series frigo frigo screw

Transcription

LIQUID CHILLER
SERIES
FRIGO
FRIGO SCREW
GB
Installation, use and maintenance manual
Manual code:
414019
Issue.Revision:
Serial number:
-1-
I_FRG_1105_1.0_GB
1.0
2
RC GROUP Spa I_FRG_1105_1.0_GB
-2-
INDEX
Chapter1 GENERAL INFORMATION AND SAFETY
1.1
OBJECTIVE OF THIS MANUAL .................................................................................. 5
1.2
GLOSSARY AND TERMS.............................................................................................. 6
1.3
MANUFACTURER AND MACHINE IDENTIFICATION ...................................... 8
1.4
INTERPRETATION OF THE MODEL’S CODE ........................................................ 9
1.5
REQUESTS FOR ASSISTANCE ................................................................................... 9
1.6
ENCLOSED DOCUMENTATION ..............................................................................10
1.7
SAFETY REGULATIONS..............................................................................................10
Chapter 2 TECHNICAL INFORMATION
2.1
GENERAL DESCRIPTION OF THE MACHINE....................................................13
2.2
DESCRIPTION OF THE MAIN COMPONENTS..................................................14
2.3
OPTIONALS DESCRIPTION.......................................................................................18
2.4
SAFETY DEVICES ..........................................................................................................18
2.5
TECHNICAL DATA ........................................................................................................19
Chapter 3 HANDLING AND TRANSPORTATION
INFORMATION
3.1
TRANSPORTATION......................................................................................................21
3.2
PACKING AND UNPACKING...................................................................................21
3.3
HANDLING AND LIFTING..........................................................................................22
Chapter 4 INSTALLATION AND TESTING
INFORMATION
4.1
SAFETY FOR INSTALLATION AND TESTING....................................................25
4.2
INSTALLATION AREA..................................................................................................25
4.3
DIMENSIONS OF THE PERIMETRICAL AREA ..................................................25
4.4
PRESETTING THE CONNECTIONS........................................................................26
4.5
INSTALLING THE MACHINE ....................................................................................27
4.6
HYDRAULIC CONNECTION TO THE EVAPORATOR......................................27
4.7
HYDRAULIC CONNECTION TO THE WATER COOLED
CONDENSER (W.NRM VERSIONS)......................................................................29
4.8
COOLING CONNECTION TO THE REMOTE AIR COOLED
CONDENSER (A.NRM VERSIONS)........................................................................31
4.9
HYDRAULIC CONNECTION TO THE RECLAIM
EXCHANGER (OPTIONAL).........................................................................................32
4.10 CLEANING AND FILLING THE HYDRAULIC CIRCUITS ................................33
4.11 ELECTRICAL CONNECTION......................................................................................34
4.12 PRE-COMMISSIONING PROCEDURES................................................................35
4.13 COMMISSIONING PROCEDURES..........................................................................36
Chapter 5 CALIBRATION AND TUNE-UP
INFORMATION
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5.1
CALIBRATION AND TUNE-UP PROCEDURES .................................................37
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INDEX
Chapter 6 INFORMATION FOR USE
6.1
RECOMMENDATIONS FOR USE............................................................................39
6.2
CONTROLS DESCRIPTION........................................................................................39
6.3
DESCRIPTION OF THE DISPLAY AND THE
MICROPROCESSOR’S KEYBOARD .......................................................................41
6.4
DESCRIPTION OF THE MICROPROCESSOR’S FUNCTIONS ......................43
6.5
SETTING THE CHILLED WATER TEMPERATURE (SET-POINT) ...............43
6.6
.DESCRIPTION OF THE ALARM SIGNALS .........................................................44
6.7
DISPLAY OF THE HOURS OF OPERATION ........................................................45
6.8
NORMAL START-UP....................................................................................................46
6.9
NORMAL STOP..............................................................................................................47
6.10 PROLONGED SHUTDOWNS OF THE MACHINE ............................................48
6.11 START-UP AFTER A PROLONGED SHUTDOWN ...........................................48
Chapter 7 MAINTENANCE INFORMATION
7.1
MAINTENANCE INFORMATION.............................................................................49
7.2
SCHEDULED MAINTENANCE .................................................................................49
7.3
TABLE OF GENERAL MAINTENANCE JOBS ....................................................50
7.4
TABLE OF MAINTENANCE JOBS ON COMPRESSORS...............................51
7.5
CHECKING OF THE PRESSURE VESSELS..........................................................53
7.6
CLEANING OF THE CONDENSING COILS ..........................................................53
7.7
CHECKING OF THE WATER FLOW AND CLEANING
OF EXCHANGERS .........................................................................................................53
7.8
CHECKING OF DRIVE BELTS ...................................................................................54
7.9
EXTRAORDINARY MAINTENANCE ......................................................................54
Chapter 8 TROUBLESHOOTING
8.1
FAULT-FINDING .............................................................................................................55
Chapter 9 REPLACEMENT INFORMATION
9.1
PARTS REPLACEMENT .............................................................................................59
9.2
MACHINE DISMISSION ..............................................................................................59
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INDEX ................................................................................................................................. 61
© 2001 Diritti riservati. Redazione testi, illustrazioni ed impaginazione a cura di IDM esperti in comunicazione tecnica - FO - con l’approvazione del Costruttore.
I testi potranno essere riutilizzati, integralmente o parzialmente, purchè venga citata la fonte.
È vietata la riproduzione, anche parziale, di questo documento senza il consenso del Costruttore. Egli è impegnato in una politica di continuo miglioramento e si riserva il diritto di modificare questa documentazione senza l’obbligo di preavviso purché ciò non costituisca rischi
per la sicurezza.
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Chapter1
GENERAL INFORMATION AND SAFETY
1.1 OBJECTIVE OF THIS MANUAL
This manual, which is an integral part of the machine(1), has been
prepared by the manufacturer in order to provide the information necessary to all persons authorized to interact with the machine during its useful life: the Purchasers, Plant Designers,
Carriers, Handlers, Installers, expert Operators, specialized Engineers and Users.
Apart from adopting a good usage technique, the persons who
receive this information must read it carefully and must implement it strictly.
The time devoted to the reading of this information will allow you
to avoid any health and safety hazard, as well as any financial
damage.
This information has been written by the manufacturer in its original language (Italian) and may be translated into other languages
in order to meet any legislative and/or business requirements.
Even though this information does not fit the machine perfectly,
this does not prejudice its function.
Keep this manual in a well-known, easily accessible place, so that
it will be always available for future reference, when necessary.
The manufacturer reserves the right to modify the product without prior notice.
In order to highlight the most important sections of this text, several symbols have been adopted whose meaning is described below.
Danger – For your safety
Indicates an imminently hazardous situation that, if not
avoided, will result in death or serious injury.
Warning - Caution
Indicates that any unsafe practices must be avoided
which could prejudice health and safety and cause financial damage.
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Important
Indicates any important technical information that must
not be neglected.
(1) this term is used for the sake of simplicity, as defined in Directive EC/98/37
(chapter 1 §2).
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Chapter1
1.2 GLOSSARY AND TERMS
Several terms that recur throughout this manual are described
below, so as to provide a more complete explanation of their
meaning.
Purchaser: he is responsible for any purchase and must supervise the organization and assignment of tasks, ensuring compliance with any and all applicable laws.
Enthalpy: a function that can be defined as the sum of the internal energy plus the product of the pressure multiplied by the fluid’s volume.
Installer: a competent skilled person duly authorized and responsible for the setting-up of the machine/plant, according to
project specifications and the manufacturer’s directions and in
conformity with the applicable industrial safety laws.
