eneren EKW Series User manual

HF61GJ0440A / 11_21
USER MANUAL
EKW
EN
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
WATER-WATER HEAT PUMPS
DISTRICT HEATING, INDUSTRIAL APPLICATIONS
HOT WATER PRODUCTION

INTRODUCTION
EKW
CWARNING
CAREFULLY READ THIS MANUAL BEFORE USING THE
UNIT.
CDECLARATION OF CONFORMITY
The declaration of conformity is attached separately to
the documents on board the unit, usually placed inside the
electrical compartment.
Dear Customer,
whilst thanking you for having chosen a product of ours, we are pleased to provide this manual for optimal use of our product
for better work results.
Please read the recommendations described in the following pages carefully and keep the manual available to personnel
who will be responsible for managing and maintaining the unit.
Our company is at your complete disposal for any and all questions that you should require both in the unit starting phase
and at any time of its utilization.
Should scheduled and unscheduled maintenance be necessary, please contact our After-sales Technical Service for assis-
tance and spare parts.
Please nd our contact details below for a more rapid service:
EKW |UsER MANUAL
3

START-UP INSTRUCTIONS
1 YOUR INSTALLATION
All the tips required for a perfect installation of the equip-
ment can be found in the installation manual.
It is important to place a net lter at all water circuit inlets.
The lter must be made of stainless steel with a mesh that
does not exceed 1 mm.
2 REQUIRED ACCESSORIES FOR A PROPER INSTALLATION OF THE UNIT
For the proper operation of the unit and for the validity of the
warranty, the installation of the following hydraulic compo-
nents will be necessary:
ŪY-strainers in the inlet pipes to the unit;
Ūanti-vibration couplings in each pipe connected to the
unit;
Ūappropriately dimensioned safety valves on each circuit
of the system;
Ūappropriately dimensioned expansion vessels on each
circuit of the system.
3 FIRST START-UP
With at least 15 working days in advance, send the machine start request via email or fax to the following contact ENEREN:
Fax. [phone]
e-mail: [email protected]
Tel. [phone]
ENEREN Assistance will organize the intervention by putting you in contact with Authorized Technical Assistance Center of
the area.
All the preliminary checks and testing of the machine will be carried out together with your staff.
Your staff will be given instructions for the correct running of the machine.
4 WARRANTY ISSUE
For the warranty to be valid, the rst start-up by an Authorized Technical Assistance Center is mandatory
After testing, the Authorized Technical Assistance Center will issue a valid test certicate for the machine warranty.
EKW |HF61GJ0440A
4

Modello - Model
Matricola - Serial number
Codice identicativo - ID code
Data di produzione - Date of production
Categoria PED/ 2014/68/EU - Category PED/ 2014/68/EU
Procedura di valutazione conformità PED - PED conformity module
Max pressione ammissibile (PS) lato alta pressione - Max allowable pressu-
re (PS) high pressure side [bar-r]
Max pressione esercizio (PS) lato bassa pressione - Max allowable pressure
(PS) low pressure side [bar-r]
Max/min temperatura di stoccaggio - Max/min storage temperature [°C]
Max/min temperatura ambiente di funzionamento - Max/min ambient
working temperature [°C]
Potenza frigorifera* - Cooling capacity* [kW]
EER*
Potenza termica* - Heating capacity* [kW]
COP*
Refrigerante - Refrigerant [Ashrae 15/1992] / GWP
Carica refrigerante - Refrigerant charge [kg]
C1 C2 C3 C4
Refrigerante aggiunto - Added refrigerant [kg]
C1 C2 C3 C4
Carica totale refrigerante - Total charge refrigerant [kg]
CO2 equivalenti - CO2 equivalent [t]
Taratura pressione lato alta - High pressure switch set [bar-r]
Taratura pressione lato bassa - Low pressure switch set [bar-r]
Taratura valvola sicurezza refrigerante lato alta/bassa pressione - Safety
valve refrigerant high/low pressure side set [bar-r]
Massima pressione esercizio circuito acqua - Max working pressure water
circuit [bar-r]
Taratura valvola sicurezza acqua - Safety valve water side set [bar-r]
Alimentazione elettrica - Power supply
Potenza massima assorbita - Max absorbed power [kW]
Corrente massima - Full load ampere FLA [A]
Corrente di spunto - Starting current LRA [A]
Schema elettrico - Wiring diagram
Schema frigorifero - Refrigeration diagram
Peso a vuoto - Empty weight [kg]
* EN14511-2
Contiene gas uorurati ad effetto serra disciplinati dal protocollo di Kyoto/
Contains uorinated greenhouse gases governed by the Kyoto protocol
Ermeticamente sigillato/Hermetically sealed
SAFETY SYMBOLS
CWARNING
With reference to additions or
recommendations for the cor-
rect use of the unit.
ADANGER
With reference to dangerous
situations that may occur with
the use of the unit to guarantee
personal safety.
BATTENTION
With reference to dangerous
situations that may occur with
the use of the unit to prevent
damage to property and to the
unit itself.
Each unit has an identication plate that is located on
its frame and inside the electrical control panel, which
shows all the data necessary for the installation, main-
tenance and traceability of the machine.
THE LABEL SHOWS THE FOLLOWING DATA:
ŪManufacturer/Marketing body
ŪCE mark, possibly accompanied by a subscript that
identies the certifying body for the Pressure Equip-
ment Directive 2014/68/EU (PED). The number of
the certifying body must be indicated for units of a
PED category equal to or greater than class 2.
ŪSeries and size of the unit
ŪDate of manufacture
ŪMain technical data
Note the model, the serial number, the nal refrigerant
charge and the machine reference diagrams attached
to this manual so that they can be easily found in case
of data plate damaging and system maintenance.
BATTENTION
Never remove the label. This shows the serial number
of the unit from which it is possible to obtain informa-
tion about the technical features and the components
installed, to then identify the unit correctly.
CWARNING
The data contained in this manual are subject to change
without notice.

