SystemAir AQWL Installation And Maintenance Manual
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SystemAir AQWL Installation And Maintenance Manual

Air cooled water chillers and heat pumps
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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
380
Air Cooled Water Chillers and Heat Pumps
Refroidisseurs de liquide à condensation par air et pompes à chaleur air-eau
634 kW
Luftgekühlte Flüssigkeitskühler und Wärmepumpen
Refrigeratori d'Acqua e Pompe di Calore Raffreddati ad Aria
418
Enfriadores de Agua y Bomba de Calor Condensadas con Aire
702 kW
Part number / Code / Code / Codice / Código: 342605/A
Supersedes / Annule et remplace / Annulliert und ersetzt / Annulla e sostituisce /
Anula y sustituye: 035B09058-000
Notified Body / Organisme Notifié / Benannte Zertifizierungsstelle / Organismo
Notificato / Organismo Notificado N°. 1115
AQWL/AQWH
AQWC/AQWR
Français
Deutsch
Italiano
"
ISO 9001:2008 certified management system
Español

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  • 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 AQWL/AQWH AQWC/AQWR English Français Deutsch Italiano Español Air Cooled Water Chillers and Heat Pumps Refroidisseurs de liquide à condensation par air et pompes à chaleur air-eau 634 kW Luftgekühlte Flüssigkeitskühler und Wärmepumpen...

  • Page 3: Table Of Contents

    Table of Contents 1 - FOREWORD 7 - PRODUCT DESCRIPTION 1.1 Introduction................2 7.1 Introduction................27 1.2 Warranty ................2 7.2 General specifications ............27 1.3 Emergency stop/Normal stop ..........2 7.3 Compressors ..............27 1.4 An introduction to this manual ..........2 7.4 Refrigeration circuits ............27 2 - SAFETY 7.5 Water heat exchanger ............27 2.1 Foreword................3...

  • Page 4: Foreword

    1 - Introdução 1 - Foreword 1.1 Introduction 1.3 Emergency stop / Normal stop Units, manufactured to state-of-the-art design and implementation The emergency stop of the unit can be enabled using the master standards, ensure top performance, reliability and fitness to any type switch on the control panel (move down the lever).

  • Page 5: Safety

    2 - Safety 2.1 Foreword The guards of the fans (only for units provided These units must be installed in conformity with the with air heat exchangers) must be always provisions of Machinery Directive 2006/42/EC, Low Voltage mounted and must never be removed before Directive 2006/95/EC, Pressure Vessels Directive 97/23/ de-energising the appliance.

  • Page 6: Definitions

    2 - Safety (continued) 2.2 Definitions disassemble connections, filters, joints or other line items do not use your hands to check for any pressure drops OWNER: means the legal representative of the company, body or individual who owns the plant where unit has been installed; he/she use tools in a good state of repair;...

  • Page 7: Precautions During Maintenance Operations

    2 - Safety (continued) periodically check the board’s internal wiring place a warning sign “do not turn on - maintenance in progress” on the external disconnecting switch do not use cables having an inadequate section or flying connections, even for limited periods of time or in an emergency make sure that on-off remote controls are inhibited Prevention of other residual risks wear suitable personal protective equipment (helmet, safety...

  • Page 8: Safety Labels

    2 - Safety (continued) 2.7 Safety labels Identification of the refrigerant - External door Identification of the unit - Outside, on the right-hand front column USARE SOLO R 410A SPECIAL ESTER OIL USE ONLY Electrical warning - Adjacent to the master switch ATTENZIONE ! ATTENTION ! Prima di...
  • Page 9 2 - Safety (continued) Start-up warning - Outside the door Final Test Certificate - Inside the external door of the electrical board ATTENZIONE INSERIRE LE RESISTENZE DI RISCALDAMENTO OLIO ALMENO 12 ORE PRIMA DI OGNI AVVIAMENTO (SE PREVISTE) PRIMA DELLA MESSA IN TENSIONE ASSICURARSI CHE LE VITI DEI CIRCUITI ELETTRICI SIANO SERRATE COMPLETAMENTE WARNING ENERGIZE THE CRANCKCASE HEATER FOR AT LEAST 12 HOURS...
  • Page 10 2 - Safety (continued) 2.8 Safety regulations REFRIGERANT DATA SAFETY DATA: R410A Toxicity 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. Unfreeze the affected skin with water. Contact with skin Remove the contaminated clothes with great care - in the presence of frost burns, the clothes may stick to the skin.
  • Page 11 2 - Safety (continued) 2.8 Safety regulations (continued) REFRIGERANT DATA SAFETY DATA: R410A Do not inhale concentrated vapours. Their concentration in the atmosphere should not exceed the minimum preset values and should be maintained below the professional threshold. Being more weighty General precautions than the air, the vapour concentrates on the bottom, in narrow areas.

