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 380-1260
Air EVO HSE CO/TR
366
1.241 kW
FrançaisEnglish
Air Cooled Water Chillers with Screw Compressors
Refroidisseurs de liquide à condensation par air avec compresseurs à vis
Luftgekühlte Wasserkühler mit Schraubenkompressoren
Refrigeratori d’Acqua Raffreddati ad Aria con compressori a vite
Enfriadores de Agua Condensadas con Aire con compresores a tornillo
Part number / Code / Code / Codice / Código: J37276
Supersedes / Annule et remplace / Annulliert und ersezt / Annulla e sostituisce /
Anula y sustituye: Notified Body /Organisme Notifié / Benannte Zertifizierungsstelle /
Organismo Notificato / Organismo Notificado N°. 0425
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 models with heat recovery included) 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.
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:
The Danger sign recalls your attention to a
certain procedure or practice which, if not
DANGER
WARNING
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.
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:
n The machine must be operated only by skilled personnel from
Authorised After-Sales Service.
n Maintenance must be performed only by skilled personnel - from
one of Authorised After-Sales Centers.
n Use only original spare parts.
n 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.
The Notes contain important observations.
NOTE
The Useful Tips provide valuable information
that optimises the efficiency of the appliance.
USEFUL TIPS
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.
2
2 - Safety
2.1 Foreword
These units must be installed in conformity with the
provisions of Machinery Directive 2006/42/EC, Pressure
Equipment Directive 2014/68/EU, Electromagnetic
Compability Directive 2014/30/EU - as per EN 55011,
Group 1, Class A, 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.
Compressors with frequency inverter (FI) are installed. Several
electrical connections are required and all are established inside the
terminal box. FI and the compressor motor are Permanently wired
and the compressor motor cannot be operated without FI. As soon as
the FI is under voltage, the capacitors in the FI intermediate circuit are
charged and from this moment on, all the electrical components in
the terminal box present risks.
Hazardous voltages in frequency inverter
housing! Any contact will cause severe injury
or death. Never open FI housing during
operation. In case of any operation in the
FI housing, switch off the main switch and
DANGER
secure it against being switched on again.
Wait for at least 5 minutes until all capacitors
have been discharged. Close perfectly the FI
housing before switching on again
The unit must be grounded and no installation
and/or maintenance operations may be
carried out before deenergising the electrical
panel of the unit and protect against restoring
DANGER
power. Wait at least 5 minutes for capacitors
to de-energize!
Failure to respect the safety measures mentioned above may result
in electrocution hazard and fire in the presence of any short-circuits.
Inside the heat exchangers, the compressors
and the refrigeration lines, this unit contains
liquid and gaseous refrigerant under
DANGER
pressure. The release of this refrigerant may
be dangerous and cause injuries.
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
DANGER
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).
English
The inverter compressor is provided with the safety fuction called
"Safe Torque Off" (STO), that is used as device for removal power
for prevention of unexpected start-up. As long as this function is
activated, no drive energy is transferred to the compressor motor,
so the compressor motor is safely free of torque, but it is not
de-energized. That means that, even if the compressor has been
stopped by the "Safe Torque Off" (STO) or "motoroff" function, the FI
remains energized.
Even in the cases described above the main
switch must be switched off and must be
waited for at least 5 minutes before any
DANGER
operation in th FI housing
Due to the use of compressor frequency inverter,
the unit may produce a strong magnetic field
Keep magnetic and magnetizable objetcs away
from the unit. Persons with cardiac pacemakers,
WARNING
implanted heart defibrillators or metallic implants
must maintain a clearance of at least 30cm from
the compressor.
n The used refrigerants are included in group II (non-hazardous
fluids).
n The maximum working pressure values are mentioned on the
unit’s data plate.
n Suitable safety devices (pressure switches and safety valves)
have been provided, to prevent any anomalous overpressure
inside the plant.
n 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.
n Dedicated guards (removable panels with tools) and danger signs
indicate the presence of hot pipes or components (high surface
temperature).
3
2 - Safety (continued)
DANGER
DANGER
DANGER
The guards of the fans (only for units provided
with air heat exchangers) must be always
mounted and must never be removed before
de-energising the appliance.
