System air VLH Series Manual

VLH/VLC
Air Cooled Water Chillers and Heat Pump
Refrigerateurs à Eau et Pompes de Chaleur Refroidies à Air
Luftgekühlte Wasserkühler und Wärmepumpen
Refrigeratori d’Acqua e Pompe di Calore Raffreddati ad Aria
Refrigeradores de Agua y Bombas de Calor Refrigerados por Aire
Installation and maintenance manual
Manuel d’installation et de maintenance
Installations- und Wartungshandbuch
Manuale di installazione e di manutenzione
Manual de instalación y de mantenimiento
English Français EspañolDeutsch Italiano
173

300 kW
200

337 kW
ISO 9001:2015 certified management system
Part number / Code / Code / Codice / Código: 342603/K
Supersedes / Annule et remplace / Annulliert und ersetzt / Annulla e sostituisce /
Anula y sustituye: 342603/J
Notified Body / Organisme Notifié / Benannte Zertifizierungsstelle / Organismo
Notificato / Organismo Notificado N°. 0425

Page 1
English
Table of contents
1 FOREWORD
1.1 Introduction 2
1.2 Warranty 2
1.3 Emergency stop/Normal stop 2
1.4 An introduction to this manual 2
2 SAFETY
2.1 Foreword 3
2.2 Definitions 3
2.3 Access to the unit 4
2.4 General precautions 4
2.5 Precautions against residual risks 4
2.6 Precautions during maintenance
operations 5
2.7 Safety labels 6
2.8 Safety regulations 8
3 TRANSPORT, LIFTING
AND POSITIONING
3.1 Inspection 11
3.2 Lifting 11
3.3 Anchoring 12
3.4 Storage 12
4 INSTALLATION
4.1 Positioning of the unit 13
4.2 Spring Isolator Installation 13
4.3 External hydraulic Circuit 14
4.4 Hydraulic connection 15
4.5 Draining the Defrosting
Waste Water (for heat pump unit only) 15
4.6 Power supply 16
4.7 Electrical connections 16
4.8 Connecting plate-type evaporator
temperature sensors 18
4.9 Total heat recovery features 18
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 Control of VLH/VLC with 4
compressors the “Chiller Control”
system 21
6.2 Display 22
6.3 Key board 22
6.4 Protection and Safety Equipment 25
6.5 HPF version configuration 26
7 GENERAL DESCRIPTION
7.1 Introduction 27
7.2 General specifications 27
7.3 Compressors 27
7.4 Refrigeration circuits 27
7.5 Water heat exchanger 27
7.6 Air heat exchanger 28
7.7 Fans 28
7.8 Electric power supply and
control system 30
7.9 Accessories 30
8 TECHNICAL DATA
8.1 Pressure drop 31
8.2 Technical data 32
8.3 Unit Electrical data 48
8.4 Position of shock adsorbers
and weight distribution on supports 52
8.5 Overall dimensions 54
8.6 Service spaces 57
9 MAINTENANCE
9.1 General requirements 58
9.2 Planned maintenance 58
9.3 Refrigerant charge 59
9.4 Compressor 59
9.5 Condenser 59
9.6 Fans 59
9.7 Dehydrating filter 60
9.8 Sight glass 60
9.9 Electronic expansion valve 60
9.10 Evaporator 60
10 TROUBLESHOOTING 61
11 SPARE PARTS
11.1 Spare part list 63
11.2 Oil for compressors 63
11.3 Wiring diagrams 63
12 DISMANTLING, DEMOLITION
AND SCRAPPING
12.1 Generalities 64
12.2 RAEE Directive 64

