HL HL-i Series Manual

USE AND
MAINTENANCE
HANDBOOK
HL-i Series
This manual has been prepared in compliance with CE certification and it is an essential part to every HL Cooling unit
HL (Europe) Ltd 92 Craven Park Road, London, NW10 4AG United Kingdom
Tel: [phone] Fax: [phone] www.hl-cooling.com [e-mail]
Company registration number: 5285108. Registered office: 270 Sutton Road Southend-on-Sea Essex SS2 5ET UK

INDEX
SAFETY
SAFETY MARKS CONTAINED IN THESE INSTRUCTIONS
DANGERS FROM NON OBSERVANCE OF SAFETY REFERENCES…..................…1
ACTIVE SAFETY …...................................................................................................… 1
PASSIVE SAFETY …..................................................................................................... 1
DECLARATION OF CONFORMITY ….....................................................................… 2
GENERAL INFORMATION …...............................................................................… 3
NAME AND MODEL …................................................................................................. 3
WORKING CONDITION …........................................................................................... 3
GENERAL SIGN INFORMATION …............................................................................ 3
TRANSPORTATION ….............................................................................................…4
INSPECTION …............................................................................................................ 4
TRANSPORT …............................................................................................................ 4
INSTALLATION …...................................................................................................... 4
POSITIONING …............................................................................................................ 4
HYDRAULIC CONNECTIONS …................................................................................. 4
ELECTRICAL CONNECTIONS …................................................................................ 5
WORKING LIMITS ….................................................................................................. 5
MAINTENANCE…......................................................................................................... 6
TYPE AND FREQUENCY OF ROUTINE MAINTENANCE ….................................. 6
MAINTENANCE OF THE COOLING CIRCUIT …...................................................6
DISMANTLING ….......................................................................................................... 7
EMERGENCIES…..........................................................................................................8
MAIN COMPONENTS …........................................ ................... ....................... 8
Appendix A COMMISIONING REPORT ……………………......…………….......………………..… i
Appendix B OVERALL DIMENSION ……………………………………………....…….....………. ii
Appendix C WIRING DIAGRAMS ……………..………………………….…………………........…vi
Appendix D TROUBLESHOOTING …………......................................................................... xvi
…..................................…………………………………………………..............…… 1
….............................… 1
.. ....
Appendix E ALARM ERROR CODE.........................................................................................xviii

THIS MANUAL REFERS TO THE FOLLOWING UNIT:
UNIT
OPTIONAL
SERIAL No.
WIRING DIAGRAM No.
ATTENTION
HL Cooling units are only intended for professional uses.
The instructions contained herein and attached to the unit are to be strictly complied with whenever
the unit is installed or serviced.
Any operation on this unit must be carried out by skilled personnel having themselves made fully
conversant with these instructions.
The guarantee for this unit shall only be valid as long as the instructions contained herein are duly
complied with.
This manual is intended for end users only in case of operations which can be carried out having the
panels closed (fixed guards are not removed).
Data on this catalogue are only guideline data. HL (Europe) Ltd reserves the right to make changes
without prior notice.
Before any operation inside the unit, turn OFF the main power safety switch; then turn OFF the unit
main switch SW0.
Operations when power is still supplied to the electrical board and the panel is open are allowed to
our skilled technicians only, who have been duly trained. In such conditions some of the system
functions are not present.
ATTENTION
Fill the Commissioning Report enclosed to the handbook during the first
start up and send a copy to HL (Europe) Ltd (Service Dept.) for warranty validity.
(see appendix "A")

SAFETY
These instructions contain basic references to correctly and safely use and service our units.
Besides general safety precautions, all specially marked points must be duly observed.
SAFETY MARKS CONTAINED IN THESE INSTRUCTIONS
This manual contains some information and references which are marked by symbols. If the safety
precautions marked by the symbol "danger from general cause" are not complied with injuries to
persons may be caused.
If the safety precautions marked by the symbol "danger from electrical causes" are not complied
with injuries to persons or damages to things may be caused.
If the safety precautions highlighted by the word
are not complied with, damages to the unit or to itsfunctions may be caused.
DANGERS FROM NON OBSERVANCE OF SAFETY REFERENCES
Non-observance of safety references may cause bodily harm to persons or damage to the equipment.
Failure to comply with safety references shall invalidate warranty and/or damage claims.
Non-compliance could have the following dangerous consequences:
-Failure of important system functions;
-Risk for the operators' safety due to electrical and/or mechanical causes.
ACTIVE SAFETY
The operating logic of our units is controlled by a microprocessor.
This microprocessor also manages faults and malfunctions (if any) of every part of the unit, thus
ensuring no risks are run by machinery, persons and the environment.
PASSIVE SAFETY
Our units are completely enclosed by panels, which prevent access to dangerous areas from outside,
including fans which are equipped with suitable protection grilles.
1

