SERVICE MANUAL
Contents
1. EE 1000 ues _ TANK MOUNTED OPTION LL Zz z WT1 Wi we Wa wa 8 FOOT 20 WT2 W5 W6 W7 1 n W8 4 zt YA ol 1 125 1 1 o i i i 2 1125 875 B 1500 B 12 L 22 Dimensions Tank Dimensions mm supply not mounted on unit 1000 CBH SBH 017 020 g CLH SLH 017 020 3750 1900 CBH SBH 023 025 028 ee CLH SLH 023 025 4750 1500 d WA WB CQH SQH 017 020 CBH SBH 030 032 CLH SLH 028 030 032 5750 2000 PRINT g e CQH SQH 023 025 028 030 2 ET BE Weight distribution without tank ege Aa ae Weight Distribution kg w7 ws aem w2 ws wa ws we 4 m Model Size 3 ol CBH 017 170 170 206 206 234 234 284 284 020 177 177 223 223 247 247 311 311 125 750 H 125 023 206 206 292 292 276 26 391 391 025 206 206 292 292 276 26 391 391 028 225 225 306 306 290 290 394 394 030 257 257 364 364 34 34 459 459 WA WB 406 kg 032 257 257 375 375 326 326 476 46 WC WD 299 kd CLH 017 183 183 222 222 240 240 291 291 020 189 189 239 239 253 253 319 319 023 220 220 33 313 282 282 400 400 025 220 220 33 282 282 400 400 028 248 248 363 33 305 305 448 44 030 257 257 369 369 325 325 467 467 032 256 256 379 379 328 328 485 485 017 193 193 258 258 251 251 336 336 020 196 196 279 279 259 259 368 368 023 225 295 346 290 290 445 42. 6 88 08 NOLLO3NNOO OMNVLOIA 1311 nO H31VM Q3TIIHO E X 2 LIN 6 ae G GI SE LSINI H31VM Q3TIIHO Gei amp NOISH3A 319NIS 1 6 88 2 08 7 7 I I NOILOANNOO md gt 1311 nO H31V AA 3IWVtd ANYL MNV1 LNOHLIM IWYH4 LINN La gt 6 88 08 MNV1 G318IW3SSV 3INVH LINN NOILOANNOO 2 LATIN ANYL H31VM Ho LINN HLIM amp NIGWASSV LON XNV L H31VM NOISH3A NOILdO HLIM 020 820 920 220 020 210 HOS 220 020 820 920 220 020 210 H1S H8S Jellluojedng LL Du 26 ll Fabbricante dichiara che questo prodotto conforme alle direttive Europee The Manufacturer hereby declares that this product conforms to the European Union directives Der Hersteller erklart hiermit dass dieses Produkt den Anforderungen der Europaischen Richtlinien gerecht wird Le Fabricant d clare que ce produit est conforme aux directives Europ ennes EI Fabricante declara que este producto es conforme a las directivas Europeas O Fabricante declara que este produto esta em conformid
3. Screw anchor CF not supplied P dd AS N X Ec base Access hole for support fixing Single support code A B P F CF G L mm mm mm mm mm mm mm 60 82 35 M10 11 0 110 128 160 190 270327 270326 83 M16 16 5 108 50 Rubber supports 1000 liters tank d Support Single support Kit support CBH CLH COH 017 020 023 025 028 030 032 Without tank 485625 270326 8 SBH SLH SOH 017 020 023 025 028 030 032 CBH CLH 017 020 023 025 028 030 032 SBH SLH SQH 017 020 023 025 028 030 032 1000 liters tank Loose supplied 485620 270327 4 Each kit is complete with stainless steel fixing screws and plain washers for unit assembly With tank 485626 270326 10 19 6 88 08NG 6 98 08NG 6 88 09NG 191110 191110 uonseuu0s PTY LINN 3INVH3 TIVH3AO 6 88 08NG 6 88 08NG 6 88 08NG I3INI L3INI I3INI SNILOANNOO LINN OMAVLOIA 0 0 820 SZ0 20 HOS HOO 020 210 HOS HOO 220 020 820 HIS HI Sc0 20 HIS H19 c 0 0 0 H amp S 820 S20 20 H8S 020
4. Vpt Tank disconnect af ter charge tO E USER laci eee t Fig b Inertia tank sizing following formula 43 x Rt Xd where Rt refrigeration capacity expressed in kW equal to the following value Vptz V Vm Vpc The total optimum hydraulic volume of the system where the Matrix S chiller is installed can be calculated by the V minimum required total water volume expressed in litres Xd differential band set on the control and expressed in degrees centigrade Please note that the sum of the hydraulic volume of the Matrix S chiller Vm plus the volume of the hydraulic circuit connected to it Vpc must be greater than or equal to the minimum required total water volume V If this condi tion is not satisfied it is necessary to install an inertia tank Vpt as indicated in the Fig a with a volume at least Fig Sizing of the expansion vessel y Cxe 1 Pi Pf where 2 5 bara pressure typical value 4 0 bara The total volume of the expansion vessel is calculated with the following formula C quantity of water inside the system expressed in litres e water expansion coefficient with water at 10 as a reference Pi absolute pressure of initial charging equivalent to the vessel p
5. Tvu31V1 XS DG ert Serr ion 6 98 08NG 191110 6 88 08NG 6 88 08NG 191110 6 88 08NG 6 88 191110 6 88 08NG I3INI I3INI I3INI 0 0 820 SZ0 20 HOS HOO 220 020 820 HIS HI c 0 0 0 H8S 020 210 HOS HOO Sc0 20 HIS H19 820 S20 20 H8S 020 210 HIS 020 410 Has LH MIIA HV3H 0770 0 61 06 o p NIA dOL 09 FN 0021 2 1916 Dou MOT TANVd dJI8vAOW3H NIA LNOYS K 06 08 060 198 x Z HoNndaud 1971 AlddNS MAIA 292 yue suoisueuuip ejeAQ 9 Du a 18vAOW3H LINN TOHLNOO TANVd IWOIWLOATA 21 suonoeuuoo sedid 4 08NG OMNVLOIA A THORSON 3 uasou 0118 suonoeuuoo sejou 70 ul SM919S OIN s did 1enno AT
6. to date information the user should always consult the manual supplied with the machine Index Introduction wie twee daga qaad ad ua qa dai Ra dU DLL Ol R E TTUUTT 12 Rhesponsibility ro EPI REG REC IET EG Mo Ree Reece Rien Mile E RUE 1 39 Inspection bate e abe is a 1 4 Generaldescription eee rte Ere EN Kona 2 Preliminary Operations ee see lil ute rerba hebr es dr CR RO xac ZA Operating tn oett repetere aulas wo tq utqa an 2 2 Soundipress re levels rt eec tt oe etie CAPE ob crt aca RT e a sa a anak ac RR e EGENT Sen FOUNGAUONS P 215 SGNVICG ANCA eee asalan Wien ceding q Rema by CAE agh eg ese ew late ete GC x Elus Pc 34 Hydraulic on a a 3 2 Connection of the safety valve discharge 3 9 IElectrical Contiectioris oo edd e eX EXTR a boi ee tec ite Yo 4 Start Up and Operation ET c EEUU 42 First start up of alter a Jong stop suyu ere D ead edes Yep eo Pre abd rp eo eae 4 3 SlartiRg arid stopping cuu osten reet Itin Dat ihi eet tono er eA QR E Reb Peak gri obrera aswa 44 Chillers serving special plants eee RII Hm he 45 Breecoolitig ore IR CROP RT tad pep OP e ep RP NP
7. 2 5 Service area In order to allow free air flow and maintenance of the unit a minimum area must be left free of obstructions around the unit see Fig 1 e Thehotair expelled by the fans must be allowed to rise unim peded by obstacles for a minimum height of 2 5 m Avoid recirculation of hot air between the suction and dis charge otherwise the unit performance may be impaired or the standard operation can be interrupted 3 Installation 3 1 Hydraulic connections 3 1 1 Hydraulic circuit construction Fig a The piping must be connected to the chiller Construct a chilled water circuit as described below see Fig a 1 Place shut off valves within the circuit to allow servicing 2 Install a pump system suitable for the flow rate required at a pressure head equal to the sum of all the pressure drops see project data Matrix S chillers can be equipped upon request with pumps having performance as indicated in Tab 8 3 Install manometers at the chiller inlet outlet 4 Install thermometers at the chiller inlet outlet 5 Connect the pipes to the chiller by flexible joints to avoid transmitting vibrations and to balance the thermal expan sion proceed in the same way even if the pump set is out side the chiller 6 Itis useful to include a water pressure switch to give an early warning of low water pressure 7 Placea mesh filter atthe inlets of the pump and water chiller Can be supplied a
8. 210 HIS 020 410 Has HED MAIA dO L 09 WALSAS ONLLO3NNOO LINN 0 1HVd h HIV T3Nvd ATaVAOWSY 060 99 x Z HoNndaud Dun Dei 131NI 318VO AlddNs MIIA WHALVT XS LNOHH B IN M n 207 8617 v3 1 EW IND e i weu UNA Beete e AB en X 3 18vAOW3H uv3uY LINN TOHLNOO sen T3NVd TVOIHL2313 IND 6 G 5 exi 13710 AY340934 88 WLOL lo LON 6 88 08 GvNOLLdO _ JIYN 1311nO AY340934 NOILO3NNOO SVD 1Y3H TVILHvd D I 318vilvAv 9 ped exi INI AHSAOO3H AH3AOD3H 1ON 88 2 WLOL V JIN 1JNNI AHHAOO3H SV9 SVO 2 VIL Hvd 2 Z 0 H1S H9S 220 H99 Gesi 110 110 HOS 15 85 HO2 H13 Hg2 yue suoisueuuip Elon S D 20 3INVH3 TIVH3AO SNILOANNOO LINN ONMAVLOIA WALSAS ONILOANNOO LINN LYWd
