CHILLER CWS AQUACONTROL Modelli CWS BASIC 121 161 201 251 301 INSTALLATION MANUAL USAGE AND SCHEMATICS A041252 16/10/2012 COMPANY WITH QUALITY SYSTEM CERTIFIED BY DNV =ISO 9001/2000 9001/2008 = ISO VECO S.p.A. via Cantore 6, 20833 Giussano (MB)(MI)ITALY Italy ViaCantore,6/8-20034Giussano Phone. +39 0362 35321 Fax. +39 0362 852995 E-mail: info@veco.net Web: www.veco.net
1 ELECTRICAL CONNECTIONS 1.1 POWER SUPPLY All the electrical connection must be carried out by technicians and must follow the security guidelines of the country where the system is installed. System must be grounded through a properly dimensioned cable. System power supply cable must be correctly dimensioned to maximum power allowed by the system components. The same must be done for the pumps' power supply cable. System power supply bust be handled by an automatic switch. Before any maintenance, power supply must be switched off completely from the system. 1.2 ELECTRICAL CONNECTION OF THE SYSTEM COMPONENTS Electrical connections inside the system electrical box must be carried out as in schema C312 (electrical schematics is in the attachment CWS AQUACONTROL POWERBOARD CONNECTIONS ). 2 SEA WATER CIRCUIT 2.1 SEA WATER PUMP Sea water pump is necessary to allow sea water circulation in the correct quantity through the heat exchanger. Therefore sea water pump has to be silent, able to work continuously and built with water resistant material. 2.2 SEA WATER PUMP POSITION A Pump must be installed orizontally, with the water exit on the top. Pump must be installed minimum 0,50 meters under the sea level. C Sea water tap, the filter and the pump must be connected without siphons; the hose must always go up; from the sea water tap to the pump. 0,5 m D The hose from the sea water tap to the pump must the the shortest possible. The sea water circuit will not work well if the hose is longer then 1 meter. B Sea water intake has to be oriented towards the prow. PROW E In order for the pump to run correctly, the hose exiting the pump has to be vertical for at least 25 cm (10 inc.). STERN
2.3 PUMP INSTALLATION The sea water pump has to be fixed with screws using the existing holes in the base of the pump or the special fixing base available for small pump models. For bigger pumps, we suggest to mount them on silentblock. 2.4 SEA WATER CIRCUIT The sea water circuit must always have a positive slope from the sea water intake to the heat exchanger. After the heat exchanger, there is no specific requirement for the circuit slope. The sea water out must be installed to avoid noises for the boat itself and for the boats around.
3- FAN COILS' FRESH WATER CIRCUIT 3.1 FRESH WATER CIRCUIT CONNECTIONS Follow the installation diagrams. It's important to follow the instruction about the direction and position of all the system components. To allow an easy maintenance, make sure all the components are accessible. For all components strictly follow the indication about water flow direction. Leave access to the air outlet valve on the fresh water circuit. Follow the nominal diameter of the collector and leave the collector accessible, with the air outlet valve on the top. If installed, check that every control valve is completely open. Follow the schematics for the expansion tank. The connection door has to be on the top to allow drainage. Follow the schematics for the fresh water pump. Fresh water circuit has to be the shortest and the simplest as possible; each single top point in the circuit has to have an air outlet valve. Avoid siphons and avoid slopes in the fresh water circuit because they may create problems while emptying the fresh water circuit from air. For each fancoil, follow the water flow direction indicator. Each fan coil has an air outlet valve that must be accessible during installation and also during maintenance. 3.2 FLOW METER (OPTIONAL) Flow meter has to be installed on the fresh water circuit. It has to be accessible for maintenance and for calibration. The flow meter switch is an additional safety equipment that will stop the system whenever the fresh water flow stops or if it is not enough. The flow meter switch has to be electrically connected to the electrical box of the fan coil as specified in the electrical schematics. 3.3 PRESSURE IN THE FRESH WATER CIRCUIT The pressure gauge kit installed on the fresh water circuit has 2 point of access to the circuit (H-H1). Each point has a manual valve and an automatic one-way valve that block the water in the circuit to go into the pressurize sanitary water circuit in case of any error. Use one of the 2 valves and the pressure gauge in order to pressurize the circuit with fresh water at 1,5 Bar; this valve must be permanently connected to the water sanitary circuit in the boat. Check that the fresh water circuit pressure remains the same over the time, which means that it has no leaks. If the leak check is successful, remove some water from the circuit to leave some space and add anti-freezing liquid to the circuit. 3.4 ANTIFREEZE LIQUID Following two methods are suggested in order to add to the circuit antifreeze liquid. a) Calculate the circuit capacity and fill it with a mix of water (80%) and antifreeze (20%), using the second valve by gravity or with a pressure pump. Connect the fresh water circuit to the water sanitary circuit and pressurize it until 1,5 Bar; then start removing the air from the circuit. If there is a lot of air that has to be removed from the circuit, it will be necessary to add more liquid to it; remember to add 80% water and 20% antifreeze. b) Completely empty the circuit after the leak check. Prepare the necessary quantity of liquid (80% water and 20% antifreeze) and fill up the circuit using a pressure pump. After the circuit is full, remove all the air in it and then fill it up again with the same liquid.
