CLIVET WSH-XSC3 User manual

M08Q40P16-0417-02-2020
WSH-XSC3 70.4-240.4
Installation and
operating manual
Water-cooled liquid chiller for indoor installation

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, eciency, 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 nally 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 General description 4
2 Reception 6
3 Positioning 8
4 Water connections 9
5 Electrical connections 15
6 Start-up 22
7 Control 33
8 Maintenance 42
9 Accessories 47
10 Decommissioning 50
11 Residual risks 51
12 Technical information 52
13 Dimensional drawings 57
3

1 General description
1.1 Manual
The manual provides correct unit installation, use and maintenance.
Pay particular attention to:
Warning, identies particularly 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 qualied 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 specic 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
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 o before any operation.
1.7 Modication
All unit modications 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 certied 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 identication”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 uorinated greenhouse gases
Type of refrigerant: R410A
1.13 Serial number
It identies 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 nd 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 identication 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
deciencies/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, ights, 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 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:
•INTERNAL
•in xed positions
Limit vibration transmission:
•use anti-vibration devices or neoprene strips on the unit support points
•install exible 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 ooding
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 airow
•diculty of exchange
•leaves or other foreign bodies that can obstruct the air coil
•winds that hinder or favour the airow
•heat or pollution sources close to the unit (chimneys, extractors etc..)
•stratication (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 stratication or recirculation phenomenons
Ignoring the previous indications could:
•reduce energy eciency
•alarm lockout due to HIGH PRESSURE (in summer) or LOW PRESSURE (in winter)
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).
3.4 Anti-vibration mount support
For details see:
9 Accessoriesp.47
8

4 Water connections
4.1 Water quality
Water features
•conrming to local regulations
•total hardness < 14°fr
•within the limits indicated by table
The water quality must be checked by qualied personnel.
Water with inadequate characteristics can cause:
•pressure drop increase
•reduces energy eciency
•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-ow must be:
•inside the exchanger operating limits (see theTECHNICAL INFORMATION section)
•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 are described within ‘General technical data’ section and they have to be satised to avoid continuous
compressor switching on and o.
9

4.6 Hydronic unit diagrams - Hot only unit
4.7 Hydraulic connections
UNIT
A
filettare – to thread
saldare –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.
10
USER SIDE/
HOT
Standard
unit
(Std)
Unit
withVARYFLOW +
(VARYH)
Unit
with 1 ON/OFF pump
(HYGH1)
Unit
with 2 ON/OFF pumps
(HYGH2)
Unit
with Hydropack
(2PMH)
SOURCE SIDE/
COLD
Unit
with Hydropack
(2PMC)
Unit
with 2-way modulating valve
(VS2MC)
Unit with 2-way modulating valve
for high DP (V2MCP)
Functionalities Diagram hydronic assemblies - Heating only unit
SOURCE SIDE/
COLD
Standard
unit (Std) Unit withVARYFLOW +
(VARYC)
Unit
with 1 ON/OFF pump
(HYGC1)
Unit
with 2 ON/OFF pumps
(HYGC2)

4.8 Hydronic unit diagrams - Cold only unit
4.9 Flow Switch
The ow 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 ow switch at the inlet arranged on the XC terminal block.
The ow switch must be set to the minimum reachable ow rate.
A
!
A
A > 5 x Ø
Ø
B < A
A. minimum distance
11
USER SIDE/
COLD
Standard
unit
(Std)
Unit
withVARYFLOW +
(VARYC)
Unit
with 1 ON/OFF pump
(HYGC1)
Unit
with 2 ON/OFF pumps
(HYGC2)
Unit
with Hydropack
(2PMC)
SOURCE SIDE/
HOT
Unit
with Hydropack
(2PMH)
Unit
with 2-way modulating valve
(VS2MH)
Unit with 2-way modulating valve
for high DP (V2MHP)
Functionalities Diagram hydronic assemblies - Cooling only unit
SOURCE SIDE/
HOT
Standard
unit (Std) Unit withVARYFLOW +
(VARYH)
Unit
with 1 ON/OFF pump
(HYGH1)
Unit
with 2 ON/OFF pumps
(HYGH2)

4.10 Recommended connection
The installer must dene:
•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
1 exchanger 11 drain
3 water temperature probe 12 Flow Switch
5 dierential pressure switch 13 System load safety pressure switch
6 antivibration joints 14 pressure gauge
7 piping support 15 non-return valve
8 exchanger chemical cleaning bypass 16 Pump
9 Cleaning system bypass 17 safety valve
10 vent 18 shut-o valve
19 lter
12

4.11 Water lter
Use lter 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 lter never should be removed, this operation invalidates the guaranty.
4.12 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: ll and drain 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 lter cleaning interventions and at worst cases can cause damages to the exchangers and the
other parts.
4.13 Partial energy recovery
Option
A conguration 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 amplies the noise generated by the operation
When the temperature of the water to be heated is particularly low, it is wise to insert a ow-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
OUT 2 1/2"
IN 2 1/2"
120.4 -240.4
519
1541
13

