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 AQVL/AQVC/AQVH/AQVR English 80 140 kW 90 150 kW Français Deutsch Italiano Español Air-Cooled Water Chillers and Heat Pumps Refroidisseurs d’Eau et Pompe à Chaleur Refroidis à l’Air Luftgekühlte Flüssigkeitskühler und Wärmepumpen Refrigeratori d’Acqua e Pompe di Calore Raffreddati ad Aria Enfriadores de A
1 FOREWORD 1.1 1.2 1.3 1.4 Introduction Warranty Emergency stop/Normal stop An introduction to this manual 2 SAFETY 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Foreword Definitions Access to the unit General precautions Precautions against residual risks Precautions during maintenance operations Safety labels Safety regulations 3 TRANSPORT, LIFTING AND POSITIONING 3.1 3.2 3.3 3.4 Inspection Lifting Anchoring Storage 4 INSTALLATION 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.
Foreword 1 FOREWORD 1.1 Introduction Units, manufactured to state-of-the-art design and implementation standards, ensure top performance, reliability and fitness to any type of air-conditioning systems. These units are designed for cooling water or glycoled water (and for water heating in heat pump models) and are unfit for any purposes other than those specified in this manual.
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.
Safety OPERATOR: means a person authorised by the owner to do on unit all the regulation and control operations expressly described in this manual, that must be strictly complied with, without exceeding the scope of the tasks entrusted to him.
n n n check all the electrical connections, the connecting cables, and in particular the insulation; replace worn or damaged cables periodically check the board’s internal wiring do not use cables having an inadequate section or flying connections, even for limited periods of time or in an emergency 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 n n n n if you have to disassemble a piece,
Safety 2.7 Safety labels The labels below will be affixed to each unit in the indicated point: Identification of the refrigerant External door CODICE PRODOTTO NEUTRO PRODUCT CODE MODELLO MODEL 0425 MO.NO MATRICOLA SERIAL NO. Instruction for the lifting ANNO DI COSTRUZIONE Manuf. Year REFR. CIRCUIT GWP 1 2 3 4 CHARGE (Kg) (tCO₂eq) PS (LATO ALTA / LATO BASSA) bar PS (HIGH / LOW SIDE) TS (ALTA / BASSA) °C TS (HIGH / LOW) ALIM.
English Safety ATTENZIONE ! ATTENTION ! ACHTUNG ! Prima di Enlever aprire togliere l’alimentation tensione electrique avant d’ouvrir CAUTION ! ATENCION ! Vor offnen des Disconnect Cortar la gehauses electrical corrente antes hauptschalter supply before de abrir ausschalten opening el aparato Electrical warning Adjacent to the master switch Grounding connection on the electrical board, adjacent to the connection Read the instruction on the electrical board Start-up warning - Outside the door of the
Safety 2.8 Safety regulations Refrigerant data Safety data: R410A Toxicity Low Contact with skin 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. 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.
General precautions 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.
Safety 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. Ingestion Seek medical advice immediately.
3 TRANSPORT, LIFTING AND POSITIONING Refrigerators are supplied assembled (apart from standard antivibrating rubber supports, that will be installed on site). The equipment are full of refrigerant and oil, in the quantity required for a proper operation. 3.1 English Transport, Lifting and Positioning It is recommended to use a spacer to prevent cables from damaging the unit (see the figure).
Transport, Lifting and Positioning During the lifting and handling of the unit, be careful not to damage the finned pack of the coils positioned on the sides of the unit. The sides of the unit must be protected by cardboard or plywood sheets. WARNING It is recommended not to remove the protective plastic envelope, that should prevent scraps from penetrating into the appliance and any damage to the surfaces, until the unit is ready for operation.
4 English Installation INSTALLATION 4.1 DANGER Positioning of the unit Before installing the unit, make sure that the structure of the building and/or the supporting surface can withstand the weight of the appliance. The weights of the units are listed in Chapter 8 of this manual. 4.2 n n Spring Isolator Installation Prepare the base, that must be flat and plane. Lift the appliance and insert shock absorbers as follows: These units have been designed for outdoor installation on a solid surface.
