SystemAir EVO CO 570, EVO CO 630, EVO CO 700, EVO CO 770, EVO CO 850 Installation And Maintenance Manual

...

Installation and maintenance manual Manuel d’installation et de maintenance Installations- und Wartungshandbuch Manuale di installazione e di manutenzione Manual de instalación y de mantenimiento

SyScrew Water EVO

CO/HP/RC

444



1567 kW

Part number / Code / Code / Codice / Código: 367236/A Supersedes / Annule et remplace / Annulliert und ersezt / Annulla e sostituisce / Anula y sustituye:

367236

Notified Body /Organisme Notifié / Benannte Zertifizierungsstelle / Organismo Notificato / Organismo Notificado

N°. 1115 ”

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FrançaisEnglish

Water/water Cooled Screw Chillers Réfrigérateurs Froid Seulement eau/eau à compresseurs à vis Wassergekulte Wasserkühler mit Schraubenkompressoren Refrigeratori Solo Freddo acqua/acqua con compressori a vite Refrigeradores Sólo Frío agua/agua con compresores a tornillo

ISO 9001:2008 certified management system

COSTRUTTORE / MANUFACTURE - ITALY

BUONE NORME DI MANUTENZIONE DEI DISPOSITIVI

DI SICUREZZA MONTATI SUL GRUPPO FRIGORIFERO

Gentile Cliente, Le ricordiamo alcune indicazioni circa le modalità di manutenzione dei dispositivi di sicurezza montati sul gruppo frigorifero da Lei acquistato. I dispositivi di sicurezza montati sul gruppo sono stati verificati dal COSTRUTTORE a norma di legge. È opportuno che l’utente provveda periodicamente (è consigliato ogni anno) a far verificare da personale qualificato la taratura ed il corretto intervento dei dispositivi di sicurezza montati sul gruppo. In particolare la taratura della/e valvole di sicurezza dovrebbe essere verificata al banco intercettando opportunamente il circuito e/o il refrigerante e registrando l’avvenuta verifica sulla scheda di manutenzione del gruppo frigorifero (a disposizione dei tecnici CE/PED che eventualmente ne prenderanno visione). L’utente avrà cura di conservare efficienti ed in buono stato l’evaporatore ed i suoi accessori e provvederà ad eventuali sostituzioni degli stessi con altri di tipo analogo. In caso di sostituzione, la valvola di sicurezza e i pressostati di alta pressione

dovranno avere caratteristiche equivalenti a quelle fornite e rilasciate con certificato CE/PED. Si consiglia in occasione della verifica delle valvole di sicurezza di far controllare il corretto intervento dei pressostati di alta pressione. Per informazioni circa le modalità operative, la strumentazione e la scelta di personale qualificato, è possibile contattare IL COSTRUTTORE.

IMPORTANT NOTICE – Maintenance instructions

Please read carefully the following instructions for the maintenance of safety devices fitted on this refrigeration machine. All safety devices fitted on the machine by MANUFACTURE have been checked and tested in accordance with European Regulations. The machine has been designed to operate continuously provided it is regularly maintained and operated within the limitations given in the “Installation, Commissioning, Operation and Maintenance Manual”. The unit should be maintained in accordance with the schedule by the operator/customer, backed up regular service and maintenance visit by an authorised service Centre. It is the responsibility of the owner to provide for these regular maintenance requirements by a competent person. If in any doubt contact your local Service Centre. In particular, all safety valves where fitted and safety pressure switches should be tested and calibrated. Where necessary test certificate provided by a certified

authority must be retained as a record together with

the Maintenance Log.

Date: 18/01/2012

Nazareno Mantovani

Service Director

English

Table of Contents

1 - FOREWORD

1.1 Introduction ..........................................................................2

1.2 Warranty ..............................................................................2

1.3 Emergency stop/Normal stop ...............................................2

1.4 An introduction to this manual ..............................................2

2 - SAFETY

2.1 Foreword ..............................................................................3

2.2 Definitions ............................................................................ 4

2.3 Access to the unit ................................................................4

2.4 General precautions..............................................................4

2.5 Precautions against residual risks .........................................4

2.6 Precautions during maintenance operations ..........................5

2.7 Safety labels ................................................................. 6 & 7

2.8 Safety regulations ........................................................ 8 to 10

3 - TRANSPORT, LIFTING AND POSITIONING

3.1 Inspection ..........................................................................11

3.2 Lifting ................................................................................11

3.3 Anchoring ..........................................................................12

3.4 Storage ..............................................................................12

4 - INSTALLATION

4.1 Positioning of the unit .........................................................13

4.2 Spring isolator installation ...................................................13

4.3 Hydraulic connection of the evaporator ...................... 14 & 15

4.4 Hydraulic connection of the condenser ..............................16

4.5 Hydraulic connections .......................................................16

4.6 Connection of water temperature sensors

(on shell and tube evaporator) ........................................... 17

4.7 Connection of water temperature sensors

(on shell and tube condenser/s)..........................................18

4.8 Power supply .....................................................................19

4.9 Electrical connections................................................ 19 & 20

5 - START-UP

5.1 Preliminary check ............................................................... 20

5.2 Start-up .............................................................................20

5.3 Checking the operation .......................................................20

5.4 Delivery to the customer .....................................................20

6 - CONTROL

6.1 Display ...............................................................................23

6.2 Setpoint .............................................................................25

6.3 Protection and Safety Equipment ........................................26

7 - PRODUCT DESCRIPTION

7.1 Introduction ........................................................................ 27

7.2 General specifications ........................................................27

7.3 Compressors .....................................................................27

7.4 Refrigeration circuits ..........................................................27

7.5 Water heat exchanger .........................................................28

7.6 Electrical power supply and control system ........................28

7.7 Accessories ....................................................................... 28

8 - TECHNICAL DATA

8.1 Pressure drops ................................................................... 31

8.2 Technical data ...........................................................33 to 38

8.3 Unit electrical data ..................................................... 39 & 40

8.4 Position of shock adsorbers

and weight distribution on supports ....................................41

8.5 Dimensional Drawings ............................................... 43 to 50

8.6 Service spaces ................................................................... 51

9 - MAINTENANCE

9.1 General requirements .........................................................52

9.2 Planned maintenance .........................................................52

9.3 Refrigerant charge ..............................................................53

9.4 Compressor .......................................................................53

9.5 Condenser .........................................................................53

9.6 Dehydrating filter ................................................................53

9.7 Sight glass .........................................................................54

9.8 Electronic expansion valve .................................................. 54

9.9 Evaporator .........................................................................54

10 - TROUBLESHOOTING .......................................... 55

11 - SPARE PARTS

11.1 Spare part list.....................................................................56

11.2 Oil for compressors ............................................................56

11.3 Wiring diagrams .................................................................56

12 - DISMANTLING, DEMOLITION AND SCRAPPING

12.1 Generalities ........................................................................57

1 - Introdução

1 - Foreword

1.1 Introduction

Units, manufactured to state-of-the-art design and implementation standards, ensure top performance, reliability and fitness to any type of air-conditioning systems.

These units are designed for cooling water or glycoled water (and for water heating in heat pump models) and are unfit for any purposes other than those specified in this manual.

This manual includes all the information required for a proper installation of the units, as well as the relevant operating and maintenance instructions.

It is therefore recommended to read this manual carefully before installation or any operation on the machine. The chiller installation and maintenance must be carried out by skilled personnel only (where possible, by one of Authorised Service Centers).

The manufacturer may not be held liable for any damage to people or property caused by improper installation, start-up and/or improper use of the unit and/or failure to implement the procedures and instructions included in this manual.

1.2 Warranty

These units are delivered complete, tested and ready for being operated. Any form of warranty will become null and void in the event that the appliance is modified without manufacturer’s preliminary written authorisation.

This warranty shall apply providing that the installation instructions have been complied with (either issued by manufacturer, or deriving from the current practice), and the Form 1 (“Start-up”) has been filled-in and mailed to manufacturer (attn. After-Sales Service).

In order for this warranty to be valid, the following conditions shall be met:

Q The machine must be operated only by skilled personnel from

Authorised After-Sales Service.

Q Maintenance must be performed only by skilled personnel - from

one of Authorised After-Sales Centers.

Q Use only original spare parts.

Q Carry out all the planned maintenance provided for by this manual

in a timely and proper way.

Failure to comply with any of these conditions will automatically void the warranty.

1.3 Emergency stop / Normal stop

The emergency stop of the unit can be enabled using the master switch on the control panel (move down the lever).

For a normal stop, press the relevant push-buttons.

To restart the appliance, follow the procedure detailed in this manual.

1.4 An introduction to the manual

For safety reasons, it is imperative to follow the instructions given in this manual. In case of any damage caused by non-compliance with these instructions, the warranty will immediately become null and void.

Conventions used throughout the manual:

DANGER

The Danger sign recalls your attention to a certain procedure or practice which, if not followed, may result in serious damage to people and property.

The Warning sign precedes those procedures that, if not followed, may result in serious damage to the appliance.

The Notes contain important observations.

The Useful Tips provide valuable information that optimises the efficiency of the appliance.

This manual and its contents, as well as the documentation which accompanies the unit, are and remain the property of manufacturer, which reserves any and all rights thereon. This manual may not be copied, in whole or in part, without manufacturer’s written authorization.

WARNING

NOTE

USEFUL TIPS

English

2 - Safety

2.1 Foreword

These units must be installed in conformity with the provisions of Machinery Directive 2006/42/EC, Low Voltage Directive 2006/95/EC, Pressure Vessels Directive 2014/68/ EU, Electromagnetic Interference Directive 2004/108/EC, as well as with other regulations applicable in the country of installation. If these provisions are not complied with, the unit must not be operated.

DANGER

The unit must be grounded, and no installation and/or maintenance operations may be carried out before deenergising the electrical panel of the unit.

Failure to respect the safety measures mentioned above may result in electrocution hazard and fire in the presence of any short-circuits.

DANGER

Inside the heat exchangers, the compressors and the refrigeration lines, this unit contains liqui d an d gas e ous refri geran t u nder pressure. The release of this refrigerant may be dangerous and cause injuries.

DANGER

The units are not designed to be operated with natural refrigerants, such as hydrocarbons. Manufacturer may not be held liable for any problems deriving from the replacement of original refrigerant or the introduction of hydrocarbons.

Units are designed and manufactured according to the requirements of European Standard PED 2014/68/EU (pressure vessels directive).

Q The used refrigerants are included in group II (non-hazardous

fluids).

Q The maximum working pressure values are mentioned on the

unit’s data plate.

Q Suitable safety devices (pressure switches and safety valves)

have been provided, to prevent any anomalous overpressure inside the plant.

Q The vents of the safety valves are positioned and oriented in such

a way as to reduce the risk of contact with the operator, in the event that the valve is operated. Anyway, the installer will convey the discharge of the valves far from the unit.

Q Dedicated guards (removable panels with tools) and danger signs

indicate the presence of hot pipes or components (high surface temperature).

DANGER

The guards of the fans (only for RC units, with remote air exchangers) must be always mounted and must never be removed before de-energising the appliance.

DANGER

It is the User’s responsibility to ensure that the unit is fit for the conditions of intended use and that both installation and maintenance are carried out by experienced personnel, capable of respecting all the recommendations provided by this manual.

It is important that the unit is adequately supported, as detailed in this manual. Noncompliance with these recommendations may create hazardous situations for the personnel.

DANGER

The unit must rest on a base which meets the characteristics specified in this manual; a base with inadequate characteristics is likely to become a source of serious injury to the personnel.

WARNING

Th e unit has not bee n de sign to wit hsta nd loads and/or stress that may be transmitted by adjacent units, piping and/or structures.

Each external load or stress transmitted to the unit m ay break or cause breakdowns in t he unit’s structure, as well as serious dangers to people. In these cases, any form of warranty will automatically become null and void.

WARNING

The packaging material must not be disposed of in the surrounding environment or burnt.

2.2 Definitions

OWNER: means the legal representative of the company, body or

individual who owns the plant where unit has been installed; he/she has the responsibility of making sure that all the safety regulations specified in this manual are complied with, along with the national laws in force.

INSTALLER: means the legal representative of the company who has been given by the owner the job of positioning and performing the hydraulic, electric and other connections of unit to the plant: he/she is responsible for handling and properly installing the appliance, as specified in this manual and according to the national regulations in force.

OPERATOR: means a person authorised by the owner to do on unit all the regulation and control operations expressly described in this manual, that must be strictly complied with, without exceeding the scope of the tasks entrusted to him.

ENGINEER: means a person authorised directly by manufacturer or, in all EC countries, excluding Italy, under his full responsibility, by the distributor of product, to perform any routine and extraordinary maintenance operations, as well as any regulation, control, servicing operations and the replacement of pieces, as may be necessary during the life of the unit.

2.3 Access to the unit

The unit must be placed in an area which can be accessed also by OPERATORS and ENGINEERS; otherwise the unit must be surrounded by a fence at not less than 2 meters from the external surface of the machine.

OPERATORS and ENGINEERS must enter the fenced area only after wearing suitable clothing (safety shoes, gloves, helmet etc.). The INSTALLER personnel or any other visitor must always be accompanied by an OPERATOR.

