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Contents
1.2. 5 2
3. 9 1 2
4. Il
5. 1 2 2 1 3
6. 5 2 5 2 1 Noise The unit generates noise while it s working do not install it in reverberating rooms The unit must be positioned with the coil sid
7. VII VI
8. 1 INTRODUCTION 1 1 GENERAL INFORMATION This manual contains the installation use and main tenance instructions for the CHA chillers and high lights all connected risks and perils Ithas been express ly prepared and written to allow authorised users to use the CHA water chillers in complete safety and with the greatest of ease Please read the whole of this manual with care paying special attention to the sections marked with as non compliance may cause harm to people deterio rate the environment and or damage the unit The company declines all responsibility fo
9. A 7 OPERATION 7 1 GENERAL Start and stop the unit with the ON OFF button lo cated on the microprocessor cover The compressors and fans will automatically start and stop depending on the temperature of the water returning from the unit while the circulation pump will remain working continuously If a fault should occur the unit will totally or partially block and will give an alarm signal the microproces sor display will indicate which safety device was ac tivated Before resetting the unit the reasons for the block must be identified and eliminated Some safety devices must be reset both physically and from the keyboard These operations must be carrie
10. all operating conditions As the demand for cooling by utilities does not generally coincide with what is delivered by the compressors they often work intermittently In units with a low water content where the effect of thermal inertia is not felt so much the system should be checked to make sure it satisfies the following relation gt 115 where V volume of water litres P power capacity of the unit Watts number of capacity steps If the above volumes are not obtained a storage tank should be installed so as to satisfy the above relation when added to the capacity of the system This tank requires no special features it just needs to be isolated just like the chill
11. disconnected from the mains power supply Please note that some surfaces inside the unit may be hot piping compressor etc cold compressor suction separator etc sharp coil fins or moving fans even when the unit is not working These operations may only be carried out by qualified staff wearing safety clothing
12. 2 3 2 2 INTENDED USE The CHA series of air condensation chillers have been designed to cool water possibly containing inhibited ethylene glycol circulating in a closed circuit The heat pump units can cool or heat the water in the closed circuit depending on which operating cycle is chosen The heat recovery units can also heat the water circulating in a second closed circuit The heat or cold produced can be used for air conditioning systems or industrial processes 2 3 CONTRAINDICATIONS Do not use inflammable products near the unit Do not use substances that can form explosive mixtures near the unit
13. 18 4 K 5 K 5 7
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15. 9 1 and consequently damage them Start the unit and make sure the following happens indications between brackets refer to units with heat pumps working in the heating cycle mode First start the pump and if the temperature of the returning water is high low enough the compressors and fans will start up automatically after about a minute When the temperature of the water returning from the unit decreases increases the compressor will step down capacity or stop in sequence The fans will stop together with the last compressor while the water circulation pump will remain operating When the temperature of the water returning from the unit increases decr
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17. 9 2 Verify the deep closing of the fuses holder cover Inspect the liquid and moisture indicator to make sure the right quantity of refrigerant is contained in the circuit Make sure that no oil is leaking from the compres sors Make sure that no water is leaking from the water circuit Drain the water circuit Make sure the flow switch water differential pres sure switch works correctly Check the heating elements in the compressor Clean the metal filters the water pipes Clean the finned coil and the relative metal fil ters if present by directing a jet of compressed air in the opposite direction from that of the air flow If the filters are very clogged use a jet of wa ter instead Check that the unit doesn t make any unusual noi
18. 10 VII VII VII Tbpa OTHOBO C
19. 5 3 2 Electrical connections to the circulation pump The circulation pump must always be connected to the unit control system as shown on the wiring diagram The pump must be started up before starting up the chiller while it must be stopped after the chiller has stopped minimum recommended delay 60 60 5 3 3 CbC 3a
20. 30 1 5
21. IV V 5 VI VII V 1
22. 3 5 2 Ha R407C R410A R134a Mepku 15
23. 8 10 5 2 2 WATER INLET Attention The water pipes must suitably supported with brackets in order not to weigh on the chiller Connect the pipes to the chiller with flexible joints in order to prevent the transmission of vibrations and to compensate thermal expansion Install the following components on the pipes shut off valve moisters for shutting off the water mains temperature and pressure gauges for routine maintenance and inspection purposes e check points on the inlet and outlet pipes for measuring temperatures if temperature indicators are not fitted metal filter inlet pipe with a maximum mesh aperture of 1 mm to protect the exchanger from waste or impurities in the pipes relief v
