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 SYSCROLL AIR CO/HP 40-75 SYSCROLL AIR RE 40-75 English 40 75 kW 40 Français Deutsch Italiano Español Air Cooled Water Chillers and Heat Pumps Refroidisseurs de liquide à condensation par air et pompes à chaleur air-eau Luftgekühlte Flüssigkeitskühler und Wärmepumpen Refrigeratori d’Acqua e Pompe di Calore Ra
1 - FOREWORD 7 - SYSCROLL AIR RE CONTROL 1.1 Introduction ..........................................................................2 7.1 Control system ...................................................................26 1.2 Warranty ..............................................................................2 7.2 Display...............................................................................27 1.3 Emergency stop / Normal stop .............................................2 7.3 Keyboard ...
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 Vessels Directive 97/23/EC, Electromagnetic Interference Directive 2004/108/EC, 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 disassemble connections, filters, joints or other line items 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.
Q periodically check the board’s internal wiring Q Q do not use cables having an inadequate section or flying connections, even for limited periods of time or in an emergency place a warning sign “do not turn on - maintenance in progress” on the external disconnecting switch Q make sure that on-off remote controls are inhibited Q wear suitable personal protective equipment (helmet, safety gloves, goggles and shoes etc.
2 - Safety 2.
English 2 - Safety Electrical warning Adjacent to the master switch Grounding connection on the electrical board, adjacent to the connection Read the instruction on the electrical board On voltage - Adjacent to the master switch Fan Danger ATTENZIONE ! ATTENTION ! Prima di Enlever aprire togliere l’alimentation tensione electrique avant d’ouvrir ACHTUNG ! CAUTION ! ATENCION ! Vor offnen des Disconnect Cortar la gehauses electrical corrente antes hauptschalter supply before de abrir ausschalten open
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 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 Q 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. Q Minimum storage temperature is -25 °C. Q 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. Q 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 4.2 External Water Circuit 4.1 Installation Site DANGER 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 - Basic Unit E D A 12 5 1 G 11 10 8 13 8 COMPONENTS 1 Plate heat exchanger 5 Water filter 8 Pressure point/drain valve 9 Water outlet 10 Water inlet 11 Globe valve 12 Flexible pipes 13 By-pass valve 11 9 G 12 I FS B INLET OUTLET SAFETY/CONTROL DEVICES A Inlet water temperature sensor B Outlet water temperature sensor D Vent valve (105 mbar) E Water safety valve (3 bar) FS Flow switch G Thermometer I Hydrometer Unit side External water circuit - 1
English 4 - Installation External water circuit - 2 Pump 11 6 11 2 E D A D 1 12 5 7 11 G 13 11 6 8 B 12 I FS COMPONENTS 1 Plate heat exchanger 2 Pump 5 Water filter 6 Non-return valve 7 Pressure expansion tank 8 Pressure point/drain valve 9 Water outlet 10 Water inlet 11 Globe valve 12 Flexible pipes 13 By-pass valve 11 11 2 INLET 10 8 OUTLET 9 G SAFETY/CONTROL DEVICES A Inlet water temperature sensor B Outlet water temperature sensor D Vent valve (105 mbar) E Water safety
4 - Installation External water circuit - 2 Pump + tank 11 6 2 7 11 E D D A 12 5 G 11 4 1 10 8 3 11 6 2 13 11 Y 11 9 8 B COMPONENTS 1 Plate heat exchanger 2 Pump 3 Draining valve 4 Water buffer tank 5 Water filter 6 Non-return valve 7 Pressure expansion tank 8 Pressure point/drain valve 9 Water outlet 10 Water inlet 11 Globe valve 12 Flexible pipes 13 By-pass valve INLET I FS SAFETY/CONTROL DEVICES A Inlet water temperature sensor B Outlet water temperature sensor D Vent valve (
4.4 WARNING Before filling the installation, remove any impurity, such as sand, crushed stones and welding scales, coating drops and any other material which might damage the evaporator. When heat pump units work in heating mode, during defrosting cycles, they may discharge water from the base. This is why the units should be installed at least 200 mm above the floor level, so as to allow the free drainage of waste water, without the risk of producing ice banks.