For no reason shall any unauthorised personnel be left alone in contact with the unit.

2.4 General precautions

The OPERATOR must simply use the controls of the unit; he must not open any panel, other than the one providing access to the control module.

The INSTALLER must simply work on the connections between plant and machine; he must not open any panels of the machine and he must not enable any control.

When you approach or work on the unit, follow the precautions listed below:

Q do not wear loose clothing or jewellery or any other accessory tat

may be caught in moving parts

Q wear suitable personal protective equipment (gloves, goggles

etc.) when you have to work in the presence of free flames (welding operations) or with compressed air

Q if the unit is placed in a closed room, wear ear protection devices

Q cut off connecting pipes, drain them in order to balance the

pressure to the atmospheric value before disconnecting them,

disassemble connections, filters, joints or other line items

Q do not use your hands to check for any pressure drops

Q use tools in a good state of repair; be sure to have understood the

instructions before using them

Q be sure to have removed all tools, electrical cables and any other

objects before closing and starting the unit again

2.5 Precautions against residual risks

Prevention of residual risks caused by the control system

Q be sure to have perfectly understood the operating instructions

before carrying out any operation on the control panel

Q when you have to work on the control panel, keep always the

operating instructions within reach

Q start the unit only after you have checked its perfect connection to

the plant

Q promptly inform the ENGINEER about any alarm involving the unit

Q do not reset manual restoration alarms unless you have identified

and removed their cause

Prevention of residual mechanical risks

Q install the unit according to the instructions provided in this

manual

Q carry out all the periodical maintenance operations prescribed by

this manual

Q wear a protective helmet before accessing the interior of the unit

Q before opening any panelling of the machine, make sure that it is

secured to it by hinges

Q do not touch air cooled coils (RC versions) or shell and tube

condensers (CO / HP versions) without protective gloves

Q do not remove the guards from moving elements while the unit is

running

Q check the correct position of the moving elements’ guards before

restarting the unit

Prevention of residual electrical risks

Q connect the unit to the mains according to the instructions

provided in this manual

Q periodically carry out all the maintenance operations specified by

this manual

Q disconnect the unit from the mains by the external disconnecting

switch before opening the electrical board

Q check the proper grounding of the unit before start-up

Q check all the electrical connections, the connecting cables, and in

particular the insulation; replace worn or damaged cables

2 - Safety (continued)

English

Q periodically check the board’s internal wiring

Q do not use cables having an inadequate section or flying

connections, even for limited periods of time or in an emergency

Prevention of other residual risks

Q make sure that the connections to the unit conform to the

instructions provided in this manual and on the unit’s panelling

Q if you have to disassemble a piece, make sure that it has been

properly mounted again before restarting the unit

Q do not touch the delivery pipes from the compressor, the

compressor and any other piping or component inside the machine before wearing protective gloves

Q keep a fire extinguisher fir for electrical appliances near the

machine

Q on the units installed indoor, connect the safety valve of the

refrigeration circuit to a piping network that can channel any overflowing refrigerant outside

Q remove and leak of fluid inside and outside the unit

Q collect the waste liquids and dry any oil spillage

Q periodically clean the compressor compartment, to remove any

fouling

Q do not store flammable liquids near the unit

Q do not disperse the refrigerant and the lubricating oil into the

environment

Q weld only empty pipes; do not approach flames or other sources

of heat to refrigerant pipes

Q do not bend/hit pipes containing fluids under pressure

2.6 Precautions during maintenance operations

Maintenance operations can be carried out by authorised technicians only.

Before performing any maintenance operations:

Q disconnect the unit from the mains with the external disconnecting

switch

2 - Safety (continued)

Q place a warning sign “do not turn on - maintenance in progress”

on the external disconnecting switch

Q make sure that on-off remote controls are inhibited

Q wear suitable personal protective equipment (helmet, safety

gloves, goggles and shoes etc.)

To carry out any measurements or checks which require the activation of the machine:

Q work with the electrical board open only for the necessary time

Q close the electrical board as soon as the measurement or check

has been completed

Q for outdoor units, do not carry out any operations in the presence

of dangerous climatic conditions (rain, snow, mist etc.)

The following precautions must be always adopted:

Q do not scatter the fluids of the refrigeration circuit in the

surrounding environment

Q when replacing an eprom or electronic cards, use always suitable

devices (extractor, antistatic bracelet, etc.)

Q to replace a compressor, the evaporator, the condensing coils or

any other weighty element, make sure that the lifting equipment is consistent with the weight to be lifted

Q in units connected to a air remote condenser, do not access the

fan compartment unless you have disconnected the machine by the disconnecting switch on the board and you have placed a warning sign “do not turn on - maintenance in progress”

Q contact manufacturer for any modifications to the refrigeration,

hydraulic or wiring diagram of the unit, as well as to its control logics

Q contact manufacturer if it is necessary to perform very difficult

disassembly and assembly operations

Q use only original spare parts purchased directly from manufacturer

or the official retailers of the companies on the recommended spare parts list

Q contact manufacturer if it is necessary to handle the unit one year

after its positioning on site or if you wish to dismantle it.

2 - Safety (continued)

2.7 Safety labels

Identification of the refrigerant - External door

USARE SOLO

R134a

RECUPERARE FLUIDO - NON DISPERDERE NELL’AMBIENTE - REGOLAMENTO CEE N° 3093/94

RECOVER - DO NOT VENT - EEC REGULATION N° 3093/94

SPECIAL ESTER OIL

USE ONLY

Electrical warning - Aåacent to the master switch

ATTENZIONE !

Prima di

aprire togliere

tensione

CAUTION !

Disconnect

electrical

supply before

opening

ACHTUNG !

Vor offn en des

gehauses

hauptschalter

ausschalten

ATENCION !

Cor tar la

corrente antes

de abrir

el aparato

ATTENTION !

Enlever

l’alimentation

electrique

avant d’ouvrir

Read the instruction on the electrical board

On the compressor box

WARNING

Circuit drain - Outside, on the right-hand front column

Identification of the unit - Outside, on the right-hand front column

Gravity centre - Base

TENERE SU QUESTA LINEA

GANCIO DI SOLLEVAMENTO

KEEP LIFT HOOK

ON THIS LINE

Grounding connection on the electrical board, aåacent to the connection

DO NOT OPEN THE PANEL

WHILE UNIT IS RUNNING

ATTENTION! Don’t leave the unit with water inside hydraulic circuit during winter or when it is in stand by. ATTENZIONE! Non lasciare l’unità con acqua nel circuito idraulico durante l’inverno o quando non è funzionante. ATTENTION! Ne laissez pas l’unitè avec de l’eau dans le circuit hydraulique pendant l’hiver ou quand elle ne travaille pas. WARNUNG! Lassen Sie nicht das Wasser in die Schaltung während des Winters oder wenn es nicht funktionient. ¡ATENCÍON! No deje el agua en el circuito hidráulico durante el invierno o cuando no esta trabajando.

English

2 - Safety (continued)

Final Test Certificate - Inside the external door

Warning - Safety valve vents

Warning - High temperature zone aåacent to hot pipes or

components

Start-up warning - Outside the door

of the electrical board

Instruction for the lifting

Fitting identification - Aåacent to fittings

EIN - INLET

ENTRÉE - ENTRATA

AUS - OUTLET

SORTIE - USCITA

2 - Safety (continued)

2.8 Safety regulations

REFRIGERANT DATA SAFETY DATA: R134a

Toxicity Low

Contact with skin

If sprayed, the refrigerant is likely to cause frost burns. If absorbed by the skin, the danger is very limited; it may cause a slight irritation, and the liquid is degreasing. Unfreeze the affected skin with water.

Remove the contaminated clothes with great care - in the presence of frost burns, the clothes may stick to the skin. Wash with plenty of warm water the affected skin.

In the presence of symptoms such as irritation or blisters, obtain medical attention.

Contact with eyes

Vapours do not cause harmful effects. The spraying of refrigerant may cause frost burns.

Wash immediately with a proper solution or with tap water for at least 10 minutes, and then obtain medical attention.

Ingestion

Very unlikely - should something happen, it will cause frost burns.

Do not induce vomiting. Only if the patient is conscious, wash out mouth with water and give some 250 ml of water to drink. Then, obtain medical attention.

Inhalation

R134a: remarkable concentrations in the air may have an anaesthetic effect, up to fainting.

The exposure to considerable amounts may cause irregular heartbeat, up to the sudden death of the patient. Very high concentrations may result in the risk of asphyxia, due to the reduction in the oxygen percentage in the atmosphere. Remove the patient to fresh air and keep warm and at rest.

If necessary, give oxygen. In case of breathing difficulties or arrest, proceed with artificial respiration.

In case of cardiac arrest, proceed with cardiac massage. Then, obtain medical attention.

Recommendations

Semiotics or support therapy is recommended. Cardiac sensitisation has been observed that, in the presence of circulating catecholamines such as adrenalin, may cause cardiac arrhythmia and accordingly, in case of exposure to high concentrations, cardiac arrest.

Prolonged exposure

R134a: a study on the effects of exposure to 50,000 ppm during the whole life of rats has identified the development of benign testicle tumour.

This situation should therefore be negligible for personnel exposed to concentrations equal to or lower than professional levels.

Professional levels R134a: Recommended threshold: 1000 ppm v/v - 8 hours TWA.

Stability R134a: Not specified

Conditions to avoid Do not use in the presence of flames, burning surfaces and excess humidity.

Hazardous reactions

May react with sodium, potassium, barium and other alkaline metals.

Incompatible substances: magnesium and alloys with magnesium concentrations > 2%.

Hazardous decomposition products

R134a: Halogen acids produced by thermal decomposition and hydrolysis.

English

2 - Safety (continued)

2.8 Safety regulations (continued)

REFRIGERANT DATA SAFETY DATA: R134a

General precautions

Do not inhale concentrated vapours. Their concentration in the atmosphere should not exceed the minimum preset values and should be maintained below the professional threshold. Being more weighty than the air, the vapour concentrates on the bottom, in narrow areas. Therefore, the exhaust system must work at low level.

Respiratory system protection

If you are in doubt about the concentration in the atmosphere, it is recommended to wear a respirator approved by an accident-prevention

Authority, of the independent or oxygen type.

Storage

Cylinders must be stored in a dry and fresh place, free from any fire hazard, far from direct sunlight or other sources of heat, radiators etc.

Keep a temperature below 45 °C.

Protective clothing Wear overalls, protective gloves and goggles or a mask.

Accidental release measures

It is important to wear protective clothing and a respirator.

Stop the source of the leak, if you can do this without danger. Negligible leaks can be left evaporating under the sun, providing that the room is well ventilated.

Considerable leaks: ventilate the room. Reduce the leak with sand, earth or other absorbing substances.

Make sure that the liquid does is not channelled into gutters, sewers or pits where the vapours are likely to create a stuffy atmosphere.

Disposal

The best method is recovery and recycling. If this method is not practicable, dispose according to an approved procedure, that shall ensure the absorption and neutralization of acids and toxic agents.

Fire fighting information R134a: Not flammable in the atmosphere.

Cylinders The cylinders, if exposed to fire, shall be cooled by water jets; otherwise, if heated, they may explode.

Protective fire fighting equipment In case of fire, wear an independent respirator and protective clothing.

2 - Safety (continued)

LUBRICANT OIL DATA SAFETY DATA: POLYESTER OIL (POE)

Classification Not harmful.

Contact with skin

May cause slight irritation. Does not require first aid measures. It is recommended to follow usual personal hygiene measures, including washing the exposed skin with soap and water several times a day.

It is also recommended to wash your overalls at least once a week.

Contact with eyes Wash thoroughly with a suitable solution or tap water.

Ingestion Seek medical advice immediately.

Inhalation Seek medical advice immediately.

Conditions to avoid

Strong oxidising substances, caustic or acid solutions, excess heat.

May corrode some types of paint or rubber.

Protection of the respiratory system

Use in well ventilated rooms.

Protective clothing

Always wear protective goggles or a mask. Wearing protective gloves is not mandatory, but is recommended in case of prolonged exposure to refrigerant oil.

Accidental release measures

It is important to wear protective clothing and, especially, goggles.

Stop the source of the leak. Reduce the leak with absorbing substances (sand, sawdust or any other absorbing material available on the market).

Disposal

The refrigerant oil and its waste will be disposed of in an approved incinerator, in conformity with the provisions and the local regulations applicable to oil waste.

Fire fighting information

In the presence of hot liquid or flames, use dry powder, carbon dioxide or foam. If the leak is not burning, use a water jet to remove any vapours and to protect the personnel responsible for stopping the leak.

Cylinders The cylinders exposed to a fire will be cooled with water jets in case of fire.

Fire fighting protective equipment In case of fire, wear an independent respirator.

2.8 Safety regulations (continued)

English

3 - Transport, Lifting and Positioning

Refrigerators are supplied assembled (apar t from standard antivibrating rubber supports, that will be installed on site). The equipment are full of refrigerant and oil, in the quantity required for a proper operation.

3.1 Inspection

When the unit is delivered, it is recommended to check it carefully and to identify any damage occurred during transportation. The goods are shipped ex-factory, at the buyer’s risk. Check that the delivery includes all the components listed in the order.

