AIR COOLED WATER CHILLERS AND HEAT PUMPS WITH AXIAL FANS
TEV LTD, ARMYTAGE ROAD, BRIGHOUSE, WEST YORKSHIRE, HD6 1QF . + 44 (0) 1484 405630 +44 (0) 1484 405620
sales@quartz.co.uk www.quartz.co.uk
EMAIL:WEB:
TEL:FAX:
06617645-02
INDEX
Page
Declaration of conformity 3
Technical features 4
Technical data 7
QLAC LS cooling capacities and compressor input power 12
QLAC /HP/LS heating capacities and compressor input power 17
Evaporator pressure drops 19
QLAC K1 – K2 Water pumps - available static pressure 20
Free cooling capacities 21
Correction tables 23
Electrical data / Sound levels 24
Installation instructions – general 25
Lifting and handling 25
Location and minimum technical clearances 25
Hydraulic connections 26
QLAC FC Free cooling version 27
Condensing pressure control 27
Operational limits 27
Electrical connections 28
Start up 28
Control and safety device settings 29
Maintenance and periodic checks 30
Refrigerant circuit repair 30
Environmental protection 31
Decommissioning 31
Dimensions 32
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06617645-02
gungsg
EC DECLARATION OF CONFORMITY
Herewith TEV Ltd declare that the air conditioning equipment designated below is in accordance with the essential
requirements of current EC Directives.
This declaration is based on the design and construction of the equipment in the form brought onto the market by TEV Ltd.
If alterations are made to the machinery without prior consultation with TEV Ltd. this declaration becomes invalid.
Relevant EC Council Directives: Machinery Directive (98/37/EC)
Applied harmonised standards: EN 292-1:1991, EN 292-2:1991, EN 294:1992, EN 349:1993, EN 55014-1:2000,
Basis of self attestation: BS EN ISO 9001:2000 BSI registered firm certificate no. FM671
EMC Directive (89/336/EEC in the versions 93/68/EEC)
Low Voltage Directive (73/23/EEC in the version 93/68/EEC)
Directive PED (97/23/EC)
EN 55014-2:1997, EN 60335-1:2002, EN 60335-2-40:2003, EN 61000-3:1995
EG KONFORMITÄTSERKLÄRUNG
Hiermit erklärt TEV Ltd, daß die unten angegebenen Klimageräte in Übereinstimmung mit den Gesundheits - und
Sicherheitsbestimmungen der gültigen EG-Direktiven stehen.
Diese Erklärung bezieht sich auf die Konzeption und die Konstruktion der Geräte, die von TEV Ltd. auf den Markt gebracht
werden.
Wenn Veränderungen an den Geräten ohne vorherige Absprache mit TEV Ltd. gemacht werden, so wird diese Erklärung
ungültig.
Angewandte Standard
Normen: EN 292-1:1991, EN 292-2:1991, EN 294:1992, EN 349:1993, EN 55014-1:2000,
EN 55014-2:1997, EN 60335-1:2002, EN 60335-2-40:2003, EN 61000-3:1995
Bestäti
rundlage: BS EN ISO 9001:2000 Zertifikat Nr. FM 671
EMV Direktive: (89/336/EWG/EEC in den Versionen 93/68/EWG)
Niederspannungsrichtlinie: (73/23/EWG/EEC in der Version 93/68/EWG)
Richtlinien PED (97/23/EC)
Model Name: Machinebeschrijving:
Nom du modèle: Modellname:
Nombre del Modelo:
Serial Number: Serienummer:
Numéro de série: Serienummer:
Numéro de Serie:
Model Part Number: Modellnummer:
Référence du modèle: Número de la Parte del Modelo:
Artikelnummer:
Signature of TEV Ltd. designated
"responsible person":
Signature d' TEV Ltd Le responsable:
Firma de TEV Ltd. designado como
"persona responsable":
Position of Signatory:
Fonction du signataire:
Cargo del firmante:
Handtekening van de gemachtigde
persoon bij TEV Ltd.:
Unterschrift von TEV Ltd.
"verantwortliche Person":
Functie van gemachtigde
Position desUnterschreibenden:
(A C HAMMERSLEY)
MANUFACTURING DIRECTOR
DIRECTEUR DE FABRICATION
DIRECTOR FABRICACIÓN
PRODUKTIE COÖRDINATOR
PRODUKTIONS DIREKTOR
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06617645-02
TECHNICAL FEATURES
Frame
All QLAC unit enclosures are manufactured from hot-galvanised sheet steel, painted with polyurethane
powder enamel and stoved at 180°C to provide a durable, corrosion resistant finish. The frame is selfsupporting with removable panels. All screws and rivets are made from stainless steel. The paint colour is
RAL 7035.
Refrigerant circuit
Refrigerant is R407C. The refrigerant circuit is assembled using quality brand components and in
accordance with ISO 97/23 concerning welding procedures. Model sizes 140 and upwards have multiple
refrigerant circuits. Each refrigerant circuit is totally independent of the other. Failure of one circuit does not
influence the other circuit. The refrigerant circuit includes:
Liquid line manual shut-off valve
Sight glass
Filter drier
Thermal expansion valve with external equalizer
Electronic expansion valve with control to optimise efficiency in part load conditions (option)
Reversing valve (heat pump version only)
Non return valve (for heat pump version only)
Liquid receiver (for heat pump version only)
Schraeder valves for maintenance and control
Pressure safety device (according to PED requirements)
Compressors
Scroll compressors are used, each fitted with a crankcase heater and provided with thermal overload
protection via a klixon embedded in the motor winding. Compressors are mounted in a separate chamber in
order to be separated from the air stream and to enable maintenance to be performed whilst the unit is still
operating. The crankcase heater is always powered when the compressors are in stand-by. All compressors
are in tandem configuration. This creates higher efficiencies uring part load conditions compared to units
with independant refrigeration circuits per compressor.
Condensers
Condensers are made of copper tubes and aluminium fins. The diameter of the copper tubes is 3/8” and the
thickness of the aluminium fins is 0.1 mm. Tubes are mechanically expanded into the aluminium fins to
maximise heat transfer. The geometry of these condensers guarantees a low air side pressure drop and
allows the use of slow running (and low noise) fans. The condensers can be protected by a metallic filter
(option).
Fans
Fans are axial type with aerofoil blades. They are statically and dynamically balanced and supplied complete
with safety fan guard that complies with the requirements of EN 294. They are mounted on the unit frame
using rubber anti-vibration mounts. The electric motors are 6 pole (approx. 900 rpm) in the low noise version
and 8 pole (approx. 750 rpm) in the extra low noise version. The fans are directly driven and are fitted with
integral overload protection. Motors have moisture protection to IP 54.
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Evaporators
The plate evaporators are made of 316 stainless steel, braze-welded. Unit sizes 040 to size 130 have a
single water side circuit. From unit size 140 upwards, the circuits are double “cross flow” type. The use of
these types of evaporator allows a significant reduction of the refrigerant charge for the unit compared to
traditional shell-in-tube evaporators and increases the efficiency of the refrigerant cycle during part load
operation. The evaporators are factory insulated with flexible close-cell insulation and can be fitted with an
antifreeze heater (optional). Each evaporator is provided with a temperature sensor as antifreeze protection.
Hydraulic circuit (K versions only)
QLAC chillers can be supplied with an optional built in hydraulic kit that includes:
Water tank: various capacities (depending on the size of the unit), factory insulated with flexible close-cell
material and ready for installation of an antifreeze kit (option). The water tank is installed on the supplied
water side (7°C) in order to minimize fluctuations in the water temperature caused by cycling of the
compressors. By installing on the supply side, the supply water temperature can be maintained for some
time after the compressors turn off, a situation that cannot be achieved if the water tank is installed on the
return water side (12°C).
Water pump: centrifugal type, is available in single (K1) or double configuration (K2). In the K2 version, one
pump is running and one pump is in stand-by. The change over can be manual (by a manual switch installed
in the electric box) or automatically controlled by the microprocessor (option). The expansion vessel, safety
valve and manual valves with fittings are sited in the hydraulic circuit.
Electrics enclosure
Access to the electrics enclosure is achieved by switching the mains isolator to "OFF" and removing the
front cover.The electrics conform to electromagnetic compatibility norms CEE 73/23 and 89/336. Moisture
protection is IP55.
All QLAC units have installed, as standard, a compressor sequence relay, which disables compressor
operation if the power supply phase sequence is incorrect (scroll compressors can be damaged if they
operate in reverse). The following components are also installed as standard:
Mains switch, Magnetic-thermal switches (MCB's) for protection of pumps and fans
Compressor fuses Control circuit automatic breakers
Compressor contactors Fan contactors, pump contactors.
The terminal board is supplied with volt free contacts for remote ON-OFF, Heat / Cool change over (heat
pumps only) and general alarms.
Microprocessors
QLAC units are supplied with microprocessor controls as standard. The specific controller used depends
upon the unit size, number of features and use of optional features e.g. electronic expansion valves.The
microprocessor controls the following basic functions:
regulation of the water temperature
antifreeze protection
compressor timing
compressor automatic starting sequence
alarm reset
volt free contact for remote common alarm
alarms and leds.
