CIAT AQUACIATCALEO ITEV 100P Instruction Manual
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CIAT AQUACIATCALEO ITEV 100P Instruction Manual

CIAT AQUACIATCALEO ITEV 100P Instruction Manual

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10842
02 - 2025
I n s t r u c t i o n m a n u a l

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Summary of Contents for CIAT AQUACIATCALEO ITEV 100P

  • Page 1 10842 02 - 2025 I n s t r u c t i o n m a n u a l...

  • Page 2: Table Of Contents

    CONTENTS 1 - INTRODUCTION AND SAFETY INSTRUCTIONS ........................4 2 - RECEIPT OF GOODS ................................4 2.1 - Checking the equipment received ............................4 3 - HANDLING AND POSITIONING ............................. 5 3.1 - Handling ....................................5 3.2 - Positioning ................................... 5 3.3 - Installation cases .................................
  • Page 3 CONTENTS 12 - OPTIONS & ACCESSORIES .............................. 43 12.1 - Tables of options & accessories ............................43 12.2 - Description ..................................44 13 - STANDARD MAINTENANCE .............................. 46 13.1 - Maintenance levels................................46 13.2 - Level 1 maintenance ............................... 46 13.3 - Level 2 maintenance ...............................

  • Page 4: Introduction And Safety Instructions

    1 - INTRODUCTION AND SAFETY INSTRUCTIONS The units are designed to heat water (heating mode) and cool water (cooling mode) for the air conditioning / heating of buildings  and industrial processes. They are designed to provide a very high level of safety and reliability, making installation, start-up, operation and maintenance easier and safer. They will provide safe and reliable service if used within their application ranges. For all safety instructions, please refer to the safety manual.

  • Page 5: Handling And Positioning

    3 - HANDLING AND POSITIONING 3.1 - Handling 3.2 - Positioning CIAT strongly recommends employing a specialised company The machine must be installed in a place that is not accessible to unload the machine. to the public and is protected against access by non-authorised persons.
  • Page 6 NOTE: If the walls are higher than 2 m, contact the factory. 3.2.2 - Positioning of potentially flammable zones The full unit, including all options & accessories that are delivered by CIAT, has been qualified for the use with R290 refrigerant. For that purpose, CIAT is compliant with EN 378-2 §6.2.14 and has defined potentially flammable zone using EN 60079-10-1 in  order to identify where ignition sources must not be present. Then CIAT has designed the machine in order that, if the unit is used the way it was designed for, there is no internal ignition source in the internal potentially flammable zone. Thus, the only residual risk is to have an ignition source introduced in the potentially flammable zone by the user. For that purpose,  CIAT has decided to represent the external potentially flammable zone where the user must not introduce ignition source.

  • Page 7: Installation Cases

    Although this information is believed to be accurate, it is presented without warranty of any kind, either express or implied. These are general recommendations and do not replace the installer’s individual advice and instructions for each specific site. CIAT shall  not be liable if the information provided is not appropriate for a specific site and/or does not comply with applicable regulations.  The manufacturer assumes no liability for actions taken by readers or users of this document that may cause unintentional damage or injury due to recommendations or inferences made from this document. The customer and the installer remain solely responsible ...
  • Page 8 3 - HANDLING AND POSITIONING Installation over a pit R290 has a density higher than air. In case of leak, the main risk is stagnation in the lowest point. If unit is mounted in or over a pit, customer must ensure evacuation of gas is possible. Commonly used solutions (non-exhaustive list) are: ■...

  • Page 9: Indoor Installation

    3 - HANDLING AND POSITIONING 3.3.3 - Indoor installation In case unit is installed in an indoor space, installation requirements provided by EN378-3 standard must be applied. In that case, the potentially flammable zone generated by the unit is enlarged vs standard potentially flammable zone that is defined  for outdoor use. All necessary protection required must be employed (detection and ventilation). Choice of used solution is under responsibility of customer, depending on site specificities. 3.3.4 - Variants and corresponding installation A high number of installation is possible. Here is a list of existing cases and the corresponding installation cases to report above. Variant Installation case to report to Sunken courtyard...

  • Page 10: Dimensions, Clearances, Minimum Installation Distances

    4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES 4.1 - AQUACIAT ITEV 100P-180P, units without hydraulic module CALEO 1145 HT CONDENSATE EVACUATION 15mm 1130 HT VICTAULIC 2" 1814 HT VICTAULIC > SCREW ACCESSORY VICTAULIC 2" UNITS Standard 155 346 462 160 264 Pump 116V 155 303 462 160 264 NOTE: Non-contractual drawings.

