Itelco-Clima CLS User manual

CLS/CLC/CLH
English Italiano Français Deutsch Español
Air-Cooled Water Chillers and Heat Pumps
Refrigeratori d’Acqua e Pompa di Calore Raffreddati ad Aria
Refroidisseurs d’Eau et Pompe à Chaleur Refroidis à l’Air
Luftgekühlte Flüssigkeitskühler und Wärmepumpen
Enfriadores de Agua y Bomba de Calor Condensadas con Aire
40 kW
150 kW
41 kW
131 kW
IOM 04 CLS/CLH I N
Code / Codice / Code / Teile-Nr. / Código 035B09043-000
Supersedes and Replaces / Annulla e sostituisce / Annule et remplace / Ersetzt und hebt auf / Anula y
sustituye: N/A / Nulla / Rien / Entfällt / Ninguna
"Notified Body No. 1115 / Organismo Notificato N° 1115 / Organisme Notifié N° 1115 /
Benannte Zertifizierungsstelle Nr.1115 / Organismo Notificado N° 1115 ”
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Installation and Maintenance Instructions
Istruzioni per l’Installazione e per la Manutenzione
Instructions pour l’Installation et pour la Maintenance
Installations- und Wartungsanleitung
Instrucciones para la Instalación y para el Mantenimiento
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Page 1
Table of contents
English
1 FOREWORD
1.1 Introduction 3
1.2 Warranty 3
1.3 Emergency stop/Normal stop 3
1.4 An introduction to this manual 3
2 SAFETY
2.1 Foreword 4
2.2 Definitions 4
2.3 Access to the unit 5
2.4 General precautions 5
2.5 Precautions against residual risks 5
2.6 Precautions during maintenance
operations 6
2.7 Safety labels 7
2.8 Safety regulations 9
3 TRANSPORT, LIFTING
AND POSITIONING
3.1 Inspection 12
3.2 Lifting 12
3.3 Anchoring 13
3.4 Storage 13
4 INSTALLATION
4.1 Positioning of the unit 14
4.2 Installation of Spring Shock
Absorbers 14
4.3 External hydraulic circuit 15
4.4 Hydraulic connection 16
4.5 Draining the Defrosting
Waste Water
(for heat pump unit only) 16
4.6 Power supply 16
4.7 Electrical connections 17
5 START-UP
5.1 Preliminary check 19
5.2 Start-up 19
5.3 Checking the operation 20
5.4 Delivery to the customer 20
6 CONTROL
6.1 General information 21
6.2 Control system 21
6.3 Display 22
6.4 Start-up 23
6.5 Switching the working temperature 23
6.6 Main alarms 24
7 GENERAL DESCRIPTION
7.1 Introduction 25
7.2 General specifications 25
7.3 Compressors 25
7.4 Refrigeration circuits 25
7.5 Water-type heat exchanger 26
7.6 Air-type heat exchanger 26
7.7 Fans 26
7.8 Power supply and control system 28
7.9 Accessories 28
8 TECHNICAL DATA
8.1 Pressure drops in the evaporator 29
8.2 Technical Data 30
8.3 Electrical data 50
8.4 Position of shock absorbers and
weight distribution on supports 62
8.5 Overall dimensions 69
8.6 Service spaces 74
Table of contents
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Page 2
Table of contents
9 MAINTENANCE
9.1 General requirements 75
9.2 Planned maintenance 75
9.3 Refrigerant charge 76
9.4 Compressor 76
9.5 Condenser 76
9.6 Fans 76
9.7 Dehydrating filter 77
9.8 Sight glass 77
9.9 Thermostatic expansion valve 77
9.10 Evaporator 77
10 TROUBLESHOOTING 78
11 SPARE PARTS
11.1 Spare parts list 80
11.2 Oil for compressors 80
11.3 Wiring diagram 80
12 DISMANTLING, DEMOLITION
AND SCRAPPING
12.1 Generalities 81
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Page 3
Foreword
English
1 FOREWORD
1.1 Introduction
Itelco-Clima units, manufactured to state-of-the-art de-
sign and implementation standards, ensure top per-
formance, reliability and fitness to any type of air-
conditioning systems.
These units are designed for cooling water or gly-
coled water (and for water heating in heat pump
models) and are unfit for any purposes other than
those specified in this manual.
This manual includes all the information required for
a proper installation of the units, as well as the rele-
vant operating and maintenance instructions.
