SystemAir WQL 30, WQL 25, WQL 20, WQL 40, WQL 45 Installation And Maintenance Manual
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Water Cooled Liquid Chillers - Water/Water Reverse Cycle Heat Pumps - Condenserless Units
Refroidisseurs de Liquid à Condensation par l’Eau - Pompes à Chaleur Réversibles Eau/Eau
Refroidisseurs de Liquid sans Condenseur
Flussigkeitsküler Wassergekühlt - Wasser/Wasser Wärmepumpen - Werdampfereinheiten
(ohn Verflüssiger)
Refrigeratori di Liquido Condensati ad Acqua - Pompe di Calore Acqua/Acqua - Unità Motoevaporanti
Enfriadoras de Fluido con Condensación por Agua - Bomba de Calor Agua/Agua
Modelo Condensador Remoto
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
WQL-WQH-WQRC
Part number / Code / Code / Codice / Código: 354455/B
Supersedes / Annule et remplace / Annulliert und ersetzt / Annulla e sostituisce /
Anula y sustituye:
354455/A
Notified Body / Organisme Notifié / Benannte Zertifizierungsstelle / Organismo
Notificato / Organismo Notificado N°. 1115
”
21
193 kW
24
211 kW
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 to 8
2.8 Safety regulations ........................................................9 to 11
3 - TRANSPORT, LIFTING AND POSITIONING
3.1 Inspection ..........................................................................12
3.2 Handling ............................................................................12
3.3 Anchoring ..........................................................................13
3.4 Storage ..............................................................................13
4 - INSTALLATION
4.1 Positioning of the unit ......................................................... 14
4.2 Spring Isolator Installation ..................................................14
4.3 Internal/external Water Circuit .................................... 15 to 21
4.4 Water connections ............................................................22
4.5 Power supply .....................................................................22
4.7 Electrical connections................................................ 23 & 24
5 - START-UP
5.1 Preliminary check ...............................................................25
5.2 Start-up .............................................................................25
5.3 Checking the operation .......................................................25
5.4 Delivery to the customer ..................................................... 25
6 - CONTROL
6.1 Control of WQL/WQH/WQRC units,
single/double compressor ..................................................26
6.2 Keypad functions ...............................................................26
6.3 Folder structure ..................................................................27
6.4 Menu structure ................................................................... 27
6.5 Alarm list ...........................................................................28
7 - PRODUCT DESCRIPTION
7.1 General Information ............................................................29
7.2 Body and Frame .................................................................29
7.3 Compressors .....................................................................29
7.4 Refrigeration circuits ..........................................................29
7.5 Evaporator .........................................................................29
7.6 Condenser (except for WQRC) ............................................ 29
7.7 Switch board ......................................................................29
7.8 Accessories ............................................................. 32 & 33
8 - TECHNICAL DATA
8.1 Pressure drops .......................................................... 34 to 40
8.2 Technical data ........................................................... 34 to 40
8.3 Unit electrical data .............................................................. 41
8.4 Hydraulic Features .....................................................43 to 47
8.5 Position of shock adsorbers
and weight distribution on supports ........................... 48 & 51
8.6 Dimensional Drawings ............................................... 52 & 54
8.7 unit clearances ................................................................... 55
9 - MAINTENANCE
9.1 General requirements ........................................................56
9.2 Planned maintenance .........................................................56
9.3 Refrigerant charge .............................................................. 57
9.4 Compressor .......................................................................57
9.5 Condenser ........................................................................57
9.6 Dehydrating filter ................................................................57
9.7 Sight glass .........................................................................57
9.8 Mechanical expansion valve ...............................................57
9.9 Evaporator .........................................................................57
10 - TROUBLESHOOTING
11 - SPARE PARTS
11.1 Spare part list.....................................................................60
11.2 Oil for compressors ............................................................60
11.3 Wiring diagrams ................................................................. 60
12 - DISMANTLING, DEMOLITION AND SCRAPPING
12.1 Generalities ........................................................................61
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 relev ant 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.
WARNING
The Warning sign precedes those procedures
that, if not followed, may result in serious
damage to the appliance.
NOTE
The Notes contain important observations.
USEFUL TIPS
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.
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
liqu i d an d ga s e o us r e frig e r ant und e r
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
pr oble ms d eriv ing from the rep lace ment
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).
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
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 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.