  • Page 11: Aquaciat Caleo Itev 200P-360P, Units Without Hydraulic Module

    4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES 4.2 - AQUACIAT ITEV 200P-360P, units without hydraulic module CALEO 2252 1122 2267 HT Condensate evacuation 15mm VICTAULIC 2" 1/2 1815 HT VICTAULIC 2" 1/2 VICTAULIC > SCREW ACCESSORY VICTAULIC 2" 1/2 NOTE: Non-contractual drawings. Key: All dimensions are given in mm.
  • Page 12 4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES The complete unit, including all the options and accessories which are provided by the manufacturer, have been certified for  use with an A3 refrigerant. To ensure this, the manufacturer complies with EN 378-2 §6.2.14 and has defined a potentially flammable zone using EN 60079-  10-1 in order to identify where no sources of ignition must be present.

  • Page 13: Aquaciat Caleo

    5 - PHYSICAL DATA FOR THE UNITS 5.1 - Physical data AQUACIAT ITEV 100P-360P CALEO MONOBLOC UNIT AQUACIAT CALEO ITEV 100P 130P 160P 180P 200P 260P 320P 360P Sound levels - Standard unit Sound power in heating mode dB(A) 75,0 77,0 78,0 78,0...
  • Page 14 5 - PHYSICAL DATA FOR THE UNITS MONOBLOC UNIT AQUACIAT ITEV CALEO 100P 130P 160P 180P 200P 260P 320P 360P Water heat exchanger Direct-expansion welded plate heat exchanger Quantity Water volume 5,33 5,33 8,13 8,13 10,66 10,66 16,26 16,26 Max. water-side operating pressure without hydraulic module Pump, cleanable screen filter, relief valve, water and air drain valve, ...

  • Page 15: Electrical Data For The Units

    6 - ELECTRICAL DATA FOR THE UNITS 6.1 - Electrical data AQUACIAT ITEV 100P-360P CALEO AQUACIAT CALEO ITEV 100P 130P 160P 180P 200P 260P 320P 360P Power circuit supply Nominal voltage V-ph-Hz 400-3-50 Voltage range 360-440 Control circuit supply 24 V via internal transformer Maximum operating input power (1) or (2) Standard unit...

  • Page 16: Electrical Data For The Hydraulic Module

    6 - ELECTRICAL DATA FOR THE UNITS 6.3 - Electrical data for the hydraulic module The pumps that are factory-installed in these units have motors with efficiency class IE3 for > 0.75 kW motors. The additional  electrical data required is as follows: Motors for high-pressure pumps variable speed units Description 100P 130P 160P 180P 200P 260P 320P 360P Nominal efficiency at full load and nominal voltage 85,9 85,9 85,9 85,9...

  • Page 17: Electrical Data For The Compressors

    6 - ELECTRICAL DATA FOR THE UNITS 6.4 - Electrical data for the compressors I Max I Max Compressor I Nom (Un) (Un - 10%) Phi nom. Phi Max. 00PSG004189700A 0,93 >0,98 00PSG004189800A 0,93 >0,98 00PSG004189900A 120A 0,93 >0,98 00PSG004190000A (1) ...

  • Page 18: Electrical Notes

    6 - ELECTRICAL DATA FOR THE UNITS 6.6 - Electrical notes Electrical data example 5. The factory-installed disconnect switch(es)/circuit breaker(s) are of a type  suitable for power interruption in accordance with EN 60947-3 (corresponds  • ITEV units have a single power connection point located immediately upstream to IEC 60947-3). of the main switch. 6. The units are designed for connection to TN networks (IEC 60364). In IT  • Control box includes: networks,if noise filters are integrated into the variable frequency drive(s), ...

  • Page 19: Electrical Connection

    6 - ELECTRICAL DATA FOR THE UNITS 6.7 - Electrical connection 6.7.3 - Power connection/disconnect switch The power connection of the unit is carried out at a single point Please refer to the certified dimensional drawings, supplied with  upstream of the unit’s disconnect switch. the unit. The earth connection must be made in the main electrical box on the PE lug opposite the cable gland plate.
  • Page 20 6 - ELECTRICAL DATA FOR THE UNITS Table of minimum and maximum cable sections (per phase) for connection to the units Cas 1 Cas 2 Calculation of unfavourable case: Calculation of favourable case: - Conductors in ducts or multi-conductor - Multi-conductor cable wires in the open air cables in closed conduits (Standardised ...