DECLARATION EC OF CONFORMITY
Standards applied: EN 50366:2003+A1:2006
EN55014-1:2006
EN55014-2:1997+A2:2008
EN60335-1:2002+A13:2008
EN60335-2-40:2003+A1:2006
EN61000-3-2:2006
EN61000-3-3:2008
Report No: Uk091202049
Uk091201050
Uk091201051
Uk091201052
Uk091201053
Uk091201054
4
2

HL i50
Company Name Cooling Capacity ( approx.: 50KW )
GENERAL INFORMATION
HL-i Series Chillers are available in different sizes and different cooling capacities ranging
from 3KW to 180KW.
HL-i Series-Standard Air Cooled Water Chiller with Axial Fans
These chillers are supplied complete with:
Control microprocessor;
Water fill & vent tank;
Special coated condenser fins for longer life;
Integral stainless steel tank;
Adjustable LP switch;
Centrifugal pump-standard 3 bar(optional 5 bar);
Heavy duties condenser fan;
Reliable compressor.
NAME AND MODEL
The machines described in this manual are called "Air Cooled Water Chillers".
Model Range Code Guide
Example: HL-i50
WORKING CONDITION
1). Ambient temperature: From -10°C to 43°C.
2). Water temperature: From -5°C to 35°C (LP Switch should be changed if it is below 0°C).
GENERAL SIGN INFORMATION
─
─
─
─
─
─
─
─
Cooled water inlet Cooled water outlet
Indications for lifting
the unit
Water drainage point from
the
machine
Water filling point Cooling air flow
Direction of the refrigerant
gas and water circuit flow
Direction of pump rotation
( if
installed) and of fan
rotation
Electric shock risk Air vent
3

4
TRANSPORTATION
INSPECTION
All units are packed with protective materials in order to safeguard the structure and the panels.
Customer is therefore required to exam the exterior package upon delivery.
Any damages shall be immediately notified in details on the carrier's delivery document, and shall report to HL
(Europe) Ltd. in writing.
TRANSPORT
To left and move the unit, please refer to – Overall Dimension Diagram for details.
CAUTION: Do not stack the unit even if they are packed.
INSTALLATION
POSITIONING
The unit is designed to be installed both indoor and outdoor.
The following consideration should be taking into account when choose a suitable location
─Length and origin of hydraulic line;
─Length and origin of the power supply;
─Free flow of air in-take;
─Easy service access;
─Strong even surface.
CAUTION: Making sure the discharged air does NOT blow back into the inlet. In some case, vibration dampers
may be applied to minimize the vibration been transmitted to the lower level.
HYDRAULIC CONNECTIONS
CAUTION: The inlet and outlet connections are NOT interchangeable, they must be connected as instructed in the
overall dimension data
The following suggestions should be considered when connect to the application system:
─Use vibration-damping joints to prevent vibration transmission and allow thermal expansion;
─Apply a shutoff valves on both inlet and outlet;
─Apply a By-pass valve.
IMPORTANT:
─When connection is completed, check for any water leakages;
─Drain the system thoroughly, making sure there is no air in the water circuit as it may damage the pump.
.
Appendix “B”
(see Appendix "B")

5
ELECTRICAL CONNECTIONS
Check power supply against name plate data on the unit (voltage, frequency, phase number). Relevant regulations
must be strictly adhered to.
Use a power supply cable whose section shall not be smaller than the value indicated in the wiring diagrams
and whose length shall be moderate to ensure there won't be excessive voltage drops.
Upstream cable shall be protected by means of an automatic circuit breaker or of three fuses whose nominal current
is equal to that of the unit's main disconnecting switch inside the unit's electric panel.
The breaking power of these elements must be at least equal to the maximum short-circuit current which is
generated if a failure occurs in the place where the unit is installed.
(see
appendix “C”)
WORKING LIMITS
The water flow rate supplied by the unit is related to a 5°C temperature jump between input and
output which depends on the supplied cooling power. The maximum allowable flow rate entails a 3°C
jump ( higher flow rates may cause too high evaporating temperatures and damage the evaporator ).
The minimum allowable flow rate entails a 7°C jump (lower flow rates may cause too low evaporating
temperatures, as a consequence the safety devices would be tripped and the unit would stop).
COOL WATER TEMPERATURE:
The minimum outlet temperature of evaporator is 5°C not included "brine" versions (*); the
maximum inlet temperature to the evaporator is 30°C.
(*): Operation with low- temperature water:
If the cool water temperature is lower than 4°C (out of the evaporator) a water-ethyl glycol mixture
should be used (see table below).The antifreeze thermostat(always 3-5°C above the mixture freezing
point), the operating thermostat and the set point (4°C above the desired water temperature out of the
evaporator) must also be set to new values.
OPERATION WITH WATER-ETHYL GLYCOL MIXTURE
DESCRIPTION PERCENTAGE OF ETHYL-GLYCOL OUT OF MIXTURE
WEIGHT
5% 10% 15% 20% 25% 30% 35% 40%
FREEZING
TEMPERATURE -2.1℃ -4.5℃ -7℃ -10℃ -13℃ -17℃ -21℃ -25℃