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 ENGINEER S; ot herwise the u nit 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 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
Q periodically check the board’s internal wiring
Q do not us e cable s havin g a n inade quate s ection or flying
2 - Safety (continued)
5
English
connections, even for limited periods of time or in an emergency
Prevention of other residual risks
Q make sure th at th e 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 no t touch the delivery pi pes 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 di s c o nnect t he u n i t fr o m the m a ins w i t h t h e ext e r n al
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 c arr y out an y 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 sc atte r t he flui ds of the refrige ration 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, or any other weighty
element, make sure that the lifting equipment is consistent with
the weight to be lifted
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 o n l y o riginal spare p a r t s purchased d i r e c t l y 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 unit Outside,
on the left -hand front column
Pump operation - Outside, on the right-hand front column
Instruction for the movimentation - Outside the packaging
Sequence phase control on the electrical board
Gravity centre - Base Instruction for the lifting
TENERE SU QUESTA LINEA
GANCIO DI SOLLEVAMENTO
KEEP LIFT HOOK
ON THIS LINE
MIN. 5 cm
7
English
2 - Safety (continued)
Grounding connection on the electrical board,
adjacent to the connection
Read the instruction on the electrical board
Fitting identification - Adjacent to fittings
Electrical warning
Adjacent 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
Commissioning - Outside, on the left-hand front column
Final Test Certificate - Inside the external door
8
2 - Safety (continued)
Identification of refrigerant - Below identification of the unit
Parameter configuration - Inside the electrical board
Pump drain - Outside, on the right-hand front column
Circuit drain - Outside, on the right-hand front column
Filter / flow switch - Outside, on the right-hand front column
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.
9
English
2 - Safety (continued)
REFRIGERANT DATA SAFETY DATA: R410A
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
R410A: 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
R410A: 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 R410A: Recommended threshold: 1000 ppm v/v - 8 hours TWA.
Stability R410A: 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
R410A: Halogen acids produced by thermal decomposition and hydrolysis.
2.8 Safety regulations
10
2 - Safety (continued)
REFRIGERANT DATA SAFETY DATA: R410A
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 50 °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 R410A: Not flammable in the atmosphere.
Cylinders The cylinders, if exposed to fire, shall be cooled by water jets; otherwise, if heated, they may explode.
Protective fire fighting equipment In case of fire, wear an independent respirator and protective clothing.
2.8 Safety regulations (continued)
11
English
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)
12
3 - Transport, Handling and Storage
WQL / WQH / WQRC units are supplied fully assembled and tested
(except for accessories supplied loose in the units – absorbers, filter,
etc.). They are ready to be installed and started on the field.
R410A units are only charged with liquid refrigerant and with oil in the
quantity required for operation.
WARNING
The low pressure side of the refrigerating circuit
on R410A units shall be charged by means
of the service valve arranged on the thermal
expansion valve before the device is operated.
3.1 Inspection
The unit shall be immediately inspected upon receipt to find out any
damage since it has been delivered ex works and transported at the
customer’s risk. It is also necessary to make sure that all the parcels
specified on the delivery note have been delivered.
Any damage you may find out shall be immediately reported in writing
to the carrier. Even if the damage is only on the surface, please notify
our local representative too.
The manufacturer disclaims all responsibility for the shipment even if
it has provided for its organisation.
3.2 Handling
WQL / WQH / WQRC units are designed to be lifted from above, by
means of cables and eyebolts. A spacer shall be arranged between
the cables in order to prevent them from damaging the unit (see the
figure aside).
Before handling the devices, make sure the site you have chosen for
the installation can withstand its weight and support its mechanical
impact.
Avoid touching sharp parts while handling the unit.
WARNING
The unit shall never be placed on rollers.
Act as follows to lift and handle the unit:
Q
Insert and secure the eyebolts into the frame holes which have
been marked on purpose.
Q
Connect the cables to the eyebolts.
Q
Insert the spacer between the cables.
Q
Provide for hooking at the centre of gravity of the device.
Q
Cables shall have such a length that the angle they form with the
horizon when under tension is not less than 45°.
Space requirements request to handling
WARNING
While lifting and handling the unit, pay attention.
Otherwise, you might damage the finned block
of the coils arranged on both sides of the unit.
The side s of the unit sh all be protec ted by
cardboard or plywood sheets.
MIN. 5 cm
13
English
3 - Transport, Handling and Storage
3.3 Anchoring
It is not essential to secure the unit to the foundations, unless in areas
where there is a serious risk of earth-quake, or if the appliance is
installed on the top of a steel frame.
3.4 Storage
If the unit is to be stored before the installation for some time, take
at least the following precautions to prevent damage, corrosion and/
or deterioration:
Q
Make sure all openings, such as for example water connections,
are well plugged and sealed.
Q
Never store the units in a room where temperature is above
50 °C (R410A units) or where the units are directly exposed to
the sunlight.
Q
Minimum storage temperature is -25 °C.
Q
Store the units in areas where minimum activity is likely to take
place in order to avoid any risk of accidental damage.
Q
Never use steam to clean the unit.
Q
Remove all the keys required to have access to the control panel
and give them to the person in charge of the field.
It is also recommended to provide for visual inspections at regular
intervals.
14
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 that:
Q the unit must not be installed in areas subject to flooding, under
gutters etc.
Q the place of installation must be have all the necessary spaces
for air circulation and maintenance operations (see Chapter 8).
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:
1) Procede to assemble the jack components. Fit the jack in the
threaded housing on the upper plate of the antivibration mount.
2) Fit the jack mounted on the antivibration mount in the hole in the
machine base.
15
English
4 - Installation (continued)
4.3 Internal/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.
WARNING
The internal/external water circuit shall guarantee
a constant water flow rate through the circulating
refrigerant/water heat exchangers under steady
operating conditions and in case of a load
variation.
The circuit shall be composed by the following elements:
Q
A circulation pump which can ensure the necessary flow rate
and head.
Q
The total content of the primary water circuit shall never be lower
than 5 l/kW in terms of refrigerating capacity. If the total water
volume in the primary circuit should be unable to reach such
a value, an additional heat-insulated storage tank should be
installed. This tank is intended to avoid any repetitive start of the
compressor.
Q
A membrane expansion tank complete with a safety valve and a
drain which shall be visible.
NOTE
The expansion tank shall be dimensioned in such
a way that it can absorb a 2% expansion of the
total volume of the water in the plant (exchanger,
pipelines, uses and storage tank, if available).
The expansion tank shall never be insulated
when the circulating fluid is not flowing through
it.
A water pressure differential switch is mounted as a standard. It will
stop the unit whenever a flow rate problem occurs.
In addition:
Q Install on/off valves (accessory) on the lines at the inlet and
outlet of the manifolds of the exchangers.
Q Arrange a by-pass complete with an on/off valve between the
manifolds of the heat exchangers.
Q Arrange air vent valves at the high points of the water lines.
Q Arrange drain points complete with plugs, clocks, etc. in the
proximity of the low points of the water lines.
Q Insulate the water lines to prevent the heat from blowing back
into the unit.
RECOMMENDED WATER COMPOSITION
PH 7,5 - 9
Electrical conductivity 10 - 500 µS/cm
Total hardness 4,5 - 8,5 dH
Temperature < 60 [°C]
Alkalinity (HCO
3
-
) 70-300 ppm
Alkalinity / Sulphates (HCO
3
-
/ SO
4
2-
) > 1 ppm
Sulphates (SO
4
2-
) < 70 ppm
Chlorides (Cl
-
) < 50 ppm
Free Chlorine < 0,5 ppm
Phosphates (PO
4
3-
) < 2 ppm
Ammonia (NH
3
) < 0,5 ppm
Ammonium Ion (NH
4
+
) < 2 ppm
Manganese Ion (Mn
2+
) < 0,05 ppm
Free Carbon Dioxide (CO
2
) < 5 ppm
Hydrogen Sufide (H
2
S) < 0,05 ppm
Oxygen Content < 0,1 ppm
Nitrates (NO
3
-
) < 100 ppm
Manganese (Mn) < 0,1 ppm
Iron (Fe) < 0,2 ppm
Aluminium (Al) < 0,2 ppm
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
16
4 - Installation (continued)
WQL - WQH 20/45 HYDRAULIC SYSTEM BASIC
COMPONENTS
1 Plate heat exchanger
2 Water filter
3 Water outlet
4 Water inlet
5 Globe valve
6 Flexible pipes
7 By-pass valve
8 Pressure point/drainage
SAFETY/CONTROL DEVICES
A Water differential pressure switch.......( )
B Inlet water temperature sensor
C Outlet water temperature sensor
D Vent valve
E Thermometer
Unit side
Probes
1
4
2
E
E
3
5
5
6
6
7
INLET
OUTLET
D
C
B
A
8
8
17
English
4 - Installation (continued)
WQL - WQH 20/45 HYDRAULIC SYSTEM 1P CONDENSER
COMPONENTS
1 Plate heat exchanger
2 Pump
3 Water filter
4 Water outlet
5 Water inlet
6 Globe valve
7 Flexible pipes
8 By-pass valve
9 Pressure point/drainage
SAFETY/CONTROL DEVICES
A Water differential pressure switch.......( )
B Inlet water temperature sensor
C Outlet water temperature sensor
D Vent valve
E Thermometer
Unit side
Probes
2
OUTLET
INLET
8
7
7
6
6
4
E
E
3
5
1
D
A
B
C
9
9
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