  • Page 21: Electrical Power Reserve For The User

    6 - ELECTRICAL DATA FOR THE UNITS 6.7.5 - Power cable access routing 6.7.6 - Field-installed control wiring The power cable access can be routed in the electrical box by Field connection of interface circuits may lead to the back of it. A plate with cable glands is design for standard safety risks: Any modification to the electrics box cable sizing as per table above.
  • Page 22 7 - APPLICATION DATA Heating mode / Cooling mode Heating mode Cooling mode Water heat exchanger Minimum Maximum Minimum Maximum Entering temperature at start-up °C Leaving temperature during operation °C Air heat exchanger Minimum Maximum Minimum Maximum Outdoor ambient operating temperature Outdoor ambient temperature at start-up °C (4)(5)

  • Page 23: Minimum Heat Transfer Fluid Flow Rate (Units Without Factory-Fitted Hydraulic Module)

    7 - APPLICATION DATA 7.2 - Minimum heat transfer fluid flow 7.3 - Maximum heat transfer fluid flow rate (units without factory-fitted hydraulic rate (units without factory-fitted hydraulic module) module) The minimum heat transfer fluid flow rate for different unit sizes  The maximum heat transfer fluid flow rate for different unit sizes  is given in the tables in paragraph “Water type heat exchanger is given in the tables in paragraph “Water type heat exchanger flow rate”.

  • Page 24: Maximum System Water Volume

    7 - APPLICATION DATA 7.6 - Maximum system water volume Units with a hydraulic module include an expansion vessel which limits the volume in the water loop. The table below gives the maximum loop volume compatible with the expansion vessel (for pure water or ethylene glycol depending  on the system’s various concentrations and static pressures). If this volume is less than the volume of the loop installed, then an  additional expansion vessel must be added to the installation. AQUACIAT CALEO ITEV 35°C 55°C...

  • Page 25: Pressure Drop Curves For The Water Exchanger And Standard Water Inlet/Outlet Piping

    7 - APPLICATION DATA 7.8 - Pressure drop curves for the water exchanger and standard water inlet/outlet piping Data applicable for pure water at 20 °C. ITEV 100P-360P units 140,0 120,0 100,0 80,0 60,0 40,0 20,0 Water flow rate, l/s AQUACIAT CALEO ITEV 100P-130P AQUACIAT CALEO ITEV 200P-260P...

  • Page 26: Water Connections

    8 - WATER CONNECTIONS 8.1 - Operating precautions and When connecting units to the water distribution pipe work, refer recommendations to the certified dimensional drawings supplied with the unit for  the dimensions and position of the water inlet and outlet Before commissioning, make sure the hydraulic circuits are connections. connected to the appropriate heat exchangers.

  • Page 27: Water Connections

    8 - WATER CONNECTIONS 8.2 - Water connections The hydraulic module options are only compatible with closed loops. The use of the hydraulic module on open systems is prohibited. Schematic diagram of the hydraulic circuit without the hydraulic module Installation components Key Components of the base unit One-circuit unit (without pump)
  • Page 28 8 - WATER CONNECTIONS Schematic diagram of the hydraulic circuit with the hydraulic module Installation components Key Components of the unit with hydraulic module One-circuit unit (without pump) Two-circuits unit ( with single pump per circuit) Temperature sensor Flow rate sensor (flow switch)  Pressure sensor Air vent Heater Water drain tap...
  • Page 29 8 - WATER CONNECTIONS One-circuit unit ( without pump) Two-circuits unit ( without pump) One-circuit unit ( with single pump) Two-circuits unit ( with single pump per circuit) Temperature sensor Water filter Pressure sensor Isolation valve Heater Flow rate sensor (flow switch)  Pump Air vent Antifreeze valve + Vacuum breaker Water drain tap Gas separator + Relief valve...

  • Page 30: Units Without Hydraulic Module

    8 - WATER CONNECTIONS Refer to the diagram in the “Hydraulic connections” section 8.3.2 - Hydraulic circuit cleaning procedure for all references points mentioned in this chapter. ■ Open the valve completely (item 22). The water circulation pumps for the units in the range have been ■...