  • Page 12: Safety Regulations

    2 - Safety (continued) 2.8 Safety regulations (continued) LUBRICANT OIL DATA SAFETY DATA: POLYESTER OIL (POE) Classification Not harmful. May cause slight irritation. Does not require first aid measures. It is recommended to follow usual personal hygiene measures, including washing the exposed skin with soap and water several times a day. Contact with skin It is also recommended to wash your overalls at least once a week.

  • Page 13: Transport, Lifting And Positioning

    3 - Transport, Lifting and Positioning Refrigerators are supplied assembled (apart from standard It is recommended to use a spacer to prevent cables from antivibrating rubber supports, that will be installed on site). The damaging the unit (see the figure). equipment are full of refrigerant and oil, in the quantity required for a proper operation.

  • Page 14: Anchoring

    3 - Transport, Lifting and Positioning (continued) The eyebolts must be mounted on the unit whenever it shall be During the lifting and handling of the unit, be displaced and then lifted again. careful not to damage the finned pack of the coils positioned on the sides of the unit.

  • Page 15: Installation

    4 - Installation 4.1 Positioning of the unit 4.2 Spring Isolator Installation Prepare the base, that must be flat and plane. Before installing the unit, make sure that the structure of the building and/or the supporting Lift the appliance and insert shock absorbers as follows: surface can withstand the weight of the appliance.
  • Page 16 4 - Installation (continued) 4.3 External Water Circuit A flow switch, to disable the appliance when the water is not circulating. The flow switch and the filter water, although not included in the supply, must always be fitted such as plant components. Their The flow switch must be connected (terminals installation is mandatory for warranty.

  • Page 17: External Hydraulic Circuit

    4 - Installation (continued) 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.

  • Page 18: Power Supply

    4 - Installation (continued) 4.6 Power supply 4.7 Electrical connections The unit must be installed on site according to the Machinery Directive (2006/42/EC), the Low Voltage Directive (2006/95/EC), Before carrying out any operations on the the Electromagnetic Interference Directive (2004/108/EC) and electrical system, make sure that the unit is the usual procedures and standards applicable in the place of deenergised.
  • Page 19 4 - Installation (continued) AQWL/AQWH - Electrical connections REMOTE START/STOP SWITCH (SRS) (COMMON) REMOTE SUMMER/WINTER SWITCH (ONLY HEAT PUMP) (SRHP) DOUBLE SET-POINT (DAY/NIGHT) (SDN) FLOW SWITCH (SF) EXTERNAL INTERLOCK (OPTIONAL) CIRC PUMP ETC (B8) LAN WATER TEMPERATURE PROBE (GND) (NO)

  • Page 20: Connecting Plate-Type Evaporator Temperature Sensors

    4.8 Connecting plate-type evaporator temperature sensors Each fittings is complete with sensor well to fasten temperature AQWL, AQWH and AQWR units are provided with fittings for hydraulic sensor (BT-IN and BT-OUT). Fittings are supplied separate and must connections between heat exchangers and plant.

  • Page 21: Total Heat Recovery Features

    4 - Installation (continued) Water connection units with pump and buffer tank 4.9 Total heat recovery features Forced shuttering Temperature sensors When recovery system is on, a commutation from air condensing and water condensing takes place. Temperature sensors for recovery system water control, BTRin e BTRout, are supplied by factory with the unit, already wired, and At the same time compressor-tandem is automatically shuttered to must be fitted on the water connections at the heat reclaim conden-...

  • Page 22: Start-Up

    5 - Start-Up Start the pump and check that the water flow is correct. The unit must be started for the first time by Set the desired fluid temperature on the control board. personnel suitably trained by one Authorised Service Centre. Failure to meet this requirement Start the appliance (see Chapter 6).

  • Page 23: Control

    6 - Control General information 6.1 The "CHILLER CONTROL" system Introduction Units are provided with a microprocessor card which is fully programmed in factory for the control of a chiller with 2 circuits, This document contains the information and the operating 2/3 compressors per circuit, a high-pressure transducer and an instructions for the units.

