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RWH-PWH Ka
WATER COOLED CHILLERS AND HEAT PUMPS WATER CONDENSED EQUIPPED
WITH SCREW COMPRESSORS AND SHELL AND TUBE EXCHANGER
►
Chillers and heat pumps.
►
Screw compressors.
►
Shell and tube exchanger.
►
Electronic expansion valve.
►
High efficency at partial loads.
►
Compact dimensions.
►
Wide range of options.
►
Special execution.
Use and mantainance Book
Rev. 2.0 09/21
Range 300-1372 kW
1
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Summary of Contents for Emicon RWH 281 Ka
- Page 1 RWH-PWH Ka WATER COOLED CHILLERS AND HEAT PUMPS WATER CONDENSED EQUIPPED WITH SCREW COMPRESSORS AND SHELL AND TUBE EXCHANGER Range 300-1372 kW ► Chillers and heat pumps. ► Screw compressors. ► Shell and tube exchanger. ► Electronic expansion valve. ► High efficency at partial loads.
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Page 2: Table Of Contents
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ SUMMARY INTRODUCTION Foreword Simbols Reference laws and norms Identification Tag Warranty Manual readership Personnel requirement Dangerous areas Tests DESCRIPTION Nomenclature RWH – PWH Ka Series Version Models with partial and total heat recovery (RP / RT option) Main components 8-10 Options... - Page 3 ___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ 5.1.3 Safety valves check 5.1.4 Fluid to be cooled check 5.1.5 Sound and vibration check 5.1.6 Check and calibration of the refrigerant leak detector Ordinary Maintainance 5.2.1 Overcurrent protection devices check 5.2.2 Contactors check Troubleshooting Extraordinary Maintainance DEMOLITION AND DISPOSAL...
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Page 4: Introduction
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ INTRODUCTION The RWH/PWH Ka Series units, operaing with R134a refrigerant, are water chillers and heat pumps water condensed, equipped with screw compressors and shell and tube exchangers. Depending to the cooling capacity required, are available in single or multi compressor, single or double cooling indipendents circuit and single or double hydraulic circuit Those unit are suitable for indoor installations and particularly indicated for industrial and comfort applications, where is necessary to have a certain level of thermo-cooling power and guarantee excellent seasonal performance and low environment impact. -
Page 5: Identification Tag
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Identification Tag The unit is identified by an indelible label on the external panel of the electrical cabinet (Ideification Tag). Here below an example of the Identification Tag, showing ans describing all the stated information, in compliance with the applicable European directives. Manufacturer’s name and address CE mark and the Notified Organization identification number which released the PED... -
Page 6: Manual Readership
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Manual readership This manual and all its attachments are supplieed with the described unit. The manual musk be kept by the machine’s Owner or by the person in charge to care for the machine, in a proper place. To this end, a plastic bag where to store the manual has been placed inside of the electric panel board of the machine, so that it can be always easily accessible for consultation and at the same time, it can be preserved in a good state. -
Page 7: Description
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ DESCRIPTION Nomenclature /P W In the following scheme, it is explained the meaning of the device name acronym. 73-RNOMINALE x 10 (kW) 2-NUMERO CIRCUIT The nominal cooling capacity is calculated with IN/OUT evaporator water 12/7°C, and IN/OUT condenser water .30/35°C. RWH - PWK Ka –... -
Page 8: Main Components
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Main components FRAME Robuist and compact supporting structure, built with folded and painted steel profiles (RAL 9004 color –black-) that integrates the exchangers of the evaporator and tube bundle condenser unit and on which all components are mounted. On demand, the compressors can be acoustically insulated with a cabinet covered with a standard sound-proofed material (CF option) or with a double thickness sound-proofing material (CFU option) to further reduce the unit sound level. - Page 9 ___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ The unit management is realized by the management program uploaded in the electronic microprocessor. The microprocessori s made up of: • An electronic control board with terminal blocks for transmitting the functional paramenters and operating the control devices;; •...
- Page 10 ___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ SOUND ABSORBING COVER (CF/CFU OPTIONAL) SHELL AND TUBE EVAPORATOR ELECTRICAL BOARD ELECTRONIC THERMOSTATIC VALVE SCREWI COMPRESSOR DRYER FILTER RETAIN VALVE TUBE BUNDLE CONDENSERS...
