CLIVET CAS Series, CAS-41, CAS-51, CAS-31, CAS-61 Installation, Use And Maintenance Manual

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CAS-X 31-222

High efficiency cooling only packaged air-conditioner condenser, ductable for indoor installation

Installation use and maintenance manual

M04T40G12-05 28-04-14

Dear Customer, We congratulate you on choosing these product. Clivet is being working for years to offer systems able to assure the maximum

comfort for long time with high reliability, efficiency , quality and safety. The target of the company is to offer advanced systems, that assure the best comfort, reduce the energy con-sumption, the installation and maintenance costs for all the life-cycle of the system.

With this manual, we want to give you information that are useful in all the phases: from the reception, to the installation and use until the disposal so that a system so advanced offers the best procedure of installation and use.

Best regards and have a nice reading ! CLIVET Spa

The data contained in this bulletin is not binding and may be changed by the manufacturer without prior notice. All reproduction, even partial, is prohibited.

INDEX

General

Reception

Positioning

Water connections

Aeraulic connections

Electrical connections

Start-up

Control

Maintenance

Decommissioning

Technical information

Residual risks

1 - GENERAL

1.1 MANUAL

The manual provides correct unit installation, use and maintenance.

Pay particolar attention to:

Warning identifies particularly important operations or information .

Prohibited operations that must not be carried out, that compromise the operating of the equipment or may cause damage to persons or things.

• It is advisable to read it carefully so you will save time

during operations.

• Follow the written indications so you will not cause

damages to things and injuries people. The preliminary information must be read prior to carrying out any of the following operations.

1.2 GENERAL INSTRUCTIONS Preliminaries

The positioning, hydraulic system, refrigerating, electrics and the channelisation of the air must be determined by the system designer in accordance with local regulations in force.

On the unit can operate only qualified personal , as determined by the regulations in force.

Using the unit in case of breakdown or malfunction :

• voids the warranty

• may compromise the safety of the machine

• may increase time and repair costs.

Follow local safety regulations. .

Keep packing material out of children’s reach it may be dangerous. .

Recycle and dispose of packing material in conformity with local regulations. .

Risk situations

The unit has been designed and created to prevent injures to people.

During designing it is not possible to plane and operate on all risk situation.

Read carefully "Residual risk" section where all situation which may cause damages to things and injuries to people are reported.

Installation, starting, maintenance and repair required specific knowledge; if they are carried out by inexperienced personnel, they may cause damages to things and injuries people.

Intended use

Use the unit for :

within limits defined in the technical bulletin and on this manual.

Any use other than intended does not involve the manufacturer in any commitment or obligation. .

CIVIL AIR-CONDITIONING

Installation

Verify that the electrical line characteristics are in compliance with data quotes on the unit serial number label.

Maitenance

Plan periodic inspection and maintenance in order to avoid or reduce repairing costs.

Turn the machine off before any operation.

Modification

All unit modifications will end the warranty coverage and the manufacturer responsibility. .

Breakdown/Malfuction

Disable the unit immediately in case of breakdown or malfunction. .

Contact a constructor certified assistance service.

Use original spares parts only.

User training

The installer has to train the user on :

• start-up / shutdown;

• set points change;

• standby mode;

• maintenance;

• what to do / what not to do in case of breakdown.

Data update

Continual product improvements may imply manual data changes .

Visit manufacturer web site for updated data

1.3 INDICATIONS FOR THE USER

Keep this manual with the wiring diagram in an accessible place for the operator.

Note the unit lable data so you can provide them at the assistance centre in case of intervention (see "Unit identification" section).

Provide a machine notebook that allows any interventions carried out on the machine to be noted and tracked making it easier to suitably note the various interventions and aids the search for any breakdowns.

In case of breakdown or malfunction:

• immediately deactivate the unit .

• contact a constructor certified assistance service.

• use original spares parts only

Ask the installer to format on:

• start-up / shutdown;

• set points change;

• standby mode;

• maintenance;

• what to do / what not to do in case of breakdown.

1 - GENERAL

1.4 UNIT INDENTIFICATION

Serial number label

The serial number label is positioned on the unit and allows to indentify all the unit features.

It has not to be removed for any reason.

It reports the regulations indications such as:

• machine type,

Series  CAS-X

Size  31 ...... 222

• serial number

Axxxxxxxxxxx

• year of manufacture

• wiring diagram number

• electrical data

• manufacturer logo and address .

Serial number It identifies uniquely each machine.

It identifies specific spare parts for the machine. Assistance request

Note data from the serial number label and write them in the

chart on side, so you will find them easily when needed.

In case of intervention you have to provide data.

Typology

Size

1.5 UNIT DESCRIPTION

R Air intake Optional: front, bottom or rear.

S Treated air supply

Optiona: upwards or rear.