Installation 4.3 External Water Circuit 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. WARNING The external water circuit shall guarantee a constant water flow rate through the circulating refrigerant/water heat exchanger (evaporator) under steady operating conditions and in case of a load variation.
English Installation AQVL-AQVH 85-140 Hydraulic System Basic A 12 5 1 G 10 8 13 8 B INLET 11 12 FS Components: 1. 5. 8. 9. 10. 11. 12. 13. 11 9 G OUTLET Safety/control devices: Plate heat exchanger Water filter Pressure point/drain valve Water outlet Water inlet Globe valve Flexible pipes By pass valve A. B. FS. G.
Installation AQVL-AQVH 85-140 Hydraulic System 2P 6 2 E D A 7 1 12 5 G 10 8 6 11 2 8 12 FS Components: 1. 2. 5. 6. 7. 8. 9. 10. 11. 12. 13. INLET 8 13 B 11 9 G OUTLET Safety/control devices: Plate heat exchanger Pump Water filter Non-return valve Pressure expansion tank Pressure point/drain valve Water outlet Water inlet Globe valve Flexible pipes By pass valve A. B. D. E. FS. G.
English Installation AQVL-AQVH 85-140 Hydraulic System 1P+T D A 7 2 6 1 8 B Components: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. E 11 10 13 4 Plate heat exchanger Pump Draining valve Water buffer tank Water filter Non-return valve Pressure expansion tank Pressure point/drain valve Water outlet Water inlet Globe valve Flexible pipes By pass valve G 8 11 8 12 5 11 12 FS D INLET 9 G OUTLET Safety/control devices: A. B. D. E. FS. G.
Installation 4.4 Water connections The attachments at the water inlet and outlet shall be connected in compliance with the instructions which can be found on the labels in the proximity of the attachments. WARNING Connect the water lines of the plants with the attachments of the unit whose diameters and positions are shown by Chapter 8. 4.5 Defrost water drainage (only for AQVH units) When heat pump units work in heating mode, during defrosting cycles, they may discharge water from the base.
4.8 Connecting plate-type evaporator temperature sensors AQVL and AQVH units are provided with fittings for hydraulic connections between heat exchangers and plant. Each fittings is complete with sensor well to fasten temperature sensor (BT-IN and BT-OUT). Fittings are supplied separate and must be mounted during the installation of the unit, as explained in the instruction below.
Installation 4.9 Microchannel type condenser coils On cooling only unit fitted with microchannel type condensers, it is necessary to remove the fixation Page 20 screws, once unit is installed, as shown in figure below.
5 START-UP WARNING NOTE The unit must be started for the first time by personnel suitably trained by one 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.
Start-up pressor and in case of stabilised operation. n The fan’s current absorption. Check that the condensing and evaporation temperatures, during operation at high and low pressure detected by the pressure gauges of the refrigerant, are within the following range: (On the units not provided with HP/LP pressure gauges for the refrigerant, connect a pressure gauge to the Shrader valves on the refrigeration circuit). HP side Approx.
6 GENERAL INFORMATION Introduction This document contains the information and the operating instructions for AQVL-AQVH-AQVC 4 compressors & electronic control. This information is for the after-sales service and the production operators, for the end-of-line testing.
Control Access to the “display mask” of the machine status. 6.2 Display 6.3 Keyboard Esc key: allows you to move from one mask to another. Alarm key: used to display the alarms, to reset them in manual. Press it one to display the mask of the activated alarm, press it again to reset the alarm signal. Prg-Esc keys: Pressing these keys at the same time,allows you to turn the unit on/off.
n Alarms Alarm code 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 20 21 22 23 24 25 27 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 56 57 59 60 61 Description Main board - EPROM Failure Main board - Clock card Failure Main board - External air temperature sensor fault Main board - Return Water temperature sensor fault Main board - Leaving Water temperature sys 1 sensor fault Main board - Leaving Water temperature sys 2 sensor fault Main board - Low pressure sys 1 sensor fault
Control Alarm code 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 79 80 81 82 83 84 85 86 91 92 93 94 95 96 122 123 124 125 127 128 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 159 160 187 188 191 192 Page 26 Description EPROM Error Driver 2 Driver 1 S1 Sensor fault Driver 1 S3 Sensor fault Driver 1 S2 Sensor fault Driver 1 S4 Sensor fault Driver 2 S1 Sensor fault Driver 2 S2 Sensor fault EEV motor Error (Check viring) Sys 1 EEV motor Error (Check viring) Sys 2 Driver 1 Battery alarm Driver
n Setpoint Pressing the Set key allows you to enter the Set point level accessible to the user.