24. 2 4 GENERAL DESCRIPTION All the unit structures are made from galvanised sheet metal and are further protected with polyester powder paints The structure is free standing and the panels are easy to remove in order to allow access to the inside of the unit for maintenance and repair operations The functional diagrams and the components used are attached to this manual 3 SAFETY 3 1 DEFINITION This document uses the following definitions Dangerous areas any area inside and or near to the unit in which the presence of a person would give rise to a risk for that person s health Exposed person anyone who is wholly or partly inside a dangerous area Operator Maintenance man person or persons authorised to operate adjust service repair or move the unit eee CLINT 3 2 3 2 GENERAL 9 31 KbM
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26. 3 3 MOCT SAFETY REGULATIONS It is forbidden for unauthorised persons to approach the unit Scrupulously observe the contents of Chapter 9 on page 31 before carrying out each maintenance operation on the unit It is forbidden to enter the unit Access is only permitted to qualified staff when the unit is disconnected It is forbidden to remove safety guards and bypass safety and emergency devices It is forbidden to stand on the unit Only use the unit to do what it was built for The manufacturer declines all responsibility for damage deriving from improper use or technical modifications made to the unit Check the safety devices are in perfect working order on a regular basis Do not dismount modify or disconnect unit parts When working on the unit only use suitable tools and equipment in good condition Operators must wear normal personal protection equipment gloves helmet goggles etc Work on the electrical system of the unit may only be carried out by a qualif
27. A es 44 UNPACKING Only unpack the unit when it has reached the installation site and no longer needs to be moved Remove the packing material with care making sure not to damage the unit Given that various kinds of packing materials are used wood nylon polystyrene cardboard etc they should be separated and delivered to specialised disposal and recycling companies for environmental reasons 5 INSTALLATION 5 1 CHOOSING THE INSTALLATION SITE When choosing the installation site the following points should be considered The weight of the unit The supporting surface under the unit must be perfectly horizontal and able to withstand its operating weight 10 15 20090
28. 2 1 2 1 1 r Xe 1 INDUSTRIAL LOIN 938 ae 33050 Onde 1 Fax 39 0432 773855 E mail info pciint it Modello Model Matricola Serial number Alimentazione di Potenza Main Power Corrente massima assorbita Max absorbed curent Schema elettrico n Wiring diagram Nr nominale di chiusura in cortocircui
29. 4 u8 K 10 minutes if this is not the case unit inertia must be increases After afew operating hours check that the crown of the liquid and moisture indicator shows a dry circuit Make sure there are no bubbles inside the liquid indicator Bubbles indicate there is not enough re frigerant liquid in the circuit though a few bub bles are accepted A few minutes after the compressor start during the summer operating cycle make sure the con densation temperature is 18 4K higher than the temperature of the air entering the condenser
30. Less space will make it difficult or impossible to carry out maintenance operations and or lead to faults in the unit due to the reduction in the air flow on the condenser coil or its recirculation Please note that obstacles such as can opies shelters or coverings in general are not permitted Mona Please note that heat pump units cause ice and condensation to form and drain onto the floor in front of the unit This water must therefore be collected and drained to prevent the floor from becoming slippery People may not enter the unit area unless they are authorised operators and maintenance personnel He a
31. 3 5 13 Do not use the unit in conditions that could be harmful for the environment see point 3 5 on page 13 24 3 3 1
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33. IV
34. Asupporting surface with an appropriate areashould be built Thisis particularlyimportantifthe unitisinstalled on unstable ground gardens embankments etc The supporting surface must on suitable foundations be about 10 15 cm higher than the surrounding ground horizontal and able to withstand about 200 of the weight of the unit in operation suitable sealed layer of cork should be placed along the perimeter 15 lt lt CLINT IMATIZZAZIONE INTEGRATA Spaces Make sure that sufficient free space as indicated on the technical book is left around the unit
35. 3 5 1 Residue risks near the unit Electrocution if the unit is not properly corrected to the mains power supply and earth circuit Cuts or abrasions caused by sharp surfaces Extraction and subsequent dispersion in the envi ronment of substances present in the installation Site Ejection of objects falling on the fan blades Leaking water in case of malfunction Formation of condensation and ice in front of the unit while the unit heat pumps are working Alteration of the micro climate during operation Noise during operation Leaking oil in case of malfunction Leaking refrigerant liquid in case of malfunction N B Refrigerant liquid is a substance which causes a greenhouse effect Its vapours are heavier than air and can cause suffocation by reducing the amount of oxygen available for breathing Rapid evaporation of the liquid can cause freezing to occur 3 5 2 Measures to take in case of leaking refrigerant gas Product type R407C R410A 134 First aid measures General information Do not give anything to people who have fainted Inhalation Take the person out into the open air Use oxygen or artificial respiration if necessary Do not give adrenaline or similar substances Contact with eyes Carefully rinse with abundant water for at least 15 minutes and see a
