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 VLH/VLC English 173 300 kW 200 Français Deutsch Italiano Español Air Cooled Water Heat Pump Pompes de Chaleur à Eau Refroidies à Air Luftgekühlte Wärmepumpen Pompe di Calore ad Acqua Raffreddate ad Aria Bombas de Calor de Agua Refrigerados por Aire 337 kW Part number / Code / Code / Codice / Código: 3
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 ENGINEER: means a person authorised directly by manufacturer or, in all EC countries, excluding Italy, under his full responsibility, by the distributor of product, to perform any routine and extraordinary maintenance operations, as well as any regulation, control, servicing operations and the replacement of pieces, as may be necessary during the life of the unit. 2.
to the instructions provided in this manual and on the unit’s panelling n n n n if you have to disassemble a piece, make sure that it has been properly mounted again before restarting the unit do not touch the delivery pipes from the compressor, the compressor and any other piping or component inside the machine before wearing protective gloves on the units installed indoor, connect the safety valve of the refrigeration circuit to a piping network that can channel any overflowing refrigerant outside re
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 MODEL 0425 MO.NO MATRICOLA SERIAL NO. 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 EIN - INLET ENTRÉE - ENTRATA AUS - OUTLET SORTIE - USCITA Fitting identification Adjacent to fittings Start-up warning - Outside the door of the electrical board Grounding connection on the electrical board, adjacent to the connection Warning - safety valves’ vents Warning - high-temperature zones Adjacent to hot pipes or components ATTENTION! Don’t leave the unit with water inside hydraulic circuit during winter or when it is in stand by.
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 For lifting operations, use only tools and material fit for this purpose, in accordance with accident-prevention regulations. WARNING 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.
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 hydraulic 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 3)Check AVM’s heights refers to assembly’s instructions enclosed to the accesory and regulate it using an adeguate spanner. The external hydraulic circuit should consist of the following elements: n A circulation pump that can ensure the necessary capacity and discharge head.
English Installation Then: n Provide the evaporator with a by-pass circuit equipped with a valve to wash the plant. n n Insulate the piping, to prevent the risk of heat loss. Position a filter on the suction side of the evaporator of the heat recovery condenser.
Installation 4.6 Power supply Before carrying out any operations on the electrical system, make sure that the unit is deenergised. DANGER It is important that the appliance is grounded. DANGER The company in charge of the installation shall conform to the standards applicable to outdoor electrical connections. WARNING 4.
English Installation VLH Version – Electrical Connections VLS/VLH/VLC Version – Electrical Connections Page 17
Installation 4.8 Connecting plate-type evaporator temperature sensors VLH 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.
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 5.3 Checking the operation Check the following: n The temperature of the water entering the evaporator. n n n n The temperature of the water leaving the evaporator. The level of the water flow rate in the evaporator, if possible. The current absorption upon the start of the compressor and in case of stabilised operation. The fan’s current absorption.
6 English Control GENERAL INFORMATION Introduction This document contains the information and the operating instructions for 4 compressors & electronic control. This information is for the after-sales service and the production operators.
Control Access to the “display mask” of the machine status. 6.2 Display 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. Up-Down keys: allows you to set the control parameters’ values and to move from one mask to another (not backlighted).
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 24 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
6.4 Protection and Safety Equipment Defrosting System (only for VLH models) The VLH units are provided with an automatic defrosting system, which prevents the formation of excessive ice banks on coolant/air exchangers during heat pump operation.
Control 6.5 HPF version configuration Units equipped with High pressure fan (HPF) can be set-up on the field to give the unit a specific static pressure. By entering parameter in service level - Max Speed (Vdc) - it is possible to modify high static pressure.
7 English General Description PRODUCT DESCRIPTION 7.1 Introduction The VLH units are water chillers /air-water heat pumps provided with hermetic scroll compressors with two refrigeration circuits. These units are fit for cooling and heating intermediate fluids (glycoled water), for air-conditioning applications in industrial processes. These units can be installed outdoor on the roof of a building or at ground level.
General Description 7.6 7.7 Air heat exchanger Coils are made of copper pipes in staggered rows, mechanically expanded inside an aluminium finned pack. Fans Control Fans are of directly coupling propeller type, provided with aluminium blade with wing profile. Each fan is provided with galvanised steel accidentprevention guard. Finally, motors are completely closed, protection class IP54, protection thermostat immersed in windings.
