SystemAir SyScrew Water EVO CO Series Installation And Maintenance Manual
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SystemAir SyScrew Water EVO CO Series Installation And Maintenance Manual

Water/water cooled screw chillers
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Installation and maintenance manual
Manuel d'installation et de maintenance
Installations- und Wartungshandbuch
Manuale di installazione e di manutenzione
Manual de instalación y de mantenimiento
SyScrew Water EVO
English
444
Water/water Cooled Screw Chillers
Réfrigérateurs Froid Seulement eau/eau à compresseurs à vis
1567 kW
Wassergekulte Wasserkühler mit Schraubenkompressoren
Refrigeratori Solo Freddo acqua/acqua con compressori a vite
Refrigeradores Sólo Frío agua/agua con compresores a tornillo
Part number / Code / Code / Codice / Código:
Supersedes / Annule et remplace / Annulliert und ersezt / Annulla e sostituisce /
Anula y sustituye:
Notified Body /Organisme Notifié / Benannte Zertifizierungsstelle /
Organismo Notificato / Organismo Notificado
CO/HP/RC
Français
367236/A
367236
N°. 1115
Deutsch
Italiano
"
ISO 9001:2008 certified management system
Español

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Summary of Contents for SystemAir SyScrew Water EVO CO Series

  • Page 1 Installation and maintenance manual Manuel d’installation et de maintenance Installations- und Wartungshandbuch Manuale di installazione e di manutenzione Manual de instalación y de mantenimiento SyScrew Water EVO CO/HP/RC English Français Deutsch Italiano Español Water/water Cooled Screw Chillers Réfrigérateurs Froid Seulement eau/eau à compresseurs à vis 1567 kW Wassergekulte Wasserkühler mit Schraubenkompressoren Refrigeratori Solo Freddo acqua/acqua con compressori a vite...
  • Page 2 ITALY COSTRUTTORE / MANUFACTURE - BUONE NORME DI MANUTENZIONE DEI DISPOSITIVI DI SICUREZZA MONTATI SUL GRUPPO FRIGORIFERO Gentile Cliente, Le ricordiamo alcune indicazioni circa le modalità di manutenzione dei dispositivi di sicurezza montati sul gruppo frigorifero da Lei acquistato. I dispositivi di sicurezza montati sul gruppo sono stati verificati dal COSTRUTTORE a norma di legge. È...

  • Page 3: Table Of Contents

    Table of Contents 1 - FOREWORD 6 - CONTROL 6.1 Display ................23 1.1 Introduction ................2 6.2 Setpoint ................25 1.2 Warranty ................2 6.3 Protection and Safety Equipment ........26 1.3 Emergency stop/Normal stop ..........2 7 - PRODUCT DESCRIPTION 1.4 An introduction to this manual ..........2 2 - SAFETY 7.1 Introduction ................27 7.2 General specifications ............27...

  • Page 4: Foreword

    1 - Introdução 1 - Foreword 1.1 Introduction 1.3 Emergency stop / Normal stop Units, manufactured to state-of-the-art design and implementation The emergency stop of the unit can be enabled using the master standards, ensure top performance, reliability and fitness to any type switch on the control panel (move down the lever).

  • Page 5: Safety

    2 - Safety 2.1 Foreword The guards of the fans (only for RC units, These units must be installed in conformity with the with remote air exchangers) must be always provisions of Machinery Directive 2006/42/EC, Low Voltage mounted and must never be removed before Directive 2006/95/EC, Pressure Vessels Directive 2014/68/ de-energising the appliance.

  • Page 6: Definitions

    2 - Safety (continued) disassemble connections, filters, joints or other line items 2.2 Definitions do not use your hands to check for any pressure drops OWNER: means the legal representative of the company, body or individual who owns the plant where unit has been installed; he/she use tools in a good state of repair;...

  • Page 7: Precautions During Maintenance Operations

    2 - Safety (continued) periodically check the board’s internal wiring place a warning sign “do not turn on - maintenance in progress” on the external disconnecting switch do not use cables having an inadequate section or flying connections, even for limited periods of time or in an emergency make sure that on-off remote controls are inhibited wear suitable personal protective equipment (helmet, safety Prevention of other residual risks...

