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1.2. 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 collecti
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4. CWW il 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 the unions It is vitally important to connect the water circuit so that the flow of water to the exchanger is always constant under operating conditions variable flow of water is only accepted for the desuperheaters contained in units As the demand for cooling by utilities does not generally
5. THE UNIT DOESN T START A COMPRESSOR DOESN T START THE 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 1 2 4 flow switch differential pressure switch agreement The connections are faulty or the contacts are op
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9. 12 3 5 2 Measures to take case of leaking refrigerant gas Product type R410A 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 adrenaline 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 s
10. Fj CLINT 1173 060 000 ITALY Manufactured by 0 1220 Mamaia Tension droat Atrigerart charge pro Charge de n trigerant chaque circuit Press idrato hydraulic pressure Preson mad clot hydraulik 2 UNIT DESCRIPTION This chapter contains a general description of the main unit characteristics together with those of its principal standard and optional components 2 1 IDENTIFICATION 2 1 1 Unit identification The unit can be identified through the plates a
11. 1 2 2 1 3 CWW
12. 6 START UP 6 1 PRELIMINARY CONTROLS Make sure that the electrical connections have been made correctly and that all the terminals have been well tightened Verify the deep closing of the fuses holder cover Use a tester to make sure that the voltage on terminals L L L is equal to that shown 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 Make sure that the pressure gauges when fitted show the correct pressure The pressure gauges can be fitted with shut off valves These must only be opened when necessary and closed again after inspection Us
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15. CWW il 3 4 EMERGENCY AND SAFETY DEVICES An emergency external circuit breaker must be fitted by the unit 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 preventi
16. 5 3 2 5 3 3 1 5 CWW il The pump must be started up before starting up the chiller while it must be stopped after the chiller has stopped minimum recommended 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 diagram 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 p
17. 9 1 2 9 2 9 3 Verify
18. 1 INTRODUCTION 1 1 GENERAL INFORMATION This manual contains the installation use and main tenance instructions for the CWW chillers and high lights all connected risks and perils It has been express ly prepared and written to allow authorised users to use the CWW 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 deterio rate the environment and or damage the unit The company declines all responsibility for any improper use of the unit unauthorised modifications or non compliance with the instructions contained in this manual Please keep this manual in a safe place and make it available to chiller operators and main tenance men 1 2 ATTACHMENTS The d
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22. 4 6 C 4 C 6 Power the unit and check for 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 After starting the pump make sure that the correct quan tity of water is circulating The pressure gauges if fitted in stalled upline and downline from the pump may be used to carry out this check the difference between the two pressures must be equal to the pressure drop of the sys tem including the evaporator To adjust the flow
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25. 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 10 minutes if this is not the case unit inertia must be increased After a few operating hours check that the crown of the liquid and moisture indicator shows a dry circuit A few minutes after the compressor start during the summer operating cycle make sure the condensa tion temperature is 5 7K higher than the tempera ture 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 evap orating temperature is about 5K less than the tem perature 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 t
26. 44 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 polyethilene polystyrene cardboard etc they should be separated and delivered to specialised disposal and recycling companies for environmental reasons 14 CLINT CLIMATIZZAZIONE INTEGRATA 5 5 1
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28. 3 3 CWW E 3 2 GENERAL SAFETY REGULATIONS to approach the unit It is forbidden for unauthorised persons Scrupulously observe the contents of Chapter 9 on page 28 before carrying out each maintenance operation the unit 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 Donot 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 electrici
29. 9 1 1 gt CWW il 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 it When working near the finned coils pay special attention to the aluminium fins as these 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
30. 5 290 5 3 2 18 CWW 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 The unit must be connected with a three pole cable