4 - Installation 4.6 Power supply The following connections shall be provided: DANGER Before carrying out any operations on the electrical system, make sure that the unit is deenergized. Q A 3-phase and grounding connection for the power supply circuit. Q The electrical distribution system shall meet the power absorbed by the appliance. Q The disconnecting and magnetothermal switches must be sized to control the starting current of the unit.
English 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.
4 - Installation SyScroll Air CO/HP Version - Electrical Connections 20
SyScroll Air RE - Electrical Connections 21 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 - SyScroll Air CO/HP Control 6 General information Introduction This document contains the information and the operating instructions for SyScroll Air CO/HP units.
6 - SyScroll Air CO/HP Control ICON / COLOR STEADY ICON 4) Program ¤ define parameters, functions, password and to display alarm log BLINKING ICON / RED - Alarm ON - Alarm QUIT / GREEN - Mode: HEATING - Antifreeze+Heat pump ON - Heating mode by remote / GREEN - Mode: COOLING - Cooling mode by remote / GREEN - Mode: STAND-BY - Stand-by mode by remote / GREEN / / / GREEN - Configurable - Configurable / RED - Current HR - Time slots activ.
English 6 - SyScroll Air CO/HP Control 6.
7 - SyScroll Air RE Control Introduction 7.1 Control system This document contains the information and the operating instructions for SyScroll Air RE 2 compressors & electronic control. SyScroll Air RE units are provided with a microprocessor card which is fully programmed by default for the control of a condensing unit. This information is for the after-sales service and the production operators, for the end-of-line testing.
7.2 Display Access to the "display mask" of the machine status. User Manufactured Maintenance In/Out Setpoint Release On/Off Daily time zone The display is an LCD 4 lines x 20 columns. The quantities and the information about the operation of the unit are alternated in the form of subsequent screens, named. 7.3 Keyboard Esc key: allows you to move from one mask to another. Arrows key - Up/Down/Enter + Alarm key: used to display the alarms, to reset them in manual.
7 - SyScroll Air RE Control 7.
8.1 General Information Evaporators SyScroll Air CO/HP units are one-block type with one refrigerant circuit. 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. Evaporators are made of stainless steel plates. They are thermally insulated by means of a thick flexible insulating mattress with closed cells.
8 - Product Description 8.2 Accessories Water Filter - with 1 pump that guarantee 150 kPa of available static pressure; It is assembled on the unit as a standard. - with 2 pumps that guarantee 150 kPa of available static pressure Anti-Vibration Kit Water buffer tank See figure below. The hydro module is available for the units with a pump; it is fitted inside and integrated in the circuit. Flow switch kit The module is entirely enclosed in a RAL 9001 galvanised and painted steel body.
Gauges kit Gauges kit is available as accessory. It is shipped loose and it’s not possible to have it factory mounted. Fan speed control Fan speed control is available as accessory to allow the chiller to operate down to external air temperature. In/Out valve kit In/Out valve kit is available as accessory.
8 - Product Description 8.3 Refrigerant flow diagram - SyScroll Air CO 40 to 75 - R410A 12 G 2 SH A AT SL M BT 10 OIL EQUAL. 1 H 9 INLET 7 HYDRAULIC CIRCUIT E 6 D OUTLET 10 5 S SyScroll Air CO R410A (Fluid group 2): VESSEL CATEGORY (2)/EVALUATION MODULE 2 / mod. D1 2 (sizes 60 to 75) / mod. B+D SAFETY/CONTROL DEVICES A High pressure switch (40.
