associated with the analog outputs: speed control (only with DCC Head pressure control accessory). Moreover the controller allows - Alarm history (max 50m alarms managed with FIFO logic) - Time scheduling (daily and weekly) - Precise control of the water leaving temperature - Prevention of the block of the unit: In case of critical conditions the machine does not stop but is able to regulate itself and provide the maximum power that can be generated in those conditions with the compressors working inside the admissible limits. Demand Limit by Digital Input and/or by Analog Input (4-20mA) Dinamic Setpoint by Analog Input (4-20mA): for instance by an outdoor temperature probe for the climate control Second Set Point by Digital Input Connection to BMS (supervision systems) through serial port RS 485 and MODBUS protocol 3. User interfacing terminal with display. The interface consists of: - FUNCTION/ON-OFF multifunction key for quick access to the 4 main menus and for powering/switching off. - MENU multifunction key to access all the menus for controlling and configuring the unit. - Power-on LED. - RX-TX LED to indicate that the user interface and monitoring module are communicating. - Alarm indicator LED. - Check-control with alarm display. - Time band - High pressure prevention 6

7 GENERAL SPECIFICATIONS 4. Bearing structure made of galvanized sheet metal coated with polyurethane powder paint to ensure good protection against adverse weather conditions. 5. Condensing coils, the aluminium finned pack type with shaped profile to 1 5 increase the heat exchange coefficient and with copper pipes arranged in staggered rows. A sub-cooling section is integrated into the lower part. 6. Covering panels, made of galvanized 4 sheet metal coated with polyurethane powder paints to ensure the utmost ability to withstand adverse weather conditions Compressor cabinet (only for AS and ASS). They are installed in a soundproofed 3 booth made of galvanized sheet metal coated with polyurethane powder painbts and covered in soundproofing material. 8. Compressors. Suitable for outdoor installation. They are the TWIN-SCREW 2 type with 25 to 100% control capacity: in conjunction with accurate assembly, this 7 technical solution allows the refrigerant to compress and the axial thrusts on the bearings (amongst the most critical components of the compressor) to be perfectly balanced, thus guaranteeing long life. They are equipped with an asynchronous threephase motor (400V-3-50Hz) with aluminium squirrel-cage rotor, pre-engineered for part-winding or star-delta starting (so as to reduce the current input during the starting phase to the minimum) and are protected by a chain of thermostors buried in the stator windings (controlled by an electronic module) and fuses housed in the electric panel. The standard outfit includes an efficient oil separator complete with electric heater (activated when the compressor stops). To widen the field of application to an even greater extent, some models are equipped with a liquid injection system controlled by the electronic controller so that use only occurs when effectively necessary. As part of the standard supply, they are positioned on rubber vibration dampers to reduce the vibrations transmitted to the base of the unit. 9. Evaporator of the shell and tube heat exchanger type, made of carbon steel and optimized for operation with R134a. Features high-efficiency grooved pipes and also achieves low losses on the wet side. As standard, the evaporator is insulated with 19mm flexible closed-cell foam that forms barrier to prevent the formation of condensation and heat exchanges towards the outside. Standard supply also includes a differential water pressure switch built into the water supply circuit to avoid the risk of freezing if the water flow is shut off for some reason and electrical antifreeze heater that enables the exchanger to be protected against winter freezing down to a min. air temperature = -10 C. Also ensures that mechanical stress is absorbed to a good degree. As accessory it can be supplied with Water flow switch FA. Hydraulic and refrigerant circuit components 10. Refrigerant safety valve. (Conforms to the Directive governing pressurized equipments - PED)Installed on the delivery pipe of the compressors. It acts if critical service faults should occur. 11A. Liquid cock - 11B. Gas cock. Allow all the refrigerant in the coils to be pumped and then stored so as to carry out servicing work or to replace all the components of the chilling circuit without having to drain it. 12. Dehydrator filter. Of the removable cartridge type. Retains impurities and traces of moisture in the circuit. 13. Liquid injection solenoid valve, to allow a larger operating envelope directly managed by electronic controller. 14. Electronic expansion valve. It has the task of correctly feeding the evaporator insuring a steady superheat. The valve is managed by a dedicated electronic board. It has also the function to stop the liquid when the compressor is off, so avoiding the refrigerant migration from the coils to the evaporator and to the compressor. - Liquid solenoid valve.one per circuit. They shut off when the compressor switches off, preventing liquid refrigerant from flowing towards the evaporator during standstill periods. 15. Compressor delivery probe. One per compressor, installed on the delivery pipe to protect the compressor if the end of compression temperature exceeds the established limits. -Economizer. The refrigerant circuit for some models is integrated with an economizer. This device increases the cooling capacity and efficienty (EER) of the unit at all operating conditions of the compressor (from 25% to 100%). 7

8 GENERAL SPECIFICATIONS Liquid and moisture sight glass. Signals when liquid passes through the circuit, indicating that the refrigerant charge is correct. The liquid indicator also changes colour to show the amount of moisture in the refrigerant. - Pressure taps: 1/4 SAE (7/16 UNF) (schraeder). Allow the operating pressure of both the circuits to be measured in 3 main points of each refrigerant circuit: compressor discharge, thermostatic valve inlet, compressor suction. - High pressure switch. With fixed setting. It is installed on the delivery pipe and blocks the compressor of the circuit if the operating pressures exceed the tolerated values. If it activates, the circuit will block and can only be restarted by resetting via the user interface terminal. - Oil crankcase heater to heat the compressor oil. One per compressor. Activated when the compressor switches off. Their task is to keep the temperature of the oil sufficiently high so as to prevent refrigerant from migrating during these pauses. - Low pressure switch. With fixed setting. It is installed on the suction pipe and blocks the compressors if the operating pressures drop below the tolerated values. Automatically resets as the pressure increases. If it activates frequently, the unit will block and can only be restarted by resetting via the user interface terminal. Recovery Version components VD / VR 16. Heat recovery exchanger. Specially designed for the specific version. Plate type or shell and tube, it is insulated with 19mm flexible closed-cell foam that forms barrier to prevent heat exchanges towards the outside. On request for some models it can be equipped with an electric antifreeze heater to prevent the components from freezing during winter periods at a standstill if the unit is not drained. Only Recovery Version VR 17. Heat recovery management valve. This delivers refrigerant to the condensing coils or heat recovery exchanger, depending on demands for hot water. 18. Liquid receiver.this is a plenum tank that accounts for the refrigerant charge variations required by the machine as the operating modes change (condensing in air or in water). -Differential water pressure switch that disables the heat recovery function if water fails to flow to the exchangers. - Liquid solenoid valves.. Allow the refrigerant charge to be recovered after operating mode changes from recovery to cooling and vice versa. - One-way valves. Make the refrigerant obligatorily pass through the appropriate heat exchangers (coils / heat recuperator), depending on the operating mode. 11B 12 11A B B A 8

9 ACCESSORIES AND OPTIONAL EQUIPMENT Available accessories NOTE: The accessories can be of the following type: (M): only installed in the factory. (F): supplied for installation by the customer. MP (F) Storage and Pumping Module (Storage on the Delivery or Storage on Return). The purpose of the storage and pumping module is to lower the number of compressor surges, increasing the amount of water in the system and, thus, its thermal inertia. It consists of a base made of galvanized and painted sheet metal and aluminium sheet panelling suitable for outdoor installation. Designed for connection alongside the chiller, the accessory comprises an insulated carbon steel tank, a single or double centrifugal pump with on-off valves, an electric power panel, expansion tank, safety valve, air vent, pressure gauge and filling and draining valves. FLS (M) Evaporator water flow switch. RAG 8 (M) Antifreeze heating element for Water Storange Tank of Pumping Module. GM (M) Pressure gauge unit. This consists of low pressure gauges and high pressure gauges (one low and one high pressure gauge for circuit). GP (M) Protective guard for the coils. Consisting of metal guard that protect the coils. GP (M) Anti-intrusion guard. Consisting of metal guard that protect the acces to hydraulic and refrigerant circuit. RB(M) Compressor suction shut-off valve. AVG (F) Rubber vibration dampers. Consisting of an adequate number of rubber vibration dampers, which varies depending on the model, to install under the unit. They reduce the mechanical vibrations generated by the compressor and fans during their normal operation, that are then transmitted to the bearing surface of the machine. The insulation degree provided by the vibration dampers is about 90%. OP (F) Programmer Clock, applied to the remote ON/OFF function. CR (F) Remote Control. Repeats the functions of the control system installed in the unit, thus allowing this latter to be controlled at a distance (up to 100 m) from the unit. INT (M) RS485 Serial interface, for communication with the MODBUS protocol. CSF (M) Voltage monitor and sequence meter. The device enables control of the correct sequence of power phases and the lack of any phases. It also ensures that the unit works within ± 10% the rated voltage (MIN=360 V - RATED=400V - MAX=440V). It blocks the unit if the voltage is outside the limits provided for. DCC (M) Head pressure control (as standard per low noise version AS and per Extra low noise version ASS). The device is made by 2 electrical drivers that, by means of phase cutting, control the fans speed rotation, with the scope of mantaining the condensation pressure inside the correct operating limits. Incorporated Pumping Modules with 2 pumps (M) This accessory consists of 2 pumps, inlet and outlet shutoff valves, check valves, manually-operated water drain and air vent. The accessory can be supplied in 4 different configurations 2P_STD Pumps 2 poles, standard head Useful head approx. 100 kpa (min 74 kpa - max 152 kpa) 2P_HP1 Pumps 2 poles, high head Useful head approx. 180 kpa (min 128 kpa - max 213 kpa) 2P_HP2 Pumps 2 poles, very high head Useful head approx. 250 kpa (min 187 kpa - max 262 kpa) 4P_STD Pumps 4 poles, standard head Useful head approx. 100 kpa (min 81 kpa - max 156 kpa) All the units can be equipped with any of the 4 configurations. - It is advisable to use pumps with 2 poles for STANDARD VERSION (AB) units - It is advisable to use pumps with 4 poles - much quieter than those with 2 poles - for SILENCED (AS) and SUPERSILENCED (ASS) VERSION UNITS. NB For some SILENCED VERSION (AS) models, pumps with 2 poles can be used in any case (see nominal performance tables). 9

10 ACCESSORIES AND OPTIONAL EQUIPMENT MP. Pumping module. Consists of: 1. Hydraulic pump. For circulating the water in the system. The pumps have high head and allow most system requirements to be met. The pump is protected by a motor cut-out fitted in the electrical panel of the cooler. Complete with water filling and drain plugs. 2. On-off butterfly valves. They are used to shut off parts such as the water filter, expansion tank and pump (if installed) that require routine or extraordinary maintenance. 3. Non-return valves. Present only if the Pumping Module accessory with 2 pumps (one valve for each pump) is installed. 4. Air vent. Shut off by a cock, it is located on the highest part of the water pipes. Specific Incorporated Accessories for Pumping Module A. Metal gauze water filter (F). Can be turned on and off and inspected. It is installed on the pump suction side. Prevents machining residues (dust, swarf, etc.) in the water pipes from entering the pump impeller or plate-type heat exchanger. B. Water pressure gauge (M). Displays the pressure of the water in the system. C. Surge chamber (M). This is a closed, diaphragm type chamber. It absorbs the variations in the volumes of water in the system caused by temperature variations. Water safety valve. On the water tank. It acts whenever faulty service leads to an operating pressure in the plumbing system that exceeds the valve opening value. C 4 B 1 3 A 2 1 B 10

11 ACCESSORIES AND OPTIONAL EQUIPMENT Mechanical options Special finned heat exchangers Coils with copper fins Coils with copper prepainted Electrical options Compressor thermal magnetic switches Fan thermal magnetic switches Compressor power factor improvement condensers Compressor soft-start Compressor enabling selectors 11

12 GENERAL SPECIFICATIONS - IR UNIT FOR COOLING MODE ONLY General technical specifications Basic Version Unit Acoustic Version: AB (Basic Version) The following data refer to an IR unit using R134a refrigerant Model UM Cooling capacity (1)(E) kw Total power input (1)(E) kw EER (1)(E) 2,78 2,69 2,75 2,83 2,72 2,90 2,96 2,86 2,86 2,76 2,80 2,94 W/W ESEER (E) 3,63 3,51 3,62 3,74 3,60 3,85 3,85 3,82 3,81 3,72 3,78 4,01 W/W Refrigerant charge Take as reference the refrigerant charge value on the Unit Identification plate kg Compressor specifications Type DOUBLE-SCREW - Quantity 2 N Capacity control % % Starting type PART WINDING STAR-DELTA - Power input kw Evaporator data Type SHELLAND TUBE HEAT EXCHANGER - Quantity 1 N Maximum pressure on wet side 1000 kpa Total water capacity I Water flow rate (1) 15,9 17,5 19,8 22,4 24,4 29,1 31,8 35,5 38,3 42,6 47,2 53,2 l/s Water pressure drop (1) (E) kpa Fan specifications Quantity N Diameter [ ] 800 mm Maximum rotation speed 900 rpm Maximum motor input power 2 kw Total air flow rate l/s Total power imput (1) 14,4 14,4 14,4 14,4 18,0 18,0 18,0 21,6 21,6 25,2 25,2 28,8 kw Coils specifications Type Copper pipes notched aluminium fins / Quantity 4 N Total area m 2 Electrical specifications (unit without accessories) Electric power supply 400/3/50 V/ph/Hz FLA Maximum current input A FLI Maximum power input kw MIC Maximum surge current A Data for Pumping Module 2 POLES accessory (1) STD pump Power input kw STD Working head kpa STD Weight transport / operation 232/ / / / / / / / / / / /641 kg HP1 pump Power input kw HP1 Working head kpa HP1 Weight transport / operation 278/ / / / / / / / / / / /665 kg HP2 pump Power input kw HP2 Working head kpa HP2 Weight transport / operation 287/ / / / / / / / / / / /694 kg Noise levels Total SWL (E) db(a) NOTES: (E):Data certificated by EUROVENT (1): The data refer to: Water temperature: inlet: 12 C - outlet: 7 C, Outdoor air temperature 35 C D.B. SWL = Sound power levels, with reference to 2x10-12 W. The Total sound power level in db(a) measured in compliance with ISO 9614 standards, is certified according to the Eurovent certification program. 12

13 GENERAL SPECIFICATIONS - IR UNIT FOR COOLING MODE ONLY Standard performances - Basic Version VB OUTDOOR AIR TEMPERATURE ( C D.B.) MODEL TW kwf kwa kwf kwa kwf kwa kwf kwa kwf kwa kwf kwa Tw= Outlet water temperature C kwf = Cooling capacity (kw). kwa = Compressor power input (kw) The standard performances refer to a 5 C temperature difference between the water entering and leaving the heat exchanger and to operation of the unit with all fans at top speed. A 0.44 x 10-4 m 2 K/W fouling factor has also been considered with the unit installed at zero meters above sea level (Pb = 1013mbar). 13