GENERAL CAUTIONARY NOTES
The operating rules contained in this manual are an integral part
of the unit supply and are valid exclusively for the units covered by
this manual. They contain all the useful and necessary informa-
tion for safe operation and ideal, recommended use of the unit.
The declaration of conformity is attached individually to the litera-
ture kept on the machine, usually inside the control cabinet.
Please follow the instructions given below:
• Read carefully the instruction manual which should be consid-
ered an integral part of the unit.
• Every operator and the personnel in charge of unit maintenance
must read the manual throughout carefully and observe its pre-
scriptions.
• The employer is requested to make sure that the operator has the
necessary aptitude requirements for operating the unit and has
carefully read the manual.
• The instruction manual must be easily available to the operation
and maintenance personnel.
• Keep the manual for the entire working life of the unit.
• Make sure any updates that are received are integrated into the
text.
• Hand over the manual to any other user or subsequent owner.
• Use the manual so that the contents are not damaged - entirely
or in part.
• Do not remove, tear off or rewrite parts of the manual for any
reason.
• Keep the manual with care; it must be available at the unit, stored
in a special container, to protect it from moisture and heat, until
nal scrapping of the machine. The location where the manual is
kept must be known to the user of the unit, to the managers, to
the persons in charge of transportation, installation, use, mainte-
nance, repairs, and end-of-life dismantling and scrapping. If the
manual is lost or partially damaged, so that it is no longer possible
to read all of its contents, it is advisable to request a new one from
the manufacturer.
• Avoid hasty and incomplete preparation that lead to improvisa-
tion and cause many accidents.
Pay close attention to the safety symbols shown in the table on
the previous page and to their meaning.
Before starting to work, read through and strictly observe the fol-
lowing suggestions:
• the operator must always have the instruction manual readily
available at any time;
• plan each action carefully;
• before beginning to work, make sure that the safety devices work
properly and you have no doubts about their operation; otherwise,
do not under any circumstances start the unit;
• carefully observe the warnings relating to special hazards con-
tained in this manual;
• preventive and thorough maintenance guarantees constantly
high operating safety for the unit. Never delay repairs and always
have them carried out solely by qualied personnel; only original
spare parts are to be used.
THE MANUFACTURER shall not be liable for any accident to per-
sons or property which may occur due to:
• failure to comply with the instructions in this manual regarding
the operation, use and maintenance of the unit;
• violent actions or incorrect manoeuvres when performing main-
tenance on the unit;
• alterations made to the unit without prior written authorisation
from the MANUFACTURER;
• events that are, in any case, unrelated to the normal and correct
use of the unit;
• in any case, if the user attributes the incident to a defect in the
unit, he must prove that the damage caused was a main and direct
consequence of this “defect”.
This manual reects the state of the art at the time of unit sale:
The MANUFACTURER reserves the right to update its products
and manuals without any obligation to update earlier products
and manuals, except in special circumstances. These may not be
considered inadequate only because they have been subsequently
updated based on new experience.
BATTENTION
• The installer must provide adequate documentation that must
comply with EN 378-3 if applicable in the country of installation;
otherwise, reference should be made to the local regulations in
force.
• When installing or servicing the unit, the rules stipulated in this
manual must be complied with together with those on board the
unit and in any case all necessary precautions must be taken.
• The uids under pressure in the cooling circuit and the presence
of electrical components may cause hazardous situations during
installation and maintenance work.
• Any action on the unit must be carried out by qualied and au-
thorised personnel. In the event of a fault, do not attempt repairs
on your own and do not let unauthorised technicians carry out re-
pairs, or the guarantee will no longer be valid.
• The initial start-up must be carried out exclusively by qualied
personnel authorised by the marketing entity (see annex).
• Before performing any work on the unit, ensure it has been dis-
connected from the power supply.
• For maintenance service or repairs always and exclusively use
original spare parts. THE MANUFACTURER declines all responsi-
bility for damages that may occur due to non-compliance with the
above.
• The unit is guaranteed according to the contractual agreements
entered into upon its sale: however, failure to comply with the rules
and instructions contained in this manual and any modication in
the unit not previously authorised, will cause an immediate loss of
guarantee validity.
• This manual describes the intended use of the unit and provides
instructions for its handling, installation, assembly, adjustment
and use. It supplies information on the maintenance schedule,
how to order spare parts, the presence of residual risks, and staff
training. Therefore, before handling, installing, using or carrying
out any maintenance on the unit, read the manual very carefully.
• It is important to remember that the use and maintenance man-
ual can never replace adequate user experience. This manual
represents a reminder of the main operations to be performed by
operators who have received specic training, for example by at-
tending training courses held by the manufacturer, with reference
to particular maintenance operations.
• Make sure all the users have thoroughly understood the oper-
ating instructions together with the meaning of any symbols on
the unit.
• Possible accidents can be avoided by following these technical
instructions drafted in accordance with the Machinery Directive
2006/42/EC and subsequent additions.
• In any case, always comply with national safety regulations.
• Do not remove or damage guards, decals, stickers and wording,
especially any that are required by law.
• Adhesive labels intended for safer use are applied to the unit,
therefore, it is very important to replace them if they become il-
legible.
CWARNING
• The electrical wiring, hydraulic and refrigeration diagrams and
the technical data shown in this manual are supplied for guidance
only and may be changed without prior notice for the purpose of
improving the product range. For detailed information on specic
models, refer to the specic documentation attached to the each
product.
Any updates or additions to this use and maintenance manual
are to be considered an integral part of the manual and may be
requested via the contact phone numbers listed in this manual.
Contact the MANUFACTURER for additional information and to
share any feedback and recommendations aimed at improving
the manual.
If the unit is transferred to a new owner, the MANUFACTURER ex-
pects you to please notify the address where to send any manual
additions for the new user.
6