English General Description VLC refrigeration diagram Components: 1) Compressor Tandem Scroll Type 2) Air cooled condenser 3) Globe valve Safety /control devices: A - High Pressure switch (42 bar) AT - High Pressure transducer BT - Low Pressure transducer D - Air temperature sensor G - PED pressure relief valve (46 bar) S - 5/16” Shrader connenction (service only) Pipe connection with Shrader Valve Page 29
General Description 7.8 Electric power supply and control system RS-485 serial card (for MODBUS or LONWORK or BACNET ) The control compartment contains and electronic card with keyboard and a display for working parameters, alarms, if any, and operating blocks. It is complete with remote control switches and protection fuses for the motors of compressors, fans and pumps.
8 8.1 English Technical data TECHNICAL DATA Pressure drops PRESSURE DROP IN THE EVAPORATOR K Minimum flow rate VLH 704 VLH 804 VLH 904 VLH 1004 VLH 1104 VLH 1204 kPa/(l/s)^2 0,66 0,54 0,19 0,19 0,19 0,19 l/s 5,3 5,9 6,8 7,5 8,3 9,2 Nominal flow rate l/s 8,5 9,5 10,9 12 13,4 14,7 Max. water flow rate l/s 14,1 15,8 18,2 20 22,3 24,5 Min. pressure drops kPa 18,5 19,2 9 10,8 13,4 16,3 Nominal pressure drops kPa 47,5 49,1 23,1 27,7 34,4 41,7 Max.
Technical data 8.2 Technical data VLH STD Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 704 V/ph/Hz % 804 904 400 (±10%) / 3 / 50 2 2 2 20-50-70-100 25-50-75-100 28-50-78-100 R410A / 2.
VLH STD Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 1004 V/ph/Hz 1104 1204 400 (±10%) / 3 / 50 2 2 2 % 25-50-75-100 23-50-73-100 25-50-75-100 kg 30,5/30,5 34/34 37,5/37,5 tCO2eq 63,7/63,7 71,0/71,0 78,3/78,3 R410A / 2.
Technical data VLH L Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 704 V/ph/Hz % 804 904 400 (±10%) / 3 / 50 2 2 2 20-50-70-100 25-50-75-100 28-50-78-100 R410A / 2.
VLH L Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 1004 V/ph/Hz 1104 1204 400 (±10%) / 3 / 50 2 2 2 % 25-50-75-100 23-50-73-100 25-50-75-100 kg 30,5/30,5 34/34 37,5/37,5 tCO2eq 63,7/63,7 71,0/71,0 78,3/78,3 R410A / 2.
Technical data VLH S Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 704 V/ph/Hz % 804 904 400 (±10%) / 3 / 50 2 2 2 20-50-70-100 25-50-75-100 28-50-78-100 R410A / 2.
VLH S Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 1004 V/ph/Hz 1104 1204 400 (±10%) / 3 / 50 2 2 2 % 25-50-75-100 23-50-73-100 25-50-75-100 kg 30,5/30,5 34/34 37,5/37,5 tCO2eq 63,7/63,7 71,0/71,0 78,3/78,3 R410A / 2.
Technical data VLH HT Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 704 V/ph/Hz % 804 904 400 (±10%) / 3 / 50 2 2 2 20-50-70-100 25-50-75-100 28-50-78-100 R410A / 2.
VLH HT Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 1004 V/ph/Hz 1104 1204 400 (±10%) / 3 / 50 2 2 2 % 25-50-75-100 23-50-73-100 25-50-75-100 kg 30,5/30,5 34/34 37,5/37,5 tCO2eq 63,7/63,7 71,0/71,0 78,3/78,3 R410A / 2.
Technical data VLC STD Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 704 V/ph/Hz % 804 904 400 (±10%) / 3 / 50 2 2 2 20-50-70-100 25-50-75-100 28-50-78-100 R410A / 2.
VLC STD Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 1004 V/ph/Hz 1104 1204 400 (±10%) / 3 / 50 2 2 2 % 25-50-75-100 23-50-73-100 25-50-75-100 kg 30,5/30,5 34/34 37,5/37,5 tCO2eq 63,7/63,7 71,0/71,0 78,3/78,3 R410A / 2.
Technical data VLC L Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 704 V/ph/Hz % 804 904 400 (±10%) / 3 / 50 2 2 2 20-50-70-100 25-50-75-100 28-50-78-100 R410A / 2.
VLC L Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 1004 V/ph/Hz 1104 1204 400 (±10%) / 3 / 50 2 2 2 % 25-50-75-100 23-50-73-100 25-50-75-100 kg 30,5/30,5 34/34 37,5/37,5 tCO2eq 63,7/63,7 71,0/71,0 78,3/78,3 R410A / 2.
Technical data VLC S Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 704 V/ph/Hz % 804 904 400 (±10%) / 3 / 50 2 2 2 20-50-70-100 25-50-75-100 28-50-78-100 R410A / 2.