In case of damage, note it down on the carrier’s delivery note and issue a claim according to the instructions provided in the delivery note.

In the presence of any serious damage, that does not affect the surface only, it is recommended to inform manufacturer immediately.

Please note that manufacturer may not be held liable for any damage to the equipment during transportation, even though the carrier has been appointed by the factory.

3.2 Lifting

The unit must be lifted by using the hooks inserted into the relevant eyebolts (see the figure).

It is recommended to use a spacer to prevent cables from damaging the unit (see the figure). For sizes equipped with 1 compressor (440-

770) the minimum size of the spacer is 1350 mm. For sizes equipped with 2 compressors (860-1550) the minimum size of the spacer is 1520 mm.

Before positioning the unit, make sure that the place of installation is appropriate and sturdy enough to hold the weight and to withstand the stress caused by the operation of the whole assembly.

WARNING

Do not displace the unit on rollers, and do not lift it with a lift truck.

Unit must be lifted carefully. To lift unit slowly and regularly.

To lift and displace the unit:

Insert and secure eyebolts into the holes marked on the frame.

Insert spacer between cables.

Hook near the barycentre of the unit.

The cables must be long enough to form, if tensioned, an angle

of at least 45° with respect to the horizontal plane.

3 - Transport, Lifting and Positioning (continued)

WARNING

During the lifting and handling of the unit, be careful not to damage the electrical board, installed on one side of the unit.

The sides of the unit must be protected by cardboard or plywood sheets.

WARNING

It is recommended not to remove the protective plastic envelope, that should prevent scraps from penetrating into the appliance and any damage to the surfaces, until the unit is ready for operation.

3.3 Anchoring

It is not essential to secure the unit to the foundations, unless in areas where there is a serious risk of earthquake, or if the appliance is installed on the top of a steel frame.

3.4 Storage

When the unit is to be stored before installation, adopt a few precautions to prevent any damage or risk of corrosion or wear:

Q plug or seal every single opening, such as water fittings

Q do not store the appliance in a room where the temperature

exceeds 50 °C for the units using R134a and, if possible, do not expose to direct sunlight

Q minimum storage temperature is -25 °C

Q it is recommended to store the unit in a roof where traffic is

minimized, to prevent the risk of accidental damage

Q the unit must not be washed with a steam jet

Q take away and leave to the site manager all the keys providing

access to the control board

Finally, it is recommended to carry out visual inspections at regular intervals.

WARNING

For lifting operations, use only tools and material fit for this purpose, in accordance with accident-prevention regulations.

English

4 - Installation

4.1 Positioning of the unit

DANGER

Before installing the unit, make sure that the structure of the building and/or the supporting surface can withstand the weight of the appliance. The weights of the units are listed in Chapter 8 of this manual.

These units have been designed for indoor installation on a solid surface. Standard accessories include antivibrating rubber supports, that must be positioned under the base.

When the unit is to be installed on the ground, it is necessary to provide a concrete base, to ensure a uniform distribution of the weights.

As a general rule, no special sub-bases are required. However, if the unit is to be installed on the top of inhabited rooms, it is advisable to rest it on spring shock absorbers (optional), that will minimise the transmission of any vibration to the structures.

To choose the place of installation of the unit, bear in mind to guarantee all the necessary spaces for air circulation and maintenance operations (see Chapter 9).

4.2 Spring Isolator Installation

Prepare the base, that must be flat and plane.

Lift the appliance and inser t shock absorbers as follows:

4 - Installation (continued)

4.3 Hydraulic connection of the evaporator

The flow switch and the filter water, although not included in the supply, must always be fitted such as plant components. Their installation is mandatory for warranty.

WARNING

The external hydraulic circuit must ensure the water flow to the evaporator under any working or adjustment conditions.

The circuit shall be composed by the following elements:

A circulation pump which can ensure the necessary capacity

and discharge head.

The capacity of the primary hydraulic circuit should not be less

than 7.5 litres/KW of cooling capacity, in order to prevent the repeated start-up of the compressor and any damage to it. If the water capacity in the primary piping of the circuit and in the evaporator is lower than this value, an insulated storage tank shall be installed.

A membrane expansion vessel provided with safety valve with

vent, that must be visible.

NOTE

The capacity of the expansion vessel must allow for an expansion of at least 2% of the volume of the fluid in the circuit (evaporator, piping, user circuit and standby tank, if any). The expansion vessel needs not be isolated, because no water can circulate inside it.

A flow switch will stop the unit when the water is not circulating or a flow rate problem occurs.

To install the flow switch, follow the manufacturer’s instructions.

As a general rule, the flow switch shall be mounted on a horizontal pipe, at a distance from the curves equal to 10 times the diameter of the pipe and far from valves or other components that are likely to hinder the water flow upstream of or downstream from the flow switch.

The bleed valves must be mounted on the highest point of the

piping.

The stop valves must be mounted on the piping of the water ente-

ring/leaving the evaporator.

The drain points (provided with plugs, cocks etc.) must be arran-

ged in the lowest point of the piping.

WARNING

The flow switch must be connected (terminals 1-2) as shown in the wiring diagram of the “User’s Terminal Box”.

English

4 - Installation (continued)

Then:

Provide the evaporator with a by-pass circuit equipped with a

valve to wash the plant.

Insulate the piping, to prevent the risk of heat loss.

Position a filter on the suction side of the evaporator of the heat

recovery condenser.

WARNING

Before filling the circuit, it is important to check that it is free from any foreign matter, sand, gravels, rust, welding deposits, waste and other materials that may damage the evaporator.

When cleaning the lines, it is recommended to create a circuit bypass. It is important to mount a filtering medium (30 mesh) upstream of the chiller.

Standard hydraulic circuit

External water circuit

Connection Diagram

Unit

COMPONENTS

I Pressure gauge connection R Drain cock

S Gate valve T Thermometer F1 Flow Switch F Filter GA Flexible hoses I1/I2 Pressure gauge connection to measure pressure drop or head pressure

NOTE

If necessary, the water required to fill the circuit must be treated to obtain the requested pH.

4 - Installation (continued)

4.5 Hydraulic connection

The water inlet/outlet fittings shall conform to the instr uctions provided by the plates affixed neat the connection points.

4.4 Hydraulic connection of the condenser

WARNING

The external hydraulic circuit must ensure the water flow to the condenser under any working or adjustment conditions.

The cooling of the units is generally ensured by connecting the condenser to a cooling tower, though the units can be cooled also with well water.

In the presence of a water-cooled condenser, it is necessary to check the flow rate and/or the temperature of the cooling fluid that flows through the condenser, so as to maintain the refrigerant pressure at values that can ensure a satisfactory operation.

When a cooling tower is used, the simplest regulation methods consist of checking the operation or the speed of the fan or the air volume, by means of a damper, once the pilot thermostat has been installed in the basin of the tower.

Alternatively, or if no water from a cooling tower is used, you can adopt a recirculaton system provided with a 3-way valve.

This circuit shall consist of:

A circulation pump that can ensure the necessary capacity and

discharge head.

A flow meter to turn off the appliance when no water is circulating.

WARNING

The flow meter must be connected in series, as shown in the wiring diagram of the control panel.

To install the flow meter, follow the manufacturer’s instructions.

As a general rule, the flow meter shall be mounted on a horizontal pipe, at a distance from the curves equal to 10 times the diameter of the pipe and far from valves or other components that are likely to hinder the water flow upstream of or downstream from the flow meter.

The bleed valves must be mounted on the highest point of the

piping.

The stop valves must be mounted on the piping of the water

entering/leaving the condenser.

The discharge points (provided with plugs, cocks etc.) must be

arranged in the lowest point of the piping.

Furthermore:

Provide the condenser with a by-pass circuit, equipped with a

shutoff valve.

Insulate piping, to prevent the risk of heat loss.

Install a filter on the suction side of the condenser.

A three-way valve should be installed on-site. It permits to

bypass the condenser for correct operation at low return water temperature. The best position is close to the condenser.

To install the flow meter, follow the diagram illustrated in paragraph

4.3.

English

4 - Installation (continued)

4.6 Connection of water temperature sensors (on shell and tube evaporator)

The units are provided with fittings for hydraulic connections between heat exchangers and plant.

Each fitting is complete with sensor well to fasten temperature sensor (BT-IN and BT-OUT). Fittings are supplied separate and must be mounted during the installation of the unit.

OUT

FITTING

VICTAULIC JOINT

BT OUT

BT IN

4 - Installation (continued)

4.7 Connection of water temperature sensors (on shell and tube condenser/s)

Hydraulic connections between condenser/s and plant are supplied separately and must be installed during the installation of the unit. Inlet / outlet water temperature probes should be placed inside

dedicated water probes pockets to be provided over the installation. Kit manifold accessory (offered as an option for units equipped with two compressors) is already including water probes pockets.

BT OUT

CONNECTION STANDARD

BT INGRESSO

CONNECTION WITH MANIFOLD KIT

BT IN

English

4 - Installation (continued)

4.8 Power supply

DANGER

Before carrying out any operations on the electrical system, make sure that the unit is deenergised.

DANGER

It is important that the appliance is grounded.

DANGER

The company in charge of the installation shall conform to the standards applicable to outdoor electrical connections.

The manufacturer may not be held liable for any damage and/or injury caused by failure to comply with these precautions.

The unit conforms to EN 60204-1.

The following connections shall be provided:

Q A 3-phase and grounding connection for the power supply

circuit.

Q The electrical distribution system shall meet the power absorbed

by the appliance.

Q The disconnecting and magnetothermal switches must be sized to

control the starting current of the unit.

Q The power supply lines and the insulation devices must be

designed in such a way that every line independent.

Q It is recommended to install differential switches, to prevent any

damage caused by phase drops.

Q The fans and compressors are supplied through contactors

controlled from the control panel.

Q Each motor is provided with an internal safety thermal device

and external fuses.

Q The power supply cables must be inserted into dedicated

openings on the front of the unit, and the will enter the electrical board through holes drilled on the bottom of the board.

4.9 Electrical connections

The unit must be installed on site according to the Machinery Directive (2006/42/EC), the Low Voltage Directive (2006/95/EC), the Electromagnetic Interference Directive (2004/108/EC) and the usual procedures and standards applicable in the place of installation.

The unit must not be operated if its installation has not been carried out according to the instructions provided in this manual.

The power supply lines must consist of insulated copper conductors, dimensioned for the maximum absorbed current.

Connection to terminals must be performed according to the diagram of connections (User’s Terminal Box) provided in this manual and according to the wiring diagram which accompanies the unit.

WARNING

Before connecting the power supply lines, check that the available voltage value does not exceed the range specified in the Electric Data (Chapter

8).

For 3-phase systems, check also that the unbalance between the phases does not exceed 2%. To perform this check, measure the differences between the voltage of each phase couple and their mean value during operation.

The maximum % value of these differences (unbalance) must not exceed 2% of the mean voltage.

If the unbalance is unacceptable, contact the Energy Distributor to solve this problem.

WARNING

Supplying the unit through a line whose unbalance exceeds the permissible value will automatically void the warranty.

4 - Installation (continued)

Electrical connections

English

5 - Start-Up

WARNING

The unit must be started for the first time by personnel suitably trained by one Authorised Service Centre. Failure to meet this requirement will immediately void the warranty.

NOTE

The operations carried out by authorised personnel are limited to the start-up of the unit, and do not include any other operation on the plant, such as, for example, electrical and hydraulic connections etc.

All the other operations before start-up, including oil pre-heating for at least 12 hours, must be performed by the Installer.

5.1 Preliminary check

The checks listed below shall be performed before star ting the unit and before the arrival of the personnel authorised.

Q Check the section of power supply and grounding cables; make

sure that terminals are tightened and check the correct operation of contactors, with the main switch open.

Q Check that any voltage and phase variation in the power supply

does not exceed the prefixed thresholds.

Q Connect the contacts of the flow switch and the thermal relay of

the pump and of the other devices (if any), to terminals 1-2 and 3-4, respectively.

Q Check that the components of the external water circuit (pump,

user equipment, filters, power supply tank and reservoir, if any) have been installed properly, and according to the manufacturer’s instructions.

Q Check the filling of the hydraulic circuits, and make sure that

the fluid circulation is correct, without any trace of leaks and air bubbles. If you use ethylene glycol as antifreeze, check that its percentage is correct.

Q Check that the direction of rotation of the pumps is correct, and

that fluids have been circulating for at least 12 hours for both pumps. Then, clean the filters on the suction side of the pumps.

Q Adjust the liquid distribution network in such a way that the flow

rate is within the specified range.

Q Check that the water quality is up to the specifications.

Q Check that oil heaters, if any, have been turned on at least 12

hours before.

5.2 Start-up

Start-up sequence:

Q Turn on the Main switch (at least 12 hours before).

Q Check that the oil in the compressor has reached the requested

temperature (the minimum temperature outside the pan must be approx. 40°C) and that the auxiliary control circuit is energised.

Q Check the operation of all the external equipment, and make sure

that the control devices of the plant are properly calibrated.

Q Start the pump and check that the water flow is correct.

Q Set the desired fluid temperature on the control board.

Q Start the appliance (see Chapter 6).

Q Check the correct direction of rotation of compressors.