A Supply fan and air filter

Electronic control, which returns the air to the setting after having taken it in, strained it with G4 efficiency and treated it

B Internal exchanger

It transfers energy (heat/cool)to the fresh supply air

C Source side exchanger

It exchanges energy (heat or cool) with the outdoor air

D Direct expansion circuit

Produces cool or heat energy through Scroll compressors and an electronic expansion valve

E User interface

Easy to use, with automatic control sensors built-in

MAIN OPTIONS

1 Hot gas post-heating /Hot water heating

Gas post-heating recovers condensation energy in summer humidity control. The hot water heating (available as an alternative), when necessary, integrates or substitutes the workings of the direct expansion circuit

2 Electric heating

Integrates or substitutes the workings of the direct expansion circuit when necessary

Serial number

Year of manufacture

Wiring diagram

1 - GENERAL

1.6 ACCESSORIES

CONFIGURATIONS

CHW2 two-rows hot water coil

REFRIGERANT CIRCUIT

MHP high and low pressure gauges EVE Electronic expansion valves

CPHG hot gas re-heating coil (available only with options: CSOND-CTERM)

AIR SIDE FEATURES

M5 Upward supply air - standard MP Rear supply air R3 Downflow return R4 Rear air inlet RF Front air inlet - standard PCOSM Constant supply airflow FPG4 Pleated air filter class G4 (EN779 norm) - standard PSAF differential pressure switch for dirty air filters PO3X Air supply plenum on three sides (separately supplied accessories) PF500X Front air supply plenum H=500mm (separately supplied accessories)

WATER CIRCUIT

CUE External humidifier control with 0-10V command (available only with options: CSOND-CTERM) 3WVM modulating three-way valve (available only with options: CHW2) 3WVPX modulating three-way valve (separately supplied accessories) MIPC Hydraulic pipework arrangement for loop with constant flow rate with manual valves MIPV Hydraulic pipework arrangement for loop with variable flow rate with 2 way ON-OFF valve MIPM Hydraulic pipework arrangement for loop with disposable water system with 2-way modulating valve ACIS Antifreeze heater protection on the water side exchanger

IFWX Steel mesh strainer on the water side (separately supplied accessories)

SYSTEM ADMINISTRATORS

CMSLWX LonWorks serial communication module (available only with options: MOB) (separately supplied accessories) BACX BACnet serial communication module (available only with options: MOB) (separately supplied accessories)

ELECTRIC CIRCUIT

MOB serial port RS485 with Modbus protocol CTERM Remote keypad for indoor temperature and humidity control CSOND Temperature and humidity ambient control with built-in probes (available only with options: CONTE) CTEM Temperature ambient control with built-in probe (available only with options: CONTE) EH09 4,5 kW electric heaters EH10 6 kW electric heaters EH12 9 kW electric heaters EH14 12 kW electric heaters EH17 18 kW electric heaters EH22 27 kW electric heaters EH24 36 kW electric heaters CWM Electronic room control with display, for wall installation

CONTE Electronic room control with display visible on the unit (available only with options: CSOND-CTEM)

CIWM Electronic room control with display, for wall installation in built-in box PM phase monitor PFCP power factor correction capacitors (cosfi > 0.9)

INSTALLATION

AMRX Rubber antivibration mounts (separately supplied accessories)

2 - RECEPTION

2.1 PRELIMINARY INFORMATION General

Operate in compliance with safety regulations in force .

For detailed information (dimensions, weight, technical characteristics etc.) please refer to the “Technical information” section.

Use single protection devices : gloves, glasses ecc. Stocking

Observe external packing instructions . Handling

Verify unit weight and handling equipment lifting capacity .

Identify critical points during handling (disconnected routes, flights, steps, doors).

Verify the position of the barycentre in the Technical information - DIMENSIONS section.

Before handling verify that the unit keeps its balance. Packing removing

Be careful not to damage the unit.

Recycle and dispose of packing material in conformity with local regulations.

2.3 HANDLING

Considerer that the barycentre could out of centre

Use protection to avoid the unit damaging

2.2 DELIVERY CONTROL

Before accepting the delivery you have to check:

• That the unit hasn’t been damaged during tran-

sport.

• Check that the materials delivered correspond

with that indicated on the transport document comparing the data with the identification label ‘A’ positioned on the packaging.

In case of damage or anomaly:

• Write down on the transport document the da-

mage you found and quote this sentence: "Conditional acceptance — clear evidence of deficiencies/damages during transport".

• Contact supplier and the carrier by fax and regi-

stered mail with advice of receipt.

Any disputes must be made within the 8 days following the delivery. Complaints after this period are invalid.

3 - POSITIONING

3.1 PRELIMINARY INFORMATION

Operate in compliance with safety regulations in force.

For detailed information (dimensions, weight, technical characteristics etc.) please refer to the TECHNICAL INFORMATION section.