3.5 AIR REMOVAL FROM THE FRESH WATER CIRCUIT When the circuit is under pressure and already contains the antifreeze, follow these instructions to remove air from the circuit. The air must be completely removed from all the access points of the circuit (collectors, fan coils and all the other system components) starting from the lowest point and maintaining the pressure at 1,5 Bar. This must be done without using the pump. Continue to remove air from each single access point of the fresh water circuit until no air exits anymore, always maintaining the pressure at 1,5 Bar. Switch off the chiller completely (compressor) and check that the sea water intake is open. Start the system (compressor) in COOL mode. Both the pumps (sea and fresh water) will start. Leave the fresh water pump working for 30 seconds, then shut down the system completely again and start with the previous procedure to remove air from each access point to the fresh water circuit, always maintaining the pressure at 1,5 Bar. Air removal is complete when no more air exits from the access points and the fresh water pump works with no problem and with no noise. We strongly advise to install in the fresh water circuit a deaerator, right after the pump water exit. The deaerator will reduce almost to zero the need of removing air from the circuit. Deaerator is available in different measures depending on the size of the fresh water circuit. 3.6 FAN COILS FRESH WATER CIRCUIT
3.6 FAN COILS FRESH WATER CIRCUIT
4- SYSTEM STARTUP 4.1 FRESH WATER CIRCUIT Important: the fresh water flow must be calibrated with respect to the fan coil and system capacity. Verify that the flow is greater or equal to the capacity specified in the chiller. Compressor, therefore the chiller unit, cannot work without the fresh water circuit. If the flow in the fresh water circuit is not sufficient, the evaporator of the chiller unit can freeze and can even bring the system to break. Following guidelines can avoid damage to the system due to insufficient water flow. A) ANTIFREEZE LIQUID fresh water circuit needs to be filled with water (80%) and antifreeze (20%). Antifreeze will low the water freezing point, making the water not freezing. Even if the water freeze, the mix of water and antifreeze will be more soft and it is harder for this kind of ice to damage the system. Antifreeze also reduces the corrosion inside the fresh water circuit. Always check that the pressure gauge is showing 1,5 Bar in the fresh water circuit. B) FLOW METER SWITCH (Optional) The flow meter stops the system when the fresh water flow is under the safety threshold. As described in chapter 3.2, the flow meter switch is installed on the outgoing collector of the circuit. Make sure that the flow meter is correctly connected to the control box. To test it, simulate e low flow situation pressing the lever inside the protection of the switch. Attention: the flow meter switch is connected to the main electrical box and all the checks and connection have to be done by professional personnel taking all the safety precaution required. 4.2 START UP Power up the main control box Set the MODE switch on COOL or HEAT Check that the sea water intake is completely open Check that the pumps water flow is enough (both sea and fresh) When the compressor is running, fresh water temperature will start cooling down (if COOL mode) or heating up (if HEAT mode); when the temperature will reach the set value (+12 C in COOL mode, +40 in HEAT mode) the thermostat will shut down the compressor. The time that the fresh water takes to reach the set point depends from different things: the number and the capacity of the fan coils, the speed of the fan coils, the ambient temperature, therefore it is not possible to specify in how much time the temperature will reach the set point. 4.4 FAN COIL Check that the fresh water reaches each single fan coil. Measure the ingoing and the outgoing water temperature; the difference has to be between 5 and 10 C. If the difference is more, it probably means that there is still air in the circuit and that the flow in the fan coil is too slow. In case of very long fresh water circuits, it is suggested to regulate the fan coil water flow calibrating valves, closing the ones more close to the collector, in order for the water to reach the most far away fan coils. Check that the thermostat sensor is correctly positioned where the air enters in the fan coil. If the temperature control is on FAN ONLY, the thermostat stops the fan when the air temperature reaches the set point. IMPORTANT: The temperature sensor has to be positioned where the air enters in the fan coil, not on the fan coil itself. If the fan coil control is on WATER VALVE, the thermostat closes the water valve connected to the fan coil while the fan continues to work. In this case the sensor has to be on the fan coil, fixed to the apposite platelet.
