CLIVET WBAN Series, WBAN 122, WBAN 162, WBAN 82, WBAN 302 Installation, Use & Maintenance Manual
...
WBAN 82 - 302
High efficiency air-cooled heat pump for outdoor installation
Installation use and maintenance manual
M0E240G9-10
22-04-2016
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
2
INDEX
General
1
Reception
2
Positioning
3
Water connections
4
Electrical connections
5
Start-up
6
Regulation
7
Maintenance
8
Disposal
9
4
6
8
10
12
21
27
33
35
Technical information
10
Residual risks
11
36
44
3
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.
Only qualified personnel can operate on the unit, as required
by the regulation 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 cooling/heating water or a water and glycol
mix for air-conditioning only, 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. .
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 assistance service centre authorized by the
manifacturer.
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.
4
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, exmple:
Series WBAN
Size 82
serial number
12 characters 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.
Serie
Size
Serial number
Year of manufacture
Wiring diagram
1.5 UNIT DESCRIPTION
VULCAN Medium is a high temperature heat pump series
representing ideal single solution for heating, cooling and
sanitary hot water production for centralised systems, such as
in blocks of apartments, hotels and for use with collective
applications in general.
A CLASS Energy Efficiency according to Eurovent, both
for heating and cooling.
Ideal for all plant types including radiator systems using
hot water produced at a temperature of up to 60°C, and
ambient air at -10°C.
A simplified system thanks to the use of a single generator
for heating and cooling that eliminates the risks and obligatory maintenance costs associated with traditional combustion systems.
The units in the ELFOEnergy VULCAN Medium range can
autonomously produce sanitary hot water and are set up for
use in combination with solar panel storage tanks, thus enabling the direct use of solar energy.
1.6 ACCESSORIES
VERSIONS OPTIONS
D Partial energy recovery
B Water low temperature
REFRIGERANT CIRCUIT
CCCA Copper / aluminium condenser coil with acrylic lining
EOL Operating limit extension
AIR SIDE FEATURES
ECHP External fans with larger available head
"ECOBREEZE"
HYDRAULIC CIRCUIT
3DHWX Three-way valve for domestic hot water
3DHW Built-in 3-way valve for domestic hot water on the unit
IS4 Compressor insulation
- Hydronic group utility side: not required
1PUS Standard pump
1PUR Single-pump with reduced available head
1PUM Single-pump with larger available head
1PUHE High efficiency single inverter pump for primary circuit.
CACSX Domestic hot water kit control
TCDC Condensate collection pan with electric heater
ELECTRIC CIRCUIT
TASRX Compartment for multifunction keyboard
PM Phase monitor
PMX Phase monitor
SFSTR4N Disposal for inrush current reduction, for unit
400/3/50+N
PFCP Power factor correction capacitors (cosfi > 0.9)
INSTALLATION
AMRX Rubber antivibration mounts
PGFC Finned coil protection grill
PGFCX Finned coil protection grill
X = Accessory separately supplied
5
2- RECEPTION
?
2.1 PRELIMINARY INFORMATION
Operate in compliance with safety regulations in force .
For detailed information (dimensions, weight, technical cha-
racteristics etc.) please refer to the “Technical information”
section.
Use single protection devices : gloves, glasses ecc. .
2.2 DELIVERY CONTROL
Before accepting the delivery you have to check:
That the unit hasn’t been damaged during transport.
Check that the materials delivered correspond with that
indicated on the transport document comparing the data
with the identification label ‘A’ positioned on the packa-
ging.
In case of damage or anomaly:
Write down on the transport document the damage
you found and quote this sentence: "Conditional
acceptance — clear evidence of deficiencies/
damages during transport".
Contact supplier and the carrier by fax and registered
mail with advice of receipt.
Any disputes must be made within the 8 days following the
delivery. Complaints after this period are invalid..
2
3
4
2.3 HANDLING
1. Verify unit weight and handling equipment lifting capacity .
2. Identify critical points during handling (disconnected
routes, flights, steps, doors)
3. Use protection to avoid the unit damaging .
4. Lifting pipe
5. Lifting beam with spacers
6. Lifting with spacer bar
7. Align the barycentre to the lifting point
8. Use all the lifting brackets (see "Technical informations -
dimensions)
9. Gradually bring the lifting belts under tension, making sure
they are positioned correctly. .
