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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
English
Air Cooled Water Chillers and Heat Pump
173
Refrigerateurs à Eau et Pompes de Chaleur Refroidies à Air
300 kW
Luftgekühlte Wasserkühler und Wärmepumpen
Refrigeratori d'Acqua e Pompe di Calore Raffreddati ad Aria
200
Refrigeradores de Agua y Bombas de Calor Refrigerados por Aire
337 kW
Part number / Code / Code / Codice / Código: 342603/K
Supersedes / Annule et remplace / Annulliert und ersetzt / Annulla e sostituisce /
Anula y sustituye: 342603/J
Notified Body / Organisme Notifié / Benannte Zertifizierungsstelle / Organismo
Notificato / Organismo Notificado N°. 0425
VLH/VLC
Français
Deutsch
Italiano
Español
ISO 9001:2015 certified management system
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Table of Contents
Related Manuals for SystemAir VLH Series
Summary of Contents for SystemAir VLH 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 VLH/VLC English Français Deutsch Italiano Español Air Cooled Water Chillers and Heat Pump Refrigerateurs à Eau et Pompes de Chaleur Refroidies à Air 300 kW Luftgekühlte Wasserkühler und Wärmepumpen Refrigeratori d’Acqua e Pompe di Calore Raffreddati ad Aria...
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Page 2: Table Of Contents
Table of contents 1 FOREWORD 7 GENERAL DESCRIPTION Introduction Introduction Warranty General specifications Emergency stop/Normal stop Compressors An introduction to this manual Refrigeration circuits Water heat exchanger 2 SAFETY Air heat exchanger Foreword Fans Definitions Electric power supply and Access to the unit control system General precautions Accessories... -
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 The guards of the fans (only for units pro- SAFETY vided with air heat exchangers) must be al- ways mounted and must never be removed Foreword before de-energising the appliance. DANGER These units must be installed in conformity with the provisions of Machinery Directive 2006/42/EC, It is the User’s responsibility to ensure that Pressure Equipment Directive 2014/68/EU, Elec-... -
Page 5: Access To The Unit
Safety Precautions against residual risks ENGINEER: means a person authorised directly by manufacturer or, in all EC countries, excluding Italy, under his full responsibility, by the distributor of prod- Prevention of residual risks caused by the uct, to perform any routine and extraordinary mainte- control system nance operations, as well as any regulation, control, be sure to have perfectly understood the operating... -
Page 6: Precautions During Maintenance
Safety to the instructions provided in this manual and on the unit’s panelling The following precautions must be always adopted: if you have to disassemble a piece, make sure that it do not scatter the fluids of the refrigeration circuit in has been properly mounted again before restarting the surrounding environment the unit... -
Page 7: Safety Labels
(max) Kw POWER INPUT PRESS. MAX ESERCIZIO ACQUA MAX WATER OPERATING PRESSURE MASSA MASS ATTENZIONE ! ATTENTION ! SYSTEMAIR S.r.l. Via XXV Aprile 29 20825 BARLASSINA MB ITALIA MADE IN ITALY COD.NO: P35952 MODELLO: MODEL Prima di Enlever MATRICOLA: aprire togliere l’alimentation... - Page 8 Safety EIN - INLET ENTRÉE - ENTRATA AUS - OUTLET SORTIE - USCITA Fitting identification - Adjacent to fittings Grounding connection on the electrical Start-up warning - Outside the door board, adjacent to the connection of the electrical board Warning - safety valves’ vents Warning - high-temperature zones Adjacent to hot pipes or components ATTENTION! Don’t leave the unit with water inside hydraulic circuit during...
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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.
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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 For lifting operations, use only tools and ma- Storage terial fit for this purpose, in accordance with accident-prevention regulations. When the unit is to be stored before installation, adopt WARNING a few precautions to prevent any damage or risk of corrosion or wear: During the lifting and handling of the unit, be careful not to damage the finned pack of the... -
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 Hydraulic Circuit
Installation External hydraulic circuit The flow switch and the filter water, although not in- cluded in the supply, must always be fitted such as plant components. Their installation is mandatory for warranty. The external hydraulic circuit must ensure the water flow to the evaporator under any working or adjustment conditions. -
Page 16: Hydraulic Connection
Installation 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. Installation Flow Switch External Hydraulic Circuit Unit... -
Page 17: Power Supply
Installation Power supply Electrical connections Before carrying out any operations on the The unit must be installed on site according to the electrical system, make sure that the unit is Machinery Directive Machinery Directive 2006/42/ deenergised. EC, Electromagnetic Compatibility Directive 2014/30/EU and the usual procedures and stand- DANGER ards applicable in the place of installation. - Page 18 Installation VLH/VLC Version – Electrical Connections VLS/VLH/VLC Version – Electrical Connections Page 17...