  • Page 31: Units With Hydraulic Module And Variable-Speed Pump - Pressure Differential Control

    8 - WATER CONNECTIONS ■ Avoid extending the hydraulic systems when possible. The pressure differential value maintained can in certain cases  be different from the set point value: Example : Unit with specific nominal flow 3.7 l/s ■ If the set point value is too high (achieved for a higher flow  rate than the maximum value or a higher frequency than the maximum value), the system settles at the maximum flow rate  or maximum frequency and this results in a lower pressure differential than the set point.

  • Page 32: Units With Hydraulic Module And Variable-Speed Pump - Temperature Difference Control

    8 - WATER CONNECTIONS Repeat until the design pressure drop / flow rate is achieved. The delta T value maintained can in certain cases be different  from the set point value: Stop the forced operation of the pump and proceed to the ■ If the set point value is too high (achieved for a lower flow rate  configuration of the unit for the required control mode. than the minimum value or a lower frequency than the Modify the control parameters: minimum value), the system settles at the minimum flow rate  ■...
  • Page 33 8 - WATER CONNECTIONS Depending on the atmospheric conditions in your region, you need to: ■ Add an appropriate antifreeze solution agreed by the manufacturer (maximum of 45%) to protect the system down to a temperature of 10 K below the lowest temperature likely to occur locally.

  • Page 34: Nominal System Water Flow Rate Control

    9 - NOMINAL SYSTEM WATER FLOW RATE CONTROL 9.1 - Available static pressure for the installation Units with hydraulic module (fixed-speed pump or variable-speed pump at 50 Hz)  Data applicable for: ■ Pure water at 20 °C. ■ Refer to the “Water exchanger water flow” section for the maximum water flow values. ■ If ethylene glycol is used, the maximum flow rate is reduced. 9.1.1 - ITEV 100P-360P units High pressure pumps Single pumps ITEV 100P-180P 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8...

  • Page 35: System Start-Up

    10 - SYSTEM START-UP 10.1 - Checks before system start-up 10.2 - Commissioning Before starting up the thermodynamic system, the complete Always ensure you have read and fully understood the operating system, including the thermodynamic system, must be verified  instructions for the units before starting up the unit, and ensure against the installation drawings, dimensional drawings, system the following precautions have been taken: piping and instrumentation diagrams and the wiring diagrams.

  • Page 36: Essential Points To Check

    10 - SYSTEM START-UP 10.3 - Essential points to check Compressors Ensure that each compressor is rotating in the correct direction, checking that the discharge temperature rises quickly, the high pressure increases and the low pressure drops. If it is rotating in the wrong direction, the electric power supply is incorrectly wired ...

  • Page 37: Unit Start-Up Checklist For Installers Prior To Contacting The Manufacturer

    10 - SYSTEM START-UP 10.4 - UNIT START-UP CHECKLIST FOR INSTALLERS PRIOR TO CONTACTING THE MANUFACTURER Preliminary information Job name: ......................................Location: ......................................Installing contractor: ................................... Distributor: ......................................Start-up performed by..............On ....................Equipment Model ..................Serial number ................Compressors Circuit A Circuit B 1.
  • Page 38 10 - SYSTEM START-UP Unit start-up Chilled water pump contactor has been correctly cabled with the chiller Oil level is correct  The unit has been checked for leaks (including couplings) Locate, repair, and report any refrigerant leaks ............................................................................................................................ Check voltage imbalance: AB....AC....BC....Average voltage = ........ (See installation instructions) Maximum deviation = ........ (See installation instructions) Voltage imbalance = ........ (See installation instructions) ...
  • Page 39 10 - SYSTEM START-UP Carry out the QUICK TEST function (Consult the manufacturer’s Service): Check and log on to the user menu configuration Load sequence selection ..................................Capacity ramp loading selection................................. Start-up delay ..................................... Pump control ...................................... Setpoint reset mode ................................... Night-time capacity setback................................

  • Page 40: Main Components Of The Unit And Operating Characteristics

    11 - MAIN COMPONENTS OF THE UNIT AND OPERATING CHARACTERISTICS 11.1 - Compressors Too much oil in the circuit can cause the unit to malfunction. The units use hermetically sealed scroll compressors. Each compressor sub-function is equipped with: NOTE: ■ Anti-vibration mountings between the unit chassis and the Only use oils which have been approved for the compressors.

  • Page 41: Fans

    11 - MAIN COMPONENTS OF THE UNIT AND OPERATING CHARACTERISTICS 11.4 - Fans Each fan motor assembly is equipped with a high-performance impeller made from recyclable composite material. The motors are three-phase, with lifetime lubricated bearings and class F insulation (IP55 level). When the available pressure option is not selected, the pressure available at the fan outlet is zero. According to regulation No.

