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Itelco-Clima CWP-HP Installation And Maintenance Manual

Water cooled water chillers : cooling only, condenserless and heat pump versions
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Installation and maintenance manual
Manuel d'installation et de maintenance
CWP-CO/CWP-RC/CWP-HP
02 ÷ 35
English
Water cooled water chillers : cooling only, condenserless and heat pump
8
versions
136 kW
Refroidisseurs de liquide à condensation par eau : versions froid seul, sans
condenseur et pompe à chaleur
9
164 kW
IOM CWP-N.1GBF
Date : May / Mai 2006
Supersedes / Annule et remplace : IMW 910.2M/12.01
Français

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  • Page 1 Installation and maintenance manual Manuel d’installation et de maintenance CWP-CO/CWP-RC/CWP-HP 02 ÷ 35 English Français Water cooled water chillers : cooling only, condenserless and heat pump  versions 136 kW Refroidisseurs de liquide à condensation par eau : versions froid seul, sans condenseur et pompe à...

  • Page 2: Table Of Contents

    Manuale CWP 4.11.2005 11:55 Pagina 1 Table of contents Table of contents 1 FOREWORD 6 CONTROL SYSTEM 1.1 Introduction 6.1 CWP Control system µchiller 1.2 Warranty 6.2 High Pressure Control 1.3 Emergency stop/Normal stop 6.3 Low Pressure Control 1.4 An introduction to this manual 6.4 Heat Exchanger Heater Thermostat 6.5 Pressostatic Valve Kit (Optional) 2 SAFETY...

  • Page 3: Foreword

    Form 1 (“Start-up”) has been filled- The Useful Tips provide valuable informa- in and mailed to ’Itelco-Clima (attn. After-Sales Ser- tion that optimises the efficiency of the ap- vice). pliance.

  • Page 4: Safety

    OPERATOR: means a person authorised by the own- er to do on Itelco-Clima unit all the regulation and control operations expressly described in this manu- al, that must be strictly complied with, without ex- ceeding the scope of the tasks entrusted to him.

  • Page 5: Access To The Unit

    Safety ENGINEER: means a person authorised directly by 2.5 Precautions against residual risks Itelco-Clima or, in all EC countries, excluding Italy, under his full responsibility, by the distributor of Itel- Prevention of residual risks caused by the co-Clima product, to perform any routine and extra-...

  • Page 6: Precautions During Maintenance

    Itelco-Clima or the official retailers of the com- do not disperse the refrigerant and the lubricating panies on the recommended spare parts list...

  • Page 7: Safety Labels

    Manuale CWP 4.11.2005 11:56 Pagina 6 Safety 2.7 Safety labels The labels below will be affixed to each unit in the indicated point: EIN - INLET ENTRÉE - ENTRATA AUS - OUTLET SORTIE - USCITA Fitting identification - Adjacent to fittings Electrical warning Adjacent to the master switch Grounding connection - On the electrical...

  • Page 8: Safety Regulations

    Manuale CWP 4.11.2005 11:56 Pagina 7 Safety Safety regulations Refrigerant data Safety data: R407C Toxicity Contact with skin If sprayed, the refrigerant is likely to cause frost burns. If absorbed by the skin, the danger is very limited; it may cause a slight irritation, and the liquid is degreasing.
  • Page 9 Manuale CWP 4.11.2005 11:56 Pagina 8 Safety General precautions Do not inhale concentrated vapours. Their concentration in the atmos- phere should not exceed the minimum preset values and should be maintained below the professional threshold. Being more weighty than the air, the vapour concentrates on the bottom, in narrow areas. There- fore, the exhaust system must work at low level.
  • Page 10 Manuale CWP 4.11.2005 11:56 Pagina 9 Safety Refrigerant oil data Safety data: Polyolester oil (POE) Classification Not harmful Contact with skin May cause slight irritation. Does not require first aid measures. It is rec- ommended to follow usual personal hygiene measures, including wash- ing the exposed skin with soap and water several times a day.

  • Page 11: Transport, Lifting And Positioning

    50°C for the units using Itelco-Clima immediately. R407C and, if possible, do not expose to direct Please note that Itelco-Clima may not be held liable sunlight for any damage to the equipment during transporta- tion, even though the carrier has been appointed by it is recommended to store the unit in a roof where the factory.

  • Page 12: Installation

    Manuale CWP 4.11.2005 11:56 Pagina 11 Installation INSTALLATION 4.1 Positioning of the unit Before installing the unit, make sure that the Vibration eliminators in all water piping connected structure of the building and/or the support- to the units are recommended to avoid straining the ing surface can withstand the weight of the piping and transmitting vibration and noise.

  • Page 13: Hydraulic Connection Of The Condenser

    Manuale CWP 4.11.2005 11:56 Pagina 12 Installation The capacity of the expansion vessel must 4.4 Hydraulic connection allow for an expansion of at least 2% of the of the condenser volume of the fluid in the circuit (evapora- tor, piping, user circuit and standby tank, if The external hydraulic circuit must ensure any).

