Related Manuals for Ingersoll-Rand Thermocold AWA HP XEA
Summary of Contents for Ingersoll-Rand Thermocold AWA HP XEA
- Page 1 AWA HP XEA Air-water heat pumps with scroll compressors Cooling capacity 125 - 620 kW AWA HP XEA Heating capacity 133 - 652 kW Installation and Maintenance Manual Cod. MUM-AWAHPXEA-E-SAT-REV01-1019-UK...
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Page 2: Table Of Contents
INDEX 1 OVERVIEW ....................3 2 SAFETY REGULATIONS ..................3 3 OPERATING LIMITS ................... 7 4 INSTALLATION ....................10 5 ACOUSTIC PROTECTION ..................12 6 ELECTRICAL POWER SUPPLY ................12 7 WATER CONNECTIONS ..................13 8 STANDARD REFRIGERANT SCHEME ................ 31 9 ELECTRICAL PANEL .................. -
Page 3: Overview
OVERVIEW 1.1 FOREWORD These instructions are given as a guide to good practice in the installation, start-up, operation, and maintenance by the user of AWA HP XEA units. They do not contain full service procedures necessary for the continued successful operation of this equipment. The services of a qualified technician should be employed through the medium of a maintenance contract with a reputable service company. -
Page 4: General Precautions
Installer: The legal representative of the company appointed by the owner to position and hydraulically, electrically etc. connect the Thermocold unit to the plant: he or she is responsible for moving and the correct installation of the unit in accordance with the indications in this manual and with the national regulations in force. Operator: A person authorized by the owner to carry out all the operations of regulation and control on the Thermocold unit which are specifically mentioned in this manual. -
Page 5: Precautions Against Residual Risks
Administer oxygen if needed. In case the breathing has interrupted or become irregular, it is necessary to apply the artificial breathing. In case of cardiac arrest a heart massage must be applied. Contact a doctor immediately. Conditions to avoid Use in presence of exposed flames, and of high levels of humidity. Possibility of violent reactions with the sodium, the potassium, the barium and with other alkaline Dangerous reactions substances, incompatible materials and all the alloys containing more than 2% of magnesium. -
Page 6: Very Important
2.9 PRECAUTIONS TO BE OBSERVED DURING MAINTENANCE OPERATIONS Only authorised technicians may carry out maintenance operations. Before carrying out any maintenance the following must be performed: • isolate the unit from the mains electricity by using the external knife switch. •... -
Page 7: Operating Limits
OPERATING LIMITS 3.1 STORAGE The units can be stored within the following environmental conditions: Min ambient temperature -10°C Max ambient temperature 53°C Max relative humidity 95% not condensable CAUTION: The storage in a very high humidity space (condensation) can damage electronic components. 3.2 OPERATING LIMITS AWA HP XEA unit operation is permitted within the limits indicated in the diagram provided in 3.3. -
Page 8: Heat Pump Mode
HEAT PUMP MODE OAT = Outdoor Air Temperature [°C] LWT = Leaving Water Temperature [°C] Low ambient kit down to -15°C: Heater in control box • Page 8... - Page 9 ETHYLENE GLYCOL CORRECTION TABLE % Ethylene glycol weight Lowest outlet water temperature °C -2,8 °C Suggested security limit Cooling 0,99 0,985 0,981 0,977 0,974 0,971 capacity coefficient 0,993 0,99 0,988 0,986 0,984 0,982 Power input coefficient 1,04 1,05 1,07 1,08 1,09 1,11 Flow rate coefficient...