General Description 7 7.1 PRODUCT DESCRIPTION General Information AQVL/AQVH units are one-block type with two refrigerant circuits. They are intended to cool down the water required for any air-conditioning application as well as any other fluid, such as for example glycol water. These units are completely assembled at works. They are equipped with all the refrigerating connections and the internal electrical wiring required for a rapid installation on the field.
English General Description AQVL refrigeration diagram AT M S A AT A S M 7 7 1 1 OIL EQUAL. OIL EQUAL. B G 2 5 5 G 5 BT D B UNIT CONTROL 6 S EXV CONTROL S S 2 BT EXV CONTROL S D 5 UNIT CONTROL FS S Components: 1. 2. 3. 4. 5. 6. 7. 4 3 4 Safety/control devices: Vessel Category (≥ 2) / Evaluation module 2 / mod.
General Description AQVC refrigeration diagram AT M A S S OIL EQUAL. AT OIL EQUAL. B B 2 M 1 1 G A 3 3 S D D S S 3 Components: 1. 2. 3. Compressor Tandem Scroll Type Air cooled condenser Globe valve Page 30 2 S BT BT G Vessel Category (≥ 2) / Evaluation module 2 / mod. D1 3 3 3 Safety/control devices: A. B. AT. BT. D. G. M. S.
8 English Technical data TECHNICAL DATA 8.
Technical data 8.2 Technical data AQVL STD Power supply Number of refrigerant circuits Total capacity steps 85 95 V/ph/Hz 2 % 105 115 125 140 2 2 400V(± 10%)/3/50Hz 2 2 2 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75100 100 100 100 100 100 Refrigerant Type / GWP Charge 1/2 (1) R410A / 2.
AQVL S Power supply Number of refrigerant circuits Total capacity steps V/ph/Hz % 85 95 105 115 125 140 400V(± 10%)/3/50Hz 2 2 2 2 2 2 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75100 100 100 100 100 100 6/6 6/6 Refrigerant Type / GWP Charge 1/2 (1) R410A / 2.
Technical data AQVL HT Power supply Number of refrigerant circuits Total capacity steps V/ph/Hz % 85 95 105 115 125 140 400V(± 10%)/3/50Hz 2 2 2 2 2 2 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75100 100 100 100 100 100 6/6 6/6 Refrigerant Type / GWP Charge 1/2 (1) R410A / 2.
AQVH STD Power supply Number of refrigerant circuits Total capacity steps 85 V/ph/Hz % 95 105 115 125 140 400V(± 10%)/3/50Hz 2 2 2 2 2 2 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75100 100 100 100 100 100 Refrigerant Type / GWP Charge 1/2 (1) R410A / 2.
Technical data AQVH S Power supply Number of refrigerant circuits Total capacity steps 85 95 105 115 125 140 2 2 V/ph/Hz 400V(± 10%)/3/50Hz % 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75100 100 100 100 100 100 2 2 2 2 Refrigerant Type / GWP Charge 1/2 (1) R410A / 2.
AQVH HT Power supply Number of refrigerant circuits Total capacity steps 85 95 105 115 125 140 2 2 V/ph/Hz 400V(± 10%)/3/50Hz % 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75100 100 100 100 100 100 2 2 2 2 Refrigerant Type / GWP Charge 1/2 (1) R410A / 2.
Technical data AQVC STD-HT Power supply Number of circuits Capacity steps 85 95 105 115 125 140 2 2 V/ph/Hz 400V(± 10%)/3/50Hz % 0-25-50-75- 0-25-50-75- 0-24-47-74- 0-25-50-75- 0-22-43-72- 0-25-50-75100 100 100 100 100 100 2 2 2 2 Refrigerant Type / GWP Charge 1/2 (1) R410A / 2.
8.3 Unit electrical data AQVL/AQVH STD Rated voltage Max. absorbed power Rated Current Max. current FLA Max. start-up current LRA External fuses Max. cable section (*) Exchanger resistance Rated voltage Max. absorbed power AQVL/AQVH S Rated voltage Max. absorbed power Rated Current Max. current FLA Max. start-up current LRA External fuses Max. cable section (*) Exchanger resistance Rated voltage Max.
Technical data Compressor electrical data AQVL/AQVH STD-S Number Max.
8.
Technical data Pressure drop [kPa] AQVL - Evaporator pressure drop Water flow [l/s] Pressure drop [kPa] AQVH - Evaporator pressure drop Water flow [l/s] Pressure drop [kPa] AQVL - Desuperheather pressure drop Water flow [l/s] Page 42
8.
Technical data AQVL 85 - 140 Cu/Cu Version STD/S/HT AQVL Cu/Cu 85 95 105 115 125 140 85 1P 95 1P 105 1P 115 1P 125 1P 140 1P 85 2P 95 2P 105 2P 115 2P 125 2P 140 2P 85 3P 95 3P 105 3P 115 3P 125 3P 140 3P 85 1PT 95 1PT 105 1PT 115 1PT 125 1PT 140 1PT 85 2PT 95 2PT 105 2PT 115 2PT 125 2PT 140 2PT Weight distribution F1 F2 F3 F4 kg 474 481 493 521 495 541 490 532 511 539 548 563 496 537 517 545 555 570 498 539 519 546 559 574 486 528 508 535 558 573 493 535 514 542 567 582 kg 464 470 499 509 484 527 45
AQVL MCHX 85 95 105 115 125 140 85 1P 95 1P 105 1P 115 1P 125 1P 140 1P 85 2P 95 2P 105 2P 115 2P 125 2P 140 2P 85 3P 95 3P 105 3P 115 3P 125 3P 140 3P 85 1PT 95 1PT 105 1PT 115 1PT 125 1PT 140 1PT 85 2PT 95 2PT 105 2PT 115 2PT 125 2PT 140 2PT Weight distribution F1 F2 F3 F4 kg 383 481 389 392 395 388 397 406 410 413 443 418 403 409 415 418 451 426 404 413 416 419 454 429 385 394 397 401 454 429 391 400 404 407 462 437 kg 373 470 379 383 384 378 363 373 376 378 409 382 363 370 376 378 411 383 361 371
Technical data AQVH 85 - 140 Al/Cu Version STD/S/HT AQVH Al/Cu 85 95 105 115 125 140 85 1P 95 1P 105 1P 115 1P 125 1P 140 1P 85 2P 95 2P 105 2P 115 2P 125 2P 140 2P 85 3P 95 3P 105 3P 115 3P 125 3P 140 3P 85 1PT 95 1PT 105 1PT 115 1PT 125 1PT 140 1PT 85 2PT 95 2PT 105 2PT 115 2PT 125 2PT 140 2PT Weight distribution F1 F2 F3 F4 kg 416 422 431 444 435 456 427 453 443 455 489 478 433 458 449 461 497 486 434 459 450 462 500 489 415 440 431 443 500 488 421 446 437 449 508 497 kg 412 419 434 439 432 451 39
AQVH 85 - 140 Cu/Cu Version STD/S/HT AQVH Cu/Cu 85 95 105 115 125 140 85 1P 95 1P 105 1P 115 1P 125 1P 140 1P 85 2P 95 2P 105 2P 115 2P 125 2P 140 2P 85 3P 95 3P 105 3P 115 3P 125 3P 140 3P 85 1PT 95 1PT 105 1PT 115 1PT 125 1PT 140 1PT 85 2PT 95 2PT 105 2PT 115 2PT 125 2PT 140 2PT Weight distribution F1 F2 F3 F4 kg 469 476 489 515 504 549 481 529 500 526 559 571 486 535 506 532 566 578 487 536 507 533 570 582 468 517 488 514 569 581 475 523 494 520 578 590 kg 465 471 500 509 500 542 449 496 484 492 52
Technical data AQVC 85 - 140 Al/Cu Version STD/S/HT AQVC Al/Cu 85 95 105 115 125 140 Weight distribution F1 F2 F3 F4 kg 385 391 395 408 384 406 kg 384 390 403 407 385 405 kg 101 101 104 114 148 166 kg 100 101 111 114 149 165 Operating weight kg 971 983 1013 1043 1066 1142 Ship- P1-P4 coordinates* ping a b weight kg 971 983 1013 1043 1066 1142 mm 1039 1039 1039 1039 1039 1039 mm 1382 1382 1382 1382 1982 1982 CG coordinates x y mm 547 547 555 547 549 547 mm 1584 1587 1578 1569 1920 1897 AQVC
8.6 English Technical data Dimensional Drawings Units AQVL/AQVH 85-115 R410A 30 BOTTOM VIEW P3 P2 P4 4x 1040 P1 1382 492 M N 250 D A B C 575 L I G 300 230 208 369 250 965 802 304 1041 50 O 1955 2185 150 E-F SIDE VIEW 40 FRONT VIEW 4x 382 30 E-F 17 H 53 580 2555 1100 53 1250 (Only for movimentation) P2 988 988 P4 70 262 P1 1612 2256 P3 382 56 988 1100 70 56 TOP VIEW Notes: ABCD E F G H I L M WATER CONNECTION 2 1/2” GAS M.
Technical data Units AQVL/AQVH 125-140 R410A 30 BOTTOM VIEW P3 P2 P4 4x 1040 P1 382 1982 492 FRONT VIEW 30 E-F 17 SIDE VIEW 150 250 O 1625 M L N 250 304 D G 380 575 50 C H 4x A B 230 208 802 965 E-F 369 I 53 53 1180 1250(Only for movimentation) 3155 P2 988 988 P4 70 262 P1 2212 2856 P3 382 56 988 1100 70 56 TOP VIEW Notes: ABCD E F G H I L M WATER CONNECTION 2 1/2” GAS M.
8.
Maintenance MAINTENANCE Do not throw away the waste oil of the compressor, because it contains refrigerant in solution. The waste oil must be returned to the manufacturer. Check the temperature of the leaving fluid • Check the pressure drops in the heat exchanger • Check for electric absorption • Unless otherwise specified, the operations described below may be carried out only by a trained maintenance operator.
9.3 WARNING Refrigerant charge Do not inject refrigerant liquid into the LP side of the circuit. Be very careful, and charge the circuit properly. If the charge is insufficient, the efficiency of the unit will be lower than expected. (In the worst of cases the LP transducer may stop the unit.
Maintenance ence of bubbles indicates that the dehydrating filter is clogged or the charge insufficient. A colour indicator is positioned inside the sight glass. If you compare the colour of the indicator to the scale on the ring of the sight glass, you can calculate the percentage of humidity of the refrigerant. If it is excessive, replace the filter’s cartridge, operate the appliance for 1 day and then check the humidity % again.
English Troubleshooting 10 TROUBLESHOOTING 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.
Troubleshooting Anomaly Cause Operation Activation of the HP alarm, stop of the unit. Failure of the pressure switch. Check the operation of the pressure switch, replace it if defective. The delivery valve is partially closed. Open the valve and replace it, if faulty. Substances with condensable gases in the circuit. Drain the circuit. The fan of the condenser is stopped. Check cables and motor. If defective, repair or replace. The liquid line is too hot. Insufficient charge.
English Spare parts 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. Component Fan Differential water pressure switch High pressure transducer Low pressure transducer Electronic expansion valve Gas filter 4 way valve Electronic main board Auxiliary circuit trasformer Compressor contactor Pump contactor Water sensor Air sensor Auxiliary contact Driver EEV Fuses Number 2 1 2 4 2 2 2 1 1 2 1 4 1 4 2 4 11.
Dismantling, Demolition and Scrapping 12 DISMANTLING, DEMOLITION AND SCRAPPING DANGER During the draining of the refrigeration circuits, do not let the refrigerant overflow in the surrounding atmosphere. The circuit must be drained using suitable recovery equipment. Do not disperse the waste oil of the compressors in the environment, since it contains some dissolved refrigerant. DANGER For the disposal, contact the competent authority for information.
English Note Page 59
Note Page 60
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.