  • Page 24: Display

    6 - Control (continued) 6.2 Display Access to the “display mask” of the machine status. User Manufactured Maintenance In/Out Setpoint Release On/Off Daily time zone The display is an LCD 4 lines x 20 columns. The quantities and the information about the operation of the unit are alternated in the form of subsequent screens, named.
  • Page 25 6 - Control (continued) Alarms Comp SYS 1 Comp SYS 2 Fan SYS 1 Fan SYS 2 Pump Reset Alarm Description Status Status Status Status Status Auto/Man AL01 Power supply wrong AL02 Antifreeze alarm AL03 Interlock AL04 Lack of flow AL05 SYS #1 Low suction pressure AL06...
  • Page 26 6 - Control (continued) Comp SYS 1 Comp SYS 2 Fan SYS 1 Fan SYS 2 Pump Reset Alarm Description Status Status Status Status Status Auto/Man AL55 Low suction alarm SYS 1 AL58 S1 sensor fault AL59 S2 sensor fault AL61 EVD Lan disconnected AL62...

  • Page 27: Protection And Safety Equipment

    6 - Control (continued) 6.4 Protection and Safety Equipment Compressor protection Compressors are equipped with a heating element to prevent Defrosting System (only for AQWH models) oil dilution, which may result in remarkable risks of failure of compressors. The AQWH units are provided with an automatic defrosting system, which prevents the formation of excessive ice banks on coolant/air exchangers during heat pump operation.

  • Page 28: Hpf Version Configuration

    6 - Control (continued) 6.5 HPF version configuration Units equipped with special brushless fans (HPF) can be set-up on the field to give the unit a specific static pressure. By entering parameter in service level - Max Speed (Vdc) - it is possible to modify high static pressure. The table below shows the correspondance between chiller model, fan RPM, high static pressure.

  • Page 29: Product Description

    AQW units are supplied complete and provided with all connecting The outdoor AQWC units, deriving from the AQWL versions, are pipes for the refrigerant and internal wiring. marked by the absence of the evaporator, and are equipped with...

  • Page 30: Electrical Power Supply And Control System

    7 - Product Description (continued) 7.8 Electric power supply and control system Wire-type remote control kit The kit includes a remote control for wall mounting, complete with The control compartment contains and electronic card with keyboard 3m-long connecting cable, and installation manual and a transformer. and a display for working parameters, alarms, if any, and operating blocks.
  • Page 31 7 - Product Description (continued) Refrigerant flow diagram - AQWL units UNIT CONTROL CONTROL COMPONENTS VESSEL CATEGORY ( 2) / EVALUATION MODULE Tandem or trio Scroll type compressors 2/mod. D1 Air cooled condenser Filter drier Electronic expansion valve Globe valve Plate heat exchanger (Dual type) 2-3/mod.
  • Page 32 7 - Product Description (continued) Refrigerant flow diagram - AQWH units UNIT CONTROL CONTROL COMPONENTS VESSEL CATEGORY ( 2) / EVALUATION MODULE Tandem or trio Scroll type compressors 2/mod. D1 Air cooled condenser Filter drier Electronic expansion valve Globe valve Check valve Liquid receiver 3/mod.
  • Page 33 7 - Product Description (continued) Refrigerant flow diagram - AQWR units UNIT CONTROL CONTROL COMPONENTS VESSEL CATEGORY ( 2) / EVALUATION MODULE Tandem or trio Scroll type compressors 2/mod. D1 Air cooled condenser Filter drier Electronic expansion valve Globe valve Check valve Liquid receiver 3/mod.
  • Page 34 7 - Product Description (continued) Refrigerant flow diagram - AQWC units COMPONENTS VESSEL CATEGORY ( 2) / EVALUATION MODULE Tandem or trio Scroll type compressors 2/mod D1 Air cooled condenser Globe valve SAFETY / CONTROL DEVICES HAZARD CATEGORY / EVALUATION MODULE High pressure switch (40.5 bar) 4/mod B+D High pressure transducer...

