flowair AURA HCS Series User guide

FLOWAIR sp. z o.o. / OMSAC210708EN
Installation and operating instruction
Air-cooled heat pumps
R410A
AURA HCS
Heat pumps

FLOWAIR sp. z o.o. / OMSAC210708EN 1
1. Introduction........................................................................................................................................................................3
Meaning of symbols ...........................................................................................................................................................3
1.1. General equipment specification...............................................................................................................................3
1.2. AURA HCS model line.................................................................................................................................................3
Use of HCS units .................................................................................................................................................................4
Basic description of the standard execution ......................................................................................................................4
Dimensions .........................................................................................................................................................................5
1.3. Used refrigerant.........................................................................................................................................................5
1.4. Legislation and security .............................................................................................................................................6
Specialized operator...........................................................................................................................................................6
Place of installation ............................................................................................................................................................7
1.5. Device identification ..................................................................................................................................................7
2. Handling and storage..........................................................................................................................................................8
2.1. Receipt of equipment ................................................................................................................................................8
2.2. Manipulation .............................................................................................................................................................8
2.3. Storage.......................................................................................................................................................................9
3. INSTALLATION AND PREPARATION FOR COMMISSIONING..............................................................................................10
3.1. Location ...................................................................................................................................................................10
3.2. Hydraulic part ..........................................................................................................................................................12
Water treatment ..............................................................................................................................................................14
3.3. Electrical part...........................................................................................................................................................15
3.4. Cooling circuit ..........................................................................................................................................................16
4. Commissioning .................................................................................................................................................................18
4.1. Pre-commissioning inspection.................................................................................................................................18
4.2. Commissioning.........................................................................................................................................................18
Commissioning protocol...................................................................................................................................................18
Operator training..............................................................................................................................................................18
5. Operation and maintenance.............................................................................................................................................19
5.1. Principles of traffic safety ........................................................................................................................................19
5.2. Operation.................................................................................................................................................................19
Operator responsibility.....................................................................................................................................................19
5.3. Troubleshooting.......................................................................................................................................................20
5.4. Maintenance............................................................................................................................................................21
Regular service inspections ..............................................................................................................................................21
5.5. Product life cycle and disposal.................................................................................................................................22
Cooling equipment life cycle ............................................................................................................................................22
Disposal ............................................................................................................................................................................22

FLOWAIR sp. z o.o. / OMSAC210708EN 2

FLOWAIR sp. z o.o. / OMSAC210708EN 3
1. INTRODUCTION
This manual is intended for qualified operators and contains information on standard functions and operation of units of the
HCS product line, it is not intended for unprofessional personnel. Detailed information for controlling the cooling system
is given in the Manual of the ACS control system.
With the device is supplied this operating instruction and the following documents.: ACS system manual, Technical passport,
Wiring diagram, dimensional drawing, device nameplate and, if applicable, operation test protocols. In the case of different
information, the supreme documents in terms of technical specifications are documents with marked serial number of the
device (e.g. dimensional drawing with attachment points for transport).
Before installing and commissioning the device, it is essential to read the information in this manual. Improper installation
can cause very serious injuries - electric hazards, refrigerant leakage, fire, etc. or cause damage to equipment and property.
Installation work, commissioning and regular maintenance of the cooling equipment must be carried out by qualified and
trained personnel. All operations must be performed in full compliance with local laws and regulations.
If you have any questions about the documentation, contact an authorized partner or FLOWAIR service organization.
Meaning of symbols
The following types of informational alerts are used in this document:
(Other symbols of specific safety instructions are explained below)
INFORMATION
Notice of important technical information
! NOTICE !
Warning of important safety information
!!! SAFETY WARNINGS!!!
Strong warning of potential danger
1.1. General equipment specification
The air-cooled chiller or condensing unit (CU version) is intended for cooling water (possible glycol mixtures) or, in the case
of the CU version, for cooling the evaporator in air-conditioning units. The operating parameters are defined when ordering
the device and subsequently confirmed in the Technological Parameters Card (TPC) of the device.
The function of the cooling equipment is based on the heat transfer of condensation and evaporation in the cooling circuit,
which is divided into a high-pressure and a low-pressure part. The main functional parts of the device are:
Scroll type compressor, which increases the pressure of the evaporated refrigerant to the condensing pressure;
Condenser cooled by forced air flow, in which high-pressure steam condenses and thus transfers latent heat to the
surrounding air. Axial fans, fully integrated in the condenser housing, are used to ensure air flow;
Expansion valve that reduces the pressure of condensate flowing from the condenser from the condensing pressure
back to the evaporating pressure;
Evaporator in which the liquid refrigerant evaporates at low pressure and cools the water (possibly air - CU version
- condensing unit).
All cooling units are completely assembled in the factory and tested before shipment - cooling units are filled by refrigerant
and tested operationally, condensing units or coolers with a separate evaporator are tested with computer simulation.
1.2. AURA HCS model line
Water cooled units can be made with possibilities free-cooling, recuperation, reversible heat pumps or condensing units that
allow a wide range of applications

FLOWAIR sp. z o.o. / OMSAC210708EN 4
Use of HCS units
HCS cooling equipment is designed primarily for powering air conditioning systems in commercial and industrial buildings, as
well as for cooling in industrial applications. The units are a source of cooling or heating medium for secondary systems.
Basic description of the standard execution
(A detailed technical description of selected technological parts can be found later in the text of this manual.)
Operating limits
Standard design - cooling works at full load up to 0°C, with fan speed control (EC fans) and low-temperature design up to
-20°C. In the summer season, the unit operates up to 45°C. Extreme temperature protection is monitored by the ACS limiting
function. The setting of the required water temperature depends on the type of liquid used, the minimum required value for
water is 4°C (for further details see the ACS technical documentation).
The heating mode is effective down to -15°C and the water temperature is controlled by a function with restriction at very
low temperatures. The maximum set value for hot water heating is 55°C.
Condensing unit control
The CU version is externally controlled by digital or analog signals to the main controller of the unit. One or two levels of
digital control are available, depending on the number of compressors or analog control (0-10 V input) with predefined
switching levels (see ACS technical documentation for more details).
External control
Each unit can be controlled by an external on / off signal to the master controller and also sends an alarm signal to the
superior control system.
Control System
Sophisticated control system ensures data collection and subsequent control in real time, so as to ensure maximum
operational efficiency with respect to energy savings and life of technological components of the unit. The main functions of
the application are performed:
Cooling / heating power control based on measured parameters, dynamically adjusting unit power to maximize
energy efficiency.
Limitation of cooling / heating capacity in situations leading to operation at the limit of the technological possibilities
of the unit.
Three-level alarm system protects against damage caused by operation beyond the technological capabilities of the
device.
Switchboard MaR
Control panel, components and cabling manufactured in accordance with EN 60204-1. One mains connection point,
protection class IP 54, phase sequence protection and optionally heated control box. Main on / off switch installed on the
front panel, numbered and marked electrical wires for easy maintenance and service. All power components (compressors,
fans, pumps) are thermally protected.
HMI panel with protective cover or supplied for remote installation on request.
Control unit
The main microprocessor controller preconfigured during the factory test with default settings helps you get it up and running
quickly. Intuitive user interface with three levels of access - user, experienced user and technician.
The RS485 serial communication port enables remote management via ModBUS® or BacNET® control protocols. Optional
Ethernet port.
Compressors
Hermetic scroll compressors from a renowned producer with axial and radial adaptability for excellent reliability and
efficiency, equipped with crankcase heaters. Compressors with low noise and vibration levels are installed on anti-vibration
silentblocks, optionally equipped with anti-noise casings or structural covers.
Electronic discharge temperature monitoring and integrated motor thermal overload protection. Check valve on discharge.
Measuring the operating time and number of compressor starts helps to optimize the switching sequence and service
diagnostics.
Water heat exchanger
AISI 316 stainless steel plate heat exchanger, externally insulated with caoutchouc insulation is located inside the chiller
structure. The Victaulic grooved or threaded hydraulic water connection is led out of the housing of the unit.
3-step frost protection with differential pressure switch, NTC water temperature sensor and low refrigerant pressure sensor
with ACS limiting function.
Air heat exchanger with fans
Long-term reliable plate heat exchanger with aluminum fins and copper tubes, optionally equipped with a protective metal
grille.

