Swegon AQUA Link User manual

AQUA Link
Installation, use and mantenaince manual 20121205

Index
1. GENERAL INFORMATION...............................................................................................4
1.1 TECHNICAL FEATURES ...........................................................................................4
1.2 THE SERIES ..............................................................................................................4
1.3 ACCESSORIES..........................................................................................................6
1.4 FIELD OF APPLICATION...........................................................................................6
2. INSPECTION, UNPACKING, TRANSPORT.....................................................................7
2.1 INSPECTION..............................................................................................................7
2.2 UNPACKING ..............................................................................................................7
2.3 LIFTING AND TRANSPORT ......................................................................................7
2.4 POSITIONING............................................................................................................9
2.5 ANTI-VIBRATION SUPPORTS (OPTION) ...............................................................10
2.6 NON-DECLARED USES ..........................................................................................10
3. INSTALLATION...............................................................................................................11
3.1 SPACES FOR INSTALLATION................................................................................11
3.2 HYDRAULIC CONNECTIONS..................................................................................11
3.3 WATER CONTENT OF THE SYSTEM.....................................................................14
3.4 RECOMMENDATIONS FOR OUTDOOR UNIT INSTALLATION.............................14
3.5 ELECTRICAL CONNECTIONS................................................................................15
3.6 CHECKS...................................................................................................................15
4. SAFETY MEASURES.....................................................................................................16
4.1 DEFINITION OF A DANGEROUS AREA.................................................................16
4.2 SAFETY PROVISIONS.............................................................................................16
4.3 INSTALLATION IN AREAS WITH EXPLOSIVE ATMOSPHERES...........................17
4.4 PROTECTIVE DEVICES..........................................................................................17
4.5 LIGHTING.................................................................................................................17
4.6 PERSONNEL QUALIFICATIONS – OBLIGATIONS.................................................17
4.7 MISCELLANEOUS NOTES......................................................................................17
5. COMMISSIONING ..........................................................................................................18
5.1 PRELIMINARY CHECKS..........................................................................................18
5.2 UNIT START-UP ......................................................................................................18
5.3 UNIT SHUTDOWN...................................................................................................18
5.4 SEASONAL SHUTDOWN........................................................................................18
5.5 EMERGENCY STOP................................................................................................18
6. OPERATION...................................................................................................................19
6.1 GENERAL INFORMATION.......................................................................................19
6.2 START-UP OF THE UNIT AND MANAGEMENT OF THE PUMPS .........................19
7. REGULAR MAINTENANCE AND INSPECTIONS..........................................................20
7.1 WARNINGS..............................................................................................................20
7.2 GENERAL INFORMATION.......................................................................................20
7.3 PROTECTING THE ENVIRONMENT.......................................................................20
8. DECOMMISSIONING THE UNIT....................................................................................20

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1. GENERAL INFORMATION
1.1 TECHNICAL FEATURES
STRUCTURE
The supporting frame and removable panels are made of metal sheet painted with epoxy powder with an orange peel
texture, and are only suitable for indoor installation. If an outdoor application is necessary, the Outdoor OD accessory is
required, which involves the use of galvanized steel sheet, further coated with polyester powder at 180 °C which confers a
high resistance to atmospheric agents. Stainless steel screws.
ELECTRO-PUMPS
Monobloc centrifugal electric pumps are used with a motor and pump unit directly coupled through a chrome steel single
shaft. Cast iron body and rotor, ceramic/carbon/EPDM mechanical seals suitable for use with ethylene glycol, and 2-pole,
three-phase electric motor with an IP 54 electrical protection degree.
If the double pump accessory is available, the two electro-pumps will be arranged in parallel and operate alternatively: if an
alarm is triggered due to the malfunction of one of the pumps, the other pump will automatically be activated.
The pumps are variable in speed by means of an inverter, and controlled with a signal from the pressure transducers in the
hydraulic circuit.
The inverters are assembled on the machine, and each pump unit (primary and secondary) is adjusted by a specific inverter.
TANK
The tank is only included by standard in the version with glycols.
Hot galvanized iron tank insulated with 13 mm thick polyurethane foam covered in PVC.
HYDRAULIC CIRCUIT
The indoor hydraulic circuit consists of flexible rubber or steel pipes, galvanized iron pipe fittings, check valves, stop valves,
valves for discharging the air found in the hydraulic circuits, an expansion tank , and a motorised 2 way valve with actuator
and pressure transducers.
ELECTRIC CONTROL BOARD (standard units)
The electric control board with IP X4 protection class includes:
– a main isolating switch
– pump magnet circuit-breaker switches
– pump contactors
– speed governor with a three-phase inverter for each hydraulic circuit pump
– magnet circuit breaker switches to protect the inverter/s
– control module (IQnomic) for the management of I/O signals coming from loads
– an isolating transformer
– a cooling fan
1.2 THE SERIES
AQUA Link
The AQUA Link hydraulic equipment series for indoor or outdoor housing is available in various sizes in combination with a
chiller whose total rated power varies from 90 to 300 kW.
As for the utilities side, the sizing of the unit is designed to allow it to be combined to systems providing for a subdivision in
the use of the total power output of the chiller as shown in the following table

