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3. 5 INSTALLATION 5 1 CHOOSING THE INSTALLATION SITE When choosing the installatio
4. Operating checks may require the unit to work totally or partially while a panel is open In this case the panel sho
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6. SAFETY REGULATIONS It is forbidden for unauthorised persons to approach the unit Scrupulously observe the contents of Chapter 9 on page 32 before carrying out each maintenance operation on the unit It is forbidden to enter the unit
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10. 9 1 1 gt 9 ROUTINE MAINTENANCE AND CONTROLS WARNINGS Before carrying out any work on the unit or accessing internal parts make sure the unit is disconnected form the mains power supply Given the compressor delivery pipe high temperature special attention should be paid when working near pipe and wait for the pipe to cool When working near the finned coils pay special attention to the aluminium fins as th
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12. Tbpa THE UNIT DOESN T START Il A COMPRESSOR DOESN T START TH
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14. 9 1 2 9 2 9 3 R407C
15. 5 3 ELECTRICAL CONNECTIONS 5 3 1 General These operations may only be carried out by specialised staff Before carrying out any operations on electrical components make sure the unit is disconnected from the mains power supply Make sure that the mains power supply corresponds to the rated values of the unit shown on the plate voltage number of phases frequency Electrical connections must be made carefully following the instructions shown on the wiring diagram attached to the unit The earth connection is obligatory by law The earth cable must be connected to the earth bar located in the electrical panel and marked with PE Auxiliary circuit power is supplied by the power line by means of a transformer located in the electrical panel 11 2 12 2 gt 7 8 V OX 11 T E 1 1 2 A k gt j 2 D 12 10 2 3 5 2 2 1 1
16. 1 INTRODUCTION 1 1 GENERAL INFORMATION This manual contains the installation use and mainte nance instructions for the CHA chillers and highlights all connected risks and perils It has been expressly prepared and written to allow authorised users to use the CHA water chillers in complete safety and with the greatest of ease Please read the whole of this manual with care paying special attention to the sections marked with as non compliance may cause harm to people deteriorate the environment and or damage the unit The company declines all responsibility for any improper use of the unit unauthorised modifications non com pliance with the instructions contained in this manual Please keep this manual in a safe place and make it available to chiller operators and maintenance men 1 2 ATTACHMENTS The documents shown on page 2 form an integral part of this manual 1 3 WARNINGS The CHA units have been designed and built to ensure long term operating reliability and maximum safety for this reason and thanks
17. 5 2 6 1 PRELIMINARY CONTROLS Make sure that the electrical connections have been made correctly and that all the terminals have been well tightened Use a tester to make sure that the voltage on terminals L L L is equal to that shown on the rating plate permitted tolerance 5 If voltage is subject to frequent variations please contact our technical office in order to decide on suitable protection devices Use a leak tester if necessary to make sure there are no leaks of refrigerant liquid Check that the heating elements of the sump if fitted are correctly powered The heating elements must be turned on at least 12 hours before start up this takes place automatically when the main power switch is closed position To check if the heating elements work correctly make sure that the lower part of the compressor
18. nep CHA 3 4 EMERGENCY AND SAFETY DEVICES An emergency external circuit breaker must be fitted by the u
19. 7 2 7 71 Start and stop the unit with the ON OFF button lo cated on the microprocessor cover The compressors and fans will automatically start and stop depending on the temperature of the water returning from the unit while the circulation pump will remain working continuousl
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21. 5 3 2 5 3 3 1 5 The cross section of the cable and the line protections must comply with the indications shown on the wiring diagram and in the rela tive sheet attached to the unit Observe the phase sequence otherwise the unit will not work Input voltage must not exceed variations of over 5 and phase unbalance must always be less than 2 Unit operation must always take place within the above values as otherwise the guarantee will immediately become null and void 5 3 2 Electrical connections to the circulation pump The circulation pump must always be connected to the unit control system as shown on the wiring diagram The pump must be started up before starting up the chiller while it must be stopped after the chiller has stopped minimum recom mended delay 40 seconds 5 3 3 External signals If a remote ON OFF command is required connect the external enable to the contacts shown on the wiring diagra