36. 6 4 OFF ature and moisture of the external air condensation or frost will form The frost accumulated on the coil obstructs the air inlet thereby reducing air flow and the heat transfer rate The heat pump units are fitted with control devices that automatically defrost the coil whenever nec essary This control device features a temperature probe placed on the coil which when the tempera ture is equal to or lower than the set point activates the defrost cycle function which will take place only if a certain time default setting 30 minutes has elapsed since the last defrosting process Defrosting takes place as follows indications be tween brackets refer to units with condensation con trol the fans stop the operating cycle is inverted with the 4 way valve thereby making the finned coil work like a condenser The cond
37. Before carrying out any operations on electrical components make sure the unit is disconnected from the mains KbM CbC
38. 9 1 1 9 1 The unit should be controlled periodically to make sure it works correctly The controls that should be made on a monthly and four monthly basis are de scribed below Furthermore if the unit is not expect ed to be used for a long period and if the room tem peratures are lower than the fluid freezing point the fluid should be drained from the piping and the heat exchangers unless there are suited antifreeze kits 9 1 1 Monthly controls Make sure the terminals in the electrical panel and in the compressor terminal board are well tightened Check the fixed and mobile contacts of the contactors and replace them if they are worn Make sure no oil is leaking from the compressor CLIMATIZZAZIONE INTEGRATA
39. 5 3 2 5 3 3 5 3 4 seconds 5 3 3 External signals remote ON OFF command is required connect the external enable to the contacts shown on the wiring diagram For the electrical connection to the remote On off contact and remote Chiller heat pump operation do not install drive cables inside the ducts used for power cables if it is not possible a shielded cable must be used When making the gt connections described in paragraphs 5 3 2 5 3 3 and 5 3 4 carefully follow the indications shown in the wiring diagram The 1 5 connecting cables must have minimum cross section of 1 5 20 eee IMATIZZAZIONE INTEGRATA 6 6 1 L L
40. CbC After maintenance operations have been completed the unit should al ways be closed with the relative panels which should be fixed with the relative gt Screws Please remember that all the operations described in this chapter MUST ONLY BE CARRIED OUT BY QUALIFIED STAFF WEARING PERSONAL SAFETY EQUIP 9 1
41. 10 SHUT DOWN AND DISPOSAL When the unit is removed or replaced because it has reached the end of its life it must be taken to special collection centres If no specialised centres are available proceed as fol lows Collect the refrigerant taking care not to disperse it into the environment and then send it to au thorised collection centres The lubricating oil must also be collected and sent to authorised collection centres for disposal Dismount the various components and the struc ture and sort the various materials into separate groups for disposal please bear in mind that con siderable quantities of copper and aluminium are contained in the unit The above allows the various materials to be recov ered and disposed of in order to avoid environmental damages
42. Make sure that the electrical connections have been made correctly and that all the terminals have been well tightened Use a tester to make sure that the voltage on terminals L L L is equal to that shown the rating plate permitted tolerance 5 If voltage is subject to frequent variations please contact our technical office in order to decide on suitable protection devices Use a leak tester if necessary to make sure there are no leaks of refrigerant liquid Check that the heating elements of the sump if fitted are correctly powered The heating elements must be turned on at least 12 hours before start up this takes place automatically when the main power switch is closed position 1 To check if the heating elements work correctly make sure that the lower part of the compressor is 10 15 C higher than room temperature Check the water circuit is correctly connected the indications on the unit rating plate must be observed Make sure that the water circuit has been cleaned beforehand the water circuit should be washed bypassing the unit and then the system filter checked for dirt The units are despatched with the relief valves and drains open Special plates show where they are lo cated They must be closed during installation before the water circuit is filled In the models with built in hydraulic kit the pump