TABLE OF CONTENTS
1 INTRODUCTION � � � � � � � � � � � � � � � � � � � � � � � �p.3
2 START-UP INSTRUCTIONS� � � � � � � � � � � � � � �p.4
3 GENERAL DESCRIPTION � � � � � � � � � � � � � � � �p.8
3.1 PRECAUTIONS FOR USE. . . . . . . . . . . . . . . . . . . . . . .p.8
3.2 PREAMBLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.8
3.3 LIABILITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.8
3.4 INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.9
3.5 OPERATING LIMITS. . . . . . . . . . . . . . . . . . . . . . . . . . .p.9
3.6 GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . .p.10
4 SAFETY PRESCRIPTIONS � � � � � � � � � � � � � �p.11
4.1 GENERAL SAFETY RULES. . . . . . . . . . . . . . . . . . . . .p.11
4.2 GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . .p.11
4.3 LOCATION OF SAFETY DATA PLATES . . . . . . . . . . .p.14
4.4 MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . .p.15
4.5 PRECAUTIONS IN CASE OF REFRIGERANT
LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.16
5 DESCRIPTION AND TECHNICAL DATA� � � �p.17
5.1 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.17
6 INSPECTION, TRANSPORT AND
POSITIONING � � � � � � � � � � � � � � � � � � � � � � � � �p.23
6.1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.23
6.2 LIFTING AND CONVEYANCE. . . . . . . . . . . . . . . . . . .p.23
6.3 UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.23
6.4 SITING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.23
7 INSTALLATION � � � � � � � � � � � � � � � � � � � � � � � �p.25
7.1 INSTALLATION CLEARANCE REQUIREMENTS . . . .p.25
7.2 GENERAL GUIDELINES FOR PLUMBING
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.25
7.3 WATER CONNECTION TO THE EVAPORATOR . . . . .p.25
7.4 PROCEDURE FOR FILLING THE TANK (OF THE
SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.26
7.5 SAFETY MANAGEMENT HIGH PRESSURE SIDE . . .p.26
8 ELECTRICAL CONNECTIONS � � � � � � � � � � � �p.27
8.1 GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . .p.27
8.2 FLOW SWITCH OF WATER SIDE . . . . . . . . . . . . . . . .p.27
8.3 REMOTE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . .p.27
8.4 REMOTE SUMMER/WINTER SWITCHING . . . . . . . .p.28
9 START-UP � � � � � � � � � � � � � � � � � � � � � � � � � � � �p.29
9.1 PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . . . . .p.29
9.2 START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.29
9.3 INSPECTIONS DURING OPERATION . . . . . . . . . . . .p.29
9.4 REFRIGERANT CHARGE CHECKS . . . . . . . . . . . . . .p.30
9.5 EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .p.30
9.6 GROUP STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.31
10 SETTING OPERATING PARAMETERS � � � �p.32
10.1 GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . .p.32
10.2 MAXIMUM PRESSURE SWITCH . . . . . . . . . . . . . . . .p.32
10.3 MINIMUM PRESSURE SWITCH. . . . . . . . . . . . . . . . .p.32
10.4 SERVICE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . .p.32
10.5 ANTI-FREEZE THERMOSTAT FUNCTION . . . . . . . . .p.32
10.6 ANTI-RECYCLE TIMER . . . . . . . . . . . . . . . . . . . . . . .p.33
10.7 REFRIGERANT SENSORS (IF “A2L-READY” AND
“R1234ZE” REFRIGERANT OPTIONS PRESENT) . . .p.33
11 ROUTINE MAINTENANCE AND CHECKS � �p.34
11.1 WARNINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.34
11.2 GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . .p.34
11.3 REFRIGERATION CIRCUIT REPAIRS. . . . . . . . . . . . .p.35
11.4 LEAK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.35
11.5 HIGH VACUUM AND REFRIGERATION CIRCUIT
DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.35
11.6 REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . .p.35
11.7 SUBSTITUTION OF R134A WITH R1234ZE
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.36
11.8 REFRIGERANT SENSORS (IF “A2L-READY” AND
“R1234ZE” REFRIGERANT OPTIONS PRESENT) . . .p.36
12 RETIRING THE UNIT � � � � � � � � � � � � � � � � � � �p.38
12.1 WASTE ELECTRICAL AND ELECTRONIC
EQUIPMENT MANAGEMENT. . . . . . . . . . . . . . . . . . .p.38
12.2 ENVIRONMENT PROTECTION . . . . . . . . . . . . . . . . .p.38
12.3 PACKAGING DISPOSAL. . . . . . . . . . . . . . . . . . . . . . .p.38
13 TROUBLESHOOTING � � � � � � � � � � � � � � � � � � �p.40
14 SAFETY DATA SHEET OF REFRIGERANT
� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �p.41
EKW |UsER MANUAL
7