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23. Make sure is leaking from the compressor Make sure that no water is leaking from the water circuit Drain the water circuit Make sure the differential water presure switch works correctly Check the heating elements in the compressor sump Clean the metal filters in the water pipes Clean the finned coil and the relative metal fil ters if present by directing a jet of compressed air in the opposite direction from that of the air flow If the filters are very clogged use a jet of wa ter instead Check that the unit doesn t make any unusual nois es 9 1 2 Four monthly controls Make sure the fans are fixed balanced and in good condition 9 2 REPAIRING THE REFRIGERANT CIRCUIT These repairs may only be made by specialised staff using the normal tech niques for chillers that make use of hal ogen fluids as refrigerants 9 3 TOPPING UP THE REFRIGERANT This operation should only be carried out after iden tifying and repairing the leak For units using R407C or no more than two top ups are allowed If another top up is required the refrigerant circuit must be completely emptied and then filled with new refrigerant 31 IMATIZZAZIONE INTEGRATA 10
24. 22 CHA 6 2 START UP Select on the microprocessor controller the operating cycle heating or cooling use the arrow keys to move to the Mode select menu and select summer cooling or winter heating N B this operation is only required for the versions with heat pump Attention The operating cycle should be changed on a seasonal basis Frequent changes between summer and winter modes should be avoided as they can cause the compressors to work badly and consequently damage them Start the unit and make sure the following happens indications between brackets refer to units with heat pumps working in the heating cycle mode First start the pump and if the temperature of the return ing water from the playt is high low enough the fans will start up automatically after about 21 2 minute after about 40 sec later the compressor When the temperature of the water returning from the unit decreases increases the compressor will stop The fans will stop together with the compressor while the water circulation pump will remain operating When the temperature of the water returning from the unit increases decreases the compressor will start up as well as all the fans If the u
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28. na 10 minutes this is not the case unit inertia must be increases A few minutes after the compressor start during the summer operating cycle make sure the c
29. 4 2 20 50 4 3 4 INSPECTION AND TRANSPORT 4 1 INSPECTION Check the condition of the unit on receipt As the unit was carefully checked before leaving the factory any claims for damages should be addressed to the forwarder Any damage should therefore be indicated on the Delivery Note before signing it Please inform the company or the Agent of the nature of the damage to the unit immediately The Customer must always write a report describing any damage caused to the unit 4 2
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31. 2 3 4 5 6 7 8 9 10 11 12 E 1 Vibration proof joints 2 ball shut off valve 3 Check valve 4 Circulation pump 5 Mesh filter 6 Automatic water filling valve 7 Closed expansion tank 8 Safety valve 9 Water storage tank 10 Thermometers 11 Automatic air purge 12 Pressure gauge Evaporator IMATIZZAZIONE INTEGRATA 3a 5 290
32. 3 5 3 3 5 2 to take case leaking refrigerant gas Product type R407C First aid measures General information Do not give anything to people who have fainted Inhalation Take the person out into the open air Use oxygen or artificial respiration if necessary Do not give adren aline or similar substances Contact with eyes Carefully rinse with abundant water for at least 15 minutes and see a doctor Contact with the skin Wash with abundant water and remove all contaminated clothing immediately Measures to take in case of accidental leaking Personal precautions Evacuate all staff to safety areas Make sure the area is suitably ventilated Use personal protection equipment Environmental precautions to intercept the
33. KbM gt gt gt gt CHA e drain valve or where necessary drain tank for emptying the circuit for maintenance operations or seasonal shut downs 5 2 2 Evaporator It is vitally important that the water enters the unit from the connection point marked with the WATER INLET plate Threaded or flanged male unions depending on the models are used to make water connections please refer to the scale drawings which also show the position of t
34. 1 3 6 4 OFF tween brackets refer to units with condensation con trol the fans stop the operating cycle is inverted with the 4 way valve thereby making the finned coil work like a condenser The condensation heat causes the frost to melt and drain to the ground When the end of cycle temperature pressure is reached the 4 way valve is inverted once more and the winter operating cycle continues Defrosting lasts from about 1 to a maximum of 3 minutes when it is interrupted even if the end of cycle
35. 6 3 1 6 3 2 Defrosting only heat pump units 6 4 Stopping the unit 7 OPERATION 7 1 General 7 2 Seasonal shut down 8 TROUBLESHOOTING 9 ROUTINE MAINTENANCE AND CONTROLS 9 1 Warnings 9 1 1 General 9 1 2 Monthly controls 9 1 3 Four monthly controls 9 2 Repairing the refrigerant circuit 9 3 Topping up the refrigerant liquid 10 SHUT DOWN AND DISPOSAL CLINT CLIMATIZZAZIONE INTEGRATA 1 1 1