It is therefore recommended to read this manual
carefully before installation or any operation on the
machine. The chiller installation and maintenance
must be carried out by skilled personnel only (where
possible, by one of Itelco-Clima’s Authorised Service
Centers).
The manufacturer may not be held liable for any
damage to people or property caused by improper
installation, start-up and/or improper use of the unit
and/or failure to implement the procedures and in-
structions included in this manual.
1.2 Warranty
These units are delivered complete, tested and ready
for being operated. Any form of warranty will be-
come null and void in the event that the appliance is
modified without Itelco-Clima’s preliminary written
authorisation.
This warranty shall apply providing that the installa-
tion instructions have been complied with (either is-
sued by Itelco-Clima, or deriving from the current
practice), and the Form 1 (“Start-up”) has been filled-
in and mailed to Itelco-Clima (attn. After-Sales Ser-
vice).
In order for this warranty to be valid, the following
conditions shall be met:
hThe machine must be operated only by skilled per-
sonnel from Itelco-Clima’s Authorised After-Sales
Service.
hMaintenance must be performed only by skilled
personnel - from one of Itelco-Clima’s Authorised
After-Sales Centers.
hUse only original Itelco-Clima spare parts.
hCarry out all the planned maintenance provided
for by this manual in a timely and proper way.
Failure to comply with any of these conditions will
automatically void the warranty.
1.3 Emergency stop / Normal stop
The emergency stop of the unit can be enabled using
the master switch on the control panel (move down
the lever).
For a normal stop, press the relevant push-buttons.
To restart the appliance, follow the procedure de-
tailed in this manual.
1.4 An introduction to the manual
For safety reasons, it is imperative to follow the in-
structions given in this manual. In case of any dam-
age caused by non-compliance with these instruc-
tions, the warranty will immediately become null and
void.
Conventions used throughout the manual:
The Danger sign recalls your attention to a
certain procedure or practice which, if not
followed, may result in serious damage to
people and property.
The Warning sign precedes those proce-
dures that, if not followed, may result in seri-
ous damage to the appliance.
The Notes contain important observations.
The Useful Tips provide valuable informa-
tion that optimises the efficiency of the ap-
pliance.
This manual and its contents, as well as the docu-
mentation which accompanies the unit, are and re-
main the property of Itelco-Clima, which reserves
any and all rights thereon. This manual may not be
copied, in whole or in part, without Itelco-Clima’s
written authorization.
USEFUL TIPS
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Page 4
Safety
2 SAFETY
2.1 Foreword
These units must be installed in conformity with the
provisions of Machinery Directive 98/37/EC, Low
Voltage Directive 73/23/EC, Pressure Vessels Direc-
tive 97/23/EC, Electromagnetic Interference Direc-
tive 89/336/EC, as well as with other regulations
applicable in the country of installation. If these pro-
visions are not complied with, the unit must not be
operated.
The unit must be grounded, and no installa-
tion and/or maintenance operations may
be carried out before deenergising the elec-
trical panel of the unit.
Failure to respect the safety measures mentioned
above may result in electrocution hazard and fire in
the presence of any short-circuits.
Inside the heat exchangers, the compres-
sors and the refrigeration lines, this unit
contains liquid and gaseous refrigerant un-
der pressure. The release of this refrigerant
may be dangerous and cause injuries.
The units are not designed to be operated
with natural refrigerants, such as hydrocar-
bons. Itelco-Clima may not be held liable
for any problems deriving from the replace-
ment of original refrigerant or the introduc-
tion of hydrocarbons.
Itelco-Clima units are designed and manufactured
according to the requirements of European Standard
PED 97/23/EC (pressure vessels).
– The used refrigerants are included in group II (non-
hazardous fluids).
– The maximum working pressure values are men-
tioned on the unit’s data plate.
– Suitable safety devices (pressure switches and safe-
ty valves) have been provided, to prevent any
anomalous overpressure inside the plant.
– The vents of the safety valves are positioned and
oriented in such a way as to reduce the risk of con-
tact with the operator, in the event that the valve is
operated. Anyway, the installer will convey the dis-
charge of the valves far from the unit.
– Dedicated guards (removable panels with tools)
and danger signs indicate the presence of hot
pipes or components (high surface temperature).
The guards of the fans (only for units pro-
vided with air heat exchangers) must be al-
ways mounted and must never be removed
before de-energising the appliance.
