CIAT AQUACIAT CALEO TD 80 User manual

AQUACIATCALÉO™
High-temperature heat pumps
03 - 2022
10198
Instruction manual

CONTENTS
1 - INTRODUCTION...................................................................................................................................................................... 4
1.1 - Check equipment received.................................................................................................................................................. 4
1.2 - Installation safety considerations ........................................................................................................................................ 4
1.3 - Equipment and components under pressure ...................................................................................................................... 5
1.4 - Maintenance safety considerations..................................................................................................................................... 5
1.5 - Repair safety considerations............................................................................................................................................... 6
2 - PRELIMINARY CHECKS......................................................................................................................................................... 8
2.1 - Check equipment received.................................................................................................................................................. 8
2.2 - Moving and siting the unit.................................................................................................................................................... 8
2.3 - Checks before system start-up............................................................................................................................................ 8
2.4 - Lifting labels ........................................................................................................................................................................ 9
3 - DIMENSIONS, CLEARANCES.............................................................................................................................................. 10
3.1 - TD 080-100 ...................................................................................................................................................................... 10
3.2 - TD 120-150 ........................................................................................................................................................................11
3.3 - TD 200-300 ...................................................................................................................................................................... 12
3.4 - TD 100 + XtraFan option................................................................................................................................................... 13
3.5 - TD 120-150 + XtraFan option............................................................................................................................................ 14
3.6 - TD 200-300 + XtraFan option............................................................................................................................................ 15
3.7 - Multiple-unit installation..................................................................................................................................................... 15
4 - PHYSICAL DATA .................................................................................................................................................................. 16
5 - ELECTRICAL DATA .............................................................................................................................................................. 17
5.1 - Compressor usage and electrical data for standard units................................................................................................. 17
5.2 - Short-circuit stability current (TN system(1)) - standard unit (with main disconnect without fuse) ..................................... 17
6 - APPLICATION DATA............................................................................................................................................................. 19
6.1 - Unit operating range.......................................................................................................................................................... 19
6.2 - Plate heat exchanger water ow ....................................................................................................................................... 19
6.3 - Minimum water ow rate ................................................................................................................................................... 19
6.4 - Maximum plate heat exchanger water ow rate................................................................................................................ 19
6.5 - Water loop volume ............................................................................................................................................................ 20
6.6 - Plate heat exchanger pressure drop curves...................................................................................................................... 20
7 - ELECTRICAL CONNECTION ............................................................................................................................................... 21
7.1 - Power supply..................................................................................................................................................................... 21
7.2 - Voltage phase imbalance (%)............................................................................................................................................ 21
7.3 - Recommended wire sections ............................................................................................................................................ 21
7.4 - Field control wiring ............................................................................................................................................................ 21
7.5 - Power supply..................................................................................................................................................................... 21
7.6 - 24 V user power reserve ................................................................................................................................................... 22
8 - WATER CONNECTIONS ....................................................................................................................................................... 23
8.1 - Operating precautions and recommendations .................................................................................................................. 23
8.2 - Hydraulic connections ....................................................................................................................................................... 24
8.3 - Frost protection ................................................................................................................................................................. 24
8.4 - Protection against cavitation ............................................................................................................................................. 25
9 - NOMINAL SYSTEM WATER FLOW CONTROL................................................................................................................... 27
9.1 - General.............................................................................................................................................................................. 27
9.2 - Water ow control procedure (xed speed)....................................................................................................................... 27
9.3 - Water ow control procedure (variable speed).................................................................................................................. 28
9.4 - Available system pressure................................................................................................................................................. 28
10 - START-UP............................................................................................................................................................................ 29
10.1 - Preliminary checks .......................................................................................................................................................... 29
10.2 - Actual start-up ................................................................................................................................................................. 29
10.3 - Operation of two units in master/slave mode .................................................................................................................. 29
10.4 - Supplementary electric resistance heaters ..................................................................................................................... 30
AQUACIATCALÉO™ TD EN-2

CONTENTS
11 - MAJOR SYSTEM COMPONENTS ...................................................................................................................................... 31
11.1 - Compressors ................................................................................................................................................................... 31
11.2 - Lubricant.......................................................................................................................................................................... 31
11.3 - Air evaporators ................................................................................................................................................................ 31
11.4 - Fans................................................................................................................................................................................. 31
11.5 - Electronic expansion valve (EXV) of the main circuit ...................................................................................................... 31
11.6 - Electronic expansion valve (EXV) of the economised circuit........................................................................................... 31
11.7 - Four-way valve ................................................................................................................................................................ 31
11.8 - Moisture indicator ............................................................................................................................................................ 31
11.9 - Filter drier ........................................................................................................................................................................ 31
11.10 - Condenser..................................................................................................................................................................... 31
11.11 - Economiser.................................................................................................................................................................... 31
11.12 - Refrigerant..................................................................................................................................................................... 32
11.13 - High-pressure safety switch .......................................................................................................................................... 32
12 - OPTIONS AND ACCESSORIES ......................................................................................................................................... 33
13 - UNITS WITH FANS WITH AVAILABLE PRESSURE FOR INDOOR INSTALLATION XTRAFAN ..................................... 34
13.1 - Fan discharge connection .............................................................................................................................................. 34
13.2 - Applicable rules for units incorporated into an air duct system ....................................................................................... 34
13.3 - Electrical data for TD units with XtraFan......................................................................................................................... 34
14 - STANDARD MAINTENANCE.............................................................................................................................................. 35
14.1 - Level 1 maintenance ....................................................................................................................................................... 35
14.2 - Level 2 maintenance ....................................................................................................................................................... 35
14.3 - Level 3 (or higher) maintenance...................................................................................................................................... 35
14.4 - Tightening torques for the main electrical screw connections......................................................................................... 36
14.5 - Tightening torques for the main bolts and screws........................................................................................................... 36
14.6 - Evaporator coil ................................................................................................................................................................ 36
14.7 - Condenser maintenance ................................................................................................................................................. 36
14.8 - Characteristics of R-407C ............................................................................................................................................... 37
15 - START-UP CHECKLIST FOR TD HEAT PUMPS (USE FOR JOB FILE)........................................................................... 38
EN-3 AQUACIATCALÉO™ TD