English 8 - Product Description Refrigerant flow diagram - SyScroll Air HP 40 to 75 - R410A 15 3 G 2 SH A AT M H OIL EQUAL. 1 D OFF 8 BT SL 14 F I 12 INLET 10 HYDRAULIC CIRCUIT 9 5 4 7 S SyScroll Air HP R410A (Fluid group 2): VESSEL CATEGORY (2)/EVALUATION MODULE 2 / mod. D1 2 / mod. D1 2 / mod. D1 2 (sizes 60 to 75) / mod. B+D SAFETY/CONTROL DEVICES A High pressure switch (40.
8 - Product Description Refrigerant flow diagram - SyScroll Air RE 40 to 75 - R410A G 2 SH AT A SL M OIL EQUAL. BT INLET 1 D OUTLET S SyScroll Air RE R410A (Fluid group 2): COMPONENTS 1 Compressor tandem scroll type 2 Air cooled condenser VESSEL CATEGORY (2)/EVALUATION MODULE 2 / mod. D1 SAFETY / CONTROL DEVICES A High pressure switch (40.
English 9 - Technical Data 9.
9 - Technical Data Available static pressure (kPa) Optional pump available static pressure 240 230 220 210 200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 40-45 50 60-75 5500 6000 6500 7000 7500 8000 8500 9000 9500 1000 10500 11000 11500 12000 12500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 Water flow (l/h) The curves are referred to 2P+T unit. Unit without tank could have higher performance. Note: Power input (kW) Optional pump power input 1.8 1.75 1.7 1.65 1.
English 9 - Technical Data 9.
9 - Technical Data SyScroll Air CO 40 to 75 - SLN Version SyScroll AIR CO SLN Power supply Number of refrigerant circuits Total capacity steps REFRIGERANT Type Charge (1) COMPRESSOR Type Number Start-up type Oil type N°of loading stages EVAPORATOR Type Number Water flow rate Pressure drop DESUPERHEATER Type Number Water flow rate Pressure drop FANS Type Number Nominal speed Air flow rate Power input AIR COOLED CONDENSER Type Number Total coil face area per coil Number of rows HYDRAULIC CONNECTIONS (EVAPORAT
English 9 - Technical Data SyScroll Air CO 40 to 75 - HT/HPF Version SyScroll Air CO HT/HPF Power supply Number of refrigerant circuits Total capacity steps REFRIGERANT Type Charge (1) COMPRESSOR Type Number Start-up type Oil type N°of loading stages EVAPORATOR Type Number Water flow rate Pressure drop DESUPERHEATER Type Number Water flow rate Pressure drop FANS Type Number Nominal speed Air flow rate Power input AIR COOLED CONDENSER Type Number Total coil face area per coil Number of rows HYDRAULIC CONNEC
9 - Technical Data SyScroll Air HP 40 to 75 - BLN Version SyScroll Air HP BLN Power supply Number of refrigerant circuits Total capacity steps REFRIGERANT Type Charge (1) COMPRESSOR Type Number Start-up type Oil type N°of loading stages EVAPORATOR Type Number Water flow rate Pressure drop DESUPERHEATER Type Number Water flow rate Pressure drop FANS Type Number Nominal speed Air flow rate Power input AIR COOLED CONDENSER Type Number Total coil face area per coil Number of rows HYDRAULIC CONNECTIONS (EVAPORAT
English 9 - Technical Data SyScroll Air HP 40 to 75 - SLN Version SyScroll Air HP SLN Power supply Number of refrigerant circuits Total capacity steps REFRIGERANT Type Charge (1) COMPRESSOR Type Number Start-up type Oil type N°of loading stages EVAPORATOR Type Number Water flow rate Pressure drop DESUPERHEATER Type Number Water flow rate Pressure drop FANS Type Number Nominal speed Air flow rate Power input AIR COOLED CONDENSER Type Number Total coil face area per coil Number of rows HYDRAULIC CONNECTIONS