  • Page 14: Hydraulic Connection

    For 3-phase systems, check also that the unbalance between the phases does not exceed 2%. To perform Itelco-Clima may not be held liable for any damage this check, measure the differences between the volt- and/or injury caused by failure to comply with these age of each phase couple and their mean value dur- precautions.

  • Page 15: Start-Up

    Sales Service Centre. Failure to meet this re- at least 12 hours before. quirement will immediately void the warran- 5.2 Start-up The operations carried out by Itelco-Clima Start-up sequence: personnel are limited to the start-up of the unit, and do not include any other opera-...

  • Page 16: Checking The Operation

    Manuale CWP 4.11.2005 11:56 Pagina 15 Start-up Repeat the start-up procedure after removing the leaks. Check the oil level in the compressor’s sight glass. 5.3 Checking the operation Check the following: The temperature of the water entering the evapo- rator. The temperature of the water leaving the evapora- tor.
  • Page 17 Manuale CWP 4.11.2005 11:56 Pagina 16 Control System CONTROL SYSTEM µchiller Control system 6.1.1 Temperature controller In order to set the cooling set point to a value lower than the shop setting, it is essential that you add The controller mounted on COOLING ONLY units is some antifreeze to the circulating water and re-cali- shop calibrated to control the unit according to the brate accordingly all the safety components of the...
  • Page 18 Manuale CWP 4.11.2005 11:56 Pagina 17 Control System 6.1.3 Summary of the key functions The meaning of each key, in the different modes, is summed up in the table below. State of the machine Pressing the key Normal (i.e. the display shows the tem- after 5”...

  • Page 19: High Pressure Control

    Manuale CWP 4.11.2005 11:56 Pagina 18 Control System 6.2 High Pressure Control The high pressure control is a pressure activated switch that opens on a rise in pressure. When the switch opens, the safety relay de-energizes the com- pressor circuit preventing the unit operation until the high pressure control is reset.

  • Page 20: General Description

    RC only). All these 13 options are available in three models: The CWP-HP and CWP-RC feature also a 4-way CWP: “cold only”, requires a cooling tower or a valve, a non-return valve and a liquid receiver. dry cooler for heat dissipation purposes 7.5 Evaporator...
  • Page 21 Components: Compressor Cock Liquid receiver Solenoid valve Filter Sight glass Thermostatic galve Evaporator CWP-HP refrigeration circuit (02 to 05) Components: Filter P1 HP pressure switch Compressor Sight glass P2 LP pressure switch 4 way valve Thermostatic valve P3 Pressure taps...
  • Page 22 Components: Compressor Safety valve Cock Liquid receiver Solenoid valve Filter Sight glass Thermostatic valve Evaporator CWP-HP refrigeration circuit (06 to 21) Components: Compressor Safety valve 4 way valve Heat exchanger Liquid receiver Filter Sight glass P1 HP pressure switch Thermostatic...
  • Page 23 Components: Compressor Safety valve Cock Liquid receiver Solenoid valve Filter Sight glass Thermostatic valve Evaporator CWP-HP refrigeration circuit (25 to 35) Components: Compressor Safety valve 4 way valve Heat exchanger Liquid receiver Filter Sight Glass P1 HP pressure switch Thermostatic...

  • Page 24: Technical Data

    Manuale CWP 4.11.2005 11:56 Pagina 23 Technical data TECHNICAL DATA 8.1 Pressure drops PRESSURE DROPS IN THE EVAPORATOR CWP/CWP-HP/CWP-RC kPa/(m 13246.5 4657.0 4657.0 2480.0 2472.2 1477.7 1484.9 Min. water flow rate Nominal water flow rate Max. water flow rate Min. pressure drops 11.2...

  • Page 25: Technical Data

    Manuale CWP 4.11.2005 11:56 Pagina 24 Technical data 8.2 Technical data Power supply V/ph/Hz 400/3/50 Number of circuits Number of steps Refrigerant Type (1) R407C Charge (2) Compressor Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Number Start-up type Direct Direct Direct Direct...
  • Page 26 Manuale CWP 4.11.2005 11:56 Pagina 25 Technical data Power supply V/ph/Hz 400/3/50 Number of circuits Number of steps Refrigerant Type (1) R407C Charge (2) 11.2 Compressors Type Scroll Scroll Scroll Scroll Scroll Scroll Number Start-up type Direct Direct Direct Direct Direct Direct Evaporator...
  • Page 27 Manuale CWP 4.11.2005 11:56 Pagina 26 Technical data CWP-HP Power supply V/ph/Hz 400/3/50 Number of circuits Number of steps Refrigerant Type (1) R407C Charge (2) Compressor Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Number Start-up type Direct Direct Direct...
  • Page 28 Manuale CWP 4.11.2005 11:56 Pagina 27 Technical data CWP-HP Power supply V/ph/Hz 400/3/50 Number of circuits Number of steps Refrigerant Type (1) R407C Charge (2) 9:36 Compressors Type Scroll Scroll Scroll Scroll Scroll Scroll Number Start-up type Direct Direct Direct...
  • Page 29 Manuale CWP 4.11.2005 11:56 Pagina 28 Technical data CWP-RC Power supply V/ph/Hz 400/3/50 Number of circuits Number of steps Compressor Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Number Start-up type Direct Direct Direct Direct Direct Direct Direct Evaporator Type Plate type Number Minimum water content...

