Installation and maintenance manual Manuel d’installation et de maintenance Installations- und Wartungshandbuch Manuale di installazione e di manutenzione Manual de instalación y de mantenimiento Инструкция по монтажу и техобслуживанию SYSCROLL 20-30 AIR EVO HP English 7 33 kW 7 35 kW Français Deutsch Italiano Español Русское издание Air Cooled Water Chillers and Heat Pumps Refroidisseurs de liquide à condensation par air et pompes à chaleur air-eau Luftgekühlte Flüssigkeitskühler und Wärmepump
1 - FOREWORD 7 - PRODUCT DESCRIPTION 1.1 Introduction...........................................................................2 7.1 General information.............................................................26 1.2 Warranty...............................................................................2 7.2 Accessories............................................................... 27 to 29 1.3 Emergency stop / Normal stop..............................................2 7.3 Refrigeration circuits.
1 - Foreword 1.1 Introduction 1.3 Emergency stop / Normal stop Units, manufactured to state-of-the-art design and implementation standards, ensure top performance, reliability and fitness to any type of air-conditioning systems. The emergency stop of the unit can be enabled using the master switch on the control panel (move down the lever). For a normal stop, press the relevant push-buttons.
English 2 - Safety 2.1 Foreword These units must be installed in conformity with the provisions of Machinery Directive 2006/42/EC, Pressure Equipment Directive 2014/68/EU, Electromagnetic Compatibility Directive 2014/30/EU, as well as with other regulations applicable in the country of installation. If these provisions are not complied with, the unit must not be operated.
2 - Safety 2.2 Definitions OWNER: means the legal representative of the company, body or individual who owns the plant where unit has been installed; he/she has the responsibility of making sure that all the safety regulations specified in this manual are complied with, along with the national laws in force. n Use tools in a good state of repair; be sure to have understood the instructions before using them.
n Periodically check the board’s internal wiring. n Make sure that on-off remote controls are inhibited. n Do not use cables having an inadequate section or flying connections, even for limited periods of time or in an emergency. n Wear suitable personal protective equipment (helmet, safety gloves, goggles and shoes etc.). Prevention of other residual risks n Make sure that the connections to the unit conform to the instructions provided in this manual and on the unit’s panelling.
2 - Safety 2.
English 2 - Safety Start-up warning - Outside the door of the electrical board Grounding connection on the electrical board, adjacent to the connection Read the instruction on the electrical board Fitting identification - Adjacent to fittings Sequence phase control on the electrical board ATTENZIONE QUESTO COMPRESSORE RICHIEDE UN CORRETTO SENSO DI ROTAZIONE RISPETTARE LA CORRETTA SEQUENZA DELLE FASI.
2 - Safety 2.8 Safety regulations REFRIGERANT DATA Toxicity SAFETY DATA: R410A Low. If sprayed, the refrigerant is likely to cause frost burns. If absorbed by the skin, the danger is very limited; it may cause a slight irritation, and the liquid is degreasing. Unfreeze the affected skin with water. Contact with skin Remove the contaminated clothes with great care - in the presence of frost burns, the clothes may stick to the skin. Wash with plenty of warm water the affected skin.
2.8 Safety regulations (continued) REFRIGERANT DATA General precautions Respiratory system protection SAFETY DATA: R410A Do not inhale concentrated vapours. Their concentration in the atmosphere should not exceed the minimum preset values and should be maintained below the professional threshold. Being more weighty than the air, the vapour concentrates on the bottom, in narrow areas. Therefore, the exhaust system must work at low level.
2 - Safety 2.8 Safety regulations (continued) LUBRICANT OIL DATA SAFETY DATA: POLYESTER OIL (POE) Classification Not harmful. Contact with skin May cause slight irritation. Does not require first aid measures. It is recommended to follow usual personal hygiene measures, including washing the exposed skin with soap and water several times a day. It is also recommended to wash your overalls at least once a week. Contact with eyes Wash thoroughly with a suitable solution or tap water.
SYSCROLL AIR EVO HP units are supplied fully assembled and tested (except for accessories supplied loose in the units – absorbers, filter, etc.). They are ready to be installed and started on the field. Space requirements request to handling R410A units are only charged with liquid refrigerant and with oil in the quantity required for operation.
3 - Transport, Handling and Storage n Never store the units in a room where temperature is above 50 °C (R410A units) or where the units are directly exposed to the sunlight. n Minimum storage temperature is -25 °C. n It is recommended to leave the finned coils covered to protect them against any risk of corrosion, especially if building works are still in progress. n Store the units in areas where minimum activity is likely to take place in order to avoid any risk of accidental damage.
English 4 - Installation 4.1 Installation Site DANGER 4.2 External Water Circuit Before installing the unit, make sure that the building structure and/or the supporting surface can withstand the weight of the device. The weights of the units are detailed by Chapter 9 of this manual. WARNING The circuit shall be composed by the following elements: These units have been designed to be installed on the floor, in the open air.