5- OPERATING INSTRUCTION 5.1 CHILLER START UP Rotate the switch MODE on the electrical box of the chiller on HEAT, to run in heat mode, or COOL, to run in cool mode. The system will start and the compressor will start operating. 5.2 CHILLER SHUT DOWN Rotate the switch MODE on OFF. 5.3 PUMP Both the sea water pump and the fresh water pump start when the switch is moved on COOL or HEAT. IMPORTANT: Both pumps will run even if the thermostat stops the compressor. 5.4 FAN COIL CONTROL Each cabin's temperature is monitored by a thermostat that controls the fan's speed. The thermostat is connected to the display in each single room. Display can be mechanical (Fig.1) or digital (Fig.2). Please refer to the mechanical panel or to the digital display instruction for more information. Fig.1 Mechanical panel. Fig.2 Digital display Vega MKII. 6 - MAINTENANCE 6.1 CHECKS BEFORE RUNNING THE SYSTEM Before turning the system on, check that the pressure in the fresh water circuit is between 1,5 and 2 Bar (21-28 PSI). Use a pressure gauge. If the fresh water circuit pressure goes below the safety threshold, the circuit needs to be repaired, fixing every leak. Continuously adding water to the circuit is not a solution since the antifreeze quantity will go below 20%. The liquid in the circuit must be checks at least every to years, more frequently if there are leaks. Liquid inside the fresh water circuit must be 80% water and 20% antifreeze (Glicole for example) Check frequently also the sea water circuit: Check the sea water filter and clean it frequently Measure and check the water flow coming out from the sea water drain Always have a spare gasket (packing gland) for the sea water pump and one for the fresh water pump. Clean and substitute the air filters for every fan coil. A dirty air filter reduces dramatically the air flow, reducing the fan coil efficiency. At the beginning of the summer season, check that every fan coil drain is clean and that it drains correctly. Consider that when humidity and temperature are high the condense can reach 1 litre/hour for each fan coil. When the system was stopped for a long period, before starting it, it is suggested to manually check the pumps, removing the back cover cap and manually rotating the cooling fan inside the pump. IMPORTANT: Be sure to correctly fix the back cover cap correctly before running the pump at the end of the maintenance.
