CLIVET MSE-XSC3 90.4 User manual

MSE-XSC3 90.4 - 160.4
Installation and operating manual

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, efficiency, 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

Index of contents
1 4
2 6
3 8
4 10
5 14
6 18
7 26
8 35
9 47
10 52
11 53
12 54
57
General description
Reception
Positioning
Water connections
Refrigeranting connections
Electrical connections
Start-up
Control
Maintenance
Decommissioning
Residual risks
General technical data
Dimensional drawings
3

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 operate 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:
• for cooling/heating water or a water and glycol mix
• 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
Indoor / 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 before any operation.
1.7 Modication
All unit modifications 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 service 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
4

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 shows the indications foreseen by the standards, in particular:
• unit type
• serial number (12 characters)
• year of manufacture
• wiring diagram number
• electrical data
• type of refrigerant
• refrigerant charge
• manufacturer logo and address
The matriculation plate must never be removed.
It contains fluorinated greenhouse gases Type of refrigerant: R410A
The unit is shipped with only nitrogen charge
1.13 Serial number
It identifies uniquely each unit.
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 needed .
Series
Size
Serial number
Year of manufacture
Electrical wiringdiagram
5

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 identification
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 during 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.
6

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
A Supports for handling: remove after the handling.
7

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 Positioning
Units are designed to be installed:
• OUTDOOR / INDOOR
• in fixed positions
Limit vibration transmission:
• use anti-vibration devices or neoprene strips on the unit support points
• install flexible 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
• max. distance allowed by the electrical connections
•max. distance allowed by the refrigerating pipes
• install the unit raised from the ground
• verify unit weight and bearing point capacity
• verify that all bearing points are aligned and leveled
• consider the maximum possible snow level
• Avoid installations in places subject to flooding
Protect the unit with suitable fence in order to avoid access to unauthorised personnel (children, vandals, etc.)
Avoid therefore:
• heat or pollution sources close to the unit (chimneys, extractors etc..)
3.3 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).
3.4Functional spaces
3.5Anti-vibration mount support
Optional
For details see:
instructions attached to the anti-vibration mounts
For details see:
Dimensional drawings
8

4 Water connections
4.1 Water quality
Water features
• confirming to local regulations
• total hardness < 14°fr
• within the limits indicated by table
The water quality must be checked by qualified personnel .
Water with inadequate characteristics can cause:
•pressure drop increase
• reduces energy efficiency
• 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-flow must be:
• within exchanger operating range
• guarantee, also with variable system conditions (for example in systems where some circuits are bypassed in particular situations).
4.5 Minimum system water content
Minimum system water volumes have to be satisfied o avoid continuous compressor switching on and o.
9

4.6 Recommended connection
The installer must define
• component type
• position in system
Examples:
PD
TT
PD
TT
F
UNITCUSTOMER
UNIT
1
F
6
7
12
8
OPTION
3
11
9
5
10
CUSTOMER
PD
TT
F
UNITCUSTOMER
13
14
15
16
18
19
17
OPTION
Standard unit Unit with 2 pumps Unit with VARIFLOW +
6
7
12
8
11
9
10
6
7
12
8
11
9
10
18
19
13
14
15
16
17
1
3
5
1
3
5
19
22
2
1 exchanger 11 drain
2 Anti-ice electric heater 12 Flow Switch
3 water temperature probe 13 System load safety pressure switch
5 dierential pressure switch 14 pressure gauge
6 antivibration joints 15 non-return valve
7 piping support 16 Pump
8 exchanger chemical cleaning bypass 17 safety valve
9 Cleaning system bypass 18 shut-o valve
10 vent 19 lter
10

4.7 Hydraulic connections
UNIT
A
filettare – to threadsaldare –to weld
A1 A2
impianto - system
A + B : fornito da Clivet - Clivet supplied
o - or
B
A
Do not weld the system pipe with the Victaulic connection joint attached.
The rubber gasket might be irreparably damaged.
4.8 Water lter
Use filter with mesh pitch:
1,6 mm
It must be installed immediately in the water input of the unit, in a position that is easily accessible for cleaning.
The filter never should be removed, this operation invalidates the guaranty.
4.9 Flow Switch
The flow switch must be present to ensure shutdown of the unit if water is not circulating.
It has to be installed in a duct rectilinear part, not in proximity of curves that cause turbulences.
Electrically connect the fl w switch at the inlet arranged on the XC terminal block.
The fl w switch must be set to the minimum reachable fl w rate.
A
!
A
A > 5 x Ø
Ø
B < A
A. minimum distance
4.10 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
• storage tank
• free-cooling coil
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.
11