It is the User’s responsibility to ensure that
the unit is fit for the conditions of intended
use and that both installation and mainte-
nance are carried out by experienced per-
sonnel, capable of respecting all the recom-
mendations provided by this manual. It is
important that the unit is adequately sup-
ported, as detailed in this manual. Non-
compliance with these recommendations
may create hazardous situations for the
personnel.
The unit must rest on a base which meets
the characteristics specified in this manual;
a base with inadequate characteristics is
likely to become a source of serious injury
to the personnel.
The unit has not been design to withstand
loads and/or stress that may be transmitted
by adjacent units, piping and/or structures.
Each external load or stress transmitted to
the unit may break or cause breakdowns in
the unit’s structure, as well as serious dan-
gers to people. In these cases, any form of
warranty will automatically become null
and void.
The packaging material must not be dis-
posed of in the surrounding environment or
burnt.
2.2 Definitions
OWNER: means the legal representative of the com-
pany, body or individual who owns the plant where
Itelco-Clima unit has been installed; he/she has the
responsibility of making sure that all the safety regu-
lations specified in this manual are complied with,
along with the national laws in force.
INSTALLER: means the legal representative of the
company who has been given by the owner the job
of positioning and performing the hydraulic, electric
and other connections of Itelco-Clima unit to the
plant: he/she is responsible for handling and prop-
erly installing the appliance, as specified in this man-
ual and according to the national regulations in
force.
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Page 5
Safety
English
OPERATOR: means a person authorised by the own-
er to do on Itelco-Clima unit all the regulation and
control operations expressly described in this manu-
al, that must be strictly complied with, without ex-
ceeding the scope of the tasks entrusted to him.
ENGINEER: means a person authorised directly by
Itelco-Clima or, in all EC countries, excluding Italy,
under his full responsibility, by the distributor of Itel-
co-Clima product, to perform any routine and extra-
ordinary maintenance operations, as well as any
regulation, control, servicing operations and the re-
placement of pieces, as may be necessary during the
life of the unit.
2.3 Access to the unit
The unit must be placed in an area which can be ac-
cessed also by OPERATORS and ENGINEERS; oth-
erwise the unit must be surrounded by a fence at not
less than 2 meters from the external surface of the
machine.
OPERATORS and ENGINEERS must enter the fenced
area only after wearing suitable clothing (safety
shoes, gloves, helmet etc.). The INSTALLER personnel
or any other visitor must always be accompanied by
an OPERATOR.
For no reason shall any unauthorised personnel be
left alone in contact with the unit.
2.4 General precautions
The OPERATOR must simply use the controls of the
unit; he must not open any panel, other than the one
providing access to the control module.
The INSTALLER must simply work on the connections
between plant and machine; he must not open any
panels of the machine and he must not enable any
control.
When you approach or work on the unit, follow the
precautions listed below:
hdo not wear loose clothing or jewellery or any oth-
er accessory tat may be caught in moving parts
hwear suitable personal protective equipment
(gloves, goggles etc.) when you have to work in
the presence of free flames (welding operations) or
with compressed air
hif the unit is placed in a closed room, wear ear pro-
tection devices
hcut off connecting pipes, drain them in order to
balance the pressure to the atmospheric value be-
fore disconnecting them, disassemble connections,
filters, joints or other line items
hdo not use your hands to check for any pressure
drops
huse tools in a good state of repair; be sure to have
understood the instructions before using them
hbe sure to have removed all tools, electrical cables
and any other objects before closing and starting
the unit again
2.5 Precautions against residual risks
Prevention of residual risks caused by the
control system
hbe sure to have perfectly understood the operating
instructions before carrying out any operation on
the control panel
hwhen you have to work on the control panel, keep
always the operating instructions within reach
hstart the unit only after you have checked its perfect
connection to the plant
hpromptly inform the ENGINEER about any alarm
involving the unit
hdo not reset manual restoration alarms unless you
have identified and removed their cause
Prevention of residual mechanical risks
hinstall the unit according to the instructions provid-
ed in this manual
hcarry out all the periodical maintenance opera-
tions prescribed by this manual
hwear a protective helmet before accessing the inte-
rior of the unit
hbefore opening any panelling of the machine,
make sure that it is secured to it by hinges
hdo not touch air condensation coils without wear-
