CLIMAVENETA MICS FF Service manual

INSTALLATION-OPERATING-SERVICE MANUAL
D
MICS FF
MICS-N FF
0072÷0182
Air/water chillers and heat
pumps with axial-flow fans and
pump assembly.

eneral warnings 2
Fundamental safety rules 2
Identification 3
Receiving and handling the product 3
Description of standard unit 4
Dimensioned drawings 5
Installation 6
Hydraulic connections 6
Electrical connections 8
eneral technical data 12
Cooling performance MICS 13
Cooling performance MICS-N 14
Heating performance MICS-N 15
Operating limits 16
Hydraulic data 17
Checking and starting up the unit 18
Activating and deactivating the unit 20
Setting service parameters 20
Displaying alarms 21
Operating characteristics 22
Shutting down for long periods 23
Routine maintenance 23
Extraordinary maintenance 23
Troubleshooting 24
Useful information 26
U I A
U I A
U I A
I A
I A
I
I
I A
I A
I A
A
A
A
I A
I A
A
I A
A
A
I A
A
A
A
A
A
INDICE
ICS / ICS-N 1
English 07/07
70°C
A
I
U
The manufacturer reserves the right to modify the data in this manual without warning.
Eurovent certification program.
The following symbols are used in this publication and inside the unit:
U
I
I
IU
ENVIRON ENTAL INFOR ATION: This equipment contains fluorinated greenhouse gases covered by the Kyoto Protocol.
It should only be serviced or dismantled by professional trained personnel. R410A WP=1975
User
Installe
Assistance
Important
Prohibition
Danger voltage
Danger moving blades
Danger high temperatures

GENERAL WARNINGS
ICS / ICS-N
2English 07/07
These units have been designed to chill and/or
heat water and must be used in applications com-
patible with their performance characteristics.
Incorrect installation, regulation and maintenance or
improper use absolve the manufacturer from all
liability, whether contractual or otherwise, for dam-
age to people, animals or things. Only those applica-
tions specifically indicated in this list are permitted.
Read this manual carefully. All work must be
carried out by qualified personnel in conformity
with legislation in force in the country concerned.
The guarantee is invalidated if the above
instructions are not respected and if the unit is
started up for the first time without the presence
of personnel authorised by the Company (where
specified in the supply contract) who should draw
up a “start-up” report.
The documentation supplied with the unit
must be consigned to the owner who should keep
it carefully for future consultation in the event of
maintenance or service.
When the items are consigned by the carrier,
check that the packaging and the unit are undam-
aged. If damage or missing components are noted,
indicate this on the delivery note. A formal com-
plaint should be sent via fax or registered post to
the After Sales Department within eight days from
the date of receipt of the items.
When operating equipment involving the use of electricity
and water, a number of fundamental safety rules must be
observed, namely:
The unit must not be used by children or by
unfit persons without suitable supervision.
Do not touch the unit with bare feet or with
wet or damp parts of the body.
Do not carry out cleaning operations without
first disconnecting the system from the electricity
supply by placing the mains switch in the “off” posi-
tion.
Do not modify safety or regulation devices with-
out authorisation and instructions from the manu-
facturer.
Do not pull, detach or twist the electrical cables
coming from the unit, even when disconnected from
the mains electricity supply.
Do not open doors or panels providing access
to the internal parts of the unit without first ensur-
ing that the mains switch is in the off position.
Do not introduce pointed objects through the
air intake and outlet grills.
Do not dispose of, abandon or leave within reach
of children packaging materials (cardboard, staples,
plastic bags, etc.) as they may represent a hazard.
Respect safety distances between the unit and
other equipment or structures. uarantee adequate
space for access to the unit for maintenance and/or
service operations;
Power supply: the cross section of the electrical
cables must be adequate for the power of the unit
and the power supply voltage must correspond with
the value indicated on the respective units. All units
must be earthed in conformity with legislation in
force in the country concerned.
Hydraulic connections should be carried out as
indicated in the instructions to guarantee correct
operation of the unit. Empty the water circuit or add
glycol if the unit is not used during the winter.
Handle the unit with the utmost care (see weight
distribution table) to avoid damage.
FUNDA ENTAL SAFETY RULES
UA
I
UA
I

Dimensione 0072 0092 0122 0152 0182
H 1725 1725 1725 1725 1725 mm
L 1040 1040 1630 1630 1630 mm
P 790 790 790 790 790 mm
ross weight MICS 340 360 440 480 510 kg
ross weight MICS-N 360 380 470 510 540 kg
ICS / ICS-N 3
Italiano 05/07
The ICS / ICS-N chiller can be identified by the:
Rating plate
iving the technical and performance data of the unit. If
this is lost, ask the After Sales Service for a replacement.
Tampering with or
the removal or
absence of rating plates or
other means enabling the
unit to be identified causes
problems during installa-
tion and maintenance.
IDENTIFICATION
POTENZA FRIGORIFERA ------------------- kW
POTENZATERMICA ------------------- kW
TIPO REFRIGERANTE -------------------
CARICA REFRIGERANTE ------------------- Kg
PRESSIONE MASSIMA ------------------- bar
ALIMENTAZIONE ELETTRICA DI POTENZA ------------------- V---Hz
ALIMENTAZIONE ELETTRICA AUSILIARI ------------------- V---Hz
POTENZA ELETTRICA MAX.ASSORBITA ------------------- kW
CORRENTE MAX. ASSORBITA ------------------- A
CORRENTE DI SPUNTO ------------------- A
SCHEMA ELETTRICO ------------------- N°
PESO IN FUNZIONAMENTO ------------------- Kg
ANNO DI FABBRICAZIONE -------------------
RECEIVING AND HANDLING THE PRODUCT
The ICS / ICS-N chillers are supplied accompanied
by:
- installation, operating and service manual;
-guarantee certificate;
- CE declaration;
These are contained in a plastic bag attached to the top of
the chiller.
The unit should always be handled by qualified personnel
using equipment adequate for the weight of the chiller. If a
forklift truck is used, insert the forks under the base, spa-
cing the forks as wide apart as possible. If a crane is used,
pass the cables through the bottom of the base, making
sure they do not exert pressure on the unit. Once the
packaging has been removed, the appliance can be lifted
and moved by inserting two metal tubes (max. diameter
1”) into the special holes in the base and using suitable
handling equipment.
The installation, operating and service
manual is an integral part of the unit and should
therefore be read and kept carefully.
It is recommended that the packaging should
not be removed until the unit is located in the
installation site.
Do not dispose of packaging materials in the envi-
ronment or leave them within reach of children as
they may represent a hazard.
During transport, the chiller should be kept in a
vertical position
UA
I
IA

DESCRIPTION OF STANDARD UNIT
The air-cooled chillers with axial-flow fans operate with
refrigerant R410A and are suitable for installation outdoors.
The units satisfy the essential requirements of directives
98/37/EC, 73/23/EEC, 89/326/EEC, 97/23/EEC and subse-
quent amendments.
They are factory tested and on site installation is limited to
water and electrical connections.
STRUCTURE
Panels and base are made from galvanised steel plate painted
with epoxy powder to ensure total resistance to atmos-
pheric agents.
CO PRESSORS
Hermetic rotary scroll compressor with thermal cut-out..
CONDENSING COILS
Made from copper tubes and aluminium fins with a large
exchange surface.
EVAPORATOR
AISI 316 stainless steel plate type evaporator complete with
differential pressure switch. Casing lined with anti-con-
densate closed cell neoprene cladding.
PU PS
Multistage centrifugal pump with stainless steel hydraulic
assembly and corrosion prevention device to prolong the
working life of the pump. Over-sized watertight bearings
with gasket ring resistant to thermal expansion eliminate the
problem of seizure.
PU P ASSE BLY
Pump assembly with expansion tank, safety valve, manual fill-
ing assembly, pressure gauge and pump.
FANS
External impeller axial-flow fans. Six-pole electric motor
with built-in thermal cut-out. Housed in aerodynamic tubes
with accident prevention grill. Device for operation with
low outside air temperatures: continuous fan rotation
speed control via pressure transducer.
REFRIGERANT CIRCUIT
Refrigerant circuit featuring the following components: filter,
liquid flow indicator, thermostatic expansion valve with
external equaliser. Pressure switches for controlling suction
and discharge pressure. Unit supplied complete with non-
freezing oil and R410A refrigerant charge, factory tested.
POWER AND CONTROL ELECTRICAL PANEL
Power and control electrical panel constructed in accordance
with IEC 204-1/EN60204-1, complete with compressor con-
tactor and thermal solenoid switch and door lock safe-
ty device. Control via “HSW8” control panel.
OPTIONAL ACCESSORIES
- Removable metal mesh filter for water circuit
- Rubber vibration dampers.
- Remote keyboard kit.
- Coil protection grill kit.
The above accessories are optional. Consult the relative
documentation for assembly instructions and technical data.
ICS / ICS-N
4English 07/07
AI

600 600
600 600
W1
W4
W2
W3
DI ENSIONED DRAWINGS
ICS / ICS-N 5
English 07/07
A 120 120 165 165 165
B 800 800 1300 1300 1300
C 44 44 44 44 44
D 602 602 602 602 602
E 144 144 144 144 144
Dimension 0072 0092 0122 0152 0182
W1 97 103 128 141 151
W2 89 95 118 129 137
W3 58 62 77 85 90
W4 66 70 87 95 102
Tot 310 330 410 450 480
W1 103 109 138 151 160
W2 95 101 126 137 146
W3 62 66 83 90 96
W4 70 74 93 102 108
Tot 330 350 440 480 510
I
1- Hydraulic connections IN 0072÷0182 Ø1”1/4
2- Hydraulic connections OUT 0072÷0182 Ø1”1/4
Weight distribution in operation ICS 0072 0092 0122 0152 0182
Weight distribution in operation ICS-N 0072 0092 0122 0152 0182

INSTALLATION
ICS / ICS-N
HYDRAULIC CONNECTIONS
6English 07/07
CHOICE OF INSTALLATION SITE
Before installing the unit, agree with the customer the site
where it will be installed, taking the following points into consid-
eration:
- check that the fixing points are adequate to support the
weight of the unit;
- pay scrupulous respect to safety distances between the unit
and other equipment or structures to ensure that air entering
the unit and discharged by the fans is free to circulate.
- The unit must be installed in a space designed to house techni-
cal installations dimensioned according to legislation in force in
the country concerned and large enough to allow access for
maintenance.
POSITIONING
Before handling the unit, check the capacity of the lifting
equipment used, respecting the instructions on the packaging.
To move the unit in the horizontal, make appropriate use of a
lift truck or similar, bearing in mind the weight distribution of
the unit. To lift the unit, insert tubes long enough to allow
positioning of the lifting slings and safety pins in the special
holes in the base of the unit.
To avoid the slings damaging the unit, place protection
between the slings and the unit. Position the unit in the site
indicated by the customer. Place either a layer of rubber (min.
thickness 10 mm) or vibration damper feet (optional)
between the base and support surface. Fix the unit, making
sure it is level and that there is easy access to hydraulic and
electrical components. If the site is exposed to strong winds,
fix the unit adequately to the support surface using tie rods if
necessary.
The choice and installation of components is the responsibility of
the installer who should follow good working practice and cur-
rent legislation. Before connecting the pipes, make sure they do
not contain stones, sand, rust, dross or other foreign bodies whi-
ch might damage the unit. Construction of a bypass is recommen-
ded to enable the pipes to be washed through without having to
disconnect the unit (see drain valves). The connection piping
should be supported in such a way as to avoid it weighing on the
unit. It is recommended that the following devices are installed in
the water circuit of the evaporator:
1. Two pressure gauges with a suitable scale (inlet and outlet).
2. Two vibration damper joints (inlet and outlet).
3. Two gate valves (normal in inlet and calibrating in outlet).
4. A flow switch (inlet).
5. Two thermometers (inlet and outlet).
6. An inlet filter as close as possible to the evaporator and posi-
tioned to allow easy access for routine maintenance.
The flow of water to the refrigerating assembly must conform to
the values given on page 12.The flow of water must be maintai-
ned constant during operation. The water content of the unit
must be such as to avoid disturbing operation of the refrigerant
circuits. See the values given on page 17.
9
2 4
1
15
16
11
157
2 3
10
5
6
T
6
T
F
1
1
13
13
14
8
12
Collegamenti da eseguire
a cura dell'installatore
INGRESSO ACQUA IMPIANTO
USCITA ACQUA IMPIANTO
Collegamenti
eseguiti in fabbrica
1 Pressure gauge
2 Vibration damper joint
3 ate valve
4 Calibrating valve
5 Flow switch
6 Thermometer
7 Pump
8 Safety valve
9 Air vent
10 Expansion tank
11 Mesh filter
12 Fill/top-up
13 Temperature sensor
14 Differential pressure switch
15 Drain/chemical washing valve
16 Plate heat exchanger
I
AI
HYDRAULIC CIRCUIT