1 - INTRODUCTION
Prior to the initial start-up of the Aquaciat Caléo™ TD units, the
people involved should be thoroughly familiar with these
instructions and the specic project data for the installation site.
The Aquaciat Caléo™ TD heat pumps are designed to provide
a very high level of safety and reliability making installation,
start-up, operation and maintenance easier and more secure.
They will provide safe and reliable service when operated within
their application range.
They are designed for a theorical operating life of 15 years based
on loads profile defined within the applicable Ecodesign
regulations
Beyond this period, the manufacturer recommends to proceed
to a fatigue prevention survey on the refrigerating circuit
conducted by an operator qualied for the control of pressure
equipment. It is recommended to repeat this check every 5 years.
This control does not replace the requirements of applicable
national regulations.
The procedures in this manual are arranged in the sequence
required for machine installation, start-up, operation and
maintenance.
Be sure you understand and follow the procedures and safety
precautions contained in the instructions supplied with the
machine, as well as those listed in this guide, such as: protective
clothing such as gloves, safety glasses, safety shoes and
appropriate tools, and suitable qualications (electrical, air
conditioning, local legislation).
To nd out, if these products comply with European directives
(machine safety, low voltage, electromagnetic compatibility,
equipment under pressure, etc.) check the declarations of
conformity for these products.
1.1 - Check equipment received
-Inspect the unit for damage or missing parts. If damage is
detected, or if shipment is incomplete, immediately le a claim
with the shipping company.
-Conrm that the unit received is the one ordered. Compare
the name plate data with the order.
-The name plate is attached to the unit in two locations:
• on the outside on one of the unit sides
• on the control box door on the inside
-This shows the following information:
• Model number - size
• CE marking
• Serial number
• Year of manufacture and pressure and leak tightness test date
• Refrigerant used
• Refrigerant charge per circuit
• PS: Min./max. allowable pressure (high and low pressure
side)
• TS: Min./max. allowable temperature (high and low pressure
side)
• Pressure switch cut-out pressure
• Unit leak test pressure
• Voltage, frequency, number of phases
• Maximum current drawn
• Maximum power input
• Unit net weight
-Conrm that all accessories ordered for on-site installation
have been supplied, are complete and undamaged.
The unit must be checked periodically, if necessary
removing the insulation (thermal, acoustic), during its whole
operating life to ensure that no shocks (handling accessories,
tools, etc.) have damaged it. If necessary, the damaged parts
must be repaired or replaced. See also chapter “Maintenance”.
1.2 - Installation safety considerations
After the unit has been received, when it is ready to be installed
or reinstalled, and before it is started up, it must be inspected for
damage. Check that the refrigerant circuits are intact, especially
that no components or pipes have shifted or been damaged (e.g.
following a shock). If in doubt, carry out a leak tightness check. If
damage is detected upon receipt, immediately le a claim with the
shipping company.
This machine must be installed in a location that is not accessible
to the public and protected against access by non-authorised people.
Do not remove the skid or the packaging until the unit is in
its nal position. These units can be moved with a fork lift
truck, as long as the forks are positioned in the right place
and direction on the unit.
The units can also be lifted with slings, using only the
designated lifting points marked on the unit (labels on the
chassis and a label with all unit handling instructions are
attached to the unit tank - refer to chapter 2.4).
Use slings with the correct capacity, and always follow the
lifting instructions on the certied drawings supplied for
the unit.
Safety is only guaranteed, if these instructions are carefully
followed. If this is not the case, there is a risk of material
deterioration and injuries to personnel.
These units are not designed to be lifted from above.
DO NOT COVER ANY PROTECTION DEVICES.
This applies to fuse plugs and relief valve (if used) in the
refrigerant or heat transfer medium circuits. Check if the
original protection plugs are still present at the valve outlets.
These plugs are generally made of plastic and should not
be used. If they are still present, please remove them. Install
devices at the valve outlets or drain piping that prevent the
penetration of foreign bodies (dust, building debris, etc.)
and atmospheric agents (water can form rust or ice). These
devices, as well as the drain piping, must not impair
operation and not lead to a pressure drop that is higher than
10% of the control pressure.
Ensure that the valves are correctly installed, before
operating the unit.
Classication and control
In accordance with the Pressure Equipment Directive and
national usage monitoring regulations in the European
Union the protection devices for these machines are
classied as follows:
Safety
accessory(1)
Over pressure protection in case
of an external re(2)
Refrigerant side
High-pressure switch x
External relief valve(3) x
Rupture disk x
Fuse plug x
Heat transfer uid side
External relief valve (4) (4)
(1) Classied for protection in normal service situations.
(2) Classied for protection in abnormal service situations. These accessories
are sized for res with a thermal ow of 10kW/m². No combustible matter
should be placed within 6.5m of the unit.
(3) The instantaneous over-pressure limitation to 10% of the operating pressure
does not apply to this abnormal service situation. The control pressure can
be higher than the service pressure. In this case, either the design temperature
or the high-pressure switch ensures that the service pressure is not exceeded
in normal service situations.
(4) The classication of these relief valve must be made by the personnel that
completes the whole hydraulic installation.
Do not remove these valves and fuses, even if the re risk
is under control for a particular installation. There is no
guarantee that the accessories are re-installed if the
installation is changed or for transport with a gas charge.
AQUACIATCALÉO™ TD EN-4