7 TROUBLESHOOTING 7.1 CENTRAL UNIT - CHILLER AQUACONTROL The central chiller unit problems can be caused by: Insufficient sea water flow in the sea water circuit. This can be checked by looking at the sea water drain. Running the system with an insufficient sea water flow can damage the central unit. In case of any doubts, check the sea water circuit and pumps while the all system is shut off. Low power supply. Insufficient voltage to the system can damage the electrical parts and the compressor itself. 7.2 FAN COILS If the fan of the fancoil is not working, check that the control panel of the fan coil is set to the correct mode ( COOL in the summer and HEAT in the winter) and that the thermostat is at the minimum temperature in the summer and in the maximum temperature in the winter. Check the power supply. Check if the voltage is correct after setting the fan coil to the maximum speed. Voltage must be 230V. If voltage is correct, the fan engine may be broken and it has to be replaced. In order to get the correct spare part from the Veco Customer Service, provide us with all possible details of the fan coil and on the engine. Please note that the fan coil engine needs a specific condenser that is installed in the control box. 7.3 TROUBLESHOOTING FRESH WATER CIRCUIT DOES NOT COOL (in cool mode) SEA WATER PUMP AND FRESH WATER PUMP If pumps do not run, check power supply. COMPRESSOR IT IS WORKING BUT IT DOES NOT COOL The gas charge may not be enough. Check and recharge the gas circuit after repairing the leak. IT IS NOT WORKING Check the switch MODE, if it's OFF switch it on COOL IF THE SET POINT THERMOSTAT > +12 C Set the Set Point to + 12 C. If the compressor still does not work: IF THE RELAY IS OPEN Compressor relay is broken, substitute the compressor relay. IF THE RELAY IS CLOSED COMPRESSOR POWER SUPPLY IS WORKING Check and eventually substitute the compressor. COMPRESSOR POWER SUPPLY IS WORKING Check the compressor electronics. 7.4 TROUBLESHOOTING FRESH WATER CIRCUIT DOES NOT HEAT (in heat mode) SEA WATER PUMP AND FRESH WATER PUMP If pumps do not run, check power supply. COMPRESSOR IT IS WORKING BUT IT DOES NOT COOL The gas charge may not be enough. Check and recharge the gas circuit after repairing the leak. IT IS NOT WORKING Check the switch MODE, if it's OFF switch it on HEAT IF THE SET POINT THERMOSTAT < +40 C Set the Set Point to + 40 C. If the compressor still does not work: IF THE RELAY IS OPEN Compressor relay is broken, substitute the compressor relay. IF THE RELAY IS CLOSED COMPRESSOR POWER SUPPLY IS WORKING Check and eventually substitute the compressor. COMPRESSOR POWER SUPPLY IS WORKING Check the compressor electronics.
8 TECHNICAL DATA 8.1 CONDENSERS Condenser table for each fan coil. Codici ELECTRICAL BOXES FOR FANCOILS FAN CODE Condensers' codes. Codici CONDENSER CODE
C312 - CWS AQUACONTROL POWERBOARD CONNECTIONS COMPRESSOR MAINS SUPPLY 230/1/50-60 Ø = 3 x 2,5 mmq C Reverse Cycle Valve (RCV) (Up to 10 mt) Sea Water Pump Fresh Water Pump S R CM FUSE 250V 6,3A Compressor Neon Led RCV Neon Led Sea Pump Neon Led Fresh Pump Neon Led Flat Cable IMPORTANT NOTE: Local control shows/ sets temperatures, parameters, setpoints, alarms but can t switch on/off the system. To switch on/off CWS system need to use mecanical panel or touch screen Local Display LD1 BLINKING: Serial Communication Working LD2 OFF: No devices to communicate with or communication problems AQUACONTROL BASIC POWERBOARD Cod. M74330 ON S SW1 LD3 ON: LPS OPEN (Low Pressure Alarm) LD3 OFF: DEVICE OK 1 2 34 LD2 ON: HPS OPEN (High pressure Alarm) LD2 OFF: DEVICE OK LD4: NOT USED WHITE (COM) BLUE (COOL) PWM SIGNAL (NOT USED) RS 485 Modbus ORANGE (HEAT) GND DELAY * DIP SWITCH LEGEND 1 ON / 2 OFF = Reverse Cycle 1 OFF / 2 ON = Cool Only Switches 3-4 are not used INVALID SETTING display:off* To see setted configuration press Arrow down 5 time (till CON is shown on display) then press S to enter and see system configuration. CANL (-) CANH (+) TOUCH SCREEN Mec. RC Panel COOL Return Fresh Water Temp Anti Freeze Temp (Aft) Supply Sea Fresh Water Water Temp (St) Temp (SEA) (OPTIONAL) (OPTIONAL) OFF HEAT PC SUPERVISOR Mec. CO Panel COOL OFF Cod.M79290 C312 WHITE (COM) HPS FS (High Pressure Switch) LPS (Flow Switch) (Low Pressure Switch) BLUE (COOL) Cod.M78610CO