  • Page 35: Pressure Drops

    8 - Technical Data 8.1 Pressure drops PRESSURE DROP IN THE EVAPORATOR * 1404 1604 1806 2106 2406 kPa/(l/h)^2 1.18 x 10 9.51 x 10 7.56 x 10 7.56 x 10 6.42 x 10 Minimum flow rate 40850 45462 53320 60415 68198 Nominal flow rate...
  • Page 36 8 - Technical Data (continued) 8.2 Technical data AQWL STD/HSE/HPF - BLN models 1404 1604 1806 2106 2406 Power supply V/Ph/Hz 400 (±10%)/3/50 Number of refrigerant circuits Refrigerant charge 40 + 40 44 + 44 52 + 52 67 + 52...
  • Page 37 8 - Technical Data (continued) AQWL STD/HSE - LN models 1404 1604 1806 2106 2406 Power supply V/Ph/Hz 400 (±10%)/3/50 Number of refrigerant circuits Refrigerant charge 40 + 40 44 + 44 52 + 52 67 + 52 67 + 67...
  • Page 38 8 - Technical Data (continued) AQWL STD/HSE - ELN models 1404 1604 1806 2106 2406 Power supply V/Ph/Hz 400 (±10%)/3/50 Number of refrigerant circuits Refrigerant charge 40 + 40 44 + 44 52 + 52 67 + 52 67 + 67...
  • Page 39 8 - Technical Data (continued) AQWL HT 1404 1604 1806 2106 2406 Power supply V/Ph/Hz 400 (±10%)/3/50 Number of refrigerant circuits Refrigerant charge 40 + 40 44 + 44 52 + 52 67 + 52 67 + 67 Total capacity steps...
  • Page 40 8 - Technical Data (continued) AQWH STD/HSE/HPF - BLN models 1404 1604 1806 2106 2406 Power supply V/Ph/Hz 400 (±10%)/3/50 Number of refrigerant circuits Refrigerant charge 47 + 47 52 + 52 61 + 61 78 + 61 78 +78 Total capacity steps 21-50-71-100 25-50-75-100...
  • Page 41 8 - Technical Data (continued) AQWH STD/HSE - LN models 1404 1604 1806 2106 2406 Power supply V/Ph/Hz 400 (±10%)/3/50 Number of refrigerant circuits Refrigerant charge 47 + 47 52 + 52 61 + 61 78 + 61 78 +78 Total capacity steps 21-50-71-100 25-50-75-100...
  • Page 42 8 - Technical Data (continued) AQWH STD/HSE - ELN models 1404 1604 1806 2106 2406 Power supply V/Ph/Hz 400 (±10%)/3/50 Number of refrigerant circuits Refrigerant charge 47 + 47 52 + 52 61 + 61 78 + 61 78 +78 Total capacity steps 21-50-71-100 25-50-75-100...
  • Page 43 8 - Technical Data (continued) AQWH HT 1404 1604 1806 2106 2406 Power supply V/Ph/Hz 400 (±10%)/3/50 Number of refrigerant circuits Refrigerant charge 47 + 47 52 + 52 61 + 61 78 + 61 78 +78 Total capacity steps 21-50-71-100 25-50-75-100 17-33-50-67-83-100 15-29-43-62-81-100 17-33-50-67-83-100...
  • Page 44 8 - Technical Data (continued) AQWC STD/HSE/HPF - BLN models 1404 1604 1806 2106 2406 Power supply V/Ph/Hz 400 (±10%)/3/50 Refrigerant In/Out connections Inch 1 1/8" - 2 1/8" 1 3/8" - 2 1/8"- 2 5/8" 1 3/8" - 2 5/8" 1 1/8"...

  • Page 45: Technical Data

    8 - Technical Data (continued) AQWR 1404 1604 1806 2106 2406 Power supply V/Ph/Hz 400 (±10%)/3/50 Number of refrigerant circuits Total capacity steps 21-50-71-100 25-50-75-100 17-33-50-67-83-100 15-29-43-62-81-100 17-33-50-67-83-100 COMPRESSORS Number Type Scroll Oil type N° of loading stages 0/100 0/100 0/100 0/100 0/100...

  • Page 46: Unit Electrical Data

    8 - Technical Data (continued) 8.3 Unit electrical data AQWL/AQWH BLN models 1404 1604 1806 2106 2406 Maximum power input (*) Maximum current input (*) Start-up current (*) AQWL/AQWH LN models 1404 1604 1806 2106 2406 Maximum power input (*)
  • Page 47 8 - Technical Data (continued) Compressors @ 400 V / 3 Ph / 50 Hz Power input at max. conditions Current at max. conditions Crankcase Start up current Models per compressor per compressor heater LRA (A) (kW) FLA (A) 46.7 82.0 Circuit 1 36.1...

  • Page 48: Hydraulic Features

    8 - Technical Data (continued) 8.4 Hydraulic features Pump static head pressure (low head pumps) - Models 1404 & 1604 3 0 0 1604 1404 36000 41000 46000 51000 56000 61000 66000 71000 76000 81000 Q (l/h) Pump static head pressure (low head pumps) - Model 1806 1806 48000 58000...
  • Page 49 8 - Technical Data (continued) Pump static head pressure (high head pumps) - Models 1404 & 1604 1604 1404 36000 46000 56000 66000 76000 86000 Q (l/h) Pump static head pressure (high head pumps) - Model 1806 1806 54000 64000 74000 84000 94000...