FLOWAIR sp. z o.o. / OMSAC210708EN 5
Fans with the highest efficiency with optimized full diffuser and guide blades (meet the requirements of the ErP 2015
directive). Fan grid installed at the air outlet. The fans are fully installed inside the unit housing - flat-top, reducing noise
distribution and increasing condenser efficiency. In a flat installation, the suction point of the fan is closer to the central point
of the condenser.
Fan motor protection class F and internal temperature sensor guarantee reliability at high ambient temperatures. Fixed speed
and optionally variable speed with EC fans or voltage regulator.
Heat recovery
Partial (desuperheater) or complete heat recovery from stainless steel brazed plate heat exchangers located inside the unit
structure. The unit is equipped with an additional water heat exchanger mounted on the compressor discharge line in series
or in parallel with the air condenser. This solution makes it possible to recover up to 25% of energy with a desuperheater or
100% of condensing heat with complete recuperation. The heated water can be used for sanitary or other purposes.
Cooling circuit
Soldering of cooling circuits with a protective atmosphere performed by certified personnel. Before filling with R410A
refrigerant, each cooling circuit of the unit is subjected to a pressure test, a leak test and then evacuated.
Each cooling unit is subjected to a complete functional test to ensure operational quality.
The cooling circuit is equipped as standard with a hermetic or replaceable filter-dehydrator cartridge type, solenoid valve,
thermostatic or optionally electronic expansion valve, sight glass with humidity indicator, low pressure switch, high pressure
switch with manual reset, compressor discharge temperature sensor, high pressure and optionally low pressure sensor,
pressure relief valves according to the requirements of EN 378-2 and suction line insulation.
Depending on the version, the device is further equipped with a suction line temperature sensor, a four-way valve, non-
return valves, a collector and a liquid separator.
Hydraulic circuit
All parts of the hydraulic module are located completely inside the radiator.
Standard components of the chiller hydraulic circuit consist of NTC water inlet and outlet temperature sensors, a differential
water switch, a manometer with shut-off valves to measure the pressure difference on the evaporator.
The cooler can be optionally equipped with a centrifugal pump (static pressure available approx. 200 kPa), reserve centrifugal
pump with operating balance and automatic switching, non-return valves, shut-off ball valves, diaphragm expansion vessel
with maintenance shut-off valve, safety valve, automatic air release valve, filter strainer and drain valve. All pipes and vessels
are thermally insulated with caoutchouc insulation with closed cell structure technology.
Construction
Installing a flat top fan reduces the height of the unit and increases efficiency.
Unit housing made of galvanized sheet steel coated with polyester powder paint RAL 7035. Optional rubber or spring silent
blocks limit the transmission of vibrations to the supporting structure.
Dimensions
The table shows the basic external dimensions of the foundation frames and the total height of the HCS units.
Typoszereg
HCS
HCS
HCS
HCS
HCS
HCS
HCS
HCS
Model
113
219
325
332
444
454
563
575
Wymiary i masa
Długość [mm]
1150
1550
2000
2000
2000
2000
2200
2200
Szerokość [mm]
1000
1000
1100
1100
1100
1100
1100
1100
Wysokość [mm]
1100
1100
1400
1400
1750
1750
2180
2180
Waga [kg]
283
371
484
508
597
633
779
806
1.3. Used refrigerant
HCS units are manufactured with R410A or R134A refrigerants.
Properties R410A
HFC refrigerant - classification according to ISO 817 - A1 (non-toxic, non-flammable), GWP (global warming potential) 2 088,
critical pressure 49.2 bar, critical temperature 70.2°C. TO

FLOWAIR sp. z o.o. / OMSAC210708EN 6
Properties R134A
HFC refrigerant - classification according to ISO 817 - A1 (non-toxic, non-flammable), GWP (global warming potential) 1 430,
critical pressure 41 bar, critical temperature 101.1°C.
1.4. Legislation and security
FLOWAIR has implemented and applies a quality system for the design and manufacture of cooling and air conditioning
equipment according to ISO 9001: 2015. The design and manufacture of HCS units have been certified in accordance with
Directive 2014/68 / EU. The declaration of conformity is given in Annex No. 1 to this manual.
Basic European directives and standards related to ensuring the functionality and safety of cooling equipment:
Machine Directive (MD) 2006/42/EC
Electromagnetic Compatibility Directive (EMC) 2014/30/EU
Low Voltage Directive (LVD) 2014/35/EU
Pressure Equipment Directive (PED) 2014/68/EU
EU regulation Refrigerant Gases 517/2014
European standard for Refrigerating systems EN378 1 - 4
!!! SAFETY WARNINGS!!!
It is essential to follow all safety warnings and precautions contained in this manual. Failure to follow these rules
could result in serious injury or death.
Specialized operator
The operator must ensure the professional installation, operation, maintenance and servicing of the system by a specialist
operator if his organization does not meet the requirements of a specialist operator. The device must be installed and
connected to the electrical / hydraulic network by specialized and qualified persons. Maintenance should only be entrusted
to those companies that specialize in servicing cooling systems.
Easy maintenance of the device without opening the covers and without interfering with the system can be performed by
trained personnel. All other operations must be performed by qualified personnel. Servicing cooling systems can pose a real
risk of injury (especially high voltage and high pressure).
Specialized personnel are personnel who have the necessary equipment, facilities and experience, as well as the appropriate
qualifications for servicing and operating cooling and electrical equipment, as well as construction equipment.
!!! SAFETY WARNINGS!!!
Installation, commissioning and maintenance of cooling equipment are dangerous operations. The basic risks that
may occur when operating the equipment (EN ISO 12100 - Safety of machinery) are listed below.
High pressure is used in the system
The components of the electrical system are live - risk of injury due to contact with terminals and cables
Hot surfaces, pressurized components - there is a pipe with compressed gases in the system, there is a danger
- gushing operating media or flying objects
Sharp edges - air condensers have sharp aluminum fins
INFORMATION
Each device is equipped with a main / safety electrical switch, which can be used to safely disconnect the device from
the electrical network.
When operating the device, use protective equipment - gloves, goggles, etc..

FLOWAIR sp. z o.o. / OMSAC210708EN 7
Place of installation
The installation site provided by the operator must comply with the accident prevention regulations for the machinery (EN
294: 1992 - Safety of Machinery) and related regulations. This requirement also applies to the operation, maintenance and
service of the equipment.
1.5. Device identification
The basic identification, technical and safety parameters are listed on the nameplate located visibly on the outer frame of
the device. Basic data and explanations are given below:
WARNING!
AURA HCS is the trade name of the device. The proper identification mark for regulatory and certification purposes is the SAC
mark. The table below shows the equivalents of the designations.
Brand
Oznaczenie modelu
Aura HCS 113
SAC1-13HC-1IP4E
Aura HCS 219
SAC2-19HC-2IP4E
Aura HCS 325
SAC3-25HC-2IP3E
Aura HCS 332
SAC3-32HC-2IP4E
Aura HCS 444
SAC4-44HC-2IP3E
Aura HCS 454
SAC4-54HC-2IP4E
Aura HCS 563
SAC5-63HC-2IP3E
Aura HCS 575
SAC5-75HC-2IP4E
WATER CHILLER Cooling unit
CONDENSING UNIT Condensing unit
MODEL Model type
SERIAL N. Production identification number of the device
YEAR OF PROD. Year of Manufacture
Power supply Parameters of the electrical supply network
IP X4 Ingress protection rating
COOL Cooling mode parameters
HEAT Heating mode parameters
Pc / Ph Cooling / heating capacity
Pe Maximum electrical input
Imax Maximum allowable electric current
LRA Maximum starting current
Medium Type of cooled medium
VNominal flow rate of the cooled medium
Dp Nominal internal evaporator pressure drop
R410a Type of refrigerant
GWP Global warming potential of the refrigerant used
Cx The amount of refrigerant charge in each circuit
Net weight Weight of the device without packaging and cooled medium
PS HP / LP Maximum allowable pressure high / low pressure side
TS HP / LP (Min. / Max.) Lowest / Highest allowable temperature high / low side
MODEL
SERIAL N.
YEAR OF PROD.
IP X4
COOL
Pc /Ph
Pe
Imax
LRA
V
Dp
kg kg
kg kg
Net Weight kg
PS
Min.
Max.
Piletická 486, 503 41 Hradec Králové
MADE IN CZECH REPUBLIC
TS
(HP / LP)
°C
C4
(HP / LP)
bar
A
Medium
m3/h
kPa
WATER CHILLER
Power supply 400/3/N/PE, 50 Hz
HEAT
kW
kW
R410a GWP=2088
C1
C3
C2
A
ALPENTA s.r.o.