The standard unit is provided with fans
protection grill always factory mounted.
For specific customer requests, mainly due
to limiting transport conditions, it is still
possible the unit is shipped with fans not
fully assembled. In this circumstance, before
switching on the unit, it is mandatory that
the Customer/Installer completes the fans
assembling on field - including fan protection
grills -according to the instructions included
into the manual.
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.
WARNING
WARNING
The unit has not been design to withstand
loads and/or stress that may be transmitted by
adjacent units, piping and/or structures.
Each external load or stress transmitted to the
unit may break or cause breakdowns in the
unit’s structure, as well as serious dangers to
people. In these cases, any form of warranty will
automatically become null and void.
The packaging material must not be disposed of
in the surrounding environment or burnt.
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.
4
2 - Safety (continued)
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
disassemble connections, filters, joints or other line items
n do not use your hands to check for any pressure drops
n use tools in a good state of repair; be sure to have understood the
instructions before using them
n 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
n be sure to have perfectly understood the operating instructions
before carrying out any operation on the control panel
n when you have to work on the control panel, keep always the
operating instructions within reach
n start the unit only after you have checked its perfect connection to
the plant
n promptly inform the ENGINEER about any alarm involving the unit
n do not reset manual restoration alarms unless you have identified
and removed their cause
English
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:
n do not wear loose clothing or jewellery or any other accessory tat
may be caught in moving parts
n 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
Prevention of residual mechanical risks
n install the unit according to the instructions provided in this
manual
n carry out all the periodical maintenance operations prescribed by
this manual
n wear a protective helmet before accessing the interior of the unit
n before opening any panelling of the machine, make sure that it is
secured to it by hinges
n do not touch air condensation coils without wearing protective
gloves
n do not remove the guards from moving elements while the unit is
running
n check the correct position of the moving elements’ guards before
restarting the unit
Prevention of residual electrical risks
n connect the unit to the mains according to the instructions
provided in this manual
n periodically carry out all the maintenance operations specified by
this manual
n disconnect the unit from the mains by the external disconnecting
switch before opening the electrical board
n if the unit is placed in a closed room, wear ear protection devices
n cut off connecting pipes, drain them in order to balance the
pressure to the atmospheric value before disconnecting them,
n check the proper grounding of the unit before start-up
n check all the electrical connections, the connecting cables, and in
particular the insulation; replace worn or damaged cables
5
2 - Safety (continued)
n periodically check the board’s internal wiring
n 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
n make sure that the connections to the unit conform to the
instructions provided in this manual and on the unit’s panelling
n if you have to disassemble a piece, make sure that it has been
properly mounted again before restarting the unit
n do not touch the delivery pipes from the compressor, the
compressor and any other piping or component inside the
machine before wearing protective gloves
n keep a fire extinguisher fir for electrical appliances near the
machine
n on the units installed indoor, connect the safety valve of the
refrigeration circuit to a piping network that can channel any
overflowing refrigerant outside
n remove and leak of fluid inside and outside the unit
n collect the waste liquids and dry any oil spillage
n periodically clean the compressor compartment, to remove any
fouling
n place a warning sign “do not turn on - maintenance in progress”
on the external disconnecting switch
n make sure that on-off remote controls are inhibited
n 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:
n work with the electrical board open only for the necessary time
n close the electrical board as soon as the measurement or check
has been completed
n 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:
n do not scatter the fluids of the refrigeration circuit in the
surrounding environment
n when replacing an eprom or electronic cards, use always suitable
devices (extractor, antistatic bracelet, etc.)
n 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
n do not store flammable liquids near the unit
n do not disperse the refrigerant and the lubricating oil into the
environment
n weld only empty pipes; do not approach flames or other sources
of heat to refrigerant pipes
n 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:
n disconnect the unit from the mains with the external disconnecting
switch
n in air units with independent compressor compartment, 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”
n contact manufacturer for any modifications to the refrigeration,
hydraulic or wiring diagram of the unit, as well as to its control
logics
n contact manufacturer if it is necessary to perform very difficult
disassembly and assembly operations
n use only original spare parts purchased directly from manufacturer
or the official retailers of the companies on the recommended
spare parts list
n 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)
corrente antes
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.