Ordinary maintenance: all the jobs necessary for maintaining the
machine in perfect working order. These jobs are scheduled by
the manufacturer, who sets out the necessary core competences and procedures.
Extraordinary maintenance: all the jobs necessary for maintaining the machine in perfect working order. These jobs cannot be
predicted, are not scheduled by he manufacturer and must be
carried out by a specialized Engineer only.
Handlers: they arrange the machine properly and affix all the necessary markings for safe and correct handling. On receipt of the
machine, they ensure handling to the installation point, according
to the instructions affixed on it. All these operators must have adequate skills and must comply with the instructions provided for
their safety and for the safety of the people who could interact
with these jobs.
Expert operator: a person appointed and authorized by the User
or the Purchaser to proceed with the use of the machine and the
relevant ordinary maintenance jobs, according to the manufacturer’s instructions. In case of failures not covered by this manual, he must request the intervention of a skilled Engineer.
Designer: a competent skilled person appointed and authorized
to prepare a project that must take into account all the legislative, regulatory, and workmanlike performance principles applicable to the plant as a whole. In any case, apart from conforming to
the manufacturer’s instructions, he must take into account all
safety-related matters for the people who must interact with
the machine during its expected useful life.
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Skilled engineer: a person appointed and/or authorized by the
manufacturer and/or its agent to carry out any jobs on the machine requiring a specific technical expertise and particular skills.
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Chapter1
Carriers: those who deliver the machine using suitable means of
transportation. They must load and position the machine properly, so as to prevent any sudden displacement during the transportation. When any loading/unloading means are used, these must
conform to the markings affixed on the machine to ensure their
safety and for the safety of all the people who could interact with
these operations.
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User: a person authorized to control the use of the machine according to the "instructions for use" and the industrial safety laws
in force.
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Chapter1
1.3 MANUFACTURER AND MACHINE
IDENTIFICATION
This identification plate is attached directly to the machine and contains all the references and information essential for safe operation.
Manufacturer’s logo
Manufacturer’s address
Machine series
Production division’s address
Model code: Consisting of an alphanumeric
code that represents particular technical
specifications, (see paragraph 1.4)
Maximum absorption
current
Machine’s serial number
Nominal air flow of the
treatment fan
Supply voltage
Nominal air flow of the
condenser’s fan
No. of compressors
Refrigerant type
and weight
Delta T ( T) of condenser water
Net weight
Condenser water flow
Description of the installed optionals
Delta T ( T) of chilled water
Nominal heating capacity
Chilled water flow
Nominal cooling capacity
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Manufacturer’s specifications
Bar code
IDM-41401800100.tif
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Chapter1
1.4 INTERPRETATION OF THE MODEL’S CODE
The model’s alphanumeric code, specified in the identification plate,
represents particular technical specifications indicated in the figure.
MODEL CODE – AN EXAMPLE
W
NRM
86
Z
2
G2 X
Condensing type
A = Air cooled
W = Water cooled
Version
NRM = Standard version
FHR = Version with total heat reclaim
Machine's capacity (kW)
Type of compressor(s)
E = "Reciprocating hermetic"
R = "Rotative hermetic"
Z = "Scroll hermetic"
F = “Reciprocating semi-hermetic”
S = “Reciprocating semi-hermetic AMP”
V = “Screw”
No. of compressor(s)
Cabinet size
Special definitions
1.5 REQUESTS FOR ASSISTANCE
For any requirement, please contact an authorized center. For
any request for technical assistance regarding the machine,
please indicate the data specified on the identification plate, in
particular its serial number, the access conditions and the perimetrical area of installation.
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Indicate also the approximate hours of use and the type of defect
identified.
In case of alarm, indicate the relevant number and the signaled
message (see § 8.1).
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Chapter1
1.6 ENCLOSED DOCUMENTATION
The following documentation is delivered to the customer together with the machine:
– Maintenance handbook: includes the list of scheduled maintenance operations. It is preset to record all the jobs effected, including the extraordinary maintenance jobs.
– Assembly instructions for vibration dampening supports
(optional): describes the procedures for installing them on the
machine.
– Electrical system’s diagram: specific for this machine. It is
used by the operators working on the electrical system, in order to identify the various components and connections.
– Recommended spare parts list: indicates the spare parts
that should be always available.
– Dimensional lay-out: indicates the dimensions of the machine.
– CE Conformity Declaration: the machines are in compliance
with CE98/37, CE89/336, CE73/23, CE97/23norms and
subsequent modifications.
– Test Declaration: the machine passed the test with positive
result.
1.7 SAFETY REGULATIONS
During the design and production stages, the manufacturer has
paid close attention to all possible sources of safety and health
hazard to the people who interact with the machine. Apart from
complying with the applicable laws, the manufacturer has adopted all the applicable “workmanlike performance rules”. The aim of
this information is to make users aware of the attention necessary for preventing any hazard. Caution is however mandatory.
Safety is also in the hands of all operators interacting with the
machine.
Read the instructions included in the manual and those affixed directly to the machine carefully; in particular, conform to safety instructions. The time devoted to reading will prevent any nasty
accident; it’s always too late to remind of what should have been
done when an event has already occurred.
The installation of this machine within a plant requires a global
project that takes into account all “workmanlike performance” requirements, as well as legislative and regulatory principles. Special care must be devoted to all the technological instructions and
information indicated by the manufacturer.
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Do not tamper with, remove, or bypass the safety devices installed on the machine. Failure to meet this requirement will result in serious safety and health hazard to people.
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Chapter1
The personnel that carries out any type of job during the life of the
machine must be adequately qualified and skilled from a technical
standpoint and must have gained experience in this specific sector. The lack of these requirements could prejudice the health
and safety of people.
During the maintenance stage, wear only the clothing and/or
personal protective equipment indicated in the instructions for
use provided by the manufacturer.
During the normal use or for any job on the machine, keep the
perimetrical space in adequate conditions, so as to prevent any
safety and health hazard to people.
Some stages may require the help of one or more assistants. In
these cases, we recommend that you train and inform them
properly on the type of activity to be carried out, so as to prevent
any safety and health hazard to people.
Handle the machine according to the information provided directly on the packaging and in the instructions for use delivered by the
manufacturer.
During handling, if necessary, seek the help of one or more assistants in order to receive adequate signals.
The personnel that loads, unloads and handles the machine must
be adequately qualified, skilled, and experienced in this specific
sector and must be in command of the lifting equipment to be
used.
During the installation stage, respect the perimetrical space indicated by the manufacturer, considering also any other surrounding activity. This requirement must be met also according to the
applicable industrial safety laws.
The installation and connections must be carried out, as regards
the machine, according to the manufacturer’s instructions. The
person responsible for these operations must take into account
also all the applicable regulatory and legislative requirements, ensuring the workmanlike execution of the installation and connection jobs. Once the installation is completed and before starting
the machine, he must make sure, through a general check, that
these requirements have been met.
If the machine is to be transferred using any means of transportation, check that these are fit for their intended use and load/
unload the machine in such a way that there is no hazard to the
operator and the people directly involved.
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Before moving the machine using the said means of transportation, make sure that the machine and its components are anchored to such means firmly and that their profile does not
exceed the maximum fixed volume.
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Chapter1
The operator, apart from being well—informed about the use of
the machine, must be properly qualified and experienced, based
on the type of job to be effected.
Use the machine only for the purposes recommended by the
manufacturer. Using the machine for any improper job may result in serious safety and health hazard and financial damage.
The machine has been designed and manufactured in such a way
that it can satisfy all the working conditions indicated by the manufacturer. Tampering with any device in order to obtain any different performance may result in safety and health hazard and
financial damage.
Do not use the machine if the safety devices have not been perfectly installed and are not effective. Failure to meet this requirement may result in serious safety and health hazard.