Any microprocessor can, on request, be connected to a BMS system for remote control and management.
Typically, solutions can be found for MODBUS, LONWORKS, BACNET or TREND protocols.
Control and protection devices
All units are supplied with the following control and protection devices:
Return water temperature sensor, installed on the return water line from the plant (12°C)
Antifreeze protection sensor installed on the outlet water temperature (7°C)
High pressure switch with manual reset
Low pressure switch with automatic reset
High pressure safety valve
Compressor thermal overload protection
Fan thermal overload protection
Flow switch. (std versions supplied loose, K versions factory fitted)
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OTHER VERSIONS
The following versions all incorporate energy efficiency features that make a valuable contribution to
enabling compliance with the European Energy Performance of Buildings Directive and the 2006
amendments to Part L of the UK Building Regulations.
Heat pump version (HP)
Heat pump versions are provided with a 4-way reversing valve and can produce hot water up to 45-50°C.
They are always supplied with a second thermostatic valve and a liquid receiver to optimise the efficiency of
the refrigerant cycle in heating and in cooling. The microprocessor is set for automatic defrost (for operation
in severe ambient conditions) and for Heat/Cool change over by digital input.
Free cooling version (FC)
The Free Cooling option is a system designed to give important energy savings, when the cooling system is
operating continuously and when ambients are low. Free cooling units use low temperature ambient air to
cool down the water in the system. In some situations, chilled water can be produced without any
mechanical refrigeration (compressors) with consequent large reduction of power consumption. The Free
Cooling system comprises:
Free cooling coil: Heat exchanger made of copper tubes and aluminium fins, with bleed
valves.
Microprocessor control: The “heart” of the system; it allows correct control of all parameters, leading
to high efficiencies over a range of ambient conditions.
3 way valve: An ON/OFF 3 way valve that opens/closes the free cooling circuit,
depending on the signal coming from the microprocessor control.
Head pressure control: Maintains the correct condensing pressure in the refrigerant circuit when
ambient temperatures are low. In Free Cooling systems, this effect is
achieved by partially closing refrigerant circuits in the condensing coil with
solenoid valves: this reduces the heat transfer capacity and maintains a
suitable condensing pressure.
Heat Recovery Version
A version that includes heat recovery by the addition of a de-superheater heat exchanger located between
the compressor and condenser, is also available. This de-superheater can be fitted to both chiller and heat
pump versions, however, in the heat pump it must be used only when in cooling mode. In heating mode the
water circuit must be isolated. The de-superheater is capable of generating 50°C hot water for domestic use
(washing etc) and can recover up to 25% of the energy removed in cooling by this manner. Such units make
a valuable contribution to energy efficiency.
Total input current (K version) A 32,4 36 37,4 40,1 42,8 52,6 62,0 67,5
Total peak current A 121,4 148,4 154,4 194,4 194,0 235,4 265,1 275,1
Maximum input current A 39,4 45,4 49,4 54,4 59,4 69,4 81,1 91,1
Power suppy V/Ph/Hz400/3/50
(1): Sound power level according to ISO 3746.
(2): Sound pressure level measured at 10m from the unit in free field conditions: direction factor Q=2 (according to ISO 3746).
Cooling: ambient air temperature 35 °C; evaporator water temperature in/out 12°C / 7 °C.
Heating: ambient air temperature 8.3 °C db, 6.1 °C wb ; condenser water temperature in/out 40°C / 45 °C.
Total input current (K version) A 76,4 85,5 96,3 104,7 126,6 144,0 160,2 178,4
Total peak current A 322,1 333,1 290 304 351 369 431 453
Maximum input current A 102,1 113,1 119,9 138,3 167,6 185,6 211,6 233,6
Power supply V/Ph/Hz400/3/50
(1): Sound power level according to ISO 3746.
(2): Sound pressure level measured at 10m from the unit in free field conditions: direction factor Q=2 (according to ISO 3746).
Cooling: ambient air temperature 35 °C; evaporator water temperature in/out 12°C / 7 °C.
Heating: ambient air temperature 8.3 °C db, 6.1 °C wb ; condenser water temperature in/out 40°C / 45 °C.
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A
WATER CHILLERS AND HEAT PUMPS
QLAC / LS (Low noise version)
TECHNICAL DATA
MOD.