Page 2
Foreword
1 FOREWORD
1.1 Introduction
Units, manufactured to state-of-the-art design and
implementation standards, ensure top performance,
reliability and fitness to any type of air-conditioning
systems.
These units are designed for cooling water or glycoled
water (and for water heating in heat pump models)
and are unfit for any purposes other than those speci-
fied in this manual.
This manual includes all the information required for a
proper installation of the units, as well as the relevant
operating and maintenance instructions.
It is therefore recommended to read this manual care-
fully before installation or any operation on the ma-
chine. The chiller installation and maintenance must
be carried out by skilled personnel only (where pos-
sible, by one of Authorised Service Centers).
The manufacturer may not be held liable for any dam-
age to people or property caused by improper instal-
lation, start-up and/or improper use of the unit and/
or failure to implement the procedures and instructions
included in this manual.
1.2 Warranty
These units are delivered complete, tested and ready
for being operated. Any form of warranty will become
null and void in the event that the appliance is modi-
fied without manufacturer’s preliminary written au-
thorisation.
This warranty shall apply providing that the instal-
lation instructions have been complied with (either
issued by manufacturer, or deriving from the current
practice), and the Form 1 (“Start-up”) has been filled-
in and mailed to manufacturer (attn. After-Sales Ser-
vice).
In order for this warranty to be valid, the following
conditions shall be met:
nThe machine must be operated only by skilled per-
sonnel from Authorised After-Sales Service.
nMaintenance must be performed only by skilled per-
sonnel - from one of Authorised After-Sales Centers.
nUse only original spare parts.
nCarry 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 au-
tomatically 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 detailed
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 damage
caused by non-compliance with these instructions, 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 information
that optimises the efficiency of the appliance.
This manual and its contents, as well as the documen-
tation which accompanies the unit, are and remain
the property of manufacturer, which reserves any and
all rights thereon. This manual may not be copied, in
whole or in part, without manufacturer’s written au-
thorization.
DANGER
WARNING
NOTE
USEFUL TIPS

Page 3
English
2 SAFETY
2.1 Foreword
These units must be installed in conformity with the
provisions of Machinery Directive 2006/42/EC,
Pressure Equipment Directive 2014/68/EU, Elec-
tromagnetic Compatibility Directive 2014/30/EU,
as well as with other regulations applicable in the
country of installation. If these provisions are not
complied with, the unit must not be operated.
The unit must be grounded, and no instal-
lation 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. Manufacturer may not be held liable
for any problems deriving from the replace-
ment of original refrigerant or the introduc-
tion of hydrocarbons.
Units are designed and manufactured according to the
requirements of European Standard PED 2014/68/
EU (pressure equipment).
nThe used refrigerants are included in group II (non-
hazardous fluids).
nThe maximum working pressure values are men-
tioned on the unit’s data plate.
nSuitable safety devices (pressure switches and
safety valves) have been provided, to prevent any
anomalous overpressure inside the plant.
nThe 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.
nDedicated 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 rec-
ommendations provided by this manual.
It is important that the unit is adequately
supported, 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 dangers 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
unit has been installed; he/she has the responsibility
of making sure that all the safety regulations specified
in this manual are complied with, along with the na-
tional 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 unit to the plant: he/she is
responsible for handling and properly installing the
appliance, as specified in this manual and according
to the national regulations in force.
OPERATOR: means a person authorised by the owner
to do on unit all the regulation and control operations
expressly described in this manual, that must be strict-
ly complied with, without exceeding the scope of the
tasks entrusted to him.
DANGER
DANGER
DANGER
DANGER
DANGER
DANGER
WARNING
WARNING
Safety