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Page 11: Options
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Options Here below the main options which could be installed in RWH – PWH Ka Series: Amperometer: Electrical device to measure the absorbed electrical current intensity; Electrical power different than standard: Especially 230V three phase, 460V three phase, frequencies 50/60Hz; Condenser suitable for sea water: made of cupro.nichel or titanium, to be selected on request, suitable for working with seawater: Coibented condenser: Condensers isolated with a 10mm thickness coibented material (only for PWH Series) Soundproofed compressors cabinet with standard material: Insulation of compressors by a cabinet made of extruded anodized aluminium profiles, with panels... - Page 12 ___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Pressostatic valve: It is placed on condenser water side and controls the water flow rate according to the unit condensing pressure, (supplied loose – alternative to VCP); Solenoid valve: Electromagnetic solenoid valve on each cooling circuit to prevent refrigerant migratios and consequest flooding of compressors.
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Page 13: Functional Diagram
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Functional diagram RWH Ka COOLING CIRCUIT DIAGRAM (with some available options) PWH Ka COOLING CIRCUIT DIAGRAM (with some available options) LEGEND See water condenser High pressure gauge Screw compressor Low pressure gauge Tube bundle condenser Freon safety switch Anti-freezeelectronic heater High pressure switch... -
Page 14: Wiring Diagram
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Wiring diagram The wiring diagram of control unit and power, terminals and the resume tab of components, is attached to the Manual. Sound emission The unit doesn’t required operators presence cause is able to operate in total autonomy. Is not necessary provide sound emission data;... - Page 15 ___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ BASES UNIT WEIGHT MODEL PWH 281 Ka 321 Ka 361 Ka 421 Ka 452 Ka 491 Ka 562 Ka 551 Ka TRANSPORT 1990 2062 2099 2750 2604 2995 3401 3063 OPERATING 2157 2234 2272 2920 2843...
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Page 16: Installation
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ INSTALLATION The unit installation must comply with local existing Laws and Regulations. Identification The uniti s identified by the Identification Tag, described above, attached inside of the electric cabinet. The correct unit identification by means of the serial number is essential for the execution of any operation to carry out on the unit. The serial number must be always advised whenever submitting a request of Manufacturer technical service support. -
Page 17: Positioning
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Positioning The unit’s Owner is responsible for expenses of installation and he must supervise the execution operation. The execution of a correct installation presupposes than a plan has been drawn up by an expert and that is carried out by skilled trained technicians. The area used to install the unit, there must be no aggressive substance or not compatible with copper, aluminium and other materials which are used in its constuction. -
Page 18: Hydraulic Circuit
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Hydraulic circuit The uniti s designed to be connected to a refrigerant and / or heated water distribution network, depending on whether they are chiller or heat pump. The pipes must be laid by an expert installer. -
Page 19: 3.5.2 Hydraulic Connections - Evaporator
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ The unit must be connected to the hydraulic cirtuit by an expert and qualified technician, in compliance with the local Regulations in force. It is important the chilled liquid flows in the correct direction into the evaporator. So the pipes must be joined following the indication given on the connections point of the unit 3.5.2 HYDRAULIC CONNECTIONS - EVAPORATOR To connect the pipes to the evaporator it is advisable to follow the following indications:... -
Page 20: Heat Pumps Hydraulic Connections - Pwh Ka Series Version
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ 3.5.4 HEAT PUMP HYDRAULI CONNECTIONS - PWH Ka SERIES In case of heat pums (PWH Ka Series) with hydraulic cycle inversion, , the following situation occurs: • Summer operation: the chilled water produced in the evaporator is sent for use, while the hot water produced in the condenser is sent to the exchanger in which it can dissipate the accumulated heat. -
Page 21: Chemical-Physical Properties Of Water
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ 3.5.5 CHEMICAL-PHYSICAL PROPERTIES OF WATER In the following table there are, just as indication, the main values of chemical and physical properties of the water to be respected to avoid corrosion or any sediment. To this purpose it is advisable a early check of the Ph stability. -
Page 22: Hydraulic Circuit Filling
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ 3.5.6 HYDRAULIC CIRCUIT FILLING Once the hydraulic circuit is done, the unit connected and the system seal test performed, fill the circuit, following the here below described steps: Open all the vent valves on the circuit; Connect the circuit, if possible permanently, to the water supply system, using an automatic filling group provided with a manometer and a cjheck valve;... -
Page 23: Electric Connections
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Electronic connections The electrical power supply must be sized by a qualified designer and realized by qualified technicians, on behalf of the Owner, in compliance with current local Regulationa. The suplly cable upstream the unit must be protected by an automatic switch with suitable size and features and in compliance with current local dispositions. The system must be realized in order to permitt the unit power cutting, without stopping other services like lightening, ventilation, alarm and safety system. -