31. 4 8 6 4 OFF
32. 8 10 5 2 2 16 WATER INLET gt CWW E Attention The water pipes must be 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 e shut off valve moisters for shutting off the water mains e temperature and pressure gauges for routine maintenance and inspection purposes e check points on the inlet and outlet pipes for measuring temperatures if temperature indicators are not fitted e metal filter inlet pipe with a maximum mesh aperture of 1 mm to protect the exchanger from waste or impurities in the pipes e relief valves fitted in the uppermost parts of thewater
33. 15 9 1 7 22 CWW il 6 2 START UP Select the operating cycle heating or cooling For microprocessor controlled units 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 t
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35. 5 2 5 2 1 CWW 5 INSTALLATION 5 1 CHOOSING THE INSTALLATION SITE When choosing the installation 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 be 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 indicated on the technical book is left around the unit Less space will make it difficult or impossible to carry out maintenance operations People may not enter the un
36. A 7 OPERATION 7 1 GENERAL 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 continuously If a fault should occur the unit will totally or partially block and will give an alarm signal the microproces sor display will indicate which safety device was ac tivated 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 IS FORBID DEN TO TAMPER WITH SAFETY DE VICES IN SUCH A CASE WARRAN TY EXPIRES IMMEDIATELY 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 unless there are suited antifreeze kits 24 CLI IMATI ZAZIONE INTEGRATA 8
37. 5 2 6 3 1 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 val
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40. 4 2 20 50 4 3 CWW E 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 4 INSPECT
41. 6 6 1 6 2 6 3 START UP Preliminary controls Start up Checks during unit operation 6 3 1 General 6 3 2 Defrosting only heat pump units 6 4 7 1 7 2 9 9 1 Stopping the unit OPERATION General Seasonal shut down TROUBLESHOOTING ROUTINE MAINTENANCE AND CONTROLS Warnings 9 1 1 General 9 1 2 Monthly controls 9 1 3 Four monthly controls 9 2 9 3 10 Repairing the refrigerant circuit Topping up the refrigerant liquid SHUT DOWN AND DISPOSAL CLINT es CLIMATIZZAZIONE INTEGRATA 1 1 1 CWW CWW
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45. 2 2 INTENDED USE The CWW series of water condensation chillers have been designed to cool water possibly containing in hibited ethylene glycol circulating in a closed circuit The heat pump units can cool or heat the water in the closed circuit depending on which operating cy cle 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 11 4 GENERAL DESCRIPTION All the unit structures are made from steel and are further protected with polyester powder paints 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 authorised to operate adjust service repair or move the unit IMATIZZAZIONE INTEGRATA 3 2
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47. XII XIII XIV HEECTECTBEH
48. Series CWW 18 151 Manual CLM 05 ab ENGLISH INSTALLATION 5 MAINTENANCE MANUAL CLINT es CWW CLIMATIZZAZIONE INTEGRATA 0 HA Ll O 0 LIST OF ATTACHMENTS List of documents supplied with the unit and forming an integral part of this manual Technical book Ll Microprocessor manual LI Certificate of guarantee Declaration of conformity Specific electrical circuit CLINT es CWW 0 1 11 1 2 1 3 2 2 1 2 1 1 2 2 2 3
49. 2 4 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 2 5 3 3 5 0 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 Contraindications 2 4 Genera
50. 1408 115 117 0700 11 220 02 953 36 32 e mail office bgr bg cG HOLDING S p A G I HOLDING 5 Assistenza Clienti Via Max Piccini 11 13 33050 RIVIGNANO UD ITALY tel 39 0432 773220 fax 39 0432 773855 e mail info clint it A CWW il This installation use and maintenance manual must always be kept within easy reach of authorised staff who are obliged to read it before carrying out any operations on the unit For any further information or explanations please contact the company which delivered the unit or the official representative for Bulgaria BGR Group Ltd at the following address Group Ltd 1408 Sofia 115 117 Vitosha Blvd Tel 0700 11 220 Fax 02 953 36 32 e mail office begr bg or directly HOLDING S p A at the following ad dress HOLDING S p A Customer Service Via Max Piccini 11 13 33050 RIVIGNANO UD ITALY tel 39 0432 773220 fax 39 0432 773855 e mail info clint it IMATIZZAZIONE INTEGRATA 2 HA 2 1 2 1 1
51. NAHMEDES GERATS UNTER SPANNUNG SETZEN DIEKURBELWANNENHEZUNG WAHREND DER STILLSTANDSZBITEN DES GERATS NICHT AUSSCHALTEN INGRESSO ACQUA CONDENSAZIONE CHAFFEURS PENDANTS DES COURTES PERIODES DE L UNITE TELS QUE LE WEEK END USCITA ACQUA CONDENSAZIONE o L UNIT EST DE RELAIS COURT CYCLE D UN DISPOSITIF CONDENSER WATER OUTLET POUR LE REDEMARRAGE AUTOMATIQUE AVANT D OUVRIR LE GENERAL ARRETEZ L UNIT EN AGISSANT SUR LES INTERRUPTEURS DE MAACHE OU AU CAS OU IL N YA PAS SUR LE SOUPAPE DE DECHARGE COMMENDE A DISTANCE AVANT DE TOUCHER LES COMPOSANT INTERNES L UNIT COUPER LA TENSION EN OUVRANT LE SECTIONNEUR GENERAL CLINT CLIMATIZZAZIONE INTEGRATA 3 4 3 5