4 - Installation External water circuit COMPONENTS 1 Plate heat exchanger 2 Pump 3 Draining valve 4 Water buffer tank 5 Water filter 6 Automatic water charging valve 7 Pressure expansion tank 8 Water charging line 9 Water outlet 10 Water inlet 11 Globe valve 12 Flexible pipes 13 By-pass valve WARNING SAFETY/CONTROL DEVICES A Inlet water temperature sensor B Outlet water temperature sensor C Water differential pressure switch (105 mbar) D Vent valve E Water safety valve (3 bar) F Manometer FS Flow switch
English 4 - Installation 4.3 Water connections 4.5.1 Features The flow switch and the filter water, although not included in the supply, must always be fitted such as plant components. Their installation is mandatory for warranty. Units have one single tank. The kit will include an Antifreeze Electric Heater, a drain valve, an automatic filling unit and an automatic air vent. No pump is arranged on the kit since it is mounted on the unit.
4 - Installation CAUTIONS 4.6 Power supply The unit + tank system shall be equipped with a filter. Use the filter + union as it is shown by Figure 1. Figure 1 DANGER Before carrying out any operations on the electrical system, make sure that the unit is deenergized. It is important that the appliance is grounded. DANGER WARNING The company in charge of the installation shall conform to the standards applicable to outdoor electrical connections.
English 4 - Installation Antifreeze Resistance Wiring Storage Kit (112 l) - Dimensional Data Front view Side view 43 A 186 106 390 B 200 C 213 Top view 434 500 33 4 holes Ø9 62.5 62.
4 - Installation 4.7 Electrical connections For 3-phase systems, check also that the unbalance between the phases does not exceed 2%. To perform this check, measure the differences between the voltage of each phase couple and their mean value during operation. The maximum % value of these differences (unbalance) must not exceed 2% of the mean voltage. The unit must be installed on site according to the usual procedures and standards applicable in the place of installation.
Electrical Connections 19 English 4 - Installation
5 - Start-up WARNING NOTE The unit must be started for the first time by personnel suitably trained by one of Authorised Service Centre. Failure to meet this requirement will immediately void the warranty. The operations carried out by authorised personnel are limited to the start-up of the unit, and do not include any other operation on the plant, such as, for example, electrical and hydraulic connections etc.
English 6 - Control Introduction Terminal and keypad description This document contains informations and operating instructions for SYSCROLL 20/30 AIR EVO HP units. The terminal makes it possible to carry out the following operations: n Change of all the main operating parameters; Main characteristics n Display of the detected alarms; Microprocessor control: n Display of all the measured quantities.
6 - Control 6.2 Alarms 6.3 Menus All alarms have the following behavior: Press PRG from the main screen to reach the menu tree: n When an alarm is activated, the red LED flashes and the buzzer and alarm relay are activated (when configured). n Pressing the ALARM button, the red LED stays on steady, the buzzer is muted and the alarm screen is shown. n If there is more than one active alarm, all the active alarms can be scrolled using UP and DOWN buttons.
English 6 - Control 6.3.1 User Menu Enter password user: 0000 1. UNIT STATUS System Cool/heat OFF/ON COOL/HEAT 2. Setpoint Variable name Type (Write/Read) Default value Min. value Max. value Main heat W 45.0 °C 25.0 °C 55.0 °C Main cool W 7.0 °C -8.0 °C (*) 18.0 °C Secondary heat W 35.0 °C 25.0 °C 55.0 °C Secondary cool W 9.0 °C -8.0 °C (*) 18.0 °C Active R Actual active setpoint DHW W 45.0 °C 25.0 °C 55.0 °C Mixing valve W 35.0 °C 25.0 °C 55.
6 - Control DIGITAL OUTPUTS Variable name Type (Write/Read) Unit Description Fan 1 R Fan 1 status (O=open,C=close) Fan 2 R Fan 2 status (O=open,C=close) 4-way valve R 4-way status (O=open,C=close) Pump R Pump status (O=open,C=close) Evaporator heater R Evaporator heater (O=open,C=close) Crankcase heater R Compressor crankcase heater (O=open,C=close) ANALOG OUTPUTS Variable name Type (Write/Read) Unit Description Fans R V Actual fans speed expressed in Volt Variable name Type (
English 6 - Control 6.3.3 Clock Menu Set clock time and date; set time tables (day by day, up to four different timings each day). 6.
7 - Product Description for the water side and to 45 bar for the refrigerant side. Antifreeze protection for the water in the exchangers is ensured by electrical heaters and differential pressure switches. The water side of these exchangers is connected by manifolds which will provide for the connection to the plant by means of one single 1”1 gas threaded attachment. 7.1 General Information SYSCROLL AIR EVO HP units are one-block type with one refrigerant circuit.
7.2 Accessories Flow switch kit Water Filter Flow switch kit is available as an accessory. It is supplied loose and as to be mounted by the customer. Connect terminals 1-2 of the flow switch with terminals 1-2 of the electrical box. 1-1/4” filter is included in the supplied equipment. It is supplied loose and has to be mounted by the customer. Anti-Vibration Kit Intrusion proofing protection for condensing Anti-vibration kit made of special rubber pad is provided together with the unit.