Page 24: Freon Safety Valves
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Inside the alectrical cabinet there is a terminal box with digital and analogue signal for the unit operations. Since the terminal configuration can be different in each single unit, refer to the one shown in the wiring diagram enclosed in the Handbook As an example, here below the pre-arranged terminals for free contacts described in the table are represented Remote ON/OFF: Digital input... -
Page 25: Rwh/Pwh Ka Application Range
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ RWH/PWH Ka application range The nominal water flow of the standard units is referred to a Delta T 5K between inlet and outlet in connection to the supplied cooling capacity. RWH / PWH Ka UNITS MODEL 281 Ka 321 Ka... -
Page 26: Operation
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ OPERATION Before its commissioning, the operational staff must be instructed, also by means of this Handbook, on the unit manufacture, management, operation and maintainance, on safety measures and regulations to respect, as well as on any personal protective equipment to arrnage, properties and indications to handle the used refrigerant. -
Page 27: First Start-Up
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Periodically verify that the mechanical filter is clean, to prevent a decrease of the fluid to be cooled flow rate due to excessive pressure drops. During the operation, the hydraulic system pressure must be always be between 1,5 and 3,5 bar. •... -
Page 28: Switching Off
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ 4.3.2 Switching off To stop the unit, press the ON/OFF button on the microprocessor keyboard, and switch it to OFF; If the machine is expected to stay in this conditions for more than 24hours, turn the main switch in OFF position in order to cut the power supply. Any anomalies detected during unit operation must be solved as soons as possible, in order to avoid them to be present once more, when the unit will be again switched on. -
Page 29: Maintainance
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ MAINTAINANCE The Owner must take care that a suitable maintainance is carried out on the unit as indicated in the Handbook and as required by current local Laws and Regulations. The unit maintainance must be carried out by qualified and trained personnel, equipped with personal protective devices, as required by current local Laws and Regulations in force. -
Page 30: Leak Detection
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Sight inspection CASE Pressure test Leak detection (par. 4.2, p.ti a - l) Inspection, after an intervention, with possible effects on the mechanical resistance or after a change purpose or after a stop longer than 2 years; all unfit components must be replaced. -
Page 31: 5.1.6 Check And Calibration Of The Refrigerant Leak Detector
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ 5.1.6 Check and calibration of the refrigerant leak detector The maintenance (sight, operational and system one) of the detector must be done once a year to keep unchanged its safety and measurement performance and to grant the refrigerant detection alarm. -
Page 32: Ordinary Maintainance
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Ordinary maintainance 5.2.1 Overcurrent protection devices check The overcurrent protection devices must be inspected to check their integrity and functionality. Replace fuses only after the unit is disconnected from the power supply, turning the main switch to OFF position. It is forbidden by-passing the fuses used in the unit, or replacing them with bigger ones. - Page 33 ___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ FREQUENCY ACTIONS Daily Monthly Every 2 months Every 6 months Once a year Every 5 years If required COMPRESSORS Compressors visually inspect Check compressors noise and vibrations Check compressors supply voltage Check the compressors electrical connec- tions Check the conditions of the compressors electrical cables and their connections...
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Page 34: Troubleshooting
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Trouble shooting The detection of the failure occurring during the operation is made by the microprocessor, which besides signaling alarms, also shows the active failure kind. The hereafter table reports the most common miss-functioning, and for each one of the most common causes and possible solutions. In case of alarm, before any intervention, verify that: •... - Page 35 ___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Discharge pressure too high See point 7 9. High compressor suction pressure Liquid refrigerant return to the compressor suction Make sure the thermostati cavlve overheating is correct side Check the valve bulb is properly placed, fixed and insulated FAILURE PROBABLE CAUSE SUGGESTED ACTIONS...
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Page 36: Extraordinary Maintainance
___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Extraordinary maintainance The unit must be repaired by qualified and trained peronnel, equipped with individual protection devices in compliance with current local Laws and Regulations. No modification must be carried out on the unit or any components replaced, without Manufacturer’s explicit authorization. Any intervention made by technicians with specific skills (welders, electricians, programmers, etc) must be carried out under the supervision of personnel expert in refrigeration field. - Page 37 ___________________________________ RWH/PWH Ka - Kh - Ke_________________________________ Rev 2.0 09/21...
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