SystemAir AQVL Series Installation And Maintenance Manual
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SystemAir AQVL Series Installation And Maintenance Manual

Air-cooled water chillers and heat pumps
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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
AQVL/AQVC/AQVH/AQVR
English
80
Air-Cooled Water Chillers and Heat Pumps
Refroidisseurs d'Eau et Pompe à Chaleur Refroidis à l'Air
140 kW
Luftgekühlte Flüssigkeitskühler und Wärmepumpen
Refrigeratori d'Acqua e Pompe di Calore Raffreddati ad Aria
90
Enfriadores de Agua y Bomba de Calor Condensadas con Aire
150 kW
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
Français
342598/E
342598/D
N°. 0425
Deutsch
Italiano
ISO 9001:2015 certified management system
Español

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  • 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 AQVL/AQVC/AQVH/AQVR English Français Deutsch Italiano Español Air-Cooled Water Chillers and Heat Pumps  Refroidisseurs d’Eau et Pompe à Chaleur Refroidis à l’Air 140 kW Luftgekühlte Flüssigkeitskühler und Wärmepumpen Refrigeratori d’Acqua e Pompe di Calore Raffreddati ad Aria...

  • Page 2: Table Of Contents

    Table of contents 1 FOREWORD 7 GENERAL DESCRIPTION Introduction General Information Warranty Body and Frame Emergency stop/Normal stop Compressors An introduction to this manual Evaporators Condensing coils 2 SAFETY Condenser Fans Foreword Fans Control Definitions Refrigerating Circuits Access to the unit Control Supply Panel General precautions 8 TECHNICAL DATA...

  • Page 3: Foreword

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

  • Page 4: Safety

    Safety SAFETY The guards of the fans (only for units pro- Foreword vided with air heat exchangers) must be al- ways mounted and must never be removed These units must be installed in conformity with the before de-energising the appliance. DANGER provisions of Machinery Directive 2006/42/EC, Pressure Equipment Directive 2014/68/EU, Elec-...

  • Page 5: Access To The Unit

    Safety do not use your hands to check for any pressure OPERATOR: means a person authorised by the owner drops to do on unit all the regulation and control operations expressly described in this manual, that must be strict- use tools in a good state of repair; be sure to have ly complied with, without exceeding the scope of the understood the instructions before using them tasks entrusted to him.

  • Page 6: Precautions During Maintenance

    Safety check all the electrical connections, the connect- met, safety gloves, goggles and shoes etc.) ing cables, and in particular the insulation; replace worn or damaged cables To carry out any measurements or checks which re- quire the activation of the machine: periodically check the board’s internal wiring work with the electrical board open only for the nec- do not use cables having an inadequate section or...

  • Page 7: Safety Labels

    (max) POTENZA ASSORBITA (max) Kw POWER INPUT PRESS. MAX ESERCIZIO ACQUA MAX WATER OPERATING PRESSURE MASSA MASS SYSTEMAIR S.r.l. Via XXV Aprile 29 20825 BARLASSINA MB ITALIA MADE IN ITALY COD.NO: P35952 MODELLO: MODEL MATRICOLA: SERIAL NO. CODICE: ANNO DI COSTRUZIONE PRODUCT CODE Manuf.
  • Page 8 Safety ATTENZIONE ! ATTENTION ! Prima di Enlever aprire togliere l’alimentation tensione electrique avant d’ouvrir ACHTUNG ! CAUTION ! ATENCION ! Vor offnen des Disconnect Cortar la gehauses electrical corrente antes hauptschalter supply before de abrir ausschalten opening el aparato Electrical warning Grounding connection on the electrical Adjacent to the master switch...

  • Page 9: Safety Regulations

    Safety Safety regulations Safety data: R410A Refrigerant data 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 10 Safety General precautions Do not inhale concentrated vapours. Their concentration in the atmos- phere should not exceed the minimum preset values and should be main- tained below the professional threshold. Being more weighty than the air, the vapour concentrates on the bottom, in narrow areas. Therefore, the exhaust system must work at low level.
  • Page 11 Safety Safety data: Polyester oil (POE) Lubricant oil data Classification Not harmful. May cause slight irritation. Does not require first aid measures. It is rec- Contact with skin ommended to follow usual personal hygiene measures, including wash- ing the exposed skin with soap and water several times a day. It is also recommended to wash your overalls at least once a week.