10. Before handling verify that the unit keeps its balance.
1
5
6
6
7
2- RECEPTION
2.4 STORING
Observe external packing instructions .
2.5 PACKING REMOVING
Be careful not to damage the unit.
Recycle and dispose of packing material in conformity with
local regulations.
7
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:
EXTERNAL
in fixed positions.
Choose the installation place according to the following
criteria:
Customer approval
safe accessible position
technical spaces requested by the unit
spaces for the air intake/exhaust
max. distance allowed by the electrical connections
control points with capacity adequate to the unit weight
condensate water draining
Prefer places where the unit doesn't disturb the neighbours.
Avoid installations next to bedrooms or windows.
Avoid snow accumulations on batteries.
Avoid installations in places subject to flooding
In case of ground installation provide a raised base to avoid
flood damages.
Protect the unit with an appropriate fencing to avoid the
access to a not authorized personnel (babies, vandals etc.)
Limit vibration transmission:
use antivibration devices on unit bearing points;
install flexible joints on the hydraulic.
A correct circulation of the air is indispensible to guarantee the
good working order of the machine.
Avoid therefore:
obstacles to the airflow;
exchange difficulties;
leaves or other foreign bodies that can obstruct the
exchange batteries;
winds that hinder or favour the airflow;
heat or pollution sources close to the unit (chimneys,
extractors etc);
stratification (cold air that stagnates at the bottom);
recirculation (expelled air that is sucked in again);
positioning below the level of the threshold, close to very
high walls, attics or in angles that could give rise to
stratification or recirculation phenomenons.
Ignoring the previous indications could:
energy efficiency decrease;
blocks due to HIGH PRESSURE (in summer) or LOW
PRESSURE (in winter).
3.4 CONDENSATE WATER
When a heat pump is running it produces a considerable
amount of water due to the defrosting cycles of the external
coil.
The condensation must be eliminated in a manner to avoid
wetting pedestrian areas.
With extensive very cold outdoor temperatures, condensation
could freeze and block the flow, causing a slow build-up of
ice; therefore special attention must be paid to eliminating
condensation, raising the unit off the ground and evaluating
whether antifreeze elements should be installed
8
3 - POSITIONING
Condensate collection pan with electric heater - option
1
2
4
3
1 2
3
4
9
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 (both on the water technique
circuit as well as that of the hot domestic water) 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.
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 plant volume and temperature.
WATER FILTER
If not present on-board the machine, must be installed
immediately in the water input of the unit, in a position that
is easily accessible for cleaning.
The filter never should be removed, this operation
invalidates the guaranty
SUPPORTS
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
4.4 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).
Do not use different glicol mixture (i.e. ethylene with
propylene)
4.7 RECOMMENDED CONNECTION
4.3 OPERATION SEQUENCE
1. Carefully wash the system with clean water: fill and drain
the system several times.
2. Apply additives to prevent corrosion, fouling, formation of
mud and algae.
3. Fill the plant
4. Execute leakage test.
5. Isolate the pipes to avoid heat dispersions and formation of
condensate.
6. Leave various point of service free (wells, vent-holes etc).
Neglecting the washing will lead to several filter cleaning
interventions and at worst cases can cause damages to the
exchangers and the other parts.
A unit without hydronic assembly
B unit with hydronic assembly
C unit with three-way valve
1. vent
2. filter
3. pump
4. safety valve
5. three-way valve
10
6. antivibration joints
7. supports
8. expansion tank
9. flow switch
10. vent
11. Differential pressure switch
4 - WATER CONNECTIONS
4.8 PARTIAL ENERGY RECOVERY
A configuration which enables the production of hot water free
-of-charge while operating in the cooling mode.
The partial recovery device is considered to be operating
when it is powered by the water flow which is to be heated.
The customer is responsible for the management of the
circulation pump, valves, thermostats, etc.
When the temperature of the water to be heated is particularly
low, it is wise to insert a flow control valve into the system
hydraulic circuit, in order to maintain the temperature at the
recovery output at above 35°C and thus avoid the
condensation of the refrigerant into the partial energy recovery
device.
Water connections must be performed carefully as for the
evaporator (filter, circuit washing, etc).
Perform all necessary interventions to avoid the RISK OF
FREEZING (tubes insulation, emptying of circuit, addition of
glycol, anti-freeze resistances).