  • Page 30: Electrical Data

    Manuale CWP 4.11.2005 11:56 Pagina 29 Technical data 8.3 Electrical data CWP/CWP-HP/CWP RC Nominal voltage V(%)/ph/Hz 400 ±10% / 3 / 50 Max power input 12.2 15.1 Max. current (FLA) 17.3 12.0 13.0 15.1 20.7 26.0 Max. start-up current (LRA)

  • Page 31: Overall Dimensions

    Manuale CWP 4.11.2005 11:56 Pagina 30 Technical data 8.4 Overall dimensions CWP / CWP-HP / CWP-RC (02 to 15) Side view Front view 1 Evaporator inlet: 1”1/4 female (sizes 02 to 09) 1”1/2 female (sizes 15) 2 Evaporator outlet: 1”1/4 female (sizes 02 to 09) 1”1/2 female (sizes 15)
  • Page 32 Manuale CWP 4.11.2005 11:56 Pagina 31 Technical data CWP / CWP-HP / CWP-RC (18 - 21) Rear view Side view For CWP / CWP-HP 1 Evaporator inlet: 1”1/4 female 2 Evaporator outlet: 1”1/4 female 3 Condenser inlet: 1”1/4 female 4 Condenser outlet: 1”1/4 female...
  • Page 33 Manuale CWP 4.11.2005 11:56 Pagina 32 Technical data CWP / CWP-HP / CWP-RC (25 to 35) Rear view Side view For CWP / CWP-HP 1 Evaporator inlet: 2” female 2 Evaporator outlet: 2” female 3 Condenser inlet: 2” female 4 Condenser outlet: 2”...

  • Page 34: Service Spaces

    Manuale CWP 4.11.2005 11:56 Pagina 33 Technical data 8.5 Service Spaces Side view Front view Page 33...

  • Page 35: Maintenance

    Check the operation • • tions. If you are in doubt, please contact Itelco-Clima of the solenoid valve Service Centre. Page 34...

  • Page 36: Refrigerant Charge

    Manuale CWP 4.11.2005 11:56 Pagina 35 Maintenance 9.3 Refrigerant charge Compressors use polyester oil. During maintenance operations on the compressor, or if you have to open the refrigerant circuit Do not inject refrigerant liquid into the LP in any point, remember that this type of oil side of the circuit.

  • Page 37: Thermostatic Expansion Valve

    Manuale CWP 4.11.2005 11:56 Pagina 36 Maintenance If you compare the colour of the indicator to the scale In this case, the heat exchanger must be subjected to on the ring of the sight glass, you can calculate the chemical cleaning, an operation that shall be carried percentage of humidity of the refrigerant.

  • Page 38: Troubleshooting

    10 TROUBLESHOOTING The table below lists the anomalies of operation of the unit, the relevant causes and the corrective measures. For anomalies of any other type or not listed, contact one of Itelco-Clima’s Service Centre for technical assis- tance. Anomaly...
  • Page 39 Manuale CWP 4.11.2005 11:56 Pagina 38 Troubleshooting Anomaly Cause Operation One or both compressors Breaking of the electric circuit. Check the electric circuit and detect are not working. any ground dispersions and short cir- cuits. Check fuses. Intervention of the HP pressure Reset the pressure switch and the con- switch.

  • Page 40: Spare Parts

    The compressors are lubricated with polyester oil (P.O.E.). 11.3 Wiring diagrams The wiring diagrams are installed inside the doors of the electrical panels of the unit. Any request for wiring diagrams shall be forwarded to Itelco-Clima’s Service Centre. Page 39...

  • Page 41: Dismantling, Demolition And Scrapping

    Manuale CWP 4.11.2005 11:56 Pagina 40 Dismantling, Demolition and Scrapping 12 DISMANTLING, DEMOLITION AND SCRAPPING After draining operations, the piping of the hydraulic During the draining of the refrigeration cir- networks can be disconnected and disassembled. cuits, do not let the refrigerant overflow in the surrounding atmosphere.
  • Page 42 20030 Barlassina (MI) - Italy : +39 0362 6801  : +39 0362 680281 www.itelco-clima.com  Your distributor / Votre agent commercial : As part of our ongoing product improvement programme, our products are subject to change without prior notice. Non contractual photos.

This manual is also suitable for:

Cwp-rcCwp-co

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