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Page 19: Connecting Plate-Type Evaporator Temperature Sensors
Installation Connecting plate-type evaporator temperature sensors VLH units are provided with fittings for hydraulic con- nections between heat exchangers and plant. Each fit- tings is complete with sensor well to fasten 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 instruction below. -
Page 20: 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 21: Checking The Operation
Start-up Checking the operation Check the following: The temperature of the water entering the evapora- tor. The temperature of the water leaving the evapora- tor. The level of the water flow rate in the evaporator, if possible. The current absorption upon the start of the com- pressor and in case of stabilised operation. -
Page 22: Control
Control GENERAL INFORMATION The control system consists of: Introduction Keyboard & Display Terminal This document contains the information and the oper- ating instructions for 4 compressors & electronic General information control. This information is for the after-sales service and the The figure shows the terminal with the front door open. -
Page 23: 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 24 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 25 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...
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Page 26: Protection And Safety Equipment
Control Protection and Safety Compressor protection Equipment Compressors are equipped with a heating element to prevent oil dilution, which may result in remarkable Defrosting System risks of failure of compressors. (only for VLH models) The windings of the compressors’ motors are provided The VLH units are provided with an automatic defrost- with a thermal protection. -
Page 27: 6.5 Hpf Version Configuration
Control 6.5 HPF version configuration The table below shows the correspondance between Units equipped with High pressure fan (HPF) can be chiller model, fan RPM, high static pressure. set-up on the field to give the unit a specific static pres- sure. -
Page 28: General Description
General Description PRODUCT DESCRIPTION Introduction fluids (glycoled water), for air-conditioning applica- The VLH units are water chillers /air-water heat pumps tions in industrial processes. provided with hermetic scroll compressors with two These units can be installed outdoor on the roof of a refrigeration circuits. -
Page 29: Air Heat Exchanger
General Description Fans Control Air heat exchanger Fans are of directly coupling propeller type, provided Coils are made of copper pipes in staggered rows, with aluminium blade with wing profile. mechanically expanded inside an aluminium finned Each fan is provided with galvanised steel accident- pack. - Page 30 General Description VLC refrigeration diagram Components: Safety /control devices: 1) Compressor Tandem Scroll Type A - High Pressure switch (42 bar) 2) Air cooled condenser AT - High Pressure transducer 3) Globe valve BT - Low Pressure transducer D - Air temperature sensor G - PED pressure relief valve (46 bar) S - 5/16”...
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Page 31: Electric Power Supply And Control System
General Description Electric power supply and RS-485 serial card (for MODBUS or control system LONWORK or BACNET ) A communication interface makes it possible to control The control compartment contains and electronic card and manage the unit from a local station, with RS485 with keyboard and a display for working parameters, connection, up to a distance of 1,000m. -
Page 32: Technical Data
Technical data TECHNICAL DATA Pressure drops PRESSURE DROP IN THE EVAPORATOR VLH 704 VLH 804 VLH 904 VLH 1004 VLH 1104 VLH 1204 kPa/(l/s)^2 0,66 0,54 0,19 0,19 0,19 0,19 Minimum flow rate Nominal flow rate 10,9 13,4 14,7 Max. water flow rate 14,1 15,8 18,2... -
Page 33: Technical Data
Technical data Technical data VLH STD Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 20-50-70-100 25-50-75-100 28-50-78-100 Refrigerant Type / GWP R410A / 2.088 21,5/21,5 24,5/24,5 27/27 Charge 1/2 44,9/44,9 51,2/51,2 56,4/56,4 Compressor Type Scroll Number Start-up type... - Page 34 Technical data VLH STD 1004 1104 1204 Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 25-50-75-100 23-50-73-100 25-50-75-100 Refrigerant Type / GWP R410A / 2.088 30,5/30,5 34/34 37,5/37,5 Charge 1/2 63,7/63,7 71,0/71,0 78,3/78,3 Compressor Type Scroll Number...
- Page 35 Technical data VLH L Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 20-50-70-100 25-50-75-100 28-50-78-100 Refrigerant Type / GWP R410A / 2.088 21,5/21,5 24,5/24,5 27/27 Charge 1/2 44,9/44,9 51,2/51,2 56,4/56,4 Compressor Type Scroll Number Start-up type Direct N°of loading stages...
- Page 36 Technical data VLH L 1004 1104 1204 Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 25-50-75-100 23-50-73-100 25-50-75-100 Refrigerant Type / GWP R410A / 2.088 30,5/30,5 34/34 37,5/37,5 Charge 1/2 63,7/63,7 71,0/71,0 78,3/78,3 Compressor Type Scroll Number...