4.14 Modulating 2-way valve - Provided by the customer (OCO heat only unit)
Option
4.15 Modulating 2-way valve - Provided by the customer (OHO heat only unit)
Option
* If the system has a lot of inertia in the running of the water flow it is possible to increase the bypass time.
* If the system has a lot of inertia in the running of the water flow it is possible to increase the bypass time.
14

4.16Modulating 2-way valve - Provided by the customer (OCO cold only unit)
Option
4.17Modulating 2-way valve - Provided by the customer (OHO heat only unit)
Option
* If the system has a lot of inertia in the running of the water flow it is possible to increase the bypass time.
* If the system has a lot of inertia in the running of the water flow it is possible to increase the bypass time.
15

4.18Inverter pump on user side - Provided by the customer (OCO cold only unit)
Option
* Check that the minimum operating frequency of the pump is respected, if necessary act on parameter 485 or on the minimum frequency
of the inverter itself.
** If the system has a lot of inertia in the running of the water flow it is possible to increase the bypass time.
4.19Inverter pump on source side - Provided by the customer (OHO heat only unit)
Option
* Check that the minimum operating frequency of the pump is respected, if necessary act on parameter 505 or on the minimum frequency
of the inverter itself.
** If the system has a lot of inertia in the running of the water flow it is possible to increase the bypass time.
4.20 NATURAL COOLING function
For details see:
9.2 NATURAL COOLING functionp.49
16

5 Electrical connections
The characteristics of the electrical lines must be determined by qualied 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 dened in accordance with the characteristics of the protections adopted.
All electrical operations should be performed by trained personnel having the necessary qualications required by the regulations in force
and being informed about the risks relevant to these activities.
Operate in compliance with safety regulations in force.
5.1 Electrical data
The serial number label reports the unit specic 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.
5.2 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.
5.3 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.
5.4 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).
17

5.5 Connections performer by customer
ALM KMP evaporator pump contactor
APV KMRI heaters contactor
AP18 KMS condenser pump contactor
AP19 QMP motor protection switch evaporator pump
APRI QMS motor protection switch condenser pump
APSI SA1 remote on/o
APUI SA1.1 second setpoint
BT7 SA6 sanitary hot water cycle switch
HLC1-4 SA7 summer-winter switch
HLR SA9 cooling thermostat
YVHS1 SQ1 Flow Switch
YWMC SQ2 Condenser ow switch
YWMH
cumulative fault signal
0..10V analogical output
Demand limit
water reset
0..10V signal heaters
0..10V signal heating side inverter *
0..10V signal cooling side inverter *
Probe of the outdoor air temperature.
compressor status signal
alarm signal lamp electrical heater electrical panel
selector
sanitary hot water valve
modulating valve cooling side
modulating valve heating side
* The APSI and APUI signal can be used to control a single inverter, the control of multiple inverter in parallel is not allowed.
18

5.6 Power supply cables section / power bars
Size 70.4 75.4 80.4 85.4 90.4 100.4 110.4
Min. cable section Cu (mm²) 1x95 1x95 1x95 1x95 1x95 1x95 1x95
Max. cable section Cu (mm²) 1x150 1x150 1x150 1x150 1x185 1x185 1x185
Min. bar Cu section (mm²) - - - - - - -
Max. bar Cu width (mm) 32 32 32 32 32 32 32
Tightening torque (Nm) 20 20 20 20 20 20 20
Size 120.4 140.4 160.4 180.4 200.4 220.4 240.4
Min. cable section Cu (mm²) 1x150 1x150 1x240 1x240 2x150 2x150 2x150
Max. cable section Cu (mm²) 1x240 1x240 1x240 1x240 2x300 2x300 2x300
Min. bar Cu section (mm²) - - - - 2 x 30 x 5 2 x 30 x 5 2 x 30 x 5
Max. bar Cu width (mm) 32 32 40 40 50 50 50
Tightening torque (Nm) 20 20 20 20 20 20 20
5.7 Remote ON-OFF
Do not perform short On O cycles
Do not use the remote On O with thermoregulation function.
A B
AB
YES NO !
A
B
AB
19

5.8 Computer connection
1. Service keypad
2. RJ45: standard connection
3. P.C.-not supplied
4. P.C. connection, shift RJ45 from T-HI to T-IP
Congure P.C.
1. connect P.C. and main module with LAN cable
2. check in the taskbar that the connection is active
3. open Control Panel and select Network and sharing center
4. select Modify board setting
5. select Local area connection (LAN)
6. select Internet protocol version 4 (TPC) IPV4 and enter Property
7. set the IP address 192.168.1.100
8. set Subnet mask as 255.255.255.0
9. conrm (OK)
10. enter Start (Windows button)
11. write the command cmd and enter/do it
12. write and run the command Ping 192.168.1.42
13. the message, connection is OK, will appear when successful
14. enter the browser (Crhome, Firefox ecc)
15. write and run the command http:/192.168.1.42
16. Userid = WEB
17. Password = SBTAdmin!
20