AERMEC NRL FC 800 User manual



EN
INSTALLATION MANUAL
NRL free-cooling
800-1800
CHILLER
• EXTERNAL UNITS
• HIGHT EFFICIENCY
• POWER SUPPLY 60Hz
INRLFTY.1409.4086994_01

2Aermec cod. INRLFTY.1409.4086994_01
NRL FC 800-1800 60Hz
GB
AERMEC S.p.A. reserves the right at all times to make any modification for the improvement of its product and is not obliged to add these modification to machines of
previous manufacture that have already been delivered or are being built.
Dear Customer,
Thank you for choosing AERMEC. It is the fruit of many years of experience and special design studies and has
been made of the highest grade materials and with cutting edge technology.
In addition, all our products bear the EC mark indicating that they meet the requirements of the European
Machine Directive regarding safety. The standard of quality is permanently being monitored and AERMEC
products are therefore a synonym for Safety, Quality and Reliability.
The data may undergo modifications considered necessary for the improvement of the product, at any time
and without the obligation for any notice thereof.
Thank you again.
AERMEC S.p.A

3Aermec cod. INRLFTY.1409.4086994_01
NRL FC 800-1800 60Hz
GB
KEY:
1. DESCRIPTION AND CHOCE OF UNIT .................................................................................................. 4
2. CHECK LIST.......................................................................................................................................... 5
3. PRINCIPLE OF OPERATION SCHEMES ................................................................................................ 6
3.1. PRODUCTION OF COLD WATER ONLY THE SYSTEM ......................................................................... 6
 ............................. 7
4. OPERATING LIMITS.............................................................................................................................. 8
4.1. DESIGN SPECIFICATIONS .................................................................................................................... 8
5. SELECTION AND PLACE OF INSTALLATION........................................................................................ 9
5.1. POSITIONING....................................................................................................................................... 9
5.2. MINIMUM TECHNICAL SPACES ......................................................................................................... 9
6. DIMENSIONS...................................................................................................................................... 10
 ........................................................................................................................ 10
 .............................................................................................................................. 10
 .................................................................................................................... 10
7. ANTIVIBRATION POSITIONING......................................................................................................... 11
 ....................................................................................................................... 11
 .................................................................................................................... 11
 .............................................................................................................................. 12
8. HYDRAULIC CONNECTION................................................................................................................ 12
 ............................................................................................................................... 12
 .................................................................................................................... 13
 .................................................................................................................... 13
  .......................................................................................... 16
 ........................................................................................... 17
8.6. SYSTEM LOAD ................................................................................................................................... 18
8.7. EMPTYING THE SYSTEM ................................................................................................................... 18
9. ELECTRICAL WIRINGS ....................................................................................................................... 19
9.1. RECOMMENDED SECTION OF ELECTRIC CABLES ........................................................................... 19
9.2. CONNECTION TO THE POWER SUPPLY............................................................................................ 20
9.3. TO ACCESS THE ELECTRIC BOX: ...................................................................................................... 20
9.4. ELECTRICAL POWER CONNECTION.................................................................................................. 20
9.5. AUXILIARY CONNECTIONS AT THE USER/INSTALLER EXPENSE..................................................... 20
 .................................................................................................................. 20
  .................................................................................................... 20
  ..................................................................................................................... 20
9.9. CONNECTION PR3 ............................................................................................................................ 20
 ....................................................................................................... 21
10.1. PREPARATION FOR COMMISSIONING............................................................................................. 21
10.2. FIRST COMMISSIONING OF THE MACHINE..................................................................................... 21
10.3. SEASON CHANGEOVER ..................................................................................................................... 21
10.3.1. SEASON CHANGE OF THE PANEL ON THE MACHINE...................................................................... 21
10.3.2. SEASON CHANGE OF PR3.................................................................................................................. 21
11. FUNCTIONING CHARACTERISTICS................................................................................................... 22
11.1. COOLING SET POINT ......................................................................................................................... 22
11.2. COMPRESSOR START DELAY ............................................................................................................. 22
11.3. CIRCULATION PUMP ......................................................................................................................... 22
 ......................................................................................................................... 22
11.5. WATER FLOW RATE ALARM .............................................................................................................. 22
12. REGULAR MAINTENANCE................................................................................................................. 22
12.1. HYDRAULIC CIRCUIT.......................................................................................................................... 22
12.2. ELECTRIC CIRCUIT ............................................................................................................................. 22
12.3. CHILLER CIRCUIT ............................................................................................................................... 22
12.4. MECHANICAL CONTROLS ................................................................................................................. 22
13. EXTRAORDINARY MAINTENANCE.................................................................................................... 23
13.1. LOADING PROCEDURE...................................................................................................................... 23

