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Emicon PAS Kp Manual

Semi-hermetic reciprocating compressors and axial fans
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PAS Kp
EXTERNAL PACKAGED AIR COOLED REVERSIBLE CHILLERS WITH
SEMI-HERMETIC RECIPROCATING COMPRESSORS AND AXIAL FANS
►
Reversible Chillers.
►
Packaged external installation.
►
ATEX semi-hermetic reciprocating compressors.
►
Axial fans.
►
Natural refrigerant unit with no environmental impact.
►
Max efficiency with minimum noise level.
►
Many available options.
Technical Handbook
Rel. 1.0 12/18

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Summary of Contents for Emicon PAS Kp

  • Page 1 PAS Kp EXTERNAL PACKAGED AIR COOLED REVERSIBLE CHILLERS WITH SEMI-HERMETIC RECIPROCATING COMPRESSORS AND AXIAL FANS ► Reversible Chillers. ► Packaged external installation. ► ATEX semi-hermetic reciprocating compressors. ► Axial fans. ► Natural refrigerant unit with no environmental impact. ► Max efficiency with minimum noise level. ► Many available options. Technical Handbook Rel. 1.0 12/18...
  • Page 2 ____________________________________PAS Kp_________________________________...

  • Page 3: Table Of Contents

    ____________________________________PAS Kp_________________________________ INTRODUCTION Preface General warnings Symbols Identification tag Warranty Manual readership Personnel requirements Dangerous areas Tests and trials UNIT DESCRIPTION Nomenclature Versions REFERENCE LAWS AND NORMS R290 refrigerant (Propane) Refrigerant safety sheet 10-28 CONSTRUCTION FEATURES Frame Compressors Gas safety sensor Axial fans Aeraulic Coils User side exchanger...
  • Page 4 ____________________________________PAS Kp_________________________________ 11.1 Intended use 11.2 Documentation 11.3 Initial checks 45-46 11.4 First start-up 11.5 Winter arrest 11.6 Switching off 11.7 Microprocessor control MAINTENANCE CHECKS 12.1 Scheduled maintenance 12.2 Semi-hermetic compressors maintenance 12.3 Leak detection 12.4 Safety pressure switch check 12.5 Safety valves check 12.6...

  • Page 5: Introduction

    The non compliance with these indications during installation, functioning, servicing, reparation and disposal of the unit, can cause great damage to people, objects and the environment. In case of doubt on correct interpretation of the instructions of the Manual, please ask for all necessary questions to Emicon A.C. S.p.A. (here in after: Manufacturer).

  • Page 6: Identification Tag

    ____________________________________PAS Kp_________________________________ 1.4 Identification Tag The equipment is identified through an undeletable label on the external panel of the electrical board (here in after: Identification Tag). It is possible to see a sample of the identification tag in image 1.1, with the description of the listed information, in conformity with applicable EU regulation. ...

  • Page 7: Warranty

    ____________________________________PAS Kp_________________________________ Warranty The Manufacturer guarantees the units, in compliance with General Sales conditions and, eventually, with the contract agreements. Manufacturer warranty will expire, in the event the manual indications are not attentively respected. The Manufacturer declines any responsibility for any damage to people, animals, objects or the environment, due to mistakes in the installation , servicing or setting, i.e.

  • Page 8: Tests And Trials

    ____________________________________PAS Kp_________________________________ STORAGE Test and trials Once the unit has been compleeted, its circuit is tested, as established in the Manifacturer Quality Warranty system, for mechanical resistance for pressure and for leakeges tightness. Before shipping, the unit is subject to a complete operation test.

  • Page 9: Unit Description

    * nominal condition referred to: chilled water +12 /+7°C and external air +32°C with humidity at 50% Versions Reversible Chiller PAS KC range is available in different versions: • Standard version – PAS Kp • Silenced version – PAS S Kp STANDARD VERSION: These units are suitable for outdoor installation on the roof of the building rather than at ground level.