14 GENERAL SPECIFICATIONS - IR UNIT FOR COOLING MODE ONLY Acoustic Version: AS (Low noise version) The following data refer to an IR unit using R134a refrigerant Model UM Cooling capacity (1)(E) kw Total power input (1)(E) kw EER (1)(E) 2,72 2,61 2,63 2,68 2,64 2,64 2,73 2,70 2,65 2,62 2,61 2,76 W/W ESEER (E) 3,75 3,58 3,61 3,67 3,61 3,60 3,74 3,68 3,64 3,61 3,60 3,86 W/W Refrigerant charge Take as reference the refrigerant charge value on the Unit Identification plate kg Compressor specifications Type TWIN-SCREW - Quantity 2 N Capacity control % % Starting type PART WINDING STAR-DELTA - Power input kw Evaporator data Type SHELLAND TUBE HEAT EXCHANGER - Quantity 1 N Maximum pressure on wet side 1000 kpa Total water capacity I Water flow rate (1) 15,3 16,9 19,1 21,4 23,6 27,1 30,7 34,2 36,7 40,9 45,1 51,6 l/s Water pressure drop (1) (E) ka Fan specifications Quantity N Diameter [ ] 800 Nominal/Maximum rotation speed 700/900 rpm Maximum motor input power 2 kw Total air flow rate nom l/s max l/s Total power imput (1) nom 8,0 8,0 8,0 8,0 10,0 10,0 10,0 12,0 12,0 14,0 14,0 16,0 kw max 14,4 14,4 14,4 14,4 18,0 18,0 18,0 21,6 21,6 25,2 25,2 28,8 kw Coils specifications Type Copper pipes notched aluminium fins / Quantity 4 N Total area m 2 Electrical specifications (unit without accessories) Electric power supply 400/3/50 V/ph/Hz FLA Maximum current input A FLI Maximum power input kw MIC Maximum surge current A Spec. of Pumping module 2 POLES (1) USABLE NOT RECOMMENDED UM STD pump Power input kw STD Working head kpa STD Weight transport / operation 232/ / / / / / / / / / / /641 kg HP1 pump Power input kw HP1 Working head kpa HP1 Weight transport / operation 278/ / / / / / / / / / / /665 kg HP2 pump Power input kw HP2 Working head kpa HP2 Weight transport / operation 287/ / / / / / / / / / / /694 kg Spec. of Pumping module 4 POLES (1) RECOMMENDED UM Pump Power input kw Working head kpa Weight transport / operation 372/ / / / / / / / / / / /908 kg Noise levels Total SWL (E) db(a) NOTES: (E):Data certificated by EUROVENT (1): The data refer to: Water temperature: inlet: 12 C - outlet: 7 C, Outdoor air temperature 35 C D.B. SWL = Sound power levels, with reference to 2x10-12 W. The Total sound power level in db(a) measured in compliance with ISO 9614 standards, is certified according to the Eurovent certification program. 14

15 GENERAL SPECIFICATIONS - IR UNIT FOR COOLING MODE ONLY Standard performances - Low noise version AS MODEL TW OUTDOOR AIR TEMPERATURE ( C D.B.) kwf kwa kwf kwa kwf kwa kwf kwa kwf kwa kwf kwa Tw= Outlet water temperature C kwf = Cooling capacity (kw). kwa = Compressor power input (kw) The standard performances refer to a 5 C temperature difference between the water entering and leaving the heat exchanger and to operation of the unit with all fans at nominal or maximum speed. A 0.44 x 10-4 m 2 K/W fouling factor has also been considered with the unit installed at zero meters above sea level (Pb = 1013mbar). : in these working points the unit works with fans at the maximum speed. 15

16 GENERAL SPECIFICATIONS - IR UNIT FOR COOLING MODE ONLY Acoustic Version: ASS (Extra Low Noise Version) The following data refer to an IR unit using R134a refrigerant Model UM Cooling capacity (1)(E) kw Total power input (1)(E) kw EER (1)(E) 2,49 2,55 2,52 2,51 2,58 2,44 2,60 2,56 2,53 2,63 2,56 2,67 W/W ESEER (E) 3,50 3,58 3,50 3,48 3,56 3,37 3,61 3,56 3,52 3,69 3,59 3,78 W/W Refrigerant charge Take as reference the refrigerant charge value on the Unit Identification plate kg Compressor specifications Type TWIN-SCREW - Quantity 2 N Capacity control % % Starting type PART WINDING STAR-DELTA - Power input kw Evaporator data Type SHELLAND TUBE HEAT EXCHANGER - Quantity 1 N Maximum pressure on wet side kpa Total water capacity I Water flow rate (1) 14,6 16,8 18,7 20,8 23,4 26,3 30,4 33,4 36,0 41,3 45,1 51,4 l/s Water pressure drop (1) (E) ka Fan specifications Quantity N Diameter [ ] 800 Nominal/Maximum rotation speed 550/670 rpm Maximum motor input power 2 kw Total air flow rate nom l/s max l/s Total power imput (1) nom 5,6 5,6 5,6 5,6 7,0 7,0 8,4 9,8 9,8 11,2 11,2 14,0 kw max 8,8 8,8 8,8 8,8 11,0 11,0 13,2 15,4 15,4 17,6 17,6 22,0 kw Coils specifications Type Copper pipes notched aluminium fins / Quantity 4 8 N Total area m 2 Electrical specifications (unit without accessories) Electric power supply 400/3/50 V/ph/Hz FLA Maximum current input A FLI Maximum power input kw MIC Maximum surge current A Spec. of Pumping module 4 POLES (1) Pump Power input kw Working head kpa Weight transport / operation 372/ / / / / / / / / / / /908 kg Noise levels Total SWL (E) db(a) NOTES: (E):Data certificated by EUROVENT (1): The data refer to: Water temperature: inlet: 12 C - outlet: 7 C, Outdoor air temperature 35 C D.B. SWL = Sound power levels, with reference to 2x10-12 W. The Total sound power level in db(a) measured in compliance with ISO 9614 standards, is certified according to the Eurovent certification program. 16

17 GENERAL SPECIFICATIONS - IR UNIT FOR COOLING MODE ONLY Standard performances - Extra low noise Version ASS OUTDOOR AIR TEMPERATURE ( C D.B.) MODEL TW kwf kwa kwf kwa kwf kwa kwf kwa kwf kwa kwf kwa Tw= Outlet water temperature C kwf = Cooling capacity (kw). kwa = Compressor power input (kw) The standard performances refer to a 5 C temperature difference between the water entering and leaving the heat exchanger and to operation of the unit with all fans at nominal or maximum speed. A 0.44 x 10-4 m 2 K/W fouling factor has also been considered with the unit installed at zero meters above sea level (Pb = 1013mbar). : in these working points the unit works with fans at the maximum speed. 17

18 GENERAL SPECIFICATIONS - BRINE VERSION (VI) Brine Version (VI) Correction factors to apply to the basic version data Brine pencentage 20% Ethylene Glycol freezing point [ C] -8 Produced water temperature Refrigerating power c.f. 0,912 0,855 0,798 0,738 0, Power input c.f. 0,967 0,957 0,947 0,927 0, Water flow rate c.f. 0,984 0,899 0,821 0,750 0,685 0,620 0,561 Water pressure drop c.f. 1,289 1,071 0,890 0,740 0,615 0,490 0,390 Brine pencentage 30% Ethylene Glycol freezing point [ C] -14 Produced water temperature Refrigerating power c.f. 0,899 0,842 0,785 0,725 0,670 0,613 0,562 Power input c.f. 0,960 0,950 0,940 0,920 0,890 0,870 0,840 Water flow rate c.f. 1,013 0,928 0,851 0,780 0,715 0,650 0,591 Water pressure drop c.f. 1,431 1,184 0,979 0,810 0,670 0,530 0,419 Brine pencentage 40% Ethylene Glycol freezing point [ C] -22 Produced water temperature Refrigerating power c.f. 0,884 0,827 0,770 0,710 0,655 0,598 0,547 Power input c.f. 0,880 0,870 0,860 0,840 0,810 0,790 0,760 Water flow rate c.f. 1,062 0,970 0,887 0,810 0,740 0,670 0,607 Water pressure drop c.f. 1,542 1,279 1,061 0,880 0,730 0,580 0,461 A calculation example showing how the table is used is given below. Consider unit IR in the Basic Version with: - Refrigerating power of the Basic Version unit (VB): Pf VB = 594 kw - Power draw of the Compressors in the Basic Version unit (VB): Pass CP,VB = 191 kw - Water Flow Rate of the Basic Version unit (VB): Q VB = 28.4 l/s - Load losses of the Basic Version unit (VB): Δp VB = 53 kpa - with 30% brine and -2 C temperature of the water produced The corresponding values for the Brine Version are: - Refrigerating power Pf VI =Pf VB x(0.725) = 431 kw - Compressor power draw Pass CP,VI =Pass CP,VB x(0.92)= 176 kw - Water flow rate Q VI =Q VB x(0.78)= 22.2 l/s - Losses of head Δp VI =Δp VB x(0.81)= 43 kpa If you need to calculate the performances of the unit with outdoor air temp. different than 35 C, you have to use the values for Pf VB and Pass CP,VB reported on the tables standard performances for the requisited air temp. and with water leaving temp=7 C. With Pf VB calculate Q VB and using the graph water pressure drop Basic Version you have Δp VB. Then apply the corrective coefficients indicated on the tables for VI. For use with other types of non-freezing mixtures, please contact our sales department. 18

19 TECHNICAL SPECIFICATIONS FOR RECOVERY VERSION IR UNITS FOR COOLING ONLY Version with Desuperheater (VD) Recovery heat exchanger specifications Model UM Type of recovery exchanger A B Quantity 2 N Max. operating pressure on wet side 1000 kpa Total water content of recovery exchangers l A: STAINLESS STEEL BRAZE PLATES B: SHELL AND TUBE The data refer to: Water temperature: evaporator inlet :12 C - evaporator outlet: 7 C, Outdoor air temperature 35 C. The data refer to: Water temperature: recovery inlet :40 C - recovery outlet: 45 C. Technical specifications of Basic Version Model UM Recovered heating capacity kw Recovered water flow rate 4,5 5,2 5,8 6,4 7,2 8,2 8,8 10,1 11,1 12,7 14,0 15,0 l/s Recovered water pressure drop kpa Technical specifications of Low noise version Model UM Recovered heating capacity kw Recovered water flow rate 4,6 5,4 6,1 6,7 7,5 8,7 9,6 10,8 11,8 13,3 14,8 15,9 l/s Recovered water pressure drop kpa Technical specifications of Extra low noise Version Model UM Recovered heating capacity kw Recovered water flow rate 5,0 5,6 6,4 7,2 7,8 9,3 10,1 11,2 12,3 13,6 15,2 16,6 l/s Recovered water pressure drop kpa 19

20 TECHNICAL SPECIFICATIONS FOR RECOVERY VERSION IR UNITS FOR COOLING ONLY Recovered heating capacity in Version with Desuperheater (VD) MODEL TWR OUTDOOR AIR TEMPERATURE ( C D.B.) Basic version Low noise version Extra low noise version kwt r = RECOVERED HEATING CAPACITY [KW] ,6 70,4 91,9 102,3 114,6 126,9 67,4 73,4 95,9 106,7 119,5 132,3 73,0 79,5 103,8 115,5 129,4 143, ,7 64,0 83, ,2 115,3 49,7 66,8 87, ,6 120,3 53,8 72,3 94, ,6 130, ,7 47,2 67,0 83,7 94,9 106,3 32,0 49,3 69,8 87,3 98,9 110,8 34,7 53,3 75,6 94,5 107,1 120, ,8 82,5 107,8 119,9 134,3 148,7 78,5 85,6 111,7 124,3 139,2 154,1 82,0 89,3 116,6 129,8 145,4 161, ,9 75,0 98, ,1 135,2 57,9 77,8 101, ,6 140,1 60,5 81,2 106, ,2 146, ,0 55,4 78,5 98,1 111,2 124,5 37,3 57,4 81,4 101,7 115,3 129,1 38,9 59,9 85,0 106,2 120,4 134, ,8 92,4 120,6 134,2 150,3 166,4 88,3 96,2 125,5 139,7 156,5 173,2 93,1 101,5 132,5 147,4 165,1 182, ,5 84,0 109, ,6 151,3 65,1 87,4 114, ,2 157,5 68,7 92,2 120, ,1 166, ,3 62,0 87,8 109,8 124,4 139,4 41,9 64,5 91,4 114,3 129,5 145,1 44,2 68,0 96,5 120,6 136,7 153, ,8 102,2 133,5 148,5 166,3 184,1 98,0 106,8 139,4 155,1 173,7 192,3 104,3 113,6 148,3 165,0 184,8 204, ,2 92,9 121, ,2 167,4 72,3 97,1 126, ,9 174,8 76,9 103,2 134, ,0 186, ,6 68,6 97,2 121,5 137,7 154,2 46,5 71,6 101,5 126,9 143,8 161,1 49,5 76,2 108,0 135,0 153,0 171, ,6 115,1 150,3 167,2 187,3 207,3 109,1 118,9 155,2 172,7 193,4 214,1 114,0 124,2 162,1 180,4 202,0 223, ,9 104,6 136, ,2 188,5 80,5 108,1 141, ,8 194,7 84,1 112,9 147, ,7 203, ,2 77,2 109,4 136,8 155,0 173,7 51,8 79,7 113,0 141,3 160,1 179,4 54,1 83,3 118,1 147,6 167,3 187, ,9 129,5 169,0 188,1 210,7 233,2 126,5 137,8 179,9 200,2 224,2 248,2 135,5 147,6 192,8 214,5 240,2 266, ,6 117,7 153, ,5 212,0 93,3 125,3 163, ,8 225,7 100,0 134,2 175, ,4 241, ,4 86,8 123,1 153,9 174,4 195,4 60,1 92,4 131,0 163,8 185,6 208,0 64,4 99,0 140,4 175,5 198,9 222, ,6 140,1 182,9 203,5 227,9 252,3 139,0 151,4 197,7 220,0 246,4 272,8 146,7 159,8 208,6 232,1 260,0 287, ,8 127,3 166, ,2 229,4 102,5 137,7 179, ,0 248,0 108,2 145,2 189, ,3 261, ,1 93,9 133,2 166,5 188,7 211,4 66,0 101,6 144,0 180,0 204,0 228,5 69,6 107,1 151,9 189,9 215,2 241, ,4 160,5 209,6 233,2 261,2 289,2 156,4 170,4 222,4 247,5 277,2 306,9 163,3 177,9 232,3 258,5 289,5 320, ,7 145,9 190, ,4 262,9 115,3 154,9 202, ,0 279,0 120,5 161,8 211, ,2 291, ,0 107,7 152,6 190,8 216,2 242,2 74,3 114,3 162,0 202,5 229,5 257,1 77,6 119,3 169,2 211,5 239,7 268, ,6 174,9 228,4 254,1 284,6 315,1 171,7 187,0 244,2 271,7 304,3 336,9 178,6 194,6 254,1 282,7 316,6 350, ,4 159,0 207, ,7 286,4 126,6 170,0 222, ,6 306,3 131,7 176,9 231, ,8 318, ,2 117,3 166,3 207,9 235,6 263,9 81,5 125,4 177,8 222,3 251,9 282,2 84,8 130,5 185,0 231,3 262,1 293, ,9 201,4 263,0 292,6 327,7 362,8 193,2 210,5 274,8 305,8 342,5 379,2 197,4 215,0 280,7 312,4 349,9 387, ,3 183,1 239, ,9 329,8 142,5 191,4 249, ,4 344,7 145,6 195,5 255, ,1 352, ,8 135,1 191,5 239,4 271,3 303,9 91,8 141,2 200,2 250,2 283,6 317,6 93,7 144,2 204,5 255,6 289,7 324, ,0 221,1 288,7 321,2 359,7 398,3 214,8 234,0 305,5 339,9 380,7 421,5 221,0 240,8 314,4 349,8 391,8 433, ,7 201,0 262, ,0 362,1 158,4 212,7 277, ,1 383,2 163,0 218,9 285, ,2 394, ,4 148,3 210,2 262,8 297,8 333,6 102,0 156,9 222,5 278,1 315,2 353,1 105,0 161,5 229,0 286,2 324,4 363, ,6 237,0 309,4 344,3 385,6 426,9 232,2 252,9 330,2 367,4 411,5 455,6 241,2 262,7 343,0 381,7 427,5 473, ,4 215,4 281, ,6 388,1 171,2 229,9 300, ,1 414,2 177,9 238,8 311, ,6 430, ,3 158,9 225,4 281,7 319,3 357,6 110,2 169,6 240,5 300,6 340,7 381,6 114,5 176,2 249,8 312,3 353,9 396,5 The standard performances refer to a 5 C temperature difference between the water entering and leaving the heat exchanger and to operation of the unit with all fans at top speed. A 0.44 x 10-4 m 2 K/W fouling factor has also been considered with the unit installed at zero meters above sea level (Pb = 1013mbar). TWE: Evaporator outlet water temperature ( C) TWR: Recovered water temperature ( C) 20

