d2itsu CSAD UiAWP 100 PS Series User manual

MODULAR CHILLER INVERTER
CSAD UiAWP 100 PS
CSAD UiAWP 200 PS
CSAD UiAWP 300 PS
SERIE
CSAD UiAWP 100/200/300 PS
EDITION
04/09
IMEn
INSTALLATION
MANUAL
Models:

ACCESSORIES
1
1 1
Purpose
Shape
Quantity
Unit
1
CONTENTS PAGE
1INTRODUCTION.....................................................................1
2SAFETY CONSIDERATIONS.................................................2
3BEFORE INSTALLATION......................................................3
4 IMPORTANT INFORMATION ON REFRIGERANT...............4
5SELECTION OF INSTALLATION SITE..................................4
6PRECAUTIONS ON THE INSTALLATION............................4
7 CONNECTION DRAWING OF PIPELINE SYSTEM...............9
8OVERVIEW OF THE UNIT.....................................................10
9 START-UP AND CONFIGURATION.....................................36
10 TEST RUN AND FINAL CHECK...........................................37
11 MAINTENANCE AND UPKEEP............................................39
12 APPLICABLE MODELS AND MAIN PARAMETERS...........47
13 INFORMATION REQIUREMENTS .......................................48
ACCESSORIES
Total water outlet
temperature
Sensor Casing
Installation &
Operation
manual
Installation
manual of
wired controller
Transformer
Use for installation
(only need for setting the main module)
Installation Manual___________________________________________________________________________________

Use conditions of the unit
1. INTRODUCTION
Ambient temperature (℃)
a. The standard voltage of power supply is 380-415V 3N~50Hz, the minimum allowable voltage is 342V, and the maximum voltage is 456V.
b. The unit must be operated as the following outdoor temperature:
CSAD UiAWP 100 PS
CSAD UiAWP 200 PS
Outlet water temperature (℃)
CSAD UiAWP 300 PS
CSAD UiAWP 100 PS
CSAD UiAWP 200 PS
CSAD UiAWP 300 PS
-20
-10
Fig. 1-1 Cooling operating range of CSAD UiAWP 100 PS
and CSAD UiAWP 200 PS
Ambient temperature (℃)
Ambient temperature (℃)
Ambient temperature (℃)
Outlet water temperature (℃)
Outlet water temperature (℃)
Fig. 1-2 Cooling operating range of CSAD UiAWP 300 PS
Fig. 1-3 Heating operating range of CSAD UiAWP 100 PS
and CSAD UiAWP 200 PS
0
10
20
30
40
50
0 10 20 30
-20
-10
0
10
20
30
40
50
0 10 20 30
-25
-15
-5
5
15
25
35
20 30 40 50 60
-25
-15
-5
5
15
25
35
20 30 40 50 60
Outlet water temperature (℃)
Fig. 1-4 Heating operating range of CSAD UiAWP 300 PS
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Installation Manual___________________________________________________________________________________

CAUTION
WARNING
WARNING
Failure to observe a warning may result in death.
CAUTION
Failure to observe a caution may result injury or damage
to the equipment.
To prevent injuries or property losses, make sure to observe the
following instructions. Failure to do so may cause injuries or losses.
There are two types of safety instructions: warning and caution.
Whichever type it is, you must read the information listed under it
carefully.
Get your distributor or a professional to install the product.
The installation personnel must be equipped with the
professional knowledge. When you install on your own, any
mistake you made during the operations may lead to a fire,
electric shock, injury or water leakage.
When purchasing items locally, purchase those designated by
our company.
Failure to do so may result in a fire, electric shock, or water
leakage. Note to entrust a professional to install those items.
When powering the unit, follow the regulations of the local
electric company.
Make sure the unit is grounded reliably in accordance with the
laws. Otherwise, it may cause electric shock. When moving or
reinstalling the modular unit, get your distributor or a
professional to do so.
If installed improperly, a fire, electric shock, injury or water
leakage may occur. Never modify or repair the unit on your own.
Otherwise, a fire, electric shock, injury or water leakage may
occur. Get your distributor or a professional to do so.
Ensure that the residual current device (RCD) is installed.
The RCD must be installed. Failure to install it may result in
electric shock.
Connect the cable properly.
Otherwise, it may cause damage to electrical parts.
Do not operate the unit near flammables (paint, coating, gasoline
and chemical reagents) lest fire or explosion may occur. In the
unlikely event of a fire, please turn off the main power immediately
and put out the fire using an extinguisher.
Do not touch refrigerant discharge parts to prevent being burnt.
Service the unit regularly according to the manual, to ensure that
the unit is in good condition.
When the unit stops due to a fault, refer to the Fault Analysis and
Troubleshooting in this manual, or contact the local customer
service centre. Do not start the unit until the fault is eliminated.
When finding refrigerant or chilled water (cooling water) leaks, turn
off all the switches immediately. If you cannot do so through
operating the controller, do not restart the unit unless the fault is
located and eliminated.
Use fuses with designated capacity. Do not use iron wires or
copper wires, as doing so may result in serious damages to the
unit or a fire.
2. SAFETY CONSIDERATION
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Installation Manual___________________________________________________________________________________