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Page 10: Installation
INSTALLATION 4.1 MOVING AND POSITIONING THE UNIT The units have been designed to be lifted from above by means of eyebolts and holes in the base members. Use retractor bars to keep the lifting wires or chains away from the unit. Figure 1 Correct lifting procedure Lifting procedures provided with the unit have to be respected. -
Page 11: Minimum Space Requirements
4.2 MINIMUM SPACE REQUIREMENTS Dimensional drawing shall be respected to avoid: • Noise • Incorrect heat exchange and ventilation • Difficult maintenance or inaccessibility to components It is fundamental to respect minimum distances on all AWA HP XEA units, in order to ensure optimum ventilation for the condenser coils. -
Page 12: Acoustic Protection
4.6 PRECAUTIONS AGAINST THE PRESENCE OF FOLIAGE AND FOREIGN BODIES Avoid installing the unit in the immediate vicinity of plants that can prevent proper intake and discharge air. 4.7 CONTROL OF COMPRESSOR FASTENING The compressors are fitted on shock absorbers. For fixing through spring anti-vibration mounts, it is necessary to remove blockages put to fasten the compressors, as indicated on the label on compressors body. -
Page 13: Water Connections
WATER CONNECTIONS 7.1 EVAPORATOR The connections schemes relating to evaporator are featured in the paragraph 7.5 HYDRAULIC VERSIONS. The connection tubes have to be supported adequately in order that their weight does not damage the plant. It is necessary that the water flow rate to the unit is compatible with the evaporator one. It is also necessary that the water flow rate is kept uniform while the unit is running: it is suggested to use always a pump system dedicated to the unit and independent from the remaining part of the plant. - Page 14 7.1.1 Calculation of total minimum water content and flow rates The machine needs a minimum water content according to the following values: cold water heat production hot water heat production AWA HP XEA Vmin Q min Q max Vmin Q min Q max [m3] [m3/h]...
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Page 15: Water Treatment
7.2 WATER TREATMENT Before putting the unit into operation, clean the hydraulic circuit. Dirt, scales, corrosion residue and other extraneous material can accumulate inside the heat exchanger and reduce its heat exchanging capacity. Pressure drops can increase, as well, thus reducing water flow. Proper water treatment therefore reduces the risk of corrosion, erosion, scaling, etc. - Page 16 7.3.1 Precaution for very low outdoor temperatures In case of installation conditions with a very low temperature: If there is a storage on board the unit, insert electric resistances to be calculated by: PrWatt = V x (10 – tmin) / 860 where: PrWatt is the resistance power (Watt) and tmin is the lower temperature (°C) If there is no storage, maintain the water temperature higher than 10°C by inserting thermostatic resistance with power calculated as in case 1.
- Page 17 HYDRAULIC VERSIONS AWA HP XEA units are available in six hydraulic versions characterized by complete kits of all major hydraulic components for an easier installation, with reduced time, cost and space. − single pump − single pump and tank − double pump −...
- Page 18 7.5.1 Water antifreeze protection kits These kits, aimed at avoiding the freezing of all the components of the hydraulic circuit inside the unit (pumps, pipes and tank) are optional and are coupled to the unit hydraulic versions. The following types of water antifreeze protection kit are available: Number of heating cables AWA HP XEA Single pump...
- Page 19 7.5.2 Hydraulic diagram for AWA HP XEA units with single pump Temperature Probe Relief Valve Supply limit Remote Connections Gauges by the Installer Safety Valve (6 bar) Shut Off Valve Pump Water Discharge Water Tank Antivibration System Flow Switch FIlter Heat Exchanger Figure 3 7.5.3 Hydraulic diagram for AWA HP XEA units with single pump and tank...
- Page 20 7.5.4 Hydraulic diagram for AWA HP XEA units with single pump + stand-by pump Temperature Probe Relief Valve Gauges Remote connections by Supply limit the installer Safety Valve (6 bar) Shut Off Valve Pump Water Discharge Check Valve Water Tank Antivibration System Flow Switch...
- Page 21 CUSTOMER PLANT SKETCHES 7.6.1 Customer plant sketch with primary pump on evaporator side for unit with no on board pump IMPORTANT: the flow switch CUSTOMER PLANT and the water strainer in the customer plant are obligatory in order to keep the warranty AIR CONDITIONING WATER PUMP Primary Pump...
- Page 22 7.6.2 Customer plant sketch without primary pump on evaporator side for a unit with on board single pump or single pump+ stand-by pump IMPORTANT: the flow switch CUSTOMER PLANT and the water strainer in the customer plant are obligatory in order to keep the warranty AIR CONDITIONING WATER PUMP Primary Pump...