43. power supply Make sure that the mains power supply corresponds to the rated values of the unit shown on the plate voltage number of phases frequency The unit must be connected with a three pole cable plus earth Electrical connections must be made carefully following the instructions shown on the wiring diagram attached to the unit The earth connection is obligatory by law The earth cable must be connected to the earth bar located in the electrical panel and marked with PE Auxiliary circuit power is supplied by the power line by means of a transformer located in the electrical panel The cross section of the cable and the line protections must comply with the indications shown on the wiring diagram and in the relative sheet attached to the 5 290 unit Observe the phase sequence otherwise
44. VI X PABO XIII XIV HEECTECTBEH LUYM OT ATPE TATA
45. 20 50 4 3 4 INSPECTION AND TRANSPORT 4 1 INSPECTION Check the condition of the unit on receipt As the unit was carefully checked before leaving the factory any claims for damages should be addressed to the forwarder Any damage should therefore be indicated on the Delivery Note before signing it Please inform the company or the Agent of the nature of the damage to the unit immediately The Customer must always write a report describing any damage caused to the unit 4 2 STORAGE The temperature in the area where the units are stored must range between 20 C and 50 C 4 3 LIFTING AND TRANSPORT When unloading and positioning the unit take great care not to make sudden and or violent manoeuvres Do not lift the unit by its piping or any other components The unit should
46. 5 3 3 CONTENTS 0 LIST OF ATTACHMENTS 1 INTRODUCTION 1 1 General information 1 2 Attachments 1 3 Warnings 2 UNIT DESCRIPTION 2 1 Identification 2 1 1 Identification 2 2 Intended use 2 3 Contraindications 2 4 General description 3 SAFETY 3 1 Definition 3 2 General safety regulations 3 3 Symbols 3 3 1 Location of safety signs 3 3 2 Safety signs 3 4 Emergency and safety devices 3 5 Description of residue risks 3 5 1 Residue risks near the unit 3 5 2 Measures to take in case of leaking refrigerant gas 3 5 3 Operations with the panels removed 4 INSPECTION AND TRANSPORT 4 1 Inspection 4 2 Storage 4 3 Lifting and transport 4 4 Unpacking 5 INSTALLATION 5 1 Choosing the installation site 5 2 Water connections 5 2 1 General 5 2 2 Evaporator 5 3 Electrical connections 5 3 1 General 5 3 2 Electrical connections to the flow switch differential water pressure switch 5 3 3 Electrical connections to the circulation pump 5 3 4 External signals IMATIZZAZIONE INTEGRATA 6 6 1 6 2 6 3 6 3 1 6 3 2 6 4 7 7 1 7 2
47. Operating checks may require the unit to work totally or partially while a panel is open In this case the panel should be removed when the unit is not working These checks are particularly dangerous and may only be carried out by highly qualified staff Proceed as follows Turn off mains power with the main power
48. 8 9 9 1 9 1 1 9 1 2 9 1 3 9 2 9 3 10 6 START UP 6 1 Preliminary controls 6 2 Start up 6 3 Checks during unit operation 6 3 1 General 6 3 2 Defrosting only heat pump units 6 4 Stopping the unit 7 OPERATION 7 1 General 7 2 Seasonal shut down 8 TROUBLESHOOTING 9 ROUTINE MAINTENANCE AND CONTROLS 9 1 Warnings 9 1 1 General 9 1 2 Monthly controls 9 1 3 Four monthly controls 9 2 Repairing the refrigerant circuit 9 3 Topping up the refrigerant liquid 10 SHUT DOWN AND DISPOSAL CLIMATIZZAZIONE INTEGRATA 1 1 1
49. Threaded or flanged male unions depending on the models are used to make water connections please refer to the scale drawings which also show the position of the unions It is vitally important to connect the water circuit so that the flow of water to the exchanger is always constant under V gt 115 V P
50. VII IMATIZZAZIONE INTEGRATA 8 TROUBLESHOOTING THE UNIT DOESN T START A COMPRESSOR DOESN T START THE COMPRESSOR STARTS AND STOPS REPEATEDLY IV A COMPRESSOR DOESN T START BECAUSE THE HIGH PRESSURE SWITCH HAS CUT IN COMPRESSOR DOESN T START BECAUSE THE LOW PRESSURE SWITCH HAS CUT IN 1 Se ye er PS S flow switch or differential pressure switch agreement The connections are faulty or the contacts are open faulty The external enables have not been given The work probe enable has not been given The antifreeze enable has not been given A safety device enable has not been given The anti recirculation time
51. IL SURELY THE ed A THE LT DURDAN Te TO DORNEI RIT THE Te AT AT Oa Gaon Ad THE STAG Soe BT THE COSTS MDA SA THE Ae POAT ST ELEC TANAL RELY Ce THE HUN TURES te a OS Se Sad TA EE Oe SSA LT 2 LA ST GEATA BOAT DAS IST SOHAL TERDI TR GST WER UNO OR ASE STAT IAT VOR OFF MRA 045 GERAT fe ANG CEREM SSO KALTER Oe EEO VIR SND 7021 Pee OG ASE eee Geto MAN BTA OR OMTEN MUS GEOFF HET MATA TAME OT AL AAT SO LUE OA CSU PAF LA Te ALY SAT TS a AT LUTE LE Wi
52. ASLAM ART COUNT OL eee ALL ATO TO AAT OU TL A ENAIT LES NTL TL CM FESAT TOUS LEd oT TEAS DOU LA TEMA OH LE SOTA A ING CHILLED WATER NLET KALTWASSERENTAITT ENTREE GLACEE USCITA CHILLED WATER OUTLET SOATE GLACEE ATTENZIONE ATTENTION VORSICHT SUPERFICIE SCALDATA ELETTRICAMENTE ELECTRIC SURFACE HEATING ELECT RISCHEN HERUNG SURFACE CHAU FEE ELEC TAIQUEMENT PAMA CHLDERE SAAT CHARGING THE PLANT CLOSE THE AND WALWES GEFULLT WAC 3 WERDEN TOUS VIDANGES CLIMATIZZAZIONE INTEGRATA AIR PLAGE ENTLOF TING SWENTL PURGE AIA N oF OR PAGS MOE OBJECTS HHEH Ba PR A Te
53. 5 12 6 START UP 6 1 PRELIMINARY CONTROLS 1 10 15 C
54. 1 1 1 1 2 1 3 2 2 1 2 1 1 2 2 2 3 2 4 3 3 1 3 2 3 3 3 3 1 3 3 2 3 4 3 5 3 5 1 3 5 2 3 5 3 4 4 1 4 2 4 3 4 4 5 5 1 5 2 5 2 1 5 2 2 5 3 5 3 1 5 3 2 5 3 2
55. 6 3 2 24 measurements Verify during the operation the electrical absorp tion of the water pump if installed it must cor respond to the data indicated on the wiring dia gram In contrary case it means that the pump is not working in curve 6 3 2 Defrosting Only heat pump units During operation in the winter cycle heat pump the coil works as an evaporator cooling and dehu midifying the external air Depending on the temper IMATIZZAZIONE INTEGRATA Ha