Identification of the unit - Outside, on the right-hand front column
CODICE PRODOTTO NEUTRO
PRODUCT CODE
MODELLO
MODEL
0425
MO.NO
MATRICOLA
SERIAL NO.
ANNO DI COSTRUZIONE
Manuf. Year
REFR.
PS (LATO ALTA / LATO BASSA)
PS (HIGH / LOW SIDE)
TS (ALTA / BASSA)
TS (HIGH / LOW)
ALIM. POTENZA
MAIN SUPPLY
CORRENTE DI SPUNTO
LRA
CORRENTE A PIENO CARICO
FLA
POTENZA ASSORBITA
POWER INPUT
PRESS. MAX ESERCIZIO ACQUA
MAX WATER OPERATING PRESSURE
MASSA
MASS
SYSTEMAIR S.r.l. Via XXV Aprile 29 20825 BARLASSINA MB ITALIA
MADE IN ITALY COD.NO: P35952
MODELLO:
MODEL
MATRICOLA:
SERIAL NO.
CODICE:
PRODUCT CODE
MODELLO:
MODEL
MATRICOLA:
SERIAL NO.
CODICE:
PRODUCT CODE
MODELLO:
MODEL
MATRICOLA:
SERIAL NO.
CODICE:
GWP
CIRCUIT 1 2 3 4
CHARGE (Kg)
(tCO₂eq)
bar
°C
V / PH / Hz
(max) A
(max) A
(max) Kw
bar
Kg
ANNO DI COSTRUZIONE
Manuf. Year
ANNO DI COSTRUZIONE
Manuf. Year
ANNO DI COSTRUZIONE
Manuf. Year
Gravity centre - Base
English
On the compressor box
BEFORE OPENING THE PANEL, THE
UNIT MUST STAY SWITCHED OFF
FOR AT LEAST 5 MINUTES
WARNING
PRIMA DI APRIRE IL PANNELLO
L'UNITÀ DEVE RESTARE SPENTA PER
ALMENO 5 MINUTI
Circuit drain - Outside, on the right-hand front column
ON THIS LINE
KEEP LIFT HOOK
TENERE SU QUESTA LINEA
GANCIO DI SOLLEVAMENTO
Grounding connection on the electrical board, adjacent to the connection
7
2 - Safety (continued)
ATENCION! PERFIL AFILADO
Start-up warning - Outside the door
of the electrical board
INSERIRE LE RESISTENZE DI RISCALDAMENTO OLIO ALMENO 12
ORE PRIMA DI OGNI AVVIAMENTO (SE PREVISTE)
PRIMA DELLA MESSA IN TENSIONE ASSICURARSI CHE LE VITI DEI
CIRCUITI ELETTRICI SIANO SERRATE COMPLETAMENTE
ENERGIZE THE CRANCKCASE HEATER FOR AT LEAST 12 HOURS
BEFORE EACH STARTING (IF FITTED)
BEFORE TIGHTENING-UP, TO TIGHTEN ALL TERMINAL SCREWS
ESPECIALLY THOSE IN MAIN CIRCUIT
OLSUMPFHEIZUNG (FALLS VORHANDEN) 12 STUNDEN VOR DEM
START EINSCHALTEN
VOR INBETRIEBNAHME ALLE SCHRAUBENVERBINDUNGEN
NACHZIEHEN, BESONDERS DIE ELEKTRISCHEN ANSCHLUSSE
ALIMENTER ELECTRIQUEMENT LA RESISTANCE DE CARTER AU
MOINS 12 HEURES AVANT CHAQUE DEMARRAGE (SI MONTE SUR
LE PRODUIT)
AVANT DE DEMARRER LA MACHINE, VERIFIER LE SERRAGE DE
TOUTES LES BORNES A VIS, SPECIALEMENT DANS LE BOITIER
ELECTRIQUE
ATENCIÓN ALIMENTAR ELÉCTRICAMENTE LA RESISTENCIA DE
CARTER AL MENOS 12 HORAS ANTES DE CADA PUESTA EN
MARCHA (SI ESTA EQUIPADA EN LA UNIDAD)
ANTES DE LA PUESTA EN MARCHA, COMPROBAR QUE LOS
BORNES ESTAN BIEN APRETADOS, ESPECIALMENTE EN EL
CUADRO ELÉCTRICO
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.
