Veco CLIMMA CWS DC INVERTER Series Setup guide

Installation, usage and
maintenance manual
CLIMMA CWS
DC
INVERTER
Rev. 14
11
04

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Table of Contents
1. Introduction .................................................................................................................................................................................................... 3
1.1. General information .......................................................................................................................................................................... 3
1.2. System features ................................................................................................................................................................................... 3
1.3. Installation ............................................................................................................................................................................................ 4
1.4. Transport and handling ................................................................................................................................................................... 4
1.5. Unpacking ............................................................................................................................................................................................. 4
1.6. Directives ............................................................................................................................................................................................... 4
1.7. General safety ...................................................................................................................................................................................... 4
2. Installation ....................................................................................................................................................................................................... 5
2.1. Climma DC chiller positioning ...................................................................................................................................................... 5
2.2. Electronic control box and display .............................................................................................................................................. 5
2.3. Flow switch installation ................................................................................................................................................................... 5
2.4. Grounding ............................................................................................................................................................................................. 5
2.5. Chiller condensate ............................................................................................................................................................................. 6
2.6. Other system components: fancoils ........................................................................................................................................... 6
2.7. Other system components: sea water circuit .......................................................................................................................... 6
2.8. Other system components: fresh water circuit ...................................................................................................................... 7
2.9. Electrical connections ....................................................................................................................................................................... 8
2.10. Installation checks ........................................................................................................................................................................ 8
3. Operating instructions ................................................................................................................................................................................ 9
3.1. The electrical control box ................................................................................................................................................................ 9
3.2. The display ............................................................................................................................................................................................ 9
3.3. Modes of operation ........................................................................................................................................................................... 9
3.4. Climma functions ............................................................................................................................................................................ 10
3.5. Starting the unit ............................................................................................................................................................................... 10
3.6. Shut off procedure .......................................................................................................................................................................... 11
3.7. Switching between modes .......................................................................................................................................................... 11
3.8. Programming .................................................................................................................................................................................... 11
3.9. Warnings and errors ....................................................................................................................................................................... 12
3.10. System information ................................................................................................................................................................... 12
4. Maintenance and cleaning ..................................................................................................................................................................... 14
4.1. Basic maintenance .......................................................................................................................................................................... 14
4.2. Extended maintenance ................................................................................................................................................................. 14
4.3. Winterization ..................................................................................................................................................................................... 14
5. Warnings, alarms and troubleshooting ............................................................................................................................................. 15
5.1. Warnings and alarms ..................................................................................................................................................................... 15
5.2. Basic troubleshooting.................................................................................................................................................................... 20

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1. Introduction
1.1. General information
Thank you for purchasing a Climma CWS system!
This manual will provide necessary information for the proper installation, operation, and maintenance of
your Climma system.
Climma chiller and products are designed and produced to the highest standards and they are all tested
in the factory. If your Climma system is used according to the guidelines in this manual, it will guarantee
you trouble free operation for many years.
If you require assistance, please contact one of our many authorized service centers. To find the service
center please check our website www.veco.net or write us at customers[email protected].
WARNING
This unit should only be used for the purposes for which it was designed. The manufacturer declines all
responsibility for any damage caused by incorrect or unreasonable use, such as:
 improper use by untrained persons;
 technical modifications or operations not suited to specific models;
 use of non-original or non-specific spare parts;
1.2. System features
Following the main features of the Climma DC chillers:
 Variable Output from a Single Air-conditioning Unit. Depending on the heat load requirements,
the compressor frequency varies controlling the output capacity, to produce faster cooling and
heating, significantly improving the comfort on-board.
 Water Cooled Inverter Compressor. Climma’s water cooled inverter protects the DC brushless
compressor from excessive temperature, current overload and irregular voltage supply, allowing
it to be installed in the engine room without additional ventilation. Added to this, the electronic
control provides continuous monitoring of the compressor curve to keep the unit within safe
operating limits, eliminating also stop-start cycles.
 Eco mode. This function has been specifically developed to optimize the power consumption of
the system in three principle ways: it enables the chiller to work more efficiently with a smaller
output generator than would ideally be required; in ECO mode the power consumption is further
reduced during night operation when only a courtesy/night generator is working running and
less power is needed; ECO mode allows the air-conditioning to run while on the dock with a
limited shore power supply.
 No Start Load. By using a DC compressor with inverter the Climma compressor starts at a low
frequency requiring a fraction of the power.
 Up to 50% energy saving
A Climma centralized air-conditioning system includes different products: the Climma DC chiller, fancoils
installed in each cabins, fresh water piping that connects the chiller to the fancoils, sea water piping
bringing sea water to the chiller condenser, the fresh and the sea water pumps.
While the Climma system is running in cool mode, the Climma DC chiller is cooling the fresh water that
circulates in the fresh water circuit to the fancoils; heat is removed from the cabins through fancoils,
blowing fresh air into the cabins.
While in heat mode (reverse cycle mode), the Climma DC chiller is heating the fancoil water circuit that
brings heated water to the fancoils, allowing them to blow heated air in the cabins.

