CLIVET CRH-XHE2 14.2-44.4 User manual

M07W40D16-00(EC1) 15-12-16
CRH-XHE2 14.2-44.4
Installation and
operating manual
“Roof top” water cooled heat pump

Dear Customer,
We congratulate you on choosing this product
For many years Clivet has been oering systems that provide maximum comfort, together with high
reliability, efficie y, quality and safety.
The aim of the company is to oer advanced systems, that assure the best comfort, reduce energy
consumption and the installation and maintenance cost for the life cycle of the system.
The purpose of this manual is to provide you with information that is useful from reception of
the equipment, through installation, operational usage and finally disposal so that this advanced
system oers the beat solution.
Yours faithfully.
CLIVET Spa
The data contained in this manual is not binding and may be changed by the manufacturer without
prior notice.
Reproduction, even is part, is FORBIDDEN © Copyright - CLIVET S.p.A. - Feltre (BL) - Italia

CRH-XHE2 14.2-44.4 3
Index of contents
1 General description 4
2 Reception 6
3 Positioning 8
4 Water connections 10
5 Aeraulic connections 12
6 Electrical connections 13
7 Start-up 17
8 Control 24
9 Maintenance 30
10 Accessories 36
11 Decommissioning 44
12 Residual risks 45
13 Technical information 46
14 Dimensional drawings 47
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4 CRH-XHE2 14.2-44.4
1 General description
1.1 Manual
The manual provides correct unit installation, use and maintenance.
Pay particular attention to:
Warning, identifies pa ticularly important operations or information.
Prohibited operations that must not be carried out, that compromise the operating of the unit or may cause damage to persons or things.
•It is advisable to read it carefully so you will save time during operations.
•Follow the written indications so you will not cause damages to things and injuries people.
1.2 Preliminaries
Only qualified personnel can ope ate on the unit, as required by the regulation in force.
1.3 Risk situations
The unit has been designed and created to prevent injures to people.
During designing it is not possible to plane and operate on all risk situation.
Read carefully “Residual risk” section where all situation which may cause damages to things and injuries to people are reported.
Installation, starting, maintenance and repair required specific knowledge; if they are carried out by inexperienced personnel, they may cause
damages to things and injuries people.
1.4 Intended use
Use the unit only:
•civil air-conditioning
•keep to the limits foreseen in the technical schedule and in this manual
The manufacturer accepts no responsibility if the equipment is used for any purpose other than the intended use.
1.5 Installation
Outdoor installation
The positioning, hydraulic system, refrigerating, electrics and the ducting of the air must be determined by the system designer in accordance
with local regulations in force.
Follow local safety regulations.
Verify that the electrical line characteristics are in compliance with data quotes on the unit serial number label.
1.6 Maintenance
Plan periodic inspection and maintenance in order to avoid or reduce repairing costs.
Turn the unit off be ore any operation.
1.7 Modication
All unit modific tions will end the warranty coverage and the manufacturer responsibility.
1.8 Breakdown/Malfuction
Disable the unit immediately in case of breakdown or malfunction.
Contact a certified se vice agent.
Use original spares parts only.
Using the unit in case of breakdown or malfunction:
•voids the warranty
•it may compromise the safety of the unit
•may increase time and repair costs
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CRH-XHE2 14.2-44.4 5
1.9 User training
The installer has to train the user on:
•Start-up/shutdown
•Set points change
•Standby mode
•Maintenance
•What to do / what not to do in case of breakdown
1.10 Data update
Continual product improvements may imply manual data changes.
Visit manufacturer web site for updated data.
1.11 Indications for the User
Keep this manual with the wiring diagram in an accessible place for the operator.
Note the unit data label so you can provide them to the assistance centre in case of intervention (see “Unit identific tion”section).
Provide a unit notebook that allows any interventions carried out on the unit to be noted and tracked making it easier to suitably note the
various interventions and aids the search for any breakdowns.
In case of breakdown or malfunction:
•Immediately deactivate the unit
•Contact a service centre authorized by the manufacturer
The installer must train the user, particularly on:
•Start-up/shutdown
•Set points change
•Standby mode
•Maintenance
•What to do / what not to do in case of breakdown
1.12 Unit indentication
The serial number label is positioned on the unit and allows to indentify all the unit features.
The matriculation plate must never be removed.
The matriculation plate shows the indications foreseen by the standards, in particular:
•unit type
•serial number (12 characters)
•year of manufacture
•wiring diagram number
•electrical data
•manufacturer logo and address
1.13 Serial number
It identifies uniquely each uni .
Must be quoted when ordering spare parts.
1.14 Assistance request
Note data from the serial number label and write them in the chart on side, so you will find them easily when neede .
Series
Size
Serial number
Year of manufacture
Electrical wiringdiagram
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6 CRH-XHE2 14.2-44.4
2 Reception
You have to check before accepting the delivery:
•That the unit hasn’t been damaged during transport
•That the materials delivered correspond with that indicated on the transport document comparing the data with the identific tion label
positioned on the packaging.
In case of damage or anomaly:
•Write down on the transport document the damage you found and quote this sentence: “Conditional acceptance clear evidence of
deficiencies/damages du ing transport”
•Contact by fax and registered mail with advice of receipt to supplier and the carrier.
Any disputes must be made within 8 days from the date of the delivery. Complaints after this period are invalid.
2.1 Storage
Observe external packaging instructions.
2.2 Handling
1. Verify unit weight and handling equipment lifting capacity.
2. Identify critical points during handling (disconnected routes, flig ts, steps, doors).
3. Suitably protect the unit to prevent damage.
4. lifting brackets
5. Lifting with balance
6. Lifting with spacer bar
7. Align the barycenter to the lifting point
8. Use all the lifting brackets (see the dimensional section)
9. Gradually bring the lifting belts under tension, making sure they are positioned correctly.
10. Before starting the handling, make sure that the unit is stable.
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CRH-XHE2 14.2-44.4 7
2.3 Packaging removing
Be careful not to damage the unit.
Keep packing material out of children's reach it may be dangerous.
Recycle and dispose of the packaging material in conformity with local regulations.
A Supports for handling: remove after the handling.
B Remove the coil protective mesh before the start-up
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8 CRH-XHE2 14.2-44.4
3 Positioning
During positioning consider these elements:
•Technical spaces requested by the unit
•Electrical connections
•Water connections
•Spaces for air exhaust and intake
3.1 Functional spaces
Functional spaces are designed to:
•guarantee good unit operation
•carry out maintenance operations
•protect authorized operators and exposed people
Respect all functional spaces indicated in the DIMENSIONS section.
Double all functional spaces if two or more unit are aligned.
3.2 Saftey valve gas side
The installer is responsible for evaluating the opportunity of installing drain tubes, in conformity with the local regulations in force (EN 378).
3.3 Positioning
Units are designed to be installed:
•EXTERNAL
•in fi ed positions
Limit vibration transmission:
•use anti-vibration devices or neoprene strips on the unit support points
•install fl xible joints on the hydraulic connections
•install fl xible joints on the hydraulic connections
Choose the installation place according to the following criteria:
•Customer approval
•safe accessible position
•technical spaces requested by the unit
•spaces for the air intake/exhaust
•max. distance allowed by the electrical connections
•install the unit raised from the ground
•verify unit weight and bearing point capacity
•verify that all bearing points are aligned and leveled
•condensate water draining
•consider the maximum possible snow level
•Avoid installations in places subject to floodin
Protect the unit with suitable fence in order to avoid access to unauthorised personnel (children, vandals, etc.)
A correct circulation of the air is mandatory to guarantee the good unit operating.
Avoid therefore:
•obstacles to the airfl w
•difficu y of exchange
leaves or other foreign bodies that can obstruct the ext. dampers
•heat or pollution sources close to the unit (chimneys, extractors etc..)
•stratific tion (cold air that stagnates at the bottom)
•recirculation (expelled air that is sucked in again)
•incorrect positioning, close to very high walls, attics or in angles that could give rise to stratific tion or recirculation phenomenons
Avoid the accumulation of snow and ice in front of the exhaust air outlet
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CRH-XHE2 14.2-44.4 9
1 Positioning on concrete oor 5Positioning on steel structure
2 2 cm thick neoprene strips 6 antivibration mounts
3 concrete oor 7 steel structure
4 insulation 8 steel structure
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10 CRH-XHE2 14.2-44.4
4 Water connections
4.1 Water quality
Water features
•confi ming to local regulations
•total hardness < 14°fr
•within the limits indicated by table
The water quality must be checked by qualified personne .
Water with inadequate characteristics can cause:
•pressure drop increase
•reduces energy efficie y
•increased corrosion potential
Acceptable water quality values:
SO
42-
HCO
3-
/SO
42-
Total Hardness
Cl
-
PO
43-
< 100
> 1
4,5 ÷8,5
< 50
< 2,0
NH3 < 0,5
PH 7,5 ÷9,0
ppm
dH
ppm
ppm
ppm
Fe
3+
Mn
++
CO
2
H
2
S
Temperature
< 0,5
< 0,05
< 50
< 50
< 65
Oxygen content < 0,1
Free Chlorine < 0,5
ppm
ppm
ppb
°C
ppm
ppm
ppm
Provide a water treatment system if values fall outside the limits.
The warranty does not cover damages caused by limestone formations, deposits and impurities from the water supply and / or failure from
failed system clearing to clean system.
4.2 Risk of freezing
If the unit or the relative water connections are subject to temperatures close to 0°C:
•mix water with glycol, or
•safeguard the pipes with heating cables placed under the insulation, or
•empty the system in cases of long non-use
4.3 Anti-freeze solution
The use of an anti-freeze solution results in an increase in pressure drop.
Make sure that the glycol type utilized is inhibited (not corrosive) and compatible with the water circuit components.
Do not use dierent glicol mixture (i.e. ethylene with propylene).
4.4 Water ow-rate
The project water-fl w must be:
•inside the exchanger operating limits (see the TECHNICAL INFORMATION section)
•guarantee, also with variable system conditions (for example in systems where some circuits are bypassed in particular situations).
4.5 Water lter
It must be installed immediately in the water input of the unit, in a position that is easily accessible for cleaning.
The fil er never should be removed, this operation invalidates the guaranty.
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CRH-XHE2 14.2-44.4 11
4.6 Condensate drain
The condensate must be disposed in order to avoid damages to people and things.
•Unit discharge fitting: the connection must not transmit mechanical stresses and must be performed taking care not to damage the unit
discharge fittin .
•Provide a siphon that, eliminating the negative pressure caused by the fan, prevents the air intake from the discharge duct.
•The ducting must have a min. slope of 3% to allow the runo.
•Anchor the ducting with an adequate number of supports.
•Insulate the duct and the siphon to avoid the condensate drippings.
•Connect the condensate discharge to a sewerage drainage network.
DO NOT use white water or drainage networks to avoid the aspiration of odours in the case of evaporation of water contained in the siphon.
Check at the end of the work, the regular condensate runoff pou ing some water in the tray.
For details see:
14 Dimensional drawingsp.47
4.7 Operation sequence
Close all vent valves in the high points of the unit hydraulic circuit
Close all drain valves in the low points of the unit hydraulic circuit:
•Heat exchangers
•Pumps
•collectors
1. Carefully wash the system with clean water: fill and d ain the system several times.
2. Apply additives to prevent corrosion, fouling, formation of mud and algae.
3. Fill the plant
4. Execute leakage test.
5. Isolate the pipes to avoid heat dispersions and formation of condensate.
6. Leave various point of service free (wells, vent-holes etc).
Neglecting the washing will lead to several fil er cleaning interventions and at worst cases can cause damages to the exchangers and the
other parts.
4.8 Humidier
For details see:
10 Accessoriesp.36
4.9 Hydraulic connections
UNIT
A
filettare – to threadsaldare – to weld
A1 A2
impianto - system
A + B : fornito da Clivet - Clivet supplied
o-or
B
A
Retirer le joint de connexion avant de souder le tuyau de l’installation.
The rubber gasket might be irreparably damaged.
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12 CRH-XHE2 14.2-44.4
5 Aeraulic connections
The dimensioning and correct execution of the aeraulic connections are fundamental to guarantee good unit operation and adequate level
of silence in the room.
When designing and manufacturing the ducting, consider LOAD LOSSES, AIR FLOW AND SPEED that must be consistent with the unit features.
Particularly consider that load losses higher than the unit useful prevalence, lead to reduction in fl w rate, with consequent unit blocks.
•the weight of the channels must not burden on the connection flange
•place anti-vibration joints between channels and unit
•connection to the flanges and between the various sections of the channels must guarantee air seal, avoiding dispersions penalising the
overall efficie y of the system
•limit the load losses by optimising the path, the type and number of bends and junctions
•use wide bends evaluating the opportunity of equipping them with defle tors (in particular with high air speed or bends with reduced
radius)
5.1 Treated air channelling
The internal surface of the channel must be smooth, enable its washing and must not contaminate the air.
Thermally isolate the channels and the flanges o avoid energy losses and forming of condensation.
DIFFUSERS INLETS GRILLES
A correct diffusion of the air in the oom is determining for the level of comfort.
When choosing and positioning the grilles, inlets and diffuser , avoid:
•excessive air speed
•forming of stagnant and stratific tion areas
•cold air delivery in room
•forming of localised currents (also due to uneven distribution of air)
•excessive room temperature variations, vertically and horizontally
•short circuits of the supply air towards the return air
For sound comfort, consider that:
•the air diffusers must be chosen erifying the sound power generated at nominal fl w rate conditions
•the cut-off o diffusers must be ca ried out with fl xible elements
•the return grilles must be widely dimensioned
Thermally isolate the channels and the flanges o avoid energy losses and forming of condensation.
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CRH-XHE2 14.2-44.4 13
6 Electrical connections
The characteristics of the electrical lines must be determined by qualified electrica personnel able to design electrical installations; moreover,
the lines must be in conformity with regulations in force.
The protection devices of the unit power line must be able to stop all short circuit current, the value must be determined in accordance with
system features.
The power cables and the protection cable section must be defined in a cordance with the characteristics of the protections adopted.
All electrical operations should be performed by trained personnel having the necessary qualific tions required by the regulations in force
and being informed about the risks relevant to these activities.
Operate in compliance with safety regulations in force.
6.1 Electrical data
The serial number label reports the unit specific ele trical data, included any electrical accessories.
The electrical data indicated in the technical bulletin and in the manual refer to the standard unit, accessories excluded.
The matriculation plate shows the indications foreseen by the standards, in particular:
•Voltage
•F.L.A.: full load ampere, absorbed current at maximum admitted conditions
•F.L.I.: full load input, full load power input at max. admissible condition
•Electrical wiringdiagram Nr.
6.2 Connections
1. Refer to the unit electrical diagram (the number of the diagram is shown on the serial number label).
2. Verify that the electrical supply has characteristics conforming to the data shown on the serial number label.
3. Before starting work, ensure the unit is isolated, unable to be turned on and a safety sign used.
4. Ensure correct earth connection.
5. Ensure cables are suitably protected.
6. Before powering up the unit, make sure that all the protections that were removed during the electrical connection work have been
restored.
6.3 Signals / data lines
Do not exceed the maximum power allowed, which varies, according to the type of signal.
Lay the cables far from power cables or cables having a dierent tension and that are able to emit electromagnetic disturbances.
Do not lay the cable near devices which can generate electromagnetic interferences.
Do not lay the cables parallel to other cables, cable crossings are possible, only if laid at 90°.
Connect the screen to the ground, only if there aren’t disturbances.
Guarantee the continuity of the screen during the entire extension of the cable.
Respect impendency, capacity and attenuation indications.
6.4 Power input
Fix the cables: if vacated may be subject to tearing.
The cable must not touch the compressor and the refrigerant piping (they reach high temparatures).
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14 CRH-XHE2 14.2-44.4
6.5 Connections performer by customer
6.6 SA5 input
•Summer / winter mode remote change
•function Fan only
•function CLEAN
Summer - winter mode remote change P008
enabled by SA5* 0
enabled by thermostat 1
enabled by BMS 2
automatic 3
*functions Fan /Clean from SA5 not available
function Fan only P263 GVODUJPO$-&"/P266
disabled 0 disabled 0
enabled by BMS 1 enabled by BMS 1
enabled by SA5* 2 enabled by SA5* 2
*functions Summer / winter /Clean from SA5 not available *functions Summer-winter / Clean from SA5 not available
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CRH-XHE2 14.2-44.4 15
6.7 Wall mounted electronic room control
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16 CRH-XHE2 14.2-44.4
6.8 COMMUNICATION MODULES
Serial communication module for Modbus supervisor
Serial communication module for BACnet supervisor
Serial communication module for LonWorks supervisor
DATA LINE FEATURES
Every RS485 serial line must be set up using the ‘In/Out’ bus system.
The dierence in potential between the earth of the two RS485 devices that the cable shielding needs to be connected to must be lower than
7 V
There must be suitable arresters to protect the serial lines from the eects of atmospheric discharges
A 120 ohm resistance must be located on the end of the serial line. Alternatively, when the last serial board is equipped with an internal
terminator, it must be enabled using the specific jumpe , dip switch or link.
The cable must have insulation features and non-flame p opagation in accordance with applicable regulations.
The RS485 serial line must be kept as far away as possible from sources of electromagnetic interference.
1. Unit
2. Metal conduit
3. Metal septums
4. Metal-lined sheath (sleeve)
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CRH-XHE2 14.2-44.4 17
7 Start-up
7.1 General description
The indicated operations should be done by qualified echnician with specific t aining on the product.
Upon request, the service centres performing the start-up.
The electrical, water connections and the other system works are by the installer.
Agree upon in advance the star-up data with the service centre.
Before checking, please verify the following:
•the unit should be installed properly and in conformity with this manual
•the electrical power supply line should be isolated at the beginning
•the unit isolator is open, locked and equipped with the suitable warning
•make sure no tension is present
After turning off the p wer, wait at least 5 minutes before accessing to the electrical panel or any other electrical component.
Before accessing check with a multimeter that there are no residual stresses.
7.2 Preliminary checks
For details refer to the dierent manual sections.
Unit OFF power supply
1. safety access
2. functional spaces
3. structure integrity
4. fans run freely
5. unit on vibration isolators
6. air fil ers present and clean
7. completed aeraulic system
8. unit input water fil er + shut-off alves for cleaning
9. vibration isolators on water connections
10. minimum system water content
11. cleaned system
12. loaded system + possible glycol solution + corrosion inhibitor
13. system under pressure
14. vented system
15. refrigerant circuit visual check
16. earthing connection
17. power supply features
18. electrical connections provided by the customer
7.3 Start-up sequence
For details refer to the dierent manual sections.
Unit ON power supply
1. compressor crankcase heaters operating at least since 8 hours
2. off-load oltage measure
3. phase sequence check
4. shut-off alve refrigerant circuit open
5. load voltage measure and absorptions
6. liquid sight glass check (no bubbles)
7. check all fan operating
8. air fl w rate measurement
9. supply, return and outdoor air temperature measurement
10. measure super-heating and sub-cooling
11. check no anomalous vibrations are present
12. climatic curve personalization
13. climatic curve personalization
14. scheduling personalization
15. fi e alarm configu ation *
16. complete and available unit documentation
* only if present
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18 CRH-XHE2 14.2-44.4
7.4 Refrigeration circuit
1. Check carefully the refrigerating circuit: the presence of oil stains can mean leakage caused by transportation, movements or other).
2. Verify that the refrigerating circuit is in pressure: Using the unit manometers, if present, or service manometers.
3. Make sure that all the service outlets are closed with proper caps; if caps are not present a leak of refrigerant can be possible.
4. Open the valves of the refrigerant circuit, if there are any.
7.5 Water circuit
1. Before realizing the unit connection make sure that the hydraulic system has been cleaned up and the cleaning water has been drained.
2. Check that the water circuit has been filled and p essurized.
3. Check that the shut-off alves in the circuit are in the“OPEN”position.
4. Check that there isn’t air in the circuit, if required, evacuate it using the air bleed valve placed in the system high points.
5. When using antifreeze solutions, make sure the glycol percentage is suitable for the type of use envisaged.
Neglecting the washing will lead to several fil er cleaning interventions and at worst cases can cause damages to the exchangers and the
other parts.
Weight of glycol (%) 10 20 30 40
Freezing temperature (°C) -3.9 -8.9 -15.6 -23.4
Safety temperature (°C) +1 -4 -10 -19
7.6 Electric Circuit
Verify that the unit is connected to the ground plant.
Check the conductors are tightened as: the vibrations caused by handling and transport might cause these to come loose.
Connect the unit by closing the sectioning device, but leave it on OFF.
Check the voltage and line frequency values which must be within the limits: 400/3/50 +/- 10%
Check and adjust the phase balance as necessary: it must be lower than 2%
Example
Working outside of these limits can cause irreversible damages and voids the warranty.
7.7 Compressor crankcase heaters
Connect the oil resistances on the compressor crankcase at least 8 hours before the compressor is to be starter:
•at the first unit sta t-up
•after each prolonged period of inactivity
1. Supply the resistances switching off the unit isol tor switch.
2. To make sure that heaters are working, check the power input.
3. At start-up the compressor crank-case temperature on the lower side must be higher at least of 10°C than the outside temperature.
Do not start the compressor with the crankcase oil below operating temperature.
7.8 Voltages
Check that the air and water temperatures are within in the operating limits.
Start-up the unit.
With unit operating in stable conditions, check:
•Voltage
•Total absorption of the unit
•Absorption of the single electric loads
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CRH-XHE2 14.2-44.4 19
7.9 Scroll compressor
The Scroll compressors have only one rotation direction.
In the event it is reversed, the compressor is not immediately damaged, but increases its noise and jeopardises pumping.
After a few minutes, the compressor blocks due to intervention of the thermal protection.
In this case, disconnect power supply and invert 2 phases on the machine power supply.
Avoid the compressor working for a long time with contrary rotation: more than 2-3 of these anomalous start-ups can damage it.
To ensure the rotation direction is correct, measure the condensation and suction pressure.
The pressures must significa tly dier: upon start-up, the suction pressure decreases whereas the condensation one, increases.
7.10 Remote controls
Check that the remote controls (ON-OFF etc) are connected and, if necessary, enabled with the respective parameters as indicated in the
“electrical connections” section.
Check that probes and optional components are connected and enabled with the respective parameters (“electrical connections”section and
following pages).
7.11 Air ow setting
The real unit fl w is according to the aeraulic system features.
Before checking, make sure that the system has been completed in all its parts (shunts, dampers, grilles, diffusers e c.).
Check the doors and windows of the serviced room are closed.
Calibration must be carried out with unit all in recirculation.
The unit is in full recirculation during the first 20 minu es from start-up.
Set the fl w rate:
par 57 Sf_SpeedOut (l/sec)
7.12 Air ow management
Standard mode
The air fl w supply remains constant in all heat load conditions and operation modes.
ECO mode
The air fl w supply remains constant at varied heat loads and is shutdown when setpoint is fulfille .
Variable airfl w
Option
The air fl w supply varies depending on the heat load, up to a minimum value compatible with the distribution system and the chosen air
diffusion
The ventilation remains active even when the setpoint is fulfille .
Min
123
Nominal = par 50 QSetMand
Airflow
Nominal
100% 75% 50% 25%
Compressor load
0
Airflow
Nominal
Min
100% 75% 50% 25%
Compressor load
0
Variable airflowEco mode
Standard mode
Airflow
Nominal
100% 75% 50% 25%
Compressor load
0
Min = par 51
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20 CRH-XHE2 14.2-44.4
7.13 ECO mode
The air fl w supply remains constant at varied heat loads and is shutdown when setpoint is fulfille .
To further increase the energy savings in this condition, it is also possible to set less demanding operation setpoints for the unit in respect to
the standard mode.
This function is indicated for the thermal maintenance of the served area in case it is temporarily not used, which can for example occur at
night.
The ECO mode can be activated:
•Manually: P04 Enable EcoMode = 1
•Automatically by means supervision system
Example in cooling mode:
time
time
time
SetCool
SetECOCool
TimeEco
TimeTestEco
Fan
Compressor
Air return temp
P02 Setpoint ECO Heat
P03 Setpoint ECO Cool
P04 Enable EcoMode
P18 TimeEco
P19 TimeTestEco
TimeEco TimeEco
On
Off
On
Off
Set
ECO
Heat
Set
ECO
Cool
Set
Heat Set Cool
Return
air
temp
7.14 Set-point automatic compensation
The set changes automatically according to the outside temperature.
Even the operating mode changes automatically according to the outside temperature.
The variation is defined y the climatic curve.
P16
Setpoint
Outdoor temp.
P17
P15
P14
P10 P11 P13 P12
Setpoint
COOL
Setpoint
HEAT
DeadZone
5°C 20°C 24°C 35°C
28°C
22°C
21°C
19°C
example
P05 EnableAutoSet = 1
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