Keep the machine in perfect working order, carrying out the
scheduled maintenance jobs recommended by the manufacturer. Proper maintenance will ensure better performance, longer
life, and the constant maintenance of safety requirements.
Before carrying out any regulation and maintenance job on the
machine, activate all the safety devices provided and consider
whether the personnel involved and the operators nearby must
be informed properly or not. In particular, carefully indicate the
neighboring areas and prevent the access to all devices that, if
activated, are likely to cause unpredictable dangers, causing
damage to people’s safety and health.
The regulation and maintenance jobs must be effected by authorized operators, who must arrange all the necessary safety conditions, according to the procedures indicated by the
manufacturer.
All maintenance jobs that require any specific technical skill or expertise must be carries out only by qualified personnel, adequately experienced in the relevant sector of intervention.
To carry out any maintenance jobs in areas that are difficult of access or dangerous, ensure proper safety conditions for yourself
and for other people, according to the applicable industrial safety
laws.
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Replace any worn components with original spare parts only. Use
the oils and greases recommended by the manufacturer, so as to
ensure the machine performance and the expected safety level.
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Chapter 2
TECHNICAL INFORMATION
2.1 GENERAL DESCRIPTION OF THE
MACHINE
The machines of this series are designed and manufactured for
being used in air-conditioning and industrial cooling plants. The
machine must be installed inside the room or however protected
by weathering.
The machines are equipped with a microprocessor control, that
allows the monitoring of all functions and the communication with
external supervision systems.
The machines are fully factory-assembled, provided with a refrigerant charge and control equipment, so as to reduce installation
time and costs. As a general rule, the installation simply requires
cooling (A.NRM version), hydraulic and electrical connections.
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In order to ensure top performance and safety for people, the
product and the environment, before proceeding with the installation, prepare a complete project of the plant which the machine
will belong to, analyzing all the critical points predicted or predictable during its life, from installation to dismission.
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Chapter 2
2.2 DESCRIPTION OF THE MAIN
COMPONENTS
Water cooled machine
The machines are basically made up of a heat exchange section
and one or more compressors for refrigerant, with the relevant
water condensing sections. They work cooling pure water or mixtures of water and ethylene or propylene glycol (without exceeding 40% of the weight).
The primary water circuit conveys the vector fluid to the heat exchange section, where the chilling effect is obtained through a vapour-compression thermodynamic cycle with compressor(s).
The heat, subtracted in the evaporator from the vector fluid to be
chilled, is transferred to the built-in condenser and given by this
to the water.
An expansion valve controls the refrigerant flow.
condenser
HIGH-PRESSURE
REFRIGERANT
LOW-PRESSURE
REFRIGERANT
expansion
valve
compressor (s)
evaporator
IDM-41401500100.tif
414019
– from point
– from point
liquid phase
– from point
– from point
pour phase
to point
to point
the refrigerant is in the vapour phase
the refrigerant is reduced from its vapour phase to its
to point
to point
the refrigerant is in the liquid phase
the refrigerant is reduced from its liquid phase to its va-
Air cooled machine (remote air cooled condenser)
The machines are basically made up of a heat exchange section
and one or more compressors for refrigerant, with the relevant
air condensing sections. They work cooling pure water or mixtures of water and ethylene or propylene glycol (without exceeding 40% of the weight).
The primary water circuit conveys the vector fluid to the heat exchange section, where the chilling effect is obtained through a vapour-compression thermodynamic cycle with compressor(s).
- 14 -
Chapter 2
The heat, subtracted in the evaporator from the vector fluid to be
chilled, is transferred to the condenser (remote finned coil) and
given by this to the air.
An expansion valve controls the refrigerant flow.
condenser
fan (s)
condenser
HIGH-PRESSURE
REFRIGERANT
CONDENSER
outdoor section
LOW-PRESSURE
REFRIGERANT
CONDENSERLESS
UNIT indoor section
expansion
valve
compressor (s)
evaporator
IDM-41401500200.tif
– from point
– from point
liquid phase
– from point
– from point
pour phase
to point
to point
the refrigerant is in the vapour phase
the refrigerant is reduced from its vapour phase to its
to point
to point
the refrigerant is in the liquid phase
the refrigerant is reduced from its liquid phase to its va-
PRESSURE
The graph shows the variations in the refrigerant’ pressure and
enthalpy during the entire thermodynamic cycle.
3-4
de-superheating
5-6
cooling
4-5
condensation
6-61 leaks
along the line
61-7
expansion
7-8 evaporation
8-9 overheating
2-3 leaks along the
outlet line
1-2 compression
9-1 leaks along the
suction line
ENTHALPY
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IDM-4140020030.tif
- 15 -
Chapter 2
These pictures show the main components, for the various series and cabinets.
FRIGO “G” SERIES (with hermetic compressors)
condenser
(contained in the compressors compartment, rear the
electric board)
electric
board
evaporator
(contained in the compressors compartment, rear the
electric board)
compressors
IDM-41401900100.tif
FRIGO “G” SERIES (with semihermetic compressors)
compressors
electric
board
evaporator
condenser
IDM-41401900200.tif
FRIGO “S“ SERIES (with semihermetic compressors)
compressors
electric
board
evaporator
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condenser
IDM-41401900300.tif
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Chapter 2
FRIGO “SCREW” SERIES (with screw compressors)
compressors
electric
board
evaporator
condenser
IDM-41401900400.tif
“TEAM MATE” SERIES – REMOTE AIR COOLED CONDENSER WITH AXIAL FANS (ONLY FOR A.NTM MACHINES)
condenser (installed
rear the fan)
fan/s
IDM-41401204700.tif
“TEAM MATE” SERIES – REMOTE AIR COOLED CONDENSER WITH CENTRIFUGAL FANS (ONLY FOR A.NTM MACHINES)
fan/s
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condenser (installed
rear the fan)
IDM-41401204800.tif
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Chapter 2
2.3 OPTIONALS DESCRIPTION
Because any specific requirements can be identified from the design stage, the manufacturer is ready to make the following optionals available:
– Vibration-damping supports: to eliminate vibrations.
– Refrigerant/water exchanger for partial heat reclaim: see
the diagram and operation descriptions.
– Water regulating valve (W.NRM version): for condensing
control.
Refrigerant/water exchanger for partial heat reclaim (de-superheater): recovers the heat from the refrigerant overheating.
refrigerant/water exchanger
for partial heat reclaim
stop valve
IDM-41401500400.tif
2.4 SAFETY DEVICES
During the design and production stage, the manufacturer has installed safety devices (active or passive) conforming to the laws and
regulations in force in the country where the machine will be used.
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The various types of devices that can be installed
are described below.
– Emergency push-button: stops the machine in
an emergency.
IDM-4140020090.tif
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Chapter 2
Safety valves: installed on the machine as indicated in the diagram.
condenser
safety valve
(always installed)
compressor(s)
safety valve
(installed is required by
applicable standards)
expansion valve
evaporator
IDM-4140020100.tif
2.5 TECHNICAL DATA
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The machine’s technical data are described in the enclosed documentation (“Data Sheet” and “Dimensional Lay-out”).
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Chapter 2
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PAGE LEFT INTENTIONALLY BLANK
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Chapter 3
HANDLING AND TRANSPORTATION INFORMATION
3.1 TRANSPORTATION
The means of transportation used for the machine, apart from
normal requirements, must be compatible with the loading systems adopted in the production factory and at the unloading site.
When using road transport means, the body must be open and
of the drop-side type. Loading from the top must be possible for
machines longer than 5 m.
Important
For any further information, please contact the manufacturer’s Shipping Department.
