AERMEC WRL 200 Instruction Manual

IWRLI2. 1403. 5890700_01
REVERSIBLE / CHILLER - HEAT PUMPS - 
EN
WRL 200-400-500
WRL-H 200-400-500

WATER/WATER
• HIGH EFFICIENCY
• MAXIMUM WATER OUTLET TEMPERATURE 55 °C
• DESUPERHEATER
• SUITABLE FOR GEOTHERMAL APPLICATIONS

U8131286304002



AERMEC S.p.A. reserves the right at any moment to make any modifications considered necessary to improve our products and is not obliged to add these modifications
to machines that have already been fabricated, delivered or are under construction.
Dear Customer,
Thank you for choosing an AERMEC product. This product is the result of many years of experience and
in-depth engineering research, and it is built using top quality materials and advanced technologies.
In addition, the CE mark guarantees that our appliances fully comply with the requirements of the
European Machinery Directive in terms of safety. We constantly monitor the quality level of our
products, and as a result they are synonymous with Safety, Quality, and Reliability.
Product data may be subject to modifications deemed necessary for improving the product without the
obligation to give prior notice.
Thank you again.
AERMEC S.p.A

IWRLI2_13.04_5890700_00
Sommario
1. Receipt of the product and installaon............................................. 5
1.1. Receipt and handling ........................................................................ 5
1.2. Selecon and place of installaon ................................................... 5
1.3. Handling ........................................................................................... 5
1.4. Minimum technical spaces ............................................................... 5
2. Wrl dimensions tables....................................................................... 6
3. An-vibraon posion ...................................................................... 7
4. Posion/dimension connecon wrl .................................................. 8
5. Weights and barycentres .................................................................. 9
5.1. No pump version............................................................................... 9
5.2. System side pump version ................................................................ 9
5.3. External side pump version............................................................. 10
5.4. System + external side pumps version............................................ 10
6. Electric connecons ........................................................................ 11
6.1. Recommended electric cable secon ............................................. 11
6.2. Electric power connecon to the electrical mains.......................... 11
7. Control and commissioning ............................................................ 12
7.1. Preparaon for commissioning....................................................... 12
7.2. Machine commissioning ................................................................. 12
7.3. Season changeover ......................................................................... 12
7.4. Electrical data.................................................................................. 12
8. Extraordinary maintenance............................................................. 13
9. Roune maintenance...................................................................... 13
INDEX
4

IWRLI2_13.04_5890700_00
 RECEIPT OF THE PRODUCT AND
INSTALLATION
 RECEIPT AND HANDLING
The machine is sent from the factory wrapped with
estincoil placed on a loading pallet.
Before handling the unit, verify the lifting capacity of
the machines used.
Handling must be performed by qualified, suitably
equipped staff.

- Whenever it is envisioned to lift the machine
with belts, so as not to damage the structure,
place protections between the belts and the
framework. It is prohibited to stop below the unit
during lifting.
- 

- 


 CANNOT
 SELECTION AND PLACE OF INSTALLATION
The WRL water/water INDOOR heat pump with
gas side inversion (R410A) is sent from the factory
already inspected and only requires electric and
hydraulic connections in the place of installation.
Before beginning installation consent with client and
pay attention to the following recommendations:
•The support surface must be capable of
supporng the unit weight.
•The safety distances between the units
and other appliances or structures must be
scrupulously respected.
•The unit must be installed by a skilled tech-
nician in compliance with the naonal law
in force in the country of desnaon.
•It is mandatory to foresee to the necessary
technical space in order to allow ROUTINE
AND EXTRAORDINARY MAINTENANCE in-
tervenons.
• Remember that whilst operaonal the chill-
er can cause vibraons; therefore “VT”an-
vibraon mounts (accessories) are recom-
mended, xed on the base according to the
assembly layout.
• Fix the unit, checking that it is level.
600mm
23,6 in
600mm
23,6 in
600mm
23,6 in
600mm
23,6 in

DRAWINGS ONLY INDICATIVE
THE UNIT HAS TO BE INSTALLED
IN TECHNICAL ROOMS,
OR ROOMS WHICH HAVE AT

 HANDLING
 MINIMUM TECHNICAL SPACES
5

IWRLI2_13.04_5890700_00
 WRL DIMENSIONS TABLES


DIMENSIONS WRL 500

CA
B
A1
B1
C
A
A1
B
B1
POSITION
  200 400
A
mm
800 800
A1 845 845
B 1270 1270
B1 1380 1380
C 1320 1320
A
in
31,5 31,5
A1 33,3 33,3
B 50,0 50,0
B1 54,3 54,3
C 52,0 52,0
POSITION
  500
A
mm
800
A1 845
B 1270
B1 1380
C 2060
A
in
31,5
A1 33,3
B 50,0
B1 54,3
C 81,1
6

IWRLI2_13.04_5890700_00


DIMENSIONS WRL 500

 
D
D
E
E
F
F
D E F
D E F
POSITION
  200 400
D
mm
75 75
E 1170 1170
F 75 75
D
in
3,0 3,0
E 46,1 46,1
F 3,0 3,0
POSITION
  500
D
mm
78
E 1899
F 78
D
in
3,1
E 74,8
F 3,1
7

IWRLI2_13.04_5890700_00
 POSITION/DIMENSION CONNECTION WRL
IN
OUT
OUT
IN
OUT
IN
G
H
L
M
N
O
P
I

EVAPORATOR
CONDENSER
DESUPERHEATER

WRL 200 400
IN OUT IN OUT
Evaporator 2” 2” 2” 2”
Condenser 2” 2” 2” 2”
Desuperheater 1”½ 1”½ 1”½ 1”½

WRL 500
IN OUT
Evaporator 2”½ 2”½
Condenser 2”½ 2”½
Desuperheater 1”½ 1”½
OUT
OUT
OUT
IN
IN
IN
Q
K
R
S
T
U
V
W
X
Y
Z

EVAPORATOR
CONDENSER
DESUPERHEATER


DIMENSIONS WRL 500

POSITION
  200 400
G
mm
127 127
H 94 94
I 146 146
L 114 114
M 146 146
N 300 300
O87 87
P 83 83
G
in
5,0 5,0
H 3,7 3,7
I 5,7 5,7
L 4,5 4,5
M 5,7 5,7
N 11,8 11,8
O3,4 3,4
P 3,3 3,3
POSITION
  500
K
mm
92
Q 159
R 85
S 87
T 277
U436
V277
W 277
X 246
Y75
Z 76
K
in
3,6
Q 6,3
R 3,3
S 3,4
T 10,9
U17,2
V10,9
W 10,9
X 9,7
Y3,0
Z 3,0
8

IWRLI2_13.04_5890700_00
A B C
G
Gy
Gx
D


 NO PUMP VERSION
 SYSTEM SIDE PUMP VERSION
A
G
Gx
Gy
C
B D
DIMENSIONS WRL 500

 WEIGHTS AND BARYCENTRES
WRL
  

   
Gx  Gx  Gx  Gx  A B C D
kg lb mm mm in in kg lb mm mm in in % % % %
200 325 716 424 600 17 24 349 770 417 620 16 24 27% 26% 24% 23%
400 387 853 424 542 17 21 411 907 419 562 16 22 29% 28% 21% 21%
500 528 1164 400 995 16 39 560 1235 396 1024 16 40 27% 24% 26% 23%
WRL
  

   
Gx  Gx  Gx  Gx  A B C D
kg lb mm mm in in kg lb mm mm in in % % % %
200 365 804 396 649 16 26 389 858 393 664 15 26 27% 23% 27% 23%
400 438 966 395 602 16 24 463 1020 392 617 15 24 29% 25% 25% 22%
500 585 1289 381 1034 15 41 616 1359 378 1059 15 42 27% 22% 28% 23%
WRL-H
  

   
Gx  Gx  Gx  Gx  A B C D
kg lb mm mm in in kg lb mm mm in in % % % %
200 324 715 391 599 15 24 348 767 378 619 15 24 29% 24% 26% 21%
400 386 852 397 541 16 21 410 904 385 561 15 22 31% 26% 23% 19%
500 541 1192 395 1003 16 39 574 1265 390 1032 15 41 27% 23% 27% 23%
WRL-H
  

   
Gx  Gx  Gx  Gx  A B C D
kg lb mm mm in in kg lb mm mm in in % % % %
200 364 804 370 648 15 26 388 855 360 663 14 26 29% 21% 29% 21%
400 438 966 373 601 15 24 461 1017 365 616 14 24 30% 23% 27% 20%
500 597 1316 376 1040 15 41 631 1390 373 1065 15 42 27% 21% 29% 23%
9

IWRLI2_13.04_5890700_00
A B C
G
Gy
Gx
D


A
G
Gx
Gy
C
B D
DIMENSIONS WRL 500

 EXTERNAL SIDE PUMP VERSION
WRL
  

   
Gx  Gx  Gx  Gx  A B C D
kg lb mm mm in in kg lb mm mm in in % % % %
200 365 804 425 649 17 26 389 858 419 664 17 26 25% 25% 25% 25%
400 438 966 426 602 17 24 463 1020 421 617 17 24 27% 27% 23% 23%
500 585 1289 406 1034 16 41 616 1359 402 1059 16 42 26% 23% 27% 24%
WRL-H
  

   
Gx  Gx  Gx  Gx  A B C D
kg lb mm mm in in kg lb mm mm in in % % % %
200 364 804 399 648 16 26 388 855 387 663 15 26 27% 23% 27% 23%
400 438 966 404 601 16 24 461 1017 394 616 15 24 29% 25% 25% 22%
500 597 1316 401 1040 16 41 631 1390 396 1065 16 42 26% 23% 27% 24%
 SYSTEM + EXTERNAL SIDE PUMPS VERSION
WRL
  

   
Gx  Gx  Gx  Gx  A B C D
kg lb mm mm in in kg lb mm mm in in % % % %
200 405 892 403 689 16 27 429 946 399 700 16 28 25% 22% 28% 25%
400 490 1080 402 649 16 26 514 1134 399 660 16 26 26% 24% 26% 24%
500 641 1413 388 1066 15 42 673 1484 385 1087 15 43 26% 21% 29% 24%
WRL-H
  

   
Gx  Gx  Gx  Gx  A B C D
kg lb mm mm in in kg lb mm mm in in % % % %
200 404 892 379 688 15 27 428 943 369 699 15 28 26% 21% 30% 23%
400 489 1079 383 648 15 26 513 1131 374 659 15 26 28% 22% 28% 22%
500 654 1441 383 1071 15 42 687 1515 380 1093 15 43 26% 21% 29% 24%
10

IWRLI2_13.04_5890700_00
 ELECTRIC CONNECTIONS
The WRL heat pumps are completely wired at
the factory and only require connecon to the
electrical mains, downstream from a unit switch,
according to that envisioned by the Standards in
force on this subject in the country of installation.
It is also advised to check that:
• The electrical mains features are suitable
for the absorpon values indicated in
the electrical data table, TAB. also taking
into consideraon any other machines
operang at the same me.
• The unit is only powered when installaon
has been completed (hydraulic and
electric).
• Respect the connecon indicaons of the
phase, and earth wires.
• The power supply line must have a
relevant protecon mounted upstream
against short circuits and dispersions to
earth, which isolates the system with
respect to other ulies.
• The voltage must be within a tolerance
of ±10% of the nominal power supply
voltage of the machine (for unbalanced
three-phase unit max 3% between the
phases). Whenever these parameters are
not respected, contact the electric energy
public body. For electric connecons,
use the cables with double isolaon
according to the Standards in force on this
subject in the dierent countries.
• The use of an omnipolar magnet
circuit breaker switch is mandatory, in
compliance with the IEC-EN Standards
(contact opening at least 3 mm), with
suitable cut-o power and dierenal
protecon on the basis of the electric data
table shown below, installed as near as
possible to the appliance.
• It is mandatory to make an eecve earth
connecon. The manufacturer cannot be
considered responsible for any damage
caused by the lack of or ineecve
appliance earth connecon.
• For units with three-phase power supply,
check the correct connecon of the
phases.



 RECOMMENDED ELECTRIC CABLE SEC
TION
The cable secon shown in the table are
recommended for maximum lengths of 50m.
For longer lengths or dierent cable laying, it is
up to the PLANNER to calculate the appropriate
line switch, the power supply line as well as the
connecon to the earth wire and connecon cables
depending on:
• the length
• the type of cable
• the absorpon of the unit and the physical
locaon, and the ambient temperature.
ATTENTION:






 ELECTRIC POWER CONNECTION TO THE
ELECTRICAL MAINS
1. Before connecng the unit to the power
supply mains , ensure that the isolang
switch is open.
2. Open the front panel
3. Use the holes at the top on the
framework for the main electric power
supply cable and for the cables of the
other external connecons under the
responsibility of the installer.
4. It is forbidden to access with electric
cables in posions not specically
envisioned in this manual.
5. Avoid direct contact with not insulated
copper piping and with compressor.
6. Idenfy the clamps for the electric
connecon, always refer to the electric
layout supplied with the unit.
7. For the funconal connecon of the
unit bring a power supply cable to the
electric control board inside the unit
and connect to the U-N and PE clamps
respecng (U) phase, (N) neutral, (PE)
earth in case of single-phase power
supply (230V~50Hz),
8. U-V-W like phases, N like neutral and PE
like earth in case of three-phase power
supply (400V- 3N~50Hz).
9. Re-posion the inspecon panels
10. Ensure that all protecons removed
for the electric connecon have been
restored before electrically powering
the unit.
11. Posion the main system switch (external
to the appliance) at “ON”.
All the electrical operaons must be carried out bySTAFF IN POSSESSION OF THE
NECESSARY QUALIFICATIONS BY LAW, suitably trained and informed on the risks related
to these operaons.
The characteriscs of the electrical lines and of the related components must be
determined by STAFF QUALIFIED TO DESIGN ELECTRICAL SYSTEMS, in compliance with
the internaonal and naonal regulaons of the place of installaon of the unit and in
compliance with the regulaons in force at the moment of installaon.
For the installaon requirements refer only to the electrical diagram supplied with the
appliance. The electrical diagram along with the manuals must be kept in good condion
and ALWAYS AVAILABLE FOR ANY FUTURE SERVICING ON THE UNIT.
IT ISmandatory to verify that the machine is waterght before making the electrical
connecons and it must only be powered up aer the hydraulic and electrical works have
been completed.
11

IWRLI2_13.04_5890700_00
 CONTROL AND COMMISSIONING
 PREPARATION FOR COMMISSIONING
Please note that, on request by the Aermec
customer or the legimate owner of the machine,
the units in this series can be started up by the
AERMEC Aer-Sales Service in your area (valid only
on Italian territory).
The start of operaon must be scheduled in advance
based on the meframe for the compleon of works
for the system. Prior to the work to be carried out
by the AERMEC service personnel, all other works
(electrical and hydraulic hook-ups, priming and
bleeding of air from the system) must have been
completed.
Before starng the unit make sure that:
1. All safety condions have been
respected
2. The unit is correctly xed to the support
surface
3. The minimum technical spaces have
been respected;
4. The hydraulic connecons have been
made respecng the inlet and outlet
5. The hydraulic plant has been loaded and
bled.
6. The hydraulic circuit cocks are open
7. The electric connecons have been
made correctly
8. The voltage is within the tolerance of
10% of the unit nominal value
9. Earthing is correctly made. All electric
and hydraulic connecons are correctly
ghtened.
 MACHINE COMMISSIONING
- Close the electric control board hatch.
- Position the appliance door-lock isolating switch
at ON,
turning the handle downwards.
- Press the ON key to switch the machine. When
the LED is on the unit is ready for functioning.
 SEASON CHANGEOVER
- For every season change, check that the
functioning limits lie within the limits.
- Check that the compressor input current is lower
than the maximum indicated in the technical data
table.
- Check, that in models with three-phase power
supply, that the compressor noise level is not
abnormal. If this is the case, invert a phase.
- Make sure that the voltage value lies within the
pre-fixed limits and that unbalance between the
three phases (three-phase power supply) is not
above 3%.
 SEASON CHANGEOVER FROM PANEL
ON MACHINE
How to activate season changeover:
Under the On- Off branch it is possible change the
functioning mode of the machine. In the second
selection line (can ONLY be edited if OFF was
selected in the first line) it is possible to select the
seasonal state of the heat pump
(SUMMER, WINTER, DHW ONLY). Clearly according
to the machine configured and according to the
accessories installed.

ALWAYS REFER TO THE PROCEDURE

For electric connections, use the cables with
double isolation according to the Standards in
force on this subject in the countries where the
unit is installed.
Commissioning must be performed with
standard settings. Only when the inspection
has been completed can the functioning Set
Point values by changed.
Before start-up, power the unit for at least
12-24 hours positioning the protection magnet
circuit breaker switch and the door lock
isolating switch at ON
Make sure that the control panel is off in order
to allow the compressor sup oil to heat.
On-Off/ Mode
Heat Pump Unit
SUMMER + DHW
ON
 ELECTRICAL DATA
WRL / WRL-H POWER SUPPLY  MCA [A] MOP [A] 
180
230/3/60 222 69 99,8 90
460/3/60 116 34 48,6 45
575/3/60 90 26 36,5 35
200
230/3/60 276 84 120,7 110
460/3/60 147 47 67,2 60
575/3/60 96 34 48,1 45
400
230/3/60 357 129 185,7 175
460/3/60 177 58 83,5 80
575/3/60 133 52 73,7 70

12

IWRLI2_13.04_5890700_00
 EXTRAORDINARY
MAINTENANCE
The WRL heat pumps are loaded with R410A gas
and factory inspected. Under normal condions
they do not require Technical Assistance related to
control of refrigerant gas. Through me gas leakage
may be generated from the from the joints, causing
refrigerant to escape and discharge the circuit,
causing appliance malfunconing. In these cases the
leakage points are to be discovered, repaired and
the Gas circuit is to be replenished, respecng the
December 28 1993 n°549 law.
 LOAD PROCEDURE
The load procedure is the following:
• Empty and dry the enre cooling circuit
using a vacuum pump connected to the
low and high pressure socket unl 10 Pa
is read on the vacuum meter. Wait a few
minutes and check that this value does not
rise above 50 Pa.
•Connect the refrigerant gas cylinder or
a load cylinder to the socket on the low
pressure line.
•Load the amount of refrigerant gas
indicated on the appliance features plate.
• Aer a few hours of funconing, check that
the liquid indicator indicates the dry circuit
(dry-green). In the case of paral loss, the
circuit must be emped completely before
being re-loaded.
•The R410A refrigerant must only be loaded
in the liquid state.
• Funconing condions that are dierent
to the nominal condions can give rise to
values that are greatly dierent.
•The sealing test or the search for leaks must
only be performed using R410A refrigerant
gas, checking using a suitable leak detector.
•In the cooling circuit it is prohibited to use
oxygen or acetylene or other inammable
or poisonous gases because they are a
cause of explosions or intoxicaon.
WARNING
Inspection, maintenance and
eventual repair work must be
carried out only by a legally
qualified technician.
Lack of control/maintenance can
cause damage to persons or things.
For appliances installed near to
the sea, the maintenance intervals
must be halved.
 ROUTINE
MAINTENANCE
All cleaning is prohibited unl the unit has been
disconnected from the electric power supply mains.
Make sure there is no voltage present before
operang.
Periodic maintenance is fundamental to keep the
unit perfectly ecient under a funconal and
energec point of view.
It is therefore essential to carry out periodic yearly
controls for the:
 HYDRAULIC CIRCUIT
CHECK:
• Relling of water circuit
• Cleaning the water lter
• Control of ow switch
• No air from the circuit (bleed)
• That the water ow rate to the evaporator is
constant
• The thermal insulaon of the hydraulic piping
• The percentage of glycol where necessary
• Please provide, in the periodical operaons of
ordinary maintenance, also the control and the
ghtening of hydraulic connecons.
 ELECTRICAL CIRCUIT
CHECK:
• Safety eciency
• Electric supply pressure
• Electrical Input
• Connecon ghtness
• Funconing of the compressor guard resistance
 COOLING CIRCUIT
CHECK:
• State of compressor
• Eciency of the plate heat exchanger
resistance
• Work pressure
• Leak test for waterghtness control of the
cooling circuit
• Funconing of high and low pressure pressure
switches
• Carry out the appropriate checks on the lter
dryer to check eciency
 MECHANICAL CHECKS
CHECK:
• The ghtening of the screws the compressors
and the electrical box, as well as the exterior
panelling of the unit. Insucient fastening can
lead to undesired noise and vibraons.
• The condion of the structure.
If there are any oxidised parts, treat with paint
suitable to eliminate or reduce oxidaon.
We recommend to envision a
machine book (not supplied,
but the user's responsibility),
which allows to keep track of
the interventions performed
on the unit. In this way it will
be easy to suitably organise the
interventions making research and
the prevention of any machine
breakdowns easier.
Use the date to record date, type
of intervention made (routine
maintenance, inspection or
repairs), description of the
intervention, measures actuated…
IT IS forbidden to RELOAD the
circuit with a refrigerant gas
different to the one indicated.
Using a different refrigerant gas
can cause serious damage to the
compressor.
DISPOSAL
Envisions that disposal of the
unit is carried out in conformity
with the Standards in force in the
different countries.
13

IWRLI2_13.04_5890700_00
14

IWRLI2_13.04_5890700_00 15

The technical data in the following documentation are not binding. Aermec
reserves the right to make all the
modifications considered necessary for improving the product at any time.
37040 Bevilacqua (VR) - Italy
Via Roma, 996 - Tel. [phone]
Telefax ([phone] - ([phone]
www.aermec.com
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