21 Version with total recovery on all circuits (VR) TECHNICAL SPECIFICATIONS FOR RECOVERY VERSION IR UNITS FOR COOLING ONLY Recovery heat exchanger specifications Type of recovery exchanger A B Quantity 2 N Max. operating pressure on wet side 1000 kpa Total water content of recovery exchangers l A: STAINLESS STEEL BRAZE PLATES B: SHELL AND TUBE The data refer to: Water temperature: evaporator inlet :12 C - evaporator outlet: 7 C, Outdoor air temperature 35 C. The data refer to: Water temperature: recovery inlet :40 C - recovery outlet: 45 C (except mod /45 C). Technical specifications of Total Recovery Version Model UM Recovered heating capacity kw Recovered water flow rate 20,5 22,9 26,0 29,3 32,5 37,1 40,8 46,3 50,1 56,4 62,2 69,6 l/s Recovered water pressure drop kpa Recovered heating capacity in Total Recovery Version (VR) MODEL RECOVERED WATER TEMPERATURE ( C D.B.) TWE kwt r = RECOVERED HEATING CAPACITY [KW] MODEL RECOVERED WATER TEMPERATURE ( C D.B.) TWE kwt r = RECOVERED HEATING CAPACITY [KW] The standard performances refer to a 5 C temperature difference between the water entering and leaving the heat exchanger and to operation of the unit with all fans at top speed. A 0.44 x 10-4 m 2 K/W fouling factor has also been considered with the unit installed at zero meters above sea level (Pb = 1013mbar). TWE: Evaporator outlet water temperature ( C) TWR: Recovered water temperature ( C) 21

22 NOISE LEVELS The noise levels refer to units operating in the nominal conditions (water temperature: inlet: 12 C - outlet: 7 C, Outdoor air temperature 35 C). The acoustic pressure levels are measured 1/ 5 / 10 meters away from the outer surface of the unit operating in the free field and resting on a reflecting surface (directional factor of 2). SWL = Sound power levels, with reference to 2x10-12 W. The Total sound power level in db(a) measured in compliance with ISO 9614 standards, is certified according to the Eurovent certification program. Eurovent certification (E) exclusively refers to the Total Sound Power in db(a), which is therefore the only binding acoustic specification (the values of the Octave bands in the table are indicative). SPL = Sound pressure levels, with reference to 2x10-5 Pa. The sound pressure levels are values calculated by applying the ISO-3744 relation (Eurovent 8/1) and refer to a distance of 1 meter away from the external surface of units operating in the open field with directivity factor 2 and the units operating in nominal conditions in the cooling mode. AB Basic Version SWL (db) Mod. Octave bands (Hz) Total SPL (dba) db db(a) (E) 1m 5m 10m AS Low noise version SWL (db) Mod. Octave bands (Hz) Total SPL (dba) db db(a) (E) 1m 5m 10m ASS Extra low noise version SWL (db) Mod. Octave bands (Hz) Total SPL (dba) db db(a) (E) 1m 5m 10m (E):Data certificated by EUROVENT 22

23 OPERATING RANGE Operating range Basic Version The table below lists the operating ranges within which correct operation of the units is guaranteed, depending on the Version and Operating Mode available for each type of unit. Remember that in Heat Pump units, heat recovery only takes place during operation in the cooling mode. Operating range of Basic Version Thermal gradient of the water Limit value Minimum C 4 Maximum C 8 12 [ C] WATER OUTLET TEMPERATURE ΔT Water= 5 C 7 6 OUTDOOR AIR TEMPERATURE [ C B.S.] D.B.] With accessory Head pressure control (brine is recommended) With accessory Head pressure control (standard for AS e ASS) Operating range for Recovery version Version with Desuperheater (VD) Total Recovery (VR) Limit value Recovery water temp. from 40 to 50 C (Refer to Desuperheater Standard Performances table) See graphic below 12 [ C] EVAPORATOR WATER OUTLET TEMPERATURE [ C] RECOVERED WATER OUTLET TEMPERATURE Operating range for BRINE VERSION (VI) 5 [ C] OUTLET WATER TEMPERATURE Use water glicol as specified in the paragraph Specification data for Brine Version (VI). 0-8 OUTDOOR AIR TEMPERATURE [ C B.S.] 23

24 WATER PRESSURE DROP EVAPORATOR The graph below illustrates for the evaporator the water pressure drop values in kpa depending on the flow rate in liters/second. The operating range is delimited by the minimum and maximum values given in the next table Water pressure drop (kpa) Operating range Water flow rate (l/s) Mod UM NOTES Graph reference Q l\s Q= Water flow rate Limit value Δp 20 kpa Q l\s Δp 110 kpa Δp= Water pressure drop 24

25 WORKING HEAD 2P_STD PUMPS 2 POLES, STANDARD HEAD) Working head is that at the pumping module outlet reduced by all pressure losses inside the unit. The graph below illustrates for the evaporator the working head values in kpa depending on the flow rate in liters/second. The operating range is delimited by the minimum and maximum values given in the next table Working head (kpa) Operating range Water flow rate (l/s) Mod UM NOTE Graph reference Limit value QMIN l\s ΔpMAX kpa QMAX l\s ΔpMIN 0 kpa Q= Water flow rate Δp= Working head 25

26 WORKING HEAD 2P_HP1 PUMPS 2 POLES, HIGH HEAD Working head is that at the pumping module outlet reduced by all pressure losses inside the unit. The graph below illustrates for the evaporator the working head values in kpa depending on the flow rate in liters/second. The operating range is delimited by the minimum and maximum values given in the next table Working head (kpa) Operating range Water flow rate (l/s) Mod UM NOTE Graph reference Limit value QMIN l\s ΔpMAX kpa QMAX l\s ΔpMIN 0 kpa Q= Water flow rate Δp= Working head 26

27 WORKING HEAD 2P_HP2 PUMPS 2 POLES, VERY HIGH HEAD Working head is that at the pumping module outlet reduced by all pressure losses inside the unit. The graph below illustrates for the evaporator the working head values in kpa depending on the flow rate in liters/second. The operating range is delimited by the minimum and maximum values given in the next table Working head (kpa) Operating range Water flow rate (l/s) Mod UM NOTE Graph reference Limit value QMIN l\s ΔpMAX kpa QMAX l\s ΔpMIN 0 kpa Q= Water flow rate Δp= Working head 27

28 WORKING HEAD 4P_STD PUMPS 4 POLES, STANDARD HEAD Working head is that at the pumping module outlet reduced by all pressure losses inside the unit. The graph below illustrates for the evaporator the working head values in kpa depending on the flow rate in liters/second. The operating range is delimited by the minimum and maximum values given in the next table Working head (kpa) Operating range Water flow rate (l/s) Mod UM NOTE Graph reference Limit value QMIN l\s ΔpMAX 0 kpa QMAX l\s ΔpMIN kpa 9 Q= Water flow rate Δp= Working head 28

29 WATER PRESSURE DROP DESUPERHEATER The graph below illustratesfor the desupherheater exchanger the water pressure drop values in kpa depending on the flow rate in liters/second. The operating range is delimited by the minimum and maximum values given in the next table Water pressure drop (kpa) Water flow rate (l/s) Operating range Mod UM NOTES Graph reference Lower limit value Upper limit value Q l\s Δp 10 kpa Q l\s Δp 80 kpa Q=Water flow rate Δp=Water pressure drop 29

30 WATER PRESSURE DROP RECOVERY VERSION The graph below illustrates for the recovery exchanger the water pressure drop values in kpa depending on the flow rate in liters/second. The operating range is delimited by the minimum and maximum values given in the next table Water pressure drop (kpa) Operating range Water flow rate (l/s) Mod UM NOTES Graph reference Lower limit value Upper limit value Q l\s Δp 20 kpa Q l\s Δp 100 kpa Q=Water flow rate Δp=Water pressure drop 30

31 WATER FILTER PRESSURE DROP The following graph shows the water filter pressure drop values in kpa as a function of flow rate in litres/second. The operating range is delimited by the minimum and maximum value of the corresponding model Water pressure drop (kpa) Water flow rate (l/s) Mod Graph reference

32 MAXIMUM VOLUME OF WATER Maximum volume of water of the system with Module Pumping Before filling the water supply system, it is advisable to consider the type of installation in question, i.e. check the difference in level between the wet module and user. The following table gives the maximum water content of the water supply system in liters, depending on the capacity of the standard surge chamber supplied and the pressure at which it should be charged. The surge chamber setting must be regulated to suit the maximum positive difference in level of the user. Maximum setting value 600 kpa. With a positive H of more than meters, calculate the surge chamber s service charge value in kpa using the formula below: Surge chamber service charge= [H/ ]x100 = [kpa] NOTE. In case A, make sure that the user s lowest point is able to withstand the global pressure. Tab.1 Model Surge chamber volume (liters) 24 24x2 Thermal expension of water (10-40 C) H (meters) Surge chamber pressure (kpa) Maximum total volume of water supply system (liters) Case A H <0 150 (standard) < H < (standard) Case B NOTE: If the unit operates with brine, calculate the real volume of the system by taking into account the corrective factors for the volume of the system given in the table below. Corrective factors per total maximum volume of the system with brine % of brine 0% 10% 20% 30% 40% Cooling Mode Heating Mode CASE B U CHILLER U= User CASE A U 32

33 ARRIVAL Inspections on arrival As soon as the appliance is consigned, it is essential to make sure that all the ordered items have been received and that the shipment is complete. Carefully check that the equipment has not been damaged. If visible damage is discovered, immediately inform the haulage contractor and write Collected with reserves owing to evident damage on the consignment note. Delivery ex works means that, as established by law, reimbursement of any damages is at the insurance company s charge. Safety regulations Comply with the current safety regulations concerning the equipment to use when handling the unit or the required ways of operating. Handling Check the weight of the appliance before proceeding with the moving and handling operations. The weight is indicated on the data plate of the appliance and in the WEIGHTS AND CENTERS OF GRAVITY DURING TRASPORT AND OPERATION section of this manual. Make sure that the appliance is handled with care and without jolting as rough treatment could damage the functional parts of the machine. Comply with the following instructions when lifting and positioning the appliance: Handling and lifting with a crane or similar 1) Using the brackets (Part 1 Fig.1) located by the lifting holes (refer to part 3 in the Dimensional data section). 2) Position metal pipes (Part 2 Fig.1) of adequate thickness in the holes in the base of the unit for lifting. The end portions of the pipes must stand out by an adequate extent to permit inserting the safety devices and housing the belts for lifting. Use spacer bars in the top of the unit to prevent crushing and damaging the batteries and the parts intended to cover the assembly. Consult the WEIGHTS AND CENTERS OF GRAVITY DURING TRASPORT AND OPERATION section for the center of gravity position. NOTE: To correctly lift the machine, the belts used must be longer than 3.5 meters. Refer to the data plates (Part.3 Fig.1) that identify the center of gravity position, applied to the 4 sides of the base. 87 Ø60 Ø100 L MIN 3.5m Part.1 Part.2 Part.3 Fig.1 L MIN 3.5m WARNING: To safeguard persons and property, read the information on the packing that covers the unit before handling. Also make sure to: Handle the machine with care Do not stack other objects on top of the unit Storage The units must be stored in a dry place, sheltered from the sun, rain, sand and wind. Comply with the storage conditions given below: Do not stack the units Minimum temperature = -10 C Maximum temperature = 60 C Humidity = 90% 33

34 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS / ASS AB / AS / ASS Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit The unit water inlet (IN) and outlet (OUT) occur through 4 flexible Victaulic couplings (DN 100). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 4 (DN 100) flexible joints. A W3 CP2 W1 B * EVAPORATOR W4 W2 * Center distance for vibration damper holes f=17mm W1-W4 - they indicate the position where the spring antivibration dampers (accessory) are installed. CP1 Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 WEIGHT WEIGHT AB AS ASS AB AS ASS * * - only for transport EVAPORATOR Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 34

35 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS / ASS * 1 Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit * - only for transport The unit water inlet (IN) and outlet (OUT) occur through 5 flexible Victaulic couplings (DN 125). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 4 (DN 100) flexible joints. A W3 CP2 W1 B 1978* EVAPORATOR W4 CP1 W2 * Center distance for vibration damper holes f=17mm W1-W4 - they indicate the position where the spring antivibration dampers (accessory) are installed. 384 EVAPORATOR Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 WEIGHT WEIGHT AB AS ASS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 35

36 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS / ASS * * - only for transport Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit The unit water inlet (IN) and outlet (OUT) occur through 5 flexible Victaulic couplings (DN 125). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 4 (DN 100) flexible joints. A W3 CP2 W1 B 1978* EVAPORATOR W4 CP1 W2 * Center distance for vibration damper holes f=17mm W1-W4 - they indicate the position where the spring antivibration dampers (accessory) are installed. 384 EVAPORATOR Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 WEIGHT WEIGHT AB AS ASS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 36

37 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS / ASS Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit * * - only for transport The unit water inlet (IN) and outlet (OUT) occur through 5 flexible Victaulic couplings (DN 125). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 4 (DN 100) flexible joints. A W4 CP2 B 1457* W5 EVAPORATOR 1457* CP1 * Center distance for vibration damper holes f=17mm W1-W6 - they indicate the position where the spring antivibration dampers (accessory) are installed. W6 W1 W2 W3 385 EVAPORATOR Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 WEIGHT WEIGHT AB AS ASS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 37

38 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS / ASS Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit * * - only for transport The unit water inlet (IN) and outlet (OUT) occur through 6 flexible Victaulic couplings (DN 150). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 1457* 425 W4 W5 W6 Minimum space required for operation EVAPORATOR Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply A CP2 CP1 with the measurements for the free area that must be left W1 W2 W3 around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area B of not less than 2.5 meters above unit. * Center distance for vibration damper holes f=17mm The functional areas must be W1-W6 - they indicate the position where the spring antivibration dampers (accessory) are installed. doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 WEIGHT WEIGHT AB AS ASS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 38

39 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit * * - only for transport The unit water inlet (IN) and outlet (OUT) occur through 6 flexible Victaulic couplings (DN 150). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 1457* 425 A W4 CP2 B W5 EVAPORATOR CP1 * Center distance for vibration damper holes f=17mm W1-W6 - they indicate the position where the spring antivibration dampers (accessory) are installed. W6 W1 W2 W3 Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 WEIGHT WEIGHT AB AS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 39

40 DIMENSIONAL AND PHYSICAL DATA Mod ASS * * - only for transport Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit In the following draings the measuras are refered to the base plate of the unit. The unit water inlet (IN) and outlet (OUT) occur through 6 flexible Victaulic couplings (DN 150). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 1457* 425 A W4 CP2 B W5 EVAPORATOR W6 CP1 W1 W2 W3 * Center distance for vibration damper holes f=17mm W1-W6 - they indicate the position where the spring antivibration dampers (accessory) are installed. Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 WEIGHT WEIGHT ASS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 40

41 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS * * - only for transport Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit The unit water inlet (IN) and outlet (OUT) occur through 6 flexible Victaulic couplings (DN 150). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 2155* 938* 425 W5 W6 W7 W8 Minimum space required for operation EVAPORATOR Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, A CP2 CP1 comply with the measurements for the free area that W1 W2 W3 W4 must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. B NOTE: Allow for a clear area of not less than 2.5 meters above unit. * Center distance for vibration damper holes f=17mm The functional areas must be W1-W8 - they indicate the position where the spring antivibration dampers (accessory) are installed. doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 W7 W8 WEIGHT WEIGHT AB AS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 41

42 DIMENSIONAL AND PHYSICAL DATA Mod ASS * * - only for transport Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit In the following draings the measuras are refered to the base plate of the unit. The unit water inlet (IN) and outlet (OUT) occur through 6 flexible Victaulic couplings (DN 150). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 2155* 938* 425 A W5 CP2 W1 B W6 EVAPORATOR W2 W7 W3 CP1 W8 W4 * Center distance for vibration damper holes f=17mm W1-W8 - they indicate the position where the spring antivibration dampers (accessory) are installed. Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 W7 W8 WEIGHT WEIGHT ASS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 42

43 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS * * - only for transport Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit The unit water inlet (IN) and outlet (OUT) occur through 6 flexible Victaulic couplings (DN 150). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 2155* 938* 425 A W5 CP2 W1 B W6 EVAPORATOR W2 W7 W3 CP1 Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 W7 W8 WEIGHT WEIGHT AB AS W8 W4 * Center distance for vibration damper holes f=17mm W1-W8 - they indicate the position where the spring antivibration dampers (accessory) are installed. Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 43