Use single protection devices : gloves, glasses ecc.

During positioning consider these elements :

• technical spaces required for the machine and system

• place where the machine will be installed

• electrical connections

• water connections

• air / aeraulic ducts

Do not considerer these elements could decrease performances and operational life of the unit.

3.2 FUNCTIONAL SPACES

Functional spaces are designed to:

• guarantee good unit operation

• Carry out maintenance operations

• protect authorized operators and exposed people

Respect all functional spaces indicated in the TECHNICAL INFORMATION section.

Double all functional spaces if two or more unit are aligned.

3.3 POSITIONING

Units are designed to be installed:

• INTERNAL

• in fixed positions.

Limit vibration transmission:

• use antivibration devices on unit bearing/supporting

points;

• install flexible joints on the hydraulic.

Installation standards:

• Safe accessible position;

• avoid flood-prone places;

• verify unit weight and bearing point capacity;

• verify that all bearing points are aligned and leveled;

4 - WATER CONNECTIONS

4.1 PRELIMINARY INFORMATION

Selection and installation of system components must be carry out by installer.

Following you will find some indications to integrate with what is provided by the local regulations in force and by the good technical laws.

4.2 COMPONENTS

CUT-OFF VALVES :

• installed at inlet and outlet allow maintenance

operations without having to empty the system .

THERMOMETERS AND MANOMETERS :

• installed at entry and exit of the main elements

facilitate inspection and maintenance.

AN AIR BLEED VALVE :

• installed in all of the highest points of the system

allowing the venting of the circuits air.

DRAINAGE TAPS :

• installed in the lowest points of the system to allow

bleeding.

EXPANSION TANK :

• It keeps a correct system pressure when the water

temperature changes. It must be dimensioned as a function of water content. Could be necessary install in addition on the unit one or more of it

WATER FILTER :

• must be installed immediately in the water input of

the unit, in a position that is easily accessible for cleaning.

• The filter should never be re-moved, this operation

invalidates the guaranty .

• filter features:

Size

Ø 1”

filtration mesh (micron)

SUPPORTS :

31-81 82-102 122-222

500μm 600μm 600μm

1" ½

• The hydraulic pipes weight mustn’t burden on the

unit connections ..

FLOW SWITCH

• The flow switch must be present as a component of

the system

4.3 OPERATION SEQUENCE

Before connecting the unit, carefully wash the system by filling it and emptying it several times with clean water.

In the units equipped with hydraulic pipeworks use the bypass.

Ignoring this operation will lead to several filter cleaning interventions and at worst cases can cause damages to the exchangers and the other parts.

Execute leakage test before isolate the pipes.

To avoid heat dispersions and formation of condensate isolate all the pipes.

Leave various point of service free (wells, vent-holes etc )

4.4 WATER QUALITY

The water quality is determined by the following factors, avoid therefore:

• Inorganic salts

• pH

• Biological load (seaweeds etc)

• Suspended solids

• Dissolved oxygen

Water with inadequate characteristics can cause:

• pressure drop increase

• energy efficiency decrease

• corrosive symptom increase

4.5 RISK OF FREEZE

If the unit or the relative water connections can be subject to temperatures close to 0°C adopt measures for prevent risk of freeze.

For example:

• Mix water with ethylene glycol

• Safeguard the pipes with heating cables placed

under the insulation

• Empty the system in cases of long non-use and

check that:

• there are no closed taps present that could trap

water even after emptying

• there are no low points in which water can

stagnate even after emptying; carry out any blowing required .

4.6 ANTI-FREEZE SOLUTION

Consider that the use of anti-freeze solution determines an increase in a pressure drop.

Make sure that the glycol type utilized is inhibited (not corrosive) and compatible with the hydraulic circuit components (pump etc).

CONNECTION SOURCE SIDE

4.7 STANDARD UNIT

4 - WATER CONNECTIONS

The standard unit is equipped with the following components:

1. plate heat exchanger complete with water side differential pressure switch and a water temperature control probe

2. drain bibcock

3. bleed bibcock

4.8 PLUMBING ASSEMBLY

FOR LOOP WITH CONSTANT

The plumbing assembly for the constant flow rate loop includes, in addition to 1, 2 and 3 standard components :

4 two-way manually activated valves to make it possible

to disconnect the unit from the plumbing system for maintenance.

5 manually activated three-way valve for loop wash by-

pass (to allow washing of the pipes of the system and protect the heat exchanger against fouling);

4.10 PLUMBING ASSEMBLY FOR LOOP WITH DISPOSABLE WATER

The plumbing assembly for systems with disposable water (from well or groundwater) includes in addition to 1, 2 and 3 standard components :

1 2-way motorised modulating valve at the exchanger

outlet (the operation is linked to that of the refrigeration circuit:modulating the valve opening by 010V signal the water content is reduced and the unit operation values are maintained within the limits allowed)

2 manually activated three-way valve for loop wash by-

pass (to allow washing of the pipes of the system and protect the heat exchanger against fouling);

In summer operation, the device, complete with modulating valve, makes it possible to maximize the thermal differential of the water and hence to reduce the water flow rate. In winter operation, modulation of the water flow rate allows the unit to function with the water loop at high temperature. An additional advantage of using this device is the extension of the operating limits of the unit in summer and winter.

