FRIULAIR CWE Series Operating instructions

CWE CHILLERS
Air Coooled Liquid Chillers
Water Chillers/Heat Pumps
USER AND MAINTENANCE MANUAL
CWE CHILLERS
BY FRIULAIR

Editions Record
Code
Revision
Edition
Changes
7425MUM541
11
04/2018
Original instructions: ITALIAN
EN Translation of the original instructions

Dear Customer,
Thank you for the trust you have placed in us. Please read this manual carefully to obtain the best
performance from our product.
In order to avoid incorrect operating conditions and danger for the operators, it is essential that you
follow the instructions meticulously as well as the current accident -prevention laws in the country of
use.
Every chiller/heat pump in the CWE/HWE series is tested thoroughly before being packed.
At this stage, checks are made to verify that there are no manufacturing defects and that the machine
performs correctly the functions for which it was designed.
This manual must be kept for future reference and is an integral part of the chille r you have
purchased.
Due to continuous technical development, we reserve the right to make the necessary modifications
without any obligation to give advance notice.
Do not hesitate to contact us if you have any problems or need more information.
The product identification plate, located on the side of the chiller, contains all essential information
about the machine.
You will have to give this data to the manufacturer, or reseller, whenever you request information,
spare parts, etc., during the warranty period.
Removing or tampering with the identification plate will void the warranty.
Warranty conditions:
For 12 months from the commissioning date, and no more than 14 months from the shipping date, any
parts that were originally defective will be repaired or replaced at no charge. Expenses for transport
and travel, room and board for our technicians are excluded.
The warranty excludes any liability for direct or indirect damage to persons, animals and/or property
that are caused by incorrect use or inadequate maintenance and is exclusively limited to
manufacturing defects.
The right to service under the warranty is secondary to your faultless observance of the installation,
use and maintenance instructions in this manual.
The warranty will be voided immediately if the chiller is modified or tampered with, even slightly.
When requesting warranty service, you must provide the data on the product's identification plate.

CONTENTS
1SAFETY RULES ..................................................................................................................1
1.1 DEFINITIONS OF THE SYMBOLS USED ...........................................................................................................1
1.2 WARNINGS ............................................................................................................................................2
1.3 PROPER USE OF THE CHILLER .....................................................................................................................2
1.4 INSTRUCTIONS FOR USING EQUIPMENT UNDER PRESSURE CONFORMING TO PED DIRECTIVE 2014/68/EU............3
2OPERATION AND MAIN COMPONENTS.............................................................................4
2.1 REFRIGERANT CIRCUIT..............................................................................................................................4
2.2 WATER CIRCUIT ......................................................................................................................................5
2.3 FANS.....................................................................................................................................................5
2.4 CONDENSATION CONTROL ........................................................................................................................5
2.5 CONTROL OF THE WATER TEMPERATURE .....................................................................................................5
2.6 PROTECTING THE INTEGRITY OF THE MACHINE..............................................................................................5
2.7 CWE/HWE UNITS:IDENTIFICATION OF THE MAIN COMPONENTS....................................................................6
2.7.1 TANF –Non ferrous atmospheric water circuit ............................................................................................ 6
2.7.2 TP P3 - Pressurized water tank with single P3 pump .................................................................................... 6
2.8 SPARE PARTS ..........................................................................................................................................7
3INSTALLATION .................................................................................................................8
3.1 TRANSPORT............................................................................................................................................8
3.1.1 Handling the unit with a forklift truck or pallet jack ..................................................................................... 8
3.1.2 Lifting with belts and tubes........................................................................................................................... 8
3.2 STORAGE ...............................................................................................................................................8
3.3 PLACE OF INSTALLATION ...........................................................................................................................9
3.3.1 Installation spaces......................................................................................................................................... 9
3.4 WATER CONNECTIONS ...........................................................................................................................10
3.4.1 Recommended water system ..................................................................................................................... 11
3.4.2 Use of ethylene glycol as a winter anti-freeze............................................................................................ 11
3.4.3 Charging the water circuit........................................................................................................................... 11
3.5 ELECTRICAL CONNECTIONS......................................................................................................................12
3.5.1 Connecting a remote on/off switch and a remote alarm indicator light .................................................... 12
4PRELIMINARY CHECKS AND START-UP............................................................................ 13
4.1 PRELIMINARY CHECKS AND PREPARATION FOR THE FIRST START-UP ................................................................13
4.2 START-UP ............................................................................................................................................13
4.2.1 Start-up under critical conditions ............................................................................................................... 14
4.3 TURNING OFF THE UNIT ..........................................................................................................................14
5ELECTRONIC CONTROLLER.............................................................................................. 15
5.1 MAIN FUNCTIONS OF THE ELECTRONIC CONTROLLER BUTTONS AND MEANINGS OF THE ICONS ............................15
5.2 SWITCHING ON/OFF ..............................................................................................................................16
5.3 CONTROLLING WATER TEMPERATURE .......................................................................................................16
5.4 CHANGING THE COOLING SET POINT .........................................................................................................17
5.5 CHANGING THE HEATING SET POINT..........................................................................................................18
5.6 DISPLAY OF INPUTS AND OUTPUTS............................................................................................................18
5.7 ALARMS ..............................................................................................................................................18
5.7.1 Displaying and resetting alarms.................................................................................................................. 18
5.7.2 Table of alarm codes................................................................................................................................... 19

5.7.3 Displaying alarm history.............................................................................................................................. 19
5.8 PARAMETERS CHANGING ........................................................................................................................20
5.9 SETTING THE DATE AND TIME ..................................................................................................................20
5.10 LOW WATER TEMPERATURES (<32°F//0°C)..............................................................................................20
6SAFETY DEVICES............................................................................................................. 21
6.1 CALIBRATION OF THE SAFETY DEVICES AND TYPE OF REARM ..........................................................................21
6.2 REARMING THE HIGH-PRESSURE PRESSURE SWITCH .....................................................................................22
7OPERATING LIMITS ........................................................................................................ 23
7.1 MINIMUM WATER FLOW ........................................................................................................................24
8SEPR - SEASONAL ENERGY PERFORMANCE RATIO According to Commission Regulation (EU)
2016/2281 ....................................................................................................................... 25
9MAINTENANCE, INSPECTIONS AND PERIODIC CHECKS .................................................... 26
10 TROUBLESHOOTING....................................................................................................... 27
11 DISMANTLING THE CHILLER............................................................................................ 30
12 WATER DIAGRAMS ........................................................................................................ 31
13 REFRIGERANT DIAGRAMS .............................................................................................. 34
14 DIMENSIONAL DRAWINGS ............................................................................................. 36

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7425MUM541 Model: CWE/HWE - Use and Maintenance Manual Rev. 11
1
SAFETY RULES
1.1 DEFINITIONS OF THE SYMBOLS USED
Read this use and maintenance manual carefully before performing any repairs on the
chiller.
Warnings of a general character; risk of danger or possibility of damaging the machine,
pay particular attention to the phrase following this symbol.
Risk of electrical danger; the phrase highlights conditions that could be fatal. Follow the
instructions provided meticulously.
Risk of danger; component or system under pressure.
Risk of danger; component or system that can reach high temperatures during operation.
Risk of danger; it is absolutely forbidden to use water to extinguish fires near or on the
chiller.
Risk of danger; it is absolutely forbidden to operate the machine with the panel
open.
Service that can be performed by the machine’s operator, if qualified (1).
Water input connection point.
Water output connection point.
Dispose of each type of material in accordance with the requirements of the country of
use.
NOTE
Phrases to be emphasized that do not contain safety rules.

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7425MUM541 Model: CWE/HWE - Use and Maintenance Manual Rev. 11
This chiller has been carefully designed and constructed to be environmentally
friendly:
Refrigerants without CFC;
Expanded foam insulation without CFC;
Energy-saving techniques;
Reduced noise;
The chiller and its packing materials are recyclable.
In order not to hinder our efforts, the user is required to obey the simple ecological
warnings indicated by this symbol.
(1) These are persons with the experience, technical preparation and knowledge of standards and
regulations who are qualified to perform the necessary actions and able to recognize and avoid
possible dangers while handling, installing, using and maintaining the machine.
1.2 WARNINGS
Only qualified persons may use and maintain electrically-powered equipment.
Before commencing maintenance operations ensure no parts of the machine are
live and it cannot be re-connected to the electrical power supply.
These chillers contain R410A refrigerant fluids. Service of the refrigerant circuit must be
performed by specialized personnel using proper tools.
Any modifications to the machine or related operating parameters not previously
verified and authorized by the Manufacturer may be hazardous and will invalidate
the guarantee.
Do not use water to extinguish fires near or on the chiller.
1.3 PROPER USE OF THE CHILLER
CWE/HWE units are monobloc water chillers/heat pumps with air-condensation.
They are intended for use in industrial process or air-conditioning systems requiring chilled water.
Any other use is considered improper.
The manufacturer is not liable for damage resulting from inappropriate use; in all cases, the user is
liable for any resulting hazards.
Proper use requires conforming to the installation conditions and, in particular:
Power voltage and frequency;
Pressure, temperature and flow-capacity of the incoming water;
Surrounding temperature.
The chiller has been tested and completely assembled. The user must only make the connections to
other systems, as described in the chapters that follow.