9 - Technical Data SyScroll Air HP 40 to 75 - HT/HPF Version SyScroll Air HP HT/HPF Power supply Number of refrigerant circuits Total capacity steps REFRIGERANT Type Charge (1) COMPRESSOR Type Number Start-up type Oil type N°of loading stages EVAPORATOR Type Number Water flow rate Pressure drop DESUPERHEATER Type Number Water flow rate Pressure drop FANS Type Number Nominal speed Air flow rate Power input AIR COOLED CONDENSER Type Number Total coil face area per coil Number of rows HYDRAULIC CONNECTIONS (EV
English 9 - Technical Data SyScroll Air RE 40 to 75 - BLN Version SyScroll Air RE BLN Power supply 40 Number of refrigerant circuits Total capacity steps 45 V/ph/Hz % 50 60 65 75 400V/3/50Hz 1 1 0-50-100 0-50-100 1 1 1 0-50-100 0-44-56-100 0-50-100 1 0-50-100 REFRIGERANT Type R410A COMPRESSOR Type Scroll Number 2 2 2 Start-up type 2 2 2 0/100 0/100 0/100 Direct Oil type POE N°of loading stages 0/100 0/100 0/100 1 1 1 1 1 1 FANS Type Axial Number Nominal speed
9 - Technical Data SyScroll Air RE 40 to 75 - SLN Version SyScroll Air RE SLN Power supply 40 Number of refrigerant circuits Total capacity steps 45 V/ph/Hz % 50 60 65 75 400V/3/50Hz 1 1 0-50-100 0-50-100 1 1 1 0-50-100 0-44-56-100 0-50-100 1 0-50-100 REFRIGERANT Type R410A COMPRESSOR Type Scroll Number 2 2 2 Start-up type 2 2 2 0/100 0/100 0/100 Direct Oil type POE N°of loading stages 0/100 0/100 0/100 1 1 1 1 1 1 FANS Type Axial Number Nominal speed rpm 53
English 9 - Technical Data SyScroll Air RE 40 to 75 - HT/HPF Version SyScroll Air RE HT/HPF Power supply 40 Number of refrigerant circuits Total capacity steps 45 V/ph/Hz % 50 60 65 75 400V/3/50Hz 1 1 0-50-100 0-50-100 1 1 1 0-50-100 0-44-56-100 0-50-100 1 0-50-100 REFRIGERANT Type R410A COMPRESSOR Type Scroll Number 2 2 2 Start-up type 2 2 2 0/100 0/100 0/100 Direct Oil type POE N°of loading stages 0/100 0/100 0/100 1 1 1 1 1 1 FANS Type Axial Number Nominal
9 - Technical Data SyScroll Air RE Refrigerant Lines SyScroll Air RE Unit 40 45 50 60 65 SyScroll Air RE 40 45 50 60 65 Unit connections Suction Liquid [inch] [inch] 5/8” 1”3/8 5/8” 1”3/8 5/8” 1”3/8 7/8” 1”3/8 7/8” 1”3/8 Line length [m] 10 20 30 10 20 30 10 20 30 10 20 30 10 20 30 Suction line dimensions [inch] Total equivalent lenght [m] 10 20 30 1”3/8 1”3/8 1”3/8 1”3/8 1”3/8 1”5/8 1”3/8 1”3/8 1”5/8 1”3/8 1”3/8 1”5/8 1”3/8 1”5/8 1”5/8 ø Suction line [inch] [mm] 1”3/8 34,93 1”3/8 34,93 1”3/8 34,93
English 9 - Technical Data 9.3 Electrical data SyScroll Air CO/HP/RE BLN without pump Rated voltage Max. absorbed power with pump Max. current FLA Max. start-up current LRA External fuses Max. cable section (*) EXCHANGER RESISTANCE Rated voltage Max. absorbed power SyScroll Air CO/HP/RE SLN without pump Rated voltage Max. absorbed power with pump Max. current FLA Max. start-up current LRA External fuses Max. cable section (*) EXCHANGER RESISTANCE Rated voltage Max.