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 15 minutes, and then obtain
medical attention.
English
Very unlikely - should something happen, it will cause frost burns.
Ingestion
Inhalation
Recommendations
Prolonged exposure
Professional levelsRecommended threshold: 1000 ppm v/v - 8 hours TWA.
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.
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.
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.
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.
StabilityNot specified
Conditions to avoidDo not use in the presence of flames, burning surfaces and excess humidity.
9
2 - Safety (continued)
2.8 Safety regulations (continued)
REFRIGERANT DATASAFETY DATA: R134a/R513A
Hazardous reactions
Hazardous decomposition
products
General precautions
Respiratory system protection
Storage
Protective clothing
Accidental release measures
May react with sodium, potassium, barium and other alkaline metals.
Incompatible substances: magnesium and alloys with magnesium concentrations > 2%.
Halogen acids produced by thermal decomposition and hydrolysis.
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.
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.
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 50 °C.
Wear overalls, protective gloves and goggles or a mask.
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
Fire fighting informationNot flammable in the atmosphere.
CylindersThe 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.
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.
10
2 - Safety (continued)
2.8 Safety regulations (continued)
LUBRICANT OIL DATASAFETY DATA: ESTER OIL
ClassificationNot harmful.
May cause slight irritation. Does not require first aid measures. It is recommended to follow usual
Contact with skin
Contact with eyesWash thoroughly with a suitable solution or tap water.
IngestionSeek medical advice immediately.
InhalationSeek medical advice immediately.
Conditions to avoid
Protection of the
respiratory system
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.
Strong oxidising substances, caustic or acid solutions, excess heat.
May corrode some types of paint or rubber.
Use in well ventilated rooms.
English
Protective clothing
Accidental release measures
Disposal
Fire fighting information
CylindersThe 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.
Always wear protective goggles or a mask. Wearing protective gloves is not mandatory, but is
recommended in case of prolonged exposure to refrigerant oil.
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).
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.
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.
11
3 - Transport, Lifting and Positioning
Refrigerators are supplied assembled (apart 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).
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.
Do not displace the unit on rollers, and do not
lift it with a lift truck.
Unit must be lifted carefully.
WARNING
To lift unit slowly and regularly.
To lift and displace the unit:
n
Insert and secure eyebolts into the holes marked on the frame.
n
Insert spacer between cables.
n
Hook near the barycentre of the unit.
n
The cables must be long enough to form, if tensioned, an angle
of at least 45° with respect to the horizontal plane.
For lifting operations, use only tools and
material fit for this purpose, in accordance with
WARNING
accident-prevention regulations.
12
WARNING
3 - Transport, Lifting and Positioning (continued)
During the lifting and handling of the unit, be
careful not to damage the finned pack of the
coils positioned on the sides of the unit.
The sides of the unit must be protected by
cardboard or plywood sheets.
English
The eyebolts must be mounted on the unit whenever it shall be
displaced and then lifted again.
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.
WARNING
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.
The lifting eyebolts protrude from the base
of the unit; it is therefore recommended to
remove them once the unit has been lifted and
positioned, if in your opinion they are likely to
become a source of hazard and injury.
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:
n plug or seal every single opening, such as water fittings
n do not store the appliance in a room where the temperature
exceeds 50 °C and, if possible, do not expose to direct sunlight
n minimum storage temperature is -20 °C
n it is recommended to store the unit in a roof where traffic is
minimized, to prevent the risk of accidental damage
n the unit must not be washed with a steam jet
n 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.
13
4 - Installation
4.1 Positioning of the unit
Before installing the unit, make sure that the
structure of the building and/or the supporting
surface can withstand the weight of the
DANGER
These units have been designed for outdoor 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 that:
n the longitudinal axis of the unit must be parallel to the direction of
prevailing winds, so as to ensure a uniform distribution of the air
on finned exchangers
appliance. The weights of the units are listed in
Chapter 8 of this manual.