- Page 37 Technical data VLH S Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 20-50-70-100 25-50-75-100 28-50-78-100 Refrigerant Type / GWP R410A / 2.088 21,5/21,5 24,5/24,5 27/27 Charge 1/2 44,9/44,9 51,2/51,2 56,4/56,4 Compressor Type Scroll Number Start-up type Direct N°of loading stages...
- Page 38 Technical data VLH S 1004 1104 1204 Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 25-50-75-100 23-50-73-100 25-50-75-100 Refrigerant Type / GWP R410A / 2.088 30,5/30,5 34/34 37,5/37,5 Charge 1/2 63,7/63,7 71,0/71,0 78,3/78,3 Compressor Type Scroll Number...
- Page 39 Technical data VLH HT Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 20-50-70-100 25-50-75-100 28-50-78-100 Refrigerant Type / GWP R410A / 2.088 21,5/21,5 24,5/24,5 27/27 Charge 1/2 44,9/44,9 51,2/51,2 56,4/56,4 Compressor Type Scroll Number Start-up type Direct N°of loading stages...
- Page 40 Technical data VLH HT 1004 1104 1204 Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 25-50-75-100 23-50-73-100 25-50-75-100 Refrigerant Type / GWP R410A / 2.088 30,5/30,5 34/34 37,5/37,5 Charge 1/2 63,7/63,7 71,0/71,0 78,3/78,3 Compressor Type Scroll Number...
- Page 41 Technical data VLC STD Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 20-50-70-100 25-50-75-100 28-50-78-100 Refrigerant Type / GWP R410A / 2.088 21,5/21,5 24,5/24,5 27/27 Charge 1/2 44,9/44,9 51,2/51,2 56,4/56,4 Compressor Type Scroll Number Start-up type Direct N°of loading stages...
- Page 42 Technical data VLC STD 1004 1104 1204 Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 25-50-75-100 23-50-73-100 25-50-75-100 Refrigerant Type / GWP R410A / 2.088 30,5/30,5 34/34 37,5/37,5 Charge 1/2 63,7/63,7 71,0/71,0 78,3/78,3 Compressor Type Scroll Number...
- Page 43 Technical data VLC L Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 20-50-70-100 25-50-75-100 28-50-78-100 Refrigerant Type / GWP R410A / 2.088 21,5/21,5 24,5/24,5 27/27 Charge 1/2 44,9/44,9 51,2/51,2 56,4/56,4 Compressor Type Scroll Number Start-up type Direct N°of loading stages...
- Page 44 Technical data VLC L 1004 1104 1204 Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 25-50-75-100 23-50-73-100 25-50-75-100 Refrigerant Type / GWP R410A / 2.088 30,5/30,5 34/34 37,5/37,5 Charge 1/2 63,7/63,7 71,0/71,0 78,3/78,3 Compressor Type Scroll Number...
- Page 45 Technical data VLC S Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 20-50-70-100 25-50-75-100 28-50-78-100 Refrigerant Type / GWP R410A / 2.088 21,5/21,5 24,5/24,5 27/27 Charge 1/2 44,9/44,9 51,2/51,2 56,4/56,4 Compressor Type Scroll Number Start-up type Direct N°of loading stages...
- Page 46 Technical data VLC S 1004 1104 1204 Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 25-50-75-100 23-50-73-100 25-50-75-100 Refrigerant Type / GWP R410A / 2.088 30,5/30,5 34/34 37,5/37,5 Charge 1/2 63,7/63,7 71,0/71,0 78,3/78,3 Compressor Type Scroll Number...
- Page 47 Technical data VLC HT Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 20-50-70-100 25-50-75-100 28-50-78-100 Refrigerant Type / GWP R410A / 2.088 21,5/21,5 24,5/24,5 27/27 Charge 1/2 44,9/44,9 51,2/51,2 56,4/56,4 Compressor Type Scroll Number Start-up type Direct N°of loading stages...
- Page 48 Technical data VLC HT 1004 1104 1204 Power supply V/ph/Hz 400 (±10%) / 3 / 50 Number of circuits Capacity steps 25-50-75-100 23-50-73-100 25-50-75-100 Refrigerant Type / GWP R410A / 2.088 30,5/30,5 34/34 37,5/37,5 Charge 1/2 63,7/63,7 71,0/71,0 78,3/78,3 Compressor Type Scroll Number...