52. circuit for expelling air e expansion tank if not already fitted 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 e drain valve where necessary drain tank for emptying the circuit for maintenance operations or seasonal shut downs Attention A safety flow switch has to be installed if the flow switch differential water pressure switch are not already fitted along a straight section of piping at a distance from the exchanger outlet of not less than 8 10 times the diameter of the piping The guarantee will immedi ately become null and void if the above is not complied with 5 2 2 Evaporator is vitally important that the water enters the unit from the connection point marked with the WATER INLET plate i OT
53. 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 Fix the pipes with brackets Install correctly IMATIZZAZIONE INTEGRATA 9
54. of water turn the valve located downline from the pump For units fitted with two pumps both of them must be adjusted Mark the position of each valve so that if they are closed for maintenance operations they can be moved to the same place before starting up the unit again To set adequately the water flow check the water temperature rise between inlet and outlet when the units is full load working all the compressors on the temperature rise should range from 4 C to 6 C If it is less than 4 C the water flow is too high shut slightly the pump supply valve If it exceeds 6 C check the water system pressure drops 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
55. plus earth 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 The cross section of the cable and the line protections must comply with the indications shown on the wiring diagram and in the relative 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 IMATIZZAZIONE INTEGRATA Nomnata 40 5 3 3
56. ION 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 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 1 CLINT CWW E Attention Make sure the unit is securely anchored before lifting it in order to prevent it from accidentally overturning or falling 4 4 e
57. an Work onthe refrigerant circuit may only be carried out by specialised staff 3 3 SYMBOLS Check the state of the plates on a regular basis and repair them if necessary CLINT es CWW CLIMATIZZAZIONE INTEGRATA 3 3 1 Ha 3 3 1 Safety signs placement 3 3 2 3 3 2 Safety signs ATTENZIONE DARE TENSIONE RISCALDATOR DEL CARTER ALMENO 12 ORE PRIMA REFRIGERAT DELL DELL UNIT NEGLI INTERVALLI Di FUNZIONAMENTO AD ES ee INLET PAUSA DEL FINE SETTIMANA TOGLIERE L ALIMENTAZIONE ELETTRICA L UNIT MUNITA DI UN RITARDATORE ANTIRICIRCOLO DI DISPOSITIVO PER LA RIPARTENZA AUTOMATICA PRIMA DI APRIRE IL SEZIONATORE FERMARE L UNIT AGENDO SUGLI APPOSIT INTERRUTTOR Di MARCIA IN ASSENZA SUL COMANDO DISTANZA PRIMA DI ACCEDERE A PARATI INTERNE DELL UNIT TOGLIERE TENSIONE APRENDO IL SEZONATORE GENERALE WARNING SUPPLY THE CRANKCASE HEATERS AT LEAST 12 HOURS 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 PRESENT ON THE REMOTE CONTROL BEFORE SERVICING THE INNER COMPONENTS DISCONNECT ELECTRICAL SUPPLY BY OPENING THE MAIN SWATCH ACHTUNG DIEKURBELWANNENHEIZUNG MINDESTENS 12 STUNDEN VORDERINBETRIEB
58. ck 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 lt 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 clogged 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
59. coincide with what is delivered by the compressors they often work intermittently In units with a low water content where the effect of thermal inertia is not felt so much the system should be checked to make sure it satisfies the following relation gt 45 where V volume of water litres P power capacity of the unit Watts n number of capacity steps If the above volumes are not obtained a storage tank should be installed so as to satisfy the above relation when added to the capacity of the system This tank requires no special features it just needs to be isolated just like the chilled water pipes so as not to affect the performance of the system and to prevent the formation of condensation 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
60. e 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 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 dispatched with the relief valves and drains open Special plates show where they are located They must be closed during installation before the water circuit is filled In the models with built in hydraulic kit the pump water drain plug has been removed for discarge of the water therein and to prevent freezing during winter season The plug is included into the enve lope containing the documentation of the unit Make sure the water circuit has been well vented 20 CLINT ess CWW CLIMATIZZAZIONE INTEGRATA
61. en The 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 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 There s not enough refrigerant liquid The pressure switch doesn t work The end of defrosting pressure switch doesn t work There s 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 There s air in the water circuit The circulation pump is faulty The pressure switch doesn t work The unit is completely empty The thermostatic 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