VLC S Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 1004 V/ph/Hz 1104 1204 400 (±10%) / 3 / 50 2 2 2 % 25-50-75-100 23-50-73-100 25-50-75-100 kg 30,5/30,5 34/34 37,5/37,5 tCO2eq 63,7/63,7 71,0/71,0 78,3/78,3 R410A / 2.
Technical data VLC HT Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 704 V/ph/Hz % 804 904 400 (±10%) / 3 / 50 2 2 2 20-50-70-100 25-50-75-100 28-50-78-100 R410A / 2.
VLC HT Power supply Number of circuits Capacity steps Refrigerant Type / GWP Charge 1/2 (1) 1004 V/ph/Hz 1104 1204 400 (±10%) / 3 / 50 2 2 2 % 25-50-75-100 23-50-73-100 25-50-75-100 kg 30,5/30,5 34/34 37,5/37,5 tCO2eq 63,7/63,7 71,0/71,0 78,3/78,3 R410A / 2.
Technical data 8.3 Unit electrical data VLH/VLC 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 VLH/VLC L 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 VLH/VLC S Rated voltage Max. absorbed power Rated current Max.
VLH/VLC HSE 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 VLH/VLC HSE L 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 VLH/VLC HSE S Rated voltage Max. absorbed power Rated current Max. current FLA Max.
Technical data VLH/VLC HPF 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.
Fans electrical data VLH/VLC STD Rated voltage Number Rated power Absorbed rated current FLA VLH/VLC L/S Rated voltage Number Rated power Absorbed rated current FLA VLH/VLC HSE STD/L/S Rated voltage Number Rated power Absorbed rated current FLA VLH/VLC HPF Rated voltage Number Rated power Absorbed rated current FLA 704 804 3 3 kW 2 2 A 4 4 704 804 V/ph/Hz V/ph/Hz 3 3 kW 1,25 1,25 A 2,3 2,3 704 804 3 3 kW 2,6 2,6 A 4,1 4,1 704 804 V/ph/Hz V/ph/Hz 3 3 kW 2,6 2,6 A 4,
Technical data 8.
English Technical data VLH 704 - 1204 Cu/Cu STD/L/S/HT Version VLH Cu/Cu 704 804 904 1004 1104 1204 Weight distribution F1 F2 F3 F4 F5 F6 kg 401 447 485 531 561 563 kg 414 437 458 530 591 593 kg 364 400 436 477 506 509 kg 368 380 398 464 525 526 kg 317 343 376 411 440 442 kg 330 333 349 410 471 472 OpeShiprating ping weight weight kg 2195 2340 2500 2825 3095 3105 kg 2183 2326 2475 2800 3070 3080 P1-P6 coordinates* CG coordinates a b c d x y mm 1044 1044 1044 1044 1044 1044 mm 1985
Technical data 8.
English Technical data VLC 704-1204 STD/L/S/HT 704-804 904-1204 H1 279 273 H2 393 387 C 83 86 D1 703 698 D2 713 709 S 1” 5/8 2” 1/8 L 7/8” 1” 1/8 Page 55
Technical data VLH 704-1204 with hidrokit 704-804 904-1204 H1 233 213 H2 960 990 L 1186 1208 (**) Max with desuperheater WATER CONNECTIONS 704-804 904-1204 WATER OUTLET “A” 2” 1/2 M 3” M WATER INLET (with pump) “B” 2” 1/2 M 3” M DESUPERHEATER IN/OUT “D” Page 56 4x 1” 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 9.7 Dehydrating filter The refrigeration circuits are provided with dehydrating filters. The filter clogging is marked by the presence of air bubbles in the sight glass, or by the difference between the temperatures measured downstream from and upstream of the drying filter. If, once the cartridge has been cleaned, there are still some air bubbles, the appliance has lost a part of the refrigerant charge in one or more points, that must be identified and serviced. 9.
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. Increase overheating.
Troubleshooting Anomaly Cause Operation One or both compressors are not working. Breaking of the electric circuit. Check the electric circuit and detect any ground dispersions and short circuits. Check fuses. Intervention of the HP pressure switch. Reset the pressure switch and the control panel and restart the appliance. Identify and remove the cause that enabled the pressure switch. The fuse of the control circuit is broken. Check for ground dispersions and short circuits. Replace fuses.
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 HP pressure switch LP pressure switch Gas filter Electronic expansion valve Auxiliary relays Fan’s fuses Compressor’s fuses Auxiliary fuses Set of compressor contactors Fan’s contactor Water sensor Air sensor Electronic card Keyboard Compressor oil resistor Number 1 1 2 2 2 6 6 6 1 1 1 1 1 1 1 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.
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.