3.2 PACKING AND UNPACKING
The machine can be transported with different types of packing,
according to its predetermined destination, transport procedures and technical/commercial specifications.
Warning - Caution
If the machine must be shipped without a commercial
container, it is necessary to provide special packaging to
ensure that it remains intact.
Unpack the machine on receipt to check whether it is intact and
conforming to the order.
Important
In case of any damage or if some parts are missing, contact the manufacturer’s Sales Department to agree the
procedures to be adopted.
If the machine is not installed on receipt and is stored for a long
time, store it in a protected place, at temperatures ranging between –10° and + 45°.
Warning - Caution
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If the place where the machine is stored is too hot, the
refrigerant’ pressure is likely to rise too much, causing
the activation of the safety valves.
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Chapter 3
3.3 HANDLING AND LIFTING
Lifting and handling operations must be carried out with
suitable means by qualified trained personnel, authorized to perform this type of maneuvers.
Unit should be lifted through forklifts.
Use bands or ropes for the lifting, be sure not to overstrain the
upper sides of the unit or package.
Handle the unit with care, avoiding overstrain on machine components.
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To avoid machine damages during handling, machines must always remain in the position planned for operation.
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Chapter 3
lifting bar
lifting bar
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lifting bar
IDM-41401900500.tif
- 23 -
Chapter 3
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- 24 -
Chapter 4
INSTALLATION AND TESTING INFORMATION
4.1 SAFETY FOR INSTALLATION AND
TESTING
All the installation stages must be an integral part of the general
project. Before starting these stages, the person authorized to
carry out these operations, apart from identifying the technical
requirements, must implement a “safety plan”, if necessary, to
protect the personal safety of the directly involved people and
must strictly implement the safety regulations, in particular any
laws on mobile yards.
4.2 INSTALLATION AREA
During the design stage, the area were the machine is to be installed must be identified, taking into account a series of requirements, in particular:
– the area must be perfectly flat and must ensure stability over
time
– if installed on the floor of a building, this must be of adequate
capacity
– its position must not disturb the peace
– it must be easily accessible to all people who must interact with
it during its expected useful life
– all maintenance and replacement jobs (either ordinary or extraordinary) must be carried out easily and without any hazard
to people, according to the applicable industrial safety laws.
– the volumetric spaces must be adequate to ensure the air inflow necessary for the machine’s proper operation and ventilation, in particular to condensing coils (for A.NRM version)
– if the passage of people and vehicles near the machine is expected, install a suitable fence conforming to any applicable
standard, leaving the minimum space allowed for all jobs on the
machine
4.3 DIMENSIONS OF THE PERIMETRICAL
AREA
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This area must be designed according to the model, the number
of units and the characteristics of the installation site.
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Chapter 4
4.4 PRESETTING THE CONNECTIONS
Before installing the machine, make sure that the electrical connection conforms to the design specifications and the data reported in the identification plate.
Warning - Caution
The power line must be provided with a main switch, so
that the machine can be insulated from the power
source.
Regarding cooling connections, (A.NRM version) these must conform to the project specifications.
Regarding design connections, these must conform to the
project specifications, so as to ensure:
– a constant flow to the evaporator;
– that the variations in the inlet temperature of the evaporator,
condenser (for W.NRM version) and heat reclaim exchanger
(optional) are compatible with the activation time of the machine’s regulation and safety systems;
– that the amount of water in the plant can allow minimum working times for compressor.
Warning - Caution
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The water pressure inside the evaporator and the reclaim exchanger (optional) cannot exceed 10 bar, including the hydrostatic head.
Therefore, the maximum inlet pressure may not exceed
Pmax=10 bar - Pbi
Pmax=maximum allowable inlet pressure (bar)
Pbi=hydrostatic head pressure (bar)
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Chapter 4
4.5 INSTALLING THE MACHINE
Important
Before positioning the machine, while it is still lifted, fit the
vibration dampening supports, if any, in the relevant seats.
To do so, follow the scheme included in the ”Assembly instructions for vibration dampening supports”.
If the assembly of vibration dampening supports is not contemplated, we recommend that you install a rubber or cork sheet between the base and the supporting surface, covering the entire
supporting surface.
Once the machine has been positioned, check leveling in the four
positions indicated in the figure.
level
IDM-41401900600.tif
4.6 HYDRAULIC CONNECTION TO THE
EVAPORATOR
The inlet and outlet connection must be carried out as specified
during the design stage.
The water inlet/outlet pipes are
identified by the plates directly affixed to the machine (see figure).
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IDM-4140020130.tif
- 27 -
Chapter 4
Thermometer
Air vent
Pressure gauge
Pipe’s draining valve
Anti-vibration connection
Gauze filter
Shutoff
valve
Evaporator
Pressure gauge
Shutoff
valve
Flow switch
Water flow meter
Calibration valve
Anti-vibration connection
Thermometer
Air vent
IDM-4140020140.tif
414019
During the design stage, the installation of the following components in the water supply line must be contemplated.
– Shutoff valve: for the hydraulic insulation of the evaporator
from the plant during maintenance.
– Vibration damper: for dampening the vibrations that are likely
to break the connection.
– Pressure gauge (with stop cock): indicates the water pressure
in the inlet line.
– Thermometer: indicates the water temperature in the inlet
line.
– Air vent: removes the air from the inlet line.
– Pipe’s draining valve: drains the water from the plant. To be
used also for connecting an external pump for the chemical
wash.
– Gauze filter: separates the impurities from the water.
- 28 -
Chapter 4
Install the following components in the water discharge line.
– Flow switch (optional, but recommended): indicates the presence of flow in the plant. It is installed in series to the other
safety equipment. Supplied by the manufacturer as an accessory.
– Water flow meter (optional, but recommended): measures
the water flow in the plant. Supplied by the manufacturer as an
accessory.
– Pipe’s draining valve: drains the water from the plant. To be used
also for connecting an external pump for the chemical wash.
– Air vent: removes the air from the outlet line.
– Thermometer: indicates the water temperature in the outlet
line.
– Pressure gauge (with stop cock): indicates the water pressure
in the outlet line.
– Vibration damper: for dampening the vibrations that are likely
to break the connection.
– Calibration valve: calibrates the water flow and can replace
the shutoff valve, if perfectly watertight.
Install an expansion tanks wit safety valve in the evaporator’s circuit. Its size must be designed and implemented according to the
applicable laws.
A connection is provided below the evaporator’s outlet end, that
can be connected to an outlet equipped with a cock for draining
the water.
WATER COOLED CONDENSER (W.NRM
VERSIONS)
The inlet and outlet connection must be carried out as specified
during the design stage.
The water inlet/outlet pipes are
414019
IDM-41401201900.tif
- 29 -
Chapter 4
Shutoff
valve
Air vent
Water
regulating valve
condenser
Air vent
Shutoff
valve
Gauze filter
IDM-41401500700.tif
– Shutoff valve: for the hydraulic insulation of the exchanger
wash.
– Water regulating valve: pressure regulated system for the
control of the condensing temperature. Supplied by the manufacturer as an accessory.
wash.
Install an expansion tanks with safety valve in the hydraulic circuit.
414019
Its size must be designed and implemented according to the applicable laws.
- 30 -
Chapter 4
4.8 COOLING CONNECTION TO THE REMOTE
AIR COOLED CONDENSER (A.NRM
VERSIONS)
The connection to remote air cooled
condenser must be carried out as
specified during the design stage. Inlet and outlet refrigerant pipes are
identified by the plates directly affixed
to the machine (see figure).
Machines are fitted with refrigerant
charge only for the indoor unit. It is
necessary to provide the refrigerant
charge for the pipes and the remote
air cooled condenser.