- Page 23 7.6.3 Customer plant sketch on partial recovery exchanger (desuperheater) side CUSTOMER PLANT AIR CONDITIONING WATER PUMP Primary Pump Secondary Pump Temperature Probe Flow Switch WATER TANK FANCOIL Drainage Vent Valve Expansion Vessel Filling Group Steel Mesh Strainer Check Valve Safety Valve Interception Valve Figure 9 IMPORTANT: the flow switch and the water strainer in the customer plant are obligatory in order to keep the...
- Page 24 7.6.4 Flow switch installation To ensure adequate water flow through the evaporator, it is essential to install a flow switch on the water circuit. The flow switch must be be installed according to the relevant hydraulic diagram among those reported in the par 7.5 HYDRAULIC VERSIONS.
- Page 25 PUMPS CHARACTERISTICS 7.7.1 Low head pressure pump charcteristics for sizes 2120 – 2130 – 2140 – 2145 – 2170 – 2180 - 2195 – 2200 – 2215 – 2220 – 2230 - 2240 Ref. Expansion F.L.I. F.L.A. Curve vessel Mod. [kW] [kPa] [kW]...
- Page 26 7.7.2 Medium head pressure pump charcteristics for sizes 2120 – 2130 – 2140 – 2145 – 2170 – 2180 - 2195 – 2200 – 2215 – 2220 – 2230 – 2240 Ref. Expansion F.L.I. F.L.A. Curve vessel Mod. [kW] [kPa] [kW] [kPa] [kPa]...
- Page 27 7.7.3 High head pressure pump charcteristics for sizes 2120 – 2130 – 2140 – 2145 – 2170 – 2180 - 2195 – 2200 – 2215 – 2220 – 2230 – 2240 Ref. Expansion F.L.I. F.L.A. Curve vessel Mod. [kW] [kPa] [kW] [kPa] [kPa]...
- Page 28 7.7.4 Low head pressure pump charcteristics for sizes 2245 – 2265 – 2295 – 2340 – 2375 – 2420 - 2465 – 2495 – 2545 – 2585 – 2620 Ref. Expansion F.L.I. F.L.A. Curve vessel Mod. [kW] [kPa] [kW] [kPa] [kPa] 2245 3,44...
- Page 29 7.7.5 Medium head pressure pump charcteristics for sizes 2245 – 2265 – 2295 – 2340 – 2375 – 2420 - 2465 – 2495 – 2545 – 2585 – 2620 Ref. Expansion F.L.I. F.L.A. Curve vessel Mod. [kW] [kPa] [kW] [kPa] [kPa] 2245 4,52...
- Page 30 7.7.6 High head pressure pump charcteristics for sizes 2245 – 2265 – 2295 – 2340 – 2375 – 2420 - 2465 – 2495 – 2545 – 2585 – 2620 Ref. Expansion F.L.I. F.L.A. Curve vessel Mod. [kW] [kPa] [kW] [kPa] [kPa] 2245 6,09 10,6...
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Page 31: Standard Refrigerant Scheme
STANDARD REFRIGERANT SCHEME 8.1 STANDARD REFRIGERANT SCHEME FOR SIZES 2120 – 2130 – 2140 – 2145 – 2170 – 2180 - 2195 – 2200 – 2215 – 2220 – 2230 - 2240 REFRIGERANT = R410a INDEX INDEX COMPRESSOR ELECTRONIC EXPANSION VALVE CONDENSER COIL EVAPORATOR/CONDENSER HP PRESSURE SWITCH... - Page 32 8.2 STANDARD REFRIGERANT SCHEME FOR SIZES 2245 – 2265 – 2295 – 2340 – 2375 – 2420 - - 2465 – 2495 – 2545 – 2585 - 2620 REFRIGERANT = R410a INDEX INDEX COMPRESSOR ELECTRONIC EXPANSION VALVE CONDENSER COIL EVAPORATOR/CONDENSER HP PRESSURE SWITCH RLiq LIQUID RECEIVER...