ing protective gloves
hdo not remove the guards from moving elements
while the unit is running
hcheck the correct position of the moving elements’
guards before restarting the unit
Prevention of residual electrical risks
hconnect the unit to the mains according to the in-
structions provided in this manual
hperiodically carry out all the maintenance opera-
tions specified by this manual
hdisconnect the unit from the mains by the external
disconnecting switch before opening the electrical
board
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Page 6
Safety
hcheck the proper grounding of the unit before start-
up
hcheck all the electrical connections, the connecting
cables, and in particular the insulation; replace
worn or damaged cables
hperiodically check the board’s internal wiring
hdo not use cables having an inadequate section or
flying connections, even for limited periods of time
or in an emergency
Prevention of other residual risks
hmake sure that the connections to the unit conform
to the instructions provided in this manual and on
the unit’s panelling
hif you have to disassemble a piece, make sure that
it has been properly mounted again before restart-
ing the unit
hdo not touch the delivery pipes from the compres-
sor, the compressor and any other piping or com-
ponent inside the machine before wearing protec-
tive gloves
hkeep a fire extinguisher fir for electrical appliances
near the machine
hon the units installed indoor, connect the safety
valve of the refrigeration circuit to a piping net-
work that can channel any overflowing refrigerant
outside
hremove and leak of fluid inside and outside the unit
hcollect the waste liquids and dry any oil spillage
hperiodically clean the compressor compartment, to
remove any fouling
hdo not store flammable liquids near the unit
hdo not disperse the refrigerant and the lubricating
oil into the environment
hweld only empty pipes; do not approach flames or
other sources of heat to refrigerant pipes
hdo not bend/hit pipes containing fluids under pres-
sure
2.6 Precautions during maintenance
operations
Maintenance operations can be carried out by au-
thorised technicians only.
Before performing any maintenance operations:
hdisconnect the unit from the mains with the external
disconnecting switch
hplace a warning sign “do not turn on - mainte-
nance in progress” on the external disconnecting
switch
hmake sure that on-off remote controls are inhibited
hwear suitable personal protective equipment (hel-
met, safety gloves, goggles and shoes etc.)
To carry out any measurements or checks which re-
quire the activation of the machine:
hwork with the electrical board open only for the
necessary time
hclose the electrical board as soon as the measure-
ment or check has been completed
hfor outdoor units, do not carry out any operations
in the presence of dangerous climatic conditions
(rain, snow, mist etc.)
The following precautions must be always adopted:
hdo not scatter the fluids of the refrigeration circuit
in the surrounding environment
hwhen replacing an eprom or electronic cards, use
always suitable devices (extractor, antistatic
bracelet, etc.)
ho replace a compressor, the evaporator, the con-
densing coils or any other weighty element, make
sure that the lifting equipment is consistent with the
weight to be lifted
hin air units with independent compressor compart-
ment, do not access the fan compartment unless
you have disconnected the machine by the discon-
necting switch on the board and you have placed
a warning sign “do not turn on - maintenance in
progress”
hcontact Itelco-Clima for any modifications to the re-
frigeration, hydraulic or wiring diagram of the
unit, as well as to its control logics
hcontact Itelco-Clima if it is necessary to perform
very difficult disassembly and assembly operations
huse only original spare parts purchased directly
from Itelco-Clima or the official retailers of the com-
panies on the recommended spare parts list
hcontact Itelco-Clima if it is necessary to handle the
unit one year after its positioning on site or if you
wish to dismantle it.
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Page 7
Safety
English
2.7 Safety plates
The labels below will be affixed to each unit in the in-
dicated point:
Identification of the refrigerant - External door
Identification of the unit -
Outside, on the right-hand front column
R407C
Electrical warning
Adjacent to the master switch
Gravity centre - Base
TENERE SU QUESTA LINEA
GANCIO DI SOLLEVAMENTO
KEEP LIFT HOOK
ON THIS LINE
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Page 8
Grounding connection - On the electrical
board, adjacent to the connection
Start-up warning - Outside the door of
the electrical board
Final Test Certificate -
Inside the external door
Warning - safety
valves’ vents Warning - high- temperature zones
Adjacent to hot
pipes or
components
Lifting point - Base
Fitting identification -
Adjacent to fittings
ATTENZIONE
INSERIRE LE RESISTENZE DI RISCALDAMENTO OLIO ALMENO
12 ORE PRIMA DI OGNI AVVIAMENTO (SE PREVISTE).
PRIMA DELLA MESSA IN TENSIONE ASSICURARSI CHE LE VITI DEI CIRCUITI
ELETTRICI SIANO SERRATE COMPLETAMENTE
.
