USE AND MAINTENANCE MANUAL AIR COOLED WATER CHILLERS AND HEAT PUMPS R-PAE / R-PAH / EAH Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 TABLE OF CONTENTS 1. INTRODUCTION ........................................................................................................................... pag. 2 1.1 Manual content ... .................................................................................................................................... 1.2 Safety marks .......................................................................
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 1. INTRODUCTION 1.1 Manual content The present handbook, originally written in Italian, was completed in compliance with the “Machinery Directive”. It contains all the necessary information for carrying out without any risk transportation, installation, startup, operation, setting, maintenance and dismantling of the air cooled water chillers and heat pumps of series R-PAE / R-PAH / EAH.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 Warning: on the first startup, duly fill in the relevant report attached to this manual and send a copy to Emicon A.C. (Customer Service), in order to make the warranty valid. 1.5 Readers of the Manual This manual and all its attachments are supplied with the described unit. The manual must be kept by the machine’s owner in a proper place.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 2.4 Dangerous areas On the unit there are dangerous areas for electric risk and hot temperatures. The unit can be closed by case panels; in this case the dangerous parts inside the unit are not accessible from outside. Only qualified and trained personnel can remove the covering panels.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 3.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 RAH Picture 4 Key 1) Electric panel 2) Compressor 3) Heat exchange coil 4) Evaporator 5) Tank 3.
Use and Maintenance Manual Picture 6 Picture 7 8 Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev.
Use and Maintenance Manual Picture 10 Picture 11 10 Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev.
Use and Maintenance Manual Picture 14 Picture 15 12 Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 3.3.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 CS: Compressor inrush counter DS: Star/Delta compressors startup FA: Condensing coil protection filters GP: Protection grid for condensing coil GP1: Protection grid for the technical section (compressors, pump group) HG: Hot gas by-pass. IG: Watch card IH: Serial interface RS485.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 4. INSTALLATION 4.1 Identification tag The data for the identification of the unit are marked on a permanent tag (Picture 18). Picture 18 – Identification tag The correct unit identification by means of the serial number is essential for the execution of any operation to carry out on the unit. The serial number must be always advised whenever submitting a request of technical service support. 4.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 4.3 Handling The handling of the unit must be carried out by expert personnel, equipped with appropriate equipment in relation to the weight and to the dimensions of the machine. During the handling operation, the machine must be always kept upright. The weight of some models is unbalanced: check the unit stability before starting to handle it.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Picture 20 – Lifting of centrifugal units Picture 21 – Lifting of RAE / PAE 752 - 3172 18 Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 In case the manufacturer lifting kit (option) is not employed, make sure that the lifting equipment used, the cables and the belts are in compliance with the relevant local regulation. The overall dimensions of the units, packaging included, are indicated in the packing list sent by e-mail in order to organise the loading. 4.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Picture 25 – Service Area for RAE / PAE 131 - 822 Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Picture 27 – Service Area for RAH / PAH TWIN 2102 - 8802 Picture 28 – Service Area for RAH / EAH 301 - 2214 22 Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 Picture 31 – Distances in case of coverings Before starting to handle the unit to position it, it is necessary to identify the best way to arrive to the place, taking into consideration the unit overall dimensions and weight, the available lifting equipment and any optional accessory dimensions.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 Ø The unit must be connected to the hydraulic system by using the appropriate areas as indicated in the commercial drawing here attached. Ø The diameter of the hydraulic connections are shown in the commercial drawing here attached. For the connections dimension, see the commercial drawing here attached. 4.5.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 Use of anti-freeze mixtures In case an anti-freeze mixture is used, it is necessary to follow some precautionary measures: Ø The temperatures shown in the above table are approximate. Sometimes suppliers dilute the product and therefore it is necessary to follow the dilution percentage recommended by the anti-freeze liquid manufacturer.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 4.6 Electric connections Check the electric circuits have not been damaged during transportation. Check all terminals screws are tight. Make sure the power tension and frequency match the same data as specified on the unit identification tag. Before starting the electric connection, it is advisable to check the wiring diagram contained in the unit electric panel. 4.6.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 4.6.2 Warning in case of connection to the terminal board when optional “ TE” is installed In case the unit is provided with optional TE (electronic thermostatic valve), pay the maximum attention to the spare battery power supply.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 4.6.3 User’s terminal board connection A user terminal board (Picture 35) is available with free contacts designed for: Ø Generic alarm state (1); Ø Unit remote ON/OFF (2). Check the wiring diagram for the exact correspondence of the terminals numbers.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 4.6.4 Instructions for the electric connection The electric connection must be carried out by skilled personnel. The power cable input is shown in the attached dimensional scheme. Picture 36 The power cable conductors must be connected to the free terminals upstream the main disconnecting switch, while the grounding conductor must be connected to the appropriate terminal PE or to the ground bar.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 Picture 39 4.6.5 Phases sequence in the power supply line The rotation direction of all electric motors installed on the unit (compressors, fans, pumps) are checked and harmonized during the operational test performed by the manufacturer (at the exception of units supplied with arrangements for special power supply tension).