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DC50: The Climma DC chiller is designed for boats that require a load up to 50.000 Btu/h, which means
that in standard conditions, it is suited for motor boat from 50’ up to 65’ (15-20 meters) and sailing boats
between 60’ and 70’ (18-22 meters).
1.3. Installation
The unit must be installed by an authorized Climma service center and in compliance with the
instructions given in this manual.
1.4. Transport and handling
When loading or unloading the unit, use a fork lift equipped with forks at least 2/3 the length of the
shipping base.
Use an overhead lift if the unit is equipped with lifting eye-bolts.
Select lifting equipment suited to the weight and overall dimensions of the packaged unit or
components.
Take every precaution to prevent damage, when handling the unit or components keeping in
compliance with the information given on the packaging material.
1.5. Unpacking
Remove all cardboard, wood or other materials from the wood base. Lift the unit or components by
suitable means (e.g. lift truck), remove the wood base, then set the unit or components into position.
Once all packing material has been removed, check that the unit has not been damaged in any way.
Caution: Wear protective gloves when handling any packing materials and the wood base. Dispose of all
packaging materials appropriately in accordance to local codes.
1.6. Directives
Climma DC chillers respect the following directives.
 CE
 Low voltage: 2006/95/EC
 Electromagnetic Compatibility: 2004/108/EC
 Machinery Directive: 2006/42/CE
 Manufacturing quality Standards UNI EN ISO 9001:2008
1.7. General safety
Injuries or accidents caused by failure to comply with the recommendations of this manual are solely the
responsibility of the unit operator.
Basic Rules for Safe Operation:
 do not touch the unit with moist or wet hands or feet;
 never operate the unit while barefoot;
 before installation and maintenance operations, disconnect the unit from the power supply.
failure to comply may result in injury or death;
 installation and maintenance of this system can be hazardous due to system working pressure
and electrical components. Only a Climma certified service center should install and maintain the
system;
 to minimize the hazard of electrical shock and personal injury, this component must be
effectively grounded;
 during installation and maintenance follow safety codes, wear safety glasses and work gloves;

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2. Installation
WARNINGS
 Failure to follow all the instructions in this manual can cause property damage, injury or death.
 Improper installation, adjustment or alteration can cause property damage, injury or death.
 Electrical connections should be performed only by a certified professional.
 Electrical and grounding connections must comply with the National Electric Code and local
electric codes. Failure to comply with this procedure can cause property damage, injury or death.
 Before connecting the unit to the electrical supply, verify that the electrical connection agrees
with the specifications on the data plate, placed on the main electrical box of the unit. Failure to
comply with this procedure can cause property damage, injury or death.
 This appliance must be connected to a grounded, metal, permanent wiring system. Failure to
comply with this procedure can cause property damage, injury or death.
2.1. Climma DC chiller positioning
The Climma DC chiller must be installed in the engine room, technical space or similar area.
Normal engine room temperatures will not affect the Climma DC chiller, since the condenser and inverter
are water cooled. Climma DC chiller does not require additional ventilation during operation.
The unit must be accessible for service.
The unit must be secured on a surface using the mounting brackets below the drain pan.
WARNINGS
The Climma DC chiller is provided with an inverter mounted on the unit (VDF - Variable Frequency Drive) .
The inverter is IP20, therefore the Climma DC chiller must be installed where it would not get wet.
2.2. Electronic control box and display
The electronic control box of the Climma DC chiller is already completely connected to the chiller.
The control box has to be installed close enough to the chiller, due to the connection to the unit, and to a
flat horizontal or vertical surface.
The control box has to be installed in a location free from water, water spray and moisture and it has to
be accessible for operation and maintenance.
The standard version has the display on the control box itself, but the display can be also remote.
If the display is remote, the distance between the control box and the display has to be:
 50 meters with standard cable
 500 meters with AWG22 twisted pair cable. Note: please contact Veco if you plan to install the
display at a distance exceeding 50mt.
2.3. Flow switch installation
Flow switch has to be connected to the electronic control box and it needs to be installed in the fancoil
water circulation system.
Please refer to instruction C897 for the correct installation.
WARNING: Failure to properly install the flow switch will void the warranty on the Climma DC chiller.
2.4. Grounding
The Climma DC chiller has to be properly grounded to prevent corrosion due to stray current.