4.9 PLUMBING ASSEMBLY FOR LOOP WITH VARIABLE

The plumbing assembly for the constant flow rate loop includes, in addition to 1, 2 and 3 standard components :

4 two-way motorize ON/OFF valve, operation is linked

to that of the refrigeration circuit: with the compressor off the valve stays closed and as a result less water is used

5 manually activated three-way valve for loop wash by-

pass (to allow washing of the pipes of the system and protect the heat exchanger against fouling);

MAX. WORKING PRESSURE

• Standard unit = 700 kPa

• With ON/OFF valves = 700 kPa

• With manual valves = 700 kPa

• With modulating valve = 300 kPa

Aries effects and air bubbles can produce the overcoming and cause water drops.

4 - WATER CONNECTIONS

4.11 CONDENSATE DISCHARGE

The condensate must be dispersed to avoid damages to persons and property .

• Unit discharge fitting : the connection must avoid the

transmission of mechanical stresses and must be performed paying attention to avoid the damaging of the unit discharge fitting .

• Make a trap that, eliminating the depression caused

by the fan, stops the return of gas from the discharge pipe

• The ducting must have an appropriate slope to allow

the downflow

• Anchor the ducting with an appropriate number of

supports. Otherwise are generated ducting failures and air pockets that prevent the downflow.

• Insulate the ducting and the siphon to avoid

condensate drippings

• Connect the condensate discharge to a rainwater

drain.

• Do NOT use sewerage drains, so as to avoid the

return of odours if the water contained in the trap evaporates

• Finally, check that the condensate will drain

correctly by pouring water into the tray stud

Calculation of the siphon height T = 2P S = T/2 P is the pressure determinate by the fan in correspondence of the drain pain (1mm c.a = 9.81 Pa)

4.12 HEATING COIL - OPTION

A drain cock

B air vent

Supplied by the customer :

1 vibration isolators

2 ducting supports

3 shutoff valves

Exsample :

P = 300 Pa = 30 mm T = 2P = 60 mm

S = T/2 = 30 mm

5 - AERAULIC CONNECTIONS

5.1 GENERAL

Proper execution and sizing of air connections are essential for ensuring correct operation of the unit and an acceptable level of silence in the room.

When designing and creating ducts, consider PRESSURE DROPS, FLOW RATE and AIR SPEED which need to be compatible with the characteristics of the unit.

Special consideration needs to be made for pressure drops that are greater than the unit's static pressure, which would lead to a reduction in flow rate resulting in unit shutdown.

• the weight of the ducts must not be supported by the

connection flanges

• place anti-vibration joints between the ducts and the unit

• the connection to the flanges and between the various

sections of the ducts must ensure an airtight seal, preventing leakage in delivery and return which would compromise overall system efficiency.

• limit pressure drops by optimizing the path, the type and

number of curves and the branches

• use curves with a wide radius. Consider whether it might

be useful to equip them with deflectors (especially if the air speed is high or if curves are tight )

For purposes of comfort, the following things need to be considered:

• air diffusers must be selected by checking the sound

power generated at nominal flow rate conditions

• the disconnections to the diffusers are to be made

using flexible elements

• the return grilles must be amply sized

APPLICATIONS AT HIGH DEGREE OF SILENCE

For applications that require a high degree of silence in the system:

• In delivery and return, provide septum silencers, pre-

ferably inserted in sections of ducts located outside the building. The septums must ensure the required dampening with minimum pressure drops (ONLY OUTDOOR UNITS – do not print note).

• Equip all curves with deflectors.

5.2 FEATURES FOR DUCTS FOR TREATED AIR

• The inner surface of the duct must be smooth and washa-

ble. It must not contaminate the air.

• Thermally insulate the ducts and the flanges so as to pre-

vent loss of energy and condensation build-up.

GRILLES OUTLETS DIFFUSERS

Proper distribution of air in the room is essential for ensuring comfort levels.

In the selection and positioning of grilles, outlets and diffusers, the following are to be avoided:

• excessive air speed

• formation of stagnant zones and layering

• entry of cold air into the room

• formation of localized currents (due to uneven air

distribution)

• excessive variations in ambient temperature in the

vertical and horizontal planes

• short circuiting of delivery air towards return air

+ 28 hidden pages

CLIVET CAS Series, CAS-41, CAS-51, CAS-31, CAS-61 Installation, Use And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual