FRIULAIR PURESTREAM CWB FC Operating instructions

WATER CHILLER
Model: CWB FC (Free Cooling)
User and Maintenance Manual
BY FRIULAIR
CHILLERS
PURESTREAM

Editions Record
Code
Revision
Edition
Notes
7425MUM661
02
09/2019
Original instructions: ENGLISH

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 directions meticulously as well as the current accident-prevention laws in
the country of use.
Each CWB FC chiller is rigorously tested before being packed.
This verifies 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 chiller 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.
Warranty conditions:
The warranty is valid for 12 months from the machine being powered-up and no longer than 14
months from the delivery date. Any part which is recognised as being faulty at source shall be
repaired or replaced free of charge. This does not include transport costs, travel, room and board
for technicians. 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.
Repair under warranty is subject to compliance with the installation, use and maintenance
instructions contained in the "User manual and maintenance."
The warranty is considered void if the product is modified or tampered with in any way. When
making a warranty request, please supply the information available in the product identification
label.

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 und. press. conforming to PED Directive 2014/68/EU.....3
2OPERATION AND MAIN COMPONENTS ............................................................4
2.1 Refrigerant circuit...................................................................................................................4
2.2 Water circuit...........................................................................................................................4
2.3 Free Cooling system: Working mode....................................................................................5
2.4 Fans .......................................................................................................................................5
2.5 Condensation control.............................................................................................................5
2.6 Control of the water temperature...........................................................................................5
2.7 Protecting the integrity of the machine..................................................................................5
2.8 Identification of the main components...................................................................................6
3INSTALLATION ....................................................................................................9
3.1 Transport................................................................................................................................9
3.1.1 Lifting unit with belts and positioning of leveling feet............................................................9
3.2 Storage.................................................................................................................................10
3.3 Place of installation..............................................................................................................11
3.3.1 Installation spaces...............................................................................................................11
3.4 Water connections...............................................................................................................12
3.4.1 Recommended water system..............................................................................................12
3.4.2 Use of ethylene glycol as a winter anti-freeze ....................................................................13
3.4.3 Charging the water circuit....................................................................................................14
3.5 Electrical connections..........................................................................................................14
3.5.1 Remote on/off switch and alarm indicators.........................................................................14
4PRELIMINARY CHECKS AND START-UP.........................................................15
4.1Preliminary checks and preparation for the first start-up....................................................15
4.2 Start-up ................................................................................................................................15
4.2.1 Start-up under critical conditions.........................................................................................16
4.3 Turning off the unit...............................................................................................................16
5ELECTRONIC CONTROLLER............................................................................17
5.1 Main functions of the electronic controller buttons and meanings of the icons..................18
5.2 Turning on and off................................................................................................................18
5.3 Changing the set point.........................................................................................................18
5.4 Changing the type of restart after a power failure...............................................................19
5.5 Changing the serial address (MODBUS and CAN)............................................................20
5.6 Display of inputs and outputs ..............................................................................................20
5.7 Display expansion valve working parameters.....................................................................22
5.8 Display software release of the electronic controller...........................................................23

5.9 Displaying the compressor and pump counters..................................................................23
5.10 Alarms..................................................................................................................................23
5.10.1 Table of alarm codes...........................................................................................................23
5.10.2 Displaying and resetting alarms..........................................................................................24
5.10.3 Displaying alarms history.....................................................................................................25
6TEMPERATURE REGULATION.........................................................................26
6.1 Factory type of regulation: Neutral zone control (chiller side) ............................................26
6.1.1 Neutral zone control: how it works ......................................................................................26
6.2 Low water temperatures (<32°F/0°C)..................................................................................26
6.3 Neutral zone regulation based on outlet water temperature (Standard)............................27
6.3.1 Recommended setting for operating with low water temperatures.....................................28
7SAFETY DEVICES..............................................................................................29
7.1 Calibration of the safety devices and type of rearm............................................................29
7.2 Resetting the high-pressure pressure switch......................................................................30
8OPERATING LIMITS...........................................................................................31
9MAINTENANCE, INSPECTIONS AND PERIODIC CHECKS..............................34
10 TROUBLESHOOTING ........................................................................................35
11 DISMANTLING THE CHILLER............................................................................39
12 WATER DIAGRAMS...........................................................................................40
13 REFRIGERANT CIRCUIT....................................................................................41
14 DIMENSIONAL DRAWINGS...............................................................................42

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7425MUM661 Model: CWB FC - Use and Maintenance Manual Rev02
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.