9. The working life of some of the main components such as the fans and the compressors depends on the maintenance that they receive If the unit has to be dismantled the job must be done by skilled refrigeration technicians The refrigerant and the lubricating oil in the circuit must be dis posed of in conformity with the laws in force in your country Check that the fan motor rotates freely without any abnormal noise and ensure that the bearings are not running hot Also check the current absorption Check the conditions of the filters if they are supplied if necessary clean them including CONDENSER AND AIR FILTER the electrical panel ventilation filter e Check the condenser coils and clean if necessary with compressed air or soft brushes CONTROL Check that the control equipment LEDs and display are operating correctly ELECTRICAL CIRCUIT e Check the electrical supply on all phases Ensure that all electrical connections are tight e Check the condensing and the evaporating pressures to be done by a refrigeration techni cian Check the compressor s current absorption the delivery temperature and possible unusual noises REFRIGERATION CIRCUIT Check the refrigerant charge by means of the sight glass Check that the safety devices operate correctly Check the correct operation of the thermostatic valve superheating between 5 C 8 C Check that the oil level indicated by the compressor s
10. ing conditions must be in the range of 25 C 45 C with an out let differential of between 3 5 C 8 C 8 3 Water chiller with total heat recovery 100 All heat discharged by the unit to the condenser is recovered see Tab 3 The system includes an additional refrigerating circuit made up of 2 two way solenoid valves supplying in case of hot water demand a plate exchanger usually by passed and sized so as to discharge all condensing heat also installed before the finned air condenser in series with it a check valve a liquid re ceiver at the exit of the finned air condenser working as storage for the needed additional refrigerant charge see refrigerating scheme The recuperator is insulated with closed cell polyure thane and is equipped with heaters activated when the recuper ator is deactivated to prevent frost in winter with the system stopped or not perfectly drained The operation in total recovery mode is enabled by an external contact The Microface control will simultaneously suit the fan speed changing the fan speed setpoint differently from the stan dard operation without recovery practically slowing the fans down till they switch off anyway the operation in recovery mode is enabled also without load at the users Indeed if the us ers do not demand heat the water flowing to the condenser reaches a temperature that does not enable the total condensa tion of the compressed gas and the r
11. 39 56 116 39 69 114 39 19 117 1 2 65 230 2 3 0 59 3 0 59 69 3 139 2 36 76 176 36 81 176 36 38 179 1 2 65 260 2 4 0 63 4 0 63 74 3 149 2 39 56 165 39 69 162 39 19 166 1 2 4 0 63 44 86 141 45 48 139 43 67 149 44 86 227 45 48 224 43 67 232 55 16 91 51 35 105 49 55 119 1 2 65 260 2 4 0 63 74 3 149 2 53 16 188 51 35 199 49 55 210 1 2 65 340 2 5 5 63 89 2 178 9 57 02 55 55 83 67 57 02 159 55 83 169 oo os oso le 31 91 34 52 107 83 30 71 33 14 kPa 117 95 31 58 34 21 kPa 127 107 1 2 1 2 65 260 2 4 0 4 0 63 74 3 149 2 43 66 131 42 18 144 42 52 132 1 2 5 5 63 46 77 101 45 06 118 45 60 103 1 2 65 340 2 5 5 63 89 2 178 9 51 05 86 52 22 61 51 46 101 1 2 5 5 63 62 43 75 62 00 102 57 51 147 1 2 66 46 25 66 16 54 1 2 65 410 2 7 5 68 7 5 68 91 1 182 7 oo os oso os2 31 91 34 52 187 165 30 71 33 14 197 176 31 58 34 21 kPa 207 189 1 2 1 2 65 340 2 5 5 5 5 63 89 2 178 9 43 66 223 42 18 234 42 52 223 1 2 7 5 68 46 77 195 45 06 211 45 60 196 1 2 65 410 2 7 5 68 91 1 182 7 51 05 174 52 22 150 51 46 188 1 2 7 5 68 62 43 139 62 00 166 57 51 206 1 2 66 46 95 66 16 123 1 2 65 460 2 11 0 65 11 0 65 149 4 306 4 14 Fig 1 Service a
12. 451 451 377 377 377 467 467 390 390 390 030 453 453 386 386 386 479 479 408 408 408 032 448 448 395 395 395 479 479 422 422 422 CQH 017 436 436 280 280 280 452 452 290 290 290 020 430 430 300 300 300 453 453 315 315 315 023 436 436 360 360 360 462 462 382 382 382 025 436 436 360 360 360 462 462 382 382 382 028 451 451 377 377 377 467 467 390 390 390 030 449 449 392 392 392 479 479 418 418 418 SBH 017 472 472 286 286 286 453 453 274 274 274 020 469 469 304 304 304 459 459 297 297 297 023 478 478 384 384 384 463 463 372 372 372 025 478 478 384 384 384 463 463 372 372 372 028 481 481 385 385 385 469 469 376 376 376 030 497 497 450 450 450 482 482 436 436 436 032 492 492 459 459 459 482 482 450 450 450 SLH 017 471 471 289 289 289 455 455 279 279 279 020 468 468 307 307 307 460 460 303 303 303 023 476 476 388 388 388 464 464 378 378 378 025 476 476 388 388 388 464 464 378 378 378 028 494 494 444 444 444 472 472 424 424 424 030 481 481 433 433 433 483 483 435 435 435 032 477 477 442 442 442 483 483 448 448 448 SQH 017 484 484 348 348 348 454 454 326 326 326 020 478 478 368 368 368 456 456 351 351 351 023 491 491 443 443 443 466 466 421 421 421 025 491 491 443 443 443 466 466 421 421 421 028 477 477 429 429 429 474 474 426 426 426 030 478 478 439 439 439 484 484 444 444 444 18 Fig 4 Rubber anti vibration support 1000 liters tank Rubber support dimensions Rubber support installation A Unit base Fixing screw
13. High pressure manometer Opt 19 Charge connection 6 Low pressure manometer Opt 20 Antifreeze sensor 7 Safety valve 21 Partial recovery heat exchanger Opt 8 Condenser 22 Antifreeze heater Std with heat recovery 9 Fans 10 Pressure transducer Opt on Mod without heat recovery 11 Shut off valve 12 Filter dryer Shut off solenoid valve Sight glass 23 Fig 9 Refrigerant circuit with total recovery opt CBH CLH 017 020 023 025 028 030 032 017 020 023 025 028 030 NOT PRESENT FOR NOT PRESENT FOR CBH 017 020 CBH 017 020 5 C amp HEAT RECOVERY WATER INLET ICTAULIC COUPLING OPT p 29 eu i AG y X6 91 29 CT OF 9 lt s amp 3 SP Q EZ WATER OUTLET VICTAULIC COUPLING CHILLED WATER INLET 19 DN 80 3 88 ST VICTAULIC COUPLING k 19 OO Dee ha fg G 0 1 Se CHILLED WATER OUTLET VICTAULIC COUPLING DN 80 3 88 9 mm Refrigerant components eed Description 1 Compressor 15 Thermostatic expansion valve 2 High pressure
14. ambient temperature of 30 C 12 7 Operating limits CBH R 407C 017 020 023 025 028 O32 Working Range Max outdoor air temperature 7 45 0 41 5 45 0 43 0 44 0 45 0 43 5 Safety Device Settings High pressure switch 7 High pressure safety valve Low pressure switch 1 With nominal air flow water flow outlet at 7 C full load CLH R 407C Working Range Max outdoor air temperature 7 Safety Device Settings High pressure switch 1 High pressure safety valve Low pressure switch 1 With nominal air flow water flow outlet at 7 C full load R 407C Working Range Max outdoor air temperature 7 Safety Device Settings High pressure switch 1 High pressure safety valve Low pressure switch 1 With nominal air flow water flow outlet at 7 C full load SBH R 407C 017 020 023 025 2 oso 032 Working Range Safety Device Settings High pressure switch 2 High pressure safety valve Low pressure switch 2 With nominal air flow mixture flow outlet at 10 C full load SLH R 407C 017 o20 o23 025 o28 oso 2 Working Range Safety Device Settings High pressure switch 2 High pressure safety valve Low pressure switch 2 With nominal air flow mixture flow outlet at 10 C full load SQH R 407C Working Range Max outdoor air temperature 2 Safety Device Settings Hig