36. CHA WP 2 3 3 5 13 2 4
37. 3 3 1 3 2 3 3 3 3 1 3 3 2 3 4 3 5 3 5 1 3 5 2 3 5 3 4 4 1 4 2 4 3 4 4 5 5 1 5 2 5 2 1 5 2 2 5 3 5 3 1 5 3 2 5 3 3 6 6 1 6 2 6 3 CONTENTS O LIST OF ATTACHMENTS 1 INTRODUCTION 1 1 General information 1 2 Attachments 1 3 Warnings 2 UNIT DESCRIPTION 2 1 Identification 2 1 1 Identification 2 2 Intended use 2 3 Contraindicati
38. Attention Before starting up the unit make sure that all the external panels are in place and fixed with screws 21 CLINT CLIMATIZZAZIONE INTEGRATA 6 2 Mode select Summer Winter N B
39. 10 SHUT DOWN AND DISPOSAL When the unit is removed or replaced because it has reached the end of its life it must be taken to special collection centres If no specialised centres are available proceed as fol lows Collect the refrigerant taking care not to disperse it into the environment and then send it to au thorised collection centres The lubricating oil must also be collected and sent to authorised collection centres for disposal Dismount the various components and the struc ture and sort the various materials into separate groups for disposal please bear in mind that con siderable quantities of copper and aluminium are contained in the unit The above allows the various materials to be recov ered and disposed of in order to avoid environmental damages 32
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41. G I HOLDING S p A Via Max Piccini 11 13 33050 RIVIGNANO UD ITALY CLNT Manufactured by BV ITA 40 02 1230 Modello Model Modell Mod le Matricola Serial number Matrikelnr Matricule Tensioni Fasi Frequenza Tensioni circuiti ausiliari Voltage Phases Frequency Spannung Phasen Frequenz Tension Phases Fr quence Corrente massima assorbita Max absorbed current Maximale Stromaufnahme Courant maxi absorb e Tipo di refrigerante Refrigerant type K ltemittel Typ Type de r frigerant Taratura pressostato di alta High pressure switch setting HD W chter Einstellung Pr ssion maxi refrigerant Gruppo del fluido frigorifero Group of the refrigerant fluid K ltemittel Klasse Groupe de fluide frigorifique Auxiliary circuit voltage Hilfstromkreisspannung Tension circuits auxiliaires Corrente massima di spunto Max starting current Max Anlaufstrom Courant maxi de d marrage Carica refrigerante per circuito Refrigerant charge per circuit Kaltemittelfullung pro Kreislauf Charge de r frigerant chaque circuit Press massima circuito idraulico Max hydraulic circuit pressure Max Druck im hydraul Kreislauf Pr ssion maxi circuit hydraulique Data di produzione Manufacturing date Herstellungsdatum Date de fabrication 2 UNIT DESCRIPTION This chapter contains a general description of the main unit characteristics together with those of its principal standard and optional components
42. 3 3 1 OTO gt gt 2 2 INTENDED USE The CHA series of air condensation chillers have been designed to cool water possibly containing inhibited ethylene glycol circulating in a closed circuit The heat pump units CHA WP can cool or heat the water in the closed circuit depending on which operating cycle is chosen The heat or cold produced can be used for air conditioning systems or industrial processes 2 3 CONTRAINDICATIONS Do not use inflammable products near the unit Do not use substances that can form explosive mixtures near the unit Do not use the unit in conditions that could be harmful for the environment see point 3 5 on page 13 2 4 GENERAL DESCRIPTION All the unit structures are made from pe
43. CLM01 1 ab ENGLISH Cam a CLINT INSTALLATION USE AND MAINTENANCE MANUAL CLINT CLIMATIZZAZIONE INTEGRATA 0 HA C LJ O LJ 0 LIST OF ATTACHMENTS List of documents supplied with the unit and forming an integral part of this manual L Technical book Ll Microprocessor manual Certificate of guarantee Declaration of conformity Specific electrical circuit CLINT 0 1 11 1 2 1 3 2 2 1 2 1 1 2 2 2 3 2 4
44. Access is only permitted to qualified staff when the unit is disconnected It is forbidden to remove safety guards and bypass safety and emergency devices It is forbidden to stand on the unit Only use the unit to do what it was built for The manufacturer declines all responsibility for damage deriving from improper use or technical modifications made to the unit Check the safety devices are in perfect working order on a regular basis Do not dismount modify or disconnect unit parts When working on the unit only use suitable tools and equipment in good condition Operators must wear normal personal protection equipment gloves helmet goggles etc Work on the electrical system of the unit may only be carried out by a qualified electrician Work on the refrigerant circuit may only be carried out by specialised staff 3 3 3 3 SYMBOLS Ha Check the state of the plates a regular basis Te repair them if necessary MOCT CLINT m CLIMATIZZAZIONE INTEGRATA 3 3 1 3 3 1 Safety signs placement 3 3 2 3 3 2 Safety signs ATTENZIONE SFIATO ARIA DARE TENSIONE AI RISCALDATORI OLIO DEL CARTERALMENO 12 ORE PRI
45. The unit must be 15 CLINT CLIMATIZZAZIONE INTEGRATA 5 2 5 2 1