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NOTE
Phrases to be emphasized that do not contain safety rules.
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 authorised 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
CWB FC units are packaged water chillers 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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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 properly within the temperature limits shown in the operating limits
stated on the manufacturer’s name/data plate;
•Do not solder on the exchangers or refrigerant fluid pipes;
•Do not install the equipment in insufficiently ventilated rooms, areas ex
posed 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 working pressure stated on the manufacturer’s data plate must not be
exceeded. Prior to use, the user must fit safety/pressure relief devices.

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2
OPERATION AND MAIN COMPONENTS
2.1 REFRIGERANT CIRCUIT
CWB FC chillers use a vapour-compression cycle in a Refrigerant circuit that essentially
consists of the following components: evaporator, compressor, condenser and thermostatic
expansion valve.
Evaporator: this is a braise-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 braise-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. CWB FC chillers uses scroll compressors; they feature a
low level of vibration and noise; they are protected by magnetothermic circuit breakers and a
temperature sensor in the motor winding.
Condenser: this is a microchannel heat exchanger made entirely of aluminium that
exchanges heat between the refrigerant and the air; it condenses the refrigerant gas (which
flows inside the exchanger) transferring its condensation heat to the air (which flows outside);
this produces refrigerant liquid under high pressure.
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 sub cooled.
The flow of refrigerant liquid then passes through the lamination valve (thermostatic
expansion valve), which drastically reduces its pressure: the refrigerant liquid returns to the
evaporator at a reduced pressure where it again evaporates, taking heat from the water.
2.2 WATER CIRCUIT
A general water circuit mainly consists of: evaporator, pump, three way valve and free
cooling coils.
The water flows into the machine, the three way valve (in function of the difference of the
ambient temperature and the inlet water temperature) distribute the water flow into the free
cooling coils or into the evaporator directly.
When the water is chilled, it is drawn by the pump, which sends it to the user.
A differential pressure switch on the evaporator checks that the flow of water is sufficient and
stops the chiller compressors if the flow-is too low.
Automatic vent valves fitted on plumbing remove any air bubbles in the circuit.
A fine mesh metal filter ought to be fitted at the entrance to the machine in order to catch any
solid residues that could damage the evaporator.
A water gauge and safety valve should complete the water circuit.

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2.3 FREE COOLING SYSTEM:WORKING MODE
The Free cooling equipment allows to supply completely or partially the cooling capacity
produced by the chiller. The unit is equipped with two additional water coils and when the
external ambient temperature is at least 5°C less the water returning from the plant, the free
cooling coils can pre-cool or fully cool the water flow.
Free cooling operation provides an energy saving and this energy conservation increases as
the difference between the water to cool and the external ambient temperature increases.
There are three working mode:
•SUMMER MODE – FREE COOLING OFF: during the summer months and when the
ambient temperature is higher than the temperature of the water returning from the
plant, the CWB FC unit works like a traditional chiller;
•INTERMEDIATE MODE – FREE COOLING ON + CHILLER: when the temperature of
the ambient air is lower than the temperature returning from the plant, the CWB FC
works in the partial free cooling. Free cooling coils pre-cool the water flow and after
the chiller side cools the water flow to the desired outlet water temperature;
•WINTER MODE – 100% FREE COOLING: during the winter months and when the
ambient temperature is lower than the temperature of the water returning from the
plant, the CWB FC works 100% Free cooling mode. The water is completely cooled in
the water coils.
The three way valve grants the correct operation of the machine.
2.4 FANS
The fans force air through the condenser’s fins to remove the heat from the condensation of
the refrigerant gas, thus limiting the pressure inside the condenser.
CWB FC chillers use external-rotor axial fans with thermal protection inside the motor
winding.
2.5 CONDENSATION CONTROL
When the temperature of the surrounding air drops, the cooling capacity of the air flow is
significantly increased, causing the pressure inside the condenser to drop; in order to keep
this drop of the condensation pressure from falling below the tolerable limit for the good
functioning of the Refrigerant circuit, the fans slow their rotation, reducing the flow of air.
The speed is controlled by an electronic regulator based on the condensation pressure; this
allows the machine to operate properly even when the temperature of the outside air is low
(see Chapter 8 Operating Limits) and also maintains a low level of noise compered to its
nominal operating conditions.
2.6 CONTROL OF THE WATER TEMPERATURE
The purpose of the chiller is to maintain the temperature of the water produced within a
desired interval as the load on the system varies; this is handled by an electronic controller
and a temperature probe that turn the compressors on and off appropriately (see Chapter 6
Temperature Regulation)
2.7 PROTECTING THE INTEGRITY OF THE MACHINE
In addition to controlling the temperature, the electronic controller uses pressure switches,
thermostats and timers to prevent and handle situations that could compromise the integrity
of the machine (also see Chapter 7 Safety Devices).