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7425MUM541 Model: CWE/HWE - Use and Maintenance Manual Rev. 11
1.4 INSTRUCTIONS FOR USING EQUIPMENT UNDER PRESSURE CONFORMING TO
PED DIRECTIVE 2014/68/EU
The proper use of equipment under pressure is an essential prerequisite for ensuring safety.
To this end, the user must proceed as follows:
Use the equipment within the temperature range outlined in the operating limits on the
manufacturer's plate;
Do not solder on the exchangers or refrigerant fluid pipes;
Do not install the equipment in insufficiently ventilated rooms, areas expo sed to sources of
heat or near inflammable substances;
During operation, the equipment must not be subjected to vibrations that could cause fatigue
failures;
Keep the documentation attached to the equipment (user manual, declaration of conformity,
etc.) for future reference;
The maximum operating pressure shown on the manufacturer's plate must not be exceeded.
The user is responsible for fitting appropriate safety/control devices.

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7425MUM541 Model: CWE/HWE - Use and Maintenance Manual Rev. 11
2
OPERATION AND MAIN COMPONENTS
2.1 REFRIGERANT CIRCUIT
Operation of the CWE/HWE chillers/heat pumps is based on a vapour compression cycle implemented
within the chiller circuit and made up of the following components - evaporator, compressor,
condenser and thermostatic expansion valve.
Evaporator: this is a braze-welded plate exchanger that exchanges heat between water and a
refrigerant fluid without their coming into contact with each other. It consists of corrugated stainless
steel plates braze-welded to each other with copper. The evaporator is protected against a lack of
water by a differential pressure-switch and against the formation of ice by an anti-freeze system
managed by the chiller's electronic controller.
Compressor: this compresses the vapours coming from the evaporator and sends them to the
condenser at a higher pressure. The CWE/HWE series has scroll compressors which are characterized
by low noise and vibration levels. They are protected by thermal magnetic circuit breakers and a
temperature sensor inside the motor windings.
Condenser: heat exchanger with copper pipes and aluminum fins which enables heat exchange
between the refrigerant and the air. It condenses the refrigerant gas by transferring condensation heat
from the refrigerant gas to the air (which flows to the outside). As a result high pressure liquid
refrigerant is produced.
Thermostatic expansion valve: this reduces the pressure of the refrigerant liquid coming from the
condenser and sends it to the evaporator. This valve modulates the flow of refrigerant in such a way
as to maintain the constancy of the superheating of the gas exiting to the evaporator under its various
working conditions and, thus ensures that the flow of gas entering the compressor contains no liquid.
Thanks to these components, the vapour-compression cycle works as follows: the refrigerant liquid
evaporates in the evaporator, chilling the water; the refrigerant vapours are then aspirated from the
compressor, which compresses them and sends them to the condenser under high pressure; here,
thanks to a flow of forced air from the fans, the high-pressure refrigerant gas is cooled, making it
condensed and undercooled.
The flow of refrigerant liquid then passes through the lamination valve (thermostatic expansion
valve), which drastically reduces its pressure: the refrigerant liquid retu rns to the evaporator at a
reduced pressure where it again evaporates, taking heat from the water.
Heat pump operation: In addition to cooling water the heat pump models (HWE) also heat water.
This is made possible via a switchover valve which intercepts the hot high pressure gas produced by
the compressor and sends it to the plate exchanger (which the water flows through). Condensing the
refrigerant heats the water. The flow of condensed refrigerant then passes through the thermal
expansion valve, which reduces the pressure drastically - the reduced pressure liquid refrigerant enters
the finned tube exchanger (which the air flows through) where it can evaporate by drawing heat from
the outside air. The switchover valve intercepts the evaporated refrigerant and sends it for compressor
suction.
De-icing: When the heat pump is operating condensation may freeze on the external finned tube
exchanger (which acts as an evaporator in the heat pump mode) as a result of certain external air
conditions (e.g. high level of humidity). This layer of ice impedes heat exchange and must be
removed, therefore the machine switches operation mode from heat pump to chiller for a few minutes
when appropriate, sending the hot refrigerant to the external finned tube exchanger. The heat from the
hot refrigerant melts the ice. During this de-icing phase the water drained from the exchanger is
collected in the relevant tank and drained out of the machine.