Refrigerant R407C R407C R407C R407C R407C
Cooling capacity kW 290 321 383 432 481
Compressor input power kW 92,4 100,6 126,4 138,7 150,9
Water flow rate l/h 4988055200 65800 74300 82700
Water pressure drop kPa 34 39 32 38 44
Free cooling capacity kW 185 185 235 245 240
input power kW 12 12 16 16 16
Water flow rate l/h 4988055200 65800 74300 82700
Water pressure drop kPa 107 121 113 121 141
Total input current (K version) A
Total peak current A
Maximum input current A
Power supply V/Ph/Hz400/3/50
irflow m°/h 8900088500 119000 118000 118000
Fans n° x kW6x2 6x2 8x2 8x2 8x2
Compressors
Refrigerant circuits n° 2 2 2 2 2
Control steps n° 4 4 6 6 6
Sound power level
Sound pressure level
Water pump (option) kW 4 5,5 7,5 7,5 7,5
Pump available pressure (option) kPa 160 172 210 190 160
Water tank capacity (option) l 670 670 670 670 670
Expansion vessel (option) l 25 25 50 50 50
(1)
dB(A) 90 90 91 91 91
(2)
dB(A) 62 62 63 63 63
Length
Width mm 2201 2201 2201 2201 2201
Height mm 2262 2262 2262 2262 2262
Weight (Standard configuration) kg 2750 2800 3100 3150 3210
Weight (with hydraulic kit) kg 3150 3220 3550 3610 3690
type Scroll
n° 4 4 6 6 6
mm 4108 4108 4708 4708 4708
300 320 380 430 500
201,4 220 279,2 301,7 324,2
510 534 582 641 672,5
262,6 287,2 362 393,5 425
Performances are rated at:
Cooling: ambient air temperature 35 °C; evaporator water temperature in/out 12°C / 7 °C.
Free cooling: ambient air temperature 2 °C; water inlet temperature 15°C, glycol 20%, nominal waterflow, compressors switched off
(1): Sound power level according to ISO 3746.
(2): Sound pressure level measured at 10m from the unit in free field conditions: direction factor Q=2 (according to ISO 3746).
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A
WATER CHILLERS AND HEAT PUMPS
QLAC / XL (Extra Low noise version)
TECHNICAL DATA
MOD.
Refrigerant R407C R407C R407C R407C R407C R407C
Cooling capacity kW
Compressor input power kW 17,2 19,3 21,5 25,8 29,9 33,9
Water flow rate l/h 9290 10320 11520 13590 15650 18400
Water pressure drop KPa 31,5 23,3 30,1 30,4 27,6 26,5
Heating capacity kW 55,0 62,0 68,0 83,0 95,0 107,0
Compressor input power kW 17,3 19,5 21,7 26,4 30,3 34,2
Water flow rate l/h 9460 10665 11695 14275 16340 18400
Water pressure drop kPa 32,6 24,8 31,0 33,5 30,0 26,5
Total input current (K version) A
Total peak current A
Maximum input current A
Power suppy V/Ph/Hz400/3/50
irflow m³/h 24000 24000 24000 23600 35000 35000
Fans n° x kW2 x 1.23 2 x 1.23 2 x 1.23 2 x 1.23 3 x 1.23 3 x 1.23
Compressors
Refrigerant circuits n° 1 1 1 1 1 1
Control steps n° 2 2 2 2 2 2
Sound power level
Sound pressure level
Water pump (option) kW 1,1 1,1 1,1 1,5 1,5 2,2
Pump available pressure (option) kPa 141 125 110 150 130 150
Water tank capacity (option) l 300300300300530 530
Expansion vessel (option) l 18 18 18 18 18 18
Length mm 2608 2608 2608 2608 3608 3608
Width mm 1105 1105 1105 1105 1105 1105
Height mm 1842 1842 1842 1842 1842 1842
Weight (Standard configuration) kg 710 725 760 810 1070 1150
Weight (with hydraulic kit) kg 880 895 930 980 1280 1360
# # # XL Models in these sizes are available as a special unit. Contact QUARTZ technical department for details.
Performances are rated at:
Cooling: ambient air temperature 35 °C; evaporator water temperature in/out 12°C / 7 °C.
Heating: ambient air temperature 8.3 °C db, 6.1 °C wb ; condenser water temperature in/out 40°C / 45 °C.
(1): Sound power level according to ISO 3746.
(2): Sound pressure level measured at 10m from the unit in free field conditions: direction factor Q=2 (according to ISO 3746).
Heating capacity kW 120 132 150 165 189 217
Compressor input power kW 38,5 42,9 48,1 52,8 60,6 68,4
Water flow rate l/h 20640 22700 2580028380 32510 37320
Water pressure drop kPa 29,4 31,3 33,8 39,2 40,9 45,1
Total input current (K version) A
Total peak current A
Maximum input current A
Power supply V/Ph/Hz400/3/50
irflow m°/h 33000 33000 3300033000 64000 62000
Fans n° x kW 3 x 1.23 3 x 1.23 3 x 1.23 3 x 1.23 4 x 1,25 4 x 1,25
Compressors
Refrigerant circuits n° 1 1 2 2 2 2
Control steps n° 2 2 4 4 4 4
Sound power level
Sound pressure level
Water pump (option) kW 2,2 2,2 2,2 3,0 3,0 3,0
Pump available pressure (option) kPa 120 130 105 180 140 110
Water tank capacity (option) l 530 530 530 670 670 670
Expansion vessel (option) l 18 18 18 18 18 18
(1)
dB(A) 80,1 80,5 81 81,3 84 84
(2)
dB(A) 52,1 52,5 53 53,3 58 58
Length
Width mm 1105 1105 1105 1105 1105 1105
Height mm 1842 1842 226222622262 2262
Weight (Standard configuration) kg 1200 1230 1650 1700 1960 2050
Weight (with hydraulic kit) kg 1410 1440 1860 2000 2260 2350
# # # XL Models in these sizes are available as a special unit. Contact QUARTZ technical department for details.
Performances are rated at:
(1): Sound power level according to ISO 3746.
(2): Sound pressure level measured at 10m from the unit in free field conditions: direction factor Q=2 (according to ISO 3746).
Cooling: ambient air temperature 35 °C; evaporator water temperature in/out 12°C / 7 °C.
Heating: ambient air temperature 8.3 °C db, 6.1 °C wb ; condenser water temperature in/out 40°C / 45 °C.
The nominal Free Cooling capacity is obtained when all compressors are OFF, the return water temperature
from the system is 15°C and the ambient temperature is 2°C. to calculate the free cooling capacity in
different conditions please refer to the above diagram. To obtain free cooling duty multiply the nominal Free
Cooling capacity by the CFC factor obtained.
The nominal value refers to an ambient temperature 35°C and outlet water temperature 50°C (Dt 5°C).
1,5
040 045 050 060 070 080 090 110
120 130 140 160 190 210 240 260
300 320 380 430 500
1,4
1,3
1,2
1,1
Ambient temperature 40°C
1
0,9
0,8
4041424344454647484950
Outlet water temperature °C
Ambient temperature 35°C
Ambient temperature 30°C
Ambient temperature 25°C
Ambient temperature 20°C
The heat recovery capacity in different conditions can be obtained multiplying the nominal capacity (See above), by the correction
factor indicated in the table.
Warning Partial heat recovery can only work in cooling mode. In the heat pump version it is
necessary to isolate the heat recovery circuit when in heating mode to prevent damage.
Failure to comply with this will invalidate the warranty.
WFCF = Water flow correction factor PDCF = Pressure drop correction factor
The water flow rate and pressure drop correction factors are to be applied directly to the values given for
operation without glycol. The water flow rate correction factor is calculated in order to maintain the same
temperature difference as that which would be obtained without glycol. The pressure drop correction factor
takes into account the different flow rate obtained from the application of the flow rate correction factor.
When the new flow rate is determind the capacity can be calculated using the formula Q=4.19m ΔT, where Q
is the duty in kw, m is the flow rate in kg/s and ΔT is the fluid temperature difference.
--- (not availble)
Lw – Sound power level according to ISO 3746.
Lp – Sound pressure level measured at 10 mt from the unit in free field conditions direction factor Q = 2 according to ISO 3746.
- When installing or servicing the unit, you must follow the instructions given in this manual and on labels
attached to the unit.
- As the chiller is charged with refrigerant under pressure and unauthorised access to the electrical
components provides a shock hazard, any work performed on the unit must be by suitably trained personnel only.
- Failure to observe the instructions provided in this manual, or any modification of the unit without explicit
previous authorisation, will invalidate the warranty.
Attention: before servicing the unit ensure that the electric supply is disconnected.
Inspection
After receiving the unit, immediately check its integrity. The unit left the factory in perfect condition; any
eventual damage must be reported to the carrier and be recorded on the Delivery Note before it is signed.
TEV Ltd must be informed, within 8 days, of the extent of the damage. The customer should prepare a
written statement of any severe damage: digital photos of any damage is useful.
Lifting and site handling
When unloading the unit, care must be taken to prevent damage to the refrigerant circuit, condensing coils
or unit casing.
When using a crane, pass bars through the base frame lifting holes (marked with yellow arrows) and attach
the cable or chains to these bars. Ensure that they are clamped firmly. Protect the sides of the chiller with
boarding or material of a similar nature.
Forklift forks must be inserted in the base pallet: care must be taken to prevent them hitting the base or
panels. Keep the unit horizontal to avoid damage to the internal components.
IMPORTANT: be sure that the method of lifting does not allow the unit to slip from chains or slings,
turn over or slide from lifting devices.
Unpacking
When unpacking, be careful not to damage the unit. The packing is made up of different materials: wood,
cardboard, polythene etc. We recommend that they are sent to a re-cycling centre in order to reduce their
environmental impact.
LOCATION AND MINIMUM CLEARANCES
QLAC units are designed for external installation. Any overhang or cover above the unit should be avoided
as this can cause air re-circulation. It is advisable to create a firm base for the unit, with a size similar to unit
foot-print. Normal unit vibration levels are very low: it is good practice, however, to fit a rigid rubber interface
between base and unit frame. Where desirable, fit anti-vibration mounts (spring or rubber), to keep vibration
to a minimum. For future maintenance, these clearances are recommended:-
Warning: The unit should be installed such that there is suitable access for maintenance and/or
repair.
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06617645-02
HYDRAULIC CONNECTIONS
Unit water pipe-work must be installed in accordance with national and local regulations. Pipes can be steel,
galvanized steel, copper or PVC. Pipes have to be designed depending on the nominal water flow and the
hydraulic pressure drops of the system. All pipes must be insulated with closed-cell material of adequate
thickness. The chiller must be connected to the pipework using flexible joints. Piping should include:
• Temperature and pressure gauges for maintenance or servicing operations.
• Manual shut-off valves to separate the unit from the hydraulic circuit.
• Metallic supply water filter to be sited at the inlet pipe, with a mesh not larger than 1 mm.
• Vent valves, expansion tank with water filling, discharge valve.
The water inlet must correspond with the connection labelled ”USER WATER INLET”, otherwise the
evaporator may freeze.
You must fit a metallic filter with a mesh not larger than 1 mm at the ‘USER WATER INLET’
connection. If the flow switch is altered or the water filter is not fitted, the warranty will be
invalidated. All units are supplied with flow switch, on ‘K’ versions it is factory installed, on standard
versions it is supplied loose. The flow switch MUST be installed on the water outlet pipe. Please refer
to the wiring diagram for the flow switch electrical connections
LAC
Standard
LAC / K
A Water tank F Water strainer
B Flexible connection G Water pump
C Ball shut-off valve H Expansion vessel
D Vent valve I Safety valve
E System filling group
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(QLAC / FC FREE COOLING VERSION)
FREE COOLING SYSTEMS MUST ALWAYS BE FILLED WITH GLYCOL SOLUTION
The free cooling versions can operate in 3 different operating modes. The free-cooling coil is installed in
series with the water chiller evaporator; the 3 way valve controls the water flow through the coil. When the
ambient temperature is lower than the return water temperature, the microprocessor allows the water flow to
pass through the free-cooling coil first, then through the evaporator.
Cooling mode (Summer operation) Ambient temperature is higher than the
return water temperature. In
this case, the ambient conditions are not suitable to allow Free Cooling operation; the 3 way valve is closed
and the water flows to the evaporator, where it is cooled. The compressors, fans, and the water pump are
activated; the unit operates like a normal liquid cooler.
Free cooling mode (Winter operation) Ambient temperature is much lower than the return water
temperature. In this case, the ambient conditions are suitable to allow Free Cooling operation; the 3 way
valve opens and the water flows into the free cooling coil, where the ambient conditions are sufficient to give
the total required load. In this case the pump and the fans are in operation, while the compressors are
stopped. In this case, the free cooling system works in substitution of the water chiller.
Cooling mode + Free cooling (Mid-season operation) Ambient temperature is lower than the return water
temperature. In this case, the ambient conditions are suitable to allow Free Cooling operation; the 3 way
valve opens and water flow passes into the free cooling coil although the ambient conditions are not
sufficiently low to give the total required load. The microprocessor control activates the compressors (pump
and fans are already in operation) to satisfy the required load. In this case the free cooling system works in
conjunction with the water chiller. In these circumstances the head pressure control device is activated.
CONDENSING PRESSURE CONTROL (optional)
If unit operation below 20°C is expected, a condensing pressure control must be fitted in the unit. This
device will allow unit operation under low ambient temperature, by reducing condenser air flow and
obtaining acceptable operating parameters. This device modulates the fan speed in proportion to the
condensing pressure measured by the pressure transducer.
This device is factory pre-set. The values must never be modified.
OPERATIONAL LIMITS
Evaporator water flow rate
The nominal water flow rates are based on a delta T (W
- W
in
) of 5 °C. The maximum flow rate allowed is
out
that achieved with a delta T of 3 °C: higher values may cause too high pressure drop. The minimum water
flow rate allowed is that achieved with a delta T of 8 °C. Insufficient values cause too low evaporating
temperatures, tripping safety devices which stop the unit.
Chilled water temperature (summer operation)
The minimum temperature allowed at the evaporator outlet is 5 °C. To work below this limit, the unit
requires modification - please contact TEV Ltd. The maximum temperature allowed at the evaporator inlet is
20 °C.
Hot water temperature (winter operation)
Once the system is at temperature, the water temperature at the condenser inlet should not be less than 23
°C: lower values could cause incorrect working operation of the compressor and compressor failure may
occur. The maximum water temperature at the condenser outlet should not exceed 48 °C: higher values will
cause safety devices to trip and stop operation.
Ambient air temperature
The units are designed and manufactured to operate, in cooling, with ambient air temperature between 20°C
to 42 °C If a fan speed control is installed then the minimum ambient air temperature is -10°C. In winter
operation (heat pump cycle) operates from -5°C to 20°C.
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06617645-02
ELECTRICAL CONNECTIONS
Disconnect the electrical supply before undertaking any work on the unit.
All electrical work must be undertaken by suitably qualified personnel
.
The electrical supply must match the nominal electrical data (voltage, phase, frequency) shown on the label
in the front panel of the unit. Power connections must be made in accordance to the wiring diagram enclosed
with the unit and in accordance current local and national regulations. Power cable and line protection must
be sized according to the specification stated on the wiring diagram enclosed with the unit.
The variation in line voltage must not be more than ±5% of the nominal value, whilst the voltage imbalance
between phases must not exceed 2%. If those tolerances are likely to be exceeded, please contact TEV
Ltd., as further protection devices are required.
Electrical supply must be as described, otherwise warranty will be invalid.
START UP
Before start-up
- Check that all power cables are connected in the correct sequence and that all terminals are tight.
- The voltage measured at the R Y B phase clamps must be 400 V ± 5% (or the value given on the rating
plate for special voltages). If the voltage is incorrect, do not proceed.
- Check for any refrigerant leaks using a leak detector. Should a leak be found do not proceed. All leaks
must be rectified and the unit re-charged by trained personnel.
- Check that the crankcase heaters are energised.
Crankcase heaters must be energised at least 12 hours before start up by switching on the unit at
the main switch.
- Verify that heaters are working correctly. After a short warm up period, the compressor crankcase must be
warm to the touch and must have a temperature at least 10K higher than ambient temperature.
- Check that all hydraulic connections have been made correctly and that all information given on the unit's
labels have been observed.
- The system must be filled with water and bled to eliminate any air.
Caution: before starting the unit up, check that all cover panels are correctly located and securely
fastened.
Start up
Please refer to the microprocessor manual enclosed with the unit.
If the unit fails to start:
• Check that the control thermostat is set to the correct value.
• Do not modify any internal wiring, otherwise warranty will be invalidated.
Controls during unit operation
• Check the rotation of the fans. If the rotation is incorrect, disconnect the main switch and change over any
two phases of the incoming main supply to reverse motor rotation:
• Check that water temperature at evaporator inlet is near to the set point of the control thermostat.
• For “K” version units (units with pumps and storage tank) if the motor driven pump is noisy, slowly
close the discharge shut-off valve until normal working conditions are restored.
This trouble may occur when system pressure drop is significantly different from pump available
pressure.
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Refrigerant charge checking
• A few minutes after start up, working on cooling operating mode, check that condensing temperature, is
approximately 15 °C higher than condenser inlet air temperature. Also check that the evaporation
temperature is about 5 °C lower than the evaporator outlet temperature.
• When the unit has stabilised, check that the sight glass core shows green: if the core is yellow,
moisture is present in the circuit. In this case it is necessary to dehydrate the circuit (qualified personnel
only). Check at the sight glass that there are no continuous vapour bubbles present. If so, additional
refrigerant charge may be required. (A few vapour bubbles are acceptable).
• Check that refrigerant superheat on the evaporator is about 5-7 °C
• Check if refrigerant sub-cooling on the condenser is about 5-7 °C.
Unit switch OFF
Please refer to the microprocessor manual enclosed with the unit.