46. is 10 15 C higher than room temperature Check the water circuit is correctly connected the indications on the unit rating plate must be observed Make sure that the water circuit has been cleaned beforehand the water circuit should be washed bypassing the unit and then the system filter checked for dirt The units are despatched with the relief valves and drains open Special plates show where they are lo cated They must be closed during installation before the water circuit is filled Make sure the water circuit has been well vented to eliminate any air residues this operation is carried out by gradually loading and opening the relief valves fitted to the uppermost part of the unit by the installer please consult section 5 2 for further information In case water with glycol is used the anti freezing set point can be moved the value must be equal to the value of the freezing temperature of the fluid plus 6 20 CLINT 6 3
47. 1 Before starting the pump make sure that the moving parts turn freely To do so remove the fan cover 3 from the rear motor cover 1 insert a screwdriver into the notch on the ventilation side of the motor shaft and rotate it If it blocks rotate the screwdriver by gently hitting it with a hammer fig A Then put the fan cover back Power the unit and check for the three phase version the motor rotates clockwise looking at it from the fan side fig B If this is not the case invert any two phase wires
48. 2 1 IDENTIFICATION 2 1 1 Unit identification The unit can be identified throug the plats attached on the frame and in the electrical box This label contains the following information Manufacturer s name Manufacturer s address Description of the series and type of unit Series number Year of construction Type and quantity of refrigerant liquid Max allowable pressure Pressure switch set point EC certification symbol Electrical characteristics Wiring diagram identification CLINT G I HOLDING S p A Via Max Piccini 11 13 33050 RIVIGNANO UD ITALY Tel 39 0432 773220 Fax 39 0432 773855 E mail info clint it Web www clint it Manufactured by BV ITA 40 02 1230 DIRETTIVA 97 23 CE del 29 maggio 1997 P E D cat Modello Model Modell Mod le Matricola Serial number Matrikelnr Matricule Anno di costruzione Construction year Baujahr Ann e de fabrication C ALTA HIGH PRESS 1 HOCHDUCK PS Max Press ammissibile HAUTE Max Working press Refrig side BASSA LOW PRESS Max Betriebsdruck Kaltemittelseitu meverouck BASSE Press max de travail cute refrigerar IMATIZZAZIONE INTEGRATA 2 2 CHA
49. emission Cleaning methods to employ absorbent products 3 5 3 Operations with the panels removed Some of the following operations and or controls require the panels of the unit to be removed in order to access the inside of the unit Before removing an outer panel except for the one protecting the electrical panel the unit must be disconnected from the mains power supply Please note that some surfaces inside the unit may be hot piping compressor cold compressor suction separator etc sharp coil fins or moving fans even when the unit is not working These operations only be carried out by qualified staff wearing safety clothing 12 IMATIZZAZIONE INTEGRATA Ha
50. them by referring to the information shown on the microprocessor programme See point VII Check and replace Remove the excess refrigerant liquid from the system Drain the circuit pressurise and recharge the unit Check and replace Clean the filters with compressed air or water See point VI Vent the water circuit Check the pump and replace if necessary Check and replace See point VII Check clean and replace if necessary Check and replace Clean the filters with compressed air or water See point VI See point XIII Check the pump and replace if necessary Check the voltage at the ends of the contactor coil and the continuity of the coil Replace if faulty Inspect the insulation between the windings and between the windings and the earth Check and tighten Check and replace if necessary The microprocessor indicates when the safety devices cut in see attached manual CLINT es VIL LACK OF REFRIGERANT LIQUID VIII THE FLUID PIPE IS IX THE FLUID PIPE IS COVERED WITH FROST X THE UNIT CON TINUES TO WORK WITHOUT STOP PING THE UNIT WORKS REGULARLY BUT HAS AN INSUFFI CIENT OUTPUT XII THE COMPRESSOR SUCTION LINE IS COVERED WITH FROST XIII THE DEFROSTING CYCLE IS NEVER ACTUATED XIV ABNORMAL NOISE IN THE SYSTEM 1 There s a leak in the refrigerant circuit There s not enough refrigerant liquid in the circuit The fluid filter is cl
51. E COMPRESSOR STARTS AND STOPS REPEATEDLY IV A COMPRESSOR DOESN T START BECAUSE THE HIGH PRESSURE SWITCH HAS CUT IN COMPRESSOR DOESN T START BECAUSE THE LOW PRESSURE SWITCH HAS CUT IN Vi THE FANS DON T START Conta GP wy No flow switch or differential pressure switch agreement The connections are faulty or the contacts are open compressor s faulty The external enables have not been given The work probe enable has not been given The antifreeze enable has not been given A safety device enable has not been given The anti recirculation timer is active The fan thermal cut outs trip The compressor has blown The power circuit is open The motor protection is open The compressor contactor is disabled The compressor is faulty The low pressure switch has cut in The compressor contactor is faulty The set point values are incorrectly set 5 not enough refrigerant liquid The pressure switch doesn t work too much refrigerant liquid There s non condensable gas in the refrigerant circuit The refrigerant filter is clogged The metal filters of the condenser if fitted are clogged The air flow is too low The condenser fans do not work air in the water circuit The circulation pump is faulty The pressure switch doesn t work The unit is completely empty The thermosta