  • Page 50: Position Of Shock Adsorbers And Weight Distribution On Supports

    Operating Shipping Weight distribution (kg) P1-P6 coordinates* CG coordinates AQWL/AQWH weight weight Al/Cu a (mm) b (mm) x (mm) y (mm) (kg) (kg) AQWL 1404 2668 2633 1070 1678 2070 2680 STD-LN AQWL 1604 2887 2850 1070 1703 2070 2680...
  • Page 51 8 - Technical Data (continued) 8.6 Dimensional drawings - AQWL/AQWH 1404 & 1604 1253 ** 147 ** 55 ** 2680 LIFT 3881 2680 AVM 2146 Hydraulic option Water in Water out Water connection 4” Victaulic Ø104 mm Water connection 4” Victaulic Ø104 mm 1P/2P Water connection 4”...
  • Page 52 8 - Technical Data (continued) 8.6 Dimensional drawings - AQWL/AQWH 1806 1640 ** 55 ** 147 ** 1379 3400 LIFT 4851 3400 AVM 2180 Hydraulic option Water in Water out Water connection 4” Victaulic Ø104 mm Water connection 4” Victaulic Ø104 mm 1P/2P Water connection 4”...

  • Page 53: Dimensional Drawings

    8 - Technical Data (continued) 8.6 Dimensional drawings - AQWL/AQWH 2106 & 2406 2123 ** 55 ** 147 ** 1864 3900 LIFT 5821 2180 3900 AVM Hydraulic option Water in Water out Water connection 4” Victaulic Ø104 mm Water connection 4” Victaulic Ø104 mm 1P/2P Water connection 4”...

  • Page 54: Service Spaces

    8 - Technical Data (continued) 8.7 Service spaces - All versions Installation of single units 3.0 m 2.0 m 2.0 m 2.0 m 2.0 m Installation of several units WALL A 1.5 m WALL D WALL B WALL A 1.5 m 2.0 m WALL D WALL B...

  • Page 55: Maintenance

    9 - Maintenance Carefully read the “Safety” section of this manual before carrying out any maintenance operations. Operations Do not discharge the refrigerant into the atmosphere while the refrigeration circuits Check the temperature are being drained. Use appropriate recovery of the leaving fluid equipment.

  • Page 56: Refrigerant Charge

    9 - Maintenance (continued) 9.3 Refrigerant charge Compressors use polyester oil. During maintenance operations on the compressor, or if you have to open the refrigerant circuit in any Do not inject refrigerant liquid into the LP side point, remember that this type of oil is highly of the circuit.

  • Page 57: Sight Glass

    9 - Maintenance (continued) 9.8 Sight glass Overheating calculation (S): The sight glass is used for inspecting the refrigerant flow and the humidity % of the refrigerant. The presence of bubbles indicates that Overheating is regulated through the expansion valve. the dehydrating filter is clogged or the charge insufficient.

  • Page 58: 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 59: Spare Parts

    11 - Spare Parts 11.1 Spare part list The table below shows the list of spare parts recommended 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 60: Dismantling, Demolition And Scrapping

    12 - Dismantling, Demolition and Scrapping After draining operations, the piping of the hydraulic networks can be disconnected and disassembled. During the draining of the refrigeration circuits, do not let the refrigerant overflow in Once they have been disconnected as specified, the packaged units the surrounding atmosphere.
  • Page 61 En g l i s h...
  • Page 62 Note...
  • Page 63 COSTRUTTORE / MANUFACTURE - ITALY BUONE NORME DI MANUTENZIONE DEI DISPOSITIVI DI SICUREZZA MONTATI SUL GRUPPO FRIGORIFERO Gentile Cliente, Le ricordiamo alcune indicazioni circa le modalità di manutenzione dei dispositivi di sicurezza montati sul gruppo frigorifero da Lei acquistato. I dispositivi di sicurezza montati sul gruppo sono stati verificati dal COSTRUTTORE a norma di legge. È...
  • Page 64 As part of our ongoing product improvement programme, our products are subject to change without prior notice. Non contractual photos. Dans un souci d’amélioration constante, nos produits peuvent être modifiés sans préavis. Photos non contractuelles. In dem Bemühen um ständige Verbesserung können unsere Erzeugnisse ohne vorherige Ankündigung geändert werden.

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