  • Page 10: Reference Laws And Norms

    ____________________________________PAS Kp_________________________________ REFERENCE LAWS AND NORMS Unless differently specified, units described in this manual are in compliance with relevant legislation of European Community and, in particular, with following safety requirements: • 2014/68/EU, • 2004/108/CE (Electromagnetic compatibility), • 2006/42/CE (Units directive), •...

  • Page 11: Refrigerant Safety Sheet

    ____________________________________PAS Kp_________________________________ REFRIGERANT SAFETY DATA SHEET MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 SECTION 1 IDENTIFICATION OF THE SUBSTANCE/MIXTURE AND OF THE COMPANY/UNDERTAKING 1.1 1.1 Product Identifier Commercial name...

  • Page 12: Composition/Information On Ingredients

    ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 P403 Store in well place PRECAUTIONARY STATEMENT DISPOSAL P501 Dispose of contents/containers in accordance with local regulation ADDITIONAL PHRASES OF THE MANUFACTURER - To be used far away from sparkles, open fire, heating sources, functioning electrical devises.

  • Page 13: Section 4 First Aid Measures

    ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 Flammable gas, hazard class 1 H220 extremely flammable gas Gas under pressure: Liquefied gas H280 contains gas under pressure; may explode if heated. INCI name: n-Butane It does not contain other products and/or impurity which may influence the product classification SECTION 4...

  • Page 14: Accidental Release Measures

    ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 Advice for firefighters The special equipment for firefighter operators must include fire retardant clothing, helmets, visors, gloves and in severe conditions breathing apparatus.

  • Page 15: Section 8 Exposure Controls/Personal Protection

    ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 use compressed air during loading and unloading operations. Avoid sucking of water/moisture. The whole operating system (tanks, pipes, equipments...) should be specific for the operation to be performed and provided with security systems/devices to be tested periodically in accordance with current regulations.
  • Page 16 ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 PNEC VALUES IN WATER (CONTINUOUS RELEASE): Not derived as the substance does not contain environmentally hazardous compounds. PNEC VALUES IN WATER (INTERMITTENT RELEASE) Not derived as the substance does not contain environmentally hazardous compounds.

  • Page 17: Section 9 Physical And Chemical Properties

    ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 SECTION 9 PHYSICAL AND CHEMICAL PROPERTIES Information on basic physical and chemical properties Appearance Liquefied Gas under pressure Color Clear...
  • Page 18 ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 room temperature, it tends to form explosive mixtures with air. A high risk of fire or explosion would be associated with any significant concentrations test.
  • Page 19 ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 room temperature, it tends to form explosive mixtures with air. A high risk of fire or explosion would be associated with any significant concentrations test.
  • Page 20 ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 SECTION 1 IDENTIFICATION OF THE SUBSTANCE/MIXTURE AND OF THE COMPANY/UNDERTAKING 1.1 1.1 Product Identifier Commercial name : Kryon®...

  • Page 21: Section 13 Disposal Considerations

    ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 SECTION 13 DISPOSAL CONSIDERATIONS 13.1 Waste Treatment Methods : Follow all in force applicable local laws. The gas should be disposed of with appropriate devices (torches) equipped with not backfire systems.
  • Page 22 ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 SECTION 13 DISPOSAL CONSIDERATIONS 13.1 Waste Treatment Methods : Follow all in force applicable local laws. The gas should be disposed of with appropriate devices (torches) equipped with not backfire systems.