IDM-41401202800.tif
Warning - Caution
The project and the performance of the refrigeration connection must be made by qualified personnel in order to
guarantee the unit optimal operation. Mistakes in the design and/or in the performance of the refrigeration connection may cause either unrecoverable damages to the
compressor or unit malfunctions. These instructions are
aimed to supply elements to verify the correct installation.
Act as follows:
– Pressurize refrigerant pipes and make sure that the circuits
are not leaking (checking with leak detector or soapwort).
– Open valves on remote condenser and vacuum cooling pipes
up to 270 Pa absolute pressure.
– Stop vacuum pump and after 3 hours check vacuum keeping.
– Open valves on indoor machine.
– Charge refrigerant in the suitable quantity and lubricant oil in
10% ratio of charged refrigerant.
414019
Lubricant oil must be the same type as the charged one
as shown on the compressor plate.
- 31 -
Chapter 4
RECLAIM EXCHANGER (OPTIONAL)
The inlet and outlet connection
must be carried out in the manner
set out during the design stage.
The water supply/outlet pipes are
IDM-4140020150.tif
Shutoff
valve
Air vent
Reclaim
exchanger
Air vent
Gauze filter
Shutoff
valve
IDM-41401202000.tif
414019
– Shutoff valve: for the hydraulic insulation of the exchanger
wash.
- 32 -
Chapter 4
wash.
Install an expansion tanks with safety valve in the hydraulic circuit.
Its size must be designed and implemented according to the applicable laws.
4.10 CLEANING AND FILLING THE HYDRAULIC
CIRCUITS
Before starting the machine, wash the hydraulic circuits’ piping
thoroughly, so as to remove any residues and dirt.
Warning - Caution
It’s absolutely imperative that this operation is carried
out, so as to prevent any damage to the machine’s components.
After the wash, make sure that the hydraulic circuits are not leaking. To do so, fill the circuits at a pressure higher than the atmospheric pressure, making sure that there are no pressure drops
over the time.
Important
The piping’s thermal insulation must be carried out only after
making sure that there are no leaks.
Check that the gauze filter has been fit in the water supply line
(see diagrams in paragraphs 4.6 and 4.7).
414019
Fill hydraulic circuits with the type of liquid specified during the design stage (pure water or mixtures of water and ethylene or propylene glycol).
- 33 -
Chapter 4
4.11 ELECTRICAL CONNECTION
The electrical connection must be designed and carried
out only by operators who have specific technical expertise or particular skills in this sector.
Before proceeding with it,
these operators must disconL1
nect the electricity supply,
L2
making sure that nobody conL3
nects it again.
N
The plant power factor (cosφ)
must be compatible with the one
suggested by the principals constructors of electric motor for
compressors (included between
0,9 and 0,93). It is necessary to
avoid over compensations.
External enabling
ELECTRIC BOARD INPUT (IN)
Check that the mains voltage is included between +/-10% of the
nominal voltage of the machine.
Electrical input
Water flow meter
External compensation of
the Set Point, with signal
0,,,10 VDC or 0,,,20 VDC
Input of external alarm 2
The electrical connection to the
machine is shown, in general, in
the diagram. For further information, consult the chapter “Wiring
diagram”.
General alarm 1
ELECTRIC BOARD OUTPUT (OUT)
Compressor 1
Compressor 2
Flow meter
Alarms
Routine
Maintenance
External
alarm 2-3-5
General
alarm 2
Routine
Alarms
Alarm of compressor 3
414019
IDM-41401900700.tif
- 34 -
Chapter 4
4.12 PRE-COMMISSIONING PROCEDURES
Before contacting the specialized Engineer who will execute the
commissioning for testing, the Installer must carefully check that
the installation conforms to the requirements and specifications
laid-down during the design stage, making sure:
– that the electrical connection is correct;
– that the hydraulic connection is ended correctly;
– that the plumbing is filled with liquid under pressure;
– that pumping systems are working;
– that all shutoff valves are open.
At least six hours before the arrival of the specialized Engineer responsible for the commissioning, turn-on the compressors’ oil
pre-heater as follows.
1. Check
that the system’s master switch is in
the ON position.
2. Open the switchboard’s external door and turn
auxiliary operation
switch
the auxiliary operation switch to OFF.
IDM-4140020180.tif
3. Turn the door locking switch OFF and open the
switchboard’s internal door.
door locking
switch
4. Turn
the magnetic switch that supplies the
auxiliary circuits ON. To identify this switch,
consult the “Wiring Diagram”.
5. Close the internal door and turn the door locking switch ON.
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IDM-4140020190.tif
- 35 -
Chapter 4
6. Check that the emergency push-button is not
activated. If it is not so, turn it clockwise to disconnect it.
emergency
push-button
IDM-4140020090.tif
7. If these operations have been carried out properly, the microprocessor’s display must be ON.
8. Close the external door.
IDM-4140020200.tif
4.13 COMMISSIONING PROCEDURES
The commissioning must be carried out by a specialized Engineer, in the presence of the Installer and the expert Operator.
The specialized Engineer will test the plant, carrying out checks,
calibrations and the commissioning according to the applicable
procedures and his competence.
The expert Operator must address questions to the specialized
Engineer in order to obtain adequate notions, so as to carry out
the checks and applications pertaining to him.
Regarding large-sized machines, their operation must be
checked during the first days (three to ten). To this end, the Installer or the expert Operator must keep the data relating to
working parameters and notify them to the specialized Engineer
every day.
414019
After the first days of operation, they must check the hydraulic
circuit’s gauze filters (see diagram in paragraphs 4.6 and 4.7)
and clean them, if necessary.
- 36 -
Chapter 5
CALIBRATION AND TUNE-UP INFORMATION
5.1 CALIBRATION AND TUNE-UP
PROCEDURES
Upon the commissioning of the machine, after any failure or replacement, upon any ordinary or extraordinary maintenance
jobs, the operation checking devices could need a re-calibration
or tune-up.
These jobs (the most important are listed below) must be effected by a specialized Engineer:
– Expansion valve calibration.
– Water flow calibration.
– Calibration of the refrigerating circuit parameters.
414019
– Microprocessor calibration.
- 37 -
Chapter 5
CALIBRATION AND TUNE-UP INFORMATION
414019
- 38 -
Chapter 6
INFORMATION FOR USE
6.1 RECOMMENDATIONS FOR USE
The day-to-day use of the plant does not require the Operator’s
presence: he must intervene to conduct periodical checks, in an
emergency or to carry out the foreseen start-up and stop stages.
The regular and constant execution of these jobs will allow the
machine and the plant to deliver proper performance over the
time.
Warning - Caution
Failure to comply with these procedures may be a cause
of poor performance of the machine/plant as a whole
and of wear.
6.2 CONTROLS DESCRIPTION
The various controls are shown below, as well as their description and function. These controls are positioned on the switchboard, that can be accessed opening the external door.
Door locking switch: opens and closes the power
circuit.
– OFF (0) Position: the machine is not powered.
– ON (I) Position: the machine is powered.
IDM-4140020280.tif
414019
Microprocessor: controls the working process
and allows the parameter setting and the monitoring of the real conditions. More detailed instructions are reported in paragraphs 6.3 and
6.4.
IDM-4140020190.tif
- 39 -
Chapter 6
INFORMATION FOR USE
Emergency push-button: stops the machine in an
emergency. Once pressed, turn it clockwise to disable it.
Warning - Caution
The push-button must be used only in an
emergency, because the correct stop procedure is not followed in case of a sudden
stop.
IDM-4140020090.tif
414019
Auxiliary operation switch: selects the machine
running state.
– Position O - OFF: the machine is OFF.
– Position I - MAN: the machine is ON and maintains constantly the water temperature at the
outlet, based on the conditions set on the microprocessor. The eventual “EXTERNAL ENABLING” (see diagram in paragraph 4.11) is
excluded (bypassed).