6
EXTERNAL AIR TEMPRATURE:
To ensure the unit can properly perform cooling, the external air temperature must be between -15°C and 40°C. For
different requirements please contact our Engineering Division.
NOTE: Using the unit improperly forthwith voids the guarantee; moreover it may cause unit failures and the
tripping of safety devices
NOTE: If the unit is installed outdoors, it is recommended that a min. 15% of glycol is added into the water circuit..
MAINTENANCE
IMPORTANT: BEFORE ANY OPERATION INSIDE THE UNIT TURN OFF THE MAIN SWITCH UPSTREAM
THE UNIT POWER LINE. THEN OPEN THE FRONT PANEL AND TURN OFF THE UNIT MAIN SWITCH TOO.
IMPORTANT: ONLY OUR TRAINED TECHNICIANS ARE DULY QUALIFIED TO SERVICE THE UNIT
WHEN POWER IS SUPPLIED TO THE ELECTRICAL BOARD AND THE PANEL IS OPEN. IN THESE
CONDITIONS SOME OF THE SYSTEM FUNCTIONS ARE NOT PRESENT.
TYPE AND FREQUENCY OF ROUTINE MAINTENANCE
Periodical maintenance is a good practice to check if the unit works properly.
Please note that these services, including possible maintenance operations, should be carried out by qualified
personnel only.
Every month:
─Check if the electrical terminals on the electric board and on the terminal boxes of the various electric parts are
correctly clamped;
─Check if the contacts of the remote control switches are clean and in sound conditions (if necessary, replace
them);
─Check if the water circuit is uniformly filled (no air inside of it);
─Check if the water differential pressure switch operates correctly;
─Clean fins of condensing coil by blowing compressed air or, if necessary, flushing them with water (operate in the
opposite direction with respect to airflow);
─Check if the defrost procedure is correctly performed.
If, after a few working hours, the unit makes anomalous noises an extraordinary check shall be carried out to detect
and eliminate their causes.
MAINTENANCE OF THE COOLING CIRCUIT
IMPORTANT: During any operation requiring the cooling circuit to be exhausted, it is necessary, to ensure
environmental safety, that the gas is collected into a proper receiver.
After the cooling circuit is repaired, carry out the following operations:
─Tightness test;
─Cooling system draining and drying;
─Refrigerant charge.

7
TIGHTNESS TEST
Fill the cooling circuit with gaseous R407C and reach a 1 bar pressure. Then add nitrogen through bombs equipped
with a reducing valve and reach a 15 bar pressure. Check leaks with the leak detector. If leaks are detected exhaust
the cooling circuit before welding (with copper-phosphor alloy and 2% silver).
It is important that the cooling system is completely exhausted before welding, to prevent explosions. Never
use oxygen as a substitute of nitrogen, otherwise explosions might occur.
COOLING CIRCUIT DRAINING AND DRYING
For a good vacuum condition use a suitable pump (1.4 mbar absolute pressure, 30 l/min. capacity). When the circuit
is opened for a very short time, with this pump you normally need only one vacuum operation to reach the absolute
pressure of 1.4 mbar.
If such a vacuum pump is not available, or if the circuit remains open for a long time, we strongly recommend that
you follow the three-fold pumping method.
Such method is also advisable if moisture is present in the circuit.
The vacuum pump must be connected to the intake openings.
Comply with the following procedure:
─Evacuate the circuit up to a 35 mbar absolute pressure at least, then fill the cooling circuit with R407 C and reach
an about 1 bar pressure;
─Repeat the above described operation and reach an absolute pressure of 35 mbar;
─Repeat the above described procedure a third time and reach an absolute pressure which should be as low as
possible.
REFRIGERANT CHARGE
Always follow this procedure:
─Connect the refrigerant bomb to the 1/4” SAE male intake on the liquid line, blow out some gas to exhaust air from
the interconnection tube;
─Capsize the bomb and fill the circuit with liquid refrigerant: fill 75% of total charge;
─Now connect it to the intake on the suction line and, holding the bomb upright, fill the line completely until in the
chiller the temperature of the liquid tube, before the filter, is 7-8°C lower (or 4°C lower in case of heat pumps) than
the °C temperature read on the R407C pressure gauge on the distribution tube.
DISMANTLING
When the unit is to be dismantled, drain the cooling circuit and collect the gas through a suitable receiver.
This operation ensures safety to persons and environment.
IMPORTANT: DO NOT DISPOSE OF GAS CONTAINED IN THE COOLING CIRCUIT IMPROPERLY
FOR ANY REASON.
When the unit is dismantled or the compressor is replaced carefully pour compressor's oil into a suitable
receiver and send it to a specialised centre for oil disposal.
IMPORTANT: DO NOT DISPOSE OF COMPRESSOR OIL IMPROPERLY FOR ANY REASON.