When the unit is subjected to re, safety devices prevent
rupture due to over-pressure by releasing the refrigerant.
The uid may then be decomposed into toxic residues when
subjected to the ame:
-Stay away from the unit.
-Set up warnings and recommendations for personnel in
charge to stop the re.
-Fire extinguishers appropriate to the system and the
refrigerant type must be easily accessible.
All factory-installed relief valve are lead-sealed to prevent
any calibration change.
The external relief valve must always be connected to drain
pipes for units installed in a closed room. Refer to the
installation regulations, for example those of European
standard EN 378 and EN 13136.
These pipes must be installed in a way that ensures that
people and property are not exposed to refrigerant leaks.
As the uids can be diffused in the air, ensure that the outlet
is far away from any building air intake, or that they are
discharged in a quantity that is appropriate for a suitably
absorbing environment. Relief valve must be checked
periodically. See paragraph “Repair safety considerations”.
If the relief valves are installed on a reversing valve
(changeover), this is equipped with a relief valve on each of
the two outlets. Only one of the two relief valve is in
operation, the other one is isolated. Never leave the
reversing valve in the intermediate position, i.e. with both
ways open (locate the control element in the stop position).
If a relief valve is removed for checking or replacement
please ensure that there is always an active relief valve on
each of the reversing valves installed in the unit.
Provide a drain in the drain pipe, close to each relief valve,
to avoid an accumulation of condensate or rain water.
All precautions concerning handling of refrigerant must be
observed in accordance with local regulations.
Accumulation of refrigerant in an enclosed space can
displace oxygen and cause asphyxiation or explosions.
Inhalation of high concentrations of vapour is harmful and
may cause heart irregularities, unconsciousness, or death.
Vapour is heavier than air and reduces the amount of oxygen
available for breathing. These products cause eye and skin
irritation. Decomposition products can be hazardous.
1.3 - Equipment and components under
pressure
These products incorporate equipment or components under
pressure, manufactured by CIAT or other manufacturers. We
recommend that you consult your appropriate national trade
association or the owner of the equipment or components under
pressure (declaration, re-qualification, retesting, etc.). The
characteristics of this equipment/these components are given
on the nameplate or in the required documentation, supplied with
the products.
The units are intended to be stored and operate in an environment
where the ambient temperature must not be less than the lowest
allowable temperature indicated on the nameplate.
Do not introduce signicant static or dynamic pressure with
regard to the operating pressures used during operation or
for tests in the refrigerant circuit or in the heat exchange
circuits.
1.4 - Maintenance safety considerations
CIAT recommends the following drafting for a logbook (the table
below should not be considered as reference and does not
involve CIAT responsibility):
Intervention Name of the
commissioning
engineer
Applicable
national
regulations
Verication
Organism
Date Nature (1)
(1) Maintenance, repairs, regular verications (EN 378), leakage, etc.
Engineers working on the electric or refrigeration components
must be authorized, trained and fully qualied to do so (e.g.
electricians trained and qualied in accordance with IEC 60364
Classication BA4).All refrigerant circuit work must be carried
out by a trained person, fully qualied to work on these units. He
must have been trained and be familiar with the equipment and
the installation. All welding operations must be carried out by
qualied specialists.
TD units use refrigerant R-407C. Special equipment must be
used when working on the refrigerant circuit (pressure gauge,
charge transfer, etc.).
Any manipulation (opening or closing) of a shut-off valve
must be carried out by a qualied and authorised engineer,
observing applicable standards (e.g. during draining
operations). The unit must be switched off while this is done.
Equip the engineers that work on the unit as follows:
Personal protection equipment
(PPE)(1)
Operations
Handling maintenance,
service
Welding or
brazing(2)
Protective gloves,
eye protection,
safety shoe,
protective clothing.
X X X
Ear protection. X X
Filtering respirator. X
(1) We recommend to follow the instructions in EN 378-3.
(2) Performed in the presence of A1 refrigerant according to EN 378-1.
Never work on a unit that is still energized. Never work on
any of the electrical components, until the general power
supply to the unit has been cut.
If any maintenance operations are carried out on the unit,
lock the power supply circuit in the open position and secure
the machine upstream with a padlock.
If the work is interrupted, always ensure that all circuits are
still deenergized before resuming the work.
Even if the unit has been switched off, the power
circuit remains energized, unless the unit or circuit
disconnect switch is open, and remote start-up is
still possible.
Refer to the wiring diagram for further details. Attach
appropriate safety labels.
If any work is carried out in the fan area, specically
if the grilles or casings have to be removed, cut the
power supply to the fans to prevent their operation.
It is also rcommended to block the rotation of the
blades during the work.
1 - INTRODUCTION
EN-5 AQUACIATCALÉO™ TD