WARNING
ENERGIZE THE CRANCKCASE HEATER FOR AT LEAST 12
HOURS BEFORE EACH STARTING (IF FITTED).
BEFORE TIGHTENING-UP, TO TIGHTEN ALL TERMINAL SCREWS ESPECIALLY
THOSE IN MAIN CIRCUIT.
881000215/B
EIN - INLET
ENTRÉE - ENTRATA
AUS - OUTLET
SORTIE - USCITA
Safety
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Page 9
English
Safety
2.8 Safety regulations
Refrigerant data
Toxicity Low
Contact with skin If sprayed, the refrigerant is likely to cause frost burns. If absorbed by
the skin, the danger is very limited; it may cause a slight irritation, and
the liquid is degreasing. Unfreeze the affected skin with water. Remove
the contaminated clothes with great care - in the presence of frost
burns, the clothes may stick to the skin. Wash with plenty of warm wa-
ter the affected skin.
In the presence of symptoms such as irritation or blisters, obtain med-
ical attention.
Contact with eyes
Ingestion
Inhalation
Recommendations
Prolonged exposure
Vapours do not cause harmful effects. The spraying of refrigerant may
cause frost burns. Wash immediately with a proper solution or with tap
water for at least 10 minutes, and then obtain medical attention.
Very unlikely - should something happen, it will cause frost burns.
Do not induce vomiting. Only if the patient is conscious, wash out
mouth with water and give some 250 ml of water to drink. Then, obtain
medical attention.
R407C, R134a: remarkable concentrations in the air may have an
anaesthetic effect, up to fainting. The exposure to considerable
amounts may cause irregular heartbeat, up to the sudden death of the
patient. Very high concentrations may result in the risk of asphyxia, due
to the reduction in the oxygen percentage in the atmosphere. Remove
the patient to fresh air and keep warm and at rest.
If necessary, give oxygen. In case of breathing difficulties or arrest, pro-
ceed with artificial respiration. In case of cardiac arrest, proceed with
cardiac massage. Then, obtain medical attention.
Semiotics or support therapy is recommended. Cardiac sensitisation
has been observed that, in the presence of circulating catecholamines
such as adrenalin, may cause cardiac arrhythmia and accordingly, in
case of exposure to high concentrations, cardiac arrest.
R407C, R134a: a study on the effects of exposure to 50,000 ppm dur-
ing the whole life of rats has identified the development of benign testi-
cle tumour. This situation should therefore be negligible for personnel
exposed to concentrations equal to or lower than professional levels.
Professional levels
Stability R407C, R134a: Not specified
R407C, R134a: Recommended threshold: 1000 ppm v/v - 8 hours
TWA.
Conditions to avoid Do not use in the presence of flames, burning surfaces and excess hu-
midity.
Safety data: R407C, R134a
Hazardous reactions May react with sodium, potassium, barium and other alkaline metals.
Incompatible substances: magnesium and alloys with magnesium con-
centrations > 2%.
Hazardous decomposition
products R407C, R134a: Halogen acids produced by thermal decomposition and hydrolysis.
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Page 10
Respiratory system protection
Storage
Protective clothing
Accidental release measures
Disposal
Fire fighting information
Cylinders
Protective fire fighting
equipment
If you are in doubt about the concentration in the atmosphere, it is rec-
ommended to wear a respirator approved by an accident-prevention
Authority, of the independent or oxygen type.
Cylinders must be stored in a dry and fresh place, free from any fire
hazard, far from direct sunlight or other sources of heat, radiators etc.
Keep a temperature below 45°C.
Wear overalls, protective gloves and goggles or a mask.
It is important to wear protective clothing and a respirator. Stop the
source of the leak, if you can do this without danger. Negligible leaks
can be left evaporating under the sun, providing that the room is well
ventilated. Considerable leaks: ventilate the room. Reduce the leak with
sand, earth or other absorbing substances. Make sure that the liquid
does is not channelled into gutters, sewers or pits where the vapours
are likely to create a stuffy atmosphere.
The best method is recovery and recycling. If this method is not practi-
cable, dispose according to an approved procedure, that shall ensure
the absorption and neutralization of acids and toxic agents.
R407C, R134a: Not flammable in the atmosphere.
In case of fire, wear an independent respirator and protective clothing.
The cylinders, if exposed to fire, shall be cooled by water jets; other-
wise, if heated, they may explode.