Caution: For temporary stops
(night time, weekend etc.) never sw itch off the unit by opening the mains
switch: this should only be used to disconnect the unit from the power supply when current is not
passing through it, i.e. when the unit is in ‘OFF’ mode. Additionally, with no supply to the crankcase
heater, the compressor could be seriously damaged at unit start up.
CONTROL AND SAFETY DEVICE SETTINGS
Control devices - factory settings
CAPACITY STEPS 2 4
CONTROL DEVICE Set-point DifferentialSet point Differential
Control thermostat (cooling) °C
Control thermostat (heating) °C
10 2 9 3
42 2 43 3
Safety devices - factory settings
CONTROL DEVICE SET POINT DIFFERENTIAL RESET TYPE
Anti-freeze thermostat °C
Electric heater thermostat °C
High pressure switch bar
Low pressure switch bar
End defrosting pressure bar
Defrosting set-point bar
Water safety valve (Optional) bar
4 6 Manual
4 6 Manual
28 7 Manual
0,7 1 Manual
18 -- Automatic
16 2 Automatic
6 -- --
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MAINTENANCE AND PERIODIC CHECKS
All maintenance and service operations MUST BE CARRIED OUT BY TRAINED PERSONNEL.
Disconnect the electrical supply before undertaking any work on the unit.
when the supply is connected will need a suitable risk assessment).
(Any servicing performed
The compressor casing and discharge line of the compressor are usually hot. Care should be taken
when working in this area. Aluminium coil fins are very sharp and can cause serious wounds. Care
should be taken when w orking in this area. After any servicing operation ensure that all covers are
replaced and fastened with their locking screws.
It is strongly recommended that regular maintenance checks are performed to maintain correct
operation of the unit:-
Every three months:
- Check that safety and control devices work correctly as previously described.
- Check all the terminals on the electric board and on the compressor are tight. Periodic cleaning of the
terminals of the contactors should be done: if any damage is found, please replace the contactors.
- Verify refrigerant charge by checking the sight glass.
- Check that there is no oil leakage from the compressor.
- Check that there is no water leakage from the hydraulic system.
- If the unit is to be stopped for a long period, the unit hydraulic circuit, including all internal pipework and
heat exchanger, should be emptied. This operation is compulsory if, during a seasonal shutdown, the
ambient temperature is expected to go below the freezing point of the fluid in the hydraulic circuit (typical
seasonal operation).
- Check hydraulic circuit water level.
- Check the flow switch operation .
- Check the compressor crankcase heater power supply and operation.
- Check defrosting procedure.
- Clean drain pan and pipeline.
- Clean mesh on water strainers.
- Clean the finned coils metallic filters with compressed air. This should be in the opposite direction of the
normal air flow. If filters become fully clogged, clean them with a water jet.
Every six months:
- Check the colour of the sight glass core (green = no moisture, yellow = moisture present).
If it is yellow, the refrigerant circuit should be dehydrated and the refrigerant filter/drier changed.
- Check the unit noise level.
- Check mounting of fan blades and their balancing, check the tension and the wear of the belt.
REFRIGERANT CIRCUIT REPAIR
If the refrigerant circuits need to be evacuated,, all the refrigerant must be recovered using suitable
equipment. The system must be charged with nitrogen, using a gas bottle with a pressure reducing valve,
until 15 bar pressure is reached. Search for leaks with a bubble leak finder. If bubbles appear, discharge
the circuit before repairing by brazing with a suitable braze alloy. Never use oxygen instead of nitrogen:
explosions may occur.
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Environmental Protection
European legislation regarding the use of ozone depleting substances forbids the release of refrigerants to
the atmosphere. They must be reclaimed and returned to the vendor, or to authorised re-cyclers at the end
of their operating life.
R407C refrigerant is deemed to be a controlled substance and is therefore subject to this legislation.
Particular care is required during servicing operations in order to prevent refrigerant loss.
De-commissioning
When the unit reaches the end of its service life and requires removal or replacement, the following
operations are recommended:-
- the unit refrigerant must be reclaimed by trained personnel and returned to an authorised re-cycling centre
- compressor lubricating oil should be recovered and sent to an authorised re-cycling centre
- the unit frame, coil, heat exchanger etc, should be dismantled and subdivided into material type; bear in
mind that copper and aluminium are present in substantial quantities in the unit.
These operations aid material recovery and recycling processes, reducing environmental impact.
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DIMENSIONS
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TEV LTD, ARMYTAGE ROAD, BRIGHOUSE, WEST YORKSHIRE, HD6 1QF . + 44 (0) 1484 405630 +44 (0) 1484 405620
sales@quartz.co.uk www.quartz.co.uk
EMAIL:WEB:
42
TEL:FAX:
06617645-02
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