  • Page 8: Safety Labels

    2 - Safety (continued) 2.7 Safety labels Identification of the refrigerant - External door Identification of the unit - Outside, on the right-hand front column USARE SOLO R134a SPECIAL ESTER OIL USE ONLY Electrical warning - Aåacent to the master switch ATTENZIONE ! ATTENTION ! Prima di...
  • Page 9 2 - Safety (continued) Start-up warning - Outside the door Final Test Certificate - Inside the external door of the electrical board Instruction for the lifting Warning - High temperature Warning - Safety valve vents zone aåacent to hot pipes or components Fitting identification - Aåacent to fittings EIN - INLET...
  • Page 10 2 - Safety (continued) 2.8 Safety regulations REFRIGERANT DATA SAFETY DATA: R134a Toxicity 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. Unfreeze the affected skin with water. Contact with skin Remove the contaminated clothes with great care - in the presence of frost burns, the clothes may stick to the skin.
  • Page 11 2 - Safety (continued) 2.8 Safety regulations (continued) REFRIGERANT DATA SAFETY DATA: R134a Do not inhale concentrated vapours. Their concentration in the atmosphere should not exceed the minimum preset values and should be maintained below the professional threshold. Being more weighty General precautions than the air, the vapour concentrates on the bottom, in narrow areas.

  • Page 12: Safety Regulations

    2 - Safety (continued) 2.8 Safety regulations (continued) LUBRICANT OIL DATA SAFETY DATA: POLYESTER OIL (POE) Classification Not harmful. May cause slight irritation. Does not require first aid measures. It is recommended to follow usual personal hygiene measures, including washing the exposed skin with soap and water several times a day. Contact with skin It is also recommended to wash your overalls at least once a week.

  • Page 13: Transport, Lifting And Positioning

    3 - Transport, Lifting and Positioning Refrigerators are supplied assembled (apart from standard antivibrating rubber supports, that will be installed on site). The equipment are full of refrigerant and oil, in the quantity required for a proper operation. 3.1 Inspection When the unit is delivered, it is recommended to check it carefully and to identify any damage occurred during transportation.

  • Page 14: Anchoring

    3 - Transport, Lifting and Positioning (continued) During the lifting and handling of the unit, For lifting operations, use only tools and be careful not to damage the electrical board, material fit for this purpose, in accordance with installed on one side of the unit. accident-prevention regulations.

  • Page 15: Installation

    4 - Installation 4.1 Positioning of the unit 4.2 Spring Isolator Installation Prepare the base, that must be flat and plane. Before installing the unit, make sure that the structure of the building and/or the supporting Lift the appliance and insert shock absorbers as follows: surface can withstand the weight of the appliance.

  • Page 16: Hydraulic Connection Of The Evaporator

    4 - Installation (continued) 4.3 Hydraulic connection of the evaporator A flow switch will stop the unit when the water is not circulating or a flow rate problem occurs. The flow switch and the filter water, although not included in the To install the flow switch, follow the manufacturer’s instructions.
  • Page 17 4 - Installation (continued) Then: Provide the evaporator with a by-pass circuit equipped with a valve to wash the plant. Insulate the piping, to prevent the risk of heat loss. Position a filter on the suction side of the evaporator of the heat recovery condenser.

  • Page 18: Hydraulic Connection Of The Condenser

    4 - Installation (continued) 4.4 Hydraulic connection of the condenser To install the flow meter, follow the manufacturer’s instructions. The external hydraulic circuit must ensure the As a general rule, the flow meter shall be mounted on a horizontal water flow to the condenser under any working pipe, at a distance from the curves equal to 10 times the diameter or adjustment conditions.

  • Page 19: Connection Of Water Temperature Sensors (On Shell And Tube Evaporator)

    4 - Installation (continued) 4.6 Connection of water temperature sensors (on shell and tube evaporator) Each fitting is complete with sensor well to fasten temperature The units are provided with fittings for hydraulic connections between sensor (BT-IN and BT-OUT). Fittings are supplied separate and must heat exchangers and plant.

  • Page 20: Connection Of Water Temperature Sensors

    4 - Installation (continued) 4.7 Connection of water temperature sensors (on shell and tube condenser/s) dedicated water probes pockets to be provided over the installation. Hydraulic connections between condenser/s and plant are supplied Kit manifold accessory (offered as an option for units equipped with separately and must be installed during the installation of the unit.