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For specifications, available models, and technical data please refer to the AQUA Link TECHNICAL BOOKLET.
CONFIGURATIONS
EXAMPLE OF A CONFIGURATION
AQUA Link 140 1P 1PM IN LN 30
1 2 3 4 5 6 7
1: series
2: size
3: pumps set-up to the primary circuit
4: pumps set-up to the secondary circuit
5: model
6: any silenced model
7: glycol percentage
The possible values for each digit of the alpha-numerical identification code of the unit can be the following:
1: AQUA Link
2: 110 / 140 / 220 / 300 (It shows the indicative power range of the combined chiller in kW)
3: 1P / 2P / 1PM / 2PM (number and type of primary circuit pumps; M= Oversized)
4: 1P / 2P / 1PM / 2PM (number and type of secondary circuit pumps; M= Oversized. The number of secondary circuit
pumps, if available as accessories, must be in line with the number of the primary circuit pumps)
5: IN (for indoor models) / OD (for outdoor models)
6: blank / LN (any silenced models. If it is a standard model, the relevant field will not be filled in. Silenced models are only
available for indoor installation, as it is provided with containment panelling as an accessory)
7: NG /digit between 20 and 40. It shows the glycol percentage expected on the primary circuit. The acronym NG stands for
no glycols in the primary circuit.
EXAMPLE OF UNIT CLASSIFICATION
AQUA Link 140 1P 1PM IN LN 30
GLYCOL VERSION
Power to UTA Power to Chilled Beams
20% 80%
30% 70%
40% 60%
NO GLYCOL VERSION
Power to UTA Power to Chilled Beams
80% 20%
70% 30%
60% 40%
SERIES: AQUA Link
SIZE: 140 INDOOR MODEL
SETTING UP OF SECONDARY CIRCUIT
PUMPS
:
1
oversized
head pump
SILENCED VERSION
Accessory for indoor models only
GLYCOL PERCENT
30% glicole
SETTING UP PRIMARY CIRCUIT
PUMP: 1 standard head pump

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The model, serial number, features, power supply voltage, etc., are reported on the labels applied to the machine .
1.3 ACCESSORIES
- primary circuit double standard pump
- secondary circuit standard pump (single or double in line with the primary circuit one/s)
- primary circuit high head pressure pump (single or double)
- secondary circuit high head pressure pump (single or double in line with the primary circuit one/s)
- model for outdoor installation
- panelled model for indoor installation
- hydraulic pressure gauge for the primary circuit
- rubber shock absorbers
- wooden crate packaging
- special slide for container shipment
1.4 FIELD OF APPLICATION
They must be used within the application limits stated in the TECHNICAL DOCUMENT.
Units with glycols:
Indoor version
Units containing glycols in the indoor version of the primary circuit are designed and built to operate at outdoor temperatures
between +3°C and +45°C. They therefore do not provi de the installation of heating cables to protect the internal
components. For operation at temperatures outside of the aforementioned range, it is necessary to contact our Technical
Office.
Outdoor version
Units containing glycols in the outdoor version of the primary circuit are designed and built to operate within the following
limits, whose values depend on the percentage of glycol in the primary circuit.
With a 20% concentration of ethylene glycol, the minimum admissible temperature is -5°C
With a 30% concentration of ethylene glycol, the minimum admissible temperature is -10°C
With a 40% concentration of ethylene glycol, the minimum admissible temperature is -20°C
The overall maximum admissible temperature is 45°C