  • Page 42: Electronic Expansion Valve (Exv)

    11 - MAIN COMPONENTS OF THE UNIT AND OPERATING CHARACTERISTICS 11.5 - Electronic expansion valve (EXV) 11.9 - Refrigerant The  EXV  has  a  stepper  motor  and  an  external  sight  glass  is  Units operating with R-290 (A3 fluid). mounted on the same line to check the presence of the liquid Potentially flammable zones have been identified on the edge ...

  • Page 43: Options & Accessories

    12 - OPTIONS & ACCESSORIES 12.1 - Tables of options & accessories Options Description Advantages AQUACIAT CALEO Corrosion protection, Fins made of pre-treated aluminum by chemical Improved corrosion resistance, recommended • traditional coils conversion for moderate marine and urban environments Unit equipped with supplementary water outlet Optimized operation of four units connected in ...

  • Page 44: Description

    12 - OPTIONS & ACCESSORIES Options Description Advantages AQUACIAT CALEO Exchangers flexibles   Flexibles connections on the exchanger water Easy installation. Limit transmission of • connection (Accessory) side vibrations on the water network External temperature Better value of the external temperature Remote External temperature sensor •...
  • Page 45 12 - OPTIONS & ACCESSORIES Example 1: operation in parallel - control on water Example 2: operation in parallel - control on water inlet for a hydraulic module outlet for a hydraulic module Key: All dimensions are given in mm. Lead unit Lag unit Water inlet...

  • Page 46: Standard Maintenance

    13 - STANDARD MAINTENANCE 13.2 - Level 1 maintenance To ensure optimal efficiency and reliability of the equipment and  all its functions, we recommend taking out a maintenance contract with the local organisation set up by your manufacturer. These simple procedures can be carried out by the user: This contract will include regular inspections by the manufacturer’s ■...

  • Page 47: Level 3 Maintenance

    13 - STANDARD MAINTENANCE ■ Check that all heaters are operating correctly, Refrigerant circuit checks: ■ Replace the fuses every 3 years or every 15000 hours ■ The unit is subject to F-gas tight regulatory checks. Please  (ageing), refer to the table in the introduction. ■ Check that no water has penetrated into the electrical box, ■...

  • Page 48: Tightening Of The Electrical Connections

    13 - STANDARD MAINTENANCE 13.5 - Tightening of the electrical connections Screw type Value (N.m) Soldered screw (PE) customer connection Tunnel terminal screw switch Main Switch QS100 15-22 Tunnel terminal screw, compressor contactor Compressur cable W1-W2 Compressor motor Max 3 Tunnel terminal screw variable speed drive compressor Compressor variable speed drive (power) GSA-GSB...

  • Page 49: Air-Cooled Exchanger

    13 - STANDARD MAINTENANCE 13.7 - Air-cooled exchanger 13.8 - Water type heat exchanger We recommend that coils are inspected regularly to check the Check that: degree of fouling. This depends on the environment where the ■ The insulation has not been detached or torn during unit is installed, in particular urban and industrial sites, and for operations, units installed near trees that shed their leaves.

  • Page 50: Refrigerant Properties

    13 - STANDARD MAINTENANCE 13.11 - Refrigerant properties R-290 properties Saturated temperatures based on the gauge pressure (in kPag) Saturated Pressure Saturated Pressure Saturated Pressure Saturated Pressure Temp. gauge Temp. gauge Temp. gauge Temp. gauge 1027 1789 1053 1828 1079 1867 1106 1907...

  • Page 51: Final Shutdown

    14 - FINAL SHUTDOWN 14.1 - Shutting down Separate the units from their energy sources, allow them to cool then drain them completely. 14.2 - Recommendations for disassembly Read information relating to the presence of potentially dangerous substances in the product and their precautions for use (REACH, Regulation no. 1907/2006). This information is available on the Manufacturer’s website. ...
  • Page 52 CARRIER participates in the ECP programme for LCP-HP Check ongoing validity of certificate: www.eurovent-certification.com The quality management system of this product’s assembly site has been certified in accordance with the requirements of the ISO 9001 standard (latest current version) after an assessment conducted by an authorized independent third party. The environmental management system of this product’s assembly site has been certified in accordance with the requirements of the ISO 14001 standard (latest current version) after an assessment conducted by an authorized independent third party.

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