44 DIMENSIONAL AND PHYSICAL DATA Mod ASS * * - only for transport Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit In the following draings the measuras are refered to the base plate of the unit. The unit water inlet (IN) and outlet (OUT) occur through 6 flexible Victaulic couplings (DN 150). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 2155* 938* 425 A W5 CP2 W1 B W6 EVAPORATOR W2 W7 W3 CP1 W8 W4 * Center distance for vibration damper holes f=17mm W1-W8 - they indicate the position where the spring antivibration dampers (accessory) are installed. Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 W7 W8 WEIGHT WEIGHT ASS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 44

45 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS * * - only for transport Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit The unit water inlet (IN) and outlet (OUT) occur through 8 flexible Victaulic couplings (DN 200). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 1760* 1674* 474 A W5 CP2 W1 B W6 EVAPORATOR W2 Weights and position of the centre of gravity in transport and operation W7 W3 CP1 W8 W4 * Center distance for vibration damper holes f=17mm W1-W8 - they indicate the position where the spring antivibration dampers (accessory) are installed. Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 W7 W8 WEIGHT WEIGHT AB AS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 45

46 DIMENSIONAL AND PHYSICAL DATA Mod ASS * * - only for transport 1 Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit The unit water inlet (IN) and outlet (OUT) occur through 8 flexible Victaulic couplings (DN 200). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 1750* 1947* 474 A W5 CP2 W1 B W6 EVAPORATOR W2 W7 W3 W8 CP1 W4 * Center distance for vibration damper holes f=17mm W1-W8 - they indicate the position where the spring antivibration dampers (accessory) are installed. Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 W7 W8 WEIGHT WEIGHT ASS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 46

47 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS * * - only for transport 1 Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit The unit water inlet (IN) and outlet (OUT) occur through 8 flexible Victaulic couplings (DN 200). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 1760* 1674* 474 A W5 CP2 W1 B W6 EVAPORATOR W2 * Center distance for vibration damper holes f=17mm W1-W8 - they indicate the position where the spring antivibration dampers (accessory) are installed. W7 W3 W8 CP1 W4 Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 W7 W8 WEIGHT WEIGHT AB AS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 47

48 DIMENSIONAL AND PHYSICAL DATA Mod ASS * * - only for transport Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit 1 The unit water inlet (IN) and outlet (OUT) occur through 8 flexible Victaulic couplings (DN 200). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 1750* 1948* 474 A W5 CP2 W1 B W6 EVAPORATOR W2 W7 W3 W8 CP1 W4 * Center distance for vibration damper holes f=17mm W1-W8 - they indicate the position where the spring antivibration dampers (accessory) are installed. Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 W7 W8 WEIGHT WEIGHT ASS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 48

49 DIMENSIONAL AND PHYSICAL DATA Mod AB / AS * * - only for transport Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit The unit water inlet (IN) and outlet (OUT) occur through 8 flexible Victaulic couplings (DN 200). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 1750* 1948* 474 A W5 CP2 W1 B W6 EVAPORATOR W2 W7 W3 W8 CP1 W4 Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 W7 W8 WEIGHT WEIGHT AB AS * Center distance for vibration damper holes f=17mm W1-W8 - they indicate the position where the spring antivibration dampers (accessory) are installed. Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 49

50 DIMENSIONAL AND PHYSICAL DATA Mod ASS * 1 * - only for transport Description of the components 1 - Lifting points/brackets base holes = 100mm 2 - Display and keypad to control the unit In the following draings the measuras are refered to the base plate of the unit. The unit water inlet (IN) and outlet (OUT) occur through 8 flexible Victaulic couplings (DN 200). With the Pumping Module MP accessory, inlet (IN) occurs through Victaulic 6 (DN 150) flexible joints EVAPORATOR * 1750* 1948* 474 A W5 CP2 W1 B W6 EVAPORATOR W2 W7 W3 W8 CP1 W4 * Center distance for vibration damper holes f=17mm W1-W8 - they indicate the position where the spring antivibration dampers (accessory) are installed. Minimum space required for operation Refer to the figure alongside for the dimensions of the unit. To correctly install the unit, comply with the measurements for the free area that must be left around the machine, as shown in the figure. The distances must be doubled if the unit is to be installed in a pit. NOTE: Allow for a clear area of not less than 2.5 meters above unit. The functional areas must be doubled if multiple units are installed. Weights and position of the centre of gravity in transport and operation Operation Transport Mod. Antivibration dampers TOTAL TOTAL A B A B W1 W2 W3 W4 W5 W6 W7 W8 WEIGHT WEIGHT ASS NOTA: For Desuperheater versions the total weight increases of 3/4%. For Heat recovery versions the total weight increases of 8/10%. - If the unit is equipped with the Pumping Module MP accessory, refer to the extra weight indicated in the section Standard performance and technical data. 50

51 DIMENSIONAL AND PHYSICAL DATA Coils and Antintrusion Guard protection The unit is shipped with some Antintrusion guard not installed in order to avoid damages during the transport. Please refer to the attached drawings to install the guards. Each grill is fasten to the unit frame by 6 screw (4.8x13) Remove the Lift plates The lift plates could be removed unscrewing the 4 bolts fasten to base plate. In order to access to the electrical panel, at least remove the 2 lift plates in front of it. Vibration-damper installation To prevent the operating unit from transmitting vibrations to the bearing structure, vibration dampening materials should be inserted under the bearing points. The unit can be supplied with the rubber or spring vibration dampening accessory. This must be mounted by the installer. Base hole ø = 17 mm NOTE: If the unit is installed with spring vibration dampers, the height of the wet connections from the ground must be increased by the ΔH value. ΔH1 = 77±3 ΔHTOT ΔH1 ΔH0 The jack supplied with vibration-dampers gives a furter increase in weight of: ΔH0 = 40±10 Victaulic connections and water flow switch These comprise two wet connections of the Victaulic type (Fig. 1-A) composed by steel joint (Fig. 1-B) and rubber packing not installed (supplied with the unit). The steel joints are suitable to be welded or threaded. Fig.1 A VICTAULIC Nota: Supplied as accessory (see Accessory and optional equipment ) WATER FLOW SWITCH B TO WELD / TO THREAD 51

52 LAYOUT OF THE MAIN COMPONENT OF THE UNIT Mod. Mod. Mod. Mod. Mod. Mod. Mod. Mod. Mod. Mod. Mod AB / AS / ASS AB / AS / ASS AB / AS / ASS AB / AS / ASS AB / AS / ASS AB / AS / ASS AB / AS / ASS AB / AS / ASS AB / AS / ASS AB / AS AB / AS FANS CIRCUIT 1 CP2 EVAPORATOR CP1 ELECTRIC PANEL ELECTRIC PANEL FANS CIRCUIT 2 Mod. 900 ASS Mod ASS Mod AB / AS / ASS CP2 EVAPORATOR CP1 FANS CIRCUIT 1 ELECTRIC PANEL FANS CIRCUIT 2 ELECTRIC PANEL Mod ASS EVAPORATOR CP2 CP1 ELECTRIC PANEL FANS CIRCUIT 2 ELECTRIC PANEL FANS CIRCUIT 1 52

53 ELECTRICAL CONNECTIONS General rules The appliance must be wired in compliance with the laws in force in the country in which it is installed. The units are supplied fully wired in the factory and pre-engineered for connection to the electricity main. The electric panel is made in compliance with the technical standards in force in the European Union. Structure of the electric panel All the electrical components are contained in a closed casing protected against the atmospheric agents and inspectionable by opening the front door after removing the front panel. The door for accessing the power section is locked by the mechanism. Access for the supply cables and earth cable (PE) is permitted through the opening on the botton of the electric panel. Composition of the system The system comprises an electromechanical part consisting of the power circuit, with disconnecting device, contactors, fuses or thermal cutouts, transformer, and another part comprising the Microprocessor control system. NOTES: REFER TO THE WIRING DIAGRAM SUPPLIED WITH THE UNIT FOR THE LAYOUT OF THE ELECTRIC PANEL. Electrical connections All electrical connections must be carried out by qualified personnel in the absence of electric power. The table below gives the electrical specifications of the different constructional configurations of the units. Basic Version VB / VD / VR UNIT UM Power supply V-ph-Hz AB A TOTAL FLA AS A ASS A AB kw TOTAL FLI AS kw ASS kw AB A TOTAL MIC AS A ASS A NOTES: FLA= Power draw at maximum tolerated conditions LRA= Surge current Compressor specification Fan specification FLI= Electric power draw at maximum tolerated conditions MIC= Maximum surge current of the unit UNIT UM Power supply V-ph-Hz FLA CP CP A FLI CP CP kw LRA CP CP A UNIT UM Power supply V-ph-Hz AB A 4.3 FLA AS A ASS 2.3 A AB kw 2 FLI AS kw ASS 1.1 kw AB A 15 LRA AS A ASS 8.4 A For a complete information see the section Layout of the main component of the unit. 53

54 ELECTRICAL CONNECTIONS Pumps specifications PUMPS 2 POLES Pump FLA (A) FLI (kw) LRA (A) Power supply [V-ph-Hz] A 8,1 4,0 62 B 10 5,5 97 C 14 7,5 133 D E F 10 5,5 97 G H PUMPS 4 POLES Pump FLA (A) FLI (kw) LRA (A) Power supply [V-ph-Hz] A 11 5,5 65 B 15 7,5 94 C D E VB / VD / VR version + Pumping module AB_2P_STD - Standard Version Pumps 2 poles, standard head Unit UM Pump A A B B C C C D D D E E Type FLA (A) A FLI (kw) kw MIC (A) A AB_2P_HP1 - Standard Version Pumps 2 poles, high head Unit UM Pump F F C C D D D E E E G G Type FLA (A) A FLI (kw) kw MIC (A) A AB_P_HP2 - Standard Version Pumps 2 poles, very high head Unit UM Pump H C E E E E E G G G H G Type FLA A FLI kw MIC A AS_4P_STD - Silenced Version Pumps 4 poles, standard head Unit UM Pump A A A B B B C C C D D D Type FLA A FLI kw MIC A ASS_4P_STD - Super Silenced Version Pumps 4 poles, standard head Unit UM Pump A A A B B B C C C D D D Type FLA A FLI kw MIC A NOTES: Values for a power supply voltage of 400V-3~50Hz FLA= Power draw at maximum tolerated conditions LRA= Surge current FLI= Electric power draw at maximum tolerated conditions MIC= Maximum surge current of the unit 54

55 ELECTRICAL CONNECTIONS 1) Connection to the electricity main Power supply line; The machine s power supply line must be laid by following a clearly defined route in order to make it as correct as possible any without any breaks. Pass the line through the opening on the button of the electrical panel. Secure the line integral with the structure of the machine. Then continue inside the panel and connect the conductors directly to the input terminals of the main disconnecting device of the machine. Power supply system; The power cables of the machine s supply line must be taken from a system of symmetrical three-phase voltages and of a separate protection conductor. V= 400V ± 10% f= 50 Hz Protection on supply side: An automatic switch must be installed on the supply side of the side in order to protect against any overcurrents and indirect contacts that could occur when the machine is operating. It is advisable to install an automatic current limiter switch in order to limit the effective short-circuit current in the connecting point of the machine. This allows a protection device with a lower breaking capacity than that required in the connection point to be sized like the main circuit-breaker of the machine. The line and switch must be coordinated in compliance with the current laws governing electrical safety matters, regarding the type of installation and environmental conditions in which the machine must operate. Protection conductor (ground wire): The protection conductor from the feeder line must be connected straight to the ground screw identified by code PE, which ensures the equipotential connection of all metal grounding points and structural parts of the machine. 2) Electric panel Protection degree: The electric panel casing is made from sheet metal and has IP54 protection rating at the doors directly accessible from the outside. The other parts of the casing guarantee a protection degree that is at least equivalent to IP22, as established by the current laws in force: this has been achieved since the panel has further protection against the penetration of solid foreign bodies and atmospheric agents thanks to the machine structure in which it is housed. Starting and stopping function: The red handle on the panel door directly acts on the main circuit-breaker. The handle also acts as a door lock since it ensures that the machine is only powered when the door is shut. The stopping function carried out by the main circuit-breaker is classified as type 0 since the machine is stopped by immediately cutting off the power supply. 3) Reference standards The provisions established by the following Directives have been complied with to ensure the safety of the electrical products placed on the European Union market: - Low Voltage Directive 2006/95 EEC which also includes the following harmonized standards: CEI EN and Classification:CEI EN Safety of machinery. Electrical equipment of machines. Part 1: General rules. - Directive 2004/108/EEC concerning Electromagnetic compatibility. 4) User connection On the electric panel are available the terminal connection for: a) control of a pump group with 1 or 2 pumps and relative safety devices b) clear contact input for remote ON/OFF of the unit The following additional connections are present on Heat recovery versions: c) recovery circulating pump control and relative safety devices d) remote input for enabling of recovery mode For more details refer to the wiring diagram of the unit. 55

56 WET CONNECTIONS General rules A mesh filter (hole Ø 500 µm) must be installed on the unit s water inlet otherwise warranty is immediately forfeited. The filter performs the function of blocking any foreign matter in the system s plumbing circuit (shavings, machining debris, etc.). This prevents the shell and tube heat exchanger pipes from clogging then possibly freezing (and therefore bursting). Comply with the local laws governing safety matters in order to correctly design the hydraulic circuit. The following information gives suggestions on how to correctly install the unit. 1) Standard supply. Standard supply includes a differential pressure switch situated between the water inlet and outlet of the shell and tube heat exchanger to avoid freezing if the water flow stops for any reason. Activation is calibrated for a 80 mbar ±5 Δp, while resetting occurs with a Δp of 105 mbar ±5. The differential pressure switch opens the contact and shuts down the unit when the water delivery decreases and Δp 80 mbar ±5. The differential pressure switch closes and therefore the unit can restart when the water delivery increases and Δp 105 mbar ±5. The unit can be supplied (accessory) with an antifreeze heater an protection of the evaporator. This enables protecting the unit from winter frost down to an air temperature = -10 C. 2) With pumping module accessory. Besides the standard accessories, the unit is equipped with all the hydraulic components, as specified in the Options and accessories section. Hydraulic layout of the system General suggestions The pipes must have the least possible number of bends to minimize load losses and must be adequately supported in order to prevent the connections of the unit from being excessively stressed. Install on-off valves near components that need to be serviced to isolate them when maintenance work needs to be done and to allow them to be replaced without having to discharge the system. Before isolating the pipes and charging the system, carry out preliminary inspections to make sure that there are no leaks. Isolate all the chilled water pipes to prevent condensation from forming along the pipes themselves. Make sure that the material used is the steam barrier type, failing this, cover the insulation with an appropriate protection. Also make sure that the air venting valves can be accessed through the insulation. Do not forget to install or at least allow for the installation of pressure and temperature reading instruments on the inlet and outlet parts of the hydraulic circuit. These instruments will allow you to monitor the operation of the system. The circuit can be kept under pressure by means of an expansion tank and a pressure reducer. A plant filling unit can also be used in order to automatically charge the system and keep it at the desired pressure if it drops below a certain pressure value. Install manual or automatic values in the highest point of the system to eliminate air from the circuit. Fit manual or automatic valves at the highest point in the circuit in order to vent air from the circuit. If anti-vibration mounts are installed under the unit, it is recommended to use flexible couplings before and after the water circulation pump and near the unit. Install a cock on the outlet of the unit in order to regulate the water flow. Precautions for the Winter The water could freeze and damage the exchanger of the unit and other parts of the system during the winter period, if the system was to remain at a standstill. This problem can be obviated in 3 different ways: 1. Drain the system completely, taking care to drain the exchangers and the pumps (if present) in order to drain the unit s plumbing system completely, open the water drain ball valves and the air vent valves. N.B. The shell and tube evaporator is equipped with a water drain cock (Fig.1) and an air vent. EVAPORATOR AIR VENT Fig.1 PUMP AIR VENT Fig.2 2. Operate with brine mixture taking account, depending on the % of glycol, of the factor of correction of the refrigerating capacity, power input, water flow rate and losses of head (see table). 3. If it is certain that the unit will always be powered throughout the winter, the unit is able to protect itself from freezing, down to a temperature WATER DRAIN WATER DRAIN of -10 C: this is possible thanks to the antifreeze electric heating element installed on the exchanger and intelligent control of the water pump that must be governed by the microprocessor board (see the Electric Connections section). If the unit is fitted with a Storage tank, solution no. 3 requires installing the tank antifreeze heating element accessory. Correction factor for use of ethylene glycol with water produced betwen 6 12 C. % of gylcol in weight 0 10% 20% 30% 40% Freezing temperature Refrigerating power multiplier Power draw multiplier Water flow rate multiplier Load loss multiplier