3. BEFORE INSTALLATION
Handling of the unit
The angle of inclination should be between 45º and 70º when carrying the unit in case of overturn of the unit.
a. Rolling handling: several rolling rods of the same size are placed under the base of the unit, and the length of each rod must be
more than the outer frame of the base and suitable for balancing of the unit.
b. Lifting: each lifting rope (belt) should be able to bear 4 times the weight of the unit. Check the lifting hook and ensure that it is firmly
attached to the unit. To avoid damages to the unit, a protective block made of wood , cloth or hard paper should be placed between the
unit and rope when lifting, and its thickness should be 50mm or more. It is strictly forbidden to stand under the machine when it is
hoisted.
Fig. 3-1 Lifting of the unit
Lifted cable
4 protective blocks should be placed.
Unilateral distance should be 50mm or more.
The angle of inclinaton (45~70°)
Lifted hook
The angle of inclinaton (45~70°)
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Installation Manual___________________________________________________________________________________

4. IMPORTANT INFORMATION ON
REFRIGERANT
5. PRECAUTIONS OF INSTALLATION
NOTE
The selected installation site of the unit should facilitate connection
of water pipes and wires, and be free from water inlet of oil fume,
steam or other heat sources. Besides, the noise of the unit and cold
and hot air should not influence the surrounding environment.
This product contains fluorinated greenhouse gases covered
by the Kyoto Protocol. Do not vent gases into the atmosphere.
Refrigerant type: R410A
GWP value: 2088
GWP = global warming potential
5.1 Units can be installed on the ground or proper place on a roof,
provided that sufficient ventilation can be guaranteed.
5.2 Do not install the unit in a scenario with requirements on noise
and vibration.
5.3 When installing the unit, take measures to avoid exposure to
direct sunlight, and keep the unit away from boiler pipeline and
surroundings which might corrode the condenser coil and copper
pipes.
5.4 If the unit is within the reach of unauthorized personnel, take
protective measures for safety considerations, such as installing a
fence. These measures can prevent man-caused or accidental
injuries, and can also prevent the electrical parts in operation from
being exposed when the main control box is opened.
5.5 Install the unit on a foundation at least 300 mm high above the
ground, where the floor drain is provided, to ensure that water
does not accumulate.
5.6 If installing the unit on the ground, put the steel base of the
unit on the concrete foundation, which must be as deep as into
the frozen soil layer. Ensure the installation foundation is
separated from buildings, as the noises and vibration of the unit
may adversely affect the latter. By means of the installation holes
on the unit base, the unit can be fastened on the foundation
reliably.
5.7 If the unit is installed on a roof, the roof must be strong
enough to bear the weight of the unit and the weight of
maintenance personnel. The unit can be placed on the concrete
and groove-shaped steel frame, similar to the case when the unit
is installed on the ground. The weight-bearing groove-shaped
steel must match the installation holes of the shock absorber and
is wide enough to accommodate the shock absorber.
5.8 For other special requirements for installation, please consult
the building contractor, architectural designer or other
professionals.
Model
Refrigerant(kg) Tonnes CO2equivalent
10.50
17.00
27.00
21.94
35.50
56.36
Factory charge
CSAD UiAWP 100 PS
CSAD UiAWP 200 PS
CSAD UiAWP 300 PS
Table 4-1
Left view
Top view
6.1.2 CSAD UiAWP 200 PS
E
D
F
A
A
B
C
B
Left view
6. INSTALLATION OF THE UNIT
6.1 Outline dimensional drawing
6.1.1 CSAD UiAWP 100 PS
Front view
Fig. 6-1 Outline dimensional of CSAD UiAWP 100 PS
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Installation Manual___________________________________________________________________________________