56. 4 6 C the value of the freezing temperature of the fluid plus 6 K Before starting the pump make sure that the moving parts turn freely To do so remove the fan cover 3 from the rear motor cover 1 insert a screwdriver into the notch on the ventilation side of the motor shaft and rotate it If it blocks rotate the screwdriver by gently hitting it with a hammer fig A Then put the fan cover back Power the unit and check for the three phase version the motor rotates clockwise looking at it from the fan side fig B If this is not the case invert any two phase wires After starting the pump make sure that the cor rect quantity of water is circulating The pressure gauges if fitted installed upline and downline from the pump may be used to carry out this check the difference between the two pressures must be equal to the pressure drop of the system including the evaporator To adjust the flow of water turn the valve located downline from the pump For units fitted with two pumps both of them must be adjusted Mark the position of each valve so that if they are closed for maintenance operations they can be moved to the same place before starting up the unit again To set adequately the water flow
57. Ha Ka c Ap 1408 115 117 0700 11 220 02 953 36 32 e mail office begr bg cG HOLDING S p A G I HOLDING S p A Assistenza Clienti Via Max 11 13 33050 RIVIGNANO UD ITALY tel 39 0432 773220 fax 39 0432 773855 e mail info clint it any operations on the unit For any further information or explanations please contact the company which delivered the unit or the official representative for Bulgaria BGR Group Ltd at the following address Group Ltd 1408 Sofia 115 117 Vitosha Blvd Tel 0700 11 220 Fax 02 953 36 32 e mail office begr bg or directly HOLDING S p A at the following ad dress G I HOLDING S p A Customer Service Via Max Piccini 11 13 33050 RIVIGNANO UD ITALY tel 39 0432 773220 fax 39 0432 773855 e mail info clint it lt CLINT ees 2
58. check the water temperature rise between inlet and outlet when the units is full load working all the compressors on the temperature rise should range from 4 C to 6 C If it is less than 4 C the water flow is too high shut slightly the pump supply valve If it ex ceeds 6 C check the water system pressure drops 22 Attention Before starting up the unit make sure that all the external panels are in place and fixed with screws CLIMATIZZAZIONE INTEGRATA 6 2 Mode select Summer Winter 6 2 START UP Select the operating cycle heating or cooling For microprocessor controlled units use the arrow keys to move to the Mode select menu and select summer cooling or winter heating N B this o
59. 5 supply 3 5 DESCRIPTION OF RESIDUE RISKS The description of residue risks includes the following elements the kind of danger the people working on the unit are subjected to description of the main dangers who is exposed to such dangers the main safety methods used to reduce the risk of injury The following accident prevention instructions with reference to the relative areas concerned by residue risks mus
60. add refrigerant liquid Fix the pipes with brackets Install correctly 30 eee CLINT IMATIZZAZIONE INTEGRATA 9 9 ROUTINE MAINTENANCE AND CONTROLS WARNINGS Before carrying out any work on the unit or accessing internal parts make sure the unit is disconnected form the mains power supply Given the compressor delivery pipe high temperature special attention should be paid when working near pipe and wait for the pipe to cool When working near the finned coils pay special attention to the aluminium fins as these are particularly sharp
61. depending on the size of the chiller the kind of refrigerant gas used and the room temperature and that the evaporating temperature is about 5K less than the temperature of the water leaving the evaporator Make sure that the overheating temperature of the refrigerant lies between 5 and 7K Do this by mea suring the temperature with a contact thermom eter placed on the suction pipe of the compressor and that indicated on a pressure gauge connected to the suction line as well the difference between the two gives the values of overheating Make sure that the subcooling temperature of the refrigerant fluid lies between 4 and 8K Do this by measuring the temperature with a contact ther mometer placed on the suction pipe of the com pressor and that indicated on a pressure gauge connected to the suction line as well the difference between the two gives the values of subcooling The above checks can be made by using the supplied pressure gauges if fitted In this case remember to close the shut off valves if fitted after making the
62. only be moved as shown in the plate attached to it The lifting points are clearly indicated with the label ce gt Attention Make sure the unit is securely anchored before lifting it in order to prevent it 14 from accidentally overturning or falling mai a gt 57 CLINT IMATIZZAZIONE INTEGRATA 4 4 5 5 1
63. switch Open the electrical panel and remove the relative fuses to disconnect the components that do not need to be working in order to carry out the relative check Close the electrical panel Remove the panel in question Start the unit Carry out the relative check with the greatest of care and using personal protection equipment After completing the check stop the unit and put the panel back in place Turn off mains power and put back any fuses that were previously removed Close the electrical panel a 13 IMATIZZAZIONE INTEGRATA 4 4 1 4 2