Compressors cannot compress the refrigerant when they rotate in the opposite direction. To make sure that they are rotating in the correct direction, simply check that, just after the start-up of the compressor, the pressure drops on the LP side and rises on the HP side. Furthermore, if a compressor rotate in the opposite direction, there is a considerable rise in the sound level of the unit, as well as in a dramatic reduction of current absorption compared to normal values. In case of wrong rotation, the compressor can be definitely damaged. Phase monitor is assembled in the unit as a standard to prevent wrong compressors rotation.

Q After about 15 minutes of operation check that there are no

bubbles, through the sight glass on the liquid line.

WARNING

The presence of bubbles may indicate that a part of the refrigerant charge has been released in one or more points. It is important to remove these leaks before proceeding.

Q Repeat the start-up procedure after removing the leaks.

Q Check the oil level in the compressor’s sight glass.

5.3 Checking the operation

Check the following:

Q The temperature of the water entering the evaporator.

Q The temperature of the water leaving the evaporator.

Q The level of the water flow rate in the evaporator, if possible.

Q The temperature of the water entering the condenser.

Q The temperature of the water leaving the condenser.

Q The level of the water flow rate in the condenser, if possible.

Q The current absorption upon the start of the compressor and in

case of stabilised operation.

Check that the condensing and evaporation temperatures, during operation at high and low pressure detected by the pressure gauges of the refrigerant, are within the following range:

(On the units not provided with HP/LP pressure gauges for the refrigerant, connect a pressure gauge to the Shrader valves on the refrigeration circuit).

HP side

Approx. 2 to 7 °C above the temperature of condenser leaving water temperature, for 134a units.

LP side

Approx. 2 to 7 °C below the temperature of the leaving chilled water, for R134a units.

5.4 Delivery to the customer

Q Train the user according to the instructions provided in Section 6.

6 - Control

6 General information

Introduction

This document contains the information and the operating instructions for 1/2 screw compressors of step type.

This information is for the after-sales service and the production operators, for the end-of-line testing.

Main characteristics

– Microprocessor control

– User-friendly keyboard

– Proportional control (RWT)

– Neutral zone control on the leaving water temperature (LWT)

– Access code to enter the Manufacturer’s Level

– Access code to enter the Assistance Level

– Alarm and LED

– Backlighted LCD

– Rotation of the compressor operation

– Night mode (or Low Noise) control

– Counting of the pump/compressors’ hours of operation

– Display of discharge and suction pressure values

– Display of temperature sensor

– History of stored alarms (option)

– RS485 serial por t to connect the chiller control to a BMS network.

The following accessories can be also connected:

– Remote Display Terminal

– Wire Remote Control.

– Double set point.

The control system consists of:

a) Main Board. Units are provided with a microprocessor card

which is fully programmed by default for the control of a chiller equipped with a HP transducer and a LP transducer for each circuit.

b) EEV controllers (two separate drivers) to the management of the

electronic expansion valves.

C) Keyboard & Display Terminal.

The terminal makes it possible to carry out the following operations:

– the initial configuration of the machine

– the change of all the main operating parameters

– the display of the detected alarms

– the display of all the measured quantities

The terminal and the card are connected by a 6-way phone cable.

The connection of the terminal to the basic card is not essential for the normal operation of the controller.

English

6 - Control (continued)

6.1 Display/Keyboard

The display is an LCD 8 lines x 22 columns. The quantities and the information about the operation of the unit are alternated in the form of subsequent screens, named “masks”.

It is possible to move inside the masks with the terminal keys as described below.

Arrows key - Up/Down/Enter

If the cursor is in the top left-hand corner (Home), press the UP/ DOWN keys to access the subsequent masks associated to the selected branch. If a mask includes some value setting fields and you press the ENTER key, the cursor will reach these fields.

Once you have reached the quantity setting field, you can modify any value (within the expected limits) by pressing the UP/DOWN keys.

After you have selected the desired value, press the ENTER key again to store it.

Esc key: allows you to move from one mask to another.

Alarm key: used to display the alarms, to reset them in

manual. Press it one to display the mask of the activated alarm, press it again to reset the alarm signal.

Prg+Esc keys: Pressing these keys at the same time,allows you to turn the unit on/off.

Up-down keys: allows you to set the control parameters’ values and to move from one mask to another (not backlighted).

Enter key: used to move the cursor inside the masks and to save the values of the set parameters.

Alarm+Enter keys: press these keys at the same time to enter the "storical alarm" after 1’ come back at status machine menu.

6 - Control (continued)

Alarm code Description Notes

Main board - EPROM Failure

Main board - Clock card Failure

Main board - External air temperature sensor fault

Main board - Return Water temperature sensor fault (evaporator)

Main board - Leaving Water temperature Sys 1 sensor fault (evaporator)

Main board - Leaving Water temperature Sys 2 sensor fault (evaporator)

Main board - Low pressure sys 1 sensor fault

Main board - Low pressure sys 2 sensor fault

Main board - High pressure sys 1 sensor fault

Main board - High pressure sys 2 sensor fault

Main board - Discharge temperature sys 1 sensor fault

Main board - Discharge temperature sys 2 sensor fault

Main board - Return Water temperature sensor fault (condenser)

Main board - Leaving Water temperature sensor fault (condenser)

Serious alarm (SQZ)

Flow switch / Plant interlock

Oil Safety Sys 1 manual reset

Oil Safety Sys 2 manual reset

High pressure switch Sys 1

High pressure switch Sys 2

Low pressure Sys 1 switch manual reset

Low pressure Sys 2 switch manual reset

Thermal protection compressor 1 Sys 1 manual reset

Thermal protection compressor 1 Sys 2 manual reset

Remote condenser Fan Thermal protection Sys 1 (RC version only)

Remote condenser Fan Thermal protection Sys 2 (RC version only)

Low refrigerant cutout Sys 1 manual reset

Low refrigerant cutout Sys 2 manual reset

Low pressure alarm Sys 1 manual reset

Low pressure alarm Sys 2 manual reset

Out of envelope Sys 1 manual reset

Out of envelope Sys 2 manual reset

High pressure Sys 1 manual reset

High pressure Sys 2 manual reset

High limit discharge temperature Sys1 manual reset

High limit discharge temperature Sys2 manual reset

¨7:DWHU7RR+LJK6\V

¨7:DWHU7RR+LJK6\V

Wrong Water Trend Sys 1

Wrong Water Trend Sys 2

Antifreeze alarm manual reset Sys 1

Antifreeze alarm manual reset Sys 2

Plant pump maintenance

53 Compressor 1 Sys 1 maintenance 56 Compressor 1 Sys 2 maintenance 59 Driver 1 LAN disconneted manual reset 60 Driver 2 LAN disconneted manual reset 61 EPROM Error Driver 1 62 EPROM Error Driver 2 63 Driver 1 S1 Sensor fault 65 Driver 1 S2 Sensor fault 67 Driver 2 S1 Sensor fault 68 Driver 2 S2 Sensor fault 69 EEV motor Error (Check viring) Sys 1 70 EEV motor Error (Check viring) Sys 2 71 Driver 1 Battery alarm

Alarms

English

6 - Control (continued)

Alarm code Description Notes

72 Driver 2 Battery alarm 73 Autotune alarm Sys 1 74 Autotune alarm Sys 2 75 Low suction alarm Sys 1 76 Low suction alarm Sys 2 79 Expansion board 1 OFF LINE 80 Expansion board 2 OFF LINE 83 Expansion board 1 - Chillernet sensor fault 84 Expansion board 1 - 4-20 mA remote set-point fault 87 Low delta pressure Sys 1 manual reset 88 Low delta pressure Sys 2 manual reset 89 Flow switch / Source interlock

90 Source pump maintenance 118 Oil Safety Sys 1 auto reset 119 Oil Safety Sys 2 manual reset 122 Low pressure Sys 1 switch auto reset 123 Low pressure Sys 2 switch auto reset 124 Thermal protection compressor 1 Sys 1 auto reset 127 Thermal protection compressor 1 Sys 2 auto reset 132 Fan Thermal protection Group 2 Sys 1 auto reset 134 Fan Thermal protection Group 2 Sys 2 auto reset 135 Low refrigerant cutout Sys 1 auto reset 136 Low refrigerant cutout Sys 2 auto reset 137 Low pressure alarm Sys 1 auto reset 138 Low pressure alarm Sys 2 auto reset 139 Out of envelope Sys 1 auto reset 140 Out of envelope Sys 2 auto reset 141 High pressure Sys 1 auto reset 142 High pressure Sys 2 auto reset 143 High limit discharge temperature Sys1 auto reset 144 High limit discharge temperature Sys2 auto reset 159 Driver 1 LAN disconnected automatic reset 160 Driver 2 LAN disconnected automatic reset 187 Low delta pressure Sys 1 auto reset 188 Low delta pressure Sys 2 auto reset

6.2 Setpoint

Pressing the Set key allows you to enter the Set point level accessible to the user. The parameters that can be set are listed below, along with the limit values and the default values (standard shop settings):

User parameters Control mode Min value Max value Default

Cooling Setpoint

RWT Return Control 9 15 10

LWT Leaving Control 6 15 8

Heating Setpoint

RWT Return Control 25 54 40

LWT Leaving Control 30 60 45

Cooling Setpoint - glycol water

RWT Return Control -5 15 10

LWT Leaving Control -8 15 8

Proportional band RWT Return Control 1 10 5 Neutral band LWT Leaving Control 1 6 2 Languages —— ITA ENG FRE GER SPA ITA

System On/Off System 1 # —— OFF ON OFF

System 2 # —— OFF ON OFF Unit management Cooling

6 - Control (continued)

Flow switch

A flow switch must be installed, to prevent the unit working in case of insufficient circulation of the chilled fluid.

WARNING

The electrical flow switch must be carefully installed, according to the instructions given by the Manufacturer.

The electrical flow switch must be installed on the pressing side of the circulation pump for the fluid, just upstream of the heat exchanger’s inlet. The electrical flow switch must be installed in a horizontal straight length of piping, in a position reasonably far (both upstream and downstream) from localized pressure drops (curves, valves etc.).

6.3 Protection and Safety Equipment

Refrigeration system

The units are filled with R134a refrigerant fluid of non hazardous type (group II). Safety device (pressure switch and safety valves) with the sets below indicated are provided on the discharge and suction line of each circuit.

Discharge Line

Pressure relief valve 22 bar. Pressure switch 19.8 bar for HP/RC/BC version,

15.5 bar for CO version.

Suction line

Pressure relief valve 14.5 bar. Pressure switch 0.5 bar.

Frost Protection for the Chilled Fluid

If the leaving water temperature drops below 4 °C (standard value for a non-glycol unit) the machine’s antifreeze alarm is activated. If the circulating fluid is water, before the beginning of the cold season it is advisable to drain the circuit to prevent water frosting.

If the circuit cannot be drained, it is essential to avoid de-energizing the unit, so as to permit the activation, when necessary, of the frost protection.

Compressor protection

Compressors are equipped with a heating element to prevent oil dilution, which may result in remarkable risks of failure of compressors.

The windings of the compressors’ motors are provided with a thermal protection.

An accessory kit for thermal protection (ACB) is available, for any overcurrent of compressors, which shall be shop-mounted.

English

7 - Product Description

7.1 Introduction

SyScrew Water EVO units are designed for indoor installation. They can be equipped with one or two circuits (depending on the model) and may be used to cool water to the evaporator and / or to heat water to the condenser. When heating capacity is not the required useful effect, is is necessary to match the unit with a cooling tower or well water in order to reject condenser heat load.

The units are suitable for indoor installation. This series includes the following versions:

7.2 General specifications

The units are supplied complete and provided with all connecting pipes for the refrigerant and internal wiring.

The refrigeration circuit of each unit undergoes a pressure test, is drained, vacuumised, dehydrated and filled with refrigerant, and includes the necessary oil. Once assembled, each unit is subjected to a complete final testing and the correct operation of all refrigeration circuits is checked.

The base and the frame of each unit are made of very thick galvanised sheet, and are secured by screw and stainless bolts. All panels are secured by screw and tropicalised steel bolts, they can be disassembled for easy access to internal components.

All galvanised steel parts are painted with white polyester resin, to ensure the resistance of the unit to corrosion and weather agents over time.

7.3 Compressors

The units are provided with high power, high efficiency and low vibration level semi-hermetic screw compressors (oil injection or external cooling with plate-type exchangers) to reduce the compressor’s discharge temperature (on request for special application).

The capacity control can be both of the step type (as standard) or of the stepless type (on request). It is handled by capacity control solenoid valves, handled by the microprocessor of the appliance.

The motor’s terminals are weatherproof, according to standard IP-54.

7.4 Refrigeration circuits

Units are equipped with one or two independent circuits with screw compressors and shell and tube heat exchanger.

Each refrigerant circuit includes: a service valve for refrigerant filling, shutoff valves for suction lines (on request), as well as for the delivery and liquid lines, an electronic expansion valve, that completely closed (as a solenoid valve) makes it possible to start/ stop the compressor, a dehydrating cartridge filter, a sight glass with humidity indicator.

Furthermore, each circuit is equipped with safety devices in accordance with PED 2014/68/EU: high and low pressure switches, safety valves providing protection in case of fire or malfunction of compressors.