52. Fix the pipes with brackets Install correctly 29 IMATIZZAZIONE INTEGRATA 9 one 9 1
53. MA AIR PURGE DELL AVVIAMNETO DELL UNIT NEGLI INTERVALLI DI FUNZIONAMENTO AD ES PAUSA DEL FINE SETTIMANA TOGLIERE L ALIMENTAZIONE ELETTRICA ENTLUFTUNGSVENTIL E MUNITA DI UN RITARDATORE ANTIRICIRCOLO DI DISPOSITIVO PURGE AIR PER LA RIPARTENZA AUTOMATICA PRIMADIAPRIRE IL SEZIONATORE FERMARE L UNIT AGENDO SUGLIAPPOSITI INTERRUTTORI DI MARCIA O IN ASSENZA SUL COMANDO A DISTANZA PRIMA DI ACCEDERE A PARTI INTERNE DELL UNIT TOGLIERE TENSIONE APRENDO IL SEZIONATORE GENERALE WARNING 5 SUPPLY THE CRANKCASE HEATERS AT LEAST 12 HOURS BEFORE STARTING THE UNIT DURING TEMPORARY STOP PERIODS LIKE WEEK ENDSI NEVER DISCONNECT ELECTRICAL SUPPLY TO THE UNIT THE UNIT IS PROVIDED WITH DELAY RELAY AND WITH AUTOMATIC RESTART DEVICE BEFORE OPENING THE MAIN SWITCH STOP THE UNIT BY ACTING ON THE SUITABLE RUNNING SWITCHES OR THESE ARE IF NOT PRESENT ON THE REMOTE CONTROL BEFORE SERVICING THE INNER COMPONENTS DISCONNECT ELECTRICAL SUPPLY BY OPENING THE MAIN SWITCH ACHTUNG DIE KURBELWANNENHEIZUNG MINDESTENS 12 STUNDEN VOR DER INBE TRIEBNAHME DES GERATS UNTER SPANNUNG SETZEN DIE KURBELWAN NENHEIZUNG WAHREND DER STILLSTANDSZEITEN DES GERATS NICHT AUSSCHALTEN DAS GERAT IST MIT SCHALTVERZOGERUNGSTIMER UND VORRICHTUNG FUR AUTOMATISCHEN WIEDERANLAUF AUSGESTATTET VOR DEM OFFNEN DES HAUPTSCHALTERS SETZEN SIE DAS GERAT DURCH BETATIGUNG DER ENTSPRECHENDENBETRIEBSSCHALTER ODER WENN DIE SE NICHT VORHANDEN SIND DURCH FERNBEDIE
54. NUNG AUSSER BETRIEB BEVOR MAN DIE INTERNE GERATEKOMPONENTEN BERUHRT MUSS DER HAUPTSCHALTER GEOFFNET WERDEN NOTICE FOURNIR TENSION AUX RECHAUFFERS DU CARTER AU MOINS 12 HEURES AVANT QUE L UNIT SOIT DEMAREE COUPEZ PAS LA TENSION AUX R CHAFFEURS PENDANTS DES COURTES PERIODES D ARRET DEL UNITE TELS QUE LE WEEK END L UNIT EST EQUIPPEE DE RELAIS ANTI COURT CYCLE ET D UN DISPOSITIF POUR LE REDEMARRAGE AUTOMATIQUE AVANT D OUVRIRLE SECTIONNEUR GENERAL ARRETEZL UNITE ENAGISSANT SUR LES INTERRUPTEURS DE MARCHE OU AU CAS OU IL PAS SUR LE COMMENDE A DISTANCE AVANT DE TOUCHER LES COMPOSANT INTERNES A COUPER LA TENSION EN OUVRANT LE SECTIONNEUR GENERAL ANWESENHEIT VON GEGENS IN BEWEGUNG PRESENCE DES ORGANS EN MOUVEMENT INGRESSO ACQUA REFRIGERATA CHILLED WATER INLET ATTENZIONE KALTWASSEREINTRITT ATTENTION ENTREE EAU GLACEE VORSICHT INSTALLARE SEMPRE UN FILTRO ACQUA SUL CIRCUITO IDRAULICO USCITA ACQUA REFRIGERATA A PROTEZIONE DELL EVAPORATORE CHILLED WATER OUTLET PLEASE BUILT ALWAYS A WATER FILTER ON THE HYDRAULIC KALTWASSERAUSTRITT CIRCUIT TO PROTECT THE EVAPORATOR SORTIE EAU GLACEE EIN WASSERFILTER AUF DEM HYDRALISCHEN KREIS ZUM SCHUTZ DES VERDAMPFERS IMMER EINBAUEN INSTALLER TOUJOURS UN FILTRE DE 17 EAU SUR LE CIRCUIT HYDRAULIQUE A PROTECTION DE L EVAPORATEUR CLINT CLIMATIZZAZIONE INTEGRATA 3 4
55. STORAGE The temperature in the area where the units are stored must range between 20 C and 50 C 4 3 LIFTING AND TRANSPORT When unloading and positioning the unit take great care not to make sudden and or violent manoeuvres Do not lift the unit by its piping or any other components The unit should only be moved as shown in the plate attached to it Attention Make sure the unit is securely anchored before lifting it in order to prevent it from accidentally overturning or falling 4 4 PASONAKOBAHE 14 4 4 UNPACKING Only unpack the unit when it has reached the installation site and no longer needs to be moved Remove the packing material with care making sure not to damage the unit Given that various kinds of packing materials are used wood nylon polystyrene cardboard etc they should be separa
56. educing the amount of oxygen available for breathing Rapid evaporation of the liquid can cause freezing to occur a 11 IMATIZZAZIONE INTEGRATA 3 5 2 Mepku Ha R407C 15
57. ese are particularly sharp After maintenance operations have been completed the unit should al ways be closed with the relative panels which should be fixed with the relative screws Please remember that all the operations described in this chapter MUST ONLY BE CARRIED OUT BY QUALIFIED STAFF WEARING PERSONAL SAFETY EQUIP MENT 9 1 GENERAL The unit should be controlled periodically to make sure it works correctly The controls that should be made on a monthly and four monthly basis are de scribed below Furthermore if the unit is not ex pected to be used for a long period and if the room temperatures are lower than the fluid freezing point the fluid should be drained from the piping and the heat exchangers 9 1 1 Monthly controls Make sure the terminals in the electrical panel and in the compressor terminal board are well tightened Check the fixed and mobile contacts of the con tactors and replace them if they are worn 30 IMATIZZAZIONE INTEGRATA ce OT He ce OT