Page 4
ENGINEER: means a person authorised directly by
manufacturer or, in all EC countries, excluding Italy,
under his full responsibility, by the distributor of prod-
uct, to perform any routine and extraordinary mainte-
nance operations, as well as any regulation, control,
servicing operations and the replacement 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 ma-
chine.
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 OP-
ERATOR.
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:
ndo not wear loose clothing or jewellery or any other
accessory tat may be caught in moving parts
nwear suitable personal protective equipment
(gloves, goggles etc.) when you have to work in the
presence of free flames (welding operations) or with
compressed air
nif the unit is placed in a closed room, wear ear pro-
tection devices
ncut off connecting pipes, drain them in order to bal-
ance the pressure to the atmospheric value before
disconnecting them, disassemble connections, fil-
ters, joints or other line items
ndo not use your hands to check for any pressure
drops
nuse tools in a good state of repair; be sure to have
understood the instructions before using them
nbe 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
nbe sure to have perfectly understood the operating
instructions before carrying out any operation on
the control panel
nwhen you have to work on the control panel, keep
always the operating instructions within reach
nstart the unit only after you have checked its perfect
connection to the plant
npromptly inform the ENGINEER about any alarm
involving the unit
ndo not reset manual restoration alarms unless you
have identified and removed their cause
Prevention of residual mechanical risks
ninstall the unit according to the instructions provided
in this manual
ncarry out all the periodical maintenance operations
prescribed by this manual
nwear a protective helmet before accessing the inte-
rior of the unit
nbefore opening any panelling of the machine, make
sure that it is secured to it by hinges
ndo not touch air condensation coils without wearing
protective gloves
ndo not remove the guards from moving elements
while the unit is running
ncheck the correct position of the moving elements’
guards before restarting the unit
Prevention of residual electrical risks
nconnect the unit to the mains according to the in-
structions provided in this manual
nperiodically carry out all the maintenance opera-
tions specified by this manual
ndisconnect the unit from the mains by the external
disconnecting switch before opening the electrical
board
ncheck the proper grounding of the unit before start-
up
ncheck all the electrical connections, the connect-
ing cables, and in particular the insulation; replace
worn or damaged cables
nperiodically check the board’s internal wiring
ndo 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
nmake sure that the connections to the unit conform
Safety

Page 5
English
to the instructions provided in this manual and on
the unit’s panelling
nif you have to disassemble a piece, make sure that it
has been properly mounted again before restarting
the unit
ndo 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
nkeep a fire extinguisher fir for electrical appliances
near the machine
non the units installed indoor, connect the safety
valve of the refrigeration circuit to a piping network
that can channel any overflowing refrigerant out-
side
nremove and leak of fluid inside and outside the unit
ncollect the waste liquids and dry any oil spillage
nperiodically clean the compressor compartment, to
remove any fouling
ndo not store flammable liquids near the unit
ndo not disperse the refrigerant and the lubricating
oil into the environment
nweld only empty pipes; do not approach flames or
other sources of heat to refrigerant pipes
ndo not bend/hit pipes containing fluids under pres-
sure
2.6 Precautions during maintenance
operations
Maintenance operations can be carried out by author-
ised technicians only.
Before performing any maintenance operations:
ndisconnect the unit from the mains with the external
disconnecting switch
nplace a warning sign “do not turn on - maintenance
in progress” on the external disconnecting switch
nmake sure that on-off remote controls are inhibited
nwear 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:
nwork with the electrical board open only for the nec-
essary time
nclose the electrical board as soon as the measure-
ment or check has been completed
nfor 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:
ndo not scatter the fluids of the refrigeration circuit in
the surrounding environment
nwhen replacing an eprom or electronic cards, use
always suitable devices (extractor, antistatic brace-
let, etc.)
nto 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
nin 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”
ncontact manufacturer for any modifications to the
refrigeration, hydraulic or wiring diagram of the
unit, as well as to its control logics
ncontact manufacturer if it is necessary to perform
very difficult disassembly and assembly operations
nuse only original spare parts purchased directly
from manufacturer or the official retailers of the
companies on the recommended spare parts list
ncontact manufacturer if it is necessary to handle the
unit one year after its positioning on site or if you
wish to dismantle it.
Safety