  • Page 23: Section 16 Other Information

    ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 SECTION 16 OTHER INFORMATION Texts of danger phrases warnings H220: Extremely flammable gas H280 Contains gas under pressure; may explode if heated Dangers that may arise for the improper use are mainly those relating to a fire or explosion or asphyxiation in the event of not fired leakages in confined areas.
  • Page 24 ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 SECTION 16 OTHER INFORMATION Texts of danger phrases warnings H220: Extremely flammable gas H280 Contains gas under pressure; may explode if heated Dangers that may arise for the improper use are mainly those relating to a fire or explosion or asphyxiation in the event of not fired leakages in confined areas.
  • Page 25 ____________________________________PAS Kp_________________________________ MATERIAL SAFETY DATA SHEET GG_GF 081 ACCORDING TO REGOLATION (EC) N. 1907/2006, Revision date: November 2016 ATTACHMENT II Pag. 1 of 15 KRYON® 290 This Safety Data Sheet has been compiled in accordance with the applicable European Directives and is applicable to all countries that have translated the Directives within their national legislation.
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  • Page 30: Construction Features

    ____________________________________PAS Kp_________________________________ CONSTRUCTION FEATURES The units of PAS Kp series are designed for outdoor installation. They are equipped with axial fans made in composite material, micro-finned copper coils, highly effi- cient plate exchangers and semi-hermetic reciprocating compressors running on one, two or four independent cooling circuits in single configuration.

  • Page 31: User Side Exchanger

    ____________________________________PAS Kp_________________________________ User’s side exchanger User’s side exchanger of plate type realized in AISI 316, with single or double circuit, with channels and patented manifold which allow to reach a high heat exchange coefficient. Their design helps a uniform water distribution compatibly with the pressure drops. It is supplied with close cell insulating material covering. Moreover the exchanger is provided with a safety water flow switch that doesn’t allow the unit operation in case of low water flow to the exchanger.

  • Page 32: Main Components / Accessories

    ____________________________________PAS Kp_________________________________ 4.10 Leak detection sensor operatio PAS Kp When the unit starts (power ON), there is the heating/initialising of the sensor (about 1min duration). In this period the internal led is lamping, the leakage alarm is active (alarm lamp ON) on the electical panel, the control auxiliary circuit, 24Vac will be not powered and the compressor cabinet forced ventilation will be activated.
  • Page 33 ____________________________________PAS Kp_________________________________ 4.10 Main components and accessories HEAT EXCHANGE GP PROTECTION GRID COILS (OPTIONS) AXIAL FANS ELECTRI- CAL BOARD LIFTING EYE-BOLT SEMI-HERMETIC COMPRESSORS ATEX EXTRACTION...

  • Page 34: Available Accessories

    ____________________________________PAS Kp_________________________________ 4.11 Available accessories Amperometer: Electrical device to measure the electrical current absorbed by the unit. Electrical power supply different than standard: 230 V three-phase, 460 V three-phase.Frequency 50/60 Hz. Low temperature operation (-8°C): Electronic device for the continuous modulating voltage control of the condensing pressure through the variation of the fan rotation speed (Alternative to BF) Low ambient temperature operation (down to -20°C): Electronic device, frequency converter type, for the continuous modulating voltage control of the con- densing pressure through the vairtion of the fan rotation speed, allowing the unit operation down to -20°C ambient temperature.

  • Page 35: Cycle Description

    ____________________________________PAS Kp_________________________________ COOLING CIRCUIT PAS Kp Cycle Description Here below is represented the cooling circuit for chilled water production The suction gas (1) is compressed and discharged into the discharge side (2). the discharge side line takes the refrigerant to the condenser inlet (3). The sub-cooled and condensed refrigerant in condenser outlet (4) it is taken to the liquid side entrance of the regenerative heat exchanger (sub-cooler).

  • Page 36: Installation

    ____________________________________PAS Kp_________________________________...

  • Page 37: Do Not Smoke

    ____________________________________PAS Kp_________________________________ 6. INSTALLATION 6.1 Transport and Handling According to EN 378-1, the unit can be classified as an indirect closed system (par. 4.1.3 and 4.4.2.1, fig. 2). Refrigerant type and charge are written on the unit identification TAG. The location of the unit has to be chosen taking into account the load limits imposed by the EN 378-1, att. C and, in particular, as provided in the tab. C.1 for refrigerants A3 Group.