4Aermec cod. INRLFTY.1409.4086994_01
NRL FC 800-1800 60Hz
GB
The NRL Free-cooling series appliances are water
chillers equipped with an external air cooling capacity
recovery system called "free-cooling".
The water free-cooling system consists in integrating
and eventually completely replacing the cooling capaci-
ty delivered by the compressors through an additional
water coil that exploits the low temperature of the
external air to cool the system's return water.
Maximum reliability
The presence of several scroll compressors allows NRL
chillers various partialisations of the cooling capacity.
OPERATING MODE:
FREE-COOLING ONLY:
when the external temperature is sufficiently low to
allow water cooling inside the free-cooling coils at
the desired temperature. This is the most economical
mode of the unit with only the fans operating in speed
modulation.
MIXED FREE-COOLING + COMPRESSORS:
the compressors operate in integration with the free-
cooling when the cooling capacity recovered from the
external air is no longer sufficient for the power requi-
red by the system. The higher the cooling capacity
recovery with free-cooling the lower the integration is.
COMPRESSORS ONLY:
when the external air temperature is greater than the
return temperature of the system water.
Models:
1. NRL "F" free-cooling
The versions can be in different set-ups at the same
time in order to satisfy a wide range of plant enginee-
ring solutions:
1. "A" HIGH EFFICIENCY
2. "E" SILENCED HIGH EFFICIENCY
3. "D" WITH DESUPERHEATER
The units with desuperheater (D) are not available in
the versions:
1. YD
2. XD
1. DESCRIPTION AND CHOCE OF UNIT
Standards and Directives respected on
designing and constructing the unit:
PROTECTION RATING
1. IP 24
ACOUSTIC PART:
1. ISO DIS 9614/2

2. 
3. SOUND PRESSURE (EN ISO 3744)
REFRIGERANT GAS:
This unit contains fluoride gases with
greenhouse effect covered by the
Kyoto Protocol. Maintenance and
disposal must only be performed by
qualified staff.
STANDARD:
UL 1995
Heating and cooling equipment.
ANSI/NFPA
Standard 70 National Electrical code
(N.E.C.).
CSA C.22.1.- C.22.2
Safety Standard Electrical Installation.

5Aermec cod. INRLFTY.1409.4086994_01
NRL FC 800-1800 60Hz
GB
2. CHECK LIST
Ciruit Components
Cooling circuit Model F with D
Resistance carter compressor
yes yes
High pressure switch yes yes
Low pressure switch no no
High pressure trasducer
yes yes
Low pressure trasducer yes yes
Solenoid valve of hot gas injecton no yes
By-pass valve of hot gas yes yes
Exchanger (EV- EV/CN) yes yes
Exchanger (desuperheater) no yes
Exchanger (glycol free) no no
Cock the liquid and discharge yes yes
hydraulic circuit Version "F 00" 800 900 1000 1250 1400 1500 1650 1800
Water filter
yes yes yes yes yes yes yes yes
Flow switch yes yes yes yes yes yes yes yes
Air vent yes yes yes yes yes yes yes yes
hydraulic circuit Version "P3…P4" 800 900 1000 1250 1400 1500 1650 1800
Water filter
yes yes yes yes yes yes yes yes
Flow switch yes yes yes yes yes yes yes yes
Safety valve yes yes yes yes yes yes yes yes
Air vent yes yes yes yes yes yes yes yes
Pump yes yes yes yes yes yes yes yes
Expansion tank yes yes yes yes yes yes yes yes
hydraulic circuit Version "03…04 " 800 900 1000 1250 1400 1500 1650 1800
Water filter
yes yes yes yes yes yes yes yes
Flow switch yes yes yes yes yes yes yes yes
Safety valve yes yes yes yes yes yes yes yes
Air vent yes yes yes yes yes yes yes yes
Pump yes yes yes yes yes yes yes yes
Expansion tank yes yes yes yes yes yes yes yes
Storage tank yes yes yes yes yes yes yes yes
Version with DESUPERHEATER "D"
hydraulic circuit Version "F with D" 800 900 1000 1250 1400 1500 1650 1800
Water filter no no no no no no no no
Differential pressure switch no no no no no no no no
Flow switch no no no no no no no no
Exchanger (desuperheater)
yes yes yes yes yes yes yes yes
hydraulic circuit "storage thank with D " 800 900 1000 1250 1400 1500 1650 1800
Water filter
(desuperheater) no no no no no no no no
Differential pressure switch
(desuperheater)
no no no no no no no no
Flow switch
(desuperheater) no no no no no no no no
Exchanger (desuperheater)
yes yes yes yes yes yes yes yes
Safety valve yes yes yes yes yes yes yes yes
Air vent yes yes yes yes yes yes yes yes
Pump yes yes yes yes yes yes yes yes
Expansion tank yes yes yes yes yes yes yes yes
Storage tank yes yes yes yes yes yes yes yes

6Aermec cod. INRLFTY.1409.4086994_01
NRL FC 800-1800 60Hz
GB
CN
CN
CN
CPCP
TEV
TEV
BHE
V3V
3. PRINCIPLE OF OPERATION SCHEMES
3.1. PRODUCTION OF COLD WATER ONLY THE SYSTEM
Description Operation
1exchanger
SYSTEM SIDE
(EVAPORATION)
Production cold water
2exchanger
SOURCE SIDE
(CONDENSATION)
Heat exchange with the air
3exchanger
SYSTEM SIDE
(EVAPORATION FREE-COOLING)
Production cold water
H2O RETURN
SYSTEM
H2O DISCHARGE
SYSTEM
1
2
3
2Sign Description
CP compressor
CN Air side exchange
TEV Thermostatic valve
BHE Exchanger plate
V3V three-way valve

7Aermec cod. INRLFTY.1409.4086994_01
NRL FC 800-1800 60Hz
GB
CN
CN
CN
CPCP
TEV
TEV
BHE
V3V
BHE
3.2. COLD WATER PRODUCTION AND THE SYSTEM RECOVERY (DESUPERHEATER)
H2O SUPPLY
H2O DISCHARGE
Description Operation
1exchanger
SYSTEM SIDE
(EVAPORATION)
Production of cold water
2exchanger
SOURCE SIDE
(CONDENSATION)
Heat exchange with the air
3exchanger
SYSTEM SIDE
(EVAPORATION FREE-COOLING)
Production cold water
4exchanger
DESUPERHEATER
(CONDENSATION)
hot water (after heating - Swim-
ming pools ...)
H2O RETURN
SYSTEM
H2O SUPPLY
SYSTEM
1
3
Sign Description
CP Compressor
CN Air side exchange
TEV Thermostatic valve
BHE Exchanger plate
V3V three-way valve
2
2
4

8Aermec cod. INRLFTY.1409.4086994_01
NRL FC 800-1800 60Hz
GB
4. SELECTION AND PLACE OF INSTALLATION
Before beginning installation consent with client and pay atten-
tion to the following recommendations:
1. The support surface must be capable of supporting the
unit weight;
2. The safety differences between the unit and ther applian-
ces or structures must be scrupulously respected so that
the inlet and outlet AIR from the fans is free to circulate;
3. The unit must be installed by an enabled technician in
compliance with the national legislation in force in the
country of destination, respecting the minimum technical
spaces in order to allow maintenance.
4.1. POSITIONING
The machine is delivered from the factory wrapped in estincoil.
Before moving the unit, check the lifting capacity of the machi-
nes used.
Once the packaging has been removed, the unit must be
handled by qualified personnel with the suitable equipment. To
handle the machine: see figure hook up the lifting belts to the
provided eyebolts (as indicated in figure).
WARNING: ALWAYS USE ALL THE PROVIDED EYEBOLTS
Interpose protections between the straps and the machine to
prevent the structure of the unit being damaged by the straps.
It is absolutely forbidden to stand under the unit.
Take into account that when the chiller is working, vibrations
may be generated; it is therefore advisable to install anti-vibra-
tion supports (AVX accessories), fitting them to the holes in the
base according to the assembly diagram.
It is compulsory to provide the necessary technical spaces, to
allow REGULAR AND EXTRAORDINARY MAINTENANCE INTER-
VENTIONS Fasten the unit by checking carefully that its on the
same level; check that easy access to the hydraulic and electric
part is allowed.
4.2. MINIMUM TECHNICAL SPACES
3000 mm 110.11 in HEIGHT
ATTENTION:
ALWAYS USE THE
RELEVANT EYE-
BOLTS
800 mm
31 in
1100 mm
43 in
800 mm
31 in
800 mm
31 in
The unit must be installed by a qualified and suitably trained technician, in compliance with the
national legislation in force in the country of destination (Ministerial Decree 329/2004).
AERMEC will not assume any responsibility for damage due to failure to follow these instructions.
Before beginning any operation, READ THESE INSTRUCTIONS CAREFULLY AND CARRY OUT THE SA-
FETY CHECKS TO REDUCE ALL RISK OF DANGER TO A MINIMUM. All the staff involved must have
thorough knowledge of the operations and any dangers that may arise at the moment in which
the installation operations are carried out.

9Aermec cod. INRLFTY.1409.4086994_01
NRL FC 800-1800 60Hz
GB
5. DIMENSIONS
5.1. NRL 800 - 900 - 1000 F 5.2. NRL 1250 - 1400 - 1500 F
5.3. NRL 1650 - 1800 F
3400 mm
134 in
2200 mm
87 in
2450 mm
96 in 2450 mm
96 in
2200 mm
87 in
4250 mm
167 in
5750 mm
226 in
2200 mm
87 in
2450 mm
96 in

10 Aermec cod. INRLFTY.1409.4086994_01
NRL FC 800-1800 60Hz
GB
7.2. NRL 1250 - 1400 - 1500 F
7. ANTIVIBRATION POSITIONING
7.1. NRL 800 - 900 - 1000 F
100 mm
4 in
2800 mm
110 in
100 mm
4 in
100 mm 4 in
100 mm 4 in
2000 mm 79 in
2100 mm 83 in
1825 mm
72 in
2000 mm 79 in
2100 mm 83 in
1825 mm
72 in
100 mm
4 in
100 mm
4 in
100 mm 4 in
100 mm 4 in