62. is faulty Operation only during cooling cycle Operation only during heating cycle 27 NaS Sy Nr 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 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 them by referring to the information shown on the microprocessor programme See point VII Check and replace 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 Che
63. it area unless they are authorised operators and maintenance personnel Noise The unit generates noise while it s working do not install it in reverberating rooms Vibrations Although the units transmit a low level of vibra tions 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 SSS SSS 5
64. l 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 flow switch differential water pressure switch 5 3 3 Electrical connections to the circulation pump 5 3 4 External signals CLINT es CWW 6 6 1 6 2 6 3 6 3 1 6 3 2 6 4 7 7 1 7 2 9 9 1 9 1 1 9 1 2 9 1 3 9 2 9 3 10
65. o units with heat pumps working in the heating cycle mode First start the pump and if the temperature of the returning water is high low enough the compressors and fans will start up automatically after about a minute When the temperature of the water returning from the unit decreases increases the compressor will step down capacity or stop in sequence The fans will stop together with the last compressor while the water circulation pump will remain operating When the temperature of the water returning from the unit increases decreases the compressors will start up in sequence as well as all the fans N B not all the fans may start up in the units fitted with condensation control devices that started when the external air temperature was lower than 15 C If the unit 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 CLINT es CWW CLIMATIZZAZIONE INTEGRATA 6 3 6 3 1
66. ocuments shown on page 2 form an integral part of this manual 1 3 WARNINGS The CWW units have been designed and built to en sure long term operating reliability and maximum safety for this reason and thanks 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 CLINT
67. on 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
68. on 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 in the envi ronment of substances present in the installation site 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 The sound pressure levels of each unit are carried in technical manual 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 reducing the amount of oxygen available for breathing Rapid evaporation of the liquid can cause freezing to occur CLINT es CWW CLIMATIZZAZIONE INTEGRATA 3 5 2 Ha R410A
69. ossible a shielded cable must be used When making the connections described in paragraphs 5 3 2 and 5 3 3 carefully follow the indications shown thewiringdiagram Theconnectingcables must have a minimum cross section of 1 5 mm CLINT CWW CLIMATIZZAZIONE INTEGRATA 6 6 1 L L 4596
70. 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 expect ed to be used for a long period and if the room tem peratures are lower than the fluid freezing point the fluid should be drained from the piping and the heat exchangers unless there are suited antifreeze kits 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 contactors and replace them if they are worn IMATIZZAZIONE INTEGRATA
71. taff to safety areas Make sure the area is suitably ventilated Use personal protection equipment Environmental precautions The gas evaporates Cleaning methods The gas evaporates 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 etc cold compressor suction separator etc sharp coil fins or moving fans even when the unit is not working These operations may only be carried out by qualified staff wearing safety clothing Operating checks may require the unit to work totally or partially while a panel is open In this case the panel should be removed when the unit is not IMATIZZAZIONE INTEGRATA
72. the deep closing of the fuses holder cover Inspect the liquid and moisture indicator to make sure the right quantity of refrigerant is contained in the circuit Make sure that no oil is leaking from the compres sor Make sure that no water is leaking from the water circuit Drain the water circuit Make sure the flow switch water differential pres sure 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 noises Make sure the possible antifreeze kit works cor rectly 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 IMATIZZAZIONE INTEGRATA 10
73. ttached 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 xe CLINT GUL HOLDING Piccini 1153 33050 CUD ITALY Tel 0430 23 0432 773855 Emak info cint tt Wen wenw cfint tt Manufactured by EVITA 40 02 1220 DIRETTIVA 97 del 29 maggio 1997 0 cat IMATIZZAZIONE INTEGRATA 2 2 CWW 2 3
74. ue must be equal to the value of the freezing temperature of the fluid plus 6 K 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
75. wo gives the value 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 value 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 4 STOPPING THE UNIT Stop the unit by pressing the OFF key placed on the microprocessor front Attention Do not stop the unit by turn ing off the main power switch as this would also disconnect the heating el ements of the sump and the possible antifreeze kits which would affect com pressor operation after start up 23 IMATIZZAZIONE INTEGRATA 7 PABOTA 7 1
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