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2.8 IDENTIFICATION OF THE MAIN COMPONENTS
1
Refrigerant safety valve
8
Compressor
2
High pressure switch
9
Suction temperature probe
3
High pressure transducer
10
Low pressure refrigerant gauge
4
Condenser
11
High pressure refrigerant gauge
5
Low pressure transducer
12
Water gauge
6
Liquid refrigerant solenoid valve
13
Air temperature probe
7
Refrigerant filter
14
Fan

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15
Liquid sight glass
19
Pump
16
Electronic thermostatic valve
20
Three way valve
17
Water differential pressure switch
21
Valve actuator
18
Evaporator

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22
Electrical panel cut-off switch
25
Water inlet
23
Electrical control panel
26
Water outlet
24
Power input cable openings
27
Free cooling coils drain

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3
INSTALLATION
3.1 TRANSPORT
The units are supplied on a wooden pallet and wrapped in a plastic film.
After checking that the packing is undamaged, position the unit near the installation site and
unpack it.
Always keep the chiller vertical: turning it upside down can irreparably damage
several parts of the unit.
Handle with care. Violent falls can cause irreparable damage. The units can be
handled using belts.
3.1.1 Lifting unit with belts and positioning of leveling feet
All units have lifting holes in the base.
Lock the belts so that they won't slip off during lifting (see figure).

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Install the leveling feet that are supplied with the machine and which are inside the electrical panel.
Please follow the assembly instructions reported into the User Manual. Without doing so, it will
avoid the warranty in case of breakages.
3.2 STORAGE
Protect the machine from bad weather, even if packed.
Always keep the chiller vertical, even when in storage.
Turning it upside down can irreparably damage several parts of the unit.
If not used, the chiller can be stored packed in an enclosed place, free of dust, with a
maximum temperature of 60°C//140°F and specific humidity of no higher than 90%.
The packing material is recyclable.
Dispose of each type of material in acco
rdance with the requirements in the
country of use.

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3.3 PLACE OF INSTALLATION
The CWB FC unit can be installed either inside or outside.
To determine the best place to install the unit, it is important to consider the following
aspects:
•The dimensions and source of the water pipes;
•The location of the power supply;
•The solidity of the support surface;
•Avoid any obstacles to the flow of the fan which could cause the recirculation of air to
the condenser;
•Avoid the possible reflection of sound waves: (do not install in narrow or tight spaces);
•Provide access for maintenance or repair (see paragraph 3.3.1 Installation spaces);
•The air temperatures in the area selected for installation (see Chapter 8 Operating
Limits).
Attention!If the machine is installed outside, it could find itself at a temperature
lower than 0°C//32°F , when stopped; the formation of ice could damage
the evaporator. If you do not intend to drain the
machine during the
winter, you must add anti-freeze to the water circuit (see paragraph 6.2
Low water temperatures (<32°F/0°C)).
3.3.1 Installation spaces
To ensure the good functioning of the unit and access for maintenance, you must respect the
minimum installation space shown in the figure in this paragraph [mm]/[in].
The exit of air from the fans must not be obstructed.
In any case, avoid all situations in which hot air exiting the unit, can be drawn directly to the
air intake of the machine.

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3.4 WATER CONNECTIONS
Connect the machine to the water pipes following the instructions located near its water
fittings (see figures).
Important! Install the mechanical water filter, provided with the machine, on its
input: scum and impurities can seriously damage the evaporator. Not doing so will
void the warranty in case of breakages.
We recommend an extraordinary cleaning of the mechanical water
filter after the machine has been running for the first week
(also see Chapter 9 Maintenance and periodic inspections).
3.4.1 Recommended water system
The standard equipment of a water circuit should include tank, pumps, expansion vessel,
safety valve, filter, shut-off taps.
In particular, we recommend that the water circuit also be equipped with:
•A mechanical filter and a check valve upstream from the charging tap;
•An air vent at the highest point of the plant;
•A drain tap in the lowest point of the plant;
•Manometers and thermometers at the machine’s water input and output to check its
functioning;
•Vibration damping joints on the pipes to avoid the transmission of vibration to the
plant;
•In the case of water circuits with considerable capacity, we recommend checking
whether it is necessary to supplement the expansion vessel already on the unit with
another additional one.
Water input to the chiller
Water exit from the chiller