57 WET CONNECTIONS Basic diagram for units with Heat Recovery [HOT WATER CIRCUIT] The basic diagram given is valid for all the Special Versions VD - VR The figure below shows the basic diagram of the portion of the system with the heat exchanger used for recovering partially or totally heating power that would otherwise be disposed of in the air. Basic diagram Basic Version VB [COOL WATER CIRCUIT] The following figures represent connections to the evaporator circuit. IMPORTANT: There must be a constant flow of water to the exchanger. OUT REC IN REC IN EV OUT EV CHILLER OUT IN IN QAB QB QA I QAB QB OUT Recovered hot water tank I = User system C = Chiller Pressure gauge Pump Air vent valve Water filling unit Thermometer Filter Safety valve B A AB Three-way driven valve On-off and/or water flow rate regulating valve Monitoring electronics (governor) Tank Expansion tank Coupling Recovery water flow inlet probe 57

58 WET CONNECTIONS Valve regulating diagram Three-way driven valve To prevent problems from occurring when the machine is started with very cold water, you are strongly advised to install a mixer valve as shown in the diagram. The valve must be regulated to suit the temperature at which the water flows into the recovery part (see diagram): the graph on the right shows the type of adjustment to use. QAB= 100% PORTATA WATER ACQUA FLOW RATE QA QB 0 30 c 35 c Recovery Temperatura INLET INGRESSO temperature Recupero PROTECTION DEVICES Protection devices The unit is protected against risk of overpressure by means of 4 levels protection chain. Each compressor and so each circuit is equipped with: 1) high pressure transducer connected to electronic controller 2) high pressure automatic switch connected to electronic controller 3) high pressure manual switch connected to compressor contactor command and to electronic controller 4) high pressure safety valve Protection devices technical data LEVEL DEVICE High pressure transducer High pressure automatic switch High pressure manual switch High pressure safety valve TRIP OUT 17.5 bar 18 bar 20 bar 22 bar TRIP IN 15 bar 14 bar MANUAL RESET 20 bar CONNECTED TO electronic controller electronic controller compressor contactor command and electronic cotroller to atmosphere EFFECT stop the compressor stop the compressor stop the compressor Discharge the refrigerant to and the fans. and the fans. and the fans. atmosphere to reduce the The electronic expansion The electronic expansion The electronic expansion system pressure valve closed valve closed valve closed RESET * YES by keyboard after the solution of the problem that generates the alarm YES by keyboard if the high pressure switch has trip-in and after the solution of the problem that generates the alarm 1) reset the button present on the manual pressure switch 2) then reset the alarm by keyboard Not Necessary *: For more details refers to section monitoring basic system. 58

59 REFRIGERANT FLOW DIAGRAM Refrigerant flow diagram basic version PPS (service) PAM TAP PAA VPI VPD TBP PBA PPS (service) TC V V BA BA PPS (service) PPS (service) VSF TC TC VSF RL RL SIL FD FD SIL SMC SMC RM RCO IDL IDL RIL RIL PPS (service) PPS (service) RM RCO CP CP VEE VEE SAC PPS (service) PPS (service) SAC TC TC SFT SIW SUW RA MA RA PDW MA FA IN OUT RAE R SF VE VSI VU VU SF P P F :Accessorio / optional :Iniezione liquido (optional) / Liquid injection (optional) :Rubinetto aspirazione (optional) / Suction valve (optional) R :Gruppo compressore / Compressor group IN :Tubazioni da isolare / Insulated pipes TC PPS (service) VPI VPD TBP PAM TAP PAA PBA PPS (service) BA CP FD IDL MA P PAM PDW RL RM SFT SCAMBIATORE A FASCIO TUBIERO SHELL AND TUBE HEAT EXCHANGER SIL SOLENOIDE INIEZIONE LIQUIDO (OPTIONAL) SIW SONDA INGRESSO ACQUA SMC SONDA MANDATA COMPRESSORE SUW SONDA USCITA ACQUA TAP TRASDUTTORE ALTA PRESSIONE TBP TRASDUTTORE BASSA PRESSIONE TC V VE Descrizione BATTERIA ALETTATA COMPRESSORE VITE F FILTRO ACQUA FILTRO DEIDRATORE INDICATORE LIQUIDO E UMIDITA' MANOMETRO ACQUA POMPA PAA PRESSOSTATO DI ALTA RIARMO AUTOMATICO AUTOMATIC RESET HIGH PRESSURE SWITCH PBA PRESSOSTATO DI BASSA AUTOMATICO AUTOMATIC LOW PRESSURE SWITCH PRESSOSTATO DI ALTA RIARMO MANUALE PRESSOSTATO DIFFERENZIALE ACQUA PPS PRESA DI PRESSIONE ¼ SAE CON SPILLO PRESSURE GAUGE WITH SCHRAEDER RAE RCO RESISTENZA ANTIGELO EVAPORATORE (OPTIONAL) RESISTENZA CARTER OLIO RUBINETTO DEL LIQUIDO RUBINETTO DI MANDATA TRONCHETTO DI CARICA VENTILATORE VASO DI ESPANSIONE Description COIL SCREW COMPRESSOR WATER FILTER FA FLUSSOSTATO ACQUA WATER FLOW SWITCH DRIER FILTER LIQUID AND MOISTURE INDICATOR WATER PRESSURE GAUGE PUMP MANUAL RESET HIGH PRESSURE SWITCH DIFFERENTIAL WATER PRESSURE SWITCH R RUBINETTO INTERCETTAZIONE SHUT-OFF VALVE RA RUBINETTO APIRAZIONE (OPTIONAL) SUCTION VALVE (OPTIONAL) EVAPORATOR ANTIFREEZE HEATER (OPTIONAL) OIL CRANKASE HEATER RIL RUBINETTO INIEZIONE DEL LIQUIDO (OPTIONAL) LIQUID INJECTION BALL VALVE (OPTIONAL) LIQUID VALVE DISCHARGE VALVE SAC SONDA ASPIRAZIONE COMPRESSORE SUCTION TEMPERATURE PROBE SF VALVOLA SFIATO ARIA AIR VENT VALVE LIQUID INJECTION SOLENOID VALVE (OPTIONAL) WATER INLET PROBE DISCHARGE TEMPERATURE PROBE WATER OUTLET PROBE HIGH PRESSURE TRANSDUCER LOW PRESSURE TRANSDUCER PIPE FOR REFRIGERANT FILLING FAN EXPANSION TANK VEE VALVOLA ESPANSIONE ELETTRONICA ELECTRONIC EXPANSION VALVE VPD VALVOLA PARZIALIZZAZIONE DECREMENTO DECREASING CONTROL CAPACITY VALVE VPI VALVOLA PARZIALIZZAZIONE INCREMENTO INCREASING CONTROL CAPACITY VALVE VSF VALVOLA DI SICUREZZA CIRCUITO FRIGO REFRIGERANT SAFETY VALVE VSI VALVOLA DI SICUREZZA ACQUA WATER SAFETY VALVE VU VALVOLA UNIDIREZIONALE CHECK VALVE 59

60 REFRIGERANT FLOW DIAGRAM Refrigerant flow diagram basic version with ECONOMIZER ONLY FOR MOD AND SMC RM RCO CP SAC TC VSF V BA RA VSE VU P E CO VTE R F R TC IN V PPS (service) PPS (service) BA TC RL RL VSF FD FD E CO VSE SMC VTE IDL IDL RM RCO PPS (service) PPS (service) CP VEE VEE PPS (service) PPS (service) SAC FA SIW SFT SUW MA PDW MA IN OUT RAE RA TC SF VE VSI VU SF P :Accessorio / optional :Rubinetto aspirazione (optional) / Suction valve (optional) :Gruppo compressore / Compressor group :Tubazioni da isolare / Insulated pipes TC PPS (service) PAM TAP PAA VPI VPD TBP PBA PPS (service) Descrizione Description BA BATTERIA ALETTATA COIL ECO ECONOMIZZATORE ECONOMIZER CP COMPRESSORE VITE SCREW COMPRESSOR F FILTRO ACQUA WATER FILTER FA FLUSSOSTATO ACQUA WATER FLOW SWITCH FD IDL MA P FILTRO DEIDRATORE INDICATORE LIQUIDO E UMIDITA' MANOMETRO ACQUA POMPA DRIER FILTER LIQUID AND MOISTURE INDICATOR WATER PRESSURE GAUGE PUMP PAA PRESSOSTATO DI ALTA RIARMO AUTOMATICO AUTOMATIC RESET HIGH PRESSURE SWITCH PBA PRESSOSTATO DI BASSA AUTOMATICO AUTOMATIC LOW PRESSURE SWITCH PAM PDW PRESSOSTATO DI ALTA RIARMO MANUALE PRESSOSTATO DIFFERENZIALE ACQUA MANUAL RESET HIGH PRESSURE SWITCH DIFFERENTIAL WATER PRESSURE SWITCH PPS PRESA DI PRESSIONE ¼ SAE CON SPILLO PRESSURE GAUGE WITH SCHRAEDER R RUBINETTO INTERCETTAZIONE SHUT-OFF VALVE RA RUBINETTO APIRAZIONE (OPTIONAL) SUCTION VALVE (OPTIONAL) RAE RCO RL RM RESISTENZA ANTIGELO EVAPORATORE (OPTIONAL) RESISTENZA CARTER OLIO RUBINETTO DEL LIQUIDO RUBINETTO DI MANDATA EVAPORATOR ANTIFREEZE HEATER (OPTIONAL) OIL CRANKASE HEATER LIQUID VALVE DISCHARGE VALVE SAC SONDA ASPIRAZIONE COMPRESSORE SUCTION TEMPERATURE PROBE SF SFT SIW VALVOLA SFIATO ARIA SCAMBIATORE A FASCIO TUBIERO SONDA INGRESSO ACQUA AIR VENT VALVE SHELL AND TUBE HEAT EXCHANGER WATER INLET PROBE SMC SONDA MANDATA COMPRESSORE DISCHARGE TEMPERATURE PROBE SUW SONDA USCITA ACQUA TAP TRASDUTTORE ALTA PRESSIONE WATER OUTLET PROBE HIGH PRESSURE TRANSDUCER TBP TRASDUTTORE BASSA PRESSIONE LOW PRESSURE TRANSDUCER TC V VE TRONCHETTO DI CARICA VENTILATORE VASO DI ESPANSIONE PIPE FOR REFRIGERANT FILLING FAN EXPANSION TANK VEE VALVOLA ESPANSIONE ELETTRONICA ELECTRONIC EXPANSION VALVE VPD VALVOLA PARZIALIZZAZIONE DECREMENTO DECREASING CONTROL CAPACITY VALVE VPI VALVOLA PARZIALIZZAZIONE INCREMENTO INCREASING CONTROL CAPACITY VALVE VSE VALVOLA SOLENOIDE ECONOMIZZATORE ECONOMIZER SOLENOID VALVE VSF VALVOLA DI SICUREZZA CIRCUITO FRIGO REFRIGERANT SAFETY VALVE VSI VALVOLA DI SICUREZZA ACQUA WATER SAFETY VALVE VTE VALVOLA TERMOSTATICA ECONOMIZZATORE ECONOMIZER THERMOSTATIC VALVE VU VALVOLA UNIDIREZIONALE CHECK VALVE 60 TC PPS (service) PAM TAP PAA VPI VPD TBP PBA PPS (service)

61 MONITORING SYSTEM BASIC VERSION CAUTION: IF THE ALARM SIGNAL RTC (REAL TIME CLOCK) APPEARS WHEN STARTING FOR THE FIRST TIME, SET THE DATE AND TIME IN THE RESPECTIVE DATE AND TIME MENU. User interface Control panel: composed of the instrument s front panel, equipped with an LCD display, three indicator LEDs and two joystick buttons, it enables viewing and/or checking the operating mode and parameters, resources and complete alarm diagnostics. In particular, it enables: Managing alarm situations Checking the status of resources. KEY 1.Display 2.Power supply LED 3.Joystick Function Button 4.LED for communication between the motherboard governing the unit and the keypad 5.Alarms LED 6.Joystick Menu Button 17:25 01/03 Cooling WATER in 12.0 C WATER out 7.0 C Joystick button: FUNCTION Using the four external positions (F1-F2-F3-F4) enables accessing the main functions directly: Pressing a single time: shows the main menu on the display. Pressing for a few seconds: directly accesses the menu associated with that particular position. KEY F1 : show the I/O base resources. KEY F2 : show the PARAMETER submenu (for the support service only, with password). KEY F3 : show the ALARMS submenu. KEY F4 : show the COMPRESSOR submenu. N.B. PRESSING THE BUTTON IN THE MIDDLE SWITCHES THE MACHINE ON-OFF (ON-OFF). Joystick button: MENU Used to scroll through the menus by acting on the four positions (UP; DOWN; LEFT; RIGHT) pressing a single time; in particular: Position UP: scrolls through the menu items upwards or increases the value of a parameter. Position LEFT (ESC): returns to the previous menu. Position DOWN: scrolls through the menu items downwards or decreases the value of a parameter. Position RIGHT: moves into the submenu, confirms an action, enters editing a value or again confirms a changed value. N.B. PRESSING THE (ENTER) BUTTON IN THE MIDDLE CONFIRMS THE COMMAND OR ACCESS- ES THE DISPLAYED MENU. 61

62 MONITORING SYSTEM BASIC VERSION Interface views With the LCD display and the three LEDs on the front panel, the device is able to communicate information on the machine status, configuration and alarms. On pressing any of the buttons the display will light up for a few seconds; without pressing any of the buttons, the display will go out after a few seconds. When switching on, the instrument will go into the state saved at the last machine shutdown or stand-by. LED STATUS LEDs ( ) The first LED (green) indicates there is supply voltage: LED ON means that the controller is powered LED OFF means that the controller is not powered RX-TX LED The second LED (amber) indicates there is communication between the controller and the keypad: ON when there is communication OFF when there is no communication LEDs ( ) The third LED (red) indicates there are alarms: ON if there is at least one active alarm OFF if there are no active alarms BLINKING if there are alarms that have ended but have not yet been manually reset. BLINKING without alarms to indicate that the PAP (High Pressure Prevention) function is on. The alarm reset procedure is explained under the ALARMS heading When the unit switches on, the display shows the first page of the main screen On the top line there is the current time (14:36) and the page no. (1/3) comprising the screen. Afterwards there is the unit status (off-cooling-shutdown) and the water inlet and outlet temperature. 14:36 Off Water In Water Out 01/ C 7.0 C Pressing the DOWN button takes you to page 02/03 Here there is the power output, set point and proportional adjustment band. By using the UP/DOWN-ENTER buttons to select the Set point and/or proportional band lines it is possible to change the adjustment settings. 14:36 Power Set Point Prop Band 02/03 70% 7.0 C 1.0 C 62

63 MONITORING SYSTEM BASIC VERSION Pressing the DOWN button takes you to page 03/03. - REM ON/OFF enables switching off the unit via digital input. This function has priority over keypad commands. On the RH side of the display YES/NO appears depending on the enabling. 14:36 REM ON/OFF Menu get special menu 03/03 Yes Get special menu is reserved for the support service. By selecting menu pressing Enter, with the up/dw buttons it is possible to access the following 4 pages: MENU Inputs and outputs Alarms Date and time DISPLAY 01/03 Inputs and outputs Alarms Date and time DESCRIPTION Page 1 of 3 Displays the status and values of the digital and analog inputs/outputs Used to see and/or reset the status of the alarms Used to set the current date and time Page 2 of 3 MENU Pumps Circuits Compressors 02/03 Pumps Circuits Used to see the activation status of the pumps Used to see the activation status of the circuits Compressors Used to see the activation status of the compressors Page 3 of 3 MENU Fans Time bands Language selection 03/03 Fans Time bands Used to see the activation status of the fans Used to set the operating time bands Language selection Used to select the language (Italian by default) 63