VERSION DESCRIPTION

Super Low Noise version (S)

Water cooled or air cooled (RC version) chillers operating with R134a refrigerant.

OPTIONS DESCRIPTION

Desuperheater (D) The heat recovery is carried out by a desuperheater mounted on the compressor’s discharge line.

Totaly heat recovery Not available. For information, please contact commercial office.

Available options:

CO versions are equipped with dedicated compressors optimized for low condensing pressure.

Special Version

Brine version: units with dedicated evaporators to allow operation with brine (ethylene or propylene) temperature down to -8 °C.

7 - Product Description (continued)

7.5 Water heat exchangers

Evaporator

The units are provided with a direct-expansion refrigerant/water shell and tube heat exchanger with several refrigeration circuits.

Evaporators are insulated with flexible insulation, based on closed cell synthetic rubber in black color, 9 mm thick, highly resistant to water and to water vapour. A synthetic leather coating, 1.1 mm thick, protects the outer surface.

Condenser

All units are equipped with one or two condensers, one each circuit. Heat exchanger is shell and tube type, arranged for ispection, cleaning and maintenance operation.

Desuperheater

All units are available with desuperheaters (DSH). DSH is refrigerant/ water heat exchanger with brazed plates.

DSH is fitted on the compressor discharge pipe and it’s dimensioned to recover about the 10% of total rejected heat. Units with a single compressor are provided with a single heat exchanger, while units with two compressors are provided with two heat exchangers, one each circuit

Total heat recovery condenser

All units are available with total heat recovery condenser (THRC). THRC is refrigerant / water heat exchanger with brazed plates or shell and tube, according to chiller size. THRC is fitted on the compressor discharge line in series with the standard condensing circuit. Heat recovery function is enabled supplying heat recovery exchanger with water. Units with a single compressor are provided with a single heat exchanger, while units with two compressors are provided with two heat exchangers, one each circuit. Heat recovery condensers are insulated with flexible insulation, based on closed cell synthetic rubber in black color, 9 mm thick.

7.6 Electric power supply and control system

All units are provided with a microprocessor and a “Chiller Control” system.

The electrical connection of the controls and the startup units for the motor are carried out and tested in the factory. The power supply and control components are separate and accessible from different doors.

A door stop disconnecting switch is always mounted on the door of the unit. Protection level is in accordance with IP54 standard.

The power supply compartment includes:

Master switch

Network isolator, contactors, compressor fuses

Control panel includes:

A transformer for auxiliaries, fuses, relay and electronic card, a

thermostat for the compressor’s delivery temperature

The keyboard and the display of the “Chiller-Control”

microcomputer, mounted on the door of the control section.

7.7 Accessories

List of available accessories, provided separately, to be mounted on site by the installer:

Water flow switch

Prevents the operation of the unit when the chilled fluid is insufficient. It is advisablem to install a flow switch, to ensure the correct operation of the unit.

Water filter

Filter to be mounted on the suction side of the water heat exchanger. It is mandatory to install a water filter to remove impurities from the water suplly.

Antivibrating supports (AVM)

Isolating spring supports, equipped with bolts for fastening to the base. They are supplied separated from the unit and must be mounted on site by the customer, at his own expense.

Remote wall terminal

Makes it possible to check the unit through a remote terminal, up to a maximum distance of 400 meters.

Modem GSM

Makes it possible to check the working mode or the switching on/off of the unit via SMS. In case of any alarms, the unit sends an SMS to the user.

RS-485 serial card (for MODBUS or LONWORK or BACNET)

A communication interface makes it possible to control and manage the unit from a local station, with RS485 connection, up to a distance of 1000 m.

It is possible to obtain the remote control and the management, by inserting the control into the management plant of the building.

English

7 - Product Description (continued)

Refrigerant circuit - CO/HP/BC versions

SAFETY / CONTROL DEVICES

High pressure switch 15.5 bar (CO)

19.8 bar (HP/BC)

B Low pressure switch (0.5 bar)

AT High pressure transducer

BT Low pressure transducer

D Suction temperature sensor E Outlet water temperature sensor F Inlet water temperature sensor G PED pressure relief valve HP side (22 bar) H PED pressure relief valve LP side (14.5 bar) S Shrader connection (Service only)

Pipe connection with Shrader valve

COMPONENTS 1 Compressor (Screw type) 2 Water cooled condenser 3 Filter drier 4 Electronic expansion valve 5 Globe valve 6 Heat exchanger (Shell & Tube Type) 7 Desuperheater (Optional)

Water temperature sensor (HP version only)

9 Sight glass

Note: For reasons of readability, one circuit only is shown.

EXV

CONTROL

UNIT

CONTROL

7 - Product Description (continued)

Refrigerant circuit - RC version

EXV

CONTROL

UNIT

CONTROL

SAFETY / CONTROL DEVICES A High pressure switch (19.8 bar) B Low pressure switch (0.5 bar)

AT High pressure transducer BT Low pressure transducer

Pipe connection with Shrader valve

COMPONENTS 1 Compressor (Screw type) 3 Filter drier 4 Electronic expansion valve 5 Globe valve 6 Heat exchanger (Shell & Tube Type) 7 Desuperheater (Optional) 9 Sight glass

English

8.1 Pressure drops

Evaporator Pressure drop

8 - Technical Data

Model

Nom. Capacity Qnom. Qmax. Qmin. K Dp nom DP max DP min

kW l/h l/h l/h kPa/(l/h)^2 kPa kPa kPa

440 446 76696 127827 54783 7.297E-09 42.9 119.2 21.9 490 496 85256 142094 60897 4.149E-09 30.2 83.8 15.4 570 573 98502 164170 70359 5.354E-09 52.0 144.3 26.5 630 639 109937 183229 78527 5.354E-09 64.7 179.8 33.0 700 710 122159 203598 87256 2.021E-09 30.2 83.8 15.4 770 789 135759 226266 96971 2.021E-09 37.2 103.5 19.0 860 878 151049 251749 107892 1.824E-09 41.6 115.6 21.2 920 939 161546 269244 115390 1.824E-09 47.6 132.2 24.3

990 1002 172290 287150 123064 1.435E-09 42.6 118.3 21.7 1070 1075 184901 308168 132072 1.392E-09 47.6 132.2 24.3 1130 1137 195575 325959 139697 1.392E-09 53.2 147.9 27.2 1220 1227 211038 351730 150742 7.245E-10 32.3 89.6 16.5 1280 1289 221624 369374 158303 7.245E-10 35.6 98.8 18.2 1400 1434 246703 411172 176217 1.020E-09 62.1 172.5 31.7 1550 1574 270809 451349 193435 1.020E-09 74.8 207.8 38.2

Condenser pressure drops

Model

Nom. Capacity Qnom. Qmax. Qmin. K Dp nom DP max DP min

kW l/h l/h l/h kPa/(l/h)^2 kPa kPa kPa

440 530 91178 151964 56987 6.320E-09 52.5 146.0 20.5

490 590 101472 169120 63420 4.928E-09 50.7 141.0 19.8

570 680 116977 194961 73110 3.997E-09 54.7 151.9 21.4

630 760 130648 217746 81655 2.007E-09 34.3 95.2 13.4

700 846 145519 242532 90949 2.007E-09 42.5 118.0 16.6

770 939 161566 269276 100979 1.958E-09 51.1 142.0 20.0

860 522 89857 149761 56160 6.320E-09 51.0 141.8 19.9

920

525 90315 150525 56447 6.320E-09 51.6 143.2 20.1 592 101844 169741 63653 4.928E-09 51.1 142.0 20.0

990 596 102507 170845 64067 4.928E-09 51.8 143.8 20.2

1070

601 103347 172245 64592 4.928E-09 52.6 146.2 20.6 678 116541 194234 72838 3.997E-09 54.3 150.8 21.2

1130 676 116249 193749 72656 3.997E-09 54.0 150.1 21.1

1220

686 118001 196668 73751 3.997E-09 55.7 154.6 21.7 774 133065 221775 83166 3.138E-09 55.6 154.3 21.7

1280 767 131888 219813 82430 3.138E-09 54.6 151.6 21.3 1400 853 146721 244535 91701 1.958E-09 42.2 117.1 16.5 1550 935 160884 268140 100552 1.958E-09 50.7 140.8 19.8

8 - Technical Data (continued)

Desuperheater pressure drop

(*) Capacity referred to only one circuit.

Model

Nom. Capacity Qnom. Qmax. Qmin. K Dp nom DP max DP min

kW l/h l/h l/h kPa/(l/h)^2 kPa kPa kPa

440 34 5927 9878 3704 2.285E-08 0.8 2.2 0.3

490 38 6596 10993 4122 2.285E-08 1.0 2.8 0.4

570 44 7603 12672 4752 1.380E-08 0.8 2.2 0.3

630 49 8492 14154 5308 1.380E-08 1.0 2.8 0.4

700 not available

770 not available

860 34 5841 9734 3650 2.285E-08 0.8 2.2 0.3

920

36 6245 10409 3903 2.285E-08 0.9 2.5 0.3

990 39 6663 11105 4164 2.285E-08 1.0 2.8 0.4

1070

42 7146 11911 4466 1.380E-08 0.7 2.0 0.3

1130 44 7556 12594 4723 1.380E-08 0.8 2.2 0.3

1220

47 8160 13599 5100 1.380E-08 0.9 2.6 0.4

1280 50 8573 14288 5358 1.380E-08 1.0 2.8 0.4 1400 not available 1550 not available

English

8 - Technical Data (continued)

8.2 Technical data

SyScrew Water EVO CO _ / S 440 490 570 630 700 770 860

Power supply V/Ph/Hz 400 (± 10%) / 3 / 50

Number of refrigerant circuits 1 2

Start-up Type SD

Total capacity steps % 50-75-100

25-50-62-

75-87-100

COMPRESSOR

Number 1 2

Type Screw

INTERNAL HEAT EXCHANGER (EVAPORATOR)

Number 1

Type Shell & tube (Pure counterflow)

Water connections inch 6 6 6 6 8 8 8

EXTERNAL HEAT EXCHANGER (CONDENSER)

Number 1 2

Type Shell & tube

Water connections inch 4 4 5 5 5 5 4

REFRIGERANT

Type R134a

DESUPERHEATER

Number 1 2

Type PHE

Water connections inch 2”1/2 N.A. 2”1/2

WEIGHT (_ VERSION)

Shipping kg 2509 2538 2701 2807 3185 3252 5124

Operating kg 2690 2725 2918 3040 3523 3597 5579

WEIGHT (S VERSION)

Shipping kg 2703 2732 2895 3001 3379 3446 5511

Operating kg 2884 2919 3112 3234 3717 3791 5966

DIMENSIONS (_ VERSION)

Length mm 3620 3620 4210 4210 4180 4180 4400

Width mm 1350 1350 1350 1350 1350 1350 1520

Height mm 1650 1650 1650 1650 1650 1650 1710

DIMENSIONS (S VERSION)

Length mm 3620 3620 4210 4210 4180 4180 4650

Width mm 1350 1350 1350 1350 1350 1350 1520

Height mm 1750 1750 1750 1750 1750 1750 1770

8 - Technical Data (continued)

SyScrew Water EVO CO _ / S 920 990 1070 1130 1220 1280 1400 1550

Power supply V/Ph/Hz 400 (± 10%) / 3 / 50

Number of refrigerant circuits 2

Start-up Type SD

Total capacity steps % 25-50-62-75-87-100

COMPRESSOR

Number 2

Type Screw

INTERNAL HEAT EXCHANGER (EVAPORATOR)

Number 1

Type Shell & tube (Pure counterflow)

Water connections inch 8 8 8 8 8 8 10 10

EXTERNAL HEAT EXCHANGER (CONDENSER)

Number 2

Type Shell & tube

Water connections inch 4 4 4 / 5 5 5 5 5 5

REFRIGERANT

Type R134a

DESUPERHEATER

Number 2

Type PHE

Water connections inch 2”1/2 N.A.