General precautions Do not inhale concentrated vapours. Their concentration in the atmos-
phere should not exceed the minimum preset values and should be
maintained below the professional threshold. Being more weighty than
the air, the vapour concentrates on the bottom, in narrow areas. There-
fore, the exhaust system must work at low level.
Safety
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Page 11
English
Safety
Refrigerant oil data Safety data: Polyolester oil (POE)
Classification
Contact with skin
Contact with eyes
Ingestion
Inhalation
Conditions to avoid
Protection of the respiratory
system
Protective clothing
Accidental release measures
Disposal
Fire fighting information
Cylinders
Fire fighting protective
equipment
Not harmful
May cause slight irritation. Does not require first aid measures. It is rec-
ommended to follow usual personal hygiene measures, including wash-
ing the exposed skin with soap and water several times a day. It is also
recommended to wash your overalls at least once a week.
Wash thoroughly with a suitable solution or tap water.
Seek medical advice immediately.
Seek medical advice immediately.
Strong oxidising substances, caustic or acid solutions, excess heat.
May corrode some types of paint or rubber.
Use in well ventilated rooms.
Always wear protective goggles or a mask. Wearing protective gloves
is not mandatory, but is recommended in case of prolonged exposure
to refrigerant oil.
It is important to wear protective clothing and, especially, goggles.
Stop the source of the leak. Reduce the leak with absorbing substances
(sand, sawdust or any other absorbing material available on the mar-
ket).
The refrigerant oil and its waste will be disposed of in an approved in-
cinerator, in conformity with the provisions and the local regulations
applicable to oil waste.
In the presence of hot liquid or flames, use dry powder, carbon dioxide
or foam. If the leak is not burning, use a water jet to remove any
vapours and to protect the personnel responsible for stopping the leak.
The cylinders exposed to a fire will be cooled with water jets in case of
fire.
In case of fire, wear an independent respirator.
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Page 12
Transport, Lifting and Positioning
3 TRANSPORT, LIFTING
AND POSITIONING
Refrigerators are supplied assembled (apart from
standard antivibrating rubber supports, that will be
installed on site). The equipment are full of refriger-
ant and oil (except to the condensing unit), in the
quantity required for a proper operation.
3.1 Inspection
When the unit is delivered, it is recommended to
check it carefully and to identify any damage oc-
curred during transportation. The goods are shipped
ex-factory, at the buyer’s risk. Check that the delivery
includes all the components listed in the order.
In case of damage, note it down on the carrier’s de-
livery note and issue a claim according to the instruc-
tions provided in the delivery note.
In the presence of any serious damage, that does not
affect the surface only, it is recommended to inform
Itelco-Clima immediately.
Please note that Itelco-Clima may not be held liable
for any damage to the equipment during transporta-
tion, even though the carrier has been appointed by
the factory.
3.2 Lifting
The unit must lifted with cables inserted in the eye-
bolts provided. It is recommended to use a spacer to
prevent the cables from damaging the unit (see the
figure).
Before positioning the unit, make sure that the place
of installation is appropriate and sturdy enough to
hold the weight and to withstand the stress caused
by the operation of the whole assembly.
Do not displace the unit on rollers, and do
not lift it with a lift truck.
To lift and displace the unit:
hInsert and secure eyebolts into the holes marked
on the frame.
hConnect cables to eyebolts.
hInsert spacer between cables.
L
L = Depth
Eyebolts
hHook near the barycentre of the unit.
hThe cables must be long enough to form, if ten-
sioned, an angle of at least 45° with respect to the
horizontal plane.
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Page 13
English
Transport, Lifting and Positioning
For lifting operations, use only tools and
material fit for this purpose, in accordance
with accident-prevention regulations.
During the lifting and handling of the unit,
be careful not to damage the finned pack of
the coils positioned on the sides of the unit.
The sides of the unit must be protected by
cardboard or plywood sheets.
It is recommended not to remove the protec-
tive plastic envelope, that should prevent
scraps from penetrating into the appliance
and any damage to the surfaces, until the
unit is ready for operation.
3.3 Anchoring
It is not essential to secure the unit to the foundations,
unless in areas where there is a serious risk of earth-
quake, or if the appliance is installed on the top of a
steel frame.
3.4 Storage
When the unit is to be stored before installation,
adopt a few precautions to prevent any damage or
risk of corrosion or wear:
hplug or seal every single opening, such as water
fittings
hdo not store the appliance in a room where the
temperature exceeds 50°C for the units using
R407C and, if possible, do not expose to direct
sunlight
hit is recommended to store the unit in a roof where
traffic is minimized, to prevent the risk of acciden-
tal damage
hthe unit must not be washed with a steam jet
htake away and leave to the site manager all the
keys providing access to the control board
Finally, it is recommended to carry out visual inspec-
tions at regular intervals.
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Page 14
Installation
4 INSTALLATION
4.1 Positioning of the unit
Before installing the unit, make sure that the
structure of the building and/or the support-
ing surface can withstand the weight of the
appliance. The weights of the units are list-
ed in Chapter 8 of this manual.
These units have been designed for outdoor installa-
tion on a solid surface. Standard accessories include
antivibrating rubber supports, that must be posi-
tioned under the base.
When the unit is to be installed on the ground, it is
necessary to provide a concrete base, to ensure a
uniform distribution of the weights.
As a general rule, no special sub-bases are required.
However, if the unit is to be installed on the top of in-
habited rooms, it is advisable to rest it on spring
shock absorbers (optional), that will minimise the
transmission of any vibration to the structures.
To choose the place of installation of the unit, bear in
mind that:
hthe longitudinal axis of the unit must be parallel to
the direction of prevailing winds, so as to ensure a
uniform distribution of the air on finned exchang-
ers
hthe unit must not be installed near boilers’ vent
pipes
hthe unit must not be installed leeward with respect
to sources of air contaminated by greases, such
as, for example, the outlets to kitchen exhaust
hoods into the atmosphere. Otherwise, the grease
is likely to deposit on the fins of the refrigerant /air
exchangers, and would fix every type of atmos-
pheric impurity, resulting in the quick clogging of
the exchangers
hthe unit must not be installed in areas subject to
considerable snow falling
hthe unit must not be installed in areas subject to
flooding, under gutters etc.
hthe unit must not be installed in air shafts, narrow
courts or other small places, where the noise may
be reflected by the walls or the air ejected by fans
may short-circuit itself on refrigerant/air heat ex-
changers or condenser
hthe place of installation must be have all the neces-
sary spaces for air circulation and maintenance
operations (see Chapter 9).
4.2 Installation of Spring Shock
Absorbers
hPrepare the base, that must be flat and plane.
hLift the appliance and insert shock absorbers as
follows:
1) proceed with the assembly of the jack components
2) insert the jack into the threaded seat provided on
the upper plate of the shock absorber. Then insert the
jack mounted on the shock absorber, in the hole pro-
vided on the base of the machine.
Insert
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Page 15
English
3) make sure that the base of the machine is resting
on the flat washer (E) of the jack. To offset any dif-
ference in height, work on high nut (D), using a
24 wrench. Clamp in the obtain position with the
grower washer (F) and the relevant low nut (C).
At the end of this operation, check that the machine
is elastic on its axes, and preset for the installation of
antivibrating joints in the water connections.
4.3 External hydraulic circuit
The external hydraulic circuit must ensure
the water flow to the evaporator under any
working conditions and with any adjust-
ment.
The external hydraulic circuit should consist of the fol-
lowing elements:
hA circulation pump which delivers a sufficient wa-
ter flow and discharge head.
hThe capacity of the primary hydraulic circuit
should not be less than 5 litres/KW of cooling ca-
pacity, in order to prevent the repeated start-up of
the compressor and any damage to it. If the water
capacity in the primary piping of the circuit and in
the evaporator is lower than this value, an insulat-
ed storage tank shall be installed.
hA membrane expansion vessel provided with safe-
ty valve with vent, that must be visible.
Installation
The capacity of the expansion vessel must
allow for an expansion of at least 2% of the
volume of the fluid in the circuit (evapora-
tor, piping, user circuit and standby tank, if
any). The expansion vessel needs not be
isolated, because no water can circulate in-
side it.
hA flow meter, to disable the appliance when the
water is not circulating.
The flow meter must be connected in series,
as shown in the wiring diagram of the con-
trol panel.
To install the flow meter, conform to the manufactur-
er’s instructions.
As a general rule, the flow meter must be mounted
on a horizontal pipe, and its distance from the
curves must be 10 times the diameter of the pipe, far
from valves or other components that may hinder the
water flow upstream of or downstream from the flow
meter.
hThe air exhaust valves must be mounted in the
highest point of the piping.
hThe stop valves must be mounted on the water in-
let/outlet piping of the evaporator and the heat re-
covery condenser.
hThe drain points (provided with plugs, cocks etc.)
must be positioned in the lowest point of the pip-
ing.
Furthermore:
hProvide the evaporator with a by-pass circuit
equipped with valve, to wash the plant.
hInsulate the piping, to prevent the risk of heat loss.
hInstall a filter on the suction side of the evaporator
or the heat recovery condenser.
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Page 16
Installation
Before filling the circuit, it is important to
check that it is free from any foreign matter,
sand, gravels, rust, welding deposits, waste
and other materials that may damage the
evaporator.
When cleaning the lines, it is recommended to cre-
ate a circuit by-pass. It is important to mount a filter-
ing medium (30 mesh) upstream of the chiller.
If necessary, the water required to fill the
circuit must be treated to obtain the request-
ed PH.
4.4 Hydraulic connection
The water inlet/outlet fittings shall conform to the in-
structions provided by the plates affixed neat the
connection points.
4.5 Draining the defrosting
waste water
(for heat pump unit only)
When heat pump units work in heating mode, dur-
ing defrosting cycles, they may discharge water from
the base. This is why the units should be installed at
least 200 mm above the floor level, so as to allow
the free drainage of waste water, without the risk of
producing ice banks.
The heat pump units must be installed in positions
where the defrosting water cannot create any dam-
age.
4.6 Power supply
Before carrying out any operations on the
electrical system, make sure that the unit is
deenergised.
It is important that the appliance is ground-
ed.
Legends:
I: Pressure gauge connection
S: Gate valve
Fl: Flow meter
GA: Flexible hoses
R: Drain cock
T: Thermometer
F: Filter
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English
Installation
The company in charge of the installation
shall conform to the standards applicable to
outdoor electrical connections.
Itelco-Clima may not be held liable for any damage
and/or injury caused by failure to comply with these
precautions.
The unit conforms to EN 60204-1.
The following connections shall be provided:
hA 3-phase and grounding connection for the pow-
er supply circuit.
hThe electrical distribution system shall meet the
power absorbed by the appliance.
hThe disconnecting and magnetothermal switches
must be sized to control the starting current of the
unit.
hThe power supply lines and the insulation devices
must be designed in such a way that every line in-
dependent.
hIt is recommended to install differential switches,
to prevent any damage caused by phase drops.
hThe fans and compressors are supplied through
contactors controlled from the control panel.
hEach motor is provided with an internal safety
thermal device and external fuses.
hThe power supply cables must be inserted into
dedicated openings on the front of the unit, and
the will enter the electrical board through holes
drilled on the bottom of the board.
4.7 Electrical connections
The unit must be installed on site according to the
Machinery Directive (98/37/EC), the Low Voltage Di-
rective (73/23/EC), the Electromagnetic Interference
Directive (89/336/EC) and the usual procedures and
standards applicable in the place of installation. The
unit must not be operated if its installation has not
been carried out according to the instructions provid-
ed in this manual.
The power supply lines must consist of insulated cop-
per conductors, dimensioned for the maximum ab-
sorbed current.
Connection to terminals must be performed accord-
ing to the diagram of connections provided in this
manual and according to the wiring diagram which
accompanies the unit.
Before connecting the power supply lines,
check that the available voltage value does
not exceed the range specified in the Elec-
tric Data (Chapter 8).
For 3-phase systems, check also that the unbalance
between the phases does not exceed 2%. To perform
this check, measure the differences between the volt-
age of each phase couple and their mean value dur-
ing operation. The maximum % value of these differ-
ences (unbalance) must not exceed 2% of the mean
voltage. If the unbalance is unacceptable, contact
the Energy Distributor to solve this problem.
Supplying the unit through a line whose un-
balance exceeds the permissible value will
automatically void the warranty.
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Page 18
Installation
Terminal box CLS/CLH/CLC STD-LN-ELN-HPF-HT
REMOTE START/STOP SWITCH
REMOTE SEL. OF COOLING/HEATING MODES
FLOW METER
EXTERNAL INTERLOK/PUMP CONSENT
COMMON
ANTIFREEZE CONTROL (MAX 0,5 AMP 230 Vac)
EXTERNAL PUMP CONTROL (MAX 0,5 AMP 230 Vac)
ALARMED MACHINE 1-2
COMPRESSOR 1 ON
COMPRESSOR 2 ON
LOW WATER LEVEL IN TANK
FORCED HEATING ENABLED - II DEGREE
(SRS)
(COMMON)
(SRHP)
(SF)
Terminal box CLH EH
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