64 MONITORING SYSTEM BASIC VERSION User Settings UNIT ON/OFF To switch the machine on and off, from the main menu, press the on/off Function joystick in the middle for a few seconds. SETTING THE OPERATING SET POINT From the main screen, press the Up and Down buttons to access SET POINT and press ENTER. The CHILLER setpoint temp screen will appear. Press ENTER to make the temperature value 7.0 C blink and change it with the Up and Down buttons as required. Press ENTER to confirm. 14:36 Power Set Point Prop Band 02/03 70% 7.0 C 1.0 C SET POINT 01/01 CHILLER SET POINT TEMP 7.0 C To return to the main screen, press the LEFT (ESC) button several times: To modify the proportional band (prop band) proceed in a similar manner to the one described for setting the operating SET POINT. IMPORTANT NOTE: In time proportional regulation is reccomended to keep the proportional band=1 C. 64

65 MONITORING SYSTEM BASIC VERSION REMOTE OFF SETTING FROM DIGITAL INPUT To activate this function, select REM ON-OFF from the main screen and with the joystick-menu buttons set YES. NOTE: IF YOU ENABLE REM ON-OFF WHILE THE UNIT IS ON, THE UNIT COULD SWITCH OFF IF THE REMOTE OFF CONTACT IS OPEN. TERMOREGULATION TIME PROPORTIONAL (factory setting) The main function of the temperature control consists in enabling a specific number of resources (capacity steps), which is proportional to the time elapsed from when the outlet water temperatura hexchanger has exceeded a specific value called threshold: Threshold = CHILLER setpoint temp + PROPORTIONAL BAND / 2. (Cooling) The proportional band is symmetrical to the set point value. When the temperature exceeds the threshold value, after the time specified by parameter Chiller INC power time has elapsed, a capacity step is enabled. The same occurs for the disabling, which occurs after the time specified by parameter Chiller DEC power time has elapsed. There is no hysteresis in this algorithm. This concept is illustrated in greater detail in the following diagram referred to the Cooling mode: TEMPERATURE WATER OUTLET a TEMPERATURE READ BY WATER OUTLET SENSOR Set Point BP TIME a: Chiller INC power time (TIME INCREASING POWER IN COOLING) b: Chiller DEC power time (TIME DECREASING POWER IN COOLING) BP: COOLING PROPORTIONAL BAND SET POINT: SET POINT TEMPERATURE IN COOLING b IMPORTANT NOTE: In time proportional regulation is reccomended to keep the proportional band=1 C. 65

66 MONITORING SYSTEM BASIC VERSION DATE AND TIME The Date and time menu is used to set the date and time on the instrument. To set the date and time, go to the Date and time menu with the joystick-menu buttons. STATE OF OPERATION To know the machine s operating status, scroll through the main menu down to the bottom and select menu, then press Enter. Use the Up and Down buttons to scroll through the menu to display the items: Pumps Circuits Compressors Fans Under Pumps, there will be a list of the machine s pumps and for each one of them: Operating status Days of operation Hours of operation Under Circuits there will be a list of the machine s circuits and, for each one of them, there will be displayed: The compressor suction pressure read by the low-pressure transducer The compressor discharge pressure read by the high-pressure transducer The current operating status (alarm or power) The power of the circuits The PAP s status (high pressure prevention) The PBP s status (low pressure prevention) (not used) Under Compressor there will be a list of the machine s compressors and, for each one of them, there will be displayed: Power output expressed as a % Compressor discharge temperature Hours of operation Days of operation Under Fans there will be a list of the machine s fans and, for each one of them, there will be displayed: Power output expressed as a % 66

67 MONITORING SYSTEM BASIC VERSION TIME SCHEDULING MANAGEMENT Premise: For the correct working of the time bands is necessary to set up current day and hour Selecting the TIME SCHEDULING item takes you the following screen : TIMER : used to enable/disabile the time scheduling management: Timer Yes = enable time scheduling Timer No = disable time scheduling TIMER TYPE : enable selecting from 3 (0-1-2) different types of time scheduling management: TIME BANDS Timer Timer type Setup 01/01 NO 0 TIMER TYPE = 0: Daily : With this timer type you can select a different time scheduling for each day of the week. Under SETUP line you can set up max 4 time bands- singularly activable- for each different day of the week. Time band 1 Time band 2 Time band 3 Time band 4 MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY TIMER TYPE = 1: Weekly : With this timer type for all days the unit will work with the same time scheduling. Under SETUP line you can set up max 4 time bands- singularly activable- for all the days of the week. Time band 1 Time band 2 Time band 3 Time band 4 WEEKLY TIMER TYPE = 2: week end (5+2) : With this timer type you can select 2 different time scheduling: one for working days and one for weekend. Under SETUP line you can set up max 4 time bands- singularly activable- for the working days (from Monday to Friday) and for the weekend days (Saturday and Sunday). Time band 1 Time band 2 Time band 3 Time band 4 MONDAY - FRIDAY SATURDAY - SUNDAY 67

68 MONITORING SYSTEM BASIC VERSION After timer type set you have to go to SETUP line to actually setup the start, the end, the unit mode and water temp setup for each time band. SETUP: according to the different timer type selected on the display there will be different lines: TIMER TYPE = 0 (Daily) SETUP 01/03 Monday Twesday Wednesday SETUP 02/03 Thursday Friday Saturday SETUP 03/03 Sunday TIMER TYPE = 1 (Weekly) TIMER TYPE = 3 (Week-end 5+2) SETUP 01/03 Weekly SETUP 01/03 Monday - Friday Saturday - Sunday IMPORTANT NOTE For the chiller working, the time scheduling setup is always priority on the setup done by keyboard control, except the remote ON/OFF by digital input The digital input remote ON/OFF -IF ENABLED- is always priority on time scheduling: If the unit is in OFF mode by remote (remote ON/OFF) and the time scheduling are enabled the unit remains OFF. When you switch ON the unit by remote ON/OFF the unit starts to work following the time bands setup. Time bands management is disabled even if the configuration mode is activated. For instance for TIMER TYPE = 0 (daily) in submenu SETUP you have to move on MONDAY line then press ENTER and so setup for each time band the parameters showed: TIME BAND 1 ENABLE FLAG: this parameter enable/disables the first time band TIME BAND 1 HOUR: this parameter allows the setup of the starting hour of the first time band TIME BAND 1 MINUTES: this parameter allows the setup of the starting minutes (from o to 59 inside the time band hour) of the first time band. 68

69 MONITORING SYSTEM BASIC VERSION TIME BAND 1 MODE: this parameter allows the setup of the unit working mode in the first time band: 1 = OFF Enabling this mode the unit is off and it is not possible to switch on neither by display user interface nor by digital input (for instance by remote) 2 = COOLING Enabling this mode the unit is on and in cooling mode. The working water set point is the value fixed on TIME BAND 1 CH TEMP SETPOINT It is not possible to switch off the unit by display user interface, but only by digital input (Remote ON/OFF) - if activated -. 3 = MANUAL MODE (not used) 4 = LOCAL SET (only cool) Enabling this mode the unit is on and in cooling mode. The working water set point is the value fixed by display user interface (we can define standard set point). It is not possible to switch off the unit by display user interface, but only by digital input (Remote ON/OFF) - if activated -. TIME BAND 1 CH TEMP SETPOINT: this parameter allows the setup of the water temperature setup of the time band TIME BAND 1 HP TEMP SETPOINT: not used for only cooling units. This parameter can be used only for heat pump units: it allows the setup on heating mode of the water temperature setup For each working mode the standard set point is stored in a non volatile memory of the control board and it will be used again by the unit when the time bands are disabled. 69

70 MONITORING SYSTEM BASIC VERSION Alarms When there is an alarm the red LED comes on with a steady light. When an alarm has ended and can be reset, the red LED passes from a steady to a blinking light. The alarms menu is used to display and reset any active alarms and display the alarm log. There are 2 different ways of accessing the alarms menu: Mode 1: Scroll through the main menu down to the bottom and select Menu, then press Enter, then select Alarms and press Enter. Mode 2 :Press and hold down button F3 for a few seconds. The alarm menu is displayed as follow 1 VIEW 2 VIEW ALARMS 01/02 BIOS Alarms USER Alarms Reset Alarms ALARMS 02/02 History Automatic alarms Select the relevant item and press Enter. When an alarm is present, the red led is ON. When an alarm is resettable, the red led is blinking. In order to reset an alarm, select alarm reset and press ENTER. Descriptions of alarm types Bios alarms They concern solely HW and SW operation of the micro-controller and do not involve the machine components (compressors, fans, pumps, sensors, etc.) After selecting the bios alarms menu, all active bios alarms are displayed. The bios alarms can end automatically or can last until operator intervention. For example: The RTC battery alarm (RTC= Real Time Clock), while not being a cause of failure, shuts down the machine until the current date and time are set correctly. Examples of bios alarms on the display: ALL. BIOS 01/05 LOW BATTERY RTC ON ALL. BIOS 01/05 TIME OUT EXP 1 ON Bios alarms list View display description recovery action TIMEOUT INTERNAL EXP TIMEOUT EXP.1 Communication error TIMEOUT EXP.2 Impossibile to resolve TIMEOUT EXP.3 with the expansions Switch off the system and call TIMEOUT EXP.4 the service BIOS AREA CRC ERR EXTERNAL EEPROM USER AREA CRC ERR EXTERNAL EEPROM Sw error N/A Not used Low battery RTC data and time are lost date and time must be setted Communication RTC ERR Sw error Registers RTC ERROR Sw error Impossibile to resolve Modem connection ERR Sw error Switch off the system and call Hardware modem ERR Sw error the service Software modem ERR Sw error If there is no bios alarm EMPTY is displayed for 2 seconds. 70

71 MONITORING SYSTEM BASIC VERSION User alarms They are only manual reset alarms and concern solely the machine s components (compressors, fans, pumps, sensors, pressure switches, etc.) and do not involve the HW and SW operation of the micro-controller. In the case of these alarms, after removing the cause, in order to restart the system it is necessary to reset manually from the alarm reset menu and press enter. User alarms table Alarms shown on display Alarm effect Components involved Cause of alarm High temp plant Low temp plant Evaporator 1 antifreeze High press CIR 1 High press CIR 2 Low press CIR 1 Low press CIR 2 Compressor 1 thermal protection Compressor 2 thermal protection Stop compressor and fan The pump stays on Stop compressor and fan The pump stays on H2O inlet sensor in chiller mode H2O inlet sensor in heat pump mode H2O outlet sensor High press transducer cir.1 High press transducer cir.2 low press transducer cir.1 low press transducer cir.1 Compressor electronic protector Discharge pipe compressor switch (if installed) Values outside limit Values outside limit -current value outside limit -electronic thermal protector damaged Compressor 1 discharge temp Compressor 2 discharge temp Discharge pipe compressor 1 sensor Discharge pipe compressor 1 sensor - Values outside limit Pump 1 unavailable Stop pump 1 Water pump of the circuit 1 Pump not available from the controller Pump 2 unavailable Stop pump 2 Water pump of the circuit 2 Pump 1 thermal protection Stop pump 1 Water pump of the circuit 1 Pump 2 thermal protection Stop pump 2 Water pump of the circuit 2 current value outside limit Chiller Water Flow Stop unit with only 1 pump present. Swap to the other pump if two pump are present If the alarm persist, stop the unit. Water cooler differential pressure switch or flowswitch. -no water circulation or insufficent water flow rate -defective sensors switch not correct Fans 1 thermal protection Stop compressor and fan thermal protection Fans 1 Fans 2 thermal protection The pump stays on thermal protection Fans 2 EEV alarm cicuit 1 EEV alarm cicuit 2 Stop compressor and fan The pump stays on electronic expansion valv 1 error electronic expansion valv 2 error Electrical panel high temperature Stop the unit Electrical panel temperature switch value outside limit value outside limit - too high temperature inside the electrical panel - electrical panel fans damaged - fans filters dirty If there are no active user alarms, the message EMPTY is displayed for 2 seconds. 71

72 MONITORING SYSTEM BASIC VERSION Automatic alarms In case of these alarms the unit start automatically after removing the cause. Manual reset is not required. Automatic alarms table Alarms shown on display Alarm effect Components involved Cause of alarm Dinamic setpoint sens ERR (only if present) Water IN sens ERR Stop dinamic setpoint function dinamic setpoint probe Evaporator Water inlet sensor error Water OUT sens ERR Evaporator Water outlet sensor error circuit 1 High press sens ERR High press transducer cir.1 circuit 2 High press sens ERR comp 1 Temp disch sens ERR Stop compressor and fan The pump stays on. High press transducer cir.2 Discharge pipe compressor 1 sensor Sensor faulty, Interrupted or in short circuit comp 2 Temp disch sens ERR Discharge pipe compressor 2 sensor circuit 1 Low press sens ERR oil press transducer comp 1 circuit 2 Low press sens ERR oil press transducer comp 2 Phase sequence alarm Stop unit Phase sequence monitor Incorrect sequence or no power supply phases Blackbox OpenError file Blackbox WriteError file Blackbox CloseError file No effect on the unit Black box files SW Error If there are no active user alarms, the message EMPTY is displayed for 2 seconds. 72

73 MONITORING SYSTEM BASIC VERSION Alarms log The last 50 unit alarms are saved in code under the alarm log item The following data is stored for each alarm: Alarm identification code (xy) and system index (zw): Exyzw Activation time: hh Activation date: dd/mm/yy Hourly frequency, i.e. number of activations in hour E.g., E /04/05-01 List of alarms and their identification code Alarms list Alarm code System index Error plant water inlet probe 00 0 Error plant water outlet probe 01 0 Error dynamic setpoint current probe (if present) 02 0 Alarm high temperature water plant 03 0 Alarm low temperature water plant 04 0 Error circuit high pressure transducer Alarm circuit high pressure Alarm circuit low pressure Error compressor delivery probe Alarm compressor thermal protection Alarm compressor delivery temperature Alarm evaporator thermal protection pump Alarm evaporator water flow 12 0 Alarm circuit fans thermal protection Error evaporator water outlet probe Alarm evaporator antifreeze Error condenser probe Error circuit low pressure transducer Alarm power supply phase sequence check 20 0 Alarm Electronic Expansion Valve (EEV) Error compressor suction probe Alarm electrical panel high temperature 27 0 DISPLAYING THE ALARMS LOG The alarms log can be displayed from the specific menu using the keys on the keypad. When first opened, the oldest alarm in the log number 1 in the list) is shown. Press ENTER on the keypad to scroll through the stored alarms to the most recent. The number of the last alarm in the list is equal to the total number of alarms stored in the log. The number of alarms stored is shown on the right of the number of the alarm displayed. If you access the alarms log display menu after having browsed through the alarms log, the display will show the last alarm to be displayed instead of the the last alarm to be activated. The screens of the alarms log display the following information: -01/05 E /06/07-02 total number of alarms in the log number of alarm displayed hourly frequency of the alarm (the alarm was activated twice in 1 hour) date eleventh hour out of 24 circuit 1 low pressure alarm -01/05 E /06/07-02 NEXT NEXT pressing ENTER on the MENU joystick displays the next alarm in the list; the alarm list number will therefore be increased. When you arrive at the end of the list, pressing ENTER will return you to the first alarm in the alarms log. 73

74 MONITORING SYSTEM RECOVERY VERSION CAUTION: IF THE ALARM SIGNAL RTC (REAL TIME CLOCK) APPEARS WHEN STARTING FOR THE FIRST TIME, SET THE DATE AND TIME IN THE RESPECTIVE DATE AND TIME MENU. User interface Control panel: composed of the instrument s front panel, equipped with an LCD display, three indicator LEDs and two joystick buttons, it enables viewing and/or checking the operating mode and parameters, resources and complete alarm diagnostics. In particular, it enables: Managing alarm situations Checking the status of resources. Setting the heat recovery function KEY 1.Display 2.Power supply LED 3.Joystick Function Button 4.LED for communication between the motherboard governing the unit and the keypad 5.Alarms LED 6.Joystick Menu Button 17:25 01/04 Cooling WATER in 12.0 C WATER out 7.0 C Joystick button: FUNCTION Using the four external positions (F1-F2-F3-F4) enables accessing the main functions directly: Pressing a single time: shows the main menu on the display. Pressing for a few seconds: directly accesses the menu associated with that particular position. KEY F1 : show the I/O base resources. KEY F2 : show the PARAMETER submenu (for the support service only, with password). KEY F3 : show the ALARMS submenu. KEY F4 : show the COMPRESSOR submenu. N.B. PRESSING THE BUTTON IN THE MIDDLE SWITCHES THE MACHINE ON-OFF (ON-OFF). Joystick button: MENU Used to scroll through the menus by acting on the four positions (UP; DOWN; LEFT; RIGHT) pressing a single time; in particular: Position UP: scrolls through the menu items upwards or increases the value of a parameter. Position LEFT (ESC): returns to the previous menu. Position DOWN: scrolls through the menu items downwards or decreases the value of a parameter. Position RIGHT: moves into the submenu, confirms an action, enters editing a value or again confirms a changed value. N.B. PRESSING THE (ENTER) BUTTON IN THE MIDDLE CONFIRMS THE COMMAND OR ACCESS- ES THE DISPLAYED MENU. 74