58. he unions It is vitally important to connect the water circuit so that the flow of water to the exchanger is always constant under all operating conditions A safety valve should be installed on the water circuit In case of serious system faults e g fire this will allow the system to be drained in order to prevent the risk of explosions Always connect the drain to a pipe with a diameter not less than that of the valve open ing and install the outlet in an area where the jet cannot cause harm to people Attention While connecting the water circuit never work with naked flames near to or inside the unit 17 IMATIZZAZIONE INTEGRATA 5 3 5 3 1
59. ioned with the coil side facing the direction where noise is less critical Prevailing winds Wind may alter operating conditions to minimise its effects the unit should be positioned with the long side parallel to the direction of prevailing winds Vibrations Although the units transmit a low level of vibrations to the ground a sheet of rigid rubber should always be placed between the unit base and the supporting surface If greater insulation is required vibration moisting supports should be used 5 2 WATER CONNECTIONS 5 2 1 General Please carefully carry out the following instructions and observe current law when installing the chilled water circuit Attention The water pipes must suitably supported with brackets in order not to weigh on the chiller Connect the pipes to the chiller with flexible joints in order to prevent the transmission of vibrations and to compensate thermal expansion Install the following components on the pipes shut off valve moisters for shutting off the water mains temperature and pressure gauges for routine main tenance and inspection purposes e check points the inlet and outlet pipes for meas uring temperatures if temperature indicators are not fitted metal filter inlet pipe with a maximum mesh ap erture of 1 mm to protect the exchanger from waste or impurities in the pipes waterflow control valve e relief valves fitted the uppermost pa
60. m For the electrical connection to the remote On off contact and remote Chiller heat pump operation do not install drive cables inside the ducts used for power cables if it is not possible a shielded cable must be used When making the connections described in paragraphs 5 3 2 5 3 3 carefully follow the indications shownin thewiringdiagram Theconnectingcables must have a minimum cross section of 1 5 19 CLINT 6 START UP CLIMATIZZAZIONE INTEGRATA 6 6 1 L 5
61. n site the following points should be considered The weight of the unit The supporting surface under the unit must be perfectly horizontal and able to withstand its operating weight Asupporting surface with an appropriate areashouldbe built Thisis particularlyimportantifthe unitis installed on unstable ground gardens embankments etc The supporting surface must lie on suitable foundations and be about 10 15 cm higher than the surrounding ground horizontal and able to withstand about 200 of the weight of the unit in operation A suitable sealed layer of cork should be placed along the perimeter Spaces Make sure that sufficient free space as in dicated on the scale drawing is left around the unit Less space will make it difficult or impossible to carry out maintenance operations and or lead to faults in the unit due to the reduction in the air flow on the condenser coil or its recirculation Please note that obstacles such as can Opies shelters or coverings in general are not permitted Please note that the heat pump units cause ice and condensation to form and drain onto the floor in front of the unit This water must therefore be collected and drained to prevent the floor from becoming slippery People may not enter the unit area unless they are authorised operators and mainte nance personnel Noise The unit generates noise while it s working do not install it in reverberating rooms
62. ndensation or frost will form The frost accumulated on the coil obstructs the air inlet thereby reducing air flow and the heat trans fer rate The heat pump units are fitted with control devices that automatically defrost the coil when ever necessary This control device features a tem perature probe placed on the coil which when the temperature is equal to or lower than the set point activates the defrost cycle function which will take place only if a certain time has elapsed since the last defrosting process Defrosting takes place as follows indications be 23 IMATIZZAZIONE INTEGRATA Taka CKO
63. nit doesn t start please consult ch 9 part 1 The power supply must switched off while the unit is stopped Power should only be switched off for prolonged pauses e g seasonal shut downs To shut down the unit for short periods please carefully follow the instructions shown in paragraph 7 6 3 CHECKS DURING UNIT OPERATION 6 3 1 General Check the unit for strange sounds or excessive vi brations Check that the above sequence is repeated regu larly leaving the compressor working for at least CLINT CLIMATIZZAZIONE INTEGRATA 10 18 4 5
64. nit installer to disconnect the unit from the power supply 3 5 DESCRIPTION OF RESIDUE RISKS The description of residue risks includes the following elements the kind of danger the people working on the unit are subjected to description of the main dangers who is exposed to such dangers the main safety methods used to reduce the risk of injury The following accident prevention instructions with reference to the relative areas concerned by residue risks must be integrated with all the general indications contained in the present chapter and with the accident prevention regulations in force in the country of installation 3 5 1 Residue risks near the unit Electrocution if the unit is not properly corrected to the mains power supply and earth circuit Cuts or abrasions caused by sharp surfaces Extraction and subsequent dispersion the envi ronment of substances present in the installation site Ejection of objects falling on the fan blades Leaking water in case of malfunction Formation of condensation and ice in front of the unit while the unit heat pumps are working Alteration of the micro climate during operation Noise during operation Leaking oil in case of malfunction Leaking refrigerant liquid in case of malfunction N B Refrigerant liquid is a substance which causes a greenhouse effect Its vapours are heavier than air and can cause suffocation by r
65. ogged Lack of refrigerant gas Compressor not performing as expected The heat load is excessive The thermostat is badly adjusted or broken The liquid filter is clogged There isn t enough refrigerant liquid Moisture in the refrigerant circuit The thermostatic expansion valve doesn t work properly There isn t enough refrigerant liquid The filter on the liquid line is clogged The water circulation pump is faulty The 4 way inversion valve is not energised The defrosting thermostat set point is incorrect or the probe is faulty The compressor is noisy The thermostatic valve is noisy There are vibrations in the piping The panels vibrate 1 After pressurising the circuit at about 10 bar check with a leak tester Repair depressurise and fill with refrigerant liquid See previous point VII Replace the filter cartridge or the filter depending on the model See point VII Inspect and replace or overhaul Reduce the heat load Check the thermostat set point and replace the thermostat if necessary Replace See point VII Empty the cooling circuit dry it replace the filter do the charge again Check clean and replace if necessary See point VII Clean or replace Inspect the pump and replace it if necessary Check valve coils Replace the inversion valve if necessary Change the set point or replace the probe if necessary Check and replace if necessary Check and add refrigerant liquid
66. on densation temperature is 18 4K higher than the temperature of the air entering the condenser depending on the size of the chiller the kind of refrigerant gas used and the room temperature and that the evaporating temperature is about 5K less than the temperature of the water leaving the evaporator Make sure that the overheating temperature of the refrigerant lies between 5 and 7K Do this by mea suring the temperature with a contact thermom eter placed on the suction pipe of the compressor and that indicated on a pressure gauge connected to the suction line as well the difference between the two gives the values of overheating Make sure that the subcooling temperature of the refrigerant fluid lies between 4 and 8K Do this by measuring the temperature with a contact ther mometer placed on the suction pipe of the com pressor and that indicated on a pressure gauge connected to the suction line as well the difference between the two gives the values of subcooling Verify during the operation the electrical absorp tion of the water pump if installed it must cor respond to the data indicated on the wiring dia gram In contrary case it means that the pump is not working in curve 6 3 2 Defrosting Only heat pump units During operation in the winter cycle heat pump the coil works as an evaporator cooling and dehu midifying the external air Depending on the temper ature and moisture of the external air co
67. ons 2 4 General description 3 SAFETY 3 1 Definition 3 2 General safety regulations 3 3 Symbols 3 3 1 Location of safety signs 3 3 2 Safety signs 3 4 Emergency and safety devices 3 5 Description of residue risks 3 5 1 Residue risks near the unit 3 5 2 Measures to take in case of leaking refrigerant gas 3 5 3 Operations with the panels removed 4 INSPECTION AND TRANSPORT 4 1 Inspection 4 2 Storage 4 3 Lifting and transport 4 4 Unpacking 5 INSTALLATION 5 1 Choosing the installation site 5 2 Water connections 5 2 1 General 5 2 2 Evaporator 5 3 Electrical connections 5 3 1 General 5 3 2 Electrical connections to the circulation pump 5 3 3 External signals 6 START UP 6 1 Preliminary controls 6 2 Start up 6 3 Checks during unit operation CLINT CLIMATIZZAZIONE INTEGRATA 6 3 1 6 3 2 6 4 7 7 1 7 2 8 9 9 1 9 1 1 9 1 2 9 1 3 9 2 9 3 10
68. raluman The structure is free standing and the panels are easy to remove in order to allow access to the inside of the unit for maintenance and repair operations The functional diagrams and the components used are attached to this manual 3 SAFETY 3 1 DEFINITION This document uses the following definitions Dangerous areas any area inside and or near to the unit in which the presence of a person would give rise to a risk for that person s health Exposed person anyone who is wholly or partly inside a dangerous area Operator Maintenance man person or persons au thorised to operate adjust service repair or move the unit IMATIZZAZIONE INTEGRATA CHA 3 2 3 2 GENERAL 9 32