4.2 Spring Isolator Installation
n
Prepare the base, that must be flat and plane.
n
Lift the appliance and inser t shock absorbers as follows:
n the unit must not be installed near boilers’ vent pipes
n the unit must not be installed leeward with respect to sources of
air contaminated by greases, such as, for example, the outlets
to kitchen exhaust hoods into the atmosphere. Otherwise,
the grease is likely to deposit on the fins of the refrigerant /air
exchangers, and would fix every type of atmospheric impurity,
resulting in the quick clogging of the exchangers
n the unit must not be installed in areas subject to considerable
snow falling
n the unit must not be installed in areas subject to flooding, under
gutters etc.
n the unit must not be installed in air shafts, narrow courts or other
small places, where the noise may be reflected by the walls or
the air ejected by fans may short-circuit itself on refrigerant/air
heat exchangers or condenser
n the place of installation must be have all the necessary spaces
for air circulation and maintenance operations (see Chapter 8).
4.3 Place of installation
In the place of installation the air temperature average during 24
hours must be lower than 40°C.
The place of installation's altitude must be lower than 2000 m.
14
4 - Installation (continued)
4.4 External Water Circuit
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.
The external hydraulic circuit must ensure the
water flow to the evaporator under any working
WARNING
The circuit shall be composed by the following elements:
n
A circulation pump which can ensure the necessary capacity
and discharge head.
n
The capacity of the primary hydraulic circuit should not be less
than the minimum water volumes shown in the table below, 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.
SYSCREW AIR EVO HSE 380-450-510-590-660 730-810
Recommended system chilled
water volume
SYSCREW AIR EVO HSE 900-9801060-1160-1260
Recommended system chilled
water volume
4
Minimum water contents at normal air conditioning applications
The following formula must be respected
Vmin = Cap * MinCapStep * 28,8 , where
Cap = Nominal Unit Capacity [kW] at conditions of installation
MinCapStep = Minimum unit capacity step [%] shown in Technical Data
Table
If the application is a process cooling type, the minimum system chilled water
volume is generally higher than above recommended.
In this case, please contact your nearest Systemair Sales Office
n
A membrane expansion vessel provided with safety valve with
vent, that must be visible.
NOTE
or adjustment conditions.
MINIMUM WATER VOLUMES
4
4
l23342953
l36085017
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.
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.
n
The bleed valves must be mounted on the highest point of the pip-
ing.
n
The stop valves must be mounted on the piping of the water en-
tering/leaving the evaporator.
n
The drain points (provided with plugs, cocks etc.) must be ar-
ranged in the lowest point of the piping.
The flow switch must be connected (terminals
1-2) as shown in the wiring diagram of the
WARNING
PH 7,5 - 9
Electrical conductivity 10 - 500μS/cm
Total hardness 4,5 - 8,5dH
Temperature < 60[°C]
Alkalinity (HCO
Alkalinity / Sulphates (HCO
Sulphates (SO
Chlorides (Cl-) < 50ppm
Free Chlorine< 0,5ppm
Phosphates (PO
Ammonia (NH3)< 0,5ppm
Ammonium Ion (NH
Manganese Ion (Mn2+)< 0,05ppm
Free Carbon Dioxide (CO2)< 5ppm
Hydrogen Sufide (H2S)< 0,05ppm
Oxygen Content < 0,1ppm
Nitrates (NO
Manganese (Mn)< 0,1ppm
Iron (Fe)< 0,2ppm
Aluminium (Al)< 0,2ppm
Caution
If the water circuit is to be drained for a time exceeding one month, the
circuit must be fully charged with nitrogen to prevent any risk of corrosion
by differential venting
“User’s Terminal Box”.
RECOMMENDED WATER COMPOSITION
-
)70-300ppm
3
2-
) < 70ppm
4
3-
4
-
) < 100ppm
3
-
2-
/ SO
)> 1ppm
3
4
) < 2ppm
+
)< 2ppm
4
English
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.
15
4 - Installation (continued)
Then:
n
Provide the evaporator with a by-pass circuit equipped with a
valve to wash the plant.
n
Insulate the piping, to prevent the risk of heat loss.
n
Position a filter on the suction side of the evaporator of the heat
recovery condenser.
Standard hydraulic circuit
User side
Unit side
INLET
OUTLET
COMPONENTS
1 Shell & Tube Heat Exchanger
2 Water Filter
3 Pressure point/drain
4 Water outlet
5 Water inlet
6 Globe valve
7 Flexible pipe
8 By-pass valve
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
WARNING
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.
If necessary, the water required to fill the circuit
must be treated to obtain the requested pH.
NOTE
SAFETY/CONTROL DEVICES
AInlet water temp. sensor
BOutlet water temp. sensor
CThermometer
FSFlow switch
Probes
16
4 - Installation (continued)
4.5 Water connections for base unit
configuration (without hydraulic options)
The units are provided with fittings for hydraulic connections between
heat exchangers and plant.
BT OUT
English
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.
BT IN
OUT
VICTAULIC JOINT
FITTING
VICTAULIC JOINT
IN
FITTING
17
4 - Installation (continued)
4.6 Water connections for unit provided with
hydraulic option
In case of hydraulic option installed (single/double pump), the water
inlet/outlet fittings shall conform to the instructions provided by the
plates affixed near the connection points.
General hydraulic layout with pump/s installed is shown in the image
below.
DESCRIPTION
1 Pressure transducer (Outlet of HE)*
2 Pressure transducer (Inlet of HE)*
3 Air vent
4 Non-return valve
5 Butter fly valve
6 Pump
7 Safety valve
* Only for Variable flow hydraulic module
18
4 - Installation (continued)
4.7 Power supply
Before carrying out any operations on the
electrical system, make sure that the unit is
DANGER
DANGER
DANGER
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:
n A 3-phase and grounding connection for the power supply
circuit.
n The electrical distribution system shall meet the power absorbed
by the appliance.
n The disconnecting and magnetothermal switches must be sized to
control the starting current of the unit.
n The power supply lines and the insulation devices must be
designed in such a way that every line independent.
n It is recommended to install differential switches, to prevent any
damage caused by phase drops.
n The fans and compressors are supplied through contactors
controlled from the control panel.
n Each motor is provided with an internal safety thermal device
and external fuses.
n 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.
deenergised.
It is important that the appliance is grounded.
The company in charge of the installation shall
conform to the standards applicable to outdoor
electrical connections.
4.8 Electrical connections
The unit must be installed on site according to the Machinery
Directive 2006/42/EC, Electromagnetic Compatibility Directive
2014/30/EU - as per EN 55011, Group 1, Class A, Pressure
Equipment Directive 2014/68/EU and the usual procedures and
standards applicable in the place of installation.
This equipment is intended only for industrial
applications and must be installed on side
according to the standards mentioned above
WARNING
The installar is responsible for ensuring the correct electrical
installation and the use of correct materials.
WARNING
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
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.
and according also to the usual procedures and
standards applicable in the place of installation.
Incorrect electrical installation and/or using
incorrect materials may cause additional
radio frequency emissions which may require
mitigation measures
Before connecting the power supply lines, check
that the available voltage value does not exceed
the range specified in the Electric Data (Chapter
8).
English
If the unbalance is unacceptable, contact the Energy Distributor to
solve this problem.
Supplying the unit through a line whose
unbalance exceeds the permissible value will
WARNING
automatically void the warranty.
19
Electrical connections
4 - Installation (continued)
20
5 - Start-Up
The unit must be started for the first time by
personnel suitably trained by one Authorised
Service Centre. Failure to meet this requirement
WARNING
will immediately void the warranty.
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.