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Attention! Never work with an open flame near or inside the unit when making
connections to the water system.
Important! If the machine charged with pure water, is stopped during the winter,
you drain water from the chiller (see paragraph 3.4.2) to avoid damage
due to ice.
Important! When charging water, purge air for circuit of free cooling coils (see
vent valve on image at page 8 – point 27). Plug definitel
y the vent
valve with the screw tap once the water circuit i
s filled (see picture
below).
3.4.2 Use of ethylene glycol as a winter anti-freeze
Instead of emptying the system in the winter, you can charge the system with a mixture of
water and a suitable percentage of ethylene glycol, chosen as a function of the lowest
expected temperature of the outside air.
Percentages of ethylene glycol recommended as a function
of the expected temperature of the outside air
Outside air temperature [°C]
0
-5
-10
-12
-15
-25
-30
Outside air temperature [°F]
32
23
14
10,2
5
-13
-22
Percentage of ethylene glycol [%]
10
15
20
25
30
40
50
Attention! Maximum concentration of ethylene glycol allowed: 50%. Anyway, for glycol
concentrations higher than 30%, contact our company's sales offices to make sure that
the mechanical seal and the pump motor are suitable for the type and concentration of
fluid loaded in the hydraulic system

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3.4.3 Charging the water circuit
•Check that the drain taps of the water tank are turned off;
•Open all the system’s vent valves;
•Open the system's shut-off devices;
•Ensure that no air is on the pump suction piping and on the pump itself (see picture on
the previous page);
•Start filling by slowly turning on the system's water-charging tap;
•When water starts coming out of the vent valves, close them and continue charging
until the manometer shows at least 1 bar;
•Check for any leaks by looking at the manometer and inspecting the circuit.
3.5 ELECTRICAL CONNECTIONS
The machines must be connected to the electricity following the electrical diagram
and conforming to the current laws and regulations in the place of installation.
•The voltage, frequency and number of phases must conform to the data shown on the
machine's identification plate;
•The power supply voltage must not vary by more than ±10% from its nominal value;
•The frequency must not vary by more than ±1% from its nominal value (±2% for brief
periods);
•The imbalance between power phases must be <2%;
•Upstream from the electrical panel, insta
ll a differential switch (IDn=0,03A) (main
power switch) and slow-
blow fuses with the specifications shown on the electrical
diagram.
Use wires of the section shown on the electrical diagram of the unit.
Attention! Never change the internal electrical connections, as the warranty will be
immediately voided.
Important! Screw the wires solidly to the terminal strip of the cut-off switch and
lock the wire with a cable-gland.
Important! Make the cable entering the machine enters the cable-gland from
below: this prevents rain from dripping inside the machine
Important! The earth connection is obligatory: connect the earth wire to the
terminal provided in the electrical panel.
The ground wire must be longer than the other wires so that it will be the last one to be pulled
if the device holding the cable loosens.
3.5.1 Remote on/off switch and alarm indicators
On the CWB FC’s terminal block are indicated connections to remote ON/OFF switch and
general alarm signal. Please, refer to wiring diagram.

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4
PRELIMINARY CHECKS AND START-UP
4.1 PRELIMINARY CHECKS AND PREPARATION FOR THE FIRST START-UP
Important! At start-up, it is necessary to give off air from inlet water pipe using
the air relief valve (see paragraph 3.4.1 Recommen
ded water
system).
Before starting up the unit, do the following:
•Check that the water shut-off valves are open;
•Check that the pressure shown on water gauge, is at least 1 bar 7/15 PSI;
•Check that the surrounding temperature is in the range for the machine to function
(see Chapter 8 Operating Limits);
•Check that the CWB FC chiller’s main switch is open (O position);
•Check that the CWB FC chillers’ Local/O/Remote switch on the electrical panel door is
in the “O” position;
•Check that the mains voltage matches the voltage on the machine's identification plate
with a tolerance of ±10%;
•Close the main power supply switch;
•Turn on one pump of the plant (if needed);
•Close the main switch on the chiller electrical panel (I position).
This puts the machines under voltage without starting it up.
Attention! Apply voltage to the machine at least two hours before start-up to give
the heating elements in the compressor housing time to he
at the oil
inside.
The heating elements limit the quantity of refrigerant dissolved in the oil and prevent the oil
from migrating when the compressors start.
Before start-up, check that the temperature of the lower part of the compressors is at least
10÷15°C//18÷28°F higher than the surrounding temperature.
4.2 START-UP
To proceed to start-up:
•Put the “Local/O/Remote” switch on “Local” position;
•Turn the units on by holding down the “UP” button on the electronic controller for
five seconds;
Will appear: