SERVICE MANUAL
Contents
1. As JE CHILLED WATER OUTLET 21 5 GAS MALE Hydraulic components 1 Evaporator 14a Flow switch unit without tank Opt without pumps 2 Evaporator antifreeze heater Opt 14b Flow switch unit with tank Opt without pumps 3 Rubber flexible pipe only with pumps and or tank 15 Rubber flexible pipe only with pumps without tank 4 Manual air valve 16 Filter Opt 5 Gate valve 17 Non return valve 6 Pump 18 Air temperature sensor 7 Safety valve 19 3 way valve 8 Expansion tank 20 Freecooling control temperature sensor 9 Service ball valve 21 Fans 10 Drain valve 22 Freecooling coil 11 Control temperature sensor 23 Rubber flexible pipe 12 Antifreeze temperature sensor 24 Expansion tank Safety valve Opt without tank 18 Tank antifreeze heater Opt 33 ll Fabbricante dichiara che questo prodotto conforme alle direttive Europee The Manufacturer hereby declares that this product conforms to the European Union directives Der Hersteller erkl rt hiermit dass dieses Produkt den Anforderungen der Europ ischen Richtlinien gerecht wird Le Fabricant d clare que ce produit est conforme aux directives Europ ennes El Fabricante declara que este producto es conforme a las directivas Europeas O Fabricante declara que este produto est em conformidade com as directivas Europeia2. 40 160 40 Std head pressure pump mot nom power 1 10 1 50 1 10 1 50 1 85 4 0 Std head pressure pump mot max power 1 44 1 92 1 44 1 92 2 45 4 0 Std head pressure pump max current 2 67 3 90 2 67 3 90 4 61 8 50 FHE high head pressure pump model Opt 32 160 30 32 160 30 32 160 30 32 160 30 T 40 ra High head pressure pump motor power 3 0 3 0 3 0 3 0 High head pressure pump max current 6 50 6 50 6 50 6 50 30 e A Electrical cable section min 16 16 1 Outdoor air temperature 35 30 glycol water mixture water inlet outlet temperature 15 10 SQH R 407C Power supply Ee 400 V 3 Ph 50 Hz OA 1 35 44 36 49 FLA 53 72 61 67 LRA 218 273 162 180 Compressors power input 7 18 8 24 8 18 5 25 1 Compressors nominal current 1 32 41 34 46 Compressor max current 50 69 29 32 Fan power input Fan nominal current Fan max current SHC std head pressure pump model Opt 12 136 20 128 12 136 20 128 20 134 FHE std head pressure pump model Opt 40 160 40 Std head pressure pump mot nom power 1 10 1 50 1 10 1 50 1 85 4 0 Std head pressure pump mot max power 1 44 1 92 1 44 1 92 2 45 4 0 Std head pressure pump max current 2 67 3 90 2 67 3 90 4 61 8 50 FHE high head pressure pump model Opt 32 160 30 32 160 30 32 160 30 32 160 30 40 160 40 40 200 75 High head pressure pump motor power 4 0 High head pressure pump max current 8 50 Ele
3. 24 SEIN ale 10 800 POW erew seo IS 10 800 POW ere seo 2 12 sen 17 sen 17 402 902 400 900 POW ere seo 102 90 00 900 Dol seo duse EUM ANI 191110 191100 uonpeuuoo ere 10 800 Doll ere seo 2 2 10 800 pONW ere seo 2 2 NE HEM DAIS sen 17 402 902 400 900 POW ere seo 02 902 400 900 POWN seo Iuno Vom aXe 191110 191100 JINI 9007 900 9007 Yue s dund B 910 10 110 HOS HOO 800 402 902 200 900 HOS HOO 702 700 HOS HOO 910 10 HIS HTO 110 800 402 200 HIS 902 vO2 900 700 HIS s duind Xue 910 H8S YLO 110 800 H8S HA9 LD 902 v02 400 900 r00H8S H8O ue PIS MIIA dOL J18vilvAv LON s W SI dWAd LNOHLIWHLIM NOISH3A STAGOW 405 902 POS E m N TANVd O 4 n 8 318vAON39 LINN 15 AH3AOO3MH 1V3H MIIA HV3H MIIA HV3H NIA 11 vi Ot t V CH MAIA 1NOtd 299 HONNdAHd LIINI 318VO AddNS th hh FT
4. CHILLED WATER INLET 2 GAS MALE loo AQ ONLY FOR 004 006 007 MODELS CHILLED WATER OUTLET 2 GAS MALE ONLY FOR 204 206 207 MODELS of Hydraulic components Item OANDOARWN Evaporator Evaporator antifreeze heater Opt Rubber flexible pipe only with pumps and or tank Manual air valve Gate valve Pump Safety valve Expansion tank Service ball valve Drain valve Control temperature sensor Antifreeze temperature sensor Tank antifreeze heater Opt 32 Description Flow switch unit without tank Opt without pumps Flow switch unit with tank Opt without pumps Rubber flexible pipe only with pumps without tank Filter Opt Non return valve Air temperature sensor 3 way valve Freecooling control temperature sensor Fan s Freecooling coil Rubber flexible pipe Expansion tank Safety valve Opt without tank Fig 15 Hydraulic circuit SBH SLH SQH 008 011 014 016 LIEBERT HIROSS UNIT ONLY WITH TANK VERSION Kis ONLY WITH PUMP VERSION 9 i p CHILLED WATER INLET 4 21 5 GAS MALE 5 94 595
5. Pump weight 10 4 2 pole pump set high head pressure data refers to each pump Water flow m3h 683 942 1136 683 9 27 11 53 13 35 18 39 22 20 28 36 Available head pressure 169 156 140 198 182 166 167 184 151 170 Water flow m3h 6 66 9 32 11 67 666 9 16 11 85 1295 1819 2290 27 28 Available head pressure 171 156 137 199 182 165 168 185 149 182 Water flow m3h 689 9 65 1141 689 949 1157 1345 1872 22 16 27 40 Available head pressure 169 154 139 198 181 166 165 182 151 180 Nominal motor power 40 2 pole pump set standard head pressure data refers to each pump 3096 glycol water mixture flow 7 90 10 86 13 26 7 90 10 68 13 45 15 68 21 53 2627 33 58 Available head pressure kPa 93 93 63 135 130 101 64 90 17 16 30 glycol water mixture flow 7 64 1093 1351 7 64 1077 1371 1512 21 67 26 83 32 09 Available head pressure 101 98 76 141 136 115 72 96 20 42 30 glycol water mixture flow 7 93 11 20 13 11 7 93 11 01 13 29 15 75 22 07 25 75 32 48 Available head pressure 124 104 82 166 143 120 103 95 29 66 Pump rotor model Nominal motor power Noise level Pump weight 30 glycol water mixture flow 790 1086 13 26 790 10 68 1345 15 68 2153 26 27 33 58 Available head pressure kPa 228 210 165 270 247 203 162 174 108 158 3096 glycol water mixture flow 7 64 1093 1351 7 64 1077 1371 15 12 21 67 26 83 32 09 Available head pressure kPa 236 214 178 276 252 217 171 180 111 185 3096 glycol water mixture flow 793 1120 13 11 793 1101 1329 1575 2
6. cian e Check the compressor s current absorption the delivery temperature and possible unusual noises REFRIGERATION CIRCUIT Check the refrigerant charge by means of the sight glass e Check that the safety devices operate correctly Check the correct operation of the thermostatic valve superheating between 5 C 8 C Check that the oil level indicated by the compressor sight glass is higher than the min value CHILLED WATER CIRCUIT Ensure that there are no water leaks Bleed any air out of the hydraulic circuit using the bleed valves Verify that the water flow rate is correct Check the inlet outlet liquid temperature and pressure Check the correct operation of the three way valve Versions with free cooling only Check if the system is charged with the specified glycol percentage and that no ice has formed in the hydraulic circuit e Check the evaporator cleanliness 8 Options and Accessories 8 1 Pump set The centrifugal pump units are direct driven with close coupled motors and a single shaft the induction motor has 2 poles with IP 54 protection and class F insulation The materials used for the pump main components are Pump body in plastic material PA 6 6 cast iron in all high pressure freecooling versions and on model 016 in the Chil ler high head pressure version and Superchiller standard head pressure version Impeller in in plastic material PPO stainless steel in all
7. 12 Fig 13 Fig 14 and Fig 15 e Expansion vessel volume 8 litres for all units It is recommended that the total required expansion vessel ca pacity is always checked depending on the unit s internal hy draulic volume with the volume of the buffer tank if installed the user circuit volume the glycol percentage in the mixture and the expected maximum temperature variation of the mixture The water flow switch is a compulsory device protecting the unit It is installed as standard on units with the optional on board pump set and is available as a option for units without pumps on board in the latter case the flow switch if not installed on the machine must be installed on the hydraulic circuit by the install er and wiredto the electric panelterminal board as indicated on the wiring diagram 8 5 Water chiller with inertia tank The machine can be supplied complete with a buffer tank it per forms the inertial stabilizer function for better compressor op eration summed up in the following two points itreduces the frequency of the compressor peaks which is higher the lower the system thermal inertia improving their performance itnaturally eliminates the operational problems caused by sudden load variations shown by variations of the chilled water temperature The buffer tank is supplied insulated with a drain valve vent valve and connection for immersion electric heaters maximum operating press
8. 134 1 85 2 45 4 61 40 160 40 4 0 4 0 8 50 SBH R 407C Power supply ES 400 V 3 Ph 50 Hz OA 1 39 49 FLA A 25 62 68 LRA 219 274 163 181 Compressors power input 7 19 7 24 4 19 4 24 8 Compressors nominal current 1 33 40 35 45 Compressor max current 50 69 29 32 Fan power input Fan nominal current Fan max current SHC std head pressure pump model Opt 12 136 20 128 12 136 20 128 20 134 FHE std head pressure pump model Opt 40 160 40 Std head pressure pump mot nom power 1 10 1 50 1 10 1 50 1 85 4 0 Std head pressure pump mot max power 1 44 1 92 1 44 1 92 2 45 4 0 Std head pressure pump max current 2 67 3 90 2 67 3 90 4 61 8 50 FHE high head pressure pump model Opt 32 160 30 32 160 30 32 160 30 32 160 30 40 160 40 40 200 75 High head pressure pump motor power 3 0 3 0 3 0 3 0 4 0 High head pressure pump max current 6 50 6 50 6 50 6 50 8 50 1 Outdoor air temperature 35 C 30 glycol water mixture water inlet outlet temperature 15 10 C SLH R 407C 204 206 207 008 011 014 016 45 37 49 57 FLA 74 60 69 75 LRA 217 275 161 182 215 Compressors power input 7 19 6 23 7 d 19 3 24 1 30 4 Compressors nominal current 1 33 40 35 44 52 Compressor max current 50 69 29 32 35 Fan power input Fan nominal current Fan max current SHC std head pressure pump model Opt 12 136 20 128 12 136 20 128 20 134 FHE std head pressure pump model Opt
9. 2 Open the shut off valve on the liquid line 3 Ensure that the intake pressure is higher than 4 0 bar if this is not the case prolong pre heating of the compressor if possible and check that the refrigerant shut off valve is properly sealed see Fig 10 and Fig 11 4 Open all isolating valves and or water ball valves 5 Incase of climates with temperatures below zero degrees C make sure the chilled water circuit is filled with the correct concentration of water glycol 6 Bleed all air out of the chilled water circuit 7 Verify the water flow rate and its direction 8 Ensure that the thermal load is sufficient for start up Caution The ambient air temperature probe must be positioned in the shade and protected against the weather 4 2 First start up or after a long stop Operate as follows 1 At least 8 hours before the start up power the crank case heaters if any see point 4 by setting the main iso lator switch ON Make sure the auxiliary circuit has been powered and check the operation a fault due to an in correct procedure will invalidate the compressor guar antee 2 Open the valves of the refrigeration circuit that had been closed before the initial check 3 Checkthe machinery supplying the thermal load connected with the unit and start the system pump s 4 MAKE SURE THE COMPRESSOR OIL HAS BEEN HEATED FOR AT LEAST 8 HOURS start the unit only then In the units not equipped with crank
10. Opt 19 Charge connection 6 Low pressure manometer Opt 20 Antifreeze sensor 7 Safety valve 21 Partial recovery heat exchanger Opt 8 Condenser 22 Antifreeze heater Std with heat recovery 9 Fan s 10 Pressure transducer Opt on CBH CLH CQH without heat recovery 11 Shut off valve 12 Filter dryer 18 Shut off solenoid valve 14 Sight glass 27 Fig 10 Refrigerant circuit with total recovery opt CBH CLH CQH 004 006 007 ONLY FOR CBH 007 CLH CQH 006 007 HEAT RECOVERY WATER OUTLET 2 GAS MALE Nut TO ka lt iG Mmm HEAT RECOVERY G2 Ex WATER INLET A 3 2 GAS MALE On GG Gi OG Lay MC V CHILLED WATER INLET 4 2 GAS MALE CHILLED WATER OUTLET GAS MALE eg e UR Refrigerant components 1 Compressor 15 Thermostatic expansion valve 2 High pressure switch HP 16 Evaporator 3 Low pressure switch LP 17 Antifreeze heater Opt 4 Crankcase heater 18 Control temperature sensor 5 High pressure manometer Opt 19 Charge connection 6 Low pressure manometer Opt 20 Antifreeze sensor 7 Safety valve 21 Total recovery heat exchanger 8 Condenser 22 Three way valve 9 Fan s 23 Non return valve 10 Pressure transducer 24 Antifreeze heater 11 Shut off
11. gt K SR o o WI S9 Op OG H D 2 E EIR LR EEE n N SIN m S KI t N o 1dO AH3AOO3MH 1V3H 07 5009 c S O t 19 318vAOW3H LNOYS HV3H K LINN TOHLNOO TANVd WOIlHLOATA Ho 318V1NAV TIWN qevilvAV EVA 191100 AH3AOO3H LON SVO 2 2 LON SVD Z lv3H WLOL H a av JW a 131100 AH3AOO3H GQvNOLLdO 2 SVO HILL SVO HILL SVD l SVD l AV3H WILHVd T Un 09 910 HOS qevilvAV anid NWA EDIN JANNI AH3AOO3H EECH time any ooo hn B EE E 710 HSS SCH OC SVO HL SVO HL SVD SVD ul 1v3H Tvl1HVd g o HO AINO Te Z0Z 90Z r0Z 052 905 705 tTO TTO 800 tTO TTO 800 00 900 700 00 900 700 HOS H1S H8S HOS H1S HaS HO5 H15 H82 SUOISUSUIIP 614 25 Fig 8 Refrigerant circuit std with partial recovery opt CBH CLH CQH SBH SLH SQH 004 006 007 HEAT RECOVERY WATER OUTLET 1 GAS MALE OPT lt ie 3 ES Q2 zm HEAT RECOVERY WATER INLET 1 GAS MALE OPT Jo CHILLED WATER INLET 4 2 GAS MALE A CHILLED WATER OUTLET 2 GAS MALE kg M Refrigerant components 1 Compressor 15 Thermostatic expansion valve 2 High pressure switch HP 16
12. located on the main electrical power supply This will discon nect the compressor crankcase heaters 4 4 Chillers serving special plants The units are capable of cooling a water glycol mixture to tem peratures close to 0 C withoutthe need for significant modifica tions In the case of modification the set values ofthe safety and control components must also be changed This can be carried out in the factory atthe time of testing or at the time of installa tion only by qualified and authorised personnel 4 5 Freecooling The freecooling is a system of pre cooling and or cooling the water glycol mixture using ambient air when the latter is at atem perature below the return mixture temperature If the outside temperature is sufficiently low to dissipate the entire heat load the refrigeration compressors automatically switch off and the mixture s temperature is controlled by the fan speed adjust ment If the mixture temperature is too high for freecooling the com pressors will operate as long as necessary to ensure the correct water glycol mixture temperature 4 6 Microprocessor control Consult the Microface and Hiromatic Service Manual 5 Refrigerant and Oil Charge All work on pipes or components of the refrigerating circuit un der pressure must be exclusively carried out by qualified staff competent in such works 5 1 Refrigerant charge WHILST REPAIRING THE REFRIGERATING CIRCUIT RE
13. COVER ALL THE REFRIGERANT IN A CONTAINER DO NOT ALLOW IT TO ESCAPE NEVER USE THE COMPRESSOR FOR THE SYSTEM VACUUM THIS INVALIDATES THE WARRANTY The unit is delivered charged according to the Tab 7 Warning for the refrigerant charge Ensure there are no refrigerant leaks e Check the refrigerant type in the refrigeration circuit a unit originally charged by the manufacturer with R407C cannot be charged with R22 and vice versa possibly apply to the Technical Support Department e Charge with the compressor in operation connecting the cylinder with the charge connector after the thermostatic ex pansion valve Flush the connection pipe between the cylinder and the charging point tighten the seal joint and then start charging the unit Itis imperative that the cylinder is weighed both be fore and after the operation For the units with R407C the refrigerant charge must be made exclusively with liquid refrigerant Charge the unit until the bubbles in the sight glass have dis appeared and the working conditions of the entire refrigera tion circuit have returned to normal sub cooling and su perheating within the limits indicated below Measure the superheating as follows 1 Detect the temperature on the suction line close to the bulb of the thermostatic expansion valve using a contact thermometer 2 Connecta pressure gauge by max a 30 cm pipe with the Schraeder connection and read the correspond
14. Operation with R407C R22 standard factory setting High pressure switch HP STOP 26 bar START 20 bar DIFF 6 bar fixed The settings for the safety valves installed on the machine are indicated below MODELS SETTINGS SAFETY VALVE 006 007 011 014 016 HP side 6 1 Setting valve THIS OPERATION MUST BE PERFORMED BY AN EXPERI ENCED REFRIGERATION TECHNICIAN Before beginning this adjustment be sure that the refrigerant charge is correct checking the the sub cooling 3 C 5 C as specified in par 5 1 The valve has already been factory set and should be reset when the superheating is not between 5 C 8 C as follows 1 Important Ensure that the instructions in par 5 1 have been carried out 2 Allow the compressor to operate for 15 mins 3 Measure the superheating as follows a Connect a manometer to the Schraeder connection lo cated on the evaporator outlet tube and read the mano metric temperature on the scale for the refrigerant used for the units with R407C refer to the pressure gauge scale indicated with the initials D P Dew Point b Using a contact thermometer measure the temperature on the tube coming out of the evaporator next to the socket used for the manometer c The superheating is the difference between the two readings b a thermostatic expansion 4 The superheating must be 5 C 8 C if not set the expan sion valve as follows
15. high pressure freecooling versions and on model 016 in the Chil ler high head pressure version and Superchiller standard head pressure version Stainless steel shaft Graphite impregnated ceramic mechanical seal EPDM in all high pressure freecooling versions and on model 016 in the Chiller high head pressure version and Superchiller standard head pressure version suitable for the use of mix tures containing ethylene glycol The pump units have been chosen and sized to operate within specific limits namely Water ethylene glycol mixtures up to 65 35 by weight Temperatures of the standard pumped fluid not lower than 4 C The hydraulic circuit includes for each pump a suction shut off valve and a delivery check valve if two pumps are installed or suction and delivery shut off valves if a single pump is installed In the electrical panel there are automatic circuit breakers for each pump the microprocessor control manages the operating rotation between the two pumps and start up of the stand by pump if the primary pump fails For the technical features of the pumps and the hydraulic sche matic see Tab 8 Fig 12 Fig 18 Fig 14 and Fig 15 8 2 Water chiller with partial heat recovery 20 This option enables the recovery of up to 2096 ofthe heat normal ly rejected by the condensers The system does not require any adjustment and is made up of plate heat exchangers installed on ea
16. options are installed on the machine add the weights of the installed accessories to those of the standard units see Tab 8 2 5 Service area order to allow free air flow and maintenance of the unit a minimum area must be left free of obstructions around the unit see Fig 1 e The hot air expelled by the fans must be allowed to rise unim peded by obstacles for a minimum height of 2 5 m e Avoid recirculation of hot air between the suction and dis charge otherwise the unit performance may be impaired or the standard operation can be interrupted 3 Installation 3 1 Hydraulic connections 3 1 1 Hydraulic circuit construction Fig a The piping must be connected to the chiller Construct a chilled water circuit as described below see Fig a 1 Place shut off valves within the circuit to allow servicing 2 Install a pump system suitable for the flow rate required at a pressure head equal to the sum of all the pressure drops see project data Matrix S chillers can be equipped upon request with pumps having performance as indicated in Tab 8 3 Install manometers at the chiller inlet outlet 4 Install thermometers at the chiller inlet outlet 5 Connect the pipes to the chiller by flexible joints to avoid transmitting vibrations and to balance the thermal expan sion proceed in the same way even if the pump set is out side the chiller 6 Itis useful to include a water pressure switch to giv
17. suitable panels fastened by the tightening system Maintenance programme Monthly check 7 1 Spare parts The use of original spare parts is recommended When placing an order refer to the Component List enclosed with the machine and quote the unit model no and serial no 7 2 Dismantling the unit The machine has been designed and built to ensure continuous operation The working life of some of the main components such as the fans and the compressors depends on the maintenance that they receive If the unit has to be dismantled the job must be done by skilled refrigeration technicians The refrigerant and the lubricating oil in the circuit must be dis posed of in conformity with the laws in force in your country e Check that the fan motor rotates freely without any abnormal noise and ensure that the bearings are not running hot Also check the current absorption Check the conditions of the filters if they are supplied if necessary clean them including CONDENSER AND AIR FILTER the electrical panel ventilation filter e Check the condenser coils and clean if necessary with compressed air or soft brushes CONTROL Check that the control equipment LEDs and display are operating correctly ELECTRICAL CIRCUIT e Check the electrical supply on all phases Ensure that all electrical connections are tight e Check the condensing and the evaporating pressures to be done by a refrigeration techni
18. this avoids the danger of glycol entering the sanitary water system After any topping up of the water check the concentration and add glycol if necessary 3 1 3 Water glycol mixture Water glycol mixtures are used as the thermal carrier fluid in very cold climates or with temperatures below zero degrees cen tigrade Determine the ethylene glycol which must be added to the water with the assistance of Tab a Tab a Ethylene glycol to be added to water in weight of total mixture Ethylene glycol in weight Meu pers 2 ai density at 1 017 1 033 1 048 1 064 1 080 20 C kg l Values are for Shell antifreeze 402 For different brands check manufacturer s data Forthe chiller internal water volume referto Tab 1 If the optional buffer tank is installed on the machine add the tank hydraulic ALWAYS CHARGE THE HYDRAULIC CIRCUIT WITH THE RE QUIRED GLYCOL NECESSARY FOR THE MINIMUM AMBI ENT TEMPERATURE AT THE INSTALLATION SITE FAILING TO COMPLY WITH THIS INSTRUCTION SHALL INVALIDATE THE UNIT WARRANTY 3 2 Connection of the safety valve dis charge Safety valves are installed on the high pressure side of the refrig eration circuit s the discharge of these valves must be con veyed outside through a suitable pipe having a diameter of at least that of the valve outlet without burdening the valve body Convey the discharge to areas where the jet cannot ha
19. 004 006 204 206 1 1 7 8 CQH SQH 004 204 CBH SBH 008 011 014 CLH SLH 007 207 008 011 2 1 7 4 8 SQH 006 007 206 207 008 CBH SBH 016 CLH SLH 014 016 3 1 7 4 8 SGH 011 014 016 Lifting 16 Fig 3 Lifting instructions with straight shackle N B LIFT IN THE BARICENTRE LINE G OF THE UNIT A1 E E p S A2 Q a P 0 of bo n 2 LIFTING SYSTEM WITH STRAIGHT SHACKLE N PART A yg STRAIGHT SHACKLE 14 UNI 1947 A TYPE PART A OPTIONAL N B The capacity of the lifting gear must be adequate to lift the load in question Check the weight of the unit the capacity ofthe lifting gear and ropes and the condition and suitability of the aforementioned equipment Lift the unit with a speed suitable for the load to be moved so as not to damage the structure CBH SBH 004 006 007 204 206 207 CLH SLH 004 006 204 206 1 5 CQH SQH 004 204 CBH SBH 008 011 014 CLH SLH 007 207 008 011 2 6 SQH 006 007 206 207 008 CBH SBH 016 CLH SLH 014 016 3 6 011 014 016 Lifting 17 Baricentre G CBH CLH CQH Models CBH 004 CBH 006 CBH 007 CBH 204 CBH 206 CBH 207 CBH 008 CBH 011 CBH 014 CBH 016 CLH 004 CLH 006 CLH 007 CLH 204 CLH 206 CLH 207 CLH 008 CLH 011 CLH 01
20. 014 016 Working Range Safety Device Settings High pressure switch 1 26 0 High pressure safety valve 28 0 29 0 Low pressure switch 2 8 1 With nominal air flow 30 mixture flow outlet at 10 C full load SLH R 407C 004 006 007 204 206 207 008 011 014 016 Working Range Safety Device Settings High pressure switch 1 26 0 High pressure safety valve 28 0 29 0 Low pressure switch 2 8 1 With nominal air flow 30 mixture flow outlet at 10 C full load SQH R 407C 004 006 007 204 206 207 008 011 014 016 Working Range Max outdoor air temperature 7 415 435 405 415 485 405 420 435 400 40 0 Safety Device Settings High pressure switch 1 26 0 High pressure safety valve 28 0 29 0 Low pressure switch 2 8 1 With nominal air flow 30 mixture flow outlet at 10 C full load Tab 6 Noise levels The following table indicates the overall sound pressure level at full load conditions measured 1m from the unit according to ISO 3774 with an outdoor temperature of 35 C and referred to free field conditions Total Total sound level sound level sound level dB A dB A dB A se CBH SBH 008 CLH SLH 008 CQH SQH 008 CLH SLH 011 CQH SGH 011 CBH SBH 011 CLH SLH 014 CQH SQH 014 CLH SLH 016 CQH SQH 016 CBH SBH 014 CBH SBH 016 CBH SBH 004 CLH SLH 004 CQH SQH004 58 CBH SBH 006 006 CBH SBH 204 CLH SLH 20
21. 114 _ 114 011 305 _ 127 _ 127 305 _ 127 _ 127 014 314 _ 135 _ 135 314 _ 135 _ 135 016 260 260 95 95 260 260 95 95 CLH 004 163 103 199 126 006 187 _ _ _ 114 243 _ _ _ 148 007 186 _ 95 _ 95 230 _ 117 _ 117 204 212 _ _ 124 212 _ _ 124 206 228 _ 136 228 _ _ 136 207 228 109 109 228 10 109 008 251 _ 114 _ 114 251 _ 114 _ 114 011 316 133 133 316 133 133 014 243 243 _ 95 95 243 243 _ 95 95 016 264 264 _ 95 95 264 264 _ 95 95 CQH 004 167 _ 108 203 131 006 185 _ 94 _ 94 229 _ 117 _ 117 007 186 _ 95 _ 95 230 _ 117 _ 117 204 216 _ _ _ 129 216 _ _ _ 129 206 220 108 108 20 108 108 207 228 109 109 228 109 109 008 257 _ 122 _ 122 257 _ 122 _ 122 011 240 240 _ 95 95 240 240 _ 95 95 014 243 243 _ 95 95 243 243 _ 95 95 016 270 270 _ 97 97 270 270 _ 97 97 20 Weight distribution with tank CBH CLH CQH W2 W3 W4 W5 W6 W7 Weight distribution kg Model CBH CLH CQH Size 004 006 007 204 206 207 008 011 014 016 004 006 007 204 206 207 008 011 014 016 004 006 007 204 206 207 008 011 014 016 21 wi 213 233 239 269 329 338 275 215 240 182 275 339 258 279 218 181 182 280 255 258 285 258 279 255 258 285 237 250 258 174 238 257 173 174 245 215 215 215 215 217 207 241 210 279 217 284 Not available Not available Not available 237 269 250 329 25
22. 207 2575 32 48 Available head pressure kPa 259 220 184 301 259 222 202 180 120 209 According to ISO 3744 Fig 1 Service areas top view 1000 AIR AIR 1000 Ordinary 1000 1000 maintenance area Extraordinary maintenance area Notes Minimum distance between 2 units from condensing coil side 2m Do not obstruct the air exiting the fans for a minimum distance of 2 5m 1500 mm with 160 200 Lt Tank 2500 mm with 400 Lt Tank Fig 2 Lifting instructions with tubes PROTECTION PLANK RIGID STRUTS POSSIBILY STEEL LIFTING SYSTEM WITH TUBES BELT OR CHORD BLOCKING PEG NOT SUPPLIED LIFTING TUBE NOT SUPPLIED BASE HOLES 45 SPLIT PIN NOT SUPPLIED N B Place the lifting tubes in the holes in the base indicated by the words LIFT HERE Lock the ends of the tubes in position with the locking pins and split pins as shown above A The capacity of the lifting gear must be adequate to lift the load in question Check the weight of the unit the capacity of the lifting gear and ropes and the condition and suitability of the aforementioned equipment Lift the unit with a speed suitable for the load to be moved so as not to damage the structure A B omme m m CBH SBH 004 006 007 204 206 207 CLH SLH
23. 388 EI 402 397 The maximum deviation from the average is 402 397 5 V The phase to phase variability is 5 397 100 1 26 acceptable Note he power supply should never be disconnected except when performing maintenance Operate open the main switch before carrying out any mainte nance work on electrical components Note It 15 forbidden to work on the electrical components without using insulating platforms and in the presence of water or fog or mist Note The supply to the external pump assembly must be made before starting the chiller and must be kept on as long as the chiller is in use Incorrect operation will cause the unit to lock out be cause of the internal protections flow switch intervention Note The compressors are equipped with an electronic protection de vice blocking their start if the phase sequence is not correct or stopping their operation if a thermal relay intervenes This device is essential for the integrity of the mechanical and electrical com ponents of the compressors Reset the standard functions by isolating this device and removing the causes of the lock out Note nechillers are equipped with their own microprocessor control adjustment The use of the remote ON OFF input located in the electric panel terminal board as a system temperature con trol element is forbidden 4 Start Up and Operation 4 1 Initial check 1 Check all water connections
24. 4 CBH SBH 206 CQH SQH 206 CBH SBH 207 CQH SQH 207 E De ES Tab 7 R 407C refrigerant and oil charge Models CBH 004 006 007 204 206 207 008 011 014 016 Refrigerant charge each circuit kg 7 8 12 2 15 3 5 0 6 7 8 5 8 7 12 8 16 2 18 3 Models CLH 004 006 007 204 206 207 008 011 014 016 Refrigerant charge each circuit kg 7 8 14 8 15 2 5 0 7 9 8 4 8 7 15 4 17 4 18 3 Models CQH 004 006 007 204 206 207 008 011 014 016 Refrigerant charge each circuit kg 10 9 14 6 15 2 6 6 7 8 8 4 11 2 16 6 17 4 23 7 Models SBH 004 006 007 204 206 207 008 011 014 016 Refrigerant charge each circuit kg 7 8 12 2 16 3 5 0 6 7 9 0 8 7 12 8 17 2 18 3 Models SLH 004 006 007 204 206 207 008 011 014 016 Refrigerant charge each circuit kg 7 8 15 8 15 2 5 0 8 4 8 4 8 7 16 4 17 4 18 3 Models SQH 004 006 007 204 206 207 008 011 014 016 Refrigerant charge each circuit kg 10 9 14 6 15 2 6 6 7 8 8 4 11 2 16 6 17 4 23 7 13 Tab 8 Pump set characteristics opt 2 pole pump set standard head pressure data refers to each pump Water flow m3h 6 83 942 11 36 683 927 1153 13 35 1839 22 20 28 36 Available head pressure 127 116 99 156 142 125 142 134 96 73 Water flow 6 66 9 32 11 67 666 9 16 11 85 1295 1819 2290 27 23 Available head pressure 129 116 96 157 142 124 143 135 94 90 Water flow 6 89 965 11 41 689 949 11 57 13 45 1872 2216 27 40 Available head pressure 127 114 98 156 141 125 140 132 96 87
25. 4 CLH 016 CQH 004 CQH 006 CQH 007 CQH 204 CQH 206 CQH 207 CQH 008 CQH 011 CQH 014 CQH 016 0 80 0 77 0 78 0 77 0 77 0 78 1 10 1 04 1 06 1 37 0 79 0 78 1 15 0 76 0 77 1 12 1 09 1 05 1 41 1 36 0 80 1 16 1 15 0 77 1 13 1 12 1 41 1 41 1 36 Unit baricentre position G without water 18 0 55 0 52 0 53 0 60 0 60 0 60 0 60 0 60 0 60 0 60 0 54 0 52 0 54 0 60 0 60 0 60 0 60 0 60 0 60 0 60 0 54 0 54 0 54 0 60 0 60 0 60 0 60 0 60 0 60 0 60 0 88 0 85 0 86 1 22 1 15 1 16 1 52 0 88 0 86 1 29 1 21 1 16 1 56 1 51 0 89 1 29 1 29 1 22 1 57 1 56 1 51 With tank Not available Not available Not available Not available Not available Not available Not available Not available Not available 0 55 0 54 0 54 0 60 0 60 0 60 0 60 0 55 0 53 0 55 0 60 0 60 0 60 0 60 0 55 0 54 0 55 0 60 0 60 0 60 0 60 Baricentre G SBH SLH SQH Models SBH 004 SBH 006 SBH 007 SBH 204 SBH 206 SBH 207 SBH 008 SBH 011 SBH 014 SBH 016 SLH 004 SLH 006 SLH 007 SLH 204 SLH 206 SLH 207 SLH 008 SLH 011 SLH 014 SLH 016 SQH 004 SQH 006 SQH 007 SQH 204 SQH 206 SQH 207 SQH 008 SQH 011 SQH 014 SQH 016 0 84 0 81 0 83 0 81 0 81 0 82 1 17 1 12 1 13 1 47 0 83 0 82 1 21 0 80 0 82 1 18 1 16 1 51 1 46 0 85 1 22 1 21 0 81 1 19 1 18 1 19 1 52 1 51 1 49 Unit baricentre position G wit
26. 76 _ _ _ 125 211 _ _ _ 149 006 201 _ _ 142 254 179 007 201 _ 120 _ 120 242 _ 144 _ 144 204 224 _ _ _ 147 224 _ _ 147 206 240 _ _ _ 167 240 _ _ _ 167 207 241 _ 135 _ 135 241 _ 135 _ 135 008 267 _ 145 _ 145 267 _ 145 _ 145 011 333 _ 174 _ 174 333 _ 174 _ 174 014 270 270 _ 137 137 270 270 _ 137 137 016 291 291 _ 137 137 291 291 _ 137 137 SQH 004 183 135 217 160 006 199 119 119 240 143 143 007 201 _ 120 _ 120 242 _ 144 _ 144 204 231 _ _ _ 157 231 _ _ _ 157 206 234 _ 134 _ 134 234 _ 134 _ 134 207 241 _ 135 _ 135 241 _ 135 _ 135 008 276 160 160 276 160 160 011 267 267 _ 136 136 267 267 _ 136 136 014 270 270 _ 137 137 270 270 _ 137 137 016 306 306 153 153 306 306 153 153 22 Weight distribution with tank SBH SLH SQH W2 W3 W4 W5 W6 W7 Weight distribution kg Model SBH SLH SQH Size 004 006 007 204 206 207 008 011 014 016 004 006 007 204 206 207 008 011 014 016 004 006 007 204 206 207 008 011 014 016 23 wi 225 249 253 284 348 355 302 227 253 196 290 357 285 306 234 195 196 299 282 285 321 285 306 282 285 321 268 288 298 199 269 297 199 199 283 257 257 256 257 273 229 252 238 293 246 296 Not available Not available Not available 268 284 288 348 298 355 257 302 302 229 256 245 299 199 225 Not available Not available Not availa
27. 8 338 215 275 275 206 245 216 287 174 213 Not available Not available Not available 238 275 257 339 215 258 258 215 279 279 211 248 173 212 174 213 Not available Not available Not available 245 280 215 255 255 215 258 258 217 285 285 ws 237 250 258 203 238 257 203 203 245 215 215 215 215 217 W 10 234 251 258 237 250 258 215 235 258 208 238 257 215 215 240 203 203 245 215 215 217 Fig 5 Support positions and loads Note weights refer to standard units SBH SLH SQH 17 FOOT PRINT 1161 1127 1195 5 120 Se Hp nn T Dimensions SBH SLH SQH Dimensions mm A B C D E Model Size SBH 004 006 007 204 206 207 SLH 004 006 204 206 2000 1760 SQH 004 204 SBH 008 011 014 SLH 007 207 008 011 3000 _ 1380 _ SQH 006 007 206 207 008 SBH 016 SLH 014 016 4000 1160 1440 SQH 011 014 016 Weight distribution SBH SLH SQH Weight distribution kg 1 w2 w3 w4 w5 w6 w7 W8 W9 w10 Model Size SBH 004 174 125 26 148 006 197 135 248 170 007 201 z 143 251 179 204 219 145 219 145 206 232 158 232 158 207 242 169 242 169 008 260 145 145 261 145 145 011 325 165 165 325 165 165 014 332 175 175 332 175 175 016 287 287 137 137 287 287 137 137 SLH 004 1
28. Evaporator 3 Low pressure switch LP 17 Antifreeze heater Opt 4 Crankcase heater Std with pressure transducer 18 Control temperature sensor 5 High pressure manometer Opt 19 Charge connection 6 Low pressure manometer Opt 20 Antifreeze sensor 7 Safety valve 21 Partial recovery heat exchanger Opt 8 Condenser 22 Antifreeze heater Std with heat recovery 9 Fan s 10 Pressure transducer Opt on CBH CLH CQH without heat recovery 11 Shut off valve 12 Filter dryer 18 Shut off solenoid valve 14 Sight glass 26 Fig 9 Refrigerant circuit std with partial recovery opt CBH CLH CQH SBH SLH SQH 204 206 207 008 011 014 016 gt lt HEAT RECOVERY WATER OUTLET G GAS MALE OPT 4 HEAT RECOVERY gg O O OG 9 e L 1 er Li JO lt gt V V Ag kg PL 21 7 211 21 7 Refrigerant components 1 Compressor 15 Thermostatic expansion valve 2 High pressure switch HP 16 Evaporator 3 Low pressure switch LP 17 Antifreeze heater Opt 4 Crankcase heater Std with pressure transducer 18 Control temperature sensor 5 High pressure manometer
29. Liebert HIROSS High Performance Air Conditioning SERVICE MANUAL A de Ecco Rev 25 05 2005 Issued by T D Service Network Power Caution It is recommended that e the manual is retained for the entire service life of the machine the user reads the manual carefully before carrying out any operations on the machine e the machine is used exclusively for the purpose for which it is intended incorrect use of the machine shall release the manufacturer from any liability This manual has been prepared to enable the end user to carry out only those operations that can be done with the panels closed Any operations that require the opening of doors or equipment panels must be carried out only by qualified person nel Each machine is equipped with an electric isolating device which allows the operator to work in conditions of safety This device must always be used to eliminate risks during maintenance electric shocks scalds automatic restarting moving parts and remote control The panel key supplied with the unit must be kept by the person responsible for maintenance For identification of the unit model and serial no in case of the necessity for assistance or spare parts read the identification labels affixed to the outside and inside of the unit IMPORTANT This manual may be subject to modification for complete and up to date information the user should al ways consult the manual supplied wit
30. N ee okies doy bi d reper edet cr oe See ea 5 2 Ollicharge onc toe Pone oe endene Diog tede acia ste ejoa T ip orci Piero ier s Eus 6 Safety Devices Settings sueuueeeeeseseeeess enean nhanh rn 6 1 Setting thermostatic expansion valve 1 E EE AS KO WEE e CN 7 2 Dismantling 8 Options and Accessories 8 1 Pumpset ecce Elda Red EF DEA CREE hepa alet Geir hee Ege alas deg MEE EE ie 8 2 Water chiller with partial heat recovery 20 8 3 Water chiller with total heat recovery 100 8 4 Hydraulic circuit accessories 1 m n 8 5 Water chiller with inertia tank IH EI EE ee Med EE ea Rae Ma ae Drawings aa da 15 e Tei TEEN 26 1 Introduction 1 1 Foreword This handbook is aimed at enabling both the installer and the op erator to carry outthe correct installation operation and mainte nance ofthe refrigerating machine without damaging it or caus ing injuries to the relevant staff The handbook is thus an aid for the qualified staff in the arrange mentofthe specific equipmentforthe correct installation opera tion and maintenance in compliance with the local regu
31. THE TYPE OF OIL USED TOP UPS OF UP TO 20 30 OF THE TOTAL AMOUNT OF OIL CONTAINED IN THE COMPRESSOR CRANKCASE ARE PERMITTED FOR LARGER PERCENTAGES CONTACT THE TECHNICAL SUPPORT DEPARTMENT 5 2 1 Procedure for oil topping up If there has been any loss of oil then this must be topped up as follows 6 Safety Devices Settings 1 Take a clean dry transparent container with volume cal ibrations and fill it with at least twice the amount of oil re quired 2 Isolate the compressor by closing the cock on the liquid line 3 Connect to the fittings on the compressor body Schraeder valves and empty it of refrigerant until atmospheric pres sure 1 bar is reached 4 Using a pipe connect the oil container to the oil service fitting on the lower part of the compressor 5 Open the oil service cock lifting the container so that the oil flows by gravity 6 Charge the required quantity of oil make sure the tube al ways remains below the oil level in the container 7 Stop the oil flow by closing the oil service fitting open the shut off cock on the refrigerating circuit and restore the drained refrigerant charge The water chiller has already been tested and set up by the manufacturer The following setting values are suggested in the field COMPONENT SETTING NOTES set id Z diff Operation with R407C R22 standard factory setting Low pressure switch LP START 3 6 bar DIFF 0 8 bar STOP 2 8 bar
32. a Remove the protective cover b Turn the adjustment screw to return to the optimum val ues tightening it a clockwise direction to increase the superheating or slackening it to reduce the superheat ing c Wait about 10 minutes d Measure the superheating and repeat the operation if necessary N B If the superheating is too low there is a risk of poor lubrication and consequent breakage of the compressor as a result of pres sure shock If the superheating is too high the output of the system is limited and the compressor overheats 7 Maintenance The Maintenance Programme below must be carried out by a qualified technician preferably working under a maintenance contract Before any intervention on the unit or accessing the inner com ponents removing the outer panels always ensure the ma chine is switched off If the rear panels are removed coil com partment wait for the fan s to come to a complete stop before accessing the compartment ifthe front panels are removed pay special attention when working near the compressor upper part and the discharge line they are very hot possibly wait for them to cool Be very careful when operating close to the finned coils as the fins are very sharp Do not remove the fan protection grille before electrically isolating the whole machine Do not insert foreign matter through the fan protection grille After the main tenance interventions always close the unit with the
33. ay valve 9 Fan s 23 Non return valve 10 Pressure transducer 24 Antifreeze heater 11 Shut off valve 25 Liquid receiver 12 Filter dryer 13 Shut off solenoid valve 14 Sight glass 29 Fig 12 Hydraulic circuit CBH CLH CQH 004 006 007 204 206 207 LIEBERT HIROSS UNIT ONLY WITH TANK VERSION D NOT AVAILABLE IN 204 206 207 MODELS 3 ONLY WITH PUMP VERSION eme I CHILLED WATER INLET 2 GAS MALE Co 70 ONLY FOR 004 006 007 MODELS 9 D OF 8 amp 9 oe VI 1 P CHILLED WATER OUTLET 2 GAS MALE ONLY FOR 204 206 207 MODELS p Hydraulic components Item Description Description 17 Non return valve 18 Expansion tank Safety valve Opt without tank Expansion tank Service ball valve Drain valve 1 Evaporator 11 Control temperature sensor 2 Evaporator antifreeze heater Opt 12 Antifreeze temperature sensor 3 Rubber flexible pipe only with pumps and or tank 18 Tank antifreeze heater Opt 4 Manual air valve 14a Flow switch unit without tank Opt without pumps 5 Gate valve 14b Flow switch unit with tank Opt without pumps 6 Pump 15 Rubber flexible pipe only with pump
34. ble 269 290 297 357 257 285 285 257 306 306 239 263 199 224 199 225 Not available Not available Not available 283 299 256 282 282 257 285 285 273 321 321 ws 268 288 298 229 269 297 229 229 283 257 257 256 257 273 W 10 257 280 289 268 288 298 257 259 289 229 269 297 257 257 269 229 229 283 256 257 273 Fig 6 Rubber anti vibration support Rubber support dimensions Rubber support installation Unit base Fixing screw Screw anchor not supplied VA S SN Cement base Access hole for support fixing Single support code A B P F CF G L mm mm mm mm mm mm mm 60 82 35 M10 11 0 110 128 270327 Rubber supports Support Single support Kit support CBH 204 206 207 004 006 007 204 206 004 006 CQH 204 004 4 SBH 204 206 207 004 006 007 Ke SLH 204 206 004 006 SQH 204 004 CBH 008 011 014 CLH 207 007 008 011 206 207 006 007 008 With or without SBH 008 011 014 tank 485621 270327 6 SLH 207 007 008 011 206 207 006 007 008 CBH 016 CLH 014 016 011 014 016 SBH 016 485622 8 SLH 014 016 SQH 011 014 016 Each kit is complete with stainless steel fixing screws and plain washers for unit assembly
35. case heaters Chillers for sum mer operation only without modulating fan speed control the start must be carried out in the warm season only exter nal T gt 15 C and thus oil pre heating is not necessary 5 Make sure the fans rotate in the correct direction anticlock wise check the electrical connections if necessary 6 Make sure the pumps rotate in the correct direction During the unit start up an inlet water temperature higher than 20 C is allowed Under standard operating conditions check that the limits indicated in paragraph 2 1 are not exceeded 8 Check the correct operation of the control and safety de vices 9 Check the outlet temperature of the chilled water check if the set point set on the controller is reached 10 Check the compressor oil level 11 With the compressor at full load check there are no bubbles visible in the frefrigerant sight glass If there are any charge the unit according to par 5 4 3 Starting and stopping ALWAYS ENSURE THAT THE COMPRESSOR OIL HAS BEEN PREHEATED FOR BRIEF STOPPAGES MAINTAIN THE SUPPLY TO THE CRANKCASE HEATER IF ANY Start the unit setting the Microprocessor switch ON Stop the unit setting the Microprocessor switch OFF Incase of long stops turn the machine off using the Micro processor switch OFF In this case the compressor crankcase heaters if any re main powered For seasonal shutdown of the unit operate the main switch
36. ch circuit before the condenser The exchangers are pro tected by a suitable anti frost heater that operates when the sy stem is stopped It is recommended that a safety valve be installed inthe hydraulic circuitto avoid hazards due to overpres sures if there is no water flow through the recuperator The water temperature at the recuperator inlet in stable operat ing conditions must be in the range of 25 C 45 C with an out let differential of between 3 5 C 8 C 8 3 Water chiller with total heat recovery 100 All heat discharged by the unit to the condenser is recovered The system includes an additional refrigerating circuit made up of a three way solenoid valve supplying in case of hot water demand a plate exchanger usually by passed and sized so as to discharge all condensing heat also installed before the finned air condenser in series with it a check valve a liquid re ceiver at the exit of the finned air condenser working as storage for the needed additional refrigerant charge see refrigerating scheme The recuperator is insulated with closed cell polyure thane and is equipped with heaters activated when the recuper ator is deactivated to prevent frost in winter with the system stopped or not perfectly drained The operation in total recovery mode is enabled by an external contact The Microface control will simultaneously suit the fan speed changing the fan speed setpoint differently from t
37. ction monitoring the temperature of the motor windings and the direction of rotation the latter may be enclosed in the electronics of the compressor or external depending on the model The MATRIX S water chillers are controlled by the MI CROFACE microprocessor managing all the unit operating conditions The user can change and or modify the operating parameters through the display keyboard installed on the elec trical panel The electrical control board is equipped with all the safety and operating devices required for reliable operation The compres sor motors are equipped with protection on all three phases and are started by three pole contactors 2 Preliminary Operations 2 1 Operating limits The units can operate within the indicated operating ranges see Tab 5 These limits apply to new machines subject to correct installation and maintenance Ambient air minimum temperature 25 C for Superchiller 15 C for Chiller without fan speed control Operation al lowed only in summer mode 10 C for Chiller with contin uous fan speed control Either Triac or EC fan Maximum outdoor air temperature is in relation to each mod el as indicated in Tab 5 In any case outdoor temperatures aver 45 C are not admitted such limits are determined by electrical and electronic components fitted on units Maximum water flow allowed depending on the pressure drop corresponding to the required thermal differe
38. ctrical cable section min Ea 16 16 1 Outdoor air temperature 35 C 30 glycol water mixture water inlet outlet temperature 15 10 C Nominal power supply 400 V 3 Ph 50 Hz Nominal power supply tolerance 400 V 10 96 Max voltage unbalance 3 The cables have to be sized in compliance with local standards and according to the type and characteristics of installation Suggested cables section are re ferred to PVC insulation with a max working temperature of 70 C and an ambient temperature of 30 C 11 Tab 5 Operating limits CBH R 407C 004 006 007 204 206 207 008 011 014 016 Working Range Max outdoor air temperature 7 435 440 425 435 440 425 440 445 430 440 Safety Device Settings High pressure switch 1 26 0 High pressure safety valve 28 0 29 0 Low pressure switch 2 8 1 With nominal air flow water flow outlet at 7 C full load CLH R 407C 004 006 007 204 206 207 008 011 014 016 Working Range Safety Device Settings High pressure switch 1 26 0 High pressure safety valve 28 0 29 0 Low pressure switch 2 8 1 With nominal air flow water flow outlet at 7 C full load CQH R 407C 004 006 007 204 206 207 008 011 014 016 Working Range Safety Device Settings High pressure switch 1 26 0 High pressure safety valve 28 0 29 0 Low pressure switch 2 8 1 With nominal air flow water flow outlet at 7 C full load SBH 407C 004 006 007 204 206 207 008 011
39. e an early warning of low water pressure 7 Place a mesh filter atthe inlets of the pump and water chiller Can be supplied as an optional accessory Not fitted 8 Install at the highest points in the circuit apparatus which allows the bleeding of air and possibly the filling of glycol 9 Place a drain valve at the lowest point in the circuit and im mediately at the outlet of the water chiller 10 Install a water filling set including the following a filling water meter b manometer C non return valve d air separator e removable supply tube which must be disconnected after each charge top up 11 For maximum protection ensure that all tubing exposed to low outdoor temperatures is fitted with anti freeze heaters and insulated using closed cell synthetic rubber elasto mer 12 The circuit must include an expansion vessel with safety valve of suitable capacity 13 Connect the lines avoiding stresses on the machine inner parts Note Tr the water chiller is complete with an expansion vessel sup plied as an option check if the capacity is enough and install a second vessel in the circuit if required see par 8 4 Follow the indications in Fig c for the correct sizing Note he whole circuit must contain a water volume suitable for the capacity of the installed chiller Check if the inertial capacity giv en by the sum of the hydraulic volume inside the machine in cluding the volume of
40. h the machine Index t Introduction en Sea woe g een DLL Ol 12 Rhesponsibility 1 39 Inspection dup a 1 4 Generaldescription eee eet vesener Eon esa lese Shee dock he fet 2 Preliminary Operations ee see i ee eee es aswa eee 24 Operating El LCE 2 2 Soundipressurellevels suse rt wen tt oe Hewat CAPE er Hae ete aca RT e RR e EGENT Sen FOUNGAUONS P 255 SGNVICG ANCA said ese geet EE x Elus Pc 34 Hydraulic eer eee on UR deceret eoe redi a pr deae eee Frere 3 2 Connection of the safety valve discharge 3 9 u Ml te eee e eX EXTR a boi ee tec ite Yo erm 4 Start Up and Operation Wie ET c EEUU 42 First start up or after long stop suyu ere D ebd utet edes Yep eo Pre p dob abd rp eo der puto r ds 43 SlartiRg arid stopping cuu sage rat Itin Dat arena eet tono er eA QR E Reb Peak gri obrera aswa 4 4 Chillers serving special plants ccc RII Hm he 45 Freecoollng ore IR ferskeste svak pep OP e ep RP NP T ER DIOS puas dd un 46 Microprocessor control ik sa seres age brem eedem tease re 5 Refrigerant and Oil Charge nnn nnn nn nnn 5 1 Refrigerantcharge be E
41. he stan dard operation without recovery practically slowing the fans down till they switch off anyway the operation in recovery mode is enabled also without load at the users Indeed if the us ers do not demand heat the water flowing to the condenser reaches a temperature that does not enable the total condensa tion of the compressed gas and the remaining portion of the phase change can thus take place in finned coil without inter rupting the recovery process through the intervention of the ma chine safety devices If the plate exchanger is supplied with too cold water or if the sy stem is not preset by the installation technician with a three or two way proportional adjustment valve for the exchanger by pass indispensable for cold starts see following Recom mended hydraulic circuit the condensing pressure tends to decrease too much a prolonged condition of low condensing temperature below the safety threshold leads the Microface mi croprocessor control to disable the heat recovery protecting the system from any possible malfunctioning Fig e Recommended hydraulic circuit Heat recovery Heat recovery users exchanger 4 8 4 Hydraulic circuit accessories Made up of an expansion vessel pre charged at 1 5 bar max operating pressure 10 bar and safety valve set at 5 bar Their position in the hydraulic circuit is illustrated in Fig
42. hout water 19 0 55 0 53 0 53 0 60 0 60 0 60 0 60 0 60 0 60 0 60 0 55 0 53 0 54 0 60 0 60 0 60 0 60 0 60 0 60 0 60 0 55 0 54 0 54 0 60 0 60 0 60 0 60 0 60 0 60 0 60 0 91 0 88 0 89 1 27 1 21 1 22 1 60 0 91 0 89 1 33 1 26 1 21 1 64 1 59 0 92 1 34 1 33 1 28 1 65 1 64 1 61 With tank Not available Not available Not available Not available Not available Not available Not available Not available Not available 0 56 0 54 0 54 0 60 0 60 0 60 0 60 0 55 0 54 0 55 0 60 0 60 0 60 0 60 0 56 0 55 0 55 0 60 0 60 0 60 0 60 Fig 4 Support positions and loads Note weights refer to standard units CBH CLH AT 17 FOOT PRINT 1161 1127 1195 5 5 120 n Dimensions CBH CLH CQH Dimensions mm A B C D E Model Size CBH 004 006 007 204 206 207 CLH 004 006 204 206 2000 1760 CQH 004 204 CBH 008 011 014 CLH 007 207 008 011 3000 _ 1380 CQH 006 007 206 207 008 CLH 016 CLH 014 016 4000 1160 1440 CQH 011 014 016 Weight distribution CBH CLH CQH Weight distribution kg 1 w2 w3 w4 w5 w6 w7 W8 W9 10 Model Size CBH 004 161 _ _ _ 103 195 _ _ _ 124 006 181 _ _ 108 234 _ _ 140 007 187 _ _ _ 115 240 _ _ _ 147 204 206 _ _ _ 123 206 _ _ _ 123 206 217 _ _ _ 129 217 _ _ _ 129 207 229 _ _ _ 138 229 _ _ _ 138 008 245 _ 114 _ 114 245 _
43. ical cable section min mm 1 Outdoor air temperature 35 C water inlet outlet temperature 12 7 C CQH R 407C Power supply OA 1 FLA LRA Compressors power input 1 Compressors nominal current 1 Compressor max current Fan power input Fan nominal current Fan max current SHC std head pressure pump model Opt Std head pressure pump mot nom power Std head pressure pump mot max power Std head pressure pump max current SHC high head pressure pump model Opt FHE high head pressure pump model Opt High head pressure pump mot nom power High head pressure pump mot max power High head pressure pump max current 11585 gt 55 Electrical cable section min mm 1 Outdoor air temperature 35 C water inlet outlet temperature 12 7 C 004 16 004 16 004 16 006 35 54 219 18 6 31 50 006 34 52 217 18 9 32 50 006 10 007 43 73 274 23 5 39 69 007 42 73 274 22 5 38 69 007 42 72 273 23 3 39 69 204 29 42 121 13 8 25 18 204 28 40 119 14 3 26 19 204 26 39 118 13 6 25 19 206 206 206 207 008 011 014 016 400 V 3 Ph 50 Hz 48 56 68 77 181 217 23 8 27 3 44 48 32 35 20 134 1 85 2 45 4 61 40 160 40 4 0 4 0 8 50 207 008 011 014 016 400 V 3 Ph 50 Hz 20 134 1 85 2 45 4 61 40 160 40 4 0 4 0 8 50 207 008 011 014 016 400V 3Ph 50Hz 20
44. ing saturated evaporating temperature 3 The superheating is the difference between the two readings 4 For the units with R407C refer to the pressure gauge scale indicated with the initials D P Dew Point Verify that the superheating is 5 C 8 C e Measure the sub cooling as follows 1 Detect the temperature on the liquid line using a contact thermometer 2 Connecta pressure gauge by max a 30 cm pipe with the Schraeder connection on the liquid line and read the corresponding saturated condensing temperature 3 Thesub cooling is the difference between the two read ings 4 For the units with R407C refer to the pressure gauge scale indicated with the initials B P Bubble Point Verify that at the condenser outlet sub cooling is 3 C 5 C IT IS IMPORTANT TO CARRY OUT CHARGING CORRECTLY Anexcess of refrigerant causes an increase in sub cooling and consequent operating difficulties in the hot season a shortage of charge generates an increase in superheating and possible compressor stoppages Whenever work is carried out on the unit ensure afterwards that the working conditions are correct checking sub cooling and superheating 5 2 Oil charge Contact the Technical Support Department for the specifications of the oil to be used for topping up the oil changes according to the type of used refrigerant NEVER MIX DIFFERENT OILS TOGETHER CLEAN THE PIP ING COMPLETELY BEFORE CHANGING
45. lations in force The MATRIX S water chillers can be identified as follows CBHO004 Cooling Capacity kW Nominal cooling capacity 10 Compressor H Hermetic Scroll Version B Base L Low Noise Q Quiet Execution C Chiller S Superchiller 1 2 Responsibility Liebert Hiross accepts no present or future responsibility for damage to persons things orto the machine itself due to opera tors negligence failing to comply with the installation operation and maintenance instructions of this handbook failed applica tion of the safety norms in force for the system and the qualified staff charged with the operation and maintenance 1 3 Inspection All units are fully assembled and wired in the manufacturing plant Before shipment they are charged with the necessary quantities of refrigerant and oil and then tested at the operating conditions normally required by the customer The machine s hydraulic circuit is equipped with drain plugs and open vent valves the free cooling coils are supplied dry to avoid possible problems due to frost in the storage period Immediately inspect the machine carefully on delivery to check for damage during transportation or missing components possible claims must be made immediately to the carrier and the factory or its representa tive 1 4 General description MATRIX S units with air cooled condensers have been de signed and manufactured for producing chil
46. led water They are also available in versions with a built in freecooling module in versions with heat recovery for simultaneous heating of thermal circuit water with a pump assembly installed on the machine and or inertial buffer tank inside the machine the chill ing units can be equipped with several options indicated in the price list The MATRIX S product line has been designed utilising the state of the art techniques available nowadays in the indus try and includes all the components necessary for automatic and efficient operation Each unitis completely factory assembled after evacuation the necessary quantity of refrigerant is added to the refrigerant cir cuit s and the unit is tested Alltheunits are equipped with one ortwo independentrefrigerat ing circuits each one composed of an air cooled condenser a hermetic Scroll compressor and a braze welded plate evapo rator The components ofthe liquid line are the charging valves filters dryers solenoid valve shut off valve moisture indicator and thermostatic expansion valve The hydraulic circuit is made up of hydraulic lines both in steel and flexible EPDM rubber connected by fittings and threaded joints a flow switch optional and in the freecooling versions chilled water coils and a three way valve Thehermeticscroll compressors are complete with the following protection safety devices oil heater if necessary electronic prote
47. nce usu ally not lower than 3 5 C 4 C Minimum allowed water flow compatible with a sufficient evaporation temperature to avoid the intervention of the safety devices to be evaluated for a thermal difference not higher than 8 C Temperature range of the water exiting the evaporator 4 C 15 C Maximum temperature of the water entering the unit 20 C higher temperatures are allowed only at the system start up and not during normal operation Maximum glycol concentration 50 35 with the optional pump assembly installed on the machine Minimum allowed glycol concentration depending on the minimum temperature of the ambient air expected at the installation site See Tab a Maximum pressure of the hydraulic circuit 5 bar Voltage range for the electric supply 400 V TI 10 max phase difference 3 tolerance on frequency 1 Storage conditions 20 45 C for all MATRIX S models Note Avoid positioning in areas with strong dominant winds that may impair the operation and effect the indicated limits 2 2 Sound pressure levels The Tab 6 showsthe noise data forthe units in standard config uration without pumps operating continuously and measured according to the ISO 3744 norm in free field conditions The highest noise levels are detected on the condenser coil side Note Avoid positioning in areas with possible reverberation of the sound waves which can adver
48. pressed in litres e water expansion coefficient with water at 10 C as a reference Pi absolute pressure of initial charging equivalent to the vessel pre charge pressure typical value Pf absolute final tolerated pressure lower than the operating pressure of the safety valve calibration Use the values of the water expansion coefficient indicated in the table below H20 T C Density kg m3 Expansion coefficient e 3 3 Electrical connections 1 Before proceeding with the electrical connections ensure that all electrical components are undamaged all terminal screws are tight the supply voltage and frequency are in accordance with the rating with tolerance in accordance with IEC 8 6 norms March 1990 the allowed phase to phase variability is 3 maximum see Fig d Variability in excess of 3 invalidates the guarantee 2 Supply cable connections see Tab 4 e Connect the cable to the supply terminals Use appropriately sized 3 pole cable An earth wire must also be connected After having opened the passage in the framework pre punched knock outs for the supply line entry restore the original degree of protection using suitable accesso ries for the wiring and junction boxes Fig d Example of calculating phase to phase variability 1 The 400 V supply has RS T the following variability RS 388 V ST 401 V RT 402 V The average voltage is
49. rm people and the surrounding environment Fig a Ideal chilled water circuit volume Tide ar gt lt CHILLER Vpt Tank disconnect af ter charge USER m w EC 10a 10b 10c 10d 10e Fig b Inertia tank sizing The total optimum hydraulic volume of the system where the Matrix S chiller is installed can be calculated by the following formula 43x Rt V where V minimum required total water volume expressed in litres Rt refrigeration capacity expressed in kW Xd differential band set on the control and expressed in degrees centigrade Please note that the sum of the hydraulic volume of the Matrix S chiller Vm plus the volume of the hydraulic circuit connected to it Vpc must be greater than or equal to the minimum required total water volume V If this condi tion is not satisfied it is necessary to install an inertia tank Vpt as indicated in the Fig a with a volume at least equal to the following value Vptz V Vm Vpc Fig Sizing of the expansion vessel V Cxe 1 Pi Pf where 2 5 bara pressure typical value 4 0 bara The total volume of the expansion vessel is calculated with the following formula C quantity of water inside the system ex
50. s Tillverkare forsakrar harmed att denna produkt 6verensstammer med Europeiska Uniones direktiv De Fabrikant verklaart dat dit produkt conform de Europese richtlijnen is Vaimistaja vakuuttaa t ten ett t m tuote t y tt seuraavien EU direktiivien vaatimukset Produsent erkl rer herved at dette produktet er i samsvar med EU direktiver Fabrikant erkl rer herved at dette produkt opfylder kravene i EU direktiverne O Kataorevaotis Snover ott to kovaokevaou vo ue vc OSnyies tng E E 98 37 CE 89 336 CEE 73 23 CEE 97 23 CE Since the Liebert HIROSS Company has a policy of continuous product improvement it reserves the right to change design and specifications without previous notice Zona Industriale Tognana Via Leonardo da Vinci 16 18 HIROSS 35028 Tel 39 049 9719111 Telefax 39 049 5841257 ER temet www liebert hiross com A amp Liebert HIROSS EMERSON is a division of EMERSON Network Power lt a P 2 P O x E del e gt Ee E B E E 215 o o Q gt 2 5 a 2
51. s without tank 7 Safety valve 16 Filter Opt 8 9 10 30 Fig 13 Hydraulic circuit CBH CLH CQH 008 011 014 016 LIEBERT HIROSS UNIT ONLY WITH PUMP VERSION LUA Ce CHILLED WATER INLET 21 5 GAS MALE o Ta d 9 CHILLED WATER OUTLET 21 5 GAS MALE Hydraulic components Safety valve Expansion tank Service ball valve Drain valve 16 Filter Opt 17 Non return valve 18 Expansion tank Safety valve Opt without tank 1 Evaporator 11 Control temperature sensor 2 Evaporator antifreeze heater Opt 12 Antifreeze temperature sensor 3 Rubber flexible pipe only with pumps and or tank 18 Tank antifreeze heater Opt 4 Manual air valve 14a Flow switch unit without tank Opt without pumps 5 Gate valve 14b Flow switch unit with tank Opt without pumps 6 Pump 15 Rubber flexible pipe only with pumps without tank 7 8 9 10 31 Fig 14 Hydraulic circuit SBH SLH SQH 004 006 007 204 206 207 LIEBERT HIROSS UNIT ONLY WITH PUMP VERSION XO ONLY WITH TANK VERSION NOT AVAILABLE IN 204 206 207 MODELS d lt gt lt St 9
52. sely effect the noise levels 2 3 Transport Handle the unit by lifting it with a crane from above Thelifting holes are positioned in the frame s base when lift ing use spreader bars to protect the sides see Fig 2 and Fig 3 Note Place the lifting tubes in the holes in the base indicated by LIFT HERE Lock the ends of the tubes with the locking pins and splits pins as shown in Fig 2 As an alternative shackles hooks optional fastened at the base ends can be used as a lifting sy stem in this case the lifting point must be on the vertical line passing through the machine s centre of gravity as indicated in Fig 3 to prevent any load imbalance The capacity of the lifting gear must be adequate to lift the load in question Check the weight of the units the capacity of the lift ing gear and ropes and the condition and suitability of the afore mentioned equipment 2 4 Foundations e The unit must be placed on a level surface which will support its weight e fnecessary position the unit on suitable anti vibration sup ports that can be supplied as an option in rubber or spring type Refer to the manual Installation of the spring anti vibration supports for their correct positioning When positioned level the unit Note For weight distribution see Fig 4 and Fig 5 Note ne weights and their distribution refer to standard units without options if the pump assembly or other
53. ter inlet outlet 12 7 C Chiller versions Heat recovery conditions water inlet outlet 40 45 C Tab 4 Electrical characteristics CBH R 407C Power supply OA 1 FLA LRA Compressors power input 7 Compressors nominal current 1 Compressor max current Fan power input Fan nominal current Fan max current SHC std head pressure pump model Opt Std head pressure pump mot nom power Std head pressure pump mot max power Std head pressure pump max current SHC high head pressure pump model Opt FHE high head pressure pump model Opt High head pressure pump mot nom power High head pressure pump mot max power High head pressure pump max current A A A kW A A kW A A kW kW A gt 25 Electrical cable section min mm 1 Outdoor air temperature 35 C water inlet outlet temperature 12 7 C CLH R 407C Power supply OA 1 FLA LRA Compressors power input 7 Compressors nominal current 1 Compressor max current Fan power input Fan nominal current Fan max current SHC std head pressure pump model Opt Std head pressure pump mot nom power Std head pressure pump mot max power Std head pressure pump max current SHC high head pressure pump model Opt FHE high head pressure pump model Opt High head pressure pump mot nom power High head pressure pump mot max power High head pressure pump max current 11 gt gt 25 Electr
54. the optional interna tank if fitted and the system volume is sufficient or possibly install a tank in the circuit Follow the indications in Fig b for the correct sizing Note he hydraulic circuit must ensure a constant water supply to the evaporator in every operating condition Otherwise the com pressors may be damaged by repeated returns of liquid refriger ant on their suction Note he water flow switch is a compulsory safety component that must be installed and correctly wired to the Matrix S chillers otherwise the guarantee will be invalidated It is installed as standard on units with the optional on board pump set and is available as a option for units without pumps on board in the latter case the flow switch if not installed on the machine can be installed on the hydraulic circuit by the installer but it is compulsory that it is wired to the electric panel terminal board as indicated on the wiring diagram 3 1 2 Addition of water and ethylene glycol Very important Add water and ethylene glycol to the circuit with a depending on the minimum temperature of the outside air expected at the installation site Do not exceed the nominal operating pressure of the circuit s components Notes oavoid stratification run the circulation pump for at least 30 minutes after adding any glycol After adding water to the hydraulic circuit always discon nect the water supply coming from the sanitary supply
55. ure 6 bar Built in carbon steel and coated with anti condensation insula tion It can be installed in all MATRIX S versions inside the coil compartment Mod 004 006 007 technical data e Internal volume 200 litres Net weight 110 kg Working weight 310 kg Mod 008 011 014 016 technical data e Internal volume 400 litres Net weight 140 kg Working weight 540 kg Mod 204 206 207 technical data e Internal volume 160 litres Net weight 100 kg Working weight 260 kg Tab 1 Internal hydraulic volume x Pt moder Unitvolume 1 004 8 27 004 006 007 204 CBH mis 207 008 011 014 016 Add the tank s volume for the units with optional buffer tank Tab 2 Partial heat recovery 20 Heating capacity 10 8 14 8 18 2 21 6 29 6 36 4 44 3 Water flow 0 516 0 707 0 870 1 032 1 414 1 739 2 117 Water pressure drop 11 14 21 Water connections 114 11 4 11 4 11 4 Working conditions outdoor temperature 35 C water inlet outlet 12 7 Chiller versions glycol mixture 30 inlet outlet 15 10 C SuperChiller versions Heat reco very conditions water inlet outlet 40 45 Tab 3 Total heat recovery 100 004 006 007 Heating capacity kW 53 74 91 105 144 177 223 Water flow l s 2 53 3 54 4 35 5 02 6 88 8 46 10 65 Water pressure drop kPa 60 70 70 80 Water connections BSP T 2 2 2 21 2 21 2 Working conditions wa
56. valve 25 Liquid receiver 12 Filter dryer 13 Shut off solenoid valve 14 Sight glass 28 Fig 11 Refrigerant circuit with total recovery opt CBH CLH CQH 204 206 207 008 011 014 016 ONLY FOR CBH 014 016 CLH CQH 011 014 016 ONLY FOR CBH 014 016 CLH CQH 011 014 016 2 HEAT RECOVERY WATER OUTLET G GAS MALE nee lt i E p EN OG I ea S 2 HEAT RECOVERY v r GASMALE Mer OG XQ h p 4 GAS MALE 9 o oe ER lt gt lt 90 XU 211 DIS Refrigerant components 21 5 E e Z pk CHILLED WATER OUTLET H GAS MALE Description tem Description 1 Compressor 15 Thermostatic expansion valve 2 High pressure switch HP 16 Evaporator 3 Low pressure switch LP 17 Antifreeze heater Opt 4 Crankcase heater 18 Control temperature sensor 5 High pressure manometer Opt 19 Charge connection 6 Low pressure manometer Opt 20 Antifreeze sensor 7 Safety valve 21 Total recovery heat exchanger 8 Condenser 22 Three w
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