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 ”
Español
ItalianoDeutsch
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
1
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
2
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
3
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.
4
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)
5
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.
6
2 - Safety (continued)
2.7 Safety labels
Identification of the refrigerant - External door
USARE SOLO
R134a
E
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.
7
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
8
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.
9
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.
10
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)
11
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:
Q
Insert and secure eyebolts into the holes marked on the frame.
Q
Insert spacer between cables.
Q
Hook near the barycentre of the unit.
Q
The cables must be long enough to form, if tensioned, an angle
of at least 45° with respect to the horizontal plane.
12
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.
13
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
Q
Prepare the base, that must be flat and plane.
Q
Lift the appliance and inser t shock absorbers as follows:
14
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:
Q
A circulation pump which can ensure the necessary capacity
and discharge head.
Q
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.
Q
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.
Q
The bleed valves must be mounted on the highest point of the
piping.
Q
The stop valves must be mounted on the piping of the water ente-
ring/leaving the evaporator.
Q
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”.
15
English
4 - Installation (continued)
Then:
Q
Provide the evaporator with a by-pass circuit equipped with a
valve to wash the plant.
Q
Insulate the piping, to prevent the risk of heat loss.
Q
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.
16
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:
Q
A circulation pump that can ensure the necessary capacity and
discharge head.
Q
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.
Q
The bleed valves must be mounted on the highest point of the
piping.
Q
The stop valves must be mounted on the piping of the water
entering/leaving the condenser.
Q
The discharge points (provided with plugs, cocks etc.) must be
arranged in the lowest point of the piping.
Furthermore:
Q
Provide the condenser with a by-pass circuit, equipped with a
shutoff valve.
Q
Insulate piping, to prevent the risk of heat loss.
Q
Install a filter on the suction side of the condenser.
Q
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.
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