– Position II - AUTO: this position must be selected
in the presence of an eventual “EXTERNAL ENABLING” (see diagram in paragraph 4.11).
The machine is activated and maintains constantly the water temperature at the outlet, based on the conditions set on the microprocessor providing the ”EXTERNAL
ENABLING” signal is ON – e.g. when an ON/OFF timer is in the
switching-on hours.
- 40 -
IDM-4140020290.tif
Chapter 6
INFORMATION FOR USE
6.3 DESCRIPTION OF THE DISPLAY AND THE
MICROPROCESSOR’S KEYBOARD
main screen
Display description
During normal operation, i.e. without any alarm, the
display shows the main screen detailed below.
IDM-4140020220.tif
Water temperatures in degrees centigrade.
Ti = temperature “in” (inlet)
To = temperature “out” (outlet)
IDM-4140020230.tif
Indicates the compressors’ running states (one to
four, based on the model). The following symbols
can be displayed:
indicates that it is working automatically at
full load
indicates that it is working automatically at
partial load (valid only for the machines provided with “capacity steps”)
IDM-4140020250.tif
indicates that it is working manually
/ indicates that it is locked following any failure
or because it has been cut-off manually
414019
Display not enabled
IDM-4140020260.tif
- 41 -
Chapter 6
INFORMATION FOR USE
Display not enabled
IDM-4140020270.tif
KEYBOARD DESCRIPTION
Stores the set temperature.
If pressed together with key “three” for at least
three seconds, it displays the screen for the
water temperature setting.
Decreases the displayed value
Red LED; indicates the
presence of an anomaly
in the power circuits
Increases the displayed value
Green LED; indicates that
the microprocessor is
powered
Red LED; indicates the presence
of one or more alarms
Interrupt the display or regulation
in progress
Key for the specialized
Engineer only
Key for the specialized
Engineer only
If pressed several times, displays the screen
with the hours of operation
414019
Silences the sound signal
IDM-4140020240.tif
- 42 -
Chapter 6
INFORMATION FOR USE
6.4 DESCRIPTION OF THE
MICROPROCESSOR’S FUNCTIONS
Warning - Caution
Do not interact with the functions that are not described
in this manual. They are for the specialized Engineer only.
The only functions with which the expert Operator can interact
are described below.
– Setting of the chilled water temperature (SET-POINT) (see paragraph 6.5).
– Alarm signals (see paragraph 6.6).
– Display of the hours of operation (see paragraph 6.7).
6.5 SETTING THE CHILLED WATER
TEMPERATURE (SET-POINT)
1. Display
the screen for setting the water temperature, by
pressing keys
at the same time for at least three seconds.
“SET POINT TEMP 1 XK1 8.0°C” will be displayed,
where 8.0 represents the water temperature
2. Decrease the water temperature by pressing key
crease it by pressing key
, or in-
.
The keys must be held down until the desired temperature is
reached.
3. Store the set value by pressing key
.
414019
4. Interrupt the display by pressing key
- 43 -
Chapter 6
INFORMATION FOR USE
6.6 .DESCRIPTION OF THE ALARM SIGNALS
1. In case of alarm, LED
starts blinking and a sound signal is
emitted.
Press key
to disable the sound signal, while LED
remains switched on with a fixed light.
2. If another alarm is activated, LED
starts blinking again
and the sound signal is re-activated.
3. The
display shows (see the flow diagrams below) the
screen(s) of the alarm(s) and the main screen (see paragraph 6.3), alternatively.
In case of alarm
Screen with the alarm
code and description
Main screen
414019
In case of more alarms (e.g. three)
Screen with the code
and description of the
first alarm activated
Main screen
second alarm activated
Main screen
third alarm activated
Main screen
- 44 -
Chapter 6
INFORMATION FOR USE
4. Note the codes and descriptions of the alarms activated in
the “Maintenance Handbook”.
5. Consult chapter 8 of this manual to know the behavior to be
adopted to remedy the causes of these alarms.
6. When all the alarms disappear, LED
turns off.
6.7 DISPLAY OF THE HOURS OF OPERATION
Foreword
This function allows you to display the hours of operation of the
machine, so as to carry out the scheduled maintenance based on
the intervals indicated in paragraph 7.2.
Procedure
1. Press key
several times to display the screen with the
hours of operation.
“WORKING TIME”
12345 h
will appear, where 12345 represents the hours of operation
414019
2. Interrupt the display by pressing key
- 45 -
.
Chapter 6
INFORMATION FOR USE
6.8 NORMAL START-UP
The start-up procedure is indicated below. The flow diagram
shows the variables based on the characteristics of the machine
and the water circuit.
During start-up, it’s essential that the plant water temperature stabilizes to the set point value before activating CCUs.
1. Check that CCUs are OFF (fans OFF)
NO
NO
Is the water circuit
divided into primary and
secondary circuit?
Is the machine equipped YES
with the water pumping
unit?
NO
YES
Is the water circuit
divided into primary and
secondary circuit?
2. Start the primary circuit’s pump
2. Start the machine
2. Start the machine
3. Wait for at least 1 min
and start the machine.
3. Wait for at least 1 min
and start the machine
3. Wait until the circuit
reaches the set point temperature
3. Wait until the primary
circuit reaches the set
point temperature, then
start the secondary circuit’s pump
4. Wait until the circuit
reaches the set point temperature
4. Wait until the primary
circuit reaches the set
point temperature, then
start the secondary circuit’s pump
2. Start the circuit’s pump
4. Wait until the secondary circuit reaches the set
point temperature
5. Wait until the secondary circuit reaches the set
point temperature
Turn on CCUs (fans turning on)
Warning - Caution
Do not change the plant loads suddenly.
If there are several distinct areas, spread the CCU activation,
so that the machine can adjustto the increase in load step-by-step.
414019
YES
- 46 -
Chapter 6
INFORMATION FOR USE
6.9 NORMAL STOP
The stop procedure is indicated below. The flow diagram shows
the variables based on the characteristics of the machine and
the water circuit.
1. Turn off CCUs (fans turning off)
Warning - Caution
Do not change the plant loads suddenly.
If there are several distinct areas, spread the CCU activation,
so that the machine can adjust to the increase in load step-by-step.
NO
NO
Is the water circuit divided
into primary and
secondary circuit?
Is the machine equipped
with the water pumping
unit?
YES
NO
YES
2. Wait at least 8 min and
stop the machine
stop the secondary circuit’s pump
3. Wait at least 1 min
stop the machine
Is the water circuit divided
into primary and
secondary circuit?
YES
stop the secondary circuit’s pump
414019
Stop the circuit’s pump
Stop the primary circuit’s
pump
- 47 -
Stop the machine
Chapter 6
INFORMATION FOR USE
6.10 PROLONGED SHUTDOWNS OF THE
MACHINE
If the machine must remain off-duty for a long time (e.g. seasonal
shutdown), the specialized Engineer must:
– check the pressure vessels’ state of preservation
– conduct the leak test on the system
– open the line isolator
– close the chilled water shutoff valves
– drain the chilled water from the piping of the hydraulic circuits,
the evaporator and the reclaim exchanger (if any)
6.11 START-UP AFTER A PROLONGED
SHUTDOWN
Before starting the machine, carry out all the maintenance jobs
indicated in paragraph 7.2.
414019
Moreover, the specialized Engineer must carry out adequate
checks, calibrations and the start-up procedure.
- 48 -
Chapter 7
MAINTENANCE INFORMATION
7.1 MAINTENANCE INFORMATION
Warning - Caution
Maintenance jobs must be carried out by authorized operators, who must ensure all the necessary safety conditions, according to the manufacturer’s procedures.