Installations containing antifreeze or covered by
specific legislation must be fitted with hydraulic discon-
nectors.
The manufacturer is not liable for obstruction,
breakage or noise resulting from the failure to install
filters or vibration dampers.
Particular types of water used for filling or top-
ping up must be treated with appropriate treatment
systems. For reference values, see the table.
ICS / ICS-N 7
English 07/07
SIZE AND POSITION OF CONNECTIONS
FILLING THE INSTALLATION
- Remove the inspection panel.
- Before filling, check that the installation drain valve is
closed.
- Open all installation, appliance and terminal air vents.
- Open the gate valves.
- Begin filling, slowly opening the water filling cock inside
the unit.
- When water begins to leak out of the terminal air vent
valves, close them and continue filling until the pressure
gauge indicates a pressure of 1.5 bar.
- Replace the inspection panel
The installation must be filled to a pressure of
between 1 and 2 bar.
It is recommended that this operation be repeat-
ed after the unit has been operating for a number
of hours. The pressure of the installation should be
checked regularly and if it drops below 1 bar, the
water content should be topped-up.
Check the hydraulic tightness of joints.
E PTYING THE INSTALLATION
- Remove the inspection panel.
- Before emptying, place the mains switch in the “off” posi-
tion.
-
Make sure the installation fill/top-up water cock is
closed.
- Open all the installation air vent valves, the drain cock and
the terminals.
- Replace the inspection panel
If the fluid in the circuit contains antifreeze, it
should not be allowed to drain freely as it is pollutant. It
should be collected for possible reuse. When draining
after heat pump operation, take care as the water may be
hot (up to 50°).
PH 6-8
Electrical conductivity less than 200 mV/cm (25°C)
Chlorine ions less than 50 ppm
Sulphuric acid ions less than 50 ppm
Total iron less than 0,3 ppm
Alkalinity M less than 50 ppm
Total hardness less than 50 ppm
Sulphur ions none
Ammonia ions none
Silicon ions less than 30 ppm
A (mm) 100 100 260 260 260
B (mm) 226,5 226,5 363 363 363
C (mm) 63 63 63 63 63
Hydraulic connections (Ø) 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Dimensione 0072 0092 0122 0152 0182