It is recommended to install an indicating device to
show if part of the refrigerant has leaked from the
valve. The presence of oil at the outlet orice is a
useful indicator that refrigerant has leaked. Keep
this orifice clean to ensure that any leaks are
obvious. The calibration of a valve that has leaked
is generally lower than its original calibration. The
new calibration may affect the operating range. To
avoid nuisance tripping or leaks, replace or re-
calibrate the valve.
Operating checks:
Important information regarding the refrigerant used:
This product contains uorinated greenhouse gas covered
by the Kyoto protocol.
Fluid type: R407C
Global Warming Potential (GWP): 1774
1. Any intervention on the refrigerant circuit of this
product should be performed in accordance
with the applicable legislation. In the EU, the
regulation is called F-Gas, N°517/2014.
2. Ensure that the refrigerant is never released to
the atmosphere during installation, maintenance
or equipment disposal.
3. The deliberate gas release into the atmosphere
is not allowed.
4. If a refrigerant leak is detected, ensure that it is
stopped and repaired as quickly as possible.
5. Only a qualied and certied personnel can
perform installation operations, maintenance,
refrigerant circuit leak test as well as the
equipment disposal and the refrigerant
recovering.
6. The gas recovery for recycling, regeneration or
destruction is at customer charge.
7. Periodic leak tests have to be carried out by the
customer or by third parties. The EU regulation
set the periodicity here after:
System WITHOUT leakage
detection No Check 12 Months 6 Months 3 Months
System WITH leakage
detection No Check 24 Months 12 Months 6 Months
Refrigerant charge/circuit
(CO2equivalent) < 5 Tons 5 ≤ Charge
< 50 Tons
50 ≤
Charge
< 500 Tons
Charge
> 500
Tons(1)
Refrigerant
charge/
Circuit (kg)
R134A (GWP
1430)
Charge
< 3,5 kg
3,5 ≤
Charge
< 34,9 kg
34,9 ≤
Charge
< 349,7 kg
Charge
> 349,7 kg
R407C
(GWP 1774)
Charge
< 2,8 kg
2,8 ≤
Charge
< 28,2 kg
28,2 ≤
Charge
< 281,9 kg
Charge
> 281,9 kg
R410A (GWP
2088)
Charge
< 2,4 kg
2,4 ≤
Charge
< 23,9 kg
23,9 ≤
Charge
< 239,5 kg
Charge
> 239,5 kg
HFO’s:
R1234ze No requirement
(1) From 01/01/2017, units must be equipped with a leakage detection system
8. A logbook must be established for equipments
subject to periodic leak tests. It should contain
the quantity and the type of uid present within
the installation (added and recovered), the
quantity of recycled fluid, regenerated or
destroyed, the date and output of the leak test,
the designation of the operator and its belonging
company, etc.
9. Contact your local dealer or installer if you have
any questions.
Protection device checks:
-If no national regulations exist, check the protection
devices on site in accordance with standard EN378: once
a year for the high-pressure switches, every ve years
for external relief valve.
The company or organisation that conducts a pressure switch
test shall establish and implement a detailed procedure to x:
• Safety measures
• Measuring equipment calibration
• Validating operation of protective devices
• Test protocols
• Recommissioning of the equipment.
Consult CIAT Service for this type of test. CIAT mentions here
only the principle of a test without removing the pressure switch:
• Verify and and record the set-points of pressure switches
and relief devices (valves and possible rupture discs)
• Be ready to switch-off the main disconnect switch of the
power supply if the pressure switch does not trigger (avoid
over-pressure or excess gas in case of valves on the high-
pressure side with the recovery condensers)
• Connect a pressure gauge protected against pulsations
(filled with oil with maximum pointer if mechanical),
preferably calibrated (the values displayed on the user
interface may be inaccurate in an instant reading because
of the scanning delay applied in the control)
• Complete an HP Test as provided by the software (refer to
the Control IOM for details).
If the machine operates in a corrosive environment, inspect
the protection devices more frequently.
Regularly carry out leak tests and immediately repair any
leaks.
Ensure regularly that the vibration levels remain acceptable
and close to those at the initial unit start-up.
Before opening a refrigerant circuit, transfer the refrigerant
to bottles specically provided for this purpose and consult
the pressure gauges.
Change the refrigerant after an equipment failure, following
a procedure such as the one described in NF E29-795 or
carry out a refrigerant analysis in a specialist laboratory.
If the refrigerant circuit remains open for longer than a day
after an intervention (such as a component replacement),
the openings must be plugged and the circuit must be
charged with nitrogen (inertia principle). The objective is to
prevent penetration of atmospheric humidity and the
corrosion on the unprotected internal steel walls.
1.5 - Repair safety considerations
All installation parts must be maintained by the personnel in
charge, in order to avoid deterioration and injury. Faults and leaks
must be repaired immediately. The authorized technician must
have the responsibility to repair the fault immediately. After each
repair of the unit, check the operation of the protection devices
and create a report of the parameter operation at 100%.
Comply with the regulations and recommendations in unit and
HVAC installation safety standards, such as: EN 378 and ISO 5149.
1 - INTRODUCTION
AQUACIATCALÉO™ TD EN-6

RISK OF EXPLOSION
Never use air or a gas containing oxygen during leak tests
to purge lines or to pressurise a machine. Pressurised air
mixtures or gases containing oxygen can be the cause of
an explosion. Oxygen reacts violently with oil and grease.
Only use dry nitrogen for leak tests, possibly with an
appropriate tracer gas.
If the recommendations above are not observed, this can
have serious or even fatal consequences and damage the
installation.
Never exceed the specied maximum operating pressures.
Verify the allowable maximum high- and low-side test
pressures by checking the instructions in this manual and
the pressures given on the unit name plate.
Do not unweld or amecut the refrigerant lines or any
refrigerant circuit component until all refrigerant (liquid and
vapour)as well as the oil have been been transferred from
the heat pump. Traces of vapour should be displaced with
dry air nitrogen. Refrigerant in contact with an open ame
can produce toxic gases.
The necessary protection equipment must be available, and
appropriate fire extinguishers for the system and the
refrigerant type used must be within easy reach.
Do not siphon refrigerant.
Avoid spilling liquid refrigerant on skin or splashing it into
the eyes. Use safety goggles and safety gloves. Wash any
spills from the skin with soap and water. If liquid refrigerant
enters the eyes, immediately and abundantly ush the eyes
with water and consult a doctor.
The accidental releases of the refrigerant, due to small leaks
or signicant discharges following the rupture of a pipe or
an unexpected release from a relief valve, can cause
frostbites and burns to personnel exposed. Do not ignore
such injuries. Installers, owners and especially service
engineers for these units must:
• Seek medical attention before treating such injuries.
• Have access to a rst-aid kit, especially for treating eye
injuries.
We recommend to apply standard EN 378-3 Annex 3.
Never apply an open ame (blowlamp) or overheated steam
(high-pressure cleaner) to the refrigerant circuit. Dangerous
overpressure can result.
During refrigerant removal and storage operations follow
applicable regulations. These regulations, permitting
conditioning and recovery of halogenated hydrocarbons
under optimum quality conditions for the products and
optimum safety conditions for people, property and the
environment are described in standard NF E29-795.
Refer to the certied dimensional drawings for the units.
It is dangerous and illegal to re-use disposable (non-
returnable) reclaim cylinders or attempt to rell them. When
reclaim cylinders are empty, evacuate the remaining gas
pressure, and move them to a designated place for recovery.
Do not incinerate.
Do not attempt to remove refrigerant circuit components or
ttings, while the machine is under pressure or while it is
running. Be sure pressure is at 0 kPa and that the unit has
been shut-down and de-energised before removing
components or opening a circuit.
Do not attempt to repair or recondition any safety devices
when corrosion or build-up of foreign material (rust, dirt,
scale, etc.) is found within the valve body or mechanism. If
necessary, replace the device. Do not install relief valve in
series or backwards.
No part of the unit must be used as a walkway, rack
or support. Periodically check and repair or if
necessary replace any component or piping that
shows signs of damage.
Do not step on refrigerant lines. The lines can break
under the weight and release refrigerant, causing
personal injury. Do not climb on a machine. Use a
platform, or staging to work at higher levels.
Use mechanical lifting equipment (crane, hoist,
winch, etc.) to lift or move heavy components. For
lighter components, use lifting equipment when
there is a risk of slipping or losing your balance.
Use only original replacement parts for any repair
or component replacement. Consult the list of
replacement parts for the specification of the
original equipment.
Do not drain water circuits containing industrial
brines, without informing the technical service
department at the installation site or a competent
body rst.
Close the entering and leaving water shut-off valves
and purge the unit hydraulic circuit, before working
on the components installed on the circuit (screen
lter, pump, water ow switch, etc.).
Periodically inspect all valves, ttings and pipes of
the refrigerant and hydraulic circuits to ensure that
they do not show any corrosion or any signs of
leaks.
It is recommended to wear ear defenders, when
working near the unit and the unit is in operation.
Always ensure you are using the correct refrigerant
type before recharging the unit.
Charging any refrigerant other than the original
charge type (R-407C) will impair machine operation
and can even lead to a destruction of the
compressors. The compressors operate with
R-407C and are charged with a synthetic polyol-
ester oil.
Before any intervention on the refrigerant circuit,
the complete refrigerant charge must be recovered.
1 - INTRODUCTION
EN-7 AQUACIATCALÉO™ TD

2 - PRELIMINARY CHECKS
2.1 - Check equipment received
-Check that the unit has not been damaged during transport
and that no parts are missing. If the unit has been damaged
or the shipment is incomplete, send a claim to the shipping
company.
-Compare the name plate data with the order. The name plate
is attached in two places to the unit:
• On one of the unit sides on the outside
• On the control box door on the inside.
-The unit name plate must include the following information:
• Model number - size
• CE marking
• Serial number
• Year of manufacture and pressure and leak tightness test
date
• Fluid being transported
• Refrigerant used
• Refrigerant charge per circuit
• PS: Min./max. allowable pressure (high and low pressure
side)
• TS: Min./max. allowable temperature (high and low pressure
side)
• Pressure switch cut-out pressure
• Unit leak test pressure
• Voltage, frequency, number of phases
• Maximum current drawn
• Maximum power input
• Unit net weight
-Conrm that all accessories ordered for on-site installation
have been delivered, are complete and undamaged.
-The unit must be checked periodically, if necessary removing
the insulation (thermal, acoustic), during its whole operating
life to ensure that no shocks (handling accessories, tools,
etc.) have damaged it. If necessary, the damaged parts must
be repaired or replaced. See also chapter “Maintenance”.
2.2 - Moving and siting the unit
2.2.1 - Moving
See chapter 1.2 - “Installation safety considerations”.
2.2.2 - Siting the unit
The machine must be installed in a place that is not accessible
to the public or protected against access by non-authorised
persons.
In case of extra-high units the machine environment must
permit easy access for maintenance operations.
Always refer to the chapter “Dimensions and clearances”
to conrm that there is adequate space for all connections
and service operations. For the centre of gravity coordinates,
the position of the unit mounting holes, and the weight
distribution points, refer to the certied dimensional drawing
supplied with the unit.
Typical applications of these units do not require earthquake
resistance. Earthquake resistance has not been veried and
the units are not explosion-proof.
Only use slings at the designated lifting points
which are marked on the unit.
Before siting the unit check that:
-the permitted loading at the site is adequate or that appropriate
strenghtening measures have been taken.
-if the heat pump is required to operate in temperatures below
0°C it must be raised at least 300 mm from the ground. This
is necessary to avoid ice build-up on the unit chassis and also
to permit correct unit operation in locations where the snow
level may reach this height.
-the unit is installed level on an even surface (maximum
tolerance is 5 mm in both axes).
-there is adequate space above the unit for air ow and to
ensure access to the components (see dimensional drawings).
-the number of support points is adequate and that they are
in the right places.
-the location is not subject to ooding.
-Bafes may be necessary to deect strong winds. They must
not restrict air ow into the unit.
Before lifting the unit, check that all casing panels
are securely xed in place. Lift and set down the
unit with great care. Tilting and jarring can damage
the unit and impair unit operation.
If TD units are hoisted with rigging, it is advisable to protect coils
against crushing while a unit is being moved. Use struts or a
lifting beam to spread the slings above the unit. Do not tilt a unit
more than 15°.
Never push or lever on any of the enclosure panels
of the unit. Only the base of the unit frame is
designed to withstand such stresses.
2.3 - Checks before system start-up
Before the start-up of the refrigeration system, the complete
installation, including the refrigeration system must be veried
against the installation drawings, dimensional drawings, system
piping and instrumentation diagrams and the wiring diagrams.
For these checks national regulations must be followed. If the
national regulation does not specify any details, refer to standard
EN 378 as follows:
External visual installation checks:
-Ensure that the machine is charged with refrigerant, Verify on
the unit nameplate that the ‘uid transported’ is R407C and
is not nitrogen.
-Compare the complete installation with the refrigeration
system and power circuit diagrams.
-Check that all components comply with the design
specications.
-Check that all protection documents and equipment provided
by the manufacturer (dimensional drawings, P&ID, declarations
etc.) to comply with the regulations are present.
-Verify that the environmental safety and protection and
devices and arrangements provided by the manufacturer to
comply with the regulations are in place.
-Verify that all documents for pressure containers, certicates,
name plates, files, instruction manuals provided by the
manufacturer to comply with the regulations are present.
-Verify the free passage of access and safety routes.
-Verify the instructions and directives to prevent the deliberate
removal of refrigerant gases.
-Verify the installation of connections.
-Verify the supports and xing elements (materials, routing and
connection).
-Verify the quality of welds and other joints.
-Check the protection against mechanical damage.
-Check the protection against heat.
-Check the protection of moving parts.
-Verify the accessibility for maintenance or repair and to check
the piping.
-Verify the status of the valves.
-Verify the quality of the thermal insulation and of the vapour
barriers.
-Ensure that the ventilation in the machine room is sufcient.
-Check the refrigerant detectors.
AQUACIATCALÉO™ TD EN-8

2 - PRELIMINARY CHECKS
2.4 - Lifting labels
TD 080 to 100
X (mm) Y (mm) Z (mm)
536±15 568±22 577±18
TD 120 to 150
X (mm) Y (mm) Z (mm)
841±31 521±7 563±33
TD 200 to 300
Unit with grille protection option
X (mm) Y (mm) Z (mm)
798±25 568±22 577±18
NOTES:
1. Material: self-adhesive vinyl 9800
2. The symbols must be centred.
3. The symbols are black on a red background.
EN-9 AQUACIATCALÉO™ TD

3 - DIMENSIONS, CLEARANCES
3.1 - TD 080-100
1114 ht 1339 ht
1061
300 MINI VOIR NOTICE D’INSTALLATION
REFER TO INSTALLATION MANUAL
1280
1321
1000
1000
1000
1000
1440 ht
Legend
All dimensions are given in mm. NOTES:
A. Non-certied drawings.
Refer to the certied dimensional drawings supplied
with the unit or available on request, when designing
an installation. For the location of xing points, weight
distribution and coordinates of the centre of gravity
refer to the certied dimensional drawings.
B. In multiple-unit installations (maximum four units), the
side clearance between the units should be increased
from 1000 to 2000 mm.
C. The height of the solid surface must not exceed 2 m.
Control box
Water inlet
Water outlet
B
Required clearances for air ow
C
Recommended clearances for maintenance
Air outlet, do not obstruct
Power supply and control connection
AQUACIATCALÉO™ TD EN-10

3.2 - TD 120-150
1114 ht 2110 ht
1061 HT
300 MINI VOIR NOTICE D’INSTALLATION
REFER TO INSTALLATION MANUAL
2050
1321
1000
1000
1000
1000
1440 ht
Legend
All dimensions are given in mm. NOTES:
A. Non-certied drawings.
Refer to the certied dimensional drawings supplied
with the unit or available on request, when designing
an installation. For the location of xing points, weight
distribution and coordinates of the centre of gravity
refer to the certied dimensional drawings.
B. In multiple-unit installations (maximum four units), the
side clearance between the units should be increased
from 1000 to 2000 mm.
C. The height of the solid surface must not exceed 2 m.
Control box
Water inlet
Water outlet
B
Required clearances for air ow
C
Recommended clearances for maintenance
Air outlet, do not obstruct
Power supply and control connection
3 - DIMENSIONS, CLEARANCES
EN-11 AQUACIATCALÉO™ TD

3 - DIMENSIONS, CLEARANCES
3.3 - TD 200-300
2273 ht 2122 ht
300 MINI VOIR NOTICE D’INSTALLATION
REFER TO INSTALLATION MANUAL
2050
1321
2258
1000
1000
1000
1000
1440 ht
Unit with grille protection option
Legend
All dimensions are given in mm. NOTES:
A. Non-certied drawings.
Refer to the certied dimensional drawings supplied
with the unit or available on request, when designing
an installation. For the location of xing points, weight
distribution and coordinates of the centre of gravity
refer to the certied dimensional drawings.
B. In multiple-unit installations (maximum four units), the
side clearance between the units should be increased
from 1000 to 2000 mm.
C. The height of the solid surface must not exceed 2 m.
Control box
Water inlet
Water outlet
B
Required clearances for air ow
C
Recommended clearances for maintenance
Air outlet, do not obstruct
Power supply and control connection
AQUACIATCALÉO™ TD EN-12

3.4 - TD 100 + XtraFan option
1114 HT
1061
1339 ht
300 MINI VOIR NOTICE D’INSTALLATION
REFER TO INSTALLATION MANUAL
1280
1440 HT
1000
1000
1000
1000
1321
Legend
All dimensions are given in mm. NOTES:
A. Non-certied drawings.
Refer to the certied dimensional drawings supplied
with the unit or available on request, when designing
an installation. For the location of xing points, weight
distribution and coordinates of the centre of gravity
refer to the certied dimensional drawings.
B. In multiple-unit installations (maximum four units), the
side clearance between the units should be increased
from 1000 to 2000 mm.
C. The height of the solid surface must not exceed 2 m.
Control box
Water inlet
Water outlet
B
Required clearances for air ow
C
Recommended clearances for maintenance
Air outlet, do not obstruct
Power supply and control connection
3 - DIMENSIONS, CLEARANCES
EN-13 AQUACIATCALÉO™ TD

3.5 - TD 120-150 + XtraFan option
1114 HT
1061
2110 ht
300 MINI VOIR NOTICE D’INSTALLATION
REFER TO INSTALLATION MANUAL
2050
1440 HT
1000
1000
1000
1000
1321
Legend
All dimensions are given in mm. NOTES:
A. Non-certied drawings.
Refer to the certied dimensional drawings supplied
with the unit or available on request, when designing
an installation. For the location of xing points, weight
distribution and coordinates of the centre of gravity
refer to the certied dimensional drawings.
B. In multiple-unit installations (maximum four units), the
side clearance between the units should be increased
from 1000 to 2000 mm.
C. The height of the solid surface must not exceed 2 m.
Control box
Water inlet
Water outlet
B
Required clearances for air ow
C
Recommended clearances for maintenance
Air outlet, do not obstruct
Power supply and control connection
3 - DIMENSIONS, CLEARANCES
AQUACIATCALÉO™ TD EN-14

3.6 - TD 200-300 + XtraFan option
2273 ht
1000
2050
2258
1000
1000
1000
1440 HT
1321
2122 ht
300 MINI VOIR NOTICE D’INSTALLATION
REFER TO INSTALLATION MANUAL
Unit with grille protection option
3.7 - Multiple-unit installation
Solid wall Solid wall
NOTE: If the walls are higher than 2 m, contact the factory
3 - DIMENSIONS, CLEARANCES
EN-15 AQUACIATCALÉO™ TD

4 - PHYSICAL DATA
AQUACIAT CALEO™ TD 80 100 120 150 200 300
Operating weigh (1)
Standard unit kg 418 435 555 579 919 1039
Sound levels
Sound power level (2) dB(A) 78 83 82 84 84 85
Sound pressure level at 10 m (3) dB(A) 46 51 51 53 52 53
Unit + option Low Noise
Sound power level (2) dB(A) 76 80 80 80 82 82
Sound pressure level at 10 m (3) dB(A) 44 49 48 49 50 51
Unit + option Xtra Low Noise
Sound power level (2) dB(A) 76 76 77 79 79
Sound pressure level at 10 m (3) dB(A) 45 45 45 47 47
Dimensions
Lenght mm 1110 1114 2273
Depth mm 1327 2100 2100
Height mm 1440 1440 1440
Compressor Hermetic scroll compressors, 48,3 r/s
Quantity 1 1 1 1 2 2
No. of capacity steps 1 1 1 1 2 2
Refrigerant R407C
Charge kg 8,8 9,7 10 13,2 22 26,5
teq CO215,6 17,2 17,7 23,4 39,0 47,0
Oil
Charge l 4,1 4,1 4,1 4,1 8,2 8,2
Capacity control Connect Touch
Minimum capacity % 100 100 100 100 50 50
Condenser Direct expansion, plate heat exchanger
Water volume l 6,4 8,2 9,6 12,1 16,4 22,7
Max. water-side operating pressure plus hydraulic module kPa 400 400 400 400 400 400
Fans Axial with rotating shroud
Quantity 1 1 1 1 2 2
Maximum total air ow l/s 3748 3736 4035 4036 7479 8072
Max speed, standard unit tr/s 12 12 12 12 12 12
Max speed, unit with Xtrafan tr/s - 16 16 16 16 16
Evaporator Grooved copper tubes and aluminium ns
Hydraulic module
Variable speed pump Pump, Victaulic screen lter, relief valve, water + air purge valves cavitation
pressure sensors
Water connections Victaulic
Connections inch 1"1/4 1"1/2 1"1/2 1"1/2 2'' 2''
Outside tube diameter mm 42,4 48,3 48,3 48,3 60,3 60,3
Chassis paint colour Colour code RAL7035 and RAL7024
(1) Weight shown is a guideline only. Please refer to the unit nameplate
(2) In dB ref=10-12 W, (A) weighting. Declared dualnumber noise emission values in accordance with ISO 4871 (with an associated uncertainty of +/-2dB(A)). Measured
in accordance with ISO 9614-1 and certied by Eurovent.
(3) In dB ref 20 μPa, (A) weighting. Declared dualnumber noise emission values in accordance with ISO 4871 (with an associated uncertainty of +/-2dB(A)). For
information, calculated from the sound power level Lw(A).
AQUACIATCALÉO™ TD EN-16

5 - ELECTRICAL DATA
AQUACIAT CALEO™ TD 80 100 120 150 200 300
Power circuit
Nominal power supply V-ph-Hz 400-3-50
Voltage range V 360-440
Control circuit supply 24 V, via internal transformer
Maximum start-up current (Un) (1)
Standard unit A 102 130 172 203 158 243
Unit with electronic starter option A 54 69 92 103 97 144
Unit power factor at maximum capacity (2) 0,82 0,83 0,87 0,87 0,83 0,87
Maximum unit power input (2) kW 12 16 21 25 32 48
Nominal unit current draw (3) A 16 20 25 30 42 57
Maximum unit current draw (Un) (4) A 21 27 35 41 56 79
Maximum unit current draw (Un-10%) (5) A 22 29 38 45 60 86
(1) Maximum instantaneous start-up current (maximum operating current of the compressor + fan current + locked rotor current of the compressor).
(2) Power input, compressor and fan, at the unit operating limits (saturated suction temperature 10°C, saturated condensing temperature 65°C) and nominal voltage
of 400V (data given on the unit nameplate).
(3) Standardised Eurovent conditions: evaporator entering/leaving water temperature 40°C/45°C, outside air temperature db/wb = 7°C/6°C.
(4) Maximum unit operating current at maximum unit power input and 400V (values given on the unit nameplate).
(5) Maximum unit operating current at maximum unit power input and 360V.
5.1 - Compressor usage and electrical data for standard units
Compressor I Nom I Max I Max LRA(1) LRA(2) Cosine 080 100 120 150 200 300
(Un) (Un-10%) A A phi max.
ZH24KVE 13,6 18,3 20,3 99 51 0,85 1 - - - - -
ZH33KVE 17,3 24,2 26,9 127 66 0,85 - 1 - - 2 -
ZH40KVE 20,4 30,0 33,2 167 87 0,89 - - 1 - - -
ZH48KVE 24,9 36,0 40,0 198 97 0,89 - - - 1 - 2
Legend
I Nom Nominal current draw at Eurovent conditions (see denition of conditions under nominal unit current draw), A
I Max Maximum operating current at 360 V, A
(1) Locked rotor current at nominal voltage, A
(2) Locked rotor current at nominal voltage, electronic starter
5.2 - Short-circuit stability current (TN system(1)) - standard unit (with main disconnect
without fuse)
TD 080 100 120 150 200 300
Value without upstream protection
Short-term current at 1s (Icw) kA rms 0,6 0,6 1,26 1,26 1,26 2
Admissible peak current (Ipk) kA pk 4,5 4,5 6 6 6 10
Maximum value with upstream protection by circuit breaker
Conditional short-circuit current (Icc) kA rms 7 7 7,7 7,7 6,1 10
Circuit breaker - Compact range 40 40 50 63 80 100
Reference number (2) 5SY6340-7 5SY6340-7 5SY4350-7 5SY4363-8 5SP4380-7 5SP4391-7
Value with upstream protection (fuses)
Conditional short-circuit current Icc - kA rms kA rms 50 50 50 50 14,5 22
Fuse (gL/gG) 40 40 63 63 80 125
(1) Earthing system type
(2) If another current limitation protection system is used, its time-current and thermal constraints (l²t) trip characteristics must be at least equivalent to those of the
recommended circuit breaker.
The short circuit stability current values above are suitable with TN system.
EN-17 AQUACIATCALÉO™ TD

Electrical data and operating conditions notes:
• TD 080-300 units have a single power connection point located immediately
upstream of the main disconnect switch.
• The control box includes the following standard features:
-a main disconnect switch,
-starter and motor protection devices for each compressor, the fans and the
pump,
-the control devices.
• Field connections:
All connections to the system and the electrical installations must be in full
accordance with all applicable local codes.
• The Aquaciat Caléo™ TD units are designed and built to ensure conformance
with these codes. The recommendations of European standard EN 60204-1
(machine safety - electrical machine components - part 1: general regulations
- corresponds to IEC 60204-1) are specically taken into account, when designing
the electrical equipment.
NOTES:
• Generally the recommendations of IEC 60364 are accepted as compliance with
the requirements of the installation directives. Conformance with EN 60204-1
is the best means of ensuring compliance with the Machines Directive § 1.5.1.
• Annex B of EN 60204-1 describes the electrical characteristics used for the
operation of the machines.
• The operating environment for the TD units is specied below:
1. Environment(1) - Environment as classied in EN 60721 (corresponds to
IEC 60721):
-outdoor installation(1)
-ambient temperature range: -20°C to +40°C, class 4K4H
-altitude: ≤ 2000 m
-presence of hard solids, class 4S2 (no signicant dust present)
-presence of corrosive and polluting substances, class 4C2 (negligible)
2. Power supply frequency variation: ± 2 Hz.
3. The neutral (N) conductor must not be connected directly to the unit (if
necessary use a transformer).
4. Overcurrent protection of the power supply conductors is not provided with
the unit.
5. The factory-installed disconnect switch is of a type suitable for power
interruption in accordance with EN 60947.
6. The units are designed for connection to TN networks (IEC 60364). Units
delivered with speed drive (options 116) are not compatible with IT network
due to speed drive.
Caution: If particular aspects of an actual installation do not conform to the
conditions described above, or if there are other conditions which should
be considered, always contact your local CIAT representative.
(1) The required protection level for this class is IP43BW (according to reference
document IEC 60529). All TD units are protected to IP44CW and full this
protection condition.
5 - ELECTRICAL DATA
AQUACIATCALÉO™ TD EN-18

6 - APPLICATION DATA
6.1 - Unit operating range
Condenser Minimum Maximum
Entering water temperature at start-up °C 8 57
Leaving water temperature during operation °C 30 65
Entering/leaving water temperature difference K 3 (2)
Evaporator Minimum Maximum
Entering air temperature, standard unit(1) °C -20 40
Entering air temperature, unit with XtraFan °C -15 40
Note: Do not exceed the maximum operating temperature.
(1) Outside temperature: For transport and storage of the TD units the minimum
and maximum allowable temperatures are -20°C and +50°C. It is recommended
that these temperatures are used for transport by container.
(2) Refer to the minimum water ow rate for each machine (see chapter 6.2).
Leaving water temperature, °C
Entering air temperature, °C
20
25
30
35
40
45
50
55
60
65
70
-25-20 -15-10 -5 0510 15 20 25 30 35 40 45
6.2 - Plate heat exchanger water ow
TD Maximum ow rate with hydraulic
module (1) , l/s
Maximum ow rate without
hydraulic module (2) , l/s
080 2,4 2,4
100 2,8 3,1
120 3,8 3,8
150 4,6 4,6
200 5,9 6,4
300 6,1 8,5
(1) Maximum ow rate at an available pressure of 20 kPa minimum
(2) Maximum ow rate at a water temperature difference of 3K in the plate
heat exchanger
NOTE: For a domestic hot water application (leaving water
temperature = 65°C), the water temperature difference must
be 8 K minimum for operation at 100% capacity.
6.3 - Minimum water ow rate
Operation below the minimum ow rate of the machine can cause
a risk of freezing and excessive fouling of the condenser.
Minimum water ow rate, l/s
Leaving water temperature, °C
0.35
0.40
0.45
0.50
0.55
0.60
0.65
0.70
0.75
25 35 45 55 65
B TD 080
C TD 100
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
1.25
1.30
25 35 45 55 65
Minimum water ow rate, l/s
Leaving water temperature, °C
B TD 120
C TD 150
1.00
1.20
1.40
1.60
1.80
2.00
2.20
2.40
25 35 45 55 65
Minimum water ow rate, l/s
Leaving water temperature, °C
B TD 200
C TD 300
6.4 - Maximum plate heat exchanger water
ow rate
This is limited by the permitted plate heat exchanger pressure
drop. Also, a minimum condenser ∆T of 3 K must be guaranteed,
which corresponds to a water ow rate of 0.09 l/s per kW.
EN-19 AQUACIATCALÉO™ TD

6 - APPLICATION DATA
6.5 - Water loop volume
6.5.1 - Minimum water loop volume
The heat pump is used in a domestic hot water application and
must heat an intermediate loop that supplies domestic hot water
via a heat exchanger. The primary loop is charged with softened
water. Regular checks must be carried out on the water system
to detect possible scale formation. The heat pump in this type
of application must never supply domestic hot water directly.
The minimum water loop volume, in litres, is given by the following
formula:
Volume (l) = CAP (kW) x N, where CAP is the nominal heating
capacity at nominal operating conditions.
Heating or domestic hot water application N
TD 080-150 5,0 l
TD 200-300 3,0 l
This volume is required to obtain temperature stability and
precision.
To achieve this volume, it may be necessary to add a storage
tank to the circuit. This tank should be equipped with bafes to
allow mixing of the uid (water or brine). Please refer to the
examples below.
Bad Good
Bad Good
6.5.2 - Expansion tank volume
Units do not incorporate an expansion tank. This must be
included in the water loop.
The table below gives the buffer tank volume that must be
provided, based on the water loop volume, the uid used and its
concentration.
Expansion tank volume required % of water loop volume(1)
Pure water 3,0
10% ethylene glycol 3,0
20% ethylene glycol 3,5
30% ethylene glycol 3,8
40% ethylene glycol 4,2
(1) Calculation based on a charge temperature of 10°C.
6.6 - Plate heat exchanger pressure drop
curves
For pure water at 20°C
Pressure drop, kPa
Water ow rate, l/s
0
5
10
15
20
25
30
01 23 45
1
2
3
B TD 080
C TD 100
D TD 120
0
10
20
30
40
50
02 46 810
1
2
3
Water ow rate, l/s
Pressure drop, kPa
B TD 150
C TD 200
D TD 300
AQUACIATCALÉO™ TD EN-20