3 GENERAL DESCRIPTION
3.1 Precautions for use
The operating rules contained in this manual are solely ap-
plicable for the units:
EKW
The instructions manual must be read and used as follows:
Ūevery unit operator and maintenance technician must
carefully read the entire manual and comply with that
stipulated therein;
Ūthe employer must ensure that the operator has the re-
quirements to operate the unit and has carefully read the
manual;
Ūread the instructions manual carefully and consider it an
integral part of the unit;
Ūthe instructions manual must be readily available to op-
erating personnel and maintenance technicians;
Ūkeep the manual throughout the life of the unit;
Ūmake sure that any update is included in the text;
ŪHand the manual to any other user or subsequent owner
of the unit;
ŪUse the manual so that the contents are not damaged -
entirely or in part;
Ūdo not, for any reason, remove, tear or rewrite parts of
the manual;
Ūkeep the manual away from humidity and heat;
Ūif the manual is lost or partially damaged, so that it is no
longer possible to read all of its contents, it is advisable
to request a new one from the manufacturer.
3.2 Preamble
BATTENTION
The operating rules described in this manual are an integral
part of the unit supply.
These rules are also intended for the previously trained op-
erator specically to operate this type of unit and contain all
the necessary and important information for operating safe-
ty and optimal, proper use of the unit.
ADANGER
Hurried and incomplete training leads to improvisation,
which is the cause of many accidents.
Before starting to work, read through and strictly observe the
following suggestions:
Ūthe operator must always have the instruction manual
readily available at any time;
Ūplan each action carefully;
Ūbefore starting work, make sure the safety devices func-
tion correctly and you have no doubts on how they work;
otherwise, do not start-up the unit;
Ūcarefully observe the warnings relating to special haz-
ards contained in this manual;
Ūpreventive and thorough maintenance guarantees con-
stantly high operating safety for the unit. Never delay
repairs and always have them carried out solely by qual-
ied personnel; only original spare parts are to be used.
3.3 Liability
THE MANUFACTURER shall not be liable for any accident to
persons or property which may occur due to:
Ūfailure to comply with the instructions provided in this
manual regarding unit management, use and mainte-
nance;
Ūviolent actions or incorrect manoeuvres when perform-
ing maintenance on the unit;
Ūalterations made to the unit without prior written author-
isation from the MANUFACTURER;
Ūincidents beyond the normal and correct use of the unit.
In any case, if the user attributes the incident to a defect in
the unit, he must prove that the damage caused was a main
and direct consequence of this “defect”.
BATTENTION
When installing or servicing the unit, the rules stipulated in
this manual must be complied with together with those on
board the unit and in any case all necessary precautions
must be taken.
ŪThe presence of pressurised uids in the refrigerant cir-
cuit and of electrical components can create hazardous
situations during installation and maintenance.
ŪTherefore, only qualied personnel may perform work on
the unit.
ŪThe initial start-up must be carried out EXCLUSIVELY BY
QUALIFIED PERSONNEL AUTHORIZED BY THE MAR-
KETING ENTITY (see annex).
ŪFailure to comply with the rules stipulated in this manu-
al and any alteration to the unit without prior authoriza-
tion will immediately make THE WARRANTY NULL AND
VOID.
ŪBefore performing any work on the unit, ensure it has
been disconnected from the power supply.
ŪFor maintenance service or repairs always and exclu-
sively use original spare parts. THE MANUFACTURER
declines all responsibility for damages that may occur
due to non-compliance with the above.
ŪThe unit is covered by the warranty according to the con-
tractual agreements established at the time of sale.
ŪHowever, the warranty is rendered null and void if the reg-
ulations and user instructions stipulated in this manual
are not complied with.
EKW |HF61GJ0440A
8

3.4 Intended use
The units are intended for heating water and glycol solutions
up to a maximum of 35% the weight, in civil, industrial and
technological air conditioning environments.
CWARNING
Their use is recommended within the functioning limits car-
ried in this manual, or else the warranty attached to the sales
contract would cease.
BATTENTION
Any other use is to be considered inappropriate and the
manufacturer declines all liability for any damage caused to
persons, property or the unit that may derive from such use.
ADANGER
ŪPlace the unit in environments where there is no risk of
explosion, corrosion or re.
ŪMake sure that the unit is supplied an adequate volume
of air at both intake and outlet ends.
ŪImproper use could cause serious repercussions on the
unit.
ŪAll routine and special maintenance operations must be
performed with the unit off and the power supply discon-
nected.
ŪWait approximately 30 minutes after switching off the
unit before carrying out any maintenance operations to
avoid burns.
BATTENTION
ŪBefore performing any work on the unit, each operator
must be perfectly aware of how the unit and its controls
work and must have read and understood all the techni-
cal information in this manual.
ŪIt is forbidden to use the unit in conditions or for us-
es other than what is indicated in this manual and the
MANUFACTURER may not be held responsible for break-
downs, accidents or injuries due to failure to comply with
this prohibition.
ŪDo not repair high pressure pipes with welds.
ŪIt is forbidden to tamper with, alter or modify, even par-
tially, the systems or equipment described in the instruc-
tion manual, and in particular, the guards and warning
symbols required for personal safety.
ŪIt is also forbidden to operate in manners different from
those indicated or fail to perform operations necessary
for safety reasons.
ŪSafety instructions are particularly important, as well as
general information contained in this manual.
3.5 Operating limits
Operating limits of EKW chillers or heat pump in relation to
the outlet water temperature and water dew point.
CWARNING
For details please contact the local Eneren dealer.
It is possible to produce water at temperatures below 5°C
and as low as -10°C using glycol solutions that lower the
freezing point according to the following table:
Minimum temperature of water produced 5°C 2°C -1°C -5°C -10°C
Percentage by weight of ethylene glycol 0% 10% 15% 25% 30%
Mixture freezing temperature 0°C -4°C - 8°C -14°C -18°C
Given an equal volumetric ow rate of water, pressure drops
will depend on the percentage of glycol, as shown in the fol-
lowing table:
Glycol percentage by weight % 0% 10% 15% 25% 30%
Pressure drop change % 0% +12% +21% +43% +55%
Operating limits
Thermal carrying uid Only water or glycol + water mixture with no more than 35% anti-freezing agent
Max. water operating pressure 3 bars
Max. operating P – High pressure side 32 bar-g
Maximum operating ambient T 45 °C
Minimum operating ambient T -10 °C
Max. operating P – Low pressure side 20.0 bar-g
Supply voltage +/- 5 % of rating plate voltage
Max. storage temperature + 55 °C
Min. storage temperature - 20 °C (*)
(*) -10°C in case of inverter or ow measuring instruments
EKW |UsER MANUAL
9

Evaporator and condenser water flow rate
The nominal ow rate is based on a thermal differential of
5° C between inlet and outlet water, in relation to the cooling
capacity provided at the nominal water temperatures.
Always refer to the technical selection conditions of the unit.
The maximum permitted ow rate relates to the maximum
speed in the heat exchanger. A high ow rate causes a great-
er drop in pressure.
The minimum allowed ow rate is associated to the trigger
of the safety devices and to ensure turbulent water ow.
BATTENTION
It is mandatory to install a mechanical lter (to be provid-
ed by the customer or available as an option with the unit
supply) at the inlet to the hydraulic circuit of the plate heat
exchangers, under penalty of immediate loss of the guaran-
tee validity
3.6 General instructions
BATTENTION
ŪThis manual must be read very carefully before trans-
porting, installing, using or servicing the unit.
ŪThis manual must be stored carefully in a place that is
known by the user of the unit, managers and operators
in charge of transport, installation, use, maintenance, re-
pairs and nal dismantling.
ŪThis manual indicates the intended use of the unit and
provides instructions regarding transport, installation,
assembly, adjustment and use. It provides information
regarding maintenance, ordering spare parts, the pres-
ence of residual risks and personnel training.
ŪPlease note that the use and maintenance manual is
not intended to be a substitute for adequate user experi-
ence. For particularly complex maintenance operations,
this manual serves as a reminder of the main tasks to
carry out for operators having received specic training,
for example, in the form of training courses delivered by
the manufacturer.
ŪThis manual is to be considered an integral part of the
unit and must be stored near the unit in a special contain-
er until the unit is eventually demolished. Request a new
copy from the manufacturer if it is lost or deteriorated.
ŪMake sure all the users have thoroughly understood the
operating instructions together with the meaning of any
symbols on the unit.
ŪPossible accidents can be avoided by following these
technical instructions drafted in accordance with the Ma-
chinery Directive 2006/42/EC and subsequent additions.
ŪIn any case, always comply with national safety regula-
tions.
ŪDo not remove or damage guards, decals, stickers and
wording, especially any that are required by law.
ŪAdhesive labels intended for safer use are applied to the
unit, therefore, it is very important to replace them if they
become illegible.
ŪThis manual reects the applicable technology at the time
the unit is sold and cannot be considered inadequate due
to subsequent updates based on new experience.
ŪThe manufacturer has the right to update the production
and manuals, without being obliged to update previous
production and manuals, except for exceptional cases.
ŪAny updates or additions to this use and maintenance
manual are to be considered an integral part of the man-
ual and may be requested via the contact phone num-
bers listed in this manual.
ŪContact the manufacturer for further information and to
submit any proposals on how to improve the manual.
ŪIf the unit is transferred to a new owner, the manufac-
turer expects you to please notify the address where to
send any manual additions for the new user.
EKW |HF61GJ0440A
10

4 SAFETY PRESCRIPTIONS
The following are some general rules useful for ensuring the
safety of people who are in contact with the unit.
BATTENTION
It is up to the installer and the owner of the installation site
to dene the safety and protection devices to be used for
unit maintenance operations or in dangerous situations - as
well as the emergency procedures to be adopted in the latter
case. All this in accordance with current legislation and in
conjunction with local rescue units.
4.1 General safety rules
4.1.1 Thoroughly know the unit
The unit must only be used by qualied personnel, who are
expected to know the arrangement and function of all con-
trols, instruments, indicators, indicator lights and various
data plates.
4.1.2 Wear protective clothing
Each operator must use personal protective equipment such
as gloves, headgear, safety goggles, safety shoes, and hear-
ing protection.
OS
OS
BATTENTION
Please also refer to the relevant section in chapter 14Safety
data sheet of refrigerantp.41.
4.1.3 Use safety equipment
A rst aid kit and a re extinguisher must be placed near the
unit.
OS
BATTENTION
Please also refer to the relevant section in chapter 14Safety
data sheet of refrigerantp.41.
4.1.4 Fire extinguisher and a first aid kit
Check the presence and location of the re extinguisher.
Regularly check that the re extinguishers are charged and
their operating instructions are clearly understood.
It is required to be aware of where the rst aid box is kept.
Periodically check that the rst aid kit is stocked with disin-
fectants, bandages, drugs, etc.
The personnel must know what to do in the event of a re.
Make sure that emergency help phone numbers are readily
available.
In the event of a re, use a re extinguisher in compliance
with the regulations in force. Contact the re department.
CWARNING
The owner of the building where the unit is installed must
provide the required re extinguisher.
4.2 General precautions
The Machinery Directive 2006/42/EC provides the following
denitions (Annex 1.1.1.1):
DANGER ZONE: any area next to and/or inside a machine,
where the presence of an exposed person constitutes a risk
for the safety and health of said person.
EXPOSED PERSON: any person found entirely or partially
within a danger zone.
OPERATOR: the person (or persons) appointed to install, set
up, adjust, maintain, clean, repair and transport the machine.
CWARNING
ŪBefore carrying out any operation or maintenance on the
unit it is mandatory to read and follow the instructions
given in the use and maintenance manual. During the
actual work, it would be too late: any not recommended
EKW |UsER MANUAL
11