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Page 49: Unit Electrical Data
Technical data Unit electrical data VLH/VLC STD 1004 1104 1204 Rated voltage V/ph/Hz 400 (±10%) /3/50 Max. absorbed power 80,8 96,4 105,2 112,0 130,0 148,0 Rated current 112,0 120,0 142,0 160,0 172,0 184,0 Max. current FLA 186,0 172,0 193,0 210,0 239,0 268,0 Max. - Page 50 Technical data VLH/VLC HSE STD 1004 1104 1204 Rated voltage V/ph/Hz 400 (±10%) /3/50 Max. absorbed power 82,6 98,2 107,6 114,4 132,4 150,4 Rated current 112,3 120,3 142,4 160,4 172,4 184,4 Max. current FLA 186,3 172,3 193,4 210,4 239,4 268,4 Max.
- Page 51 Technical data VLH/VLC HPF 1004 1104 1204 Rated voltage V/ph/Hz 400 (±10%) /3/50 Max. absorbed power 81,4 112,8 130,8 148,8 Rated current 111,1 119,1 140,8 158,8 170,8 182,8 Max. current FLA 185,1 171,1 191,8 208,8 237,8 266,8 Max. start-up current LRA 349,1 356,1 376,8...
- Page 52 Technical data Fans electrical data VLH/VLC STD 1004 1104 1204 Rated voltage V/ph/Hz 400 (±10%) /3/50 Number Rated power Absorbed rated current FLA VLH/VLC L/S 1004 1104 1204 Rated voltage V/ph/Hz 400 (±10%) /3/50 Number Rated power 1,25 1,25 1,25 1,25 1,25 1,25...
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Page 53: Position Of Shock Adsorbers And Weight Distribution On Supports
Technical data Position of shock absorbers and weight distribution on supports VLH/VLC 704-1204 STD/L/S/HT Version Electrical board Compressor Side P1 - P6 Unit positions VLH 704 - 1204 Al/Cu STD/L/S/HT Version Ope- Ship- Weight distribution P1-P6 coordinates* CG coordinates rating ping Al/Cu weight... - Page 54 Technical data VLH 704 - 1204 Cu/Cu STD/L/S/HT Version Ope- Ship- Weight distribution P1-P6 coordinates* CG coordinates rating ping weight weight Cu/Cu 2195 2183 1044 1985 1629 2150 2340 2326 1044 1985 1629 2150 2500 2475 1044 1985 1629 2150 1004 2825 2800...
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Page 55: Overall Dimensions
Technical data Overall dimensions VLH 704-1204 STD/L/S/HT 704-804 904-1204 (*) only with 2 pumps (**) Max with desuperheater WATER CONNECTIONS 704-804 904-1204 WATER OUTLET “A” 2” 1/2 M 3” M WATER INLET (with pump) “B” 2” 1/2 M 3” M WATER INLET (without pump) “C”... - Page 56 Technical data VLC 704-1204 STD/L/S/HT 704-804 904-1204 1” 5/8 2” 1/8 7/8” 1” 1/8 Page 55...
- Page 57 Technical data VLH 704-1204 with hidrokit 704-804 904-1204 1186 1208 (**) Max with desuperheater WATER CONNECTIONS 704-804 904-1204 WATER OUTLET “A” 2” 1/2 M 3” M WATER INLET (with pump) “B” 2” 1/2 M 3” M DESUPERHEATER IN/OUT “D” 4x 1” M Page 56...
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Page 58: Service Spaces
Technical data Service spaces VLC/VLH ALL MODELS Installation of Single Units Installation of Several Units ARRANGEMENT 1 ARRANGEMENT 2 A and C GRILLE A and B FULL A and C FULL A and B GRILLE A and D GRILLE B and D FULL C and D FULL B and D GRILLE C and D FULL... -
Page 59: 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 60: Refrigerant Charge
Maintenance Refrigerant charge Compressors use polyester oil. During main- tenance 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 61: Dehydrating Filter
Maintenance Dehydrating filter If the expansion valve cannot be regulated, it is prob- ably broken, and shall be replaced. The replacement must be carried out by a Service Centre. The refrigeration circuits are provided with dehydrat- ing filters. The filter clogging is marked by the presence of air 9.10 Evaporator bubbles in the sight glass, or by the difference be- tween the temperatures measured downstream from... -
Page 62: Troubleshooting
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 63 Troubleshooting Anomaly Cause Operation One or both com- Breaking of the electric circuit. Check the electric circuit and detect any p r e s s o r s a r e n o t ground dispersions and short circuits. Check working.
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Page 64: 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 HP pressure switch LP pressure switch Gas filter Electronic expansion valve Auxiliary relays Fan’s fuses Compressor’s fuses Auxiliary fuses... -
Page 65: 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 66 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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