9 - Technical Data Compressor electrical data SyScroll Air CO/HP/RE BLN-SLN-HT/HPF Number Max. absorbed power kW Rated current A Max current A Oil pan resistor W 40 2 9.1+9.1 95+95 16+16 90+90 45 2 10.2+10.2 111+111 21+21 90+90 50 2 12+12 118+118 22+22 90+90 60 2 14.8+12 140+118 31+22 90+90 65 2 14.8+14.8 140+140 31+31 90+90 75 2 17.1+17.1 173+173 40+40 90+90 40 45 50 60 65 75 1 0.98 2.4 1 0.98 2.4 1 2.00 4.3 1 2.00 4.3 40 45 65 75 1 0.57 1.2 1 0.57 1.2 1 1.27 2.5 1 1.27 2.
English 9 - Technical Data 9.
9 - Technical Data 9.5 Dimensional Drawings - Units SyScroll Air CO/HP 40-50 23 Bottom view 4 x Ø10 P4 1054 P1 23 P2 P3 112 1527 Front view 112 L I C 1580 1685 1395 1355 H 25 F G D 50 1000 50 4 x Ø22 Side view Top view N A 987 M P3 23 517 250 E 470 B 987 1100 P1 23 730 950 678 1054 1100 P2 112 1527 1750 188 Dimensions in mm.
English 9 - Technical Data Dimensional Drawings - Units SyScroll Air CO/HP 60-75 23 Bottom view P1 P4 1054 4 x Ø10 23 P2 P3 112 112 1977 Front view I L C 25 1580 1685 1395 1355 H F G D 50 1000 50 4 x Ø22 Side view Top view N A 987 M 23 987 1100 P1 23 730 950 763 1054 P2 1100 B P3 698 250 470 E 112 1977 2200 188 Dimensions in mm.
9 - Technical Data Dimensional Drawings - Units SyScroll Air RE 40 to 50 - R410A 23 Bottom view 4 x Ø10 P4 1054 P1 23 P2 112 P3 1527 Front view 112 L I C 1580 1685 1355 1395 H 25 F G D 50 1000 50 4 x Ø22 Side view Top view 987 P3 23 517 987 23 112 75 Electrical auxiliary lines Electrical power supply High pressure tap Low pressure tap Gauge kit (accessory) Main switch Control keypad/display 1527 1750 612 Dimensions in mm.
English 9 - Technical Data Dimensional Drawings - Units SyScroll Air RE 60 to 75 - R410A 23 Bottom view P1 P4 1054 4 x Ø10 23 P2 112 P3 112 1977 Front view I L C 25 1580 1685 1395 1355 H F G D 50 1000 50 4 x Ø22 Side view Top view 987 P3 23 698 987 1100 P1 R 23 241 Q 1054 1100 P2 112 1977 2200 75 698 Dimensions in mm.
9 - Technical Data 9.
DANGER English 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. 10.
10 - Maintenance 10.5 Condenser 10.3 Refrigerant charge 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.
10.8 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 thermostatic expansion valve. Make the adjusting screw follow a complete turn, and operate the appliance for five minutes. A colour indicator is positioned inside the sight glass.
11 - 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. Excessive noise Increase overheating.
English 12 - Spare Parts 12.1 Spare part list The table below shows the list of spare parts recommended during the first two years of operation.
13 - Dismantling, Demolition and Scrapping 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.
COSTRUTTORE / MANUFACTURE - ITALY BUONE NORME DI MANUTENZIONE DEI DISPOSITIVI DI SICUREZZA MONTATI SUL GRUPPO FRIGORIFERO Gentile Cliente, Le ricordiamo alcune indicazioni circa le modalità di manutenzione dei dispositivi di sicurezza montati sul gruppo frigorifero da Lei acquistato. I dispositivi di sicurezza montati sul gruppo sono stati verificati dal COSTRUTTORE a norma di legge.
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. Fotos nicht vertraglich bindend.