8
EMERGENCIES
By:
Floods: Immediately cut out the automatic circuit breaker that is located upstream the power supply line to
the unit and turn off the water pump (if it is part of the hydraulic system). Then repair the defective part of the
water circuit.
Fire: Immediately cut out the automatic circuit breaker which is located upstream the power supply line to
the unit and use a powder-based or CO -based fire extinguishing product.
2
MAIN COMPONENTS
PANELS AND FRAME
IMPORTANT: Panels (fixed guards) enclose potentially dangerous areas in case of failure or damage; before they
are removed disconnect the unit power supply from the main switch and turn OFF the water inlet supply.
The panels enclosing the various parts of the unit are made up of painted galvanised steel plate.
The technical compartment is closed. It contains the compressors and the main components of the unit.
COMPRESSOR
A highly reliable compressor with high-efficiency in performance, protected by an internal thermal overload.
COATED CONDENSER FINS
The aluminium fins on the condenser are coated with special anti-corrosion material ensuring the endurance of the
condenser.
INTEGRAL STAINLESS STEEL WATER TANK
The high volume integral stainless steel tank help maintaining an optimum water temperature to minimise the
compressor starts for reaching a longer compressor life.
AXAIL FANS
Axial fans are directly coupled to an electric 8-6 pole motor with overload protection, electronic balancing, and
blades with low-sound-level wing contour and complete with a special air conveyor and protection grilles.
IMPORTANT:
─The protection grille for fans is a fixed guard enclosing a risk zone of the unit;
─ Do not remove it, replace it if damaged.

9
CAREL Controller
It is the same size as a normal thermostat, for the complete management of chillers and heat pumps: it
can control air-air, air-water, water-water and condensing units. The user manual of this controller is
also supplied to users with this manual.
Display
The display feature 3 digits, with the display of the decimal point between -99.9 to 99.9.
Outside of its range of measurement, the value is automatically displayed without the decimal (even
if internally the unit still operates considering the decimal part).
In normal operation, the value displayed corresponds to the temperature read by probe B1, that is , the
evaporator water inlet temperature (for water chillers) or the ambient air temperature for direct
expansion units.
The parameters are divided into 4 different types, according to their level of access by the user
(password) and their function.
For each level, only the access to the parameters of the same of lower lever can be set. This means that
through the "factory" password, accessing the menu “levels” ( L-P ), it is possible to set the desired
level for each parameter.
2
For detailed parameter setting, please refer to the CAREL μC SE User Manual attached with every
unit.
Start up
1) Turn the main switch SW0 to “ON”,
The display shown as:

10
2) Press and hold for 5 seconds, then wait about 3 minutes, the display shown as:
Standby
Press and hold for 5 seconds, the display shown as:
Shut Down
1) Press and hold for 5 seconds;
2) Turn the main switch SW0 to “OFF”.
1) Turn the swo to “ON” → →
How to change water outlet cooling set point (r01)

11
Repeat steps as r01, select r02, and change the set point accordingly.
How to change water outlet different set point (r02)
How to change antifreeze alarm set point (A01)
Repeat steps as r01, select A01, and change the set point accordingly.