The list of the scheduled maintenance jobs is also set out in the
“Maintenance Handbook”.
All the jobs effected must be recorded in this handbook, including
any extraordinary maintenance jobs.
7.2 SCHEDULED MAINTENANCE
Carry out all the scheduled maintenance jobs at the indicated intervals.
Important
In case of non-compliance with the above recommendations, the manufacturer may not be held liable in respect of
any safety requirements of the machine and, during the
warranty period, the related rights will no longer be valid.
The tables on the next pages show the months or years elapsed
from the installation, as well as the hours of operation; the earlier
deadline is to be considered.
414019
To “read” the hours of operation, they are to be displayed on the
microprocessor’s display (see paragraph 6.7).
- 49 -
Chapter 7
7.3
TABLE OF GENERAL MAINTENANCE JOBS
INTERVAL
COMPETENCE
OPERATIONS TO BE EFFECTED
Every day
At the
beginning of
every season.
Or every 500
hours or 2
months.
Checking of any alarms (see paragraph 6.6)
External visual checking for any leak
Expert
Operator
Checking of the water temperature at the outlet
(see paragraph 6.3)
Checking of the hydraulic circuits’ filters (see diagrams in paragraphs 4.6 and 4.7)
Checking of pressure vessels (see paragraph 7.5)
Cleaning of condensing and evaporating coils (see
paragraph 7.6)
Checking of the water flow and cleaning of exchangers (see paragraph 7.7)
Checking for any leak in the refrigerating circuit
Checking of contactors
Checking of the electrical connections’ tightening
Checking of the noise produced by fans’ bearings
Checking of the refrigerating circuits’ working parameters. In every circuit check:
- the condensation pressure, comparing it with
the data of the heat source used (water or air
temperature)
Specialized
Engineer
- the evaporation pressure, comparing it with the
data of the heat source (water and air temperature)
- the suction temperature
- the manometric suction temperature
- the outlet temperature
- the manometric outlet temperature
- the liquid temperature
- overheating
- undercooling
- the line voltage on the three phases
- the ground insulation
- the absorbed current (100% and in partial load
operation)
- the hours of operation
- the number of start-ups
414019
- the oil carter temperature
- the oil pressure, acidity and humidity
- 50 -
Every 50 hours
during the first
month of operation
At the
beginning of
every season.
Or every 1000
hours or 3
months
Chapter 7
7.4 TABLE OF MAINTENANCE JOBS ON
COMPRESSORS
The jobs on compressors can change according to the type of
compressor installed on the machine.
“Hermetic”, “Reciprocating semi-hermetic” and “Reciprocating semi-hermetic AMP” Compressors
INTERVAL
COMPETENCE
Specialized
Engineer
JOB TO BE EFFECTED
After the
first 500
hours
Every
Every
Every
Every
1000
3000
5000
15000
hours or 3 hours or 9 hours or 1 hours or 3
months
months
year
years
Oil replacement (compressors
with unitary power below 180 kW
C
C
O
Oil replacement (compressors
with unitary power above 180
kW)
C
C
O
Checking of the oil level (only if the
relevant indicator is available)
O
Checking for any vibration and
noise
O
Checking of regulations and
safety devices
O
Checking of the motor insulation
O
Checking of the oil filter (if
available)
O
C
Checking of the suction filter (if
available)
Every
30000
hours
O
O
Checking of the valve state (not
valid for Hermetic compressors)
C
Compressor overhaul (non valid
for Hermetic compressors)
O
C
C = RECOMMENDED JOB
414019
O = MANDATORY JOB
- 51 -
Chapter 7
“Screw” compressors
INTERVAL
JOB TO BE
EFFECTED
COMPETENCE
Specialized
Engineer
Every
Every
Every
Every
Every
1000
2000
5000
10000
15000
hours or hours or hours or 1 hours or 2 hours or 3
3 months 6 months
year
years
years
Checking of the oil
level
O
Checking for any
vibration and noise
O
Checking of the
motor insulation
C
O
O
Checking of
regulations and
safety devices
C
C
O
Every
30000
hours or 6
years
Checking of the oil
filter
C
O
Checking of the
suction filter
C
O
Checking for any leak
C
Oil replacement
C
Replacement of
bearings and seals
O = MANDATORY JOB
C
C
O
O
C
C = RECOMMENDED JOB
414019
Every
25000
hours or
5anni
- 52 -
Chapter 7
7.5 CHECKING OF THE PRESSURE VESSELS
It is very important to prevent rust formation on the surface of
the machine’s pressure vessels (evaporator, condenser, reclaim
exchanger, liquid receiver) and that there are no warps.
In the presence of any warps, stop the machine and contact an After-Sales Service authorized by the manufacturer.
Periodically protect the pressure vessels with paints and/or antioxidant products.
7.6 CLEANING OF THE CONDENSING COILS
The accumulation of dirt on the exchange coils results in a rise in
the condensation pressure.
This situation may cause the machine to be stopped, apart from
an increase in electrical consumption and in the wear of compressors.
In this case, the exchange coils’ external surface must be cleaned
thoroughly with a water jet.
Important
The cleaning frequency must be increased in all periods
when the accumulation of dirt is substantial (e.g.: when
leaves or flowers are falling from trees).
7.7 CHECKING OF THE WATER FLOW AND
CLEANING OF EXCHANGERS
The variation in the flow rate in the exchangers can be caused by
the presence of dirt in filters, by pump wear or wrong maneuvers,
as well as by the presence of fouling inside the exchangers.
414019
In this case, a chemical wash with suitable products must be carried out.
- 53 -
Chapter 7
7.8 CHECKING OF DRIVE BELTS
In the machines equipped with centrifugal fan (see paragraph
1.4), check the drive belt.
If the belt is loose, carry out the calibration required.
Warning - Caution
If too loose, the belt can slip and cause damage. On the
contrary, if the belt is too stretched, bearings could be
damaged.
7.9 EXTRAORDINARY MAINTENANCE
In the event that any extraordinary maintenance jobs are necessary, contact an After-Sales Service authorized by the manufacturer.
414019
Important
In case of non-compliance with the above recommendations, the manufacturer may not be held liable in respect of
any safety requirements of the machine and, during the
warranty period, the related rights will no longer be valid.
- 54 -
Chapter 8
TROUBLESHOOTING
8.1 FAULT-FINDING
ALARM
DESCRIPTION
FUNCTION
CAUSE
SOLUTION
RE-START OF
THE
MACHINE
1 EXT. ENABLE
OFF
Machine disabled from an external control
Electric circuit
External control prevents
operation
Checking of
the external
control
A
Condensers’
fans
Problems with
the fans’
motors
Contact an
After-Sales
Service authorized by the
manufacturer
M
Hydraulic circuit
Insufficient
water flow
Check the
hydraulic circuit
A/M
Contact an
After-Sales
manufacturer
M
Faulty working
(refrigerating
circuit)
Contact an
After-Sales
manufacturer
M
High outside
air temperature
None
Excessive chilled water setpoint
Lower the setpoint
18 PRESS. 3
RISING
Dirty condensing coil
Clean
20 HI PRESS.
C1
High outside
air temperature
21 HI PRESS.
C2
2 COND. FAN 1
FAIL
3 COND. FAN 2
FAIL
Fans locked by motor fan alarm
4 COND. FAN 3
FAIL
8 LO PRESS. C1
9 LO PRESS. C2
10 LO PRESS.
C3
Lock caused by LP in refrigerating circuits
Refrigerating
circuit
Low refrigerant charge
Faulty working
12 OIL PRESS.
1
13 OIL PRESS.
2
Lock caused by oil LP in refrigerating circuits
Refrigerating
circuit
14 OIL PRESS.
3
16 PRESS. 1
RISING
17 PRESS. 2
RISING
Condensation pressure exceeding the regular working range
Lock caused by HP in refrigerating circuits
Refrigerating
circuit
Refrigerating
circuit
414019
22 HI PRESS.
C3
Contact an
After-Sales
manufacturer
A
M
Fans locked.