WEIGHT (_ VERSION)

Shipping kg 5154 5266 5400 5505 5596 5638 6132 6227

Operating kg 5615 5826 5948 6055 6126 6175 6793 6888

WEIGHT (S VERSION)

Shipping kg 5541 5653 5787 5892 5983 6025 6519 6614

Operating kg 6002 6213 6335 6442 6513 6562 7180 7275

DIMENSIONS (_ VERSION)

Length mm 4400 4600 4650 4650 4650 4650 5350 5350

Width mm 1520 1520 1520 1520 1520 1520 1520 1520

Height mm 1710 1710 1710 1710 1710 1710 1710 1710

DIMENSIONS (S VERSION)

Length mm 4650 4650 4650 4650 4650 4650 5350 5350

Width mm 1520 1520 1520 1520 1520 1520 1520 1520

Height mm 1770 1770 1770 1770 1770 1770 1770 1770

English

8 - Technical Data (continued)

SyScrew Water EVO HP _ / S 440 490 570 630 700 770 860

Power supply V/Ph/Hz 400 (± 10%) / 3 / 50

Number of refrigerant circuits 1 2

Start-up Type SD

Total capacity steps % 50-75-100

25-50-62-

75-87-100

COMPRESSOR

Number 1 2

Type Screw

INTERNAL HEAT EXCHANGER (EVAPORATOR)

Number 1

Type Shell & tube (Pure counterflow)

Water connections inch 6 6 6 6 8 8 8

EXTERNAL HEAT EXCHANGER (CONDENSER)

Number 1 2

Type Shell & tube

Water connections inch 4 4 5 5 5 5 4

REFRIGERANT

Type R134a

DESUPERHEATER

Number 1 2

Type PHE

Water connections inch 2”1/2 N.A. 2”1/2

WEIGHT (_ VERSION)

Shipping kg 2509 2538 2701 2807 3185 3252 5124

Operating kg 2690 2725 2918 3040 3523 3597 5579

WEIGHT (S VERSION)

Shipping kg 2703 2732 2895 3001 3379 3446 5511

Operating kg 2884 2919 3112 3234 3717 3791 5966

DIMENSIONS (_ VERSION)

Length mm 3620 3620 4210 4210 4180 4180 4400

Width mm 1350 1350 1350 1350 1350 1350 1520

Height mm 1650 1650 1650 1650 1650 1650 1710

DIMENSIONS (S VERSION)

Length mm 3620 3620 4210 4210 4180 4180 4650

Width mm 1350 1350 1350 1350 1350 1350 1520

Height mm 1750 1750 1750 1750 1750 1750 1770

8 - Technical Data (continued)

SyScrew Water EVO HP _ / S 920 990 1070 1130 1220 1280 1400 1550

Power supply V/Ph/Hz 400 (± 10%) / 3 / 50

Number of refrigerant circuits 2

Start-up Type SD

Total capacity steps % 25-50-62-75-87-100

COMPRESSOR

Number 2

Type Screw

INTERNAL HEAT EXCHANGER (EVAPORATOR)

Number 1

Type Shell & tube (Pure counterflow)

Water connections inch 8 8 8 8 8 8 10 10

EXTERNAL HEAT EXCHANGER (CONDENSER)

Number 2

Type Shell & tube

Water connections inch 4 4 4 / 5 5 5 5 5 5

REFRIGERANT

Type R134a

DESUPERHEATER

Number 2

Type PHE

Water connections inch 2”1/2 N.A.

WEIGHT (_ VERSION)

Shipping kg 5154 5266 5400 5505 5596 5638 6132 6227

Operating kg 5615 5826 5948 6055 6126 6175 6793 6888

WEIGHT (S VERSION)

Shipping kg 5541 5653 5787 5892 5983 6025 6519 6614

Operating kg 6002 6213 6335 6442 6513 6562 7180 7275

DIMENSIONS (_ VERSION)

Length mm 4400 4600 4650 4650 4650 4650 5350 5350

Width mm 1520 1520 1520 1520 1520 1520 1520 1520

Height mm 1710 1710 1710 1710 1710 1710 1710 1710

DIMENSIONS (S VERSION)

Length mm 4650 4650 4650 4650 4650 4650 5350 5350

Width mm 1520 1520 1520 1520 1520 1520 1520 1520

Height mm 1770 1770 1770 1770 1770 1770 1770 1770

English

8 - Technical Data (continued)

SyScrew Water EVO RC _ / S 440 490 570 630 700 770 860

Power supply V/Ph/Hz 400 (± 10%) / 3 / 50

Number of refrigerant circuits 1 2

Start-up Type SD

Total capacity steps % 50-75-100

25-50-62-

75-87-100

COMPRESSOR

Number 1 2

Type Screw

INTERNAL HEAT EXCHANGER (EVAPORATOR)

Number 1

Type Shell & tube (Pure counterflow)

Water connections inch 6 6 6 6 8 8 8

REMOTE CONDENSER CONNECTIONS

Type To be brazed

Inlet refrigerant connections Circuit 1 inch 1.5/8” 1.5/8” 2.1/8” 2.1/8” 2.1/8” 2.1/8” 1.5/8”

Outlet refrigerant connections Circuit 1 inch 3.1/8” 3.1/8” 3.5/8” 3.5/8” 4.1/8” 4.1/8” 3.1/8”

Inlet refrigerant connections Circuit 2 inch - - - - - - 1.5/8”

Outlet refrigerant connections Circuit 2 inch - - - - - - 3.1/8”

REFRIGERANT

Type R134a

DESUPERHEATER

Number 1 2

Type PHE

Water connections inch 2”1/2 N.A. 2”1/2

WEIGHT (_ VERSION)

Shipping kg 2159 2169 2285 2305 2676 2716 4425

Operating kg 2302 2312 2456 2476 2952 2992 4804

WEIGHT (S VERSION)

Shipping kg 2353 2363 2479 2499 2870 2910 4812

Operating kg 2496 2506 2650 2670 3146 3186 5191

DIMENSIONS (_ VERSION)

Length mm 3620 3620 4210 4210 4180 4180 4400

Width mm 1350 1350 1350 1350 1350 1350 1520

Height mm 1650 1650 1650 1650 1650 1650 1710

DIMENSIONS (S VERSION)

Length mm 3620 3620 4210 4210 4180 4180 4650

Width mm 1350 1350 1350 1350 1350 1350 1520

Height mm 1750 1750 1750 1750 1750 1750 1770

8 - Technical Data (continued)

SyScrew Water EVO RC _ / S 920 990 1070 1130 1220 1280 1400 1550

Power supply V/Ph/Hz 400 (± 10%) / 3 / 50

Number of refrigerant circuits 2

Start-up Type SD

Total capacity steps % 25-50-62-75-87-100

COMPRESSOR

Number 2

Type Screw

INTERNAL HEAT EXCHANGER (EVAPORATOR)

Number 1

Type Shell & tube (Pure counterflow)

Water connections inch 8 8 8 8 8 8 10 10

REMOTE CONDENSER CONNECTIONS

Type To be brazed

Inlet refrigerant connections Circuit 1 inch 1.5/8” 1.5/8” 1.5/8” 2.1/8” 2.1/8” 2.1/8” 2.1/8” 2.1/8”

Outlet refrigerant connections Circuit 1 inch 3.1/8” 3.1/8” 3.1/8” 3.5/8” 3.5/8” 3.5/8” 4.1/8” 4.1/8”

Inlet refrigerant connections Circuit 2 inch 1.5/8” 1.5/8” 2.1/8” 2.1/8” 2.1/8” 2.1/8” 2.1/8” 2.1/8”

Outlet refrigerant connections Circuit 2 inch 3.1/8” 3.1/8” 3.5/8” 3.5/8” 3.5/8” 3.5/8” 4.1/8” 4.1/8”

REFRIGERANT

Type R134a

DESUPERHEATER

Number 2

Type PHE

Water connections inch 2”1/2 N.A.

WEIGHT (_ VERSION)

Shipping kg 4435 4526 4613 4673 4739 4759 5073 5153

Operating kg 4814 4998 5071 5131 5170 5190 5596 5676

WEIGHT (S VERSION)

Shipping kg 4822 4913 5000 5060 5126 5146 5460 5540

Operating kg 5201 5385 5458 5518 5557 5577 5983 6063

DIMENSIONS (_ VERSION)

Length mm 4400 4600 4650 4650 4650 4650 5350 5350

Width mm 1520 1520 1520 1520 1520 1520 1520 1520

Height mm 1710 1710 1710 1710 1710 1710 1710 1710

DIMENSIONS (S VERSION)

Length mm 4650 4650 4650 4650 4650 4650 5350 5350

Width mm 1520 1520 1520 1520 1520 1520 1520 1520

Height mm 1770 1770 1770 1770 1770 1770 1770 1770

English

8 - Technical Data (continued)

8.3 Electrical data - SyScrew Water EVO CO

(*) Power factor correction capacitor option.

_ S Version 440 490 570 630 700 770 860 920 990 1070 1130 1220 1280 1400 1550

Current input

Nominal A

141

157 175 203 227 255 278 298 316 334 350 386 414 454 500

Maximum A 233 266 306 345 378 411 466 499 532 572 612 651 690 756 822

Power input

Nominal kW 84 94 107 120 136 150 167 178 190 203 215 233 245 272 296

Maximum kW 132 147 167 186 220 240 264 279 294 314 334 353 372 440 480 Max Start-up current A 318 436 465 586 650 805 551 669 702 731 771 892 931 1028 1216 UNIT (aM) FUSES A 250 315 315 400 400 500 630 630 630 630 630 800 800 800 1000 Phase WIRE SECTION mm

120 185 185 240 240 2x185 2x185 2x185 2x185 2x185 2x185 2x240 2x240 2x240 2x300

Model System Circuit

Com-

pressor

start

mode

Nominal

power

input

Nominal

current

input

Maximum

power input

Maximum

current

input - FLA

Start-up

current

- LRA

Nominal

power factor

Corrected

power

factor*

Carter oil absorbed

power

(230 Vac)

(kW) (A) (kW) (A) (A) - - (W) 440 1 1 S/D 84 141 132 233 318 0,86 > 0.90 300 490 1 1 S/D 94 157 147 266 436 0,87 > 0.90 300 570 1 1 S/D 107 175 167 306 465 0,89 > 0.90 300 630 1 1 S/D 120 203 186 345 586 0,86 > 0.90 300 700 1 1 S/D 136 227 220 378 650 0,86 > 0.90 300 770 1 1 S/D 150 255 240 411 805 0,85 > 0.90 300

860

S/D 83 139 132 233 318 0,87 > 0.90 300

2 S/D 83 139 132 233 318 0,87 > 0.90 300

920

S/D 84 141 132 233 318 0,86 > 0.90 300

2 S/D 94 157 147 266 436 0,87 > 0.90 300

990

S/D 95 158 147 266 436 0,87 > 0.90 300

2 S/D 95 158 147 266 436 0,87 > 0.90 300

1070

S/D 95 158 147 266 436 0,87 > 0.90 300

2 S/D 108 176 167 306 465 0,89 > 0.90 300

1130

S/D 107 175 167 306 465 0,89 > 0.90 300

2 S/D 107 175 167 306 465 0,89 > 0.90 300

1220

S/D 109 177 167 306 465 0,89 > 0.90 300

2 S/D 124 209 186 345 586 0,86 > 0.90 300

1280

S/D 123 207 186 345 586 0,86 > 0.90 300

2 S/D 123 207 186 345 586 0,86 > 0.90 300

1400

S/D 136 227 220 378 650 0,86 > 0.90 300

2 S/D 136 227 220 378 650 0,86 > 0.90 300

1550

1 1 S/D 148 250 240 411 805 0,86 > 0.90 300 2 2 S/D 148 250 240 411 805 0,86 > 0.90 300

8 - Technical Data (continued)

Electrical data - SyScrew Water EVO HP-RC-BC

_ S Version 440 490 570 630 700 770 860 920 990 1070 1130 1220 1280 1400 1550

Current input

Nominal A

166

181 217 242 278 300 330 346 366 403 436 466 488 556 594

Maximum A 280 310 320 360 413 447 560 590 620 630 640 680 720 826 894

Power input

Nominal kW 100 111 129 145 168 178 197 210 225 244 259 280,9 294 335 352

Maximum kW 155 175 204 222 254 277 310 330 350 379 408 426 444 508 554 Max Start-up current A 436 465 586 650 805 917 716 745 775 896 906 970 1010 1218 1364 UNIT (aM) FUSES A 315 315 400 400 500 500 630 630 630 800 800 800 800 1000 1000 Phase WIRE SECTION mm

185 185 240 240 2x185 2x185 2x185 2x185 2x185 2x240 2x240 2x240 2x240 2x300 2x300

Model System Circuit

Com-

pressor

start

mode

Nominal

power

input

Nominal

current

input

Maximum

power input

Maximum

current

input - FLA

Start-up

current

- LRA

Nominal

power

factor*

Corrected

power

factor**

Carter oil absorbed

power

(230 Vac)

(kW) (A) (kW) (A) (A) - - (W) 440 1 1 S/D 100 166 144 280 436 0,87 > 0.90 300 490 1 1 S/D 111 181 161 310 465 0,89 > 0.90 300 570 1 1 S/D 129 217 188 320 586 0,86 > 0.90 300 630 1 1 S/D 145 242 212 360 650 0,87 > 0.90 300 700 1 1 S/D 168 278 240 413 805 0,87 > 0.90 300 770 1 1 S/D 178 300 259 447 917 0,86 > 0.90 300

860

S/D 99 165 144 280 436 0,86 > 0.90 300

2 S/D 99 165 144 280 436 0,86 > 0.90 300

920

S/D 99 165 144 280 436 0,87 > 0.90 300

2 S/D 111 181 161 310 465 0,89 > 0.90 300

990

S/D 113 183 161 310 465 0,89 > 0.90 300

2 S/D 113 183 161 310 465 0,89 > 0.90 300

1070

S/D 113 183 161 310 465 0,89 > 0.90 300

2 S/D 131 220 188 320 586 0,86 > 0.90 300

1130

S/D 130 218 188 320 586 0,86 > 0.90 300

2 S/D 130 218 188 320 586 0,86 > 0.90 300

1220

S/D 132 220 188 320 586 0,86 > 0.90 300

2 S/D 149 246 212 360 650 0,88 > 0.90 300

1280

S/D 147 244 212 360 650 0,87 > 0.90 300

2 S/D 147 244 212 360 650 0,87 > 0.90 300

1400

S/D 168 278 240 413 805 0,87 > 0.90 300

2 S/D 168 278 240 413 805 0,87 > 0.90 300

1550

1 1 S/D 176 297 259 447 917 0,86 > 0.90 300 2 2 S/D 176 297 259 447 917 0,86 > 0.90 300

(*) Data valid for HP version. (**) Power factor correction capacitor option.