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 5. OPERATION 5.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 5.4 Fault alarm and display system The troubleshooting is realized by the microprocessor, which activates an alarm and shows on its display the type of fault occurred (see also the attached microprocessor manual). Since the alarm state is very often generated by an unfitted electric contact, in case of fault make sure all wiring connections are plugged in the corresponding terminals.
Use and Maintenance Manual TROUBLE Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 POSSIBLE CAUSE A) The high pressure switch is not set properly or is defective CORRECTIVE ACTION Replace the high pressure switch or reset it 5. The high pressure switch B) Discharge pressure too high See trouble 7 is activated C) The condensing water flow capacity is See trouble 4 not sufficient A) The low pressure switch is not set properly Replace the low pressure switch or reset it 6.
Use and Maintenance Manual TROUBLE Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 POSSIBLE CAUSE A) Automatic switch activated CORRECTIVE ACTION Reset the automatic switch; check the cause for the activation Check the compressor winding resistance; after 11. The compressor does B) Compressor internal heat protection reset, check the tension and the electric absorption; not work check the working parameters are in the nominal activated range of values 12.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 B) VACUUM AND DEHYDRATATION To obtain a good level of vacuum, an appropriate pump must be used (1,4 mbar of absolute pressure, 30 l/min. of water capacity). If the circuit has been open only for short time, by using this pump, only one vacuum operation is usually enough to reach the absolute pressure 1,4 mbar.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 5.6.3 Check of the setting up The setting up must be checked while the unit is working in conditions as close as possible to the nominal ones. Make sure: Ø The thermal load is adequate; Ø The water capacity and the evaporating and condensing water temperatures are close to the nominal ones.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH 5.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 5.7.1 Coils cleaning (on the floor and under coverings) Use a stiff-bristle brush and the necessary equipment; the use of an industrial vacuum cleaner may facilitate this operation. a. Disconnect the unit from the power supply by opening the main switch, b. Remove the protection grid from the coil (if present), c. Brush the coil from the top to the bottom, being careful not to damage the fins. d.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 Picture 44 5.7.7 Check of the gaskets on the centrifugal fans discharge The centrifugal fans discharge is connected to the external skirt by means of a flexible gasket; the gasket must not be damaged and must not let air pass through. In this case, its replacement is necessary, therefore contact EMICON A.C. S. p. A. After Sales Service. 5.7.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 5.7.11 Belts tension check – belts replacement While making the check, the unit main switch must be open (“0” position) and locked. The padlock key must be kept by the person in charge of the check. Centrifugal fans belts must be checked at regular intervals and must be replaced every two years of operation.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Picture 45 Rev. 1 del 03/09 Picture 46 The pictures show two different types of remote control switches: the one shown on Picture 45 is equipped with a detached protection, while the one shown on Picture 46 is equipped with an incorporated protection (automatic circuit breaker).
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Picture 47 Rev. 1 del 03/09 Picture 48 1. Remove the fusebox cover. 2. Take the extractor tool “2” located inside the electrical panel. 3. Insert the puller into the fuse spring clips (see the white circle on Picture 47) and pull the extractor down till the clips are released. 4. Pull the extractor horizontally and firmly towards you; (any different movement could detach the cover from the fuse holder). 5.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 The motor pulley is of adjustable type. If to unscrew the fixing dies the regulation must be changed, it is necessary to mark the original position with an indelible felt-tip pen and count the turns of the mobile part so that it is possible to restablish exactly the original regulation once the operation is completed.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 5.8 Special maintenance operations The operations listed here below must be performed only by skilled service personnel equipped with the suitable equipment and only when the unit is stopped and disconnected from the power supply.
Use and Maintenance Manual Air-cooled water chillers and Heat Pumps R-PAE/R-PAH/EAH Rev. 1 del 03/09 6. DISMANTLING When the unit has to be dismantled, drain the cooling circuit and collect the refrigerant gas by means of an adequate receiver, in order to protect people and environment. Never release the gas contained in the cooling circuit in the environment.
Emicon A.C. S.p.a. reserves the right to make changes to its products without any prior notice.
Emicon A.C. S.p.a. Via A.Volta 49 Meldola Tel.