69. rts of the water circuit for expelling air e expansion tank of a suitable size for the quantity of water contained in the system and the expected temperature range and an automatic inlet valve for maintaining the pressure of the system and compensating the thermal expansion of the fluid 16 CLINT CLIMATIZZAZIONE INTEGRATA 5 2 2 WATER INLET
70. rying out any operations on the unit For any further information or explanations please contact HOLDING S p A at the following address G I HOLDING 5 Customer Service Via Max Piccini 11 13 33050 RIVIGNANO UD ITALY tel 39 0432 773220 fax 39 0432 773855 e mail info clint it CLINT IMATIZZAZIONE INTEGRATA 2 HA Ha 2 1 2 1 1
71. ted and delivered to specialised disposal and recycling companies for environmental reasons CLINT CLIMATIZZAZIONE INTEGRATA 5 5 1 10 15 20090
72. temperature pressure set point has not been reached 6 4 STOPPING THE UNIT Stop the unit by pressing the OFF key placed on the microprocessor front Attention Do not stop the unit by turning off the main power switch as this would also disconnect the heating elements of the sump which would affect compressor operation after start up 24 eee IMATIZZAZIONE INTEGRATA 7 PABOTA 7 1
73. tic expansion valve doesn t work properly The refrigerant filter is clogged The metal filters of the evaporator if fitted are clogged The air flow is too low The evaporator fans do not work The evaporating coil is covered with frost The water circulation pump is faulty Fan contactor is not energised The fan thermal cut outs trip The connections are faulty The fan motor is faulty Operation only during cooling cycle Operation only during heating cycle 23 eee Give off idraulic circuit verify the right running of pumps and if valves are open Check the phase sequence check the voltage and close the contacts See point Il Check the water circulation pump and the differential water pressure switch and vent the circuit Check further external enables System on temperature no cooling demand Check adjustment and operation Check adjustment and operation See points IV or V Wait about 5 minutes See points VI Replace Close the compressor circuit breaker after identifying the reason why it cut in The compressor was working in critical conditions or there isn t enough refrigerant Check the work conditions and see point VII Check the voltage at the ends of the contactor coil and the continuity of the coil Replace if faulty Check and replace if necessary See point V Check and replace if necessary Modify
74. to the company s design and construction policy the company is able to guarantee that this product totally complies with EC safety standards A further guarantee of this is provided by the factory tests carried out on the unit The user therefore must only ensure the unit is properly used and that maintenance operations are carried out according to the indications contained in this manual The unit should not be touched until the whole of this manual has been carefully read 5 lt CLINT I HOLDING S p A G I HOLDING S p A Assistenza Clienti Max Piccini 11 13 33050 RIVIGNANO UD ITALY tel 39 0432 773220 fax 39 0432 773855 e mail info clint it A CHA This installation use and maintenance man ual must always be kept within easy reach of authorised staff who are obliged to read it before car
75. uld be removed when the unit is not working These checks are particularly dangerous and may only be carried out by highly qualified staff Proceed as follows Turn off mains power with the main power switch Open the electrical panel and remove the relative fuses to disconnect the components that do not need to be working in order to carry out the relative check Close the electrical panel Remove the panel in question Start the unit Carry out the relative check with the greatest of care and using personal protection equipment After completing the check stop the unit and put the panel back in place Turn off mains power and put back any fuses that were previously removed Close the electrical panel CLINT ees CLIMATIZZAZIONE INTEGRATA 4 4 1
76. y If a fault should occur the unit will totally or partially block and will give an alarm signal the microprocessor display will indicate which safety device was activated Before resetting the unit the reasons for the block must be identified and eliminated Some safety devices must be reset both physically and from the keyboard These operations must be carried out by specialised staff IT 15 FORBIDDEN TO TAMPER WITH SAFETY DEVICES 7 2 SEASONAL SHUT DOWN If the unit is planned to be shut down for a long time and the unit is required to be disconnected from the mains supply the minimum temperature to which the unit may be subjected must be identified It this is lower than the freezing point of the fluid contained in the exchangers these must be drained Further more in order to further drain the outstanding wa ter use the suitable little dis charge valve placed on the pipe of the wather inlet to the evaporator 25 CLINT es CLIMATI ZAZIONE INTEGRATA 8 HA IV

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