15. switch HP 16 Evaporator 3 Low pressure switch LP 17 Antifreeze heater Opt 4 Crankcase heater 18 Control temperature sensor 5 High pressure manometer Opt 19 Charge connection 6 Low pressure manometer Opt 20 Antifreeze sensor 7 Safety valve 21 Total recovery heat exchanger 8 Condenser 22 Antifreeze heater 9 Fans 23 Non return valve 10 Pressure transducer 24 Liquid receiver 11 Shut off valve 12 Filter dryer Shut off solenoid valve Sight glass 24 OL 6 ido Ayoyes yug uorsuedx3 8 2 jenuejegiq 9L ej Buis 9 deo AJLA 9IAJ9S GL S sduund MOL rL enuen v ido 1eveeu ezeejjnue MueL EL 1dO Josues ezeeJjiuv EI 2 Josues LL L uonduoseg wen uonduoseq wey sjueuoduioo oi ne4p H LINN HLIM XT18IN3SSV MNV L H31VM LINN 3SV8 SSOHIH 1H383ITT1 6 88 08 NOLLO3NNOO H31VM Q3TIIHO gt lt i 6 88 E 08 NOLLO3NNOO OMNVLOIA 9 ISINI H31VM G3TI
16. the cock on the liquid line 6 Safety Devices Settings 3 Connect to the fittings on the compressor body Schraeder valves and empty it of refrigerant until atmospheric pres sure 1 bar is reached 4 Using a pipe connect the oil container to the oil service fitting on the lower part of the compressor 5 Open the oil service cock lifting the container so that the oil flows by gravity 6 Charge the required quantity of oil make sure the tube al ways remains below the oil level in the container 7 Stop the oil flow by closing the oil service fitting open the shut off cock on the refrigerating circuit and restore the drained refrigerant charge The water chiller has already been tested and set up by the manufacturer The following setting values are suggested in the field COMPONENT SETTING NOTES set Operation with R407C R22 standard factory setting Low pressure switch LP START 3 6 bar DIFF 0 8 bar STOP 2 8 bar Operation with R407C R22 standard factory setting High pressure switch HP STOP 26 bar START 20bar DIFF 6 bar fixed The settings for the safety valves installed on the machine are indicated below MODELS SETTINGS SAFETY VALVE CBH CLH CQH 017 020 023 025 028 SBH SLH 017 020 023 025 028 29 bar high pressure side SQH 017 020 023 025 6 1 Setting thermostatic expansion valve THIS OPERATION MUST BE PERFORMED BY AN EXPERI EN
17. 340 2 1 Outdoor air temperature 35 30 glycol water mixture water inlet outlet temperature 15 10 C SQH R 407C Power supply 7 FLA LRA Compressors power input 7 Compressors nominal current 1 Compressor max current Fan power input Fan nominal current Fan max current Std head pressure pump model Opt Std head pressure pump motor max power Std head pressure pump max current High head pressure pump model Opt High head pressure pump motor max power Migh head pressure pump max current gt gt gt 65 260 2 4 0 8 00 65 340 2 1 Outdoor air temperature 35 30 glycol water mixture water inlet outlet temperature 15 10 C Nominal power supply 400 V 3 Ph 50 Hz Nominal power supply tolerance 400 V 10 Max voltage unbalance 3 400 V 3 Ph 50 Hz 187 203 229 291 301 307 492 549 555 103 8 111 5 128 6 172 184 210 69 72 72 65 410 2 400 V 3 Ph 50 Hz 178 198 222 288 294 300 489 542 548 100 4 112 7 129 4 166 186 210 69 72 72 65 340 2 65 410 2 5 5 7 5 11 20 15 20 65 410 2 65 460 2 11 0 21 40 400 V 3 Ph 50 Hz 65 340 2 65 410 2 5 5 11 20 65 410 2 The cables have to be sized in compliance with local standards and according to the type and characteristics of installation Suggested cables section are re ferred to PVC insulation with a max working temperature of 70 C and an
18. 4 025 225 225 346 346 290 290 445 44 028 248 248 363 363 305 305 448 44 030 256 256 376 376 327 327 480 480 SBH 017 232 232 263 263 265 265 300 3 020 238 238 280 280 278 278 37 327 023 279 279 370 370 30 30 412 412 025 279 279 370 370 30 30 412 412 028 284 24 369 369 39 39 415 415 030 326 326 440 440 357 357 481 481 032 325 325 450 450 360 360 498 498 SLH 017 233 233 266 266 268 268 306 306 020 230 239 284 284 281 281 333 333 023 270 279 374 34 313 33 49 419 025 270 279 374 34 313 33 49 419 028 317 317 436 436 341 341 469 469 030 304 304 420 420 351 351 485 485 032 304 304 431 431 354 354 502 502 017 267 267 333 333 286 286 37 357 020 269 269 354 354 295 295 388 388 023 312 312 438 438 3329 332 466 466 025 312 3129 438 438 332 332 466 466 028 295 295 420 420 336 336 477 477 030 304 304 47 427 353 353 497 497 17 Weight Distribution with tank Weight Distribution kg WT1 W1 w2 Ws we Model Size CBH 017 431 431 233 233 233 451 451 244 244 244 020 428 428 251 251 251 456 456 268 268 268 023 432 432 315 315 315 462 462 337 337 337 025 432 432 315 315 315 462 462 337 337 337 028 444 444 328 328 328 467 467 345 345 345 030 455 455 382 382 382 479 479 402 402 402 032 450 450 391 391 391 479 479 416 416 416 CLH 017 439 439 248 248 248 450 450 254 254 254 020 436 436 265 265 265 455 455 277 277 277 023 440 440 332 332 332 460 460 347 347 347 025 440 440 332 332 332 460 460 347 347 347 028
19. CED REFRIGERATION TECHNICIAN Before beginning this adjustment be sure that the refrigerant charge is correct checking the the sub cooling 3 C 5 C as specified in par 5 1 The valve has already been factory set and should be reset when the superheating is not between 5 C 8 C as follows 1 Important Ensure that the instructions in par 5 1 have been carried out 2 Allow the compressor to operate for 15 mins 3 Measure the superheating as follows a Connect a manometer to the Schraeder connection lo cated on the evaporator outlet tube and read the mano metric temperature on the scale for the refrigerant used for the units with R407C refer to the pressure gauge scale indicated with the initials D P Dew Point b Using a contact thermometer measure the temperature on the tube coming out of the evaporator next to the socket used for the manometer c The superheating is the difference between the two readings b a 4 Thesuperheating must be 5 C 8 if not set the expan sion valve as follows a Remove the protective cover b Turn the adjustment screw to return to the optimum val ues tightening it in a clockwise direction to increase the superheating or slackening it to reduce the superheat ing c Wait about 10 minutes d Measure the superheating and repeat the operation if necessary N B If the superheating is too low there is a risk of poor lubrication and consequent bre
20. IHO NOISH3A dnd SIONIS 6 88 08 E 7 7 7 NOLLOSNNOO OMNAVLOIA LF1LNO H31LVM ra 3INVH3 MNVL OINVL LNOHLIM IWYH4 LINN ww 6 88 08 NOLLOSNNOO OMAVLOIA a INI NN H31VM OINVL G318IW3SSV HLIM LINN 5 5 UND HLIM NOISH3A dnd KIGWASSV LON Mel H31VM NIML HLIM AINO 020 820 920 220 020 210 HOO 1311149 c 0 0 0 820 S20 20 020 410 HTO H9O Jeu OL Du 25 A uo jenuejegiq L SUE 02 OL Josues 61 BAIA BOIS 6 8L yug uorsuedx3 8 Josues einye1eduue L Z 9L ej Buis 9 deo 9IAJ9S GL juenng S sduund uewe MOL rL enuey v 1eveeu ezeejjnue MueL EL 1dO jem Josues 1nle1 duu 1 ezeeJjiuv EI 2 10898 eJnje1eduJe jonuo LL uonduoseg way uonduoseq wey sjueuoduioo oi ne4p H LINN HLIM XT8IN3SSV NOISH3A XNV L H3 1VM H LIM LINN 3SV8 SSOHIH 1H383 T1
21. Liebert HIROSS n ine aa High Performance Air Conditioning MATRIX 017 032 HIGH PERFORMANCE AIR COOLED CHILLER MANUAL 2 Y etr Power Rev 25 05 2005 Issued by T D Service Network Power Caution It is recommended that the manual is retained for the entire service life of the machine e the user reads the manual carefully before carrying out any operations on the machine the machine is used exclusively for the purpose for which it is intended incorrect use of the machine shall release the manufacturer from any liability This manual has been prepared to enable the end user to carry out only those operations that can be done with the panels closed Any operations that require the opening of doors or equipment panels must be carried out only by qualified person nel Each machine is equipped with an electric isolating device which allows the operator to work in conditions of safety This device must always be used to eliminate risks during maintenance electric shocks scalds automatic restarting moving parts and remote control The panel key supplied with the unit must be kept by the person responsible for maintenance For identification ofthe unit model and serial no in case of the necessity for assistance or spare parts read the identification labels affixed to the outside and inside of the unit IMPORTANT This manual may be subject to modification for complete and
22. QH SQH 028 CLH SLH 028 CLH SLH 030 032 CQH SGH 030 5 R 407C refrigerant and oil charge Models CBH 017 020 023 025 028 030 032 Refrigerant charge each circuit kg 19 5 20 1 28 6 28 7 34 5 42 0 42 1 Oil charge each circuit It 12 4 14 2 16 0 16 0 16 0 16 0 16 0 Models CLH 017 020 023 025 028 030 032 Refrigerant charge each circuit kg 22 5 23 1 32 8 32 9 39 4 42 0 42 1 Oil charge each circuit It 12 4 14 2 16 0 16 0 16 0 16 0 16 0 Models COH 017 020 023 025 028 030 Refrigerant charge each circuit kg 23 0 23 6 32 8 32 8 39 4 42 0 Oil charge each circuit It 12 4 14 2 16 0 16 0 16 0 16 0 Models SBH 017 020 023 025 028 030 032 Refrigerant charge each circuit kg 19 5 20 1 28 6 28 7 30 3 37 0 37 1 Oil charge each circuit It 12 4 14 2 16 0 16 0 16 0 16 0 16 0 Models SLH 017 020 023 025 028 030 032 Refrigerant charge each circuit kg 19 5 20 1 28 6 28 7 34 4 37 0 37 1 Oil charge each circuit It 12 4 14 2 16 0 16 0 16 0 16 0 16 0 Models SGH 017 020 023 025 028 030 Refrigerant charge each circuit kg 23 0 23 6 32 8 32 8 34 4 37 0 Oil charge each circuit It 12 4 14 2 16 0 16 0 16 0 16 0 10 Tab 6 Electrical characteristics CBH R 407C x ws ws ws www OA 7 FLA LRA Compressors power input 7 Compressors nominal current 7 Compressor max current Fan power input Fan nominal current Fan max current St
23. T ER DIOS puas dd un 4 6 Microprocessor control iae ecce been eedem be be undid eerie eese a 5 Refrigerant and Oil Charge eee nnn enhn nnn 54 e Retrigerant charge rg nl EN Peel toov Doy DE dope tee det cer dd edad 5 2 gt Ollicharge onn teo Pone Beag Pedir Diog todo ance IP Sb se Pho Y ip Rer ine Pide rupe P Op Eve 6 Safety Devices Settings 2 eee eee eee nah 6 1 Setting thermostatic expansion valve I 4 Maintenance TA gt e CN 1 2 Dismantling tlie Unlt 8 Options and Accessories isis oes NENNEN ENN e whan ark ENNEN SA PumpSset ect Eda RIEN EE DER UR Wer dq pru Eque d MEE EE ETE 8 2 Water chiller with partial heat recovery 2096 IH 8 3 Water chiller with total heat recovery 10096 HH 8 4 Hydraulic circuit accessories m RCR w alaasa 8 5 Water chiller with inertia tank HH ee ee ee einne is IE Hell Sea asar in 15 CC TRIER TEMP 23 1 Introduction 1 1 Foreword This handbook is aimed at enabling both the installer and the op erator to carry outthe correct installation operation and mainte nance ofthe refrigerating machine without damaging it or caus ing injuries to the relevant staff The handbook is thus an aid for the qualified staff in the arra
24. aVAOWSY haju payoddns 104 sjexoeJq Z N MAIA dOL 0001 o Q m 2 E co iO ass CH CH W3LSAS ONLLO3NNOO MNVL D 1HVd MAIA INOH4 MAIA sir 9811 al 005 008 Gert MAIA 1VH31V1 XS EE TENET Bou m p OL lt e ig E S i lt gt E 597 ave 1008 Oa 1HVd uo Ajddns suoisueuuiq j eJeAQ yUeL Du 22 Fig 8 Refrigerant circuit std with partial recovery opt CBH CLH SBH SLH 017 020 023 025 028 030 032 CQH SQH 017 020 023 025 028 030 HEAT RECOVERY WATER OUTLET 2 GAS MALE OPT 4 SE 2 GAS MALE OPT ec CHILLED WATER INLET 3 VICTAULIC COUPLING CHILLED WATER OUTLET e 3 VICTAULIC COUPLING Refrigerant components I ERN 3 Description 1 Compressor 15 Thermostatic expansion valve 2 High pressure switch HP 16 Evaporator 3 Low pressure switch LP 17 Antifreeze heater Opt 4 Crankcase heater 18 Control temperature sensor 5
25. ad the corresponding saturated condensing temperature 3 Thesub cooling is the difference between the two read ings 4 For the units with R407C refer to the pressure gauge scale indicated with the initials B P Bubble Point Verify that at the condenser outlet sub cooling is 3 C 5 C IT IS IMPORTANT TO CARRY OUT CHARGING CORRECTLY An excess of refrigerant causes an increase in sub cooling and consequent operating difficulties in the hot season a shortage of charge generates an increase in superheating and possible compressor stoppages Whenever work is carried out on the unit ensure afterwards that the working conditions are correct checking sub cooling and superheating 5 2 Oil charge Contact the Technical Support Department for the specifications ofthe oil to be used for topping up the oil changes according to the type of used refrigerant NEVER MIX DIFFERENT OILS TOGETHER CLEAN THE PIP ING COMPLETELY BEFORE CHANGING THE TYPE OF OIL USED TOP UPS OF UP TO 20 30 OF THE TOTAL AMOUNT OF OIL CONTAINED IN THE COMPRESSOR CRANKCASE ARE PERMITTED FOR LARGER PERCENTAGES CONTACT THE TECHNICAL SUPPORT DEPARTMENT 5 2 1 Procedure for oil topping up If there has been any loss of oil then this must be topped up as follows 1 Take a clean dry transparent container with volume cal ibrations and fill it with at least twice the amount of oil re quired 2 Isolate the compressor by closing
26. ade com as directivas Europeias Tillverkare forsakrar harmed att denna produkt 6verensstammer med Europeiska Uniones direktiv De Fabrikant verklaart dat dit produkt conform de Europese richtlijnen is Vaimistaja vakuuttaa taten etta tama tuote tayattaa seuraavien EU direktiivien vaatimukset Produsent erklaerer herved at dette produktet er i samsvar med EU direktiver Fabrikant erkl rer herved at dette produkt opfylder kravene i EU direktiverne Koxaokevaoujc Snover ott to kovaokevaou vo ue vc tng E E 98 37 CE 89 336 CEE 73 23 97 23 Since the Liebert HIROSS Company has a policy of continuous product improvement it reserves the right to change design and specifications without previous notice Zona Industriale Tognana Via Leonardo da Vinci 16 18 HIROSS 35028 Tel 39 049 9719111 p ss Telefax 39 049 5841257 Tn www liebert hiross com A Liebert HIROSS EMERSON is a division of EMERSON Network Power lt a P Wa P O x E del e gt E B E 215 o gt ES 5 5 a 2
27. akage of the compressor as a result of pres sure shock If the superheating is too high the output of the system is limited and the compressor overheats 7 Maintenance The Maintenance Programme below must be carried out by a qualified technician preferably working under a maintenance contract Before any intervention on the unit or accessing the inner com ponents removing the outer panels always ensure the ma chine is switched off If the front upper panels are removed coil compartment wait for the fan s to come to a complete stop be fore accessing the compartment if the front lower panels are re moved pay special attention when working near the com pressor upper part and the discharge line they are very hot possibly wait for them to cool Be very careful when operating close to the finned coils as the fins are very sharp Do notremove the fan protection grille before electrically isolating the whole machine Do not insert foreign matter through the fan protection grille After the maintenance interventions always close the unit with the suitable panels fastened by the tightening system Maintenance programme Monthly check 7 1 Spare parts The use of original spare parts is recommended When placing an order refer to the Component List enclosed with the machine and quote the unit model no and serial no 7 2 Dismantling the unit The machine has been designed and builtto ensure continuous operation
28. arate from the unit Technical data e Internal volume 1000 litres Net weight 400 kg e Working weight 1400 kg Tab 1 Internal hydraulic volume 017 020 023 025 028 030 032 017 020 023 025 028 030 032 017 020 134 023 025 164 028 170 030 032 203 017 020 134 023 025 164 028 194 030 032 166 017 020 023 025 028 030 017 020 156 023 025 188 028 157 030 166 Add the tank s volume for the units with optional buffer tank Tab 2 Partial heat recovery 20 2 96 3 25 3 77 19 16 17 2 Working conditions outdoor temperature 35 C water inlet outlet 12 7 Chiller versions glycol mixture 30 inlet outlet 15 10 C SuperChiller versions Heat recovery conditions water inlet outlet 40 45 C Tab 3 Total heat recovery 100 020 023 025 028 030 032 238 290 320 357 412 453 Us 11 37 13 86 15 29 17 06 19 68 21 64 82 83 DN inch DN80 3 Working conditions water inlet outlet 12 7 C Chiller versions Heat recovery conditions water inlet outlet 40 45 Tab 4 Noise levels The following table indicates the overall sound pressure level at full load conditions measured 1m from the unit according to ISO 3774 with an outdoor temperature of 35 C and referred to free field conditions Total sound level sound level dB A dB A 63 CLH SLH 017 020 Total sound level dB A C
29. d head pressure pump Opt 65 190 2 65 230 2 65 260 2 Std head pressure pump motor max power 2 2 3 0 4 0 Std head pressure pump max current 4 45 5 95 8 00 High head pressure pump model Opt 65 260 2 65 260 2 65 340 2 High head pressure pump motor max power 4 0 4 0 Hight head pressure pump max current 8 00 8 00 gt gt amp gt gt gt gt gt 1 Outdoor air temperature 35 C water inlet outlet temperature 12 7 C CLH R 407C 400 V 3 Ph 50 Hz 7 FLA LRA Compressors power input 7 Compressors nominal current 7 Compressor max current Fan power input Fan nominal current Fan max current Std head pressure Opt 65 190 2 65 230 2 65 260 2 Std head pressure motor power 2 2 3 0 4 0 Std head pressure pump current 4 45 5 95 8 00 High head pressure pump Opt 65 260 2 65 260 2 65 340 2 High head pressure pump motor max power 4 0 4 0 2901 head pressure current 8 00 8 00 1 Outdoor air temperature 35 water inlet outlet temperature 12 7 R 407C Power supply 400 V 3 Ph 50 Hz OA 7 FLA LRA Compressors power input 7 Compressors nominal current 7 Compressor max current Fan power input Fan nominal current Fan max current gt gt gt gt Std head pressure pump model Opt 65 190 2 65 230 2 65 260 2 Std head pre
30. emaining portion of the phase change can thus take place in finned coil without inter rupting the recovery process through the intervention of the ma chine safety devices Ifthe plate exchanger is supplied with too cold water or if the sy stem is not preset by the installation technician with a three or two way proportional adjustment valve for the exchanger by pass indispensable for cold starts see following Recom mended hydraulic circuit the condensing pressure tends to decrease too much a prolonged condition of low condensing temperature below the safety threshold leads the Microface mi croprocessor control to disable the heat recovery protecting the system from any possible malfunctioning Fig e Recommended hydraulic circuit B Heat recovery i Heat recovery users exchanger lt 4 8 4 Hydraulic circuit accessories Made up of an expansion vessel pre charged at 1 5 bar max operating pressure 10 bar and a safety valve set at 5 bar Their position in the hydraulic circuit is illustrated in Fig 10 Fig 11 e Expansion vessel volume 12 litres for all units It is recommended that the total required expansion vessel ca pacity is always checked depending on the unit s internal hy draulic volume with the volume of the buffer tank if installed the user circuit volume the glycol percentage in the mixture and the expected maximum temperatu
31. enta tive 1 4 General description MATRIX S units with air cooled condensers have been designed and manufactured for producing chilled water They are also available in versions with a built in freecooling module in versions with heat recovery for simultaneous heating of thermal circuit water with a pump assembly installed on the machine and or inertial buffer tank inside the machine the chill ing units can be equipped with several options indicated in the price list The MATRIX 5 product line has been designed utilising the state of the art techniques available nowadays in the indus try and includes all the components necessary for automatic and efficient operation Each unitis completely factory assembled after evacuation the necessary quantity of refrigerant is added to the refrigerant cir cuit s and the unit is tested Alltheunits are equipped with one ortwo independentrefrigerat ing circuits each one composed of an air cooled condenser a hermetic Scroll compressors and a braze welded plate evapo rator The components ofthe liquid line are the charging valves filters dryers solenoid valve shut off valve moisture indicator and thermostatic expansion valve The hydraulic circuit with max working pressure 5 bar is made up of carbon steel pipes connected with grooved end Victaulic fittings and couplings and include also a flow switch optional and in the freecooling versions chi
32. er standard operating conditions check that the limits indicated in paragraph 2 1 are not exceeded 8 Check the correct operation of the control and safety de vices 9 Check the outlet temperature of the chilled water check if the set point set on the controller is reached 10 Check the oil level in both compressors 11 With the compressors at full load check there are no bubbles visible in the frefrigerant sight glass If there are any charge the unit according to par 5 4 3 Starting and stopping ALWAYS ENSURE THAT THE COMPRESSOR OIL HAS BEEN PREHEATED FOR BRIEF STOPPAGES MAINTAIN THE SUPPLY TO THE CRANKCASE HEATER e Start the unit setting the Microprocessor switch ON Stop the unit setting the Microprocessor switch OFF Incase of long stops turn the machine off using the Micro processor switch OFF In this case the compressor crankcase heaters remain pow ered For seasonal shutdown of the unit operate the main switch located on the main electrical power supply This will discon nect the compressor crankcase heaters 4 4 Chillers serving special plants The units are capable of cooling a water glycol mixture to tem peratures close to 0 C withoutthe need for significant modifica tions In the case of modification the set values ofthe safety and control components must also be changed This can be carried out in the factory atthe time of testing or at the time of installa tion only b
33. h pressure switch 2 High pressure safety valve Low pressure switch 2 With nominal air flow mixture flow outlet at 10 full load 13 Tab 8 Pump set characteristics opt 2 pole pump set standard head pressure data refers to each pump Water flow CBH Available head pressure Water flow CLH Available head pressure Water flow Available head pressure Pump quantity Pump rotor model Nominal motor power Noise level Pump weight Water flow Available head pressure Water flow Available head pressure Water flow Available head pressure Pump quantity Pump rotor model Nominal motor power Noise level Pump weight 30 glycol water mixture flow Available head pressure 30 glycol water mixture flow Available head pressure 30 glycol water mixture flow Available head pressure Pump quantity Pump rotor model Nominal motor power Noise level Pump weight 30 glycol water mixture flow Available head pressure 30 glycol water mixture flow Available head pressure 30 glycol water mixture flow Available head pressure Pump quantity Pump rotor model Nominal motor power Noise level 7 Pump weight According to ISO 3744 017 26 88 29 22 119 107 26 92 29 32 119 107 27 01 29 39 119 106 1 2 1 2 65 190 2 2 2 2 2 60 57 9 116 4 017 26 88 29 22 197 187 26 92 29 32 197 186 27 01 29 39 197 186 Ne 1 2 023 36 76 130 36 81 130 36 38 133 1 2
34. ight glass is higher than the min value Ensure that there are no water leaks Bleed any air out of the hydraulic circuit using the bleed valves Verify that the water flow rate is correct CHILLED WATER CIRCUIT Check the inlet outlet liquid temperature and pressure Check the correct operation of the three way valve Versions with free cooling only Check if the system is charged with the specified glycol percentage and that no ice has formed in the hydraulic circuit Check the evaporator cleanliness 8 Options and Accessories 8 1 Pump set The centrifugal pump units are direct driven with close coupled motors and a single shaft the induction motor has 2 poles with IP 55 protection and class F insulation Pump casings and impellers are in cast iron EN GJL 200 shafts are in stainless steel the shaft seal is a unbalanced mechanical shaft seal with dimensions according to DIN 24 960 and assem bly length according to EN 12 756 brass neck ring permits ideal conditions for the use of water mixtures containing ethylene gly col The pump housing the motor stool and the motor stator housing are electrocoated The pump units have been chosen and sized to operate within specific limits namely Water ethylene glycol mixtures up to 65 35 by weight Temperatures of the standard pumped fluid not lower than 4 C The motor stool forms connection between the pump housing and the motor and is equi
35. indications in Fig b for the correct sizing Note TRenydraulic circuit must ensure a constant water supply to the evaporator in every operating condition Otherwise the com pressors may be damaged by repeated returns of liquid refriger ant on their suction Note The water flow switch is a compulsory safety component that must be installed and correctly wired to the Matrix S chillers otherwise the guarantee will be invalidated It is installed as standard on units with the optional on board pump set and is available as a option for units without pumps on board in the latter case the flow switch if not installed on the machine can be installed on the hydraulic circuit by the installer but it is compulsory that it is wired to the electric panel terminal board as indicated on the wiring diagram 3 1 2 Addition of water and ethylene glycol Very important Add water and ethylene glycol to the circuit with a depending on the minimum temperature of the outside air expected at the installation site Do not exceed the nominal operating pressure of the circuit s components Notes oavoid stratification run the circulation pump for at least 30 minutes after adding any glycol After adding water to the hydraulic circuit always discon nect the water supply coming from the sanitary supply this avoids the danger of glycol entering the sanitary water system After any topping up of the water check the concentrati
36. lled water coils and a three way valve The hermetic scroll compressors are complete with the following protection safety devices oil heater electronic protection moni toring the temperature of the motor windings and the direction of rotation the latter may be enclosed in the electronics of the compressor or external depending onthe model The MATRIX S water chillers are controlled by the MICROFACE micropro cessor managing all the unit operating conditions The user can change and or modify the operating parameters through the di splay keyboard installed on the electrical panel The electrical control board is equipped with all the safety and operating devices required for reliable operation The compres sor motors are equipped with protection on all three phases and are started by three pole contactors 2 Preliminary Operations 2 1 Operating limits The units can operate within the indicated operating ranges see Tab 7 These limits apply to new machines subject to correct installation and maintenance Ambient air minimum temperature 25 for Superchiller 15 C for Chiller without fan speed control Operation al lowed only in summer mode 10 C for Chiller with contin uous fan speed control Either Triac or EC fan Maximum outdoor air temperature is in relation to each mod el as indicated in Tab 7 In any case outdoor temperatures aver 45 C are not admitted such limits are determined b
37. nge mentofthe specific equipmentforthe correct installation opera tion and maintenance in compliance with the local regulations in force The MATRIX S 017 032 water chillers can be identified as fol lows CBHO23 Cooling Capacity kW Nominal cooling capacity x 10 Compressor H Scroll Version B Base L Low Noise Q Quiet Execution C Chiller S Superchiller 1 2 Responsibility Liebert Hiross accepts no present or future responsibility for damage to persons things orto the machine itself due to opera tors negligence failing to comply with the installation operation and maintenance instructions of this handbook failed applica tion of the safety norms in force for the system and the qualified staff charged with the operation and maintenance 1 3 Inspection All units are fully assembled and wired in the manufacturing plant Before shipment they are charged with the necessary quantities of refrigerant and oil and then tested at the operating conditions normally required by the customer The machine s hydraulic circuit is equipped with drain plugs and open vent valves the freecooling coils are supplied dry to avoid possible problems due to frost in the storage period Immediately inspect the machine carefully on delivery to check for damage during transportation or missing components possible claims must be made immediately to the carrier and the factory or its repres
38. ns The highest noise levels are detected on the condenser coil side Note Avoid positioning in areas with possible reverberation of the sound waves which can adversely effect the noise levels 2 3 Transport Handle the unit by lifting it with a crane from above Thelifting holes are positioned in the frame s base when lift ing use spreader bars to protect the sides see Fig 2 Note Place the lifting tubes in the holes in the base indicated by LIFT HERE Lock the ends of the tubes with the locking pins and splits pins as shown in Fig 2 The capacity of the lifting gear must be adequate to lift the load in question Check the weight of the units the capacity of the lift ing gear and ropes and the condition and suitability of the afore mentioned equipment 2 4 Foundations e The unit must be placed on a level surface which will support its weight fnecessary position the unit on suitable anti vibration sup ports that can be supplied as an option in rubber or spring type Refer to the manual Installation of the spring anti vibration supports for their correct positioning When positioned level the unit Note For weight distribution see Fig 3 Note ne weights and their distribution refer to standard units without options if the pump assembly or other options are installed on the machine add the weights of the installed accessories to those of the standard units see Tab 8
39. on and add glycol if necessary 3 1 3 Water glycol mixture Water glycol mixtures are used as the thermal carrier fluid in very cold climates or with temperatures below zero degrees cen tigrade Determine the ethylene glycol which must be added to the water with the assistance of Tab a Ethylene glycol to added to water in weight of total mixture Ethylene glycol in weight Ge pers 2 EA Mus Gensity at 1 017 1 083 1 048 1 064 1 080 20 i Values are for Shell antifreeze 402 For different brands check manufacturer s data For the chiller internal water volume refer to Tab 1 If the optional buffer tank is installed on the machine add the tank hydraulic volume ALWAYS CHARGE THE HYDRAULIC CIRCUIT WITH THE RE QUIRED GLYCOL NECESSARY FOR THE MINIMUM AMBI ENT TEMPERATURE AT THE INSTALLATION SITE FAILING TO COMPLY WITH THIS INSTRUCTION SHALL INVALIDATE THE UNIT WARRANTY 3 2 Connection of the safety valve discharge Safety valves are installed on the high pressure side of the refrig eration circuit the discharge of these valves must be conveyed outside through a suitable pipe having a diameter of at leastthat of the valve outlet without burdening the valve body Convey the discharge to areas where the jet cannot harm people and the surrounding environment Fig a Ideal chilled water circuit IBN CHILLER
40. pped with a manual air vent screw for venting of the pump housing and the shaft seal chamber It is very important carry out this operation as the circulation of liq uid through the duct of the air vent screw ensures lubrication and cooling of the shaft seal Between the outlets of the two chambers and the discharge flange twin head pumps have a non return flap valve in EPDM rubber The flap is opened by the flow of the pumped liq uid and cuts off the port of the idle pump chamber In the electrical panel there are automatic circuit breakers for each pump the microprocessor control manages the operating rotation between the two pumps and start up of the stand by pump if the primary pump fails For the technical features of the pumps and the hydraulic sche matic see Tab 8 Fig 10 and Fig 11 8 2 Water chiller with partial heat recovery 20 This option enables the recovery of up to 2096 ofthe heat normal ly rejected by the condensers see Tab 2 The system does not require any adjustment and is made up of plate heatexchangers installed on each circuit before the condenser The exchangers are protected by a suitable anti frost heater that operates when the system is stopped It is recommended that a safety valve be installed in the hydraulic circuit to avoid hazards due to overpres sures if there is no water flow through the recuperator The water temperature at the recuperator inlet in stable operat
41. re charge pressure typical value Pf absolute final tolerated pressure lower than the operating pressure of the safety valve calibration Use the values of the water expansion coefficient indicated in the table below 3 Do j ________ 3 3 Electrical connections 1 Before proceeding with the electrical connections ensure that all electrical components are undamaged all terminal screws are tight the supply voltage and frequency are in accordance with the rating with tolerance in accordance with IEC 8 6 norms March 1990 the allowed phase to phase variability is 3 maximum see Fig d Variability in excess of 3 invalidates the guarantee 2 Supply cable connections see Tab 6 e Connect the cable to the supply terminals Use appropriately sized 3 pole cable An earth wire must also be connected After having opened the passage in the framework pre punched knock outs for the supply line entry restore the original degree of protection using suitable accesso ries for the wiring and junction boxes Fig d Example of calculating phase to phase variability 1 The 400 V supply has RS T the following variability RS 388 V ST 401 V RT 402 V The average voltage is 388 EI 402 397 The maximum deviation from the average is 402 397 5V The phase to phase variability is 5 397 x 100 1 26 acceptable Note he power supply should ne
42. re variation of the mixture The water flow switch is a compulsory device protecting the unit It is installed as standard on units with the optional on board pump set and is available as a option for units without pumps on board in the latter case the flow switch if not installed on the machine must be installed on the hydraulic circuit by the install er and wiredto the electric panelterminal board as indicated on the wiring diagram 8 5 Water chiller with inertia tank The machine can be supplied complete with a buffer tank it per forms the inertial stabilizer function for a better compressor op eration summed up in the following two points itreducesthe frequency of the compressor start up and con sequent high current peaks which is higher when the sy stem thermal inertia is lower improving their performance itnaturally eliminates the operation troubles caused by sud den load variations shown by variations of the chilled water temperature The buffer tank is supplied complete with manometer and tem perature sensor well air purge valve discharge valve and sink ing connection for electric heaters max operating pressure 6 bar Built in carbon steel and coated with anti condensate in sulation with PVC film proper for outdoor installation It is installed inside a cabinet which can be supplied either already connected to the unit mechanically and hydraulically jointed to it or loose completely sep
43. reas top view Ordinary maintenance area Extraordinary maintenance area Notes Minimum distance between 2 units from condensing coil side 3 m Do not obstruct the air exiting the fans for a minimum distance of 2 5 m 1500 AIR 1500 1000 1000 Fig 2 Lifting instructions with tubes N B PROTECTION PLANK RIGID STRUTS POSSIBILY STEEL BELT OR CHORD BLOCKING PEG NOT SUPPLIED SPLIT PIN NOT SUPPLIED LIFTING TUBE NOT SUPPLIED BASE HOLES 0256 Place the lifting tubes in the holes in the base indicated by the words LIFT HERE Lock the ends of the tubes in position with the locking pins and split pins as shown above The capacity of the lifting gear must be adequate to lift the load in question Check the weight of the unit the capacity of the lifting gear and ropes and the condition and suitability of the aforementioned equipment Lift the unit with a speed suitable for the load to be moved so as not to damage the structure Lifting Models m CBH CLH 017 020 023 025 028 030 032 017 020 023 025 028 030 18 5 0 9 0 SBH SLH 017 020 023 025 028 030 032 SQH 017 020 023 025 028 030 16 Fig 3 Support positions and loads
44. s an optional accessory Not fitted 8 Install at the highest points in the circuit apparatus which allows the bleeding of air and possibly the filling of glycol 9 Place a drain valve at the lowest point in the circuit and im mediately at the outlet of the water chiller 10 Install a water filling set including the following a filling water meter b manometer C non return valve d air separator e removable supply tube which must be disconnected after each charge top up 11 For maximum protection ensure that all tubing exposed to low outdoor temperatures is fitted with anti freeze heaters and insulated using closed cell synthetic rubber elasto mer 12 The circuit must include an expansion vessel with safety valve of suitable capacity 13 Connect the lines avoiding stresses on the machine inner parts Note If the water chiller is complete with an expansion vessel sup plied as an option check if the capacity is enough and install a second vessel in the circuit if required see par 8 4 Follow the indications in Fig c for the correct sizing Note he whole circuit must contain a water volume suitable for the capacity of the installed chiller Check if the inertial capacity giv en by the sum of the hydraulic volume inside the machine in cluding the volume of the optional interna tank if fitted and the system volume is sufficient or possibly install a tank in the circuit Follow the
45. ssure pump motor max power 2 2 3 0 4 0 Std head pressure pump max current 4 45 5 95 8 00 High head pressure pump model Opt 65 260 2 65 260 2 65 340 2 High head pressure pump motor max power 4 0 4 0 High h head pressure pump max current 8 00 8 00 1 Outdoor air temperature 35 C water inlet outlet temperature 12 7 C 11 SBH R 407C So om os 025 osz LT A m LE OA 7 FLA LRA Compressors power input 1 Compressors nominal current 1 Compressor max current Fan power input Fan nominal current Fan max current Std head pressure pump model Opt Std head pressure pump motor max power Std head pressure pump max current High head pressure pump model Opt High head pressure pump motor max power e head pressure pump max current 65 260 2 4 0 8 00 5 340 2 1 Outdoor air temperature 35 30 glycol water mixture water inlet outlet temperature 15 10 C SLH R 407C Power supply OA 7 FLA LRA Compressors power input 7 Compressors nominal current 1 Compressor max current Fan power input Fan nominal current Fan max current Std head pressure pump model Opt Std head pressure pump motor max power Std head pressure pump max current High head pressure pump model Opt High head pressure pump motor max power High head pressure pump max current Electrical cable section min 65 260 2 4 0 8 00 65
46. t Department e Charge with the compressor in operation connecting the cylinder with the charge connector after the thermostatic ex pansion valve Flush the connection pipe between the cylinder and the charging point tighten the seal joint and then start charging the unit Itis imperative that the cylinder is weighed both be fore and after the operation For the units with R407C the refrigerant charge must made exclusively with liquid refrigerant e Charge the unit until the bubbles in the sight glass have dis appeared and the working conditions of the entire refrigera tion circuit have returned to normal sub cooling and su perheating within the limits indicated below Measure the superheating as follows 1 Detect the temperature on the suction line close to the bulb of the thermostatic expansion valve using a contact thermometer 2 Connecta pressure gauge by max a 30 cm pipe with the Schraeder connection and read the corresponding saturated evaporating temperature 3 The superheating is the difference between the two readings 4 For the units with R407C refer to the pressure gauge scale indicated with the initials D P Dew Point Verify that the superheating is 5 C 8 C e Measure the sub cooling as follows 1 Detectthe temperature on the liquid line using a contact thermometer 2 Connecta pressure gauge by max a 30 cm pipe with the Schraeder connection on the liquid line and re
47. t the refrigerant shut off valve is properly sealed see Fig 9 4 Open isolating valves and or water ball valves 5 Incase of climates with temperatures below zero degrees C make sure the chilled water circuit is filled with the correct concentration of water glycol 6 Bleed all air out of the chilled water circuit 7 Verify the water flow rate and its direction 8 Ensure that the thermal load is sufficient for start up Caution The ambient air temperature probe must be positioned in the shade and protected against the weather 4 2 First start up or after long stop Operate as follows 1 At least 8 hours before the start up power the crank case heaters by setting the main isolator switch ON Make sure the auxiliary circuit has been powered and check the operation a fault due to an incorrect proce dure will invalidate the compressor guarantee 2 Open the valves of the refrigeration circuit that had been closed before the initial check 3 Check the machinery supplying the thermal load connected with the unit and start the system pump s 4 MAKE SURE THE COMPRESSOR OIL HAS BEEN HEATED FOR AT LEAST 8 HOURS start the unit only then 5 Make sure the fans rotate in the correct direction anticlock wise check the electrical connections if necessary 6 Make sure the pumps rotate in the correct direction During the unit start up an inlet water temperature higher than 20 is allowed Und
48. ver be disconnected except when performing maintenance Operate open the main switch before carrying out any mainte nance work on electrical components Note It iS forbidden to work on the electrical components without using insulating platforms and in the presence of water or fog or mist Note The supply to the external pump assembly must be made before starting the chiller and must be kept on as long as the chiller is in use Incorrect operation will cause the unit to lock out be cause of the internal protections flow switch intervention Note The compressors are equipped with an electronic protection de vice blocking their start if the phase sequence is not correct or stopping their operation if a thermal relay intervenes This device is essential for the integrity of the mechanical and electrical com ponents of the compressors Reset the standard functions by isolating this device and removing the causes of the lock out Note Chillers are equipped with their own microprocessor control adjustment The use of the remote ON OFF input located in the electric panel terminal board as a system temperature con trol element is forbidden 4 Start Up and Operation 4 1 Initial check 1 Check all water connections 2 Open the shut off valve on the liquid line 3 Ensure that the intake pressure is higher than 4 0 bar if this is not the case prolong pre heating of the compressor if possible and check tha
49. y electrical and electronic components fitted on units e Maximum water flow allowed depending on the pressure drop corresponding to the required thermal difference usu ally not lower than 3 5 C 4 C e Minimum allowed water flow compatible with a sufficient evaporation temperature to avoid the intervention of the safety devices to be evaluated for a thermal difference not higher than 870 Temperature range of the water exiting the evaporator 4 C 15 C Maximum temperature of the water entering the unit 20 C higher temperatures are allowed only at the system start up and not during normal operation e Maximum glycol concentration 50 35 with the optional pump assembly installed on the machine e Minimum allowed glycol concentration depending on the minimum temperature of the ambient air expected at the installation site see Tab a Maximum pressure of the hydraulic circuit 5 bar Voltage range for the electric supply 400 V _10 max phase difference 3 tolerance on frequency 196 Storage conditions from 20 C to 45 C for all MATRIX S mod els Note Avoid positioning in areas with strong dominant winds that may impair the operation and effect the indicated limits 2 2 Sound pressure levels The Tab 4 shows the noise data for the units in standard config uration without pumps operating continuously and measured according to the ISO 3744 norm in free field conditio
50. y qualified and authorised personnel 4 5 Freecooling The freecooling is a system of pre cooling and or cooling the water glycol mixture using ambient air when the latter is ata tem perature below the return mixture temperature If the outside temperature is sufficiently low to dissipate the entire heat load the refrigeration compressors automatically switch off and the mixture s temperature is controlled by the fan speed adjust ment If the mixture temperature is too high for freecooling the com pressors will operate as long as necessary to ensure the correct water glycol mixture temperature 4 6 Microprocessor control Consult the Microface and Hiromatic Service Manual 5 Refrigerant and Oil Charge All work on pipes or components of the refrigerating circuit un der pressure must be exclusively carried out by qualified staff competent in such works 5 1 Refrigerant charge WHILST REPAIRING THE REFRIGERATING CIRCUIT RE COVER ALL THE REFRIGERANT IN A CONTAINER DO NOT ALLOW IT TO ESCAPE NEVER USE THE COMPRESSOR FOR THE SYSTEM VACUUM THIS INVALIDATES THE WARRANTY The unit is delivered charged according to the Tab 5 Warning for the refrigerant charge Ensure there are no refrigerant leaks Check the refrigerant type in the refrigeration circuit a unit originally charged by the manufacturer with R407C cannot be charged with R22 and vice versa possibly apply to the Technical Suppor
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