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 SYSCREW 300-1400 AIR CO/TR English 295 1395 kW Français Deutsch Italiano Español Air Cooled Water Chillers with Screw Compressors Refroidisseurs de liquide à condensation par air avec compresseurs à vis Luftgekühlte Wasserkühler mit Schraubenkompressoren Refrigeratori d’Acqua Raffreddati ad Aria con compre
1 - FOREWORD 7 - PRODUCT DESCRIPTION 1.1 Introduction...........................................................................2 7.1 Introduction.........................................................................26 1.2 Warranty...............................................................................2 7.2 General specifications.........................................................26 1.3 Emergency stop/Normal stop................................................2 7.3 Compressors.........
11--Introdução 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 Compability 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 (continued) 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.
n periodically check the board’s internal wiring n n 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 n make sure that on-off remote controls are inhibited n wear suitable personal protective equipment (helmet, safety gloves, goggles and shoes etc.
2 - Safety (continued) 2.7 Safety labels Identification of the refrigerant - External door Identification of the unit - Outside, on the right-hand front column CODICE PRODOTTO NEUTRO USARE SOLO R134a E SPECIAL ESTER OIL MODELLO MODEL RECOVER - DO NOT VENT - EEC REGULATION N° 3093/94 RECUPERARE FLUIDO - NON DISPERDERE NELL’AMBIENTE - REGOLAMENTO CEE N° 3093/94 PRODUCT CODE 0425 MO.NO MATRICOLA SERIAL NO. ANNO DI COSTRUZIONE Manuf. Year REFR.
Start-up warning - Outside the door of the electrical board English 2 - Safety (continued) Final Test Certificate - Inside the external door ATTENZIONE INSERIRE LE RESISTENZE DI RISCALDAMENTO OLIO ALMENO 12 ORE PRIMA DI OGNI AVVIAMENTO (SE PREVISTE) PRIMA DELLA MESSA IN TENSIONE ASSICURARSI CHE LE VITI DEI CIRCUITI ELETTRICI SIANO SERRATE COMPLETAMENTE WARNING ENERGIZE THE CRANCKCASE HEATER FOR AT LEAST 12 HOURS BEFORE EACH STARTING (IF FITTED) BEFORE TIGHTENING-UP, TO TIGHTEN ALL TERMINAL SCREWS ESPE
2 - Safety (continued) 2.8 Safety regulations REFRIGERANT DATA Toxicity SAFETY DATA: R134a 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: R134a 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 (continued) 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.
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. It is recommended to use a spacer to prevent cables from damaging the unit (see the figure). 3.1 Inspection When the unit is delivered, it is recommended to check it carefully and to identify any damage occurred during transportation. The goods are shipped ex-factory, at the buyer’s risk.
3 - Transport, Lifting and Positioning (continued) The eyebolts must be mounted on the unit whenever it shall be displaced and then lifted again. 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. WARNING WARNING WARNING 3.3 Anchoring The sides of the unit must be protected by cardboard or plywood sheets.
4.1 Positioning of the unit DANGER 4.2 Spring Isolator Installation 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. These units have been designed for outdoor installation on a solid surface. Standard accessories include antivibrating rubber supports, that must be positioned under the base.
4 - Installation (continued) 4.3 External Water Circuit A flow switch will stop the unit when the water is not circulating or a flow rate problem occurs. 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 To install the flow switch, follow the manufacturer’s instructions.
Then: n Provide the evaporator with a by-pass circuit equipped with a valve to wash the plant. n Insulate the piping, to prevent the risk of heat loss. n Position a filter on the suction side of the evaporator of the heat recovery condenser.
4 - Installation (continued) 4.5 Connection of water temperature sensors (on shell and tube evaporator) Each fitting 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. The units are provided with fittings for hydraulic connections between heat exchangers and plant.
4.6 Power supply DANGER 4.7 Electrical connections The unit must be installed on site according to the Machinery Directive 2006/42/EC, Electromagnetic Compatibility Directive 2014/30/EU and the usual procedures and standards applicable in the place of installation. Before carrying out any operations on the electrical system, make sure that the unit is deenergised. The unit must not be operated if its installation has not been carried out according to the instructions provided in this manual.
4 - Installation (continued) Electrical connections - Units with standard step and stepless type compressors 18
WARNING 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. n Start the pump and check that the water flow is correct. n Set the desired fluid temperature on the control board. n Start the appliance (see Chapter 6). n Check the correct direction of rotation of compressors. Scroll compressors cannot compress the refrigerant when they rotate in the opposite direction.