  • Page 21: Power Supply

    4 - Installation (continued) 4.8 Power supply 4.9 Electrical connections The unit must be installed on site according to the Machinery Directive (2006/42/EC), the Low Voltage Directive (2006/95/EC), Before carrying out any operations on the the Electromagnetic Interference Directive (2004/108/EC) and electrical system, make sure that the unit is the usual procedures and standards applicable in the place of deenergised.

  • Page 22: Electrical Connections

    4 - Installation (continued) Electrical connections...

  • Page 23: Start-Up

    5 - Start-Up Check the correct direction of rotation of compressors. The unit must be started for the first time by Compressors cannot compress the refrigerant when they rotate personnel suitably trained by one Authorised in the opposite direction. To make sure that they are rotating in Service Centre.

  • Page 24: Control

    6 - Control General information The control system consists of: a) Main Board. Units are provided with a microprocessor card Introduction which is fully programmed by default for the control of a chiller equipped with a HP transducer and a LP transducer for each This document contains the information and the operating instructions circuit.

  • Page 25: Display

    6 - Control (continued) 6.1 Display/Keyboard Esc key: allows you to move from one mask to another. Alarm key: used to display the alarms, to reset them in manual. Press it one to display the mask of the activated alarm, press it again to reset the alarm signal.
  • Page 26 6 - Control (continued) Alarms Alarm code Description Notes Main board - EPROM Failure Main board - Clock card Failure Main board - External air temperature sensor fault Main board - Return Water temperature sensor fault (evaporator) Main board - Leaving Water temperature Sys 1 sensor fault (evaporator) Main board - Leaving Water temperature Sys 2 sensor fault (evaporator) Main board - Low pressure sys 1 sensor fault Main board - Low pressure sys 2 sensor fault...

  • Page 27: Setpoint

    6 - Control (continued) Alarm code Description Notes Driver 2 Battery alarm Autotune alarm Sys 1 Autotune alarm Sys 2 Low suction alarm Sys 1 Low suction alarm Sys 2 Expansion board 1 OFF LINE Expansion board 2 OFF LINE Expansion board 1 - Chillernet sensor fault Expansion board 1 - 4-20 mA remote set-point fault Low delta pressure Sys 1 manual reset...

  • Page 28: Protection And Safety Equipment

    6 - Control (continued) 6.3 Protection and Safety Equipment Flow switch A flow switch must be installed, to prevent the unit working in case Refrigeration system of insufficient circulation of the chilled fluid. The units are filled with R134a refrigerant fluid of non hazardous type (group II).

  • Page 29: Product Description

    7 - Product Description 7.1 Introduction SyScrew Water EVO units are designed for indoor installation. The units are suitable for indoor installation. They can be equipped with one or two circuits (depending on the This series includes the following versions: model) and may be used to cool water to the evaporator and / or to heat water to the condenser.

  • Page 30: Water Heat Exchanger

    7 - Product Description (continued) 7.5 Water heat exchangers Control panel includes: A transformer for auxiliaries, fuses, relay and electronic card, a Evaporator thermostat for the compressor’s delivery temperature The units are provided with a direct-expansion refrigerant/water shell The keyboard and the display of the “Chiller-Control” and tube heat exchanger with several refrigeration circuits.
  • Page 31 7 - Product Description (continued) Refrigerant circuit - CO/HP/BC versions UNIT CONTROL CONTROL COMPONENTS SAFETY / CONTROL DEVICES High pressure switch 15.5 bar (CO) Compressor (Screw type) 19.8 bar (HP/BC) Water cooled condenser Low pressure switch (0.5 bar) Filter drier High pressure transducer Electronic expansion valve Low pressure transducer...
  • Page 32 7 - Product Description (continued) Refrigerant circuit - RC version UNIT CONTROL CONTROL COMPONENTS SAFETY / CONTROL DEVICES Compressor (Screw type) High pressure switch (19.8 bar) Filter drier Low pressure switch (0.5 bar) Electronic expansion valve High pressure transducer Globe valve Low pressure transducer Heat exchanger (Shell &...

  • Page 33: Technical Data

    8 - Technical Data 8.1 Pressure drops Evaporator Pressure drop Nom. Capacity Qnom. Qmax. Qmin. Dp nom DP max DP min Model kPa/(l/h)^2 76696 127827 54783 7.297E-09 42.9 119.2 21.9 85256 142094 60897 4.149E-09 30.2 83.8 15.4 98502 164170 70359 5.354E-09 52.0 144.3...
  • Page 34 8 - Technical Data (continued) Desuperheater pressure drop Nom. Capacity Qnom. Qmax. Qmin. Dp nom DP max DP min Model kPa/(l/h)^2 5927 9878 3704 2.285E-08 6596 10993 4122 2.285E-08 7603 12672 4752 1.380E-08 8492 14154 5308 1.380E-08 not available not available 5841 9734 3650...
  • Page 35 8 - Technical Data (continued) 8.2 Technical data SyScrew Water EVO CO _ / S Power supply V/Ph/Hz 400 (± 10%) / 3 / 50 Number of refrigerant circuits Start-up Type 25-50-62- Total capacity steps 50-75-100 75-87-100 COMPRESSOR Number Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number...
  • Page 36 8 - Technical Data (continued) SyScrew Water EVO CO _ / S 1070 1130 1220 1280 1400 1550 Power supply V/Ph/Hz 400 (± 10%) / 3 / 50 Number of refrigerant circuits Start-up Type Total capacity steps 25-50-62-75-87-100 COMPRESSOR Number Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR)
  • Page 37 8 - Technical Data (continued) SyScrew Water EVO HP _ / S Power supply V/Ph/Hz 400 (± 10%) / 3 / 50 Number of refrigerant circuits Start-up Type 25-50-62- Total capacity steps 50-75-100 75-87-100 COMPRESSOR Number Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number Type Shell &...
  • Page 38 8 - Technical Data (continued) SyScrew Water EVO HP _ / S 1070 1130 1220 1280 1400 1550 Power supply V/Ph/Hz 400 (± 10%) / 3 / 50 Number of refrigerant circuits Start-up Type Total capacity steps 25-50-62-75-87-100 COMPRESSOR Number Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR)
  • Page 39 8 - Technical Data (continued) SyScrew Water EVO RC _ / S Power supply V/Ph/Hz 400 (± 10%) / 3 / 50 Number of refrigerant circuits Start-up Type 25-50-62- Total capacity steps 50-75-100 75-87-100 COMPRESSOR Number Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number Type Shell &...

  • Page 40: Technical Data

    8 - Technical Data (continued) SyScrew Water EVO RC _ / S 1070 1130 1220 1280 1400 1550 Power supply V/Ph/Hz 400 (± 10%) / 3 / 50 Number of refrigerant circuits Start-up Type Total capacity steps 25-50-62-75-87-100 COMPRESSOR Number Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR)

  • Page 41: Unit Electrical Data

    8 - Technical Data (continued) 8.3 Electrical data - SyScrew Water EVO CO Carter oil Nominal Nominal Maximum Start-up Nominal Corrected Com- Maximum absorbed power current current current power power pressor power input power Model System Circuit input input input - FLA - LRA factor factor*...
  • Page 42 8 - Technical Data (continued) Electrical data - SyScrew Water EVO HP-RC-BC Carter oil Nominal Nominal Maximum Start-up Nominal Corrected Com- Maximum absorbed power current current current power power pressor power input power Model System Circuit input input input - FLA - LRA factor* factor**...

  • Page 43: Position Of Shock Adsorbers And Weight Distribution On Supports

    8 - Technical Data (continued) 8.4 Position of shock adsorbers and weight distribution on supports Weight distribution P coordinates Operating Shipping SYSCREW WATER weight weight CO/HP/BC _ 2690 2509 1050 2200 1069 2725 2538 1050 2200 1064 2918 2701 1050 2200 1057 3040...
  • Page 44 8 - Technical Data (continued) Position of shock adsorbers and weight distribution on supports Weight distribution P coordinates Operating Shipping SYSCREW WATER weight weight RC _ 2302 2159 1050 2200 1172 2312 2169 1050 2200 1171 2456 2285 1050 2200 1169 2476 2305...
  • Page 45 8 - Technical Data (continued) 8.6 Dimensional drawings - SyScrew 440-770 Water EVO RC Front view Side view ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM Back view Top view 1350 2200 Evaporator water inlet victaulic connection Size dia 1-2 dia 3 dia 4 Evaporator water outlet victaulic connection 440-490...
  • Page 46 8 - Technical Data (continued) Dimensional drawings - SyScrew 440-770 Water EVO RC_S Front view Side view ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM Back view Top view 1350 2200 Evaporator water inlet victaulic connection Size dia 1-2 dia 3 dia 4 Evaporator water outlet victaulic connection 440-490...
  • Page 47 8 - Technical Data (continued) Dimensional drawings - SyScrew 440-770 Water EVO CO / HP Front view Side view ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM Back view Top view SIZES 440/490 SIZES 570/770 1085 2200 1020 1350 1350 Evaporator water inlet victaulic connection Size Evaporator water outlet victaulic connection 440-490...
  • Page 48 8 - Technical Data (continued) Dimensional drawings - SyScrew 440-770 Water EVO CO / HP_S Front view Side view Back view Top view SIZES 570/770 SIZES 440/490 1085 2200 1350 1020 1350 Evaporator water inlet victaulic connection Size Evaporator water outlet victaulic connection 440-490 2410 3620...
  • Page 49 8 - Technical Data (continued) Dimensional drawings - SyScrew 860-1550 Water EVO RC Front view Side view ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM Back view Top view 1520 2400 Evaporator water inlet victaulic connection Size dia 1-2 dia 3 dia 4 Evaporator water outlet victaulic connection 1090 2310 1000 4400 DN200 (8”)
  • Page 50 8 - Technical Data (continued) Dimensional drawings - SyScrew 860-1550 Water EVO RC_S Front view Side view ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM Back view Top view 1520 2400 Evaporator water inlet victaulic connection Size dia 1-2 dia 3 dia 4 Evaporator water outlet victaulic connection 1170 2310 1170 4650 DN200 (8”)
  • Page 51 8 - Technical Data (continued) Dimensional drawings - SyScrew 860-1550 Water EVO CO / HP Front view Side view ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM Back view Top view SIZES 860/990 SIZES 1070 1175 1240 1175 1520 1520 2400 SIZES 1130/1550 Evaporator water inlet victaulic connection Evaporator water outlet victaulic connection...

  • Page 52: Dimensional Drawings

    8 - Technical Data (continued) Dimensional drawings - SyScrew 860-1550 Water EVO CO / HP_S Front view Side view ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM Back view Top view SIZES 1070 SIZES 860/990 1175 1240 1175 1520 1520 2400 SIZES 1130/1550 Evaporator water inlet victaulic connection Evaporator water outlet victaulic connection...

  • Page 53: Service Spaces

    8 - Technical Data (continued) 8.6 Service spaces 0.5 MT 1 MT 2 MT 1 MT 3 MT...

  • Page 54: Maintenance

    9 - Maintenance Carefully read the “Safety” section of this manual before carrying out any maintenance operations. Operations Do not discharge the refrigerant into the atmosphere while the refrigeration circuits Check the temperature are being drained. Use appropriate recovery of the leaving fluid equipment.

  • Page 55: Refrigerant Charge

    9 - Maintenance (continued) 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 side in any point, remember that this type of oil of the circuit.

  • Page 56: Sight Glass

    9 - Maintenance (continued) 9.7 Sight glass 9.9 Evaporator The sight glass is used for inspecting the refrigerant flow and the Check at regular intervals that the water side of the heat exchanger humidity % of the refrigerant. The presence of bubbles indicates that is perfectly clean.

  • Page 57: 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 authorised Service Centre for technical assistance. Anomaly Cause Operation The unit continues...

  • Page 58: Spare Parts

    11 - Spare Parts 11.1 Spare part list The table below shows the list of spare parts recommended during the first two years of operation. Component Number HP pressure switch 2 / 4 LP pressure switch 2 / 4 Gas filter 1 / 2 Electronic expansion valve 1 / 2...

  • Page 59: Dismantling, Demolition And Scrapping

    12 - Dismantling, Demolition and Scrapping After draining operations, the piping of the hydraulic networks can be disconnected and disassembled. During the draining of the refrigeration circuits, do not let the refrigerant overflow in Once they have been disconnected as specified, the packaged units the surrounding atmosphere.
  • Page 60 Notes...

This manual is also suitable for:

Syscrew water evo hp seriesSyscrew water evo rc seriesSyscrew water evo co 440 /sSyscrew water evo co 570 /sSyscrew water evo co 630 /sSyscrew water evo co 700 /s ... Show all

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