64. water drain plug has been removed for discarge of the water therein and to prevent freezing during winter season The plug is included into the envelope containing the documentation of the unit Make sure the water circuit has been well vented to eliminate any air residues this operation is carried out by gradually loading and opening the relief valves fitted to the uppermost part of the unit by the installer please consult section 5 2 for further information In case water with glycol is used the anti freezing set point can be moved the value must be equal to CLIMATIZZAZIONE INTEGRATA 6 K 3 1
65. 6 POINT PRES EA POAT PRESENCE OF HEAT SOURCES WOM WAAMEJLELLE PRESENCE DES SOURCES CHALEUR ATTENTION VORSICHT AMETALLARE SEMPRE UH ALTRO SUL LL oo PROTEZIOME DELL aT ORE PLEASE BUILT ALWAYS WATER FILTER THE PROTECT THE beep Of a7 EH AUF CHEW SHUTI TERDAN PF ENE TOLERI LU FLTHE SUR LE A PROTECTION 3 4 ESIH FREEBIE OF SRP AGES TH fA MW ESA HET OE PES EHE CES SUPP Pe LG LEIG 3 4 EMERGENCY AND SAFETY DEVICES An emergency external circuit breaker must be fitted by the unit installer to disconnect the unit from the power 3
66. Vent the water circuit Check the pump and replace if necessary Check and replace See point VII Check and open it completely if necessary Check clean and replace if necessary Check and replace Clean the filters with compressed air or water See point VI See point XIII Check the pump and replace if necessary The microprocessor indicates when the safety devices cut in see attached manual THE FANS DON T START LACK OF REFRIGERANT LIQUID THE FLUID PIPE IS IX THE FLUID PIPE IS COVERED WITH FROST THE UNIT CON TINUES TO WORK WITHOUT STOP PING THE UNIT WORKS REGULARLY BUT HAS AN INSUFFI CIENT OUTPUT THE COMPRESSOR SUCTION LINE IS COVERED WITH FROST XIII THE DEFROSTING CYCLE IS NEVER ACTUATED XIV ABNORMAL NOISE IN THE SYSTEM Fan contactor is not energised The fan thermal cut outs trip The connections are faulty The fan motor is faulty There s a leak in the refrigerant circuit There s not enough refrigerant liquid in the circuit The liquid shut off valve is partially closed The fluid filter is clogged Lack of refrigerant gas Compressor not performing as expected The heat load is excessive The thermostat is badly adjusted or broken The liquid filter is clogged There isn t enough refrigerant liquid Moisture in the refrigerant circuit The thermostatic expansion valve doesn t work properly There isn t enough re
67. alves fitted in the uppermost parts of the water circuit for expelling air e expansion tank if not already fitted of a suitable size for the quantity of water contained in the system and the expected temperature range and an automatic inlet valve for maintaining the pressure of the system and compensating the thermal expansion of the fluid drain valve or where necessary drain tank for emptying the circuit for maintenance operations or seasonal shut downs Attention A safety flow switch has to be installed if the flow switch differential water pressure switch are not already fitted along a straight section of piping at a distance from the exchanger outlet of not less than 8 10 times the diameter of the piping The guarantee will immedi ately become null and void if the above is not complied with 5 2 2 Evaporator It is vitally important that the water enters the unit from the connection point marked with the WATER INLET plate 17 j OT KbM
68. d out by specialised staff IT IS FORBIDDEN TO TAMPER WITH SAFETY DEVICES 7 2 Nbr AKO 7 2 SEASONAL SHUT DOWN If the unit is planned to be shut down for a long time and the unit is required to be disconnected from the mains supply the minimum temperature to which the unit may be subjected must be identified It this is lower than the freezing point of the fluid contained in the exchangers these must be drained unless there are suited antifreeze kits IMATIZZAZIONE INTEGRATA 8 1 1
69. doctor Contact with the skin Wash with abundant water and remove all contaminated clothing immediately Measures to take in case of accidental leaking Personal precautions Evacuate all staff to safety areas Make sure the area is suitably ventilated Use personal protection equipment Environmental precautions to intercept the emission 2 j 3 5 3 Cleaning methods to employ absorbent products 3 5 3 Operations with the panels removed Some of the following operations and or controls require the panels of the unit to be removed in order to access the inside of the unit Before removing an outer panel except for the one protecting the electrical panel easy to recognize due to its ventilation slits the unit must be
70. e facing the direction where noise is less critical Prevailing winds Wind may alter operating conditions to minimise its effects the unit should be positioned with the long side parallel to the direction of prevailing winds Vibrations Although the units transmit a low level of vibrations to the ground a sheet of rigid rubber should always be placed between the unit base and the supporting surface greater insulation is required vibration moisting supports should be used 5 2 WATER CONNECTIONS 5 2 1 General Please carefully carry out the following instructions and observe current law when installing the chilled water circuit 6 CLIMATIZZAZIONE INTEGRATA