elettrica F.L.I. F.L.A. L.R.A. F.L.I. F.L.A. F.L.I. F.L.A. F.L.I. F.L.A. F.L.I. F.L.A. FU1 FU4 FU5 FU6
(V-Ph-Hz) (kW) (A) (A) (kW) (A) (kW) (A) (kW) (A) (kW) (A)
0072 400-3 N ~ 50 5,9 11,2 48 0,6 2,8 0,7 4,8 7,2 18,8 9,9 23,6 1A 1A 0,5A 3,15
0092 400-3 N ~ 50 8,7 16,3 64 0,6 2,8 0,7 4,8 10,0 23,9 12 27,6 1A 1A 0,5A 3,15
0122 400-3 N ~ 50 9,5 16,6 74 1,2 5,6 0,7 4,8 11,4 27 19 40,4 1A 1A 0,5A 3,15
0152 400-3 N ~ 50 12,2 22,6 95 1,2 5,6 1,3 9,0 14,7 37,2 19,8 46,6 1A 1A 0,5A 3,15
0182
400-3 N ~ 50 14,3 25,9 111 1,2 5,6 0,9 5,4 16,4 36,9 25,1 53,0 1A 1A 0,5A 3,15
ELECTRICAL CONNECTIONS
ICS / ICS-N
8English 07/07
The ICS / ICS-N chillers leave the factory already
wired, and ready for connection to the mains electricity sup-
ply and for the flow switch and remote ON/OFF switch to be
connected. All the above operations must be carried out by
qualified personnel in compliance with the legislation in force.
For all electrical work, refer to the electrical wiring diagrams
in this manual.You are also recommended to check:
- That the characteristics of the mains electricity supply
are adequate for the power input values indicated in the
electrical characteristics table below, also bearing in mind
the possible use of other equipment at the same time.
Power to the unit must be turned on only after
installation work (mechanical, hydraulic and electri-
cal) has been completed.
All electrical connections must be carried out
by qualified personnel in accordance with legislation
in force in the country concerned.
Respect instructions for connecting phase, neu-
tral and earth conductors.The power line should be
fitted upstream with a suitable device to protect
against short-circuits and leakage to earth, isolating
the installation from other equipment.
Voltage must be within a tolerance of ±10% of the rat-
ed power supply voltage for the unit (for three phase
units, the unbalance between the phases must not
exceed 3%). If these parameters are not respected, con-
tact the electricity supply company.
For electrical connections, use double insulation
cable in conformity with current legislation in the
country concerned. Install, if possible near the unit, an
appropriate protection device to isolate the unit from
the mains supply.This should have a delayed character-
istic curve, contacts opening by at least 3 mm and an
adequate interruption and residual current protection
capacity.
If these devices are not visible from the unit,
they should be lockable.
An efficient earth connection is obligatory. Fail-
ure to earth the appliance absolves the manufactur-
er of all liability for damage.
In the case of three phase units, ensure the
phases are connected correctly.
Do not use water pipes to earth the unit.
Rated values (1) FUSES
odel Electrical Compressor Fans Pump Total Max. values (3) lass 5x20mm 250V
F.L.I. power input
F.L.A. current input
L.R.A. compressor start-up current
(1) Outside air temperature 35°C - Water temperature at evaporator 12/7°C.
(2) Outside air temperature 7°C - Water temperature at condenser 40/45°C.
(3) These values should be used to dimension protection switches and power
cables.
ICS ELECTRICAL DATA
AI
elettrica F.L.I. F.L.A. L.R.A. F.L.I. F.L.A. F.L.I. F.L.A. F.L.I. F.L.A. F.L.I. F.L.A. FU1 FU2 FU3 FU4
(V-Ph-Hz) (kW) (A) (A) (kW) (A) (kW) (A) (kW) (A) (kW) (A)
Rated values (2) FUSES
odel Electrical Compressor Fans Pump Total Max. values (3) lass 5x20mm 250V
ICS-N ELECTRICAL DATA
0072 400-3 N ~ 50 5,9 11,2 48 0,6 2,8 0,7 4,8 7,2 18,8 9,9 23,6 1A 1A 0,5A 3,15
0092 400-3 N ~ 50 8,0 14,9 64 0,6 2,8 0,7 4,8 9,3 22,5 12 27,6 1A 1A 0,5A 3,15
0122 400-3 N ~ 50 10,0 17,5 74 1,2 5,6 1,1 7,6 12,3 30,7 19,4 43,2 1A 1A 0,5A 3,15
0152 400-3 N ~ 50 12,8 23,7 95 1,2 5,6 0,9 5,4 14,9 34,7 19,4 43,0 1A 1A 0,5A 3,15
0182
400-3 N ~ 50 14,2 25,7 111 1,2 5,6 0,9 5,4 16,3 36,7 25,1 53,0 1A 1A 0,5A 3,15