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The plate exchanger is always protected by a protective heating cable for the secondary circuit containing water.
If there are pumps installed on the secondary circuit, and it is an outdoor unit, the volutes are always protected by a heating
cable as well as pre-installed pipes.
The installer must protect any connecting pipe sections between the indoor system and AQUA Link
For temperatures below -15°C (i.e. for glycol perce ntages between 30% and 40%) a series of heating elements designed to
protect the main parts (pump motors, valve bodies...) and the electrical control board must be set up
For operation at temperatures outside the aforementioned range, it is necessary to contact our Technical Office.
Units without glycols:
No glycol units in the indoor and outdoor version of the primary circuit are designed and built to operate at outdoor air
temperatures between +3°C and +45°C which therefore do not subject the water in the circuit at risk of freezing. For
operation at temperatures outside of the aforementioned range, it is necessary to contact our Technical Office. Heating
cables are part of the standard supply of units installed outdoors, against accidental low temperatures to protect: pump
volutes, mixing manifolds, pipes inside the machine. WARNING: it is the installer's responsibility to protect the sections of
the machine's infeed and outfeed pipes that lead to the chilled beam circuit and chiller, including the inertial tank.
Warning: Before performing any operation on the unit make sure the power supply has been
disconnected.
Any operation on the unit must be performed by qualified personnel.
Failure to comply with the instructions in this manual and any change made to the unit without prior written consent, will
immediately render the warranty null and void.
2. INSPECTION, UNPACKING, TRANSPORT
2.1 INSPECTION
After receiving the unit, check its integrity: the machine left the factory in perfect condition, so any damage must be
immediately reported to the carrier and noted in the Delivery Sheet before signing it.
Blue Box or your Agent should be made aware of the extent of the damage as soon as possible. The Customer must fill in a
written, photographic report concerning any relevant damage.
2.2 UNPACKING
The packaging of the unit must be removed carefully to avoid causing damage to the machine.
The packaging materials are of a different nature; wood, cardboard, nylon, etc. It is good practice to store them separately
and deliver them to specialised companies for disposal (or recycling), which must be done according to standards in force in
the Country in which installation is being carried out, thereby reducing environmental impact.
2.3 LIFTING AND TRANSPORT
Avoid any abrupt movement while unloading and positioning the unit; when transporting the equipment indoors, pay the
utmost care. Do not use the machine components as anchors. The unit must be lifted using steel pipes inserted in the
eyelets indicated on relevant plates (yellow arrow shaped plates): check the documentation supplied to identify proper
lifting points. The unit must be lifted by harnessing it as shown in the below figure: use long enough ropes or belts, and
spacer bars so as not to damage the sides and lid of the unit.
Alternatively, units can be lifted using a forklift by inserting the lifting forks into the support pallet (see figure 1)

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Figure 1: Unit lifting operation
Warning: During all lifting operations, make sure the unit is firmly secured to prevent it from tipping
over or falling.
The lifting equipment, ropes and harnesses must be chosen by personnel having appropriate skills
who are able to assume all responsibilities related to their use.
The machine is balanced. However, always keep the forks low. Apply counterweights when
balancing, if necessary. Do not hold protruding parts with your hands.
Do not walk beneath or near the suspended load. Handling must be carried out by qualified staff
(forklift truck operators and slingers) wearing the required personal protective equipment (overalls,
safety shoes, work gloves, helmets, goggles). The Manufacturer declines all liability for any
accident caused by non compliance with this warning.

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2.4 POSITIONING
The following must be taken into account when choosing the unit place of installation and making relevant connections:
– size and origin of the hydraulic piping;
– location of the power supply;
– accessibility for maintenance or repair operations;
– strength of the supporting surface;
– possible reverberation of sound waves.
The units are designed for installation in indoor technical premises. An outdoor installation model must be specifically
requested when ordering.
If the units are installed in indoor environments, it is necessary to ensure that the temperature of these rooms does not
fall below 4°C.
Provide a solid base on which to place the unit. This support must be perfectly flat and horizontal, and its size suitable
for that of the unit.
This precaution is essential when the unit is to be positioned on unstable ground (different types of soil, gardens, etc.).
Figure 2 shows what has been described.
Slab
Sealant
Cork gasket
15-20cm
Soil

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The slab must be:
– made in suitable foundation with a height of about 15-20 cm above the surrounding land,
– supplied with a cork gasket properly sealed along the perimeter,
– flat, horizontal and able to support 150% of the operating weight of the machine.
– at least 30 cm. longer and wider than the machine.
The units transmit a low level of vibrations to the ground: it is however recommended to interpose a band of rigid rubber
between the base frame and the support surface.
Anti-vibration mounts are recommended whenever thorough isolation is necessary (contact our company).
2.5 ANTI-VIBRATION SUPPORTS (OPTION)
As the unit does not have any moving components other than circulation pumps, it ensures a low level of vibrations
transmitted to the ground. Normally, the interposition of rubber strips between the ground and the base is sufficient to cancel
the effects of vibrations.
When it is necessary to further reduce vibration transmitted to the supporting structure, we recommend the use of rubber
shock absorbers available as optional accessories. The dimensional layout with the footprint on the ground, attached to the
machine, shows the position and load of each anti-vibration mount. The fixing operation of anti-vibration mounts must be
performed before placing the machine on the ground. Ensure that the lifted machine is properly secured to lifting cables.
In the event of installation on roofs or intermediate floors, the unit and the piping should be insulated from walls and ceilings.
The units should not however be placed near home offices, bedrooms or areas where low noise is required. Do not install
the unit in narrow or confined spaces in order to prevent excessive sound reverberation.
2.6 NON-DECLARED USES
The machine must not be used:
– in an explosive atmosphere;
– in inflammable atmospheres;
– in excessively dusty environments;
– by untrained personnel;
– in a manner contrary to law;
– with improper installation;
– with power supply defects;
– with total or partial non-compliance with instructions;
– with no maintenance and/or use of non-original spare parts;
– with changes or other actions not authorized by the Manufacturer;
– when the work area is not kept free of tools or objects;
– when the work area is not adequately clean;
– in the presence of abnormal vibration in the work area.