6 - Control 6 General information The control system consists of: This document contains the information and the operating instructions for screw compressors of step type. a) Main Board. The units are provided with a microprocessor card which is fully programmed by default for the control of a chiller of cold only type with 2 circuits, 1 compressor for circuit, a HP transducer and a LP transducer for Circuit.
6.1 Display/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. alarm 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).
6 - Control (continued) Alarms Alarm code 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 27 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 47 49 51 52 53 56 59 60 61 62 63 64 65 66 67 68 69 70 71 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 boar
Alarm code 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 118 119 122 123 124 127 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 187 188 Description Driver 2 Battery alarm Autotune alarm Sys 1 Autotune alarm Sys 2 Low suction alarm Sys 1 Low suction alarm Sys 2 Driver 1 Regulation Alarm Driver 2 Regulation Alarm Expansion board 1 OFF LINE Expansion board 2 OFF LINE Expansion board 1 - Sensor 1 fault Expansion board 1 - Sensor 2 fault Expansion board 1 - Sensor 3 fault Expansion board 1 - S
6 - Control (continued) 6.3 Protection and Safety Equipment Electrical flow switch Refrigeration system A electrical flow switch must be installed, to prevent the unit working in case of insufficient circulation of the chilled fluid. The units are filled with R134a refrigerant fluid of non hazardous type (group II). Safety device (pressure switch and safety valves) with the sets below indicated are provided on the discharge and suction line of each circuit.
English 6 - Control (continued) 6.4 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. The table below shows the correspondance between chiller model, fan RPM, high static pressure (approximate values).
7 - Product Description 7.1 Introduction The units are air cooled water chillers provided with screw compressors with two refrigeration circuits. These units can be installed outdoor on the roof of a building or at ground level. These units are fit for cooling intermediate fluids (glycoled water), for air-conditioning applications in industrial processes.
7.5 Water heat exchanger The power supply compartment includes: Evaporator n Master switch The units are provided with a direct-expansion refrigerant/water shell and tube heat exchanger with several refrigeration circuits. n Network isolator, contactors, compressor fuses Control panel includes: The evaporators are insulated with UV ray-proof 19 mm-thick anticondensate closed-cell polyethylene material.
7 - Product Description (continued) Refrigerant flow diagram - Unit 300-360 S AT A A 7 8 5 9 H G B S 6 BT S EXV CONTROL 5 UNIT CONTROL E 3 4 F 2 S COMPONENTS SAFETY / CONTROL DEVICES 1 Compressor (Screw type) A High pressure switch (19 bar) 2 Air cooled condenser B Low pressure switch (0.
English 7 - Product Description (continued) Refrigerant flow diagram - Unit 410-450-650-720-1000-1070-1130-1170-1300-1400 G S A A AT 2 5 D 7 5 S 8 3 9 10 13 H 1 S S 6 B 12 BT 11 S EXV CONTROL E 4 F COMPONENTS SAFETY / CONTROL DEVICES 1 Compressor (Screw type) A High pressure switch (19 bar) 2 Air cooled condenser B Low pressure switch (0.
8 - Technical Data 8.1 Pressure drops Evaporator Pressure drop Model 300 360 410 450 480 500 540 580 650 720 800 850 910 970 1000 1070 1130 1170 1200 1300 1400 Nom. Capacity Qnom. Qmax. Qmin. K Dp nom DP max DP min kW l/h l/h l/h kPa/(l/h)^2 kPa kPa kPa 296 366 415 447 482 506 541 576 653 715 796 855 913 975 1.012 1.074 1.135 1.175 1.221 1.320 1.399 50.878 63.004 71.328 76.815 82.870 87.032 93.086 99.141 112.385 122.980 136.981 147.008 157.036 167.631 174.064 184.659 195.254 202.066 210.
English 8 - Technical Data (continued) 8.