  • Page 38: Dimensional Drawings, Service Clearance And Weight Tables - Pas 1702 Kp

    ____________________________________PAS Kp_________________________________ Storage conditions: -30 / 60°C Positioning The installation of the unit must be done at the owner in charge and will have to be executed under his responsibility. A correct installation requires a project by a professional and the realization by expert personnel with the necessary information. In the environment where the unit is installed, there must not be any aggressive substances, nor substances that are incompatible with copper, carbon steel, aluminum and other materials used for producing the unit.

  • Page 39: Dimensions And Weight Tables - Pas 1702 Kp

    ____________________________________PAS Kp_________________________________ Dimensional drawings, service clearance and point loads tables – PAS 1702 Kp Here below the dimensional drawings indicating the service clearances, the total weights of the units in its standard configurations and of weight distribution of the same on the various points of support for the base vibration dampers. (Fig. 3.2)

  • Page 40: Hydraulic Circuit

    ____________________________________PAS Kp_________________________________ Dimensions and weight tables – Pas 1702 Kp MODEL 1702 Kp TOTAL TRANSPORT WEIGHT OPERATION WEIGHT OPERATION WEIGHT WITH P1 OPERATION WEIGHT WITH P1 AND 1056 OPERATION WEIGHT WITH P1H OPERATION WEIGHT WITH P1H 1062 AND MV OPERATION WEIGHT WITH P2 OPERATION WEIGHT WITH P2 AND 1088 OPERATION WEIGHT WITH P2H...

  • Page 41: Connection To Hydraulic Circuit

    The hydraulic system must be sized by a professional, and realized by qualified personnel, in compliance with local regulation in force. Diameters of the hydraulic connections are stated in the following Table. Piping diameters must be sized to keep circuit pressure drop within acceptable limits PAS KP 1702 Kp MODEL Evaporator hydraulic connections 2 x 2"...

  • Page 42: Filling The Hydraulic Circuit

    ____________________________________PAS Kp_________________________________ Connection to the hydraulic circuit Connections of the unit to the hydraulic circuit must be executed by an expert and qualified technician, in compliance with local regulations in force. It is important that connection of the unit to the plant is executed so that refrigeration fluid circulates across the evaporator in the right direction.

  • Page 43: Pump Group Features Pas 1702Kp Kp Series (P1/P2 Accessories)

    ____________________________________PAS Kp_________________________________ It is forbidden to use aggressive antifreeze mixes, or uncompatible with copper, carbon steel and other materials of the plant; Here below, we indicated the freezing temperatures for different ethylene glycol concentration in water .Values on this table are an indication and must be used only as a reference.

  • Page 44: Application Range

    ____________________________________PAS Kp_________________________________ 7.5 Pump group features PAS 1702 Kp Capacity referred to following conditions: Pure water [100%]; 4°C; 100kg/m3, 1,57mm2/s FREON SAFETY VALVES In the compressors compartment there are two safety valves whose vent has to be conveyed to a safe area to minimum 3mt heigh from condense or minimum 3mt far from the unit or others ignition sources.

  • Page 45: Check Of Correct Power Supply Phase Sequence

    ____________________________________PAS Kp_________________________________ ELECTRICAL CONNECTIONS The electrical plant for the unit power supply must be dimensioned by a certified professional and realized by qualified personnel, on charge of the Owner, in compliance with local regulations in force. Unit power supply cable must be protected by an automatic switch of suitable size and characteristics, as well as compliant with local regulations in force . The system must be realized so that it is possible to cut off power supply, without interrupting other services such as lighting, ventilation, alarms and safety systems.
  • Page 46 ____________________________________PAS Kp_________________________________ As an example, you will find here below an image representing the clamps provided for the free contacts described below. Remote ON/OFF: Input digital U2-30 Open = unit OFF (free cotact) Closed = unit ON Output digital General alarm: contact NO U9-U10 (free cotact) (Closed = Alarm)

  • Page 47: Operation

    ____________________________________PAS Kp_________________________________ OPERATION Before startup, it is necessary that personnel is instructed, also through the Manual, about the construction, management, operation and servicing of the units, safety measures, and legislation to comply with, any individual protection devices to be prepared, features and indications to handle the refrigerant The unit is provided with forced ventilation for the compressors compartment;...