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Page 33: Electrical Panel
9 ELECTRICAL PANEL When reviewing this manual keep in mind. • All field-installed wiring must be in accordance with local regulations, CE directives and guidelines. Be sure to satisfy proper equipment grounding requirements according CE • The standardized values - Maximum Amps –Maximum kWatts are displayed on unit nameplate. •... -
Page 34: Operator Responsabilities
10 OPERATOR RESPONSABILITIES It is important that the operator is properly trained and familiar with the equipment before working on the unit. In addition to reading this manual, the operator must study the manual operation of the microprocessor and the wiring diagram to understand the sequence of start- up, operation, shutdown sequences, and the criterion of operation of all safety devices. -
Page 35: Check List - Mandatory Operation Control Before Start-Up
12 CHECK LIST – MANDATORY OPERATION CONTROL BEFORE START-UP DATE UNIT SITE: CUSTOMER: ADDRESS: POSTCODE: COUNTRY: THE INTENDED PURPOSE OF AWA HP XEA UNITS IS NOT FOR INDUSTRIAL PROCESS APPLICATION. PLEASE CONTACT THERMOCOLD TECHNICAL DEPARTMENT IN CASE OF INDUSTRIAL PROCESS APPLICATION. GENERAL COMPLIANCE THE HYDRAULIC CIRCUIT IS COMPLETE AND READY TO BE USED AND THE THERMAL LOAD IS AVAILABLE. -
Page 36: Refrigerant Circuit
ELECTRIC AND ELECTRONIC COMPLIANCE THE UNIT IS ELECTRICALLY POWERED AND ALL THE RELEVANT ELECTRICAL WIRES ARE PROPERLY CONNECTED. ELECTRICAL SUPPLY HAS BEEN INSTALLED IN ACCORDANCE WITH THE INSTRUCTIONS PROVIDED IN THE NAME PLATE AND IN THE TECHNICAL DOCUMENTATION. (ELECTRICAL POWER SUPPLY: 230V/400V +/- 10% - MAXIMUM “%”... -
Page 37: Water Circuit
WATER CIRCUIT COMPLIANCE THE FILTER IS INSTALLED ON THE HEAT EXCHANGER INLET PIPES,AT A MAXIMUM DISTANCE OF 2 METERS FROM THE UNIT. PLEASE NOTE THAT THE FILTER INSTALLATION IS MANDATORY. FOR FURTHER TECHNICAL INFORMATION RELATING THE FILTER PLEASE REFER TO THE TECHNICAL DOCUMENTATIONS. THE FLOW SWITCH HAS BEEN INSTALLED AND ELECTRICALLY CONNECTED. -
Page 38: Authorized Service
FOR FURTHER TECHNICAL INFORMATION PLEASE REFER TO TECHNICAL DOCUMENTATION PROVIDED. PLEASE NOTE THAT ANTIFREEZE PROTECTIONS ARE MANDATORY FOR OUTDOOR AIR TEMPERATURE LOWER THAN 3°C. THE WATER CIRCUIT IS FILLED WITH ETHYLENE GLYCOL. ETHYLENE GLYCOL “%” SHALL CONFORM WITH THE DATA PROVIDED IN THE TECHNICAL DOCUMENTATION. ALL WATER PIPES ARE GROUND CONNECTED (IN ORDER TO AVOID ABNORMAL VOLTAGES THAT CAN CAUSE DANGEROUS CORROSIONS). -
Page 39: Refrigerant Charge
12.1 REFRIGERANT CHARGE 12.1.1 Refrigerant replacement procedure with unit stopped and in vacuum (refrigerant charge in the liquid phase) Open the shut off valve as far as possible so that it closes the service coupling. Connect the refrigerant cylinder to the service coupling without tightening the coupling. -
Page 40: Start-Up
12.1.2 Refrigerant replacement procedure with unit running (refrigerant charge in the vapour phase) Caution: charge vapour only. Do not charge liquid because it may damage the compressor. Connect the refrigerant cylinder to the service valve without tightening the coupling. Drain the connection piping and tighten the coupling. - Page 41 Danger The chilled water circuit may be under pressure. Bring down this pressure before opening up the system to rinse out or fill up the water circuit. Failure to comply with this instruction may cause accidental injury to maintenance personnel. If a cleaning solution is used in the chilled water circuit, the chiller must be isolated from the water circuit to avoid all the damage risks of the chiller and evaporator water pipes.
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Page 42: Start-Up Procedure
13.4 START UP PROCEDURE 1) With the switch closed, open the electrical panel and exclude compressor (refer to the wiring diagram on the unit). Close the panel, set switch to “ON” (to give power to the unit). 2) Wait for the start of the microprocessor and control. Make sure that the temperature of the oil is hot enough. The oil temperature must be at least 5°C higher than the saturation temperature of the refrigerant inside the compressor. - Page 43 1 annual visit for units with seasonal operation of about 90 days / year (at the start of the season) It’s important that during the initial start-up and periodically during operation routine checks are carried out. Among them we must also check the suction and condensation as well as the sight glass located on the liquid line. Check through the microprocessor installed on the unit if the unit is working within normal parameters of superheating and sub cooling.
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Page 44: Standard Controls
14.3 STANDARD CONTROLS It is mandatory to clean regularly the coils for a proper unit operation. Pollution and other residual material clearing helps extend the life of the coils and the whole unit Recommended Operations description basis Compressors oil level check monthly Inlet temperature check (overheating) monthly... - Page 45 It is mandatory to clean regularly the coils for a proper unit operation. Eliminate pollution and other residual material help to extend the life of the coils and the unit CAUTION! Equipment Damage! Do not use coil cleaning agents to clean uncoated AWA HP XEA coils. Use clean water only.
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Page 46: Ordinary Maintenance
14.5 ORDINARY MAINTENANCE Activities list week Month (note 1) Year (note 2) General: Data collection operation (Note 3) Visually inspect the unit for any damage and / or looseness Verifying the integrity of the thermal insulation Clean and paint where needed Water Analysis (5) Electric: Check the correct operation of the equipment on the unit... -
Page 47: Recommended Spare Parts
RECOMMENDED SPARE PARTS There follows a list of the recommended parts for several years’ running. Thermocold is at your disposal to recommend a personalised list of accessories according to the commissioned order, including the part number of the equipment. 1 YEAR 2 YEAR 5 YEAR COMPONENTS... -
Page 48: Troubleshooting
TROUBLESHOOTING Who can take corrective action Symptom Cooling Heating U = User Probable cause Possible remedy S = specialised personnel Probe faulty service Check and replace if necessary. A The unit does Lack of consent of the high or See points D-E not start low pressure Defective compressor... - Page 49 Who can take corrective action Symptom Cooling Heating U = User Probable cause Possible remedy S = specialised personnel Pressure switch out of order Check and replace. Machine completely void of See point G. refrigerant Finned coil clogged, airflow rate Remove dirt from the coil.
- Page 50 Who can take corrective action Symptom Cooling Heating U = User Probable cause Possible remedy S = specialised personnel Expansion device that is not Verify and replace. working properly Water circulation pump blocked Unlock the pump. M Frost in the Check the pump and replace if compressor Water circulation pump defective...
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Page 51: Improper Uses
IMPROPER USES The unit is projected and built up to grant the maximum safety in its proximity, as well as to resist to the aggressive environmental conditions. The fans are protected by grilles. Residual risks are indicated with warning labels. SAFETY SYMBOLS DANGER: DANGER:... - Page 52 Notes Page 52...
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- Page 54 Notes Page 54...
- Page 55 Technical data shown in this booklet are not binding. Thermocold shall have the right to introduce at any time whatever modifications deemed necessary to the improvement of the product. 70026 Modugno – Bari Via dei Ciclamini, 25 – Z.I. Tel. 080/5312623 Internet: http://www.thermocold.it E-Mail:...
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