Water temperature can reach high temperatures (up to 100°C)
Avoid the RISK OF BURNS by adopting the necessary
precautions (insulation of tubes, temperature detecting station
on water if the sanitary use is foreseen, etc.)
Install safety valves and specifically dimensioned expansion
tanks in the hydraulic circuit.
D - Partial recovery device
VM - adjustment charged to the customer
11
5 - ELECTRICAL CONNECTIONS
5.1 PRELIMINARY INFORMATION
The characteristics of the electrical lines must be determined
by specialized personnel able to design electrical installations;
moreover, the lines must be in conformity with regulations in
force.
The protection devices of the unit power line must be able to
stop the presumed short circuit current, whose value must be
determined in function of system features.
The power cables and the protection cable section must be
defined in accordance with the characteristics of the
protections adopted. All electrical operations should be
performed by trained personnel having the necessary
requirements by the regulations in force and being informed
about the risks relevant to these activities.
Operate in compliance with safety regulations in force .
5.2 ELECTRICAL DATA
The serial number label reports the unit specific electrical
data, included any electrical accessories .
The electrical data indicated in the technical bulletin and in the
manual refer to the standard unit, accessories excluded.
Refer to the electrical data report on the serial number label.
5.4 SIGNALS / DATA LINES
Do not overpass the maximum power allowed, which varies,
according to the type of signal.
Lay the cables far from power cables or cables having a
different tension and that are able to emit electromagnetic
disturbances.
Do not lay the cable near devices which can generate
electromagnetic interferences.
Do not lay the cables parallel to other cables; cable crossings
are possible, only if laid at 90°.
Connect the screen to the ground, only if there aren’t
disturbances
Guarantee the continuity of the screen during the entire
extension of the cable.
Respect impendency, capacity and attenuation indications.
5.5 ELECTRIC LINES INLET
serial
number
label
F.L.A. full load ampere
Full load current at max admissible conditions
F.L.I. Full load input
Full load power input
( at max. admissible condition )
5.3 CONNECTIONS
1. refer to the unit electrical diagram (the number of the
diagram is shown on the serial number label)
2. verify that the network has characteristics conforming to
the data shown on the serial number label
3. Before starting work, verify that the sectioning device at
the start of the unit power line is open, blocked and equipped with cartel warning
4. Primarily you have to realize the earthing connection
5. Shelter the cables using adequate measure fairleads
6. Before power the unit, make sure that all the protections
that were removed during the electrical connection work
have been restored.
VOLTAGE
FLA (A)
FLI (kW)
Fix the cables: if vacated may be subject to tearing.
The cable don't have to touch the compressor and the
refrigerant piping ( they reach high temparatures ).
12
5.6 ELECTRICAL PANEL
1 2
4567
2
3
5 - ELECTRICAL CONNECTIONS
AP1
AP4
AP4A-B
AP5
AP10-11
XCA
AP1
Main control module
Local base for HID-H1 interface
Fan Module
RS 485 module
Soft starter
Terminal block of Customer connections
QM1-2
QM3
KM1-2
KM3
FU1
FU2-3
FU6-7
Compressor motor overload cutout
Overload cutout switch pump
Compressor contactor
Pump contactor
Control circuit fuse
Phase monitor fuse
Fan fuse
1
2
3 terminal block XC4
4 terminal block XC5
5 terminal block XC3
6 terminal block XC2
7 terminal block XC1
RS 485 module
auxiliary fuse
13
5.7 CUSTOMER CONNECTIONS
SA2 summer - winter
The mode switching can occur
from keyboard or remote contact
Switch for remote selector
(SA2): set par. 21=0 ; In this
case, the keyboard command is
not possible
WR 4-20mA water reset
BT14 water outlet temperature probe
of hydraulic module
SA1 on-off
SA4 domestic hot water
WR 0-10V water reset
BT9 storage tank temperature probe
5 - ELECTRICAL CONNECTIONS
SA3 2nd setpoint
SQ2 flow switch
DL demand limit
HAE% humidity control probe
14
5 - ELECTRICAL CONNECTIONS
A boiler valve control
B sanitary hot water valve control
C boiler control
D cumulative fault alarm relay
E unit operating signal
HLH HEAT status
HLC COOL status
HL3 3-ways valve status
HL1-2 compressor status
KM1-2 compressor contactor
15
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