  • Page 48: First Start-Up

    ____________________________________PAS Kp_________________________________ • The hydraulic circuit valves are open; • All safety conditions have been respected; • The wiring has been correctly executed; • Tension is within a 10% tolerance than the nominal one of the units; • Shutting of all electrical and hydraulic connections has been properly executed. 11.4 First startup First startup of the units must be executed by a technician authorized by the Manufacturer.

  • Page 49: Maintenance Checks

    ____________________________________PAS Kp_________________________________ MAINTENANCE CHECKS The Owner must make sure that the unit undergoes proper maintenance, as indicated in the Manual in compliance with laws and regulations in force. Equipment maintenance must be carried out by qualified and trained personnel, provided with personal protective equipment, as requested by local laws and regulations in force.

  • Page 50: Scheduled Maintenance

    ____________________________________PAS Kp_________________________________ 12.1 Scheduled maintenance The Owner must make sure that the unit undergoes proper maintenance, as indicated in the Manual in compliance with laws and regulations in force. Equipment maintenance must be carried out by qualified and trained personnel, equipped with personal protective equipment, as provided by local laws and regulations in force.
  • Page 51 ____________________________________PAS Kp_________________________________ 12.2 Semi-hermetic compressor maintainance Before working on the cooling circuit, to replace the compressors or the oil contained in them, you will need to run the crankcase heater for at least four hours to perform the vacuum and purge the compressor with dry nitrogen, to avoid that the refrigerant dissolved in the oil, at pressure and ambient temperature , can give rise to an explosive atmosphere in the nearness of the oil surface.
  • Page 52 ____________________________________PAS Kp_________________________________ 12.3 Leak detection If no stricter requirements are present, the unit will have to be checked for leaks at least each 3 months. If, during the check, a suspect for a refrigerant leak arises, (ex. after cooling capacity reduction, or after overheating or subcooling tests), it will be necessary to detect it with adequate devices, repair it and proceed with a new tightness test, in compliance with national legislation in force.
  • Page 53 ____________________________________PAS Kp_________________________________ Monthly and daily procedures may be executed by Owner of the plant. Other service works have to be executed by certified and trained personnel. It is forbidden to touch the unit barefoot or with wet or humid body parts. It is forbidden to perform any clearing operation, before having disconnected the unit from the electrical supply network, by turning the general switch on OFF.
  • Page 54 ____________________________________PAS Kp_________________________________ MALFUNCTIONING LIKELY CAUSE SUGGESTED ACTIONS a) Calibration of control system is not correct Check calibration of control system b)The control system doesn’t work Consult the attached microprocessor manual Chilled water temperatu- re too low c) The chilled water flow is lower than estimated See point 4 a) The hydronic pump doesn’t work Check the electrical connections of the pump...
  • Page 55 ____________________________________PAS Kp_________________________________ MALFUNCTIONING LIKELY CAUSE SUGGESTED ACTIONS Check overheating and expansion valve blocked in position too open. a. Suction line is very cold (unusual) Valve on compressor suction is blocked, replace it (if present) b. Liquid return to the compressor Noisy compressor Verify functionality and overheating of the expansion valve c.

  • Page 56: Demolition And Disposal

    ____________________________________PAS Kp_________________________________ EXTRAORDINARY SERVICING OPERATIONS Repairs of the units will have to be executed by adequately qualified and informed personnel, equipped with individual protection devices, in conformity with laws and local regulations in force. No modifications to the units or components replacement are allowed without explicit Manufacturer authorisation. Procedures carried out by personnel with different skills (such as welders, electricians, programmers, etc) must be executed under the supervision of personnel with the necessary refrigeration skills.
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