4.11 Partial energy recovery
Option
A configuration which enables the production of hot water free-of-charge while operating in the cooling mode, thanks to the partial recovery
of condensation heat that would otherwise be rejected to the external heat source.
The maximum capacity available from the partial recovery is equal to the 15% of the rejected heating capacity (cooling capacity + compressor
power input)
The recovery exchanger must be always maintained full of water
The lack of water amplifies the noise generated by the operation
When the temperature of the water to be heated is particularly low, it is wise to insert a flow-rate control valve into the system water circuit,
in order to maintain the temperature at the recovery output at above 35°C and thus avoid the condensation of the refrigerant into the partial
energy recovery device.
UNIT
QAB QB
QB
QA
QAB
V
M
12

5 Refrigeranting connections
5.1 Pressure Equipment Directive
This unit is a subset: to operate it has to be combined to another unit.
It is an installer responsability:
• follow the PED Directive and to the national regulations of PED Directive realization
• consider the insertion of any additional security devices
• check the safety device operation
• write on the serial label number the amount of total refrigerant
• issue the Declaration of conformity
• inform the user of the need to carry out regular checks
5.2 Vibrations / Noise
The installation of the pipes may aect the level of noise in the system:
• install flexible joints between the unit and the pipes
• Install antivibration material between the brackets and the pipes so as to prevent the transmission of vibrations
• avoid the passage in particularly silent environments
13

5.3 General description
• The operations must be performed by an expert refrigerator technician
• use only a copper pipe for chiller operating
• pipes must be perfectly clean (perform a cleaning with nitrogen or dry air before connecting the pipes to the two units) and without
humidity to allow a good vacuum operation
• pipes must not to be too much long and with too much curves
• for a good efficie y do not perform curves with a radium too much short and avoid the pipe crushing
• to allow the vacuum and charge operations install service fittings on pipes (if the unit is not fi ed with taps with service fittings
The sizing of the refrigerating connection lines is of extreme importance for the system operating and reliability.
The diameter of the connection between the two units is function of distances, dierences in level and curve number; it has so to be
calculated by a qualified technician.
Incorrect sizing may damage the compressor or aect cooling capacity.
Provide for slopes (1/100) in the horizontal sections.
When the outdoor unit is positioned higher than the indoor unit, provide siphons every 4 m in the vertical sections. It is advisable to insert a
non-return valve in the delivery position , to avoid the return of liquid to the compressor. .
When the condenser is located above the compressor, the discharge line must make a siphon that goes down to the level of the floor.The
purpose is to reduce the risks of return of condensed liquid refrigerant in the line to the compressor, during out of service.
In the vertical delivery sections it is recommended to insert an oil siphon to allow the oil to drag into the line, in addition to the pit at the
base.
In the horizontal sections it is recommended to create a slope towards the gas flow to favor the oil flow.
L1
L2
GAS 1
GAS 2
Liquid (x 2)
Gas (x 2)
1/100
Max 20 mt Max 20 mt
4 mt
1/100
A B
4 mt
Maximum piping length and lift
Total equivalent length (m) Max. dierence in height (m)
A5020
B5020
The equivalent length is the sum of the eective length of the piping plus a length that is equivalent to the distributed and concentrated
pressure drop.
14

5.4 Risk of explosion
When you install cut-off devices (solenoid valves, taps, etc.), be aware that they may cause traps for refrigerant in the form of closed zones
upstream and downstream where the refrigerant cannot freely expand.
In this situation, if there is an increase in temperature (due to exposure to the sun, proximity of pipes or sources of heat), the expansion of the
trapped gas may cause the refrigeration pipes to explode.
Evaluate whether safety valves can be installed, especially in the liquid pipes that are most exposed to this risk.
5.5 Supply line
Insulate only if you want to prevent burns due to accidental contact.
Table of located leaks
Diameter for
pipe thickness
Standard 90°
bend
Wide radius
90° bend
Reduced
radius 90°
bend
Standard 45°
bend
Reduced
radius 45°
bend
Standard 180°
bend
Check valve
mm Equivalent length in m
28x1,2 0,8 0,5 1,2 0,4 0,6 1,2 3,5
35x1,5 1,0 0,7 1,7 0,5 0,9 1,7 4,1
42x2,0 1,2 0,8 1,9 0,6 1,0 1,9 4,7
54x2,0 1,5 1,0 2,5 0,8 1,4 2,5 6,0
Additional indicative refrigerant charge for equivalent lengths greater than 5 metres.
Diameter of the Refrigerant line tubing equal to that of the inlet/outlet of the unit.
The final charge is to be the sum of the charge of the evaporating unit, the refrigerant piping and the condensate unit (being the responsibility of the Customer)..
The values shown in the tables are indicative and are to be evaluated throughout the installation phase.
SIZE 90.4 100.4 110.4 120.4 140.4 160.4
C1 [kg] 6 6 6 6 6 9
C2 [kg] 6 6 6 6 6 8
C1+C2 [kg] 12 12 12 12 12 17
The unit is shipped charged with nitrogen, the indicated charge refers only to the evaporating unit including 5m equivalent of pipes and must be carried out during the start-up
installation phase and is the Customer's responsibility.
Refrigerant charge unit
SIZE CIRCUIT Total equivalent lenght [m eq]
5 10 20 30 40 50
90.4 C1 [kg] +0 +4 +12 +20 +28 +36
C2 [kg] +0 +4 +12 +20 +28 +36
100.4 C1 [kg] +0 +4 +13 +21 +29 +38
C2 [kg] +0 +4 +13 +21 +29 +38
110.4 C1 [kg] +0 +4 +13 +21 +29 +38
C2 [kg] +0 +4 +13 +21 +29 +38
120.4 C1 [kg] +0 +4 +13 +21 +29 +38
C2 [kg] +0 +4 +13 +21 +29 +38
140.4 C1 [kg] +0 +6 +17 +29 +40 +52
C2 [kg] +0 +6 +17 +29 +40 +52
160.4 C1 [kg] +0 +6 +18 +29 +41 +53
C2 [kg] +0 +6 +18 +29 +41 +53
Additional refrigerant charge for various equivalent lengths
15

5.9 Vacuum operations
Make sure that all the service outlets are closed with proper caps; if caps are not present a leak of refrigerant can be possible.
With the taps of the motor condenser closed, drain the system.
Using a gauge group, connect the vacuum pump on both connections of the taps, make sure that the solenoid valve or any intermediate taps
are open, proceed with the vacuum.
Stop the pump at a pressure of about 100 Pa and leave it under vacuum for a few hours; a slight initial rise of pressure is normal, followed by
stabilization.
If the pressure continues to rise, it means there are either small leaks or humidity is present. In the first case, repeat the operations in the
paragraph on checking for leaks in the manual for the refrigerant pipes.
In the second case, recharge the system with refrigerant gas up to 100KPa and re-create the vacuum as described above.
Once the pressure is permanently stable, move on to the next phase, which is charging.
5.10 Refrigerant Charge
Check the type of refrigerant on the serial number label
The unit is shipped with a nitrogen-tight charge.
The refrigerant charge must to be completed during the start-up phase, based on the type of indoor unit and on the pipe development.
Refrigerant charge for combination with remote condenser
With the system under vacuum, close the taps of the gauge group and disconnect the vacuum pump.
Connect the refrigerant gas tank, venting the air out of the hose for connection to the gauge group.
Open the tap of the liquid line.
Open the taps of the gauge group and let liquid-state refrigerant enter using an appropriate pump.
Once charging is complete, open the gas tap so that the unit is ready to be started.
5.11 Adding oil
During operation the lubricating oil is partially mixed with the refrigerant and dragged along the refrigeration lines.
It is essential to guarantee the oil return to the compressors, especially in part load operation.
Evaluate the opportunity to add oil if the connecting pipes have a particularly extensive development.
Periodically check the oil level of the compressor on the dedicated indicator or on the schrader socket, especially after periods of
reduced load operation.
Use only Copeland EMKARATE RL32 3MAF oil.
5.6 Liquid line
The liquid line must be insulated if it is exposed to the sunlight or it crosses zones with a temperature higher than the external one, otherwise
it can be free.
Avoid excessive diameters to not cause an excessive refrigerant charge.
5.7 solenoid valve on the liquid line
It is not necessary to install a solenoid valve.
The electronic thermostatic valve operates as a solenoid valve, also in case of blackout.
5.8 Checking for leaks
1 Check carefully that the evaporator unit taps are closed.
2 Connect the pressure gauges with the service ttings (on the taps or on the connection pipes).
3 Pressurise the system with nitrogen:
mode 1: up to PS (see the label) and wait few hours
mode 2: up to PS x 1,43 law (as according to UNI-EN 378-2)
CAUTION: EXPLOSION DANGER
4 Spray using a leak detector spray taps and pipes and check if bubbles are present (gas leaks).
5 Discharge the nitrogen from the unit.
16

6 Electrical connections
The characteristics of the electrical lines must be determined by qualified 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 accordance with the characteristics of the protections adopted.
All electrical operations should be performed by trained personnel having the necessary qualifications 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 electrical 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.
17

6.4 Power input
Fix the cables: if vacated may be subject to tearing.
Respect the minimum distance from the ground to allow the entry of the power line.
The cable must not touch the compressor and the refrigerant piping (they reach high temperatures).
18

Connections performed by the Customer
19

6.5Power supply cables section / power bars
Size 90.4 100.4 110.4 120.4 140.4 160.4
Min. cable section Cu (mm²) 1x95 1x95 1x150 1x150 1x150 1x240
Max. cable section Cu (mm²) 1x185 1x185 1x240 1x240 1x240 1x240
Min. bar Cu section (mm²) - - - - - -
Max. bar Cu width (mm) 32 32 32 32 32 40
Tightening torque (Nm) 20 20 20 20 20 20
6.6Remote ON-OFF
Do not perform short On Off cycles
Do not use the remote On Off with thermoregulation function.
A B
A B
YES NO !
A
B
AB
20