English

8 - Technical Data (continued)

8.4 Position of shock adsorbers and weight distribution on supports

SYSCREW WATER

CO/HP/BC _

Weight distribution

Operating

weight

Shipping

weight

P coordinates CG

F1 F2 F3 F4 a b x y

kg kg kg kg kg kg mm mm mm mm 440 619 764 581 726 2690 2509 1050 2200 582 1069 490 634 773 589 729 2725 2538 1050 2200 579 1064 570 683 832 627 776 2918 2701 1050 2200 579 1057 630 746 861 659 774 3040 2807 1050 2200 565 1037 700 826 1021 740 936 3523 3185 1050 2200 583 1047 770 849 1042 756 949 3597 3252 1050 2200 581 1043 860 1242 1783 1006 1548 5579 5124 1220 2400 728 1099 920 1254 1791 1016 1553 5615 5154 1220 2400 727 1098 990 1301 1861 1052 1612 5826 5266 1220 2400 727 1097

1070 1325 1886 1088 1649 5948 5400 1220 2400 725 1104 1130

1374 1934 1094 1654 6055 5505 1220 2400 723 1089

1220

1391 1951 1112 1672 6126 5596 1220 2400 722 1091

1280

1413 1970 1117 1674 6175 5638 1220 2400 720 1085

1400 1397 2109 1288 1999 6793 6132 1220 2400 738 1161 1550 1409 2141 1303 2035 6888 6227 1220 2400 740 1163

SYSCREW WATER

CO/HP/BC _ S

Weight distribution

Operating

weight

Shipping

weight

P coordinates CG

F1 F2 F3 F4 a b x y

kg kg kg kg kg kg mm mm mm mm 440 651 829 613 791 2884 2703 1050 2200 590 1071 490 666 838 622 794 2919 2732 1050 2200 587 1067 570 716 897 659 840 3112 2895 1050 2200 586 1060 630 778 926 691 839 3234 3001 1050 2200 573 1041 700 858 1086 773 1001 3717 3379 1050 2200 589 1049 770 882 1107 789 1014 3791 3446 1050 2200 587 1046 860 1309 1910 1073 1674 5966 5511 1220 2400 733 1105 920 1321 1918 1083 1680 6002 5541 1220 2400 731 1105 990 1368 1988 1119 1739 6213 5653 1220 2400 732 1104

1070 1392 2013 1155 1776 6335 5787 1220 2400 730 1110 1130

1440 2061 1160 1781 6442 5892 1220 2400 727 1096

1220

1457 2078 1179 1799 6513 5983 1220 2400 726 1097

1280

1480 2097 1184 1801 6562 6025 1220 2400 725 1092

1400 1400 2299 1291 2190 7180 6519 1220 2400 763 1163 1550 1412 2332 1306 2226 7275 6614 1220 2400 764 1165

8 - Technical Data (continued)

Position of shock adsorbers and weight distribution on supports

SYSCREW WATER

RC _

Weight distribution

Operating

weight

Shipping

weight

P coordinates CG

F1 F2 F3 F4 a b x y

kg kg kg kg kg kg mm mm mm mm 440 401 675 476 750 2302 2159 1050 2200 650 1172 490 402 678 478 754 2312 2169 1050 2200 650 1171 570 426 726 502 802 2456 2285 1050 2200 653 1169 630 429 732 506 809 2476 2305 1050 2200 654 1168 700 507 890 586 969 2952 2676 1050 2200 661 1159 770 513 903 593 983 2992 2716 1050 2200 662 1159 860 811 1611 791 1591 4804 4425 1220 2400 813 1190 920 810 1613 794 1597 4814 4435 1220 2400 813 1192 990 844 1676 823 1655 4998 4526 1220 2400 813 1190

1070 842 1690 846 1694 5071 4613 1220 2400 814 1202 1130

865 1727 839 1701 5131 4673 1220 2400 815 1188

1220

866 1736 849 1719 5170 4739 1220 2400 815 1192

1280

874 1749 846 1721 5190 4759 1220 2400 816 1187

1400 823 1775 1023 1975 5596 5073 1220 2400 818 1285 1550 832 1803 1035 2006 5676 5153 1220 2400 819 1286

SYSCREW WATER

RC _ S

Weight distribution

Operating

weight

Shipping

weight

P coordinates CG

F1 F2 F3 F4 a b x y

kg kg kg kg kg kg mm mm mm mm 440 433 740 508 815 2496 2353 1050 2200 654 1166 490 435 743 510 818 2506 2363 1050 2200 654 1166 570 458 790 535 867 2650 2479 1050 2200 657 1163 630 461 797 538 874 2670 2499 1050 2200 657 1163 700 540 954 619 1033 3146 2870 1050 2200 663 1155 770 546 967 626 1047 3186 2910 1050 2200 664 1155 860 878 1738 858 1718 5191 4812 1220 2400 812 1191 920 877 1739 861 1723 5201 4822 1220 2400 812 1193 990 911 1803 890 1782 5385 4913 1220 2400 812 1191

1070 908 1817 912 1821 5458 5000 1220 2400 813 1202 1130

931 1854 905 1828 5518 5060 1220 2400 814 1189

1220

933 1863 915 1845 5557 5126 1220 2400 814 1192

1280

941 1876 913 1848 5577 5146 1220 2400 815 1188

1400 827 1966 1026 2165 5983 5460 1220 2400 842 1280 1550 835 1994 1038 2196 6063 5540 1220 2400 843 1280

English

8 - Technical Data (continued)

8.6 Dimensional drawings - SyScrew 440-770 Water EVO RC

1 Evaporator water inlet victaulic connection 2 Evaporator water outlet victaulic connection 3 Liquid connection 4 Discharge connection

P1, P2, P3, P4 AVM position

Front view Side view

Top view

Back view

775

275

245

ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM

365

C A

1 2

1650

1350

150

1050 150

2200

4 x

Size A B C D dia 1-2 dia 3 dia 4

440-490 650 2410 560 3620 DN150 (6”) 1 5/8” 3 1/8” 570-630 680 2980 550 4210 DN150 (6”) 2 1/8” 3 5/8” 700-770 720 2860 600 4180 DN150 (6”) 2 1/8” 4 1/8”

8 - Technical Data (continued)

Dimensional drawings - SyScrew 440-770 Water EVO RC_S

Front view Side view

Top viewBack view

1 Evaporator water inlet victaulic connection 2 Evaporator water outlet victaulic connection 3 Liquid connection 4 Discharge connection

P1, P2, P3, P4 AVM position

Size A B C D dia 1-2 dia 3 dia 4

440-490 650 2410 560 3620 DN150 (6”) 1 5/8” 3 1/8” 570-630 680 2980 550 4210 DN150 (6”) 2 1/8” 3 5/8” 700-770 720 2860 600 4180 DN150 (6”) 2 1/8” 4 1/8”

775

275

245

ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM

365

C A

1 2

1750

1350

150 150

2200

1050

4 x

English

8 - Technical Data (continued)

Dimensional drawings - SyScrew 440-770 Water EVO CO / HP

Front view Side view

Top viewBack view

ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM

365

C A

1650

1350

E F

1085

SIZES 570/770

E F

200

130

1020

1350

SIZES 440/490

265

2200

1050 150 150

4 x

1 Evaporator water inlet victaulic connection 2 Evaporator water outlet victaulic connection 3 Condenser water outlet victaulic connection 4 Condenser water inlet victaulic connection

P1, P2, P3, P4 AVM position

Size A B C D

440-490 650 2410 560 3620

570 680 2980 550 4210 630 680 2980 550 4210

700-770 720 2860 600 4180

Size E F dia 1-2 dia 3-4

440-490 130 350 DN150 (6”) DN100 (4”)

570 680 2980 DN150 (6”) DN125 (5”) 630 680 2980 DN150 (6”) DN125 (5”)

700-770 720 2860 DN200 (8”) DN125 (5”)

8 - Technical Data (continued)

Dimensional drawings - SyScrew 440-770 Water EVO CO / HP_S

Front view Side view

Top viewBack view

365

C A

1750

E F

1085 265

1350

SIZES 570/770

E F

200

130

1020

1350

SIZES 440/490

2200

1050 150 150

4 x

1 Evaporator water inlet victaulic connection 2 Evaporator water outlet victaulic connection 3 Condenser water outlet victaulic connection 4 Condenser water inlet victaulic connection

P1, P2, P3, P4 AVM position

Size A B C D

440-490 650 2410 560 3620

570 680 2980 550 4210 630 680 2980 550 4210

700-770 720 2860 600 4180

Size E F dia 1-2 dia 3-4

440-490 130 350 DN150 (6”) DN100 (4”)

570 680 2980 DN150 (6”) DN125 (5”) 630 680 2980 DN150 (6”) DN125 (5”)

700-770 720 2860 DN200 (8”) DN125 (5”)

English

8 - Technical Data (continued)

Dimensional drawings - SyScrew 860-1550 Water EVO RC

Front view Side view

Top viewBack view

ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM

455

210

150

295

440

A C

1710

1520

150 1220 150

2400

4 x

1 Evaporator water inlet victaulic connection 2 Evaporator water outlet victaulic connection 3 Liquid connection 4 Discharge connection

P1, P2, P3, P4 AVM position

Size A B C D dia 1-2 dia 3 dia 4

860 1090 2310 1000 4400 DN200 (8”) 1 5/8” 3 1/8” 920 1090 2310 1000 4400 DN200 (8”) 1 5/8” 3 1/8”

990 850 2860 890 4600 DN200 (8”) 1 5/8” 3 1/8” 1070 850 2860 940 4650 DN200 (8”) 2 1/8” 3 1/8” 1130 850 2860 940 4650 DN200 (8”) 2 1/8” 3 1/8” 1220 850 2860 940 4650 DN200 (8”) 2 1/8” 3 1/8” 1280 850 2860 940 4650 DN200 (8”) 2 1/8” 3 1/8” 1400 830 3570 950 5350 DN250 (10”) 2 1/8” 4 1/8” 1550 830 3570 950 5350 DN250 (10”) 2 1/8” 4 1/8”

8 - Technical Data (continued)

Dimensional drawings - SyScrew 860-1550 Water EVO RC_S

Front view Side view

Top viewBack view

ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM

455

210

150

295

3 3

A B C

440

1520

1770

1220 150 150

2400

4 x

1 Evaporator water inlet victaulic connection 2 Evaporator water outlet victaulic connection 3 Liquid connection 4 Discharge connection

P1, P2, P3, P4 AVM position

Size A B C D dia 1-2 dia 3 dia 4

860 1170 2310 1170 4650 DN200 (8”) 1 5/8” 3 1/8”

920 1170 2310 1170 4650 DN200 (8”) 1 5/8” 3 1/8”

990 890 2860 900 4650 DN200 (8”) 1 5/8” 3 1/8” 1070 890 2860 900 4650 DN200 (8”) 2 1/8” 3 1/8” 1130 890 2860 900 4650 DN200 (8”) 2 1/8” 3 1/8” 1220 890 2860 900 4650 DN200 (8”) 2 1/8” 3 1/8” 1280 890 2860 960 4710 DN200 (8”) 2 1/8” 3 1/8” 1400 890 3570 950 5350 DN250 (10”) 2 1/8” 4 1/8” 1550 830 3570 950 5350 DN250 (10”) 2 1/8” 4 1/8”

English

8 - Technical Data (continued)

Dimensional drawings - SyScrew 860-1550 Water EVO CO / HP

Front view Side view

Top viewBack view

ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM

440

1710

1520

G E

1175

130

215

SIZES 860/990

E F

1710

1175 130

1240

280

1520

SIZES 1070

E F

1240 280

1520

1710

SIZES 1130/1550

1220 150 150

2400

4 x

1 Evaporator water inlet victaulic connection 2 Evaporator water outlet victaulic connection 3 Condenser water outlet victaulic connection 4 Condenser water inlet victaulic connection

P1, P2, P3, P4 AVM position

8 - Technical Data (continued)

Dimensional drawings - SyScrew 860-1550 Water EVO CO / HP_S

Front view Side view

Top viewBack view

ELECTRICAL POWER SUPPLY FROM ELECTRIC BOX BOTTOM

A B

440

1520

G E

1175

130 215

1770

SIZES 860/990

E F

1175 130

1240 280

1520

1770

SIZES 1070

E F

1240 280

1520

1770

SIZES 1130/1550

150 1220 150

2400

4 x

1 Evaporator water inlet victaulic connection 2 Evaporator water outlet victaulic connection 3 Condenser water outlet victaulic connection 4 Condenser water inlet victaulic connection

P1, P2, P3, P4 AVM position

English

8 - Technical Data (continued)

8.6 Service spaces

0.5 MT

2 MT

1 MT

3 MT

Carefully read the “Safety” section of this manual before carrying out any maintenance operations.

DANGER

Do not discharge the refrigerant into the atmosphere while the refrigeration circuits are being drained. Use appropriate recovery equipment.