13
i
Commissioning Report
Appendix A
Customer
Address
Post code Product
Make
Model
Serial No:
PRELIMINARY CHECKS (√ ) if checked
1) Positioning -----surface / access 6) Water system connection
2) Adequate ventilation to condenser 7) Isolating valves fitted
3) Power connection 8) Glycol added
4) Phase rotation 9) Refrigerant leak test
5) Load available 10) System filled and air vented
Start up Evaporator
1) Control display light up 1) Glycol mixture %
2) Pump ON 2) Leaving Temperature °c
3) Compressor ON 3) Return temperature °c
4) Condenser Fan ON 4) Water pressure in (bar)
5) Water pressure out (bar)
Control settings 6) Pressure drop (bar)
1), Cooling setting point ( r01) °c 7) Flow switch operation
2), Cooling differiential point ( r02 ) °c 8) Low level sensor
Electrical system Condenser
1) Main supply voltage 1) Fin coil condiction
2) Control circuit voltage 2) Filter condition
3) Compressor running Amps 3) Condenser fan cut in at (bar)
4) Compressor Overload setting at 4) Condenser fan cut out at (bar)
5) Pump running Amps
6) Pump Overload setting at Remarks:
7) Condenser fan running Amps
8) Condenser fan overload setting at
Refrigeration circuit
1) Liquid line sight glass
2) Oil level
3) Refrigeration charge
4) Suction pressure at (bar)
5) Discharge pressure at (bar)
6) Antifreeze cut out point at °c
7) High pressure cut out at (bar)
8) Low pressure cut out at (bar)
Installed by:
Company Print name
Address Signed
post code Date
Commissioned by:
Company Print name
Address Signed
post code Date
Site address
(if different)

Appendix B
14.7
1). HL-i3 & HL-i5
Overall Dimension
OVERALL DIMENSION
13
ii

2). HL-i8 Overall Dimension
13
iii

MODEL I J K L M N ΦHLOES O~P Q AA BB
10 500 389 74.5 894 157 45 8.5 3/4” 600 500 1000
15~20 508 590 76.5 1001 157.5 44.5 8.5 1” 600 500 1000
30 567 590 76.5 1560 159.5 46.5 12 1.1/2” 900 500 1000
40~50 620 590 76.5 1560 159.5 46.5 12 1.1/2” 900 500 1000
55 620 590 76.5 1760 159.5 46.5 12 1.1/2” 900 500 1000
70~105 676 710 91 2120 161 49 12 2” 900 1000 1500
MODEL A B C C D E F G H NO.OF FAN
10 538 1096 1219 1099 165 105 148 328 506 1
15~20 743 1203 1412 1220 265 107 150 355 600 1
30 743 1766 1415 1217 228 130 150 400 653 1
40~50 743 1766 1409 1217 248 124 150 400 653 2
55 743 1966 1519 1220 248 124 150 400 715 2
70 892 2330 2055 1770 295 150 155 435 715 2
105 892 2330 2055 1770 295 150 155 435 715 2
3). HL-i10 to HL - i105 Overall Dimension
iv

E.2 OVERALL DIMENSION
4) . HL-i150 & HL
-i180 Overall Dimension
v

TROUBLESHOOTING
Appendix D
TROUBLE PROBABLE CAUSE POSSIBLE CURE
Defective connection or open contacts Check voltage and close contacts
The unit doesn't start up Press and hold
for 5 seconds
Compress. delay timer Wait for set delay time
Safety device response is missing
The unit alarms Check for the Error Code and do the
relevant cure
A )
The unit doesn't
start up
Wrong parameters setting Reset
Burned or seized compressor Replace compressor
Compressor remote control switch is de-
energised
Check voltage at compressor coil's ends and
check out for coil continuity
Power circuit open Try to find out the reason why protection is
activated close compressor's circuit
The unit alarms See point A
B )
Compressor
doesn't start
Compressor’s thermal overload circuit
breaker acts Reset
C )
Compressor
starts and stops
repeatedly
Control temperature return diffirence setting
is too small
Raise the return diffirence setting (“r02”
parameter)
Pressure switch out of order Check and replace
Excessive refrigerant charge Recover excessive gas
Clogged air condenser Too limited air
capacity Clean with compressed air or water jet
Condenser fans are not working See point F
Condenser fans rotate in wrong direction See Electric Connections paragraph
D )
Compressor
doesn't start
Because the
max. pressure
switch has been
actuated (HP1
or HP2 alarm)
Ambient air temperature is too high
Reduce ambient temperature within design
limits, for example by increasing local
ventilation.
Pressure switch out of order Check and replace
Lack of refrigerant Call a qualified refrigeration engineer to
check for leaks and replenish refrigerant
Water outlet sensor probe sets too low so that
the water freezes Raise the set value or change the LP Switch
Water pump doesn’t work Check for the water pump
Water flow isn’t enough Check for whether the water filter is dirty
or clogged or not
Clogged freon filter Check and replace
E )
Compressor
does not start
because the
min. pressure
switch has been
actuated
Thermostatic expansion valve is not working
correctly Check, clean or, if necessary, replace
v
xi