FLOWAIR sp. z o.o. / OMSAC210708EN 8
2. HANDLING AND STORAGE
2.1. Receipt of equipment
When transporting the device, it may be damaged by a strong shock or vibration, so the device must be inspected and, if
damage is found, photo documentation must be made to agree on further action. In case of more serious damage, it is
necessary to perform a technical inspection by an authorized partner of FLOWAIR.
! NOTICE !
The cooling equipment must be visually inspected on delivery before unloading from the vehicle. If loose or damaged
parts are found, it is necessary to contact the supplier immediately to agree on further action to resolve the situation.
The company FLOWAIR demonstrates all care to prevent damage during transport of the equipment but is not liable for
damage caused during transport of the equipment to the destination.
Immediately after unloading, check the identification data of the device stated on the nameplate (chapter Identification of
the device), and the completeness of the received documentation:
The delivery of each device includes: Technical passport, Wiring diagram, drawing with dimensions for transport mounting,
production label of the device, or protocols of the operational test. The supreme documents in terms of technical
specifications are documents with the serial number of the device (e.g. dimensional drawing with attachment points for
transport).
2.2. Manipulation
The requirements of the signs (symbols) on the packaging of the device must be observed. The basic dimensions and transport
openings and holders are shown in the drawing supplied with the device. The weight of the device is indicated on the
nameplate. Follow these rules:
Use suitable unloading / lifting equipment, lifting belts (with the capacity of the total weight of the equipment for
each belt) and other equipment.
When lifting, check the correct position of the machine's center of gravity.
Hold the device in a horizontal position. Avoid excessive rotation and tilting of the device.
The lifting gear must have adequate capacity. The weight of the device is indicated on the nameplate.
Only equipment up to a maximum total length of 3.5 m can be transported with the forklift truck. The lifting gear
(forks) must have a min. the same length as the width of the device itself. Longitudinal holes for forklift forks are
located in the devices.
The crane transports equipment with a length of more than 3.5 m, which must be lifted in accordance with the
dimensional drawing supplied with the equipment - a crane with the appropriate number of spreader bars and hinge
attachment points, which are located on the equipment frame. side).
After installing the unit at the installation site, remove the protective film and shipping fasteners.
Extreme care must be taken during transport, unloading and location of the equipment. Improper handling can damage the
device:
•Fall to the ground even from a low height
•Damage to belts and chains - without the use of spacers
•Lifting for unsuitable components
•Sudden jerk by the lifting device
•Lifting the device at an angle - overloading the suspension points
The warranty does not cover this type of damage. In the event of the above event, it is necessary to contact an authorized
FLOWAIR partner to perform a technical inspection of the equipment.
The following figure shows the basic diagram of the suspension for vertical transport of the equipment lifted by a crane at 2,
3 and 4 points of the suspension on the frame of the equipment. For standard slings, the maximum angle between the lifting
slings (marking A) is 60 ° and between the chain slings (marking B) 45°.
!!! SAFETY WARNINGS !!!
It must be ensured that no persons are present under the suspended load during transport by crane. There is a risk of
loose parts falling.

FLOWAIR sp. z o.o. / OMSAC210708EN 9
2.3. Storage
If the device is to be stored before installation, several rules for protection against damage must be observed. Storage
temperature conditions should be in the range of -25°C to +45°C at a maximum relative humidity of 95%. At high
temperatures (above 50°C) refrigerant may leak through the safety valves.
! NOTICE !
Before storing in winter, when temperatures may drop below 0°C, check that there is no water in the hydraulic circuit
and loosen the drain valves and plugs. Parts of the hydraulic circuit and subsequently the cooling circuit could be
damaged by freezing the water.
Short-term storage - within 2 months of delivery
1. Do not remove protective elements and foils
2. Protect the device from external damage - mechanical, thermal, open flame, damage by animals (e.g. rodents)
3. Protect the device from dust (e.g. from construction work)
Long-term storage - more than 2 months from delivery
1. Do not remove the protective elements, but replace the foil with another solid material - a tarpaulin
2. Protect the device from external damage - mechanical, thermal, open flame, damage by animals (e.g. rodents)
3. Protect the device from dust (e.g. from construction work)
4. Check that there is no water in the hydraulic section (see previous NOTICE)
INFORMATION
If the storage period exceeds 10 months, it is necessary to perform a complete inspection of the equipment by an
authorized FLOWAIR partner before proceeding with the installation.