or wrong operation could then cause serious damage to
people or property.
ŪThe employer must inform in detail all operators about
the risks of accidents and particularly about risks relat-
ed to noise, required personal protective devices and
general accident prevention rules provided by laws or
international standards and national standards in the
Country of destination of the unit. All operators must
comply with the international accident prevention stand-
ards and standards in force in the country of destination
of the unit. Please be reminded that the European Union
has issued some directives concerning the safety and
health of workers, among which the directives 89/391/
EEC, 89/686/EEC, 89/654/EEC, 2009/104/EC, 89/656/
EEC, 2003/10/EC, 92/58/EEC and 92/57/EEC that each
employer has an obligation to observe and to enforce. In
the event that the unit is installed outside the European
union, always refer to the regulations in force in the coun-
try of installation.
ŪBefore starting any work on the unit, each operator must
be perfectly familiar with its operation and its controls,
and have read and understood all the information con-
tained in this manual.
BATTENTION
It is forbidden to tamper with or replace parts of the unit un-
less this has been expressly authorised by the MANUFAC-
TURER.
The use of accessories, tools, consumables or spare parts
other than those recommended by the MANUFACTURER
and/or specied in this manual may be a hazard to operators
and/or damage the unit.
Any alteration of the unit not expressly authorised by the
MANUFACTURER shall not imply any civil or criminal liability
for the manufacturing company.
CWARNING
ŪIt is strictly forbidden to remove or tamper with any safe-
ty devices.
ŪAny installation, ordinary and extraordinary maintenance
operations must be carried out with the unit stopped and
without power supply.
ŪOnce the unit has been cleaned, the operator must check
that there are no worn or damaged parts or parts that
are not safely xed, or if this is the case, ask the main-
tenance staff to x the problem. Special attention must
be paid to the state of repair of the pressurised pipes
or other parts exposed to wear. It must also be ensured
that there are no leaks of uid, or other dangerous sub-
stances. In these cases, it is forbidden for the operator to
restart the unit before the situation has been remedied. If
any of these occurrences are detected, the operator, be-
fore leaving the unit unattended, must display a warning
sign indicating that maintenance is in progress and it is
forbidden to start the unit.
ŪThe use of ammable uids in cleaning operations is
prohibited.
ŪPeriodically check the condition of the data plates and
arrange, if necessary, for them to be restored.
ŪThe operator work place must be kept clean, tidy and free
from any objects that may limit unhindered movement.
ŪOperators should avoid operating the device from unsafe,
uncomfortable positions that may affect their balance.
ŪOperators must be aware of possible risks of entrapment
and entanglement of clothes and/or hair in moving parts;
it is recommended to wear caps over long hair.
ŪWearing chains, bracelets and rings can also be danger-
ous.
ŪThe workplace must be adequately lit for the intended
operations. Insucient or excessively bright lighting can
imply safety risks.
ŪThe instructions, accident-prevention rules and warnings
contained in this manual must be observed at all times.
4.2.1 Safety information
The units have been designed and built according to the cur-
rent state of the art and the technical rules currently applica-
ble to uid chillers and heat pumps and/or uid chillers with
free-cooling exchange intended for cooling water or water
and anti-freezing agent mixtures, for housing air condition-
ing and industrial cooling systems. Compliance with the
laws, provisions, prescriptions, orders and directives in force
for these machines has been ensured.
The materials and the equipment parts used, as well as the
production, quality assurance and control processes meet
the highest safety and reliability requirements.
By using them for the purposes specied in this user man-
ual, by operating them with the required diligence and per-
forming accurate maintenance and overhauling in a work-
manlike manner, consistent performance and functionality
and durability can be ensured.
4.2.2 Accident prevention
The MANUFACTURER will not be liable for accidents, during
the use of the unit, due to failure by the user to comply with
laws, provisions, prescriptions and regulations applicable
to uid chillers and heat pumps and/or uid chillers with
free-cooling exchange system.
4.2.3 Operational safety
The MANUFACTURER will not be responsible in case of mal-
functions and damage if the unit:
Ūit is used for purposes other than those for which it is
intended;
Ūit is not operated and maintained according to the ser-
vice standards specied further on in this manual;
Ūit does not regularly and consistently receive mainte-
nance as prescribed or non-original spare parts are used;
Ūis modied or some components are replaced without
the MANUFACTURER’s written authorisation, especially
when the effectiveness of the safety systems has been
altered or minimised on purpose;
Ūit is used outside the permissible temperature range.
4.2.4 Residual risk areas
ADANGER
In some areas of the unit there are some residual risks that
could not be eliminated during the design phase nor isolated
with guards due to the unit’s operating characteristics. Each
operator must be aware of the residual risks present in this
unit in order to prevent any accidents.
EKW |HF61GJ0440A
12

A. Danger of re
B. Danger of explosion due to the presence of pressurised circuits
C. Danger of pollution due to the presence of refrigerant in the circuit
D. Danger of burns due to the presence of high temperature pipes
CWARNING
In order to avoid the risks listed above it is essentially im-
portant to:
Ūset the control panel according to the manufacturer’s in-
structions;
Ūto avoid the risk of impact or abrasion in the fan area, cut
off the power to the unit before intervening;
Ūnot place metal objects inside the electrical control pan-
el;
Ūnot store ammable materials near the machine;
Ūnot alter any component of the refrigerant circuit;
Ūnot let the machine work outside the limits indicated by
the manufacturer;
Ūdispose of all the materials that make up the machine
correctly, use suitable equipment for the recovery of the
refrigerant gas (see chapter “Retiring the unit “);
Ūnot touch the internal components during operation with-
out adequate protection.
EKW |UsER MANUAL
13

4.3 Location of safety data
plates
4.3.1 Description of the safety symbols
1
A. Warning: danger due to poor familiarity with all the functions of the unit and the
resulting risks.
B. Read the use and maintenance manual carefully before operating the unit.
A B
2
Electric power supply data plate (electric panel). +
3
A. Danger hot parts (compressors).
B. Electric voltage hazard (compressors)
C. Danger of burns (compressors).
AB
C
4
Anchor points for lifting.
5
Liquid refrigerant (compressors). R1234ze
EKW |HF61GJ0440A
14

4.4 Maintenance precautions
4.4.1 Tools
Use only tools suitable for safe service and maintenance op-
erations.
Personal injury is prevented by not using worn or damaged,
low quality or makeshift tools.
If tools not recommended or modied without authorisation
are used, the manufacturer will no longer be liable for dam-
ages caused.
4.4.2 Personnel
Ordinary maintenance prescribed in this manual must only
be performed by authorised and trained personnel. For the
maintenance or overhauling of components not specied in
this manual, contact the MANUFACTURER.
4.4.3 Keep the unit clean
Oil and grease stains, misplaced tools or broken pieces are
harmful to people as they can cause slipping or falls. Always
keep the area where the unit is installed clean and tidy.
Do not use diesel fuel, oil or solvents to clean the unit as the
rst two leave an oily lm that makes it easier for dust to
stick, while solvents (even milder ones) damage the paint
nish and cause rusting.
If a water jet hits the inside of electrical equipment, in addi-
tion to causing contact oxidation, it may cause the unit mal-
function.
For this reason, do not use water or steam jets on sensors,
connectors or any electrical parts.
4.4.4 Warning plates
Before starting any maintenance operation, turn off the unit.
If other people start the unit and operate the control buttons
while maintenance operations are being performed, serious
injury or even death may result.
To avoid these dangers, before carrying out maintenance,
hang caution signs around the unit.
4.4.5 Warnings for inspections and
maintenance
Display a sign with the warning: “INSPECTION IN PRO-
GRESS” on all sides of the unit.
Check the unit carefully following the list of operations con-
tained in this manual.
INSPECTION
IN PROGRESS
4.4.6 Care and maintenance
The cause of damages and accidents is often attributable to
wrong maintenance, such as:
Ūno water in the circuit;
Ūincorrect percentage of anti-freezing agent in the hydrau-
lic circuit;
Ūinadequate refrigerant;
Ūpoor cleaning in the unit setting;
Ūcircuit ineciency (damage to the exchangers, pipe con-
nections, tightening of pipes, screws, etc.).
Carry out maintenance work as required: this is also critical
for your own safety.
Never postpone scheduled repairs.
Only assign skilled or authorised personnel to repair tasks.
Always observe the following safety rules, even when you
are thoroughly familiar with the operations involved:
Ūalways keep the unit and the surrounding area clean;
Ūbefore beginning to work, check the perfect eciency of
protective devices;
Ūmake sure that no unqualied or not specially appointed
persons enter the unit operating area.
EKW |UsER MANUAL
15

4.5 Precautions in case of
refrigerant leakage
In case the unit is charged with an A2L classied refriger-
ant, (low ammable refrigerant), the unit is provided with one
refrigerant leakage sensor inside each compressor box (if
present) and inside all separated sections of the electrical
box.
The following safety chain is applied: EVENT - ACTION - SIG-
NAL
Each sensor is set on two different concentration thresh-
olds. The threshold is depending on refrigerant type, and list-
ed in the table below:
Refrigerant Classication Low level threshold High level threshold
R1234ze A2L 500 ppm 900 ppm
The following image and table describe the safety chain
EVENT - ACTION - SIGNAL
Critical alarm Sensor high level alarm, sensor breakdown
Warning signal Sensor low level alarm, air pressure switch alarm/breakdown, compressor box/auxiliary box fan breakdown
11111
7
8
9
10
6
5
4
3
2
11111
7
8
9
10
6
5
4
3
2
11111
7
8
9
10
6
5
4
3
2
11111
7
8
9
10
6
5
4
3
2
COMPRESSOR BOXELECTRICAL BOX
CRITICAL ALARM WARNING SIGNAL
EVENT ACTION SIGNAL
Compressor box fan alarm fault Electrical box fans activation (when Tair <= T limit) Dedicated warning signal
Underpressure inside electrical panel alarm/fault Compressor box fans activation Dedicated warning signal
Low level alarm Compressor box fans activation
Electrical box fans activation (when Tair <= T limit) Dedicated warning signal
Refrigerant sensor fault Switch off all the unit (electrical supply still present) General serious alarm + Dedicated serious alarm
High level alarm Switch off all the unit (electrical supply still present) General serious alarm + Dedicated serious alarm
ADANGER
Refrigerant safety devices are not active when the unit is not
powered: risk of refrigerant presence in the electrical pan-
el. Check any refrigerant leaks with a suitable device before
starting the unit.
CWARNING
Follow the instructions below in the event of a refrigerant
leak signal from the sensors installed on the machine or
possibly present near the machine:
ŪIn case of low level alarm, contact technical support.
ŪDo not stand in the vicinity of the machine.
It is necessary to have a remote refrigerant alarm signal, so
that it is not necessary to approach the machine in the event
of an alarm. This remote signal can be performed:
ŪVia remote display, available as an option and available
at any time by contacting the After-sales center.
ŪBy reading the unit alarms via remote communication
(e.g. via Modbus or Ethernet) and by remotely setting up
a specic danger signal far from the unit to activate in
the event of an alarm.
BATTENTION
In case of serious alarm:
ŪRemove voltage from the unit, keeping the dedicated
alarm signal via wired contact active (see wiring dia-
gram).
ŪCall a service centre for assistance.
Technical assistance must:
ŪWell ventilate all the closed compartments of the ma-
chine well for at least 5 minutes, before energizing.
ŪCheck the cooling circuit for leaks.
ŪOnce the circuit is set up and the refrigerant charge is re-
stored, close the compartments and power up the chiller,
if there are no alarms, the machine can be restarted.
EKW |HF61GJ0440A
16

5 DESCRIPTION AND TECHNICAL DATA
5.1 Series
5.1.1 Heating only
The EKW series of water-condensing heat pumps includes
this range of models:
ŪEKW K water-water heat pump - only heating - high User
water temperatures.
EKW heat pumps are available in versions with different
acoustic designs (“S” standard , “L” low noise ).
The EKW units are developed in a completely enclosed ver-
sion for a low noise operation making it possible to install
them in non-segregated environments. They are character-
ized by a rounded shape contributing to an attractive appear-
ance.
The EKW units can be identied by the following symbol:
1 Identication symbol of Model (e.g.: “EKW” units)
2 Size
• Heating capacity x10 [kW] (e.g.: 120 kW)
3 Efciency Pack
• 1 = 2 compressors/2 circuits
• 2 = 2 compressors / 1 circuit
• 4 = 4 compressors / 2 circuits
4 Conguration
• K = Heating-only - high User water temperatures
5 Execution
• S = Standard
• L = Low noise
EKW
5.1.2 Structure
All EKW units have a self-supporting base.
The unit features an exclusive design which lends it an at-
tractive appearance.
This characteristic, together with the extensive use of sound-
proong material inside the compartment – an optional fea-
ture of low-noise models – reduces noise to exceptionally
low levels.
5.1.3 Operating limits
5.1.3.1 Operation restrictions diagram
CWARNING
The choice of different available options can lead to chang-
es in the corresponding envelope.
Please refer to the manual of the specic selected congu-
ration.
EKW |UsER MANUAL
17

1 glycol mix on source side
3 evaporation control
5 counter ow on user side
6 ΔT>7°C user side
-15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
5 6
31
Outlet water T [°C] - user side
Inlet water T [°C] - source side
heating
5.1.3.2 Anti-vibration rubber devices
The units EKW can be equipped with the spring-type anti-vi-
bration devices.
BATTENTION
For the exact position of each foot, refer to the attached di-
mension drawing.
A
A
SECTION A-A
C
A
B H
CODE D 60-95
Amm 95
Bmm 40
Cmm M-16
Hmm 45
MAX LOAD daN 1200
fmm 8
A
A
SECTION A-A
B
A
C
D1
D2
E
F
BSB 60
BSB 80
BSB 95
BSB 110
BSB 125
BSB 150
EKW |HF61GJ0440A
18

E
F
A A
SECTION A-A
C
B
A
D1
D2
BSB 150 S.B.
BSB 160
BSB 180
BSB 220
CODE BSB150 BSB180 BSB180
Amm 155 180 180
Bmm 49 67 67
Cmm M-16 M-20 M-20
D1 mm 176 149 149
D2 mm 188 163 163
Emm 218 192 192
Fmm 14.5 14.5 14.5
WEIGHT g1818 3800 3800
LOAD kg 950 1750 2100
HARD-
NESS 50 Sh 50 Sh 60 Sh
BATTENTION
The values shown are approximate gures only - due to elas-
tomer hardness tolerance range and other factors; they can
be reassessed in case of actual need.
» OWN FREQUENCIES Type BSB
Xown frequency Hz
Yload (kg)
6
7
8
6
7
8
9
1
0
1
1
1
2
1
4
1
6
1
8
2
0
2
0
2
5
3
0
4
0
5
0
6
0
7
0
8
0
1
0
0
2
0
0
2
5
0
3
0
0
4
0
0
5
0
0
6
0
0
7
0
0
8
0
0
1
0
0
0
1
5
0
0
2
0
0
0
2
5
0
0
3
0
0
0
3
5
0
0
4
0
0
0
5
0
0
0
3
5
0
0
4
0
0
0
5
0
0
0
1
2
0
1
4
0
1
6
0
1
8
0
B
S
B
6
0
4
0
B
S
B
6
0
5
0
B
S
B
6
0
6
0
B
S
B
6
0
7
0
B
S
B
8
0
4
0
B
S
B
8
0
5
0
B
S
B
8
0
6
0
B
S
B
8
0
7
0
B
S
B
9
5
4
0
B
S
B
9
5
5
0
B
S
B
9
5
6
0
B
S
B
9
5
7
0
B
S
B
1
1
0
5
0
B
S
B
1
1
0
4
0
B
S
B
1
1
0
6
0
B
S
B
1
1
0
7
0
B
S
B
1
2
5
4
0
B
S
B
1
2
5
5
0
B
S
B
1
2
5
6
0
B
S
B
1
2
5
7
0
B
S
B
1
8
0
4
0
B
S
B
1
8
0
6
0
B
S
B
1
8
0
7
0
B
S
B
2
2
0
4
0
B
S
B
2
2
0
6
0
B
S
B
1
6
0
7
0
B
S
B
1
6
0
6
0
B
S
B
1
6
0
4
0
B
S
B
1
6
0
5
0
B
S
B
1
5
0
7
0
B
S
B
1
5
0
6
0
B
S
B
1
5
0
5
0
B
S
B
1
5
0
4
0
B
S
B
1
8
0
5
0
B
S
B
2
2
0
7
0
B
S
B
2
2
0
5
0
Y
X
» LOAD-DEFLECTION CURVES Type BSB
Zbending (mm)
Yload (kg)
0
1
8
7
6
5
4
3
2
1
2
0
2
5
3
0
4
0
5
0
6
0
7
0
8
0
1
0
0
2
0
0
2
5
0
3
0
0
4
0
0
5
0
0
6
0
0
7
0
0
8
0
0
1
0
0
0
1
5
0
0
2
0
0
0
2
5
0
0
3
0
0
0
3
5
0
0
4
0
0
0
5
0
0
0
1
2
0
1
4
0
1
6
0
1
8
0
B
S
B
6
0
4
0
B
S
B
6
0
5
0
B
S
B
6
0
6
0
B
S
B
6
0
7
0
B
S
B
8
0
4
0
B
S
B
8
0
5
0
B
S
B
8
0
6
0
=
B
S
B
9
5
5
0
B
S
B
8
0
7
0
B
S
B
9
5
4
0
B
S
B
9
5
6
0
B
S
B
9
5
7
0
B
S
B
1
1
0
4
0
B
S
B
1
1
0
5
0
B
S
B
1
1
0
6
0
B
S
B
1
1
0
7
0
B
S
B
1
2
5
4
0
B
S
B
1
2
5
5
0
B
S
B
1
2
5
6
0
B
S
B
1
2
5
7
0
B
S
B
1
8
0
4
0
B
S
B
1
8
0
6
0
B
S
B
1
8
0
7
0
B
S
B
2
2
0
4
0
B
S
B
2
2
0
6
0
B
S
B
1
6
0
4
0
B
S
B
1
6
0
5
0
B
S
B
1
6
0
6
0
B
S
B
1
6
0
7
0
B
S
B
1
5
0
4
0
B
S
B
1
5
0
6
0
B
S
B
1
5
0
7
0
B
S
B
1
5
0
5
0
B
S
B
1
8
0
5
0
B
S
B
2
2
0
5
0
B
S
B
2
2
0
7
0
Y
Z
EKW |UsER MANUAL
19

5.1.3.3 Anti-vibration spring devices
The units EKW can be equipped with the spring-type anti-vi-
bration devices shown below.
BATTENTION
For the exact position of each foot, refer to the attached di-
mension drawing.
Ø 74
M10
118
128
78
98
Frame Springanti-vibrationdevice
1EMCV 305
2EMCV 305
3EMCV 305
3+ EMCV 305
4EMCV 305
5EMCV 305
6-7 EMCV47
M12-M16-M20
M12-M16
87
8
114
Ø8,5
100
170
185
140
80
Frame Springanti-vibrationdevice
F1 RF411-Z220-124
F2 RF411-Z220-124
F3 RF411-Z220-124
F4 RF412-Z220-X108
F5 RF412-Z220-X108
F6 RF412-Z220-X108
F4S RF411-Z220-124
F5S RF411-Z220-124
F6S RF411-Z220-124
EKW |HF61GJ0440A
20