Table 6-1
6.2 Requirements of installation space of
the unit
a. To ensure adequate air flow entering the condenser, the influence
of descending air flow caused by the high-rise buildings around
upon the unit should be taken into account when installing the unit.
b. If the unit is installed where the flowing speed of air is high, such
as on the exposed roof, the measures including sunk fence and
Persian blinds can be taken, to prevent the turbulent flow from
disturbing the air entering the unit. If the unit needs to be provided
with sunk fence, the height of the latter should not be more than that
of the former; if Persian blinds are required, the total loss of static
pressure should be less than the static pressure outside the fan.
The space between the unit and sunk fence or Persian blinds
should also meet the requirement of the minimum installation space
of the unit.
c. If the unit needs to operate in winter, and the installation site may
be covered by snow, the unit should be located higher than the
snow surface, to ensure that air flows through the coils smoothly.
d. To avoid back flow of the air in the codenser and operational
faults of the unit ,the parallel installation of multiple Modular units
can follow the direction and distance as shown in Fig. 6-4, Fig. 6-5
and Table 6-2.
NOTE
After installing the spring damper, the total height of the unit will
increase by 135mm or so.
A
B
C
D
E
F
Model
CSAD UiAWP 200 PS
2220
1325
1055
234
210
470
CSAD UiAWP 100 PS
1870
1000
1175
204
200
470
CSAD UiAWP 300 PS
3220
1513
1095
286
210
470
(unit: mm)
C
Top view
F
D
E
F
D
E
Front view
Left view
Top view
B
C
6.1.3 CSAD UiAWP 300 PS
Front view
Fig. 6-2 Outline dimensional of CSAD UiAWP 200 PS
Fig. 6-3 Outline dimensional of CSAD UiAWP 300 PS
A
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Installation Manual___________________________________________________________________________________

A
B
D
C
G
Inlet of air flow
Inlet of air flow
Inlet of air flowInlet of air flow
Installation space
A
B
C
D
E
≥800
≥2000
≥2000
≥800
≥800
Table 6-2
Main unit
A
B
C
D
Inlet of air flow
Main unit
Main unit
Main unitMain unit
Main unit Main unitMain unit
Main unit Main unitMain unit
F
G
Fig. 6-4 Single unit installstion
F
E
E
E
E
E
E
F
F F
Inlet of air flow
Fig. 6-5 Multiple units installstion
≥1100
≥6000
Top view Front view
Top view
(unit: mm)
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Installation Manual___________________________________________________________________________________

6.3 Installation foundation
a. The unit should be located on the level foundation, the
ground floor or the roof which can bear operating weight of the
unit and the weight of maintenance personnel. Refer to Table
12-1 (Table of applicable models and parameters) for operating
weight.
b. If the unit is located so high that it is inconvenient for
maintenance personnel to conduct maintenance, the suitable
scaffold can be provided around the unit.
c. The scaffold must be able to bear the weight of maintenance
personnel and maintenance facilities.
d. The bottom frame of the unit is not allowed to be embedded
into the concrete of installation foundation.
e. A drainage ditch should be provided to allow drainage of
condensate that may form on the heat exchangers when the
units are running in heating mode. The drainage should ensure
that condensate is directed away from roadways and
footpaths, especially in locations where the climate is such that
condensate may freeze.
Top view of schematic diagram of installation
dimension of CSAD UiAWP 100 PS
Fig. 6-7
1870
Drainage channel
Anchor bolt
800
926
Top view of schematic diagram of installation
dimension of CSAD UiAWP 200 PS
Fig. 6-8
2200
Drainage channel
Anchor bolt
1105
958
Top view of schematic diagram of installation
dimension of CSAD UiAWP 300 PS
Fig. 6-9
3220
Anchor bolt
2116
1008
180
530
425
Electric control
inlet and outlet
box side
pipe side
inlet and outlet
pipe side
inlet and outlet
pipe side
Drainage channel
Electric control
box side
Electric control
box side
≥80mm
Fig.6-6 Front view of base structure
Concrete base
h≥200mm
Rubber anti-vibration pads
Solid ground / surface
≥200mm
a. A solid base prevents excess vibration and noise. Outdoor unit
bases should be constructed on solid ground or on structures of
sufficient strength to support the units’ weight.
b. Bases should be at least 200mm high to provide sufficient
access for installation of piping.Snow protection should also be
considered for the base height.
c. Either steel or concrete bases may be suitable.
d. A typical concrete base design is shown in Fig. 6-6. A typical
concrete specification is 1 part cement, 2 parts sand and 4 parts
crushed stone with steel reinforcing bar. The edges of the base
should be chamfered.
e. To ensure that all contact points are equally secure, bases
should be completely level. Base design should ensure that the
points on the units’ bases designed for weight-bearing support are
fully supported.
Outdoor unit base structure design should take account of the
following considerations:
6.3.1 Base structure
Outdoor unit
6.3.2 Location drawing of installation foundation
of the unit
(unit: mm)
(unit: mm)
(unit: mm)
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Installation Manual___________________________________________________________________________________

6.4 Installation of damping devices
6.4.1 Damping devices
By means of t installation holes on the steel frame of the unit
base, the unit can be fastened on the foundation through the
spring damper. See Fig.6-7,6-8,6-9(Schematic diagram of
installation dimension of the unit) for details about center
distance of the installation holes. The damper does not go with
the unit, and the user can select the damper according to the
relevant requirements. When the unit is installed on the high
roof or the area sensitive to vibration, please consult the
relevant persons before selecting the damper.
6.4.2 Installation steps of the damper
Step 1. Make sure that the flatness of the concrete foundation
is within ±3mm, and then place the unit on the cushion block.
Step 2. Raise the unit to the height suitable for installation of
the damping device.
Step 3. Remove the clamp nuts of the damper. Place the unit
on the damper, and align the fixing bolt holes of the damper
with the fixing holes on the unit base.
Step 4. Return the clamp nuts of the damper to the fixing holes
on the unit base, and tighten them into the damper.
Step 5. Adjust the operational height of the damper base, and
screw down the leveling bolts. Tighten the bolts by one circle to
ensure equal height adjustment variance of the damper.
Step 6. The lock bolts can be tightened after the correct
operational height is reached.
Damping device
Anchor bolt
Nut
Ferrol
It is recommended that the damper should be fastened on the
foundation with the provided holes. After the unit is placed on the
foundation, the damper connected with the unit should not be
moved, and the central clamp nut is not allowed to be tightened
before the damper sustains load.
Fig. 6-10 Installation of the damper
NOTE
6.5 Installation of device to prevent snow
build-up and strong breeze
(e) Equipment covered with snow
(d) Air inlet blocked by snow
(b) Snow accumulated
on the top plate
(
c) Snow falling on the equipment (a) Buried in the snow
6.5.1 Measures used to prevent problems caused by
snow
a. Measures to prevent build-up of snow
The base height should be as least the same as the predicted
snow depth in the local area.
b. Lightning protection and snow protection measures
6.5.2 Precautions for designing a snow cover
Monsoon
Outdoor
unit
Base height
Fig. 6-11 Types of problems caused by snow
Fig. 6-12 Snow prevention base height
When installing an air-cooled heat pump chiller in a place with
heavy snow, it is necessary to take snow protection measures to
ensure trouble-free operation of the equipment.
Otherwise, accumulated snow will block the air flow and may cause
equipment problems.
Check the installation site thoroughly; do not install the equipment
under awnings or trees or a place where snow is piled up.
a. To ensure a sufficient air flow required by the air-cooled heat
pump chiller, design a protective cover to make the dust
resistance 1 mm H2O or less lower than the allowable external
static pressure of air-cooled heat pump chiller.
b. The protective cover must be strong enough to withstand the
snow weight and the pressure caused by strong wind and
typhoon.
c. The protective cover must not cause short circuit of air
discharge and suction.
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Installation Manual___________________________________________________________________________________