NOTE
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.
n 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.
n Check that any voltage and phase variation in the power supply
does not exceed the prefixed thresholds.
n 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.
n 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.
n 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.
n 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.
n Adjust the liquid distribution network in such a way that the flow
rate is within the specified range.
n Check that the water quality is up to the specifications.
n Check that oil heaters, if any, have been turned on at least 12
hours before.
n Start the pump and check that the water flow is correct.
n Set the desired fluid temperature on the control board.
n Start the appliance (see Chapter 6).
n Check the correct direction of rotation of compressors. Scroll
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 star t-up
of the compressor, the pressure drops on the LP side and rises
on the HP side. Furthermore, if a scroll 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 scroll compressor can be definitely damaged. Phase
monitor is assembled in the unit as a standard to prevent wrong
compressors rotation.
n After about 15 minutes of operation check that there are no
bubbles, through the sight glass on the liquid line.
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
WARNING
n Repeat the start-up procedure after removing the leaks.
n Check the oil level in the compressor’s sight glass.
these leaks before proceeding.
5.3 Checking the operation
Check the following:
n The temperature of the water entering the evaporator.
n The temperature of the water leaving the evaporator.
n The level of the water flow rate in the evaporator, if possible.
n The current absorption upon the start of the compressor and in
case of stabilised operation.
n The fan’s current absorption.
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).
English
5.2 Start-up
Start-up sequence:
n Turn on the Main switch (at least 12 hours before).
n 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.
n Check the operation of all the external equipment, and make sure
that the control devices of the plant are properly calibrated.
HP side
LP side
Approx. 15 to 21 °C above the temperature of
the air entering the condenser.
Approx. 2 to 7 °C below the temperature of the
leaving chilled water.
5.4 Delivery to the customer
n Train the user according to the instructions provided in Section 6.
21
6.1 General information
6 - Control
Introduction
This document contains the information and the operating instructions
for 2 screw compressors (step type and inverter driven 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 and integral control of the return water temperature
or leaving water temperature (LWT or RWT)
– Access code to enter the Service Level
– Access code to enter User Level
– Basic functions without access code
– Alarm and LED
– Backlighted LCD
– Rotation of the compressor operation
The control system consists of:
a) Main Board. The units are provided with a microprocessor card
which is fully programmed by default for the control of a chiller
of cold only type with 2 circuits, 1 compressor for circuit, a HP
transducer and a LP transducer for Circuit.
b) EEV controllers (two separate drivers) for the management of the
electronic expansion valves.
C) Keyboard & Display Terminal.
– Oil return function - Standard for the inverter compressor,
optional (oil switch device) for step compressor
– 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)
– Built-in serial communication RS485 port with Modbus protocol
to connect the main board to a BMS network.
This built-in port is available as standard only in the case no
extra network control systems (netTune) are selected with the
units.
– Built-in serial communication Ethernet port with two possible
protocols (Modbus or Bacnet, in case also at the same time). In
case of Bacnet communication protocol it is needed to activate a
license.
– Custom protocols are available on request
The following accessories can be also connected:
– Remote Display Terminal.
The terminal makes it possible to carry out the following operations:
– the change of 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.
22
6 - Control (continued)
Keypad Functions
BUTTONDESCRIPTION
ESCMove back from one mask to higher level menu
ALARM
PRGUsed to enter in the main menu tree
UP
Press it to enter in
a) Alarm Status
a.1) Press again to reset each single alarm,
if present (one by one)
a.2) Scroll down up to the end of the alarm
list (if an alarm list is present) and keep
pressed it for 3 second to reset all alarms
in one time
b) Alarm Data logger
Scroll a list upwards or increase a value
highlighted by the cursor
6.2 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.
6.3 Main Control Functions
In the main mask the cursor flashes at the bottom right corner of the
display, in correspondence of the Quick Menu.
English
DOWN
ENTER
Scroll a list downwards or decrease a value
highlighted by the cursor
Enter in the selected menu or confirm a value
highlighted by the cursor
By pressing UP/DOWN keys, it is possible to select the following
items of the Quick Menu.
SettingOn/OffInformation
23
6 - Control (continued)
MAIN MASK TREE
POWER
UP and DOWN key to
switch unit ON and OFF
SETPOINT
LWT/RWT setpoints can
be modified in a range
decided by manufacturer.
The Actual Setp. is the
setpoint of regulation for
actual working mode.
READINGS
Water Outlet Temperature
Water Inlet Temperature
Outdoor Air Temperature