71. eases the compressors will Start up in sequence as well as all the fans the unit doesn t start please consult ch 9 part 1 The power supply must not be switched off while the unit is stopped Power should only be switched off for prolonged pauses e g seasonal shut downs To shut down the unit for short BT 7 6 3 6 3 1 10 periods please carefully follow the instructions shown in paragraph 7 6 3 CHECKS DURING UNIT OPERATION 6 3 1 General Check the unit for strange sounds or excessive vi brations Check that the above sequence is repeated regu larly leaving the compressor working for at least 23 IMATIZZAZIONE INTEGRATA
72. ed water pipes so as not to affect the performance of the system and to prevent the formation of condensation A safety valve should be installed on the water circuit In case of serious system faults e g fire this will allow the system to be drained in order to prevent the risk of explosions Always connect the drain to a pipe with a diameter not KbM less than that of the valve open ing and install the outlet in an area where the jet cannot cause harm to people Attention While connecting the water circuit never work with naked flames near to or inside the unit 18 CLIMATIZZAZIONE INTEGRATA 5 3 5 3 1 5 3 ELECTRICAL CONNECTIONS 5 3 1 General These operations may only be carried out by specialised staff
73. ensation heat causes the frost to melt and drain to the ground the end of cycle temperature pressure is reached the 4 way valve is inverted once more and the winter operating cycle continues Defrosting lasts from about 1 to a maximum of 5 minutes when it is interrupted even if the end of cycle temperature pressure set point has not been reached 6 4 STOPPING THE UNIT Stop the unit by pressing the OFF key placed on the microprocessor front Attention Do not stop the unit by turning off the main power switch as this would also disconnect the heating elements of the sump which would affect compressor operation after start up 25 IMATIZZAZIONE INTEGRATA 7 PABOTA 7 1 ON OFF
74. frigerant liquid The liquid shut off valve is partially closed The filter on the liquid line is clogged The water circulation pump is faulty The 4 way inversion valve is not energised The defrosting thermostat set point is incorrect or the probe is faulty The compressor is noisy The thermostatic valve is noisy There are vibrations in the piping The panels vibrate Check the voltage at the ends of the contactor coil and the continuity of the coil Replace if faulty Inspect the insulation between the windings and between the windings and the earth Check and tighten Check and replace if necessary After pressurising the circuit at about 10 bar check with a leak tester Repair depressurise and fill with refrigerant liquid See previous point VII Open the valve completely Replace the filter cartridge or the filter depending on the model See point VII Inspect and replace or overhaul Reduce the heat load Check the thermostat set point and replace the thermostat if necessary Replace See point VII Empty the cooling circuit dry it replace the filter do the charge again Check clean and replace if necessary See point VII Check and open it completely if necessary Clean or replace Inspect the pump and replace it if necessary Check valve coils Replace the inversion valve if necessary Change the set point or replace the probe if necessary Check and replace if necessary Check and
75. ied electrician Work on the refrigerant circuit may only be carried out by specialised staff 3 3 SYMBOLS Check the state of the plates on a regular basis and repair them if necessary CLINT CLIMATIZZAZIONE INT 3 3 1 3 3 1 Safety signs placement 3 3 2 4 DIS TANS LA BATTER CS TACO IM 1 9 mmi ATTENTION BETWEEN AND OBST SC LES Tao mm MIIMALE ENTFERHUAG DER LAM ELLEN FLACHE HNO ERA SEEM 1200 mm OS TANCE WHALE LES VENTUELS GES SOUVENT 806 3 3 2 Safety signs DARE CARTEA 12 ETO INTEEMALL HTO ES DEL SETTRA HA L ALBRE CHE ELE LUATA E LA PUPA RT GRID PAA A CA TR eed UH TA STI MARCA 0 H SSSR SUL PRIMA GRRE
76. new refrig erant CLIMATIZZAZIONE INTEGRATA 10
77. o 44 Series 666 18012 CHA FC 666 18012 CHA K 726 P 36012 P CHA 802 3204 CLIMATIZZAZIONE INTEGRATA 702 5602 CHA FC 642 2204 CHA Y 1202 A 4202 A CHA Y 1202 B 4202 B CHA FC 702 V 4602 V CHA K 726 P 36012 P CHA K FC 726 36012 CHA Y FC 1202 B 6002 B Bepcua Issue Replaces 05 11 09 10 Manual CLM 41 ab ENGLISH INSTALLATION 3A MOHTAM USE AND MAINTENANCE MANUAL CLINT Bes CLIMATIZZAZIONE INTEGRATA 0 HA L L 0 LIST OF ATTACHMENTS List of documents supplied with the unit and forming an integral part of this manual LJ Technical book Microprocessor manual 1 Certificate of guarantee 1 Declaration of conformity L Specific electrical circuit IMATIZZAZIONE INTEGRATA 0
78. peration is only required for the versions with heat pump Attention The operating cycle should be changed on a seasonal basis Frequent changes between summer and winter modes should be avoided as they can cause the compressors to work badly Ha
79. r any improper use of the unit unauthorised modifications or non compliance with the instructions contained in this manual Please keep this manual in a safe place and make it available to chiller operators and main tenance men 1 2 ATTACHMENTS The documents shown on page 2 form an integral part of this manual 1 3 WARNINGS The CHA units have been designed and built to ensure long term operating reliability and maximum safety for this reason and thanks to the company s design and construction policy the company is able to guaran tee that this product totally complies with EC safety standards A further guarantee of this is provided by the factory tests carried out on the unit The user therefore must only ensure the unit is properly used and that maintenance operations are carried out ac cording to the indications contained in this manual The unit should not be touched until the whole of this manual has been carefully read 5 j A This installation use and maintenance manual must always be kept within easy reach of authorised staff who are obliged to read it before carrying out A
80. r is active The fan thermal cut outs trip The compressor has blown The power circuit is open The motor protection is open The compressor contactor is disabled The compressor is faulty The low pressure switch has cut in The differential oil pressure switch has cut in only for semihermetic compressors The compressor contactor is faulty The set point values are incorrectly set There s not enough refrigerant liquid The pressure switch doesn t work The end of defrosting pressure switch doesn t work 5 too much refrigerant liquid non condensable gas in the refrigerant circuit The refrigerant filter is clogged The metal filters of the condenser if fitted are clogged The air flow is too low The condenser fans do not work There s air the water circuit The circulation pump is faulty The pressure switch doesn t work The unit is completely empty The liquid shut off valve is not completely open The thermostatic expansion valve doesn t work properly The refrigerant filter is clogged The metal filters of the evaporator if fitted are clogged The air flow is too low The evaporator fans do not work The evaporating coil is covered with frost The water circulation pump is faulty Operation only during cooling cycle Operation only during heating cycle ae 29 Give off idraulic ci
81. rcuit verify the right running of pumps and if valves are open Check the phase sequence check the voltage and close the contacts See point Il Check the water circulation pump and the differential water pressure switch and vent the circuit Check further external enables System on temperature no cooling demand Check adjustment and operation Check adjustment and operation See points IV or V Wait about 5 minutes See points VI Replace Close the compressor circuit breaker after identifying the reason why it cut in The compressor was working in critical conditions or there 15 4 enough refrigerant Check the work conditions and see point VII Check the voltage at the ends of the contactor coil and the continuity of the coil Replace if faulty Check and replace if necessary See point V Make sure the difference in pressure between the oil pump delivery and low pressure is greater than at least one bar otherwise check the oil level and top up if necessary Check the filter and the oil pump replace if faulty Have the compressor overhauled if necessary Check and replace if necessary Modify them by referring to the information shown on the microprocessor programme See point VII Check and replace Check and replace Remove the excess refrigerant liquid from the system Drain the circuit pressurise and recharge the unit Check and replace Clean the filters with compressed air or water See point VI
82. s es Make sure the possible antifreeze kit works cor rectly 9 1 2 Four monthly controls Make sure the fans are fixed balanced and in good condition Check the colour of the liquid and moisture indica tor if the colour indicates a moist circuit change the filter Check the state of the paint work touch up any scratches in order to prevent rusting 9 2 REPAIRING THE REFRIGERANT CIRCUIT 9 3 32 These repairs only be made by specialised staff using the normal tech niques for chillers that make use of hal ogen fluids as refrigerants 9 3 TOPPING UP THE REFRIGERANT This operation should only be carried out after iden tifying and repairing the leak OTHOBO HOB No more than two top ups are allowed If another top up is required the refrigerant circuit must be completely emptied and then filled with
83. t be integrated with all the general indications contained in the present chapter and with the accident prevention regulations in force in the country of installation CLIMATIZZAZIONE INTEGRATA 3 5 1 KbM
84. the unit will not work Input voltage must not exceed variations of over 5 and phase unbalance must always be less than 2 Unit operation must always take place within the above values as otherwise the guarantee will immediately become CTa 5 3 2 null and void 5 3 2 Electrical connections to the flow switch water differential pressure switch The chiller if not already fitted must only work while water is flowing The flow switch differential water pressure switch must therefore be connected as shown on the wiring diagram supplied with the unit 19 5 3 2
85. to Rated shart circuit making capacity 2 UNIT DESCRIPTION This chapter contains a general description of the main unit characteristics together with those of its principal standard and optional components 2 1 IDENTIFICATION 2 1 1 Unit identification The unit can be identified through the plates attached on the frame and in the electrical box This label contains the following information Manufacturer s name Manufacturer s address Description of the series and type of unit Series number Year of construction Type and quantity of refrigerant liquid Max allowable pressure Pressure switch set point EC certification symbol Electrical characteristics Wiring diagram identification 4 r i 1 CLINT G INDUSTRIAL ay 33050 Rivignana 39 0432 0 a Far 39 0432 773855 Emal i inti CE Matricola Seral number Anno di costruzione Construction year Refrigerante Refrigerant PS Max Press Ammissibile ba Max Allowable pressure PS ees CLIMATIZZAZIONE INTEGRATA 2 2 CHA ca
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