75 MONITORING SYSTEM RECOVERY VERSION Interface views With the LCD display and the three LEDs on the front panel, the device is able to communicate information on the machine status, configuration and alarms. On pressing any of the buttons the display will light up for a few seconds; without pressing any of the buttons, the display will go out after a few seconds. When switching on, the instrument will go into the state saved at the last machine shutdown or stand-by. LED STATUS LEDs ( ) The first LED (green) indicates there is supply voltage: LED ON means that the controller is powered LED OFF means that the controller is not powered RX-TX LED The second LED (amber) indicates there is communication between the controller and the keypad: ON when there is communication OFF when there is no communication LEDs ( ) The third LED (red) indicates there are alarms: ON if there is at least one active alarm OFF if there are no active alarms BLINKING if there are alarms that have ended but have not yet been manually reset. BLINKING without alarms to indicate that the PAP (High Pressure Prevention) function is on. The alarm reset procedure is explained under the ALARMS heading When the unit switches on, the display shows the first page of the main screen On the top line there is the current time (14:36) and the page no. (1/4) comprising the screen. Afterwards there is the unit status (off-cooling-shutdown) and the water inlet and outlet temperature. 14:36 Off Water In Water Out 01/ C 7.0 C Pressing the DOWN button takes you to page 02/04 Here there is the power output, set point and proportional adjustment band. By using the UP/DOWN-ENTER buttons to select the Set point and/or proportional band lines it is possible to change the adjustment settings. 14:36 Power Set Point Prop Band 02/04 70% 7.0 C 1.0 C 75

76 MONITORING SYSTEM RECOVERY VERSION Pressing the DOWN button takes you to page 03/04. - Pressing the up/dw buttons it is possible to select RECOVERY row and setting SET-POINT proporional band and Remote disable. - REM ON/OFF enables switching off the unit via digital input. This function has priority over keypad commands. On the RH side of the display YES/NO appears depending on the enabling. 14:36 RECOVERY REM ON/OFF Menu 03/04 35 C Yes Pressing the DOWN button takes you to page 04/04 Select special menu is reserved for the support service. 14:36 select special menu 04/04 By selecting menu pressing Enter, with the up/dw buttons it is possible to access the following 4 pages: DISPLAY DESCRIPTION Page 1 of 4 MENU Inputs and outputs Alarms Date and time 01/04 Inputs and outputs Alarms Displays the status and values of the digital and analog inputs/outputs Used to see and/or reset the status of the alarms Date and time Used to set the current date and time Page 2 of 4 MENU Pumps Circuits Compressors 02/04 Pumps Circuits Used to see the activation status of the pumps Used to see the activation status of the circuits Compressors Used to see the activation status of the compressors Page 3 of 4 MENU Fans Heat recovery Time bands 03/04 Fans Recovery Used to see the activation status of the pumps Displays the status of the Recovery units Time bands Used to set the operating time bands Page 4 of 4 MENU Language selection 04/04 Language selection Used to select the language (Italian by default) 76

77 MONITORING SYSTEM RECOVERY VERSION User Settings MACHINE ON/OFF To switch the machine on and off, from the main menu, press the on/off Function joystick in the middle for a few seconds. SETTING THE OPERATING SET POINT The procedure is similar to the one described for setting the Operating mode. From the main screen, press the Up and Down buttons to access SET POINT and press ENTER. The Set Point temperature in cooling screen will appear. Press ENTER to make the temperature value 7.0 C blink and change it with the Up and Down buttons as required. Press ENTER to confirm. 14:36 Power Set Point Prop Band 02/04 70% 7.0 C 1.0 C SET POINT 01/01 CHILLER SET POINT TEMP 7.0 C To return to the main screen, press the LEFT (ESC) button several times: To modify the proportional band (prop band) proceed in a similar manner to the one described for setting the operating SET POINT. IMPORTANT NOTE: In time proportional regulation is reccomended to keep the proportional band=1 C. 77

78 MONITORING SYSTEM RECOVERY VERSION REMOTE OFF SETTING FROM DIGITAL INPUT To activate this function, select REM ON-OFF from the main screen and with the joystick-menu buttons set YES. Note: If you enable REM ON-OFF while the unit is on, the unit could switch off if the remote OFF contact is open. TERMOREGULATION TIME PROPORTIONAL (factory setting) The main function of the temperature control consists in enabling a specific number of resources (capacity steps), which is proportional to the time elapsed from when the outlet water temperatura hexchanger has exceeded a specific value called threshold: Threshold = CHILLER setpoint temp + PROPORTIONAL BAND / 2. (Cooling) The proportional band is symmetrical to the set point value. When the temperature exceeds the threshold value, after the time specified by parameter Chiller INC power time has elapsed, a capacity step is enabled. The same occurs for the disabling, which occurs after the time specified by parameter Chiller DEC power time has elapsed. There is no hysteresis in this algorithm. This concept is illustrated in greater detail in the following diagram referred to the Cooling mode: TEMPERATURE WATER OUTLET a TEMPERATURE READ BY WATER OUTLET SENSOR Set Point BP TIME a: Chiller INC power time (TIME INCREASING POWER IN COOLING) b: Chiller DEC power time (TIME DECREASING POWER IN COOLING) BP: COOLING PROPORTIONAL BAND SET POINT: SET POINT TEMPERATURE IN COOLING b IMPORTANT NOTE: In time proportional regulation is reccomended to keep the proportional band=1 C. 78

79 MONITORING SYSTEM RECOVERY VERSION Setting the unit operating parameters in Recovery mode The recovery function heats water using heat from the condenser coils that otherwise would be dispersed in the environment. When the machine is in cool mode (compressors on), if the water in the recovery circuit is of a sufficiently low temperature to require heat, the machine switches from normal to recovery mode. When the water temperature reaches the recovery set point, the machine switches back to normal operating mode. Heating capacity is stepped according to the number of circuits involved in the recovery function. For example, if the unit has 2 cooling circuits of which only 1 is designated for Recovery, there will be only 1 Recovery step. If both circuits of the unit are designated for Recovery, then there will be 2 steps. The steps are distributed at equal intervals throughout the proportional band. HEAT CONTROL PARTIAL RECOVERY MODE (VP) on 1 cooling circuit HEAT CONTROL TOTAL RECOVERY MODE (VR) on 2 cooling circuits ON 2 ON ON 1 OFF T OFF T BANDA PROP. SET BANDA PROP. SET SET - recovery set-point PROP. BAND - proportional band T: Temperature measured by sensor at recovery water inlet SET - recovery set-point PROP. BAND - proportional band T: Temperature measured by sensor at recovery water inlet 79

80 MONITORING SYSTEM RECOVERY VERSION SETTING THE PARAMETERS To access the operating parameters for heat Recovery mode, go to the third page of the main screen. The operating parameters for Heat Recovery mode are as follows: ENABLE SET-POINT PROP. BAND REMOTE 14:25 03/04 RECOVERY REM ON-OFF MENU To change the values of these parameters, proceed as follows: From the main screen access the RECOVERY menu using the Up/Down buttons. RECOVERY 01/02 ENABLE Yes SET POINT 35.0ºC PROP. BAND 10.0ºC Select RECOVERY using the Up/Down buttons and press ENTER. The following items will appear on the display: -ENABLE -SET-POINT -PROP. BAND -REMOTE RECOVERY 02/02 REMOTE Yes ENABLE Serves to enable the Recovery function. Using the MENU joystick buttons, select ENABLE. To change the YES/NO status, press Enter twice: the value YES will start flashing ENABLE RECOVERY YES - change the value as required using the Up/Down buttons. After changing the value, press Enter to confirm and then press Left to exit. 80

81 MONITORING SYSTEM RECOVERY VERSION SET-POINT Using the MENU joystick buttons, select the SET POINT parameter. This parameter is set by default to 45.0 C. To change this set-point value, press Enter twice: the value 35.0 ºC will start flashing RECOVERY SET POINT 45.0 C - change the set-point value as required using the Up/Down buttons. After changing the value, press Enter to confirm and then press Left to exit. PROP. BAND Using the MENU joystick buttons, select the PROP. BAND parameter. This parameter is set by default to 10.0 C. To change this set-point value, press Enter twice: the value 10.0 C will start flashing RECOVERY PROP. BAND 10.0 C - change the value as required using the Up/Down buttons. After changing the value, press Enter to confirm and then press Left to exit. 81

82 MONITORING SYSTEM RECOVERY VERSION REMOTE Allows the Recovery function to be enabled from a remote digital input. Using the MENU joystick buttons, select the REMOTE parameter. To change the YES/NO status press Enter twice: the value will start flashing ENABLE REMOTE REC. YES - change the value as required using the Up/Down buttons. After changing the value, press Enter to confirm and then press Left to exit. DATE AND TIME The Date and time menu is used to set the date and time on the instrument. To set the date and time, go to the Date and time menu with the joystick-menu buttons and set the current time. STATE OF OPERATION To know the machine s operating status, scroll through the main menu down to the bottom and select menu, then press Enter. Use the Up and Down buttons to scroll through the menu to display the items: Pumps Circuits Compressors Fans Under pumps, there will be a list of the machine s pumps and for each one of them: Operating status Days of opertaion Hours of operation For the recovery pump, however, it is only possible to display the ON-OFF status. Under Circuits there will be a list of the machine s circuits and, for each one of them, there will be displayed: The compressor suction pressure read by the low-pressure transducer The compressor discharge pressure read by the high-pressure transducer The current operating status-power output (power or alarm) The power of circuit The status of the functions PAP (high pression prevenction) The status of the functions PBP (low pression prevenction) Under Compressor there will be a list of the machine s compressors and, for each one of them, there will be displayed: Power output expressed as a % Compressor discharge temperature Hours of operation Day of operation Under Fans there will be a list of the machine s fans and, for each one of them, there will be displayed: Power output expressed as a % 82

83 MONITORING SYSTEM BASIC VERSION TIME SCHEDULING MANAGEMENT Premise: For the correct working of the time bands is necessary to set up current day and hour Selecting the TIME SCHEDULING item takes you the following screen : TIMER : used to enable/disabile the time scheduling management: Timer Yes = enable time scheduling Timer No = disable time scheduling TIMER TYPE : enable selecting from 3 (0-1-2) different types of time scheduling management: TIME BANDS Timer Timer type Setup 01/01 NO 0 TIMER TYPE = 0: Daily : With this timer type you can select a different time scheduling for each day of the week. Under SETUP line you can set up max 4 time bands- singularly activable- for each different day of the week. Time band 1 Time band 2 Time band 3 Time band 4 MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY TIMER TYPE = 1: Weekly : With this timer type for all days the unit will work with the same time scheduling. Under SETUP line you can set up max 4 time bands- singularly activable- for all the days of the week. Time band 1 Time band 2 Time band 3 Time band 4 WEEKLY TIMER TYPE = 2: week end (5+2) : With this timer type you can select 2 different time scheduling: one for working days and one for weekend. Under SETUP line you can set up max 4 time bands- singularly activable- for the working days (from Monday to Friday) and for the weekend days (Saturday and Sunday). Time band 1 Time band 2 Time band 3 Time band 4 MONDAY - FRIDAY SATURDAY - SUNDAY 83

84 MONITORING SYSTEM BASIC VERSION After timer type set you have to go to SETUP line to actually setup the start, the end, the unit mode and water temp setup for each time band. SETUP: according to the different timer type selected on the display there will be different lines: TIMER TYPE = 0 (Daily) SETUP 01/03 Monday Twesday Wednesday SETUP 02/03 Thursday Friday Saturday SETUP 03/03 Sunday TIMER TYPE = 1 (Weekly) TIMER TYPE = 3 (Week-end 5+2) SETUP 01/03 Weekly SETUP 01/03 Monday - Friday Saturday - Sunday IMPORTANT NOTE For the chiller working, the time scheduling setup is always priority on the setup done by keyboard control, except the remote ON/OFF by digital input The digital input remote ON/OFF -IF ENABLED- is always priority on time scheduling: If the unit is in OFF mode by remote (remote ON/OFF) and the time scheduling are enabled the unit remains OFF. When you switch ON the unit by remote ON/OFF the unit starts to work following the time bands setup. Time bands management is disabled even if the configuration mode is activated. For instance for TIMER TYPE = 0 (daily) in submenu SETUP you have to move on MONDAY line then press ENTER and so setup for each time band the parameters showed: TIME BAND 1 ENABLE FLAG: this parameter enable/disables the first time band TIME BAND 1 HOUR: this parameter allows the setup of the starting hour of the first time band TIME BAND 1 MINUTES: this parameter allows the setup of the starting minutes (from o to 59 inside the time band hour) of the first time band. 84

85 MONITORING SYSTEM RECOVERY VERSION TIME BAND 1 MODE: this parameter allows the setup of the unit working mode in the first time band: 1 = OFF Enabling this mode the unit is off and it is not possible to switch on neither by display user interface nor by digital input (for instance by remote) 2 = COOLING Enabling this mode the unit is on and in cooling mode. The working water set point is the value fixed on TIME BAND 1 CH TEMP SETPOINT It is not possible to switch off the unit by display user interface, but only by digital input (Remote ON/OFF) - if activated -. 3 = MANUAL MODE (not used) 4 = LOCAL SET (only cool) Enabling this mode the unit is on and in cooling mode. The working water set point is the value fixed by display user interface (we can define standard set point). It is not possible to switch off the unit by display user interface, but only by digital input (Remote ON/OFF) - if activated -. TIME BAND 1 CH TEMP SETPOINT: this parameter allows the setup of the water temperature setup of the time band TIME BAND 1 HP TEMP SETPOINT: not used for only cooling units. This parameter can be used only for heat pump units: it allows the setup on heating mode of the water temperature setup For each working mode the standard set point is stored in a non volatile memory of the control board and it will be used again by the unit when the time bands are disabled. 85

86 MONITORING SYSTEM RECOVERY VERSION Alarms When there is an alarm the red LED comes on with a steady light. When an alarm has ended and can be reset, the red LED passes from a steady to a blinking light. The alarms menu is used to display and reset any active alarms and display the alarm log. There are 2 different ways of accessing the alarms menu: Mode 1: Scroll through the main menu down to the bottom and select Menu, then press Enter, then select Alarms and press Enter. Mode 2 :Press and hold down button F3 for a few seconds. The alarm menu is displayed as follow 1 VIEW 2 VIEW ALARMS 01/02 BIOS Alarms USER Alarms Reset Alarms Select the relevant item and press Enter. When an alarm is present, the red led is ON. When an alarm is resettable, the red led is blinking. In order to reset an alarm, select alarm reset and press ENTER. Descriptions of alarm types Bios alarms These alarms concern solely the HW and SW operation of the micro-controller and do not concern the machines components (compressors, fans, pumps, sensors, etc.) After selecting the bios alarms menu, all active bios alarms are displayed. The bios alarms can end automatically or can last until operator intervention For example: The RTC battery alarm (RTC= Real Time Clock), while not being a cause of failure, shuts down the machine until the current date and time are set correctly. Examples of bios alarms on the display: ALARMS 02/02 History alarms Automatic alarms ALL. BIOS 01/05 LOW BATTERY RTC ON ALL. BIOS 01/05 TIME OUT EXP 1 ON Bios alarms list View display description recovery action TIMEOUT INTERNAL EXP TIMEOUT EXP.1 Communication error TIMEOUT EXP.2 Impossibile to resolve TIMEOUT EXP.3 with the expansions Switch off the system and call TIMEOUT EXP.4 the service BIOS AREA CRC ERR EXTERNAL EEPROM USER AREA CRC ERR EXTERNAL EEPROM Errore sw N/A Non usato Low battery RTC data and time are lost date and time must be setted Communication RTC ERR Sw error ERR.registri RTC Sw error Impossibile to resolve Registers RTC ERR Sw error Switch off the system and call Hardware modem ERR Sw error the service Software modem ERR Sw error If there is no bios alarm EMPTY is displayed for 2 seconds. 86

87 MONITORING SYSTEM RECOVERY VERSION User alarms These are manual reset alarms that concern solely the machine components (compressors, fans, pumps, sensors, pressure switches, etc). They do not concern the HW and SW operation of the micro-controller. If one of the these alarms appears, after eliminating the cause, to restart the system it is necessary to reset the alarm manually from the alarm reset menu and press enter. User alarms table Alarms shown on display Alarm effect Components involved Cause of alarm High temp plant Low temp plant Evaporator 1 antifreeze High press CIR 1 High press CIR 2 Low press CIR 1 Low press CIR 2 Compressor 1 thermal protection Compressor 2 thermal protection Stop compressor and fan The pump stays on Stop compressor and fan The pump stays on H2O inlet sensor in chiller mode H2O inlet sensor in heat pump mode H2O outlet sensor High press transducer cir.1 High press transducer cir.2 low press transducer cir.1 low press transducer cir.1 Compressor electronic protector Discharge pipe compressor switch (if installed) Values outside limit Values outside limit -current value outside limit -electronic thermal protector damaged Compressor 1 discharge temp Compressor 2 discharge temp Discharge pipe compressor 1 sensor Discharge pipe compressor 1 sensor - Values outside limit Pump 1 unavailable Stop pump 1 Water pump of the circuit 1 Pump not available from the controller Pump 2 unavailable Stop pump 2 Water pump of the circuit 2 Pump 1 thermal protection Stop pump 1 Water pump of the circuit 1 Pump 2 thermal protection Stop pump 2 Water pump of the circuit 2 current value outside limit CHILLER Water Flow Stop unit with only 1 pump present. Swap to the other pump if two pump are present If the alarm persist, stop the unit. Water cooler differential pressure switch or flowswitch. -no water circulation or insufficent water flow rate -defective sensors switch not correct Fans 1 thermal protection Stop compressor and fan thermal protection Fans 1 Fans 2 thermal protection The pump stays on thermal protection Fans 2 value outside limit recovery pump thermal protection recovery pump heat recovery water flow immediate exit from recovery mode differential pressure switch and/or flow switch, recovery water heat exchanger -no water circulation or insufficent water flow rate -defective sensors switch not correct EEV alarm cicuit 1 EEV alarm cicuit 2 Stop compressor and fan The pump stays on electronic expansion valv 1 error electronic expansion valv 2 error value outside limit Electrical panel high temperature Stop the unit Electrical panel temperature switch - too high temperature inside the electrical panel - electrical panel fans damaged - fans filters dirty If there are no active user alarms, the message EMPTY is displayed for 2 seconds. 87

88 MONITORING SYSTEM RECOVERY VERSION Automatic alarms In case of these alarms the unit start automatically after removing the cause. Manual reset is not required. Automatic alarms table Alarms shown on display Alarm effect Components involved Cause of alarm Dinamic setpoint sens ERR (only if present) Water IN sens ERR Stop dinamic setpoint function dinamic setpoint prove Evaporator Water inlet sensor error Evap 1 Water Out sens ERR Evaporator Water outlet sensor error circuit 1 High press sens ERR High press transducer cir.1 circuit 2 High press sens ERR comp 1 Temp disch sens ERR Stop compressor and fan The pump stays on. High press transducer cir.2 Discharge pipe compressor 1 sensor Sensor faulty, Interrupted or in short circuit comp 2 Temp disch sens ERR Discharge pipe compressor 2 sensor circuit 1 Low press sens ERR oil press transducer comp 1 circuit 2 Low press sens ERR oil press transducer comp 2 Phase sequence alarm Stop unit Phase sequence monitor Incorrect sequence or no power supply phases Blackbox OpenError file Blackbox OpenError file Blackbox CloseError file Err. recovery water inlet sensor No effect on the unit Black box files SW Error immediate exit from heat recovery mode Recovery water inlet sensor Sensor faulty, Interrupted or in short circuit If there are no active user alarms, the message EMPTY is displayed for 2 seconds. 88

89 MONITORING SYSTEM RECOVERY VERSION Alarms log The alarms indicated in the ALARMS CODES LIST are saved in a log that can contain a maximum of 50 alarms. Whenever a new alarm is activated it is immediately entered in the log. If the alarm is already present in the log and occurred in the same hour, its hourly frequency is increased. The maximum value permitted for the hourly frequency is 99. When the log contains the maximum of 50 alarms, the next time an alarm is activated, the oldest alarm and the relative data will be deleted from the log. The following data is stored for each alarm: Alarm identification code (xy) and system index (zw): Exyzw Activation time: hh Activation date: dd/mm/yy Hourly frequency, i.e. number of activations in hour E.g., E /04/05-01 List of alarms and their identification code Alarms list Alarm code System index Error plant water inlet probe 00 0 Error plant water outlet probe 01 0 Error dynamic setpoint current probe (if present) 02 0 Alarm high temperature water plant 03 0 Alarm low temperature water plant 04 0 Error circuit high pressure transducer Alarm circuit high pressure Alarm circuit low pressure Error compressor delivery probe Alarm compressor thermal protection Alarm compressor delivery temperature Alarm evaporator thermal protection pump Alarm evaporator water flow 12 0 Alarm circuit fans thermal protection Error evaporator water outlet probe Alarm evaporator antifreeze Error condenser probe Error circuit low pressure transducer Alarm power supply phase sequence check 20 0 Alarm Electronic Expansion Valve (EEV) Error compressor suction probe Alarm heat recovery pump thermal protection 23 0 Alarm heat recovery water flow 24 0 Error heat recovery water inlet probe 25 0 Error heat recovery water outlet probe Alarm electrical panel high temperature 27 0 DISPLAYING THE ALARMS LOG The alarms log can be displayed from the specific menu using the keys on the keypad. When first opened, the oldest alarm in the log number 1 in the list) is shown. Press ENTER on the keypad to scroll through the stored alarms to the most recent. The number of the last alarm in the list is equal to the total number of alarms stored in the log. The number of alarms stored is shown on the right of the number of the alarm displayed. If you access the alarms log display menu after having browsed through the alarms log, the display will show the last alarm to be displayed instead of the the last alarm to be activated. The screens of the alarms log display the following information: -01/05 E /06/07-02 total number of alarms in the log number of alarm displayed hourly frequency of the alarm (the alarm was activated twice in 1 hour) date eleventh hour out of 24 circuit 1 low pressure alarm -01/05 E /06/07-02 NEXT NEXT pressing ENTER on the MENU joystick displays the next alarm in the list; the alarm list number will therefore be increased. When you arrive at the end of the list, pressing ENTER will return you to the first alarm in the alarms log. 89

90 SETTING AT WORK General Rules To validate the contractual warranty, the machine must be set at work by technicians from an authorized assistance center. Before they are called, check to make sure that all parts of the installation have been completed, the unit levelled, the wet connections made with the relative air vent and the electrical connections made. MAINTENANCE General Rules Maintenance is of extreme importance if the plant is to operate in a regular way and give fade-free service. Have extraordinary maintenance work done by qualified and authorized personnel. Comply with the safety precautions given in the relative section of this manual and take all the necessary precautions. The following information is only a guide for the end user. Routine maintenance The inspections described below, to which the unit must be subjected, do not require specific technical know-how. They merely include a few simple inspections involving certain parts of the unit. Call an authorized assistance center if actual maintenance work is required. The table below gives a recommended list of inspections which should be carried out at the indicated intervals. DESCRIPTION Visual inspection of the unit Inspection of hydraulic circuit Inspection of electrical system Inspection of condensing system Inspection and adjustment of operat. parameters WEEKLY MONTHLY EVERY SIX MONTHS Visual inspection of the structure of the unit When checking the condition of the parts that form the structure of the unit, pay particular attention to the parts liable to rust. If traces of rust are noted, they must be treated with rust-inhibitor paint in order to eliminate or reduce the problem. Check to make sure that the external panels of the unit are well fixed. Bad fixing gives rise to noise and abnormal vibrations. Inspection of hydraulic circuit Check visually to make sure that there are no leaks in the hydraulic circuit. If the pumping module accessory is installed, it is advisable to make sure that the water filter is clean. Inspection of electrical system Make sure that the power cable that connects the unit to the distribution panel is not torn, cracked or damaged in a way that could impair its insulation. Inspection of the condensing system WARNING: The finned pack exchanger has fins made of aluminium or some other thin material, thus even accidental contact could cause cuts. Comply with the instructions in the relative section. Condensing coils In view of the function of this component, it is very important for the surface of the exchanger to be as free as possible from clogging caused by items that could reduce the fan s air flow rate and, thus, the performances of the unit itself. The following operations may be required: - Remove all impurities (such as paper scraps, leaves, etc.) that could be clogging the surface of the bank either by hand or using a brush (comply with the above mentioned safety prescriptions). - If the dirt has deposited on the fins and is difficult to remove by hand, use a jet of compressed air or pressurized water on the aluminium surface of the coils, remembering to direct the jet in a vertical direction to prevent the fins from being damaged. - Comb the coils with the relative tool, using the appropriate comb spacing for the fins if some parts of them are bent or squashed. Helical electric fans Visually inspect these parts to make sure that the electric fans are well fixed to the bearing grille and that this latter is fixed to the structure of the unit. Bad fixing gives rise to noise and abnormal vibrations. Reading and adjustment of the operating parameters This control can be done using the pressure gauges (if installed) of the refrigerant circuits and using the pressure and temperature gauges (if installed) of the hydraulic circuits of the unit (evaporator + heat recovery - if present) 90

91 SAFETY AND POLLUTION General considerations The machine has been designed with a view to reducing the risks to persons and the environment in which it is installed, to the minimum. To eliminate residue hazards, it is therefore advisable to become as familiar as possible with the machine in order to avoid accidents that could cause injuries to persons and/or damage to property. a. Access to the unit Only qualified persons who are familiar with this type of machine and who are equipped with the necessary safety protections (footwear, gloves, helmet, etc.) may be allowed to access the machine. Moreover, in order to operate, these persons must have been authorized by the owner of the machine and be recognized by the actual Manufacturer. b. Elements of risk The machine has been designed and built so as not to create any condition of risk. However, residue hazards are impossible to eliminate during the planning phase and are therefore listed in the following table along with the instructions about how to neutralize them. Part in question Residue hazard Mode Precautions Compressor and delivery pipe Burns Contact with the pipes and/or compressor Avoid contact by wearing protective gloves Delivery pipes, heat recovery exchanger and coils Explosion Excessive pressure Turn off the machine, check the high pressure switch and safety valve, the fans and condenser Pipes in general Ice burns Leaking refrigerant Do not pull on the pipes Electrical cables, metal parts Electrocution, serious burns Defective cable insulation, live metal parts Adequate electrical protection (correctly ground the unit) Heat exchange coils Cuts Contact Wear protective gloves Fans Cuts Contact with the skin Do not push the hands or objects through the fan grille c. Pollution The unit contains refrigerant gas and lubricating oil. When scrapping the unit these fluids must be recovered and disposed of in compliance with the regulations in force in the country where it is installed. The unit must not be abandoned during the scrapping stage. 91

92 SAFETY AND POLLUTION General recommendations about the refrigerant used COMPOSITION / INFORMATION ON INGREDIENTS Substance / Preparation : Substance. Components / Impurities : R134a : Not classified as dangerous product. Contains no other components or impurities which will influence the classification of the product. HAZARDS IDENTIFICATION Hazards identification : In high concentrations may cause asphyxiation. Liquefied gas. Gas/vapour heavier than air. May reduce oxygen. FIRST AID MEASURES First aid measures - Inhalation : In high concentrations may cause asphyxiation. Symptoms may includeloss of mobility/consciousness. Victim may not be aware of asphyxiation. Remove victim to uncontaminated area wearing self contained breathing apparatus. Keep victim warm and rested. Call a doctor. Apply artificial respiration if breathing stopped. If breathing is difficult, give oxygen. - Skin contact : Flush with plenty of water. Clothing that has become saturated with the product must be removed immediately because the product is absorbed through the skin. - Eye contact : Flush with lukewarm water for 15 minutes. Seek medical advice. - Ingestion : Ingestion is not considered a potential route of exposure. General information : Obtain medical attention. FIRE-FIGHTING MEASURES Flammable class : Non flammable. Specific hazards : Exposure to fire may cause containers to rupture/explode. Hazardous combustion products : None. Extinguishing media - Suitable extinguishing media : All known extinguishants can be used. Specific methods : If possible, stop flow of product. Move away from the container and cool with water from a protected position. Special protective equipment for fire : In confined space use self-contained breathing apparatus. fighters ACCIDENTAL RELEASE MEASURES Personal precautions : Environmental precautions : Clean up methods : HANDLING AND STORAGE Precautions in handling and storage : Personal protection : Technical protective measures : Storage : Handling : Evacuate area. Ensure adequate air ventilation. Wear self-contained breathing apparatus when entering area unless atmosphere is proved to be safe. Try to stop release. Prevent from entering sewers, basements and workpits, or any place where its accumulation can be dangerous. Ventilate area. With air may form oxydant mixtures. Protect eyes, face and skin from liquid splashes. Good ventilation of the workplace required. Keep container below 50 C in a well ventilated place. Open valve slowly to avoid pressure shock. Suck back of water into the container must be prevented. Do not allow backfeed into the container. Use only properly specified equipment which is suitable for this product, its supply pressure and temperature. Contact your gas supplier if in doubt. Refer to supplier's container handling instructions. 92

93 SAFETY AND POLLUTION EXPOSURE CONTROLS / PERSONAL PROTECTION Personal protection : Ensure adequate ventilation. - Respiratory protection : In case of insufficient ventilation, wear suitable respiratory equipment. - Hand protection : Use rubber gloves. - Skin protection : Skin protection appropriate to the conditions of use should be provided. - Eye protection : Face shield. - Head protection : Protective helmet. - Foot protection : Steel pointed safety shoes (metatarsal protection is recommended). Industrial hygiene : When using, do not eat, drink or smoke. Emergency eye wash fountains and safety showers should be available in the immediate vicinity of any potential exposure. Occupational Exposure Limits : 1,1,1,2-Tetrafluoroethane (R 134a) : OEL (UK)-LTEL [ppm] : 1000 Simbology PHYSICAL AND CHEMICAL PROPERTIES Physical state at 20 C : Liquefied gas. Colour : Colourless. Odo(u)r : Ethereal. ph value : Neutral. Boiling point [ C] : Vapour pressure, 20 C : kpa Vapour pressure, 50 C : kpa Relative density, liquid (water=1) : 1.21 Kg/l Viscosity at 25 C [mpa.s] : Solubility in water [mg/l] : 0.15 wt % Flash point [ C] : Not flammable. Auto-ignition temperature [ C] : > 750 Other data : Gas/vapour heavier than air. May accumulate in confined spaces, particularly at or below ground level. STABILITY AND REACTIVITY Stability and reactivity : Hazardous decomposition products : Materials to avoid : Conditions to avoid : Stable under normal conditions. Halogenous acid, halogenous carbide. Explosives and flammable materials. Organic peroxide. Alkaline metals, Al, Zn, Be etc in powder. Not flammable with air in normal temperature and pressure conditions. TOXICOLOGICAL INFORMATION Undesirable human health effects : Heart arhythmia. Heart sensibility: 312'975 mg/m3. Anaesthetic effects: 834'600 mg/m3. - Inhalation : Lung edema. Rat inhalation LC50 [mg/l/4h] : 567 CCTN Carcinogenicity category (Italy) : Does not show any cancerogenic, teratogenic and mutagenic effects. Narcosis : Narcotic effets above TLV. 93