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WARNING: Failure to properly ground the Climma DC chiller will void warranty.
2.5. Chiller condensate
Every Climma DC chiller has two drains for condensate water.
At least one drain has to be properly connected to ensure the correct condensate water drainage.
Plastic condensate drain nipples are provided in a separate plastic bag to help the installation.
2.6. Other system components: fancoils
Climma fancoils have to be installed in a technical space inside or close to the cabin they have to
cool/heat.
Fancoils need to be properly secured on a leveled surface in order to operate correctly and remove the
condensation. Return air flow from the fancoil has to be ensured as well as the supply air flow from the
fancoil.
WARNING
No fancoil has to be installed close to engine room area and it must be ensured that no vapor or air from
the engine room can enter in the return air flow of the fancoil.
The positioning of the fancoil display is important. The temperature sensor is mounted on the display,
therefore the display has to be mounted on an inside wall, around the mid-height of the cabin where the
air can circulate so that it can sense the correct temperature.
If a correct positioning is not possible, a remote temperature sensor can be mounted; in this case, the
sensor must be placed behind the return air grill. In this case, the display temperature sensor will be
automatically excluded.
WARNING
Do not place the temperature sensor on the supply air flow or close to return/supply grills, under the
sunlight or close to heating devices.
Ducting of the return and supply air of the fancoil has to be done properly; ducts must be short and as
straight as possible, avoiding bends greater than 90° or loops.
Supply air ducting has to be at least 1.5 meter (5’) in order to reduce fan motor noise, but it should not
exceed 6 meters in order to reduce pressure drops.
Supply and return grills must be located not too close to each other, in order to avoid the supply air to
enter directly in the return air flow. Return grill should be placed below while supply grill should be
placed over the mid-height, as high as possible in the cabin.
WARNING
Failure to proper position the supply and return grills will cause no mixing between the cooler
temperatures and the warmer temperatures.
All Climma fancoils are provided with condensate drains to remove condensation produced by the
fancoil; condensation can reach 2 liters per hour, therefore condensate drains must be properly
connected and tested during installation. Drains should be as short and as downhill as possible, with no
loops and bends.
To test it, pour some water in the fancoil pan and check that all water flows out of the pan through the
drains.
2.7. Other system components: sea water circuit
The Climma DC chillers have a water cooled condenser therefore they need to be connected to sea water
to operate correctly.

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The sea water circuit includes: a sea water pump sized according to the chiller capacity, a sea water intake
and outlet and a sea water strainer.
The sea water in the circuit should not exceed 0.6 m3/h every 12.000 Btu/h (2,64 GPM or 10 lt/m per 1
TON) of chiller capacity.
Chiller rated capacity is guaranteed at 20°C (68°F) sea water temperature; the system will work in cool
mode up to 40°C (104°F) and in cool mode with a sea water temperature up to 5°C (41°F).
The sea water circuit must always have an uphill incline from the sea water inlet to the chiller condenser
to prevent the system to run properly. All hoses should be installed as straight as possible with no loops
and bends.
All metal components of the sea water circuit must be properly grounded.
SEA WATER PUMP
The sea water pump has to be properly secured on a leveled surface in order to operate correctly; Use the
special fixing kit with anti-vibration supports.
The sea water pump has to be installed below the water line in order to operate correctly.
SEA WATER INTAKE
Sea water intake has to be installed as far below the water line to ensure always that no air enters the sea
water circuit.
SEA WATER STRAINER
Sea water strainer has to be installed between the sea water intake and the sea water pump and it must
be accessible for cleaning operations. The strainer has to be cleaned periodically.
WARNING: Sea water strainer is mandatory in the seawater circuit. Failure to install the sea water strainer
will void the warranty.
SEA WATER OUTLET
The sea water outlet has to be installed above the sea water line, but as close as possible to it to reduce
noises.
2.8. Other system components: fresh water circuit
The fresh water circuit is a closed loop bringing water from the chiller to the fancoils and then back to the
chiller again. The circuit has the following components: a fresh water pump, flow switch, manifolds,
hoses, an expansion tank and an air-bleeder; everything is sized accordingly to the fancoils number, type
and overall capacity.
Water pressure in the circuit must be between 1 and 1.5 Bar (14.5 and 22 psig).
FRESH WATER PUMP (CIRCULATION PUMP)
The fresh water pump must be installed near the Climma DC chiller. The pump has to be installed on the
return line of the fresh water circuit, pumping water directly in the chiller and then to the fancoils.
FLOW SWITCH
Flow meter has to be installed on the fresh water circuit and it has to be accessible for maintenance.
The flow meter switch is mandatory safety equipment that will stop the system whenever