Faulty working
- 55 -
Chapter 8
TROUBLESHOOTING
SOLUTION
RE-START OF
THE
MACHINE
Contact an
After-Sales
manufacturer
M
Faulty working
Contact an
After-Sales
manufacturer
M
32 OVERLOAD
C1
Unbalanced
power supply
Check the line
voltage
M
33 OVERLOAD
C2
Blackout
Check the line
voltage
A
Compressor
failure
Contact an
After-Sales
manufacturer
M
Check
A
Valve calibration too open
Calibrate valve
A
Plant start
transients
None
Set-point
change transients
None
Compressors
shutdown
Check
ALARM
DESCRIPTION
FUNCTION
CAUSE
24 HI SAFETY
C1
High outside
air temperature
25 HI SAFETY
C2
Lock caused by oil HP in refrigerating circuits
Refrigerating
circuit
26 HI SAFETY
C3
Fans locked.
Faulty working
28 HI/LO
TEMP C1
28 EXPANSION VALVE 1
29 HI/LO
TEMP C2
Lock caused by irregular working
temperatures and pressures in
the refrigerating circuits
Refrigerating
circuit
30 HI/LO
TEMP C3
Lock caused by compressors’
thermal switch
Compressors
34 OVERLOAD
C3
38 LO WATER
FLOW
Dirty filters
Insufficient water flow
Hydraulic circuit
Faulty pump
Valves closed
38 HI WATER
FLOW
414019
42 HI WATER
TEMP.
Excessive water flow
High water temperature (evaporator)
Hydraulic circuit
Microprocessor sets
- 56 -
A
Chapter 8
TROUBLESHOOTING
ALARM
FUNCTION
43 LO WATER
TEMP.
Low water temperature (evaporator)
Microprocessor sets
44 HI LINE
VOLT
High voltage lock
45 LO LINE
VOLT
Low voltage lock
46 MODUL …
FAIL
46 MOD. SET
FAIL
47 T.. PROBE
FAIL
Faulty expansion card
Faulty expansion card
Faulty temperature probe
CAUSE
SOLUTION
Low water flow
Check
Plant transients
RE-START OF
THE
MACHINE
A
Set-point
change transients
None
Electric circuit
Excessive line
voltage
Check the
electric circuit
A
Electric circuit
Insufficient line
voltage
Check the
electric circuit
A
Faulty component
Contact an
After-Sales
manufacturer
A
Faulty component
Contact an
After-Sales
manufacturer
M
Faulty component
Contact an
After-Sales
manufacturer
A
A
Microprocessor
Microprocessor
Microprocessor
48 ... PROBE
FAIL
Faulty pressure probe
Microprocessor
Faulty component
Contact an
After-Sales
manufacturer
49 EXT.
ALLARM 2/3
External alarm
(available)
-
Depends on
the connected
alarm
-
A
50 EXT.
ALLARM 4/5
External alarm
(available)
-
Depends on
the connected
alarm
-
A
Check and
Contact an
After-Sales
manufacturer
M
52 HEAT
RECLAIM
53 LOW LIMIT
414019
DESCRIPTION
Excessive pressure during heat
reclaim
Heat reclaim
circuit
Lock caused by antifreeze alarm
Hydraulic circuit
- 57 -
Insufficient
reclaim water
flow
Excessive temperature
Plant transients
None
Low water flow
Check
A
Chapter 8
TROUBLESHOOTING
ALARM
53 T… PROBE
FAIL
DESCRIPTION
Faulty temperature probe
FUNCTION
Microprocessor
414019
A = AUTOMATIC RESTART (WHEN THE ALARM IS OVER)
M = MANUAL RESTART
- 58 -
CAUSE
SOLUTION
RE-START OF
THE
MACHINE
Faulty component
Contact an
After-Sales
manufacturer
A
Chapter 9
REPLACEMENT INFORMATION
9.1 PARTS REPLACEMENT
If any mechanical, electrical and electronic parts must be replaced, contact an After-Sales Service authorized by the manufacturer.
Important
To maintain the machine in perfect working order, use original spare parts (see the “Recommended spare parts list”).
414019
9.2 MACHINE DISMISSION
To dismiss the machine, contact in advance an After-Sales Service authorized y the manufacturer.
- 59 -
Chapter 9
REPLACEMENT INFORMATION
414019
- 60 -
INDEX
A
Alarm signals, description, 44
Assistance, requests for, 9
C
Calibration and tune-up procedures, 37
Checking of drive belts, 54
Checking of the pressure vessels, 53
Checking of the water flow and cleaning of exchangers, 53
Chilled water (SET-POINT), temperature setting, 43
Cleaning and filling the hydraulic circuits, 33
Cleaning of the condensing coils, 53
Code, model interpretation, 9
Commissioning preliminary procedures, 35
Commissioning procedures, 36
Condensing coils, cleaning, 53
Controls description, 39
Cooling connection to the remote air cooled
condenser (A.NRM versions), 31
D
Description of the alarm signals, 44
Description of the display and the
microprocessor’s keyboard, 41
Description of the main components, 14
Description of the microprocessor’s functions, 43
Dimensions of the perimetrical area, 25
Display and microprocessor’s keyboard, description, 41
Display of the hours of operation, 45
Drive belts, checking, 54
E
Electrical connection, 34
Enclosed documentation, 10
Extraordinary maintenance, 54
F
Fault-finding, 55
414019
G
General description of the machine, 13
Glossary and Terms, 6
- 61 -
INDEX
H
Handling and lifting, 22
Hours of operation, display, 45
Hydraulic circuits, cleaning and filling, 33
Hydraulic connection to the evaporator, 27
Hydraulic connection to the reclaim exchanger
(optional), 32
Hydraulic connection to the water cooled
condenser (W.NRM versions), 29
I
Installation and testing, safety for, 25
Installation area, 25
Installing the machine, 27
Interpretation of the model’s code, 9
L
Lifting, handling and, 22
M
Machine dismission, 59
Machine, general description, 13
Machine, manufacturer identification, 8
Main components, description, 14
Maintenance information, 49
Manufacturer and machine identification, 8
Microprocessor, description of functions, 43
Microprocessor’s keyboard and display, description, 41
Model, code interpretation, 9
N
Normal start-up, 46
Normal stop, 47
O
Objective of this manual, 5
Optionals description, 18
414019
P
Packing and Unpacking, 21
Parts replacement, 59
Perimetrical area, dimensions, 25
Pre-commissioning procedures, 35
Presetting the connections, 26
Pressure vessels, checking, 53
Prolonged shutdown of the machine, 48
- 62 -
INDEX
R
Recommendations for use, 39
Remote air cooled condenser (A.NRM versions),
cooling connection, 31
Requests for assistance, 9
S
Safety devices, 18
Safety for installation and testing, 25
Safety regulations, 10
Scheduled maintenance, 49
Setting the chilled water temperature (SET-POINT), 43
Start-up after a prolonged shutdown, 48
T
Table of general maintenance jobs, 50
Table of maintenance jobs on compressors, 51
Technical data, 19
Transportation, 21
Tune-up, calibration procedure and, 37
U
Unpacking and packing, 21
Use, recommendations for, 39
414019
W
Water cooled condenser (W.NRM versions),
hydraulic connection, 29
- 63 -
INDEX

series frigo frigo screw

Transcription

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