  • Page 12: Transport, Lifting And Positioning

    Transport, Lifting and Positioning TRANSPORT, LIFTING AND POSITIONING It is recommended to use a spacer to prevent cables Refrigerators are supplied assembled (apart from from damaging the unit (see the figure). 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 opera- tion.

  • Page 13: Anchoring

    Transport, Lifting and Positioning Storage During the lifting and handling of the unit, be careful not to damage the finned pack of the coils positioned on the sides of the unit. The When the unit is to be stored before installation, adopt sides of the unit must be protected by card- a few precautions to prevent any damage or risk of WARNING...

  • Page 14: Installation

    Installation INSTALLATION Spring Isolator Installation Positioning of the unit Prepare the base, that must be flat and plane. Before installing the unit, make sure that the structure of the building and/or the support- Lift the appliance and insert shock absorbers as fol- ing surface can withstand the weight of the lows: DANGER...

  • Page 15: External Water Circuit

    Installation External Water Circuit The expansion tank shall be dimensioned in such a way that it can absorb a 2% expan- The flow switch and the filter water, although not in- sion of the total volume of the water in the cluded in the supply, must always be fitted such as plant (exchanger, pipelines, uses and stor- plant components.
  • Page 16 Installation AQVL-AQVH 85-140 Hydraulic System Basic INLET OUTLET Components: Safety/control devices: Plate heat exchanger Inlet water temperature sensor Water filter Outlet water temperature sensor Pressure point/drain valve Flow switch Water outlet Thermometer Water inlet - - - Unit side Globe valve Flexible pipes Probes By pass valve...
  • Page 17 Installation AQVL-AQVH 85-140 Hydraulic System 2P INLET OUTLET Components: Safety/control devices: Plate heat exchanger Inlet water temperature sensor Pump Outlet water temperature sensor Water filter Vent valve Non-return valve Water safety valve (6 bar) Pressure expansion tank Flow switch Pressure point/drain valve Thermometer Water outlet - - -...
  • Page 18 Installation AQVL-AQVH 85-140 Hydraulic System 1P+T INLET OUTLET Components: Safety/control devices: Plate heat exchanger Inlet water temperature sensor Pump Outlet water temperature sensor Draining valve Vent valve Water buffer tank Water safety valve (6 bar) Water filter Flow switch Non-return valve Thermometer Pressure expansion tank - - -...

  • Page 19: Water Connections

    Installation Water connections The fans and compressors are supplied through contactors controlled from the control panel. The attachments at the water inlet and outlet Each motor is provided with an internal safety ther- shall be connected in compliance with the in- mal device and external fuses.

  • Page 20: Connecting Plate-Type Evaporator Temperature Sensors

    Installation hydraulic connections between heat exchangers and Connecting plate-type evaporator plant. Each fittings is complete with sensor well to fa- temperature sensors sten temperature sensor (BT-IN and BT-OUT). Fittings are supplied separate and must be mounted during the installation of the unit, as explained in the instruc- AQVL and AQVH units are provided with fittings for tion below.

  • Page 21: Microchannel Type Condenser Coils

    Installation Microchannel type condenser coils On cooling only unit fitted with microchannel type screws, once unit is installed, as shown in figure be- condensers, it is necessary to remove the fixation low. Page 20...

  • Page 22: Start-Up

    Start-up START-UP Start-up The unit must be started for the first time by personnel suitably trained by one Authorised Start-up sequence: Service Centre. Failure to meet this require- Turn on the Main switch (at least 12 hours before). ment will immediately void the warranty. WARNING Check that the oil in the compressor has reached the The operations carried out by authorised...

  • Page 23: Delivery To The Customer

    Start-up pressor and in case of stabilised operation. The fan’s current absorption. Check that the condensing and evaporation tempera- tures, during operation at high and low pressure de- tected by the pressure gauges of the refrigerant, are within the following range: (On the units not provided with HP/LP pressure gaug- es for the refrigerant, connect a pressure gauge to the Shrader valves on the refrigeration circuit).

  • Page 24: General Information

    Control GENERAL INFORMATION Control of AQVL-AQVH-AQVC Introduction with 4 compressors. This document contains the information and the oper- The “CHILLER CONTROL” system ating instructions for AQVL-AQVH-AQVC 4 compres- sors & electronic control. The AQVL-AQVH machines with 4 scroll compressors This information is for the after-sales service and the are provided with a microprocessor card which is fully production operators, for the end-of-line testing.