7 - Product Description Airway Packaging Domestic hot water management kit Complete wooden package for units without refrigerant and with nitrogen precharge. No refrigerant charge is shipped loose with the unit. The customer has to fill the unit through the apposite connection. It is provided as an accessory to allow the unit managing the control of a 3 ways valve, in order to switch water flow from plant to domestic hot water tank.
Set-Point secondary zone management Controller enables the management of a secondary zone with its own Set-Point. Input is received by a water temperature probe installed on the second SP zone and output is given to a mixing valve managing the control of the second Set-Point. Connect water probe to terminal B12 - GND on the control board (refer to Chapt. 4). Connect 3 ways valve to terminals Y1 - GND on the control board (refer to Chapt. 4).
7 - Product Description 7.
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8 - Technical Data Circuit pressure drop 70 60 ∆P (kPa) 50 40 20 30 30 20 10 0 0,00 0,20 0,50 0,75 1,00 1,25 1,50 1,75 2,00 2,25 2,50 G (l/s) Filter pressure drop* 35 30 ∆P (kPa) 25 20 15 10 5 0 0,00 0,25 0,50 0,75 1,00 1,25 1,50 G (l/s) * 1”1/4 diameter, filtration capacity 500 μm / 35 mesh.
English 8 - Technical Data 8.
8 - Technical Data 8.3 Electrical data SYSCROLL AIR EVO HP Power supply Maximum power input Maximum current input Start-up corrent External fuses Max cable section (*) HEAT EXCHANGER RESISTANCE Power supply Maximum power input 20 V/ph/Hz kW A A A mm2 30 400 ± ( 10%)/3+N/50 13.2 25.9 3.9 32 10 V/ph/Hz W 15.8 30.9 3.
English 8 - Technical Data 8.4 Dimensional Drawings Front view F G F G Side view E 1615 1615 B A Top view NOTES A Water inlet Ø1 1/4” Gas M. B Water outlet Ø1 1/4” Gas M.
8 - Technical Data Dimensional Hydrokit Front view Side view B 2005 B 860 860 C 250 186 D 92 287 1480 305 390 390 D 92 287 Rear view P3 P3 P1 9 9 P4 60 P2 60 P2 60 26 457 509 P1 26 Top view P3 P1 26 1480 C 75 92 287 250 A 305 1480 A 186 186 D 305 C 390 292 2005 292 2005 A 75 B 10 860 10 292 P4 60 1360 1480 860 292 A 75 1480 305 P1 26 Dimensions in mm. P3 457 509 NOTES A Water inlet Ø1 1/4” Gas M. B Water outlet Ø1 1/4” Gas M.
English 8 - Technical Data 8.
DANGER Check the temperature of the leaving fluid When the recovered refrigerant cannot be reused, return it to the manufacturer. Do not throw away the waste oil of the compressor, because it contains refrigerant in solution. DANGER The waste oil must be returned to the manufacturer. Unless otherwise specified, the operations described below may be carried out only by a trained maintenance operator. 9.
English 9 - Maintenance 9.3 Refrigerant charge 9.5 Condenser The condenser’s coils consist of copper pipes and aluminium fins. In the presence of leaks caused by any damage or shock, the coils shall be repaired or replaced by one authorised Service Center. To ensure the effective and correct operation of the condenser coils, it is important to keep the condenser’s surface perfectly clean, and to check that there is no foreign matter, such as leafs, wires, insects, waste etc.
9 - Maintenance 9.8 Sight glass Overheating calculation (S): The sight glass is used for inspecting the refrigerant flow and the humidity % of the refrigerant. The presence of bubbles indicates that the dehydrating filter is clogged or the charge insufficient. S = Tse - Tsa Overheating is regulated through the driver. If the expansion valve cannot be regulated, it is probably broken, and shall be replaced. The replacement must be carried out by a Service Centre.
The table below lists the anomalies of operation of the unit, the relevant causes and the corrective measures. For anomalies of any other type or not listed, contact one of authorised Service Centre for technical assistance. Anomaly Cause Operation The unit continues to work, but without cooling Insufficient charge of refrigerant. Refill. The dehydrating filter is clogged. Replace. Ice on the suction line Wrong calibration of overheating. Excessive noise Increase overheating. Check the charge.
11 - Spare Parts 11.1 Spare part list The table below shows the list of spare parts recommended during the first two years of operation.
After draining operations, the piping of the hydraulic networks can be disconnected and disassembled. During the draining of the refrigeration circuits, do not let the refrigerant overflow in the surrounding atmosphere. DANGER Once they have been disconnected as specified, the packaged units can be disassembled in a single piece.
Systemair srl Via XXV Aprile, 29 20825 Barlassina (MB) Italy Tel. +39 0362 680 1 Fax +39 0362 680 693 www.systemair.com As part of our ongoing product improvement programme, our products are subject to change without prior notice. Non contractual photos. Dans un souci d’amélioration constante, nos produits peuvent être modifiés sans préavis. Photos non contractuelles. In dem Bemühen um ständige Verbesserung können unsere Erzeugnisse ohne vorherige Ankündigung geändert werden.