Page 6
2.7 Safety labels
The labels below will be affixed to each unit in the indicated point:
Gravity centre - Base
TENERE SU QUESTA LINEA
GANCIO DI SOLLEVAMENTO
KEEP LIFT HOOK
ON THIS LINE
Identification of the unit Outside,
on the right-hand front column
CODICE PRODOTTO NEUTRO
PRODUCT CODE
MODELLO
MODEL
0425
MO.NO
MATRICOLA
SERIAL NO.
ANNO DI COSTRUZIONE
Manuf. Year
REFR. GWP CIRCUIT 1 2 3 4
CHARGE (Kg)
PS (LATO ALTA / LATO BASSA)
PS (HIGH / LOW SIDE)
TS (ALTA / BASSA)
TS (HIGH / LOW)
ALIM. POTENZA
MAIN SUPPLY
CORRENTE DI SPUNTO
LRA
CORRENTE A PIENO CARICO
FLA
POTENZA ASSORBITA
POWER INPUT
PRESS. MAX ESERCIZIO ACQUA
MAX WATER OPERATING PRESSURE
MASSA
MASS
SYSTEMAIR S.r.l. Via XXV Aprile 29 20825 BARLASSINA MB ITALIA
MADE IN ITALY COD.NO: P35952
MODELLO:
MODEL
MATRICOLA:
SERIAL NO.
CODICE:
PRODUCT CODE
MODELLO:
MODEL
MATRICOLA:
SERIAL NO.
CODICE:
PRODUCT CODE
MODELLO:
MODEL
MATRICOLA:
SERIAL NO.
CODICE:
PRODUCT CODE
bar
°C
V / PH / Hz
(max) A
(max) A
(max) Kw
bar
Kg
ANNO DI COSTRUZIONE
Manuf. Year
ANNO DI COSTRUZIONE
Manuf. Year
ANNO DI COSTRUZIONE
Manuf. Year
(tCO₂eq)
Identification of the refrigerant - External door
Electrical warning
Adjacent to the master switch
ATTENZIONE !
Prima di
aprire togliere
tensione
CAUTION !
Disconnect
electrical
supply before
opening
ACHTUNG !
Vor offnen des
gehauses
hauptschalter
ausschalten
ATENCION !
Cortar la
corrente antes
de abrir
el aparato
ATTENTION !
Enlever
l’alimentation
electrique
avant d’ouvrir
Safety

Page 7
English
Warning - safety valves’ vents
Start-up warning - Outside the door
of the electrical board
Final Test Certificate -
Inside the external door
Grounding connection on the electrical
board, adjacent to the connection
Safety
Circuit drain -
Outside, on the right-hand front column
ATTENTION! Don’t leave the unit with water inside hydraulic circuit during
winter or when it is in stand by.
ATTENZIONE! Non lasciare l’unità con acqua nel circuito idraulico durante
l’inverno o quando non è funzionante.
ATTENTION! Ne laissez pas l’unitè avec de l’eau dans le circuit hydraulique
pendant l’hiver ou quand elle ne travaille pas.
WARNUNG! Lassen Sie nicht das Wasser in die Schaltung während des
Winters oder wenn es nicht funktionient.
¡ATENCÍON! No deje el agua en el circuito hidráulico durante el invierno o
cuando no esta trabajando.
Fitting identification -
Adjacent to fittings
EIN - INLET
ENTRÉE - ENTRATA
AUS - OUTLET
SORTIE - USCITA
Warning - high-temperature zones
Adjacent to hot pipes or components

Page 8
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 water the affected
skin.
In the presence of symptoms such as irritation or blisters, obtain medical
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.
R410A: 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.
R410A: a study on the effects of exposure to 50,000 ppm during the
whole life of rats has identified the development of benign testicle tumour.
This situation should therefore be negligible for personnel exposed to
concentrations equal to or lower than professional levels.
Professional levels
Stability R410A: Not specified
R410A: Recommended threshold: 1000 ppm v/v - 8 hours TWA.
Conditions to avoid Do not use in the presence of flames, burning surfaces and excess humid-
ity.
Safety data: R410A
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 R410A: Halogen acids produced by thermal decomposition and hydroly- sis.

Page 9
English
Safety
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 recom-
mended to wear a respirator approved by an accident-prevention Au-
thority, of the independent or oxygen type.
Cylinders must be stored in a dry and fresh place, free from any fire haz-
ard, far from direct sunlight or other sources of heat, radiators etc. Keep a
temperature below 50 °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 venti-
lated. 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 cre-
ate a stuffy atmosphere.
The best method is recovery and recycling. If this method is not practica-
ble, dispose according to an approved procedure, that shall ensure the
absorption and neutralization of acids and toxic agents.
R410A: 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; otherwise,
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 main-
tained below the professional threshold. Being more weighty than the air,
the vapour concentrates on the bottom, in narrow areas. Therefore, the
exhaust system must work at low level.