  • Page 25: Display

    Control Display Access to the “display mask” of the machine status. Esc key: allows you to move from one mask to another. Alarm key: used to display the alarms, to re- set them in manual. Press it one to display the mask of the activa- ted alarm, press it again to reset the alarm signal.
  • Page 26 Control 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 Main board - Leaving Water temperature sys 1 sensor fault Main board - Leaving Water temperature sys 2 sensor fault Main board - Low pressure sys 1 sensor fault Main board - Low pressure sys 2 sensor fault...
  • Page 27 Control Alarm code Description Notes EPROM Error Driver 2 Driver 1 S1 Sensor fault Driver 1 S3 Sensor fault Driver 1 S2 Sensor fault Driver 1 S4 Sensor fault Driver 2 S1 Sensor fault Driver 2 S2 Sensor fault EEV motor Error (Check viring) Sys 1 EEV motor Error (Check viring) Sys 2 Driver 1 Battery alarm Driver 2 Battery alarm...

  • Page 28: Protection And Safety Equipment

    Control Setpoint Pressing the Set key allows you to enter the Set point level accessible to the user. The parameters that can be set are listed below, along with the limit values and the default values (standard shop settings): User parameters Control mode Min value Max value...

  • Page 29: General Description

    General Description PRODUCT DESCRIPTION Condensing coils General Information Condensers are coils made of copper tubes arranged AQVL/AQVH units are one-block type with two re- in staggered rows and mechanically expanded inside frigerant circuits. They are intended to cool down the an aluminium finned pack.
  • Page 30 General Description AQVL refrigeration diagram OIL EQUAL. OIL EQUAL. UNIT UNIT CONTROL CONTROL CONTROL CONTROL Components: Vessel Category (≥ 2) / Safety/control devices: Hazard Category / Evaluation module Evaluation module Compressor Tandem Scroll Type 2 / mod. D1 High Pressure switch (40,5 bar) 4 / mod.
  • Page 31 General Description AQVC refrigeration diagram OIL EQUAL. OIL EQUAL. Components: Vessel Category (≥ 2) / Safety/control devices: Hazard Category / Evaluation module Evaluation module Compressor Tandem Scroll Type 2 / mod. D1 High Pressure switch (40,5 bar) 4 / mod. B+D Air cooled condenser Low Pressure switch (1,5 bar) Globe valve...

  • Page 32: Technical Data

    Technical data TECHNICAL DATA Pressure drops PRESSURE DROP IN THE EVAPORATOR* AQVL kPa/(l/s)^2 1,49 1,49 1,15 1,15 0,76 0,76 Minimum flow rate 2,50 2,80 3,07 3,30 3,65 4,10 Nominal flow rate 3,99 4,48 4,91 5,28 5,84 6,55 Maximum flow rate 6,66 7,46 8,19...

  • Page 33: Technical Data

    Technical data Technical data AQVL BLN Power supply V/ph/Hz 400V/3/50Hz Number of refrigerant circuits 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75- Total capacity steps Refrigerant Type / GWP R410A / 2.088 6 / 6 6 / 6 6 / 6 6 / 6 8 / 8 8 / 8 Charge 1/2...
  • Page 34 Technical data AQVL ELN Power supply V/ph/Hz 400V/3/50Hz Number of refrigerant circuits 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75- Total capacity steps Refrigerant Type / GWP R410A / 2.088 6 / 6 6 / 6 6 / 6 6 / 6 8 / 8 8 / 8 Charge 1/2...
  • Page 35 Technical data AQVL HT Power supply V/ph/Hz 400V/3/50Hz Number of refrigerant circuits 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75- Total capacity steps Refrigerant Type / GWP R410A / 2.088 6 / 6 6 / 6 6 / 6 6 / 6 8 / 8 8 / 8 Charge 1/2...
  • Page 36 Technical data AQVH BLN Power supply V/ph/Hz 400V/3/50Hz Number of refrigerant circuits 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75- Total capacity steps Refrigerant Type / GWP R410A / 2.088 11 / 11 12,5 / 12,5 12,5 / 12,5 15 / 15 16,8 / 16,8 19 / 19 Charge 1/2...
  • Page 37 Technical data AQVH ELN Power supply V/ph/Hz 400V/3/50Hz Number of refrigerant circuits 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75- Total capacity steps Refrigerant Type / GWP R410A / 2.088 11 / 11 12,5 / 12,5 12,5 / 12,5 15 / 15 16,8 / 16,8 19 / 19 Charge 1/2...
  • Page 38 Technical data AQVH HT Power supply V/ph/Hz 400V/3/50Hz Number of refrigerant circuits 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75- Total capacity steps Refrigerant Type / GWP R410A / 2.088 11 / 11 12,5 / 12,5 12,5 / 12,5 15 / 15 16,8 / 16,8 19 / 19 Charge 1/2...
  • Page 39 Technical data AQVC BLN-HT Power supply V/ph/Hz 400V/3/50Hz Number of circuits 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75- Capacity steps Refrigerant Type / GWP R410A / 2.088 6 / 6 6 / 6 6 / 6 6 / 6 8 / 8 8 / 8 Charge 1/2 12,5 / 12,5 12,5 / 12,5 12,5 / 12,5 12,5 / 12,5 16,7 / 16,7 16,7 / 16,7...

  • Page 40: Unit Electrical Data

    Technical data Unit electrical data AQVL/AQVH BLN Rated voltage V/ph/Hz 400V/3/50Hz Max. absorbed power Rated Current Max. current FLA Max. start-up current LRA External fuses Max. cable section (*) Exchanger resistance Rated voltage V/ph/Hz 230/ (± 10%)/1/50 Max. absorbed power AQVL/AQVH ELN Rated voltage V/ph/Hz...
  • Page 41 Technical data Compressor electrical data AQVL/AQVH BLN-ELN Number Max. absorbed power 9,1+9,1+9,1+9,1 10,2+10,2+10,2+10,2 12+12+10,2+10,2 12+12+12+12 14,8+12+14,8+12 14,8+14,8+14,8+14,8 Rated current 95+95+95+95 111+111+111+111 118+118+111+111 118+118+118+118 140+118+140+118 140+140+140+140 Max current 16+16+16+16 21+21+21+21 22+22+21+21 22+22+22+22 31+22+31+22 31+31+31+31 Oil pan resistor 90+90+90+90 90+90+90+90 90+90+90+90 90+90+90+90 90+90+90+90 90+90+90+90 Fans electrical data...

  • Page 42: Hydraulic Features

    Technical data Hydraulic Features AQVL - 1/2 Pumps available static pressure Water flow [l/h] AQVH - 1/2 Pumps available static pressure Water flow [l/h] Page 41...
  • Page 43 Technical data AQVL - Evaporator pressure drop Water flow [l/h] AQVH - Evaporator pressure drop Water flow [l/h] AQVL - Desuperheather pressure drop Water flow [l/h] Page 42...

  • Page 44: Position Of Shock Adsorbers And Weight Distribution On Supports

    Technical data Position of shock adsorbers and weight distribution on supports Electrical board Compressor Side P1 - P4 Unit positions AQVL 85 - 140 Al/Cu Version BLN/ELN/HT Ope- Ship- Weight distribution P1-P4 coordinates* CG coordinates rating ping AQVL weight weight Al/Cu 1058 1033...
  • Page 45 Technical data AQVL 85 - 140 Cu/Cu Version BLN/ELN/HT Ope- Ship- Weight distribution P1-P4 coordinates* CG coordinates AQVL rating ping weight weight Cu/Cu 1270 1231 1039 1382 1486 1285 1260 1039 1382 1489 1359 1332 1039 1382 1474 1427 1400 1039 1382 1462...
  • Page 46 AQVL 85 - 140 MCHX Ope- Ship- Weight distribution P1-P4 coordinates* CG coordinates rating ping AQVL weight weight MCHX 1039 1382 1593 1285 1260 1039 1382 1489 1039 1382 1596 1039 1382 1594 1039 1382 1595 1035 1004 1039 1982 1956 85 1P 1022...
  • Page 47 Technical data AQVH 85 - 140 Al/Cu Version BLN/ELN/HT Ope- Weight distribution P1-P4 coordinates* CG coordinates Shipping rating AQVH weight weight Al/Cu 1090 1065 1039 1382 1539 1105 1080 1039 1382 1542 1149 1122 1039 1382 1530 1180 1153 1039 1382 1523 1227...
  • Page 48 Technical data AQVH 85 - 140 Cu/Cu Version BLN/ELN/HT Ope- Ship- Weight distribution P1-P4 coordinates* CG coordinates rating ping AQVH weight weight Cu/Cu 1303 1278 1039 1382 1480 1317 1293 1039 1382 1483 1397 1370 1039 1382 1467 1463 1436 1039 1382 1455...
  • Page 49 Technical data AQVC 85 - 140 Al/Cu Version BLN/ELN/HT Ope- Ship- Weight distribution P1-P4 coordinates* CG coordinates AQVC rating ping weight weight Al/Cu 1039 1382 1584 1039 1382 1587 1013 1013 1039 1382 1578 1043 1043 1039 1382 1569 1066 1066 1039 1982...

  • Page 50: Dimensional Drawings

    Technical data Dimensional Drawings Units AQVL/AQVH 85-115 R410A BOTTOM VIEW 1382 FRONT VIEW SIDE VIEW 1041 1100 2555 1250 (Only for movimentation) TOP VIEW Notes: A B C D WATER CONNECTION 2 1/2” GAS M. ELECTRICAL AUXILIARY LINES ELECTRICAL POWER SUPPLY HIGH PRESSURE TAP LOW PRESSURE TAP GAUGE KIT (ACCESSORY)
  • Page 51 Technical data Units AQVL/AQVH 125-140 R410A BOTTOM VIEW 1982 FRONT VIEW SIDE VIEW 1625 1180 1250(Only for movimentation) 3155 TOP VIEW Notes: A B C D WATER CONNECTION 2 1/2” GAS M. ELECTRICAL AUXILIARY LINES ELECTRICAL POWER SUPPLY HIGH PRESSURE TAP LOW PRESSURE TAP GAUGE KIT (ACCESSORY) MAIN SWITCH...

  • Page 52: Service Spaces

    Technical data Service spaces AQVL/AQVC/AQVH/AQVR All models Installation of Single Units Installation of Several Units WALL A WALL D WALL B WALL A WALL B WALL D WALL C WALL C ARRANGEMENT 1 ARRANGEMENT 2 A and C GRILLE A and B FULL A and C FULL A and B GRILLE A and D GRILLE...

  • Page 53: Maintenance

    Maintenance MAINTENANCE Planned maintenance Carefully read the “Safety” section of this manual before carrying out any maintenance operations. Do not discharge the refrigerant into the at- mosphere while the refrigeration circuits are being drained. Use appropriate recov- Operations ery equipment. DANGER When the recovered refrigerant cannot be re-used, return it to the manufacturer.

  • Page 54: Refrigerant Charge

    Maintenance Refrigerant charge In a few cases, the polyester oil may be pre- sent also in R22 units (a refrigerant that can be used also in extra UE countries). Do not inject refrigerant liquid into the LP side of the circuit. Be very careful, and charge the circuit properly.

  • Page 55: Electronic Expansion Valve

    Maintenance ence of bubbles indicates that the dehydrating filter is To obtain an effective heat exchange, the difference between the temperature of the leaving water and the clogged or the charge insufficient. saturated evaporating temperature must be in the 2 A colour indicator is positioned inside the sight glass.

  • Page 56: Troubleshooting

    Troubleshooting 10 TROUBLESHOOTING The table below lists the anomalies of operation of the unit, the relevant causes and the corrective mea- contact one of authorised Service Centre for technical sures. For anomalies of any other type or not listed, assistance. Anomaly Cause Operation...
  • Page 57 Troubleshooting Anomaly Cause Operation Activation of the HP Failure of the pressure switch. Check the operation of the pressure switch, re- alarm, stop of the place it if defective. unit. The delivery valve is partially closed. Open the valve and replace it, if faulty. Substances with condensable gases Drain the circuit.

  • Page 58: Spare Parts

    Spare parts SPARE PARTS 11.1 Spare part list The table below shows the list of spare parts recom- mended during the first two years of operation. Component Number Differential water pressure switch High pressure transducer Low pressure transducer Electronic expansion valve Gas filter 4 way valve Electronic main board...

  • Page 59: Dismantling, Demolition And Scrapping

    Dismantling, Demolition and Scrapping 12 DISMANTLING, DEMOLITION AND SCRAPPING During the draining of the refrigeration cir- After draining operations, the piping of the hydraulic cuits, do not let the refrigerant overflow in networks can be disconnected and disassembled. the surrounding atmosphere. Once they have been disconnected as specified, the The circuit must be drained using suitable DANGER...
  • Page 60 Note Page 59...
  • Page 61 Note Page 60...
  • Page 62 Systemair srl Via XXV Aprile, 29 20825 Barlassina (MB) Italy Tel. +39 0362 680 1 Fax +39 0362 680 693 www.systemair.com As part of our ongoing product improvement programme, our products are subject to change without prior notice. Non contractual photos.

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