8 - Technical Data (continued) Standard Power supply 650 Number of refrigerant circuits Start-up Type Total capacity steps 720 800 850 V/Ph/Hz 910 970 1000 2 2 2 2 SD SD SD SD 2 2 2 1 1 1 400V/3/50Hz 2 2 2 SD SD SD % 25-50-62-75-87-100 COMPRESSOR Number 2 2 2 Type 2 Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number 1 1 1 Type Water connections 1 Shall & tube (Pure counterflow) inch 6 6 8 8 8 8 8 12 12 12 14 14 15 16 EXTERNAL HEAT EXCHANGER (COILS)
Standard Power supply 1070 1170 V/Ph/Hz Number of refrigerant circuits Start-up Type Total capacity steps 1130 English 8 - Technical Data (continued) 1200 1300 1400 400V/3/50Hz 2 2 2 2 2 2 SD SD SD SD SD SD 2 2 2 1 1 1 % 25-50-62-75-87-100 COMPRESSOR Number 2 2 2 Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number 1 1 1 Type Water connections Shall & tube (Pure counterflow) inch 6 6 8 8 10 10 17 18 19 20 22 24 EXTERNAL HEAT EXCHANGER (COILS) Number T
8 - Technical Data (continued) S - Super Low Noise Version Power supply 300 Number of refrigerant circuits Start-up Type Total capacity steps 360 410 450 V/Ph/Hz 480 500 540 580 400V/3/50Hz 2 2 2 PW PW PW % 2 2 2 2 2 PW PW PW PW SD 2 2 2 2 1 1 1 1 25-50-62-75-87-100 COMPRESSOR Number 2 2 2 2 Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number 1 1 1 Type Water connections 1 Shall & tube (Pure counterflow) inch 5 5 6 6 6 6 6 6 6 6 8 8 8 8 9
S - Super Low Noise Version Power supply 650 800 850 V/Ph/Hz Number of refrigerant circuits Start-up Type Total capacity steps 720 English 8 - Technical Data (continued) 910 970 1000 2 2 2 2 SD SD SD SD 2 2 2 1 1 1 400V/3/50Hz 2 2 2 SD SD SD % 25-50-62-75-87-100 COMPRESSOR Number 2 2 2 Type 2 Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number 1 1 1 Type Water connections 1 Shall & tube (Pure counterflow) inch 6 6 8 8 8 8 8 12 12 12 14 14 15 16 EXTE
8 - Technical Data (continued) S - Super Low Noise Version Power supply 1070 Number of refrigerant circuits Start-up Type Total capacity steps 1130 1170 V/Ph/Hz 1200 1300 1400 400V/3/50Hz 2 2 2 2 2 2 SD SD SD SD SD SD 2 2 2 1 1 1 % 25-50-62-75-87-100 COMPRESSOR Number 2 2 2 Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number 1 1 1 Type Water connections Shall & tube (Pure counterflow) inch 8 8 8 8 10 10 17 18 19 20 22 24 EXTERNAL HEAT EXCHANGER (COILS
HT - High Temperature Version Power supply 300 Number of refrigerant circuits Start-up Type Total capacity steps 360 410 450 V/Ph/Hz English 8 - Technical Data (continued) 480 500 540 580 400V/3/50Hz 2 2 2 PW PW PW % 2 2 2 2 2 PW PW PW PW SD 2 2 2 2 1 1 1 1 25-50-62-75-87-100 COMPRESSOR Number 2 2 2 2 Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number 1 1 1 Type Water connections 1 Shall & tube (Pure counterflow) inch 5 5 6 6 6 6 6 6 6 6 8
8 - Technical Data (continued) HT - High Temperature Version Power supply 650 Number of refrigerant circuits Start-up Type Total capacity steps 720 800 850 V/Ph/Hz 910 970 1000 2 2 2 2 SD SD SD SD 2 2 2 1 1 1 400V/3/50Hz 2 2 2 SD SD SD % 25-50-62-75-87-100 COMPRESSOR Number 2 2 2 Type 2 Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number 1 1 1 Type Water connections 1 Shall & tube (Pure counterflow) inch 6 6 8 8 8 8 8 12 12 12 14 14 15 16 EXTERNAL HE
HT - High Temperature Version Power supply 1070 1170 V/Ph/Hz Number of refrigerant circuits Start-up Type Total capacity steps 1130 English 8 - Technical Data (continued) 1200 1300 400V/3/50Hz 2 2 2 2 2 2 SD SD SD SD SD SD 2 2 2 1 1 1 % 25-50-62-75-87-100 COMPRESSOR Number 2 2 2 Type Screw INTERNAL HEAT EXCHANGER (EVAPORATOR) Number 1 1 1 Type Water connections Shall & tube (Pure counterflow) inch 8 8 8 8 10 10 17 18 19 20 22 24 EXTERNAL HEAT EXCHANGER (
8 - Technical Data (continued) 8.
English 8 - Technical Data (continued) Compressors 400 V / 3 Ph / 50 Hz Model 300 360 410 450 480 500 540 580 650 720 800 850 910 970 1000 1070 1130 1170 1200 1300 1400 System 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Compressor start mode PW PW PW PW PW PW PW SD SD SD SD SD SD SD SD SD SD SD SD SD SD Power input nominal Cond. compressor (kW) Nom. Cond. current compressor (A) Power input max. Cond.
8 - Technical Data (continued) Fans - 400 V / 3 Ph / 50 Hz Model STD Version 300 360 400 430 460 490 540 580 650 720 800 850 910 970 1000 1070 1130 1170 1200 1300 1400 S Version 300 360 400 430 460 490 540 580 650 720 800 850 910 970 1000 1070 1130 1170 1200 1300 1400 HT/HP Version 300 360 400 430 460 490 540 580 650 720 800 850 910 970 1000 1070 1130 1170 1200 1300 1400 Number Standard fans 080 6 poli 400V-3-50 Nominal power (kW) Δ Max.
English 8 - Technical Data (continued) 8.
8 - Technical Data (continued) Available Pressure (Low Head - Pump “E”) Models 1130-1200 350 AvaliableStatic Static Pressure Avaliable Pressure[kPa] [kPa] 300 250 200 150 100 1130-1170-1200 50 0 50000 100000 150000 200000 250000 300000 Water Flow [l/h] Water Flow [l/h] Available Pressure (High Head - Pump “F”) Models 300-410 400 AvaliableStatic Static Pressure Pressure [kPa] Avaliable [kPa] 350 300 410 250 300-360 200 150 100 50 0 30000 40000 50000 60000 Water Flow [l/h] Water Fl
English 8 - Technical Data (continued) Available Pressure (High Head - Pump “G” & “H”) Models 450-720 450 Avaliable Static [kPa] Avaliable StaticPressure Pressure [kPa] 400 650-720 350 300 450-480 250 200 500-540-580 150 100 50 0 40000 50000 60000 70000 80000 90000 100000 110000 120000 130000 140000 Water Flow [l/h] Water Flow [l/h] Available Pressure (High Head - Pump “I” & “J”) Models 800-1070 500 450 Avaliable Static Pressure [kPa] Avaliable Static Pressure [kPa] 400 1070 910 3
8 - Technical Data (continued) Available Pressure (High Head - Pump “K”) Models 1130-1200 450 Avaliable Static Pressure [kPa][kPa] Avaliable Static Pressure 400 350 1130-1170-1200 300 250 200 150 100 50 0 50000 100000 150000 200000 Water Flow [l/h] Water Flow [l/h] 46 250000 300000 350000
English 8 - Technical Data (continued) 8.
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8 - Technical Data (continued) 8.6 Dimensional drawings - 9V 1070 Front view Side view L 2510 2510 L M M E F B E 530 F 366 2630 3832 23102630 3496 9488 530 LIFT / AVM B 2310 374 366 2192 9920 2510 L Back view 366 2630 3496 9488 263 NOTES: B, E - WATER CONNECTION 8" Victaulic 9920 2082 AVM LIFT / AVM F - ELECTRICAL POWER SUPPLY L - MAIN SWITCH M - CONTROL KEYPAD / DISPLAY M E Top view HYDRAULIC OPTION F 530 2310 366 2630 3496 9488 t.b.d DESUPERHEATERS t.b.
English 8 - Technical Data (continued) 8.
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8 - Technical Data (continued) 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.
9 - Maintenance (continued) 9.3 Refrigerant charge Do not inject refrigerant liquid into the LP side of the circuit. Be very careful, and charge the circuit properly. WARNING If the charge is insufficient, the efficiency of the unit will be lower than expected. In the worst of cases the LP pressure switch may be activated, resulting in the halting of the unit. WARNING Compressors use polyester oil.
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 expansion valve. If the electronic expansion valve cannot be regulated, it is probably broken, and shall be replaced. The replacement must be carried out by a Service Centre.
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. Excessive noise Increase overheating.
English 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 Number HP pressure switch 1 LP pressure switch 1 Gas filter 2 Electronic expansion valve 2 Auxiliary relays 2 Fan’s fuses 6 Compressor’s fuses 6 Auxiliary fuses 6 Set of compressor contactors 1 Fan’s contactor 1 Water sensor 1 Air sensor 1 Electronic card 1 Keyboard 1 Compressor oil resistor 1 11.
12 - 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.
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.