When the recovered refrigerant cannot be reused, return it to the manufacturer.

DANGER

Do not throw away the waste oil of the compressor, because it contains refrigerant in solution.

The waste oil must be returned to the manufacturer.

Unless otherwise specified, the operations described below may be carried out only by a trained maintenance operator.

9.1 General requirements

Units have been designed for continuous operation, providing that they are subjected to regular maintenance, within the limits specified in this manual. Each unit must be serviced according to the programme by the User/Customer, and must be inspected at regular intervals by the personnel of one authorised Service Centers.

It is the responsibility of the User to meet these maintenance requirements and/or to enter into an agreement with one of authorised Service Centers, so as to properly safeguard the operation of the appliance.

During the warranty period, in case of damage or failures caused by improper maintenance, manufacturer will not refund the costs incurred to repair the appliance in its original state.

The provisions of this section apply only to standard units; according to the order requirements, other documentation may be added, concerning any modifications or supplementary accessories.

9.2 Planned maintenance

Maintenance inspections must be carried out according to the program below, by a qualified person.

As a general rule, units cannot be repaired directly by the user, who shall not try to service or repair any failures or anomalies identified during daily inspections. If you are in doubt, please contact authorised Service Centre.

9 - Maintenance

Operations

Daily

Weekly

Monthly

Beginning

of season

End of

season

Check the temperature of the leaving fluid



Check the pressure drops in the heat exchanger



Check for electric absorption



Check suction pressure and temperature



Check delivery pressure and temperature



Check the oil level in the compressor



Check that there are no gas bubbles in the liquid line



Check that the fins of the external coil are clean (if any)



Check the operation of the oil heaters



Check the remote control switches



Check the operation of the LP pressure switch



Check the operation of the HP pressure switch



Check the insulation of the heat exchanger



Check that terminals are tightened



Check that the terminals’ screws are tightened



Clean the exterior of the unit with water and soap



Check the density of the antifreeze (if any)

 

Check the operation of the flow switches



Check the operation of the solenoid valve

 

English

9.3 Refrigerant charge

WARNING

Do not inject refrigerant liquid into the LP side of the circuit. Be very careful, and charge the circuit properly.

If the charge is insufficient, the efficiency of the unit will be lower than expected. In the worst of cases the LP pressure switch may be activated, resulting in the halting of the unit.

In the presence of an excess charge, the condensing pressure will rise (in the worst of cases, the HP pressure switch may be activated, resulting in the stop of the equipment), and the consumption will increase as well.

WARNING

It is strictly forbidden to use the compressor as a vacuum pump to drain the plant.

Fill the refrigeration circuit after it has been drained for maintenance purposes (leaks, replacement of the compressor etc.). The amount of the charge is indicated on the plate affixed to the unit.

Before refilling, it is important to drain and de-hydrate the circuit, thus obtaining a minimum abs. pressure value of 0.06 mbar.

Inject the refrigerant fluid before removing the vacuum, then fill the circuit up to 90% of the total gas requirement (in liquid form). The appliance must be filled through the filling valve on the liquid line, on the outlet side of the condenser.

It is recommended to connect the refrigerant cylinder to the filling valve on the liquid line, and to arrange it in such a way as to inject only liquid refrigerant.

Then start the compressor and let the gas flow from the cylinder, up until the liquid flow, which can be observed through the sight glass, is limpid.

9.4 Compressor

Compressors are delivered with the necessary charge of lubricating oil. During normal operation, this charge is sufficient for the whole life of the unit, providing that the efficiency of the refrigeration circuit is satisfactory and if it has not been overhauled.

If the compressor needs to be replaced (following a mechanical failure or if burnt), contact one of manufacturer.

WARNING

Compressors use polyester oil. During maintenance operations on the compressor, or if you have to open the refrigerant circuit in any point, remember that this type of oil is highly hygroscopic, and accordingly it is important that it is not left exposed to the weather for prolonged periods, as this would require the replacement of the oil.

9.5 Condenser

Check at regular intervals that the water side of the heat exchanger is perfectly clean. To do this, measure the pressure drop, water side or measure the temperature of the liquid leaving and entering the heat exchanger, and compare it to the condensing temperature..

To obtain an effective heat exchange, the difference between the temperature of the leaving water and the saturated condensing temperature must be in the 3 - 5°C range. A greater difference would indicate a low efficiency of the heat exchanger (i.e. the heat exchanger is dirty).

In this case, the heat exchanger must be subjected to chemical cleaning, an operation that shall be carried out by authorised engineers.

For other maintenance operations (extraordinary overhauling, replacement of the heat exchanger etc.), contact an authorised Service Centre.

9.6 Dehydrating filter

The refrigeration circuits are provided with dehydrating filters.

The filter clogging is marked by the presence of air bubbles in the sight glass, or by the difference between the temperatures measured downstream from and upstream of the drying filter. If, once the cartridge has been cleaned, there are still some air bubbles, the appliance has lost a part of the refrigerant charge in one or more points, that must be identified and serviced.

9 - Maintenance (continued)

WARNING

If the compressor had to be replaced (due to burning of the winding or to mechanical failure), please contact one of the Authorized Service Centers.

9.7 Sight glass

The sight glass is used for inspecting the refrigerant flow and the humidity % of the refrigerant. The presence of bubbles indicates that the dehydrating filter is clogged or the charge insufficient.

A colour indicator is positioned inside the sight glass. If you compare the colour of the indicator to the scale on the ring of the sight glass, you can calculate the percentage of humidity of the refrigerant. If it is excessive, replace the filter’s cartridge, operate the appliance for 1 day and then check the humidity % again. When the humidity % is within the pre-determined range, no other operations are required. If the humidity % is still too high, replace the dehydrating filter again, start the unit and operate it for another day.

9.8 Electronic expansion valve

The circuit of the unit is equipped with electronic expansion valve.

The valve is calibrated for an overheating of 6 °C.

Procedure to check for overheating:

– Measure the suction pressure with the pressure gauges on the

board of the unit o using a pressure gauge connected to the service valve on the suction side.

– From the pressure gauge’s temperature scale, measure the

saturated suction temperature (Tsa) which corresponds to the pressure value.

– Using a contact pressure gauge affixed to the outlet fitting of the

gas of the evaporator, measure the actual temperature (Tse).

Overheating calculation (S):

S = Tse - Tsa

Overheating is regulated through the expansion valve.

If the electronic expansion valve cannot be regulated, it is probably broken, and shall be replaced. The replacement must be carried out by a Service Centre.

9 - Maintenance (continued)

9.9 Evaporator

Check at regular intervals that the water side of the heat exchanger is perfectly clean. To do this, measure the pressure drop, water side (see Section 8) or measure the temperature of the liquid leaving and entering the heat exchanger, and compare it to the evaporation temperature.

To obtain an effective heat exchange, the difference between the temperature of the leaving water and the saturated evaporating temperature must be in the 2 - 4 °C range. A greater difference would indicate a low efficiency of the heat exchanger (i.e. the heat exchanger is dirty).

In this case, the heat exchanger must be subjected to chemical cleaning, an operation that shall be carried out by authorised engineers.

For other maintenance operations (extraordinary overhauling, replacement of the heat exchanger etc.), contact an authorised Service Centre.

English

The table below lists the anomalies of operation of the unit, the relevant causes and the corrective measures. For anomalies of any other type or not listed, contact one of authorised Service Centre for technical assistance.

Anomaly Cause Operation The unit continues

to work, but without cooling

Insufficient charge of refrigerant. Refill.

The dehydrating filter is clogged. Replace.

Ice on the suction line Wrong calibration of overheating.

Increase overheating.

Check the charge.

Excessive noise

Vibration of lines. Check the clamping brackets, if any.

Whistler emitted by the thermostatic expansion valve.

Refill.

Check the dehydrating filter.

Noisy compressor.

Seized bearings; replace the compressor.

Check that the compressor’s locknuts are tightened.

Low oil level in the compressor

One or more gas or oil leaks in the circuit. Identify and remove leaks.

Mechanical failure of the compressor. Request the intervention of a Service Centre.

Anomaly of the oil heater of the compressor’s base.

Check the electric circuit and the resistor of the heater of the motor base, and replace defective components.

One or both compressors are not working

Breaking of the electric circuit.

Check the electric circuit and detect any ground dispersions and short circuits. Check fuses.

Intervention of the HP pressure switch.

Reset the pressure switch and the control panel and restart the appliance. Identify and remove the cause that enabled the pressure switch.

The fuse of the control circuit is broken. Check for ground dispersions and short circuits. Replace fuses.

Loosened terminals. Check and tighten.

Halt caused by thermal overload of the electric circuit.

Check the operation of check and safety devices. Identify and remove the cause.

Wrong wiring. Check wiring of check and safety devices.

The line voltage is too low.

Check voltage. If problems regard the system, solve them. If they are caused by the distribution network, inform the Energy Distributor.

Short-circuit of the compressor’s motor. Check the continuity of the winding.

Seized compressor. Replace the compressor.

Activation of the LP alarm, stop of the unit

Gas leak. Identify and remove the leak.

Insufficient charge. Refill.

Failure of the pressure switch. Replace the pressure switch.

Activation of the HP alarm, stop of the unit

Failure of the pressure switch.

Check the operation of the pressure switch, replace it if defective.

The delivery valve is partially closed. Open the valve and replace it, if faulty.

Substances with condensable gases in the circuit.

Drain the circuit.

The fan of the condenser is stopped. Check cables and motor. If defective, repair or replace.

The liquid line is too hot Insufficient charge. Identify and remove the cause of the loss of charge and refill.

Frosting of the liquid line

The valve of the liquid line is partially closed. Check that valves are open.

The liquid filter is clogged. Replace the cartridge or the filter.

10 - Troubleshooting

11.1 Spare part list

The table below shows the list of spare parts recommended during the first two years of operation.

11.2 Oil for compressors

The compressors are lubricated with Ester oil BSE 170 (Viscosity of 170 St / 40 °C).

11.3 Wiring diagrams

The wiring diagrams are installed inside the doors of the electrical panels of the unit. Any request for wiring diagrams shall be forwarded to manufacturer’s Service Centre.

Component Number

HP pressure switch 2 / 4

LP pressure switch 2 / 4

Gas filter 1 / 2

Electronic expansion valve 1 / 2

Auxiliary relays 2

Compressor’s fuses 3 / 6

Auxiliary fuses 6

Set of compressor contactors 1

Water sensor 2

Electronic card 1

Keyboard 1

Compressor oil resistor 1 / 2

11 - Spare Parts

English

12 - Dismantling, Demolition and Scrapping

DANGER

During the draining of the refrigeration circuits, do not let the refrigerant overflow in the surrounding atmosphere.

The circuit must be drained using suitable recovery equipment.

DANGER

Do not disperse the waste oil of the compressors in the environment, since it contains some dissolved refrigerant.

For the disposal, contact the competent authority for information.

Unless otherwise specified, the maintenance operations listed below may be carried out by any trained maintenance operator.

12.1 Generalities

Open each line that supplies the unit, including the ones of control circuits. Make sure that all disconnecting switches are secured in the off position. The power cables can be disconnected and disassembled. Refer to Chapter 4 for the position of connection points.

Remove all the refrigerant from the refrigeration circuits of the unit and store it in suitable containers, using a recovery unit. If its characteristics have remained the same, the refrigerant can be used again. Contact the competent authority to obtain information about disposal. In NO event shall the refrigerant be discharged into the atmosphere. The oil in each refrigeration circuit must be drained and collected into a suitable container; then it shall be disposes of in conformity with local regulations that apply to the disposal of waste lubricants. Any oil spillage must be recovered and disposed of in like manner.

Isolate the unit’s heat exchangers from the external hydraulic circuits and drain the heat exchange sections of the plant.

DANGER

If no shutoff valves have been provided, it may be necessary to drain the whole plant.

If a glycoled solution or a similar fluid has been used in the hydraulic circuits, or if chemical additives have been added to the circulating water, the circulating fluid MUST be drained in a proper way.

For NO reason shall a circuit containing glycoled water or a similar solution be discharged directly into the drains or surface waters.

After draining operations, the piping of the hydraulic networks can be disconnected and disassembled.

Once they have been disconnected as specified, the packaged units can be disassembled in a single piece. First of all, disassemble the anchoring screws and then lift the unit from the position of installation, and hook it to the lifting points provided, using suitable lifting equipment.

To this end, refer to Chapter 4 for the installation of these appliances, to Chapter 8 for their weights and Chapter 3 for handling.

The units that, once disconnected, cannot be removed in a single piece, must be dismantled on site; in this case, be very careful with the weight and handling of every single component.

It is always advisable to dismantle the units following the installation steps, but in reverse.

DANGER

Some residues of oil, glycoled water or similar solutions may remain in certain parts of the unit. These residues must be recovered and disposed of according to the procedures specified above.

It is very important to ensure that, while a component of the unit is being removed, all the others are properly supported.

DANGER

Use only lifting means of adequate capacity.

Once disassembled, the components of the unit can be disposed of in conformity with current regulations.

Notes

SystemAir EVO CO 570, EVO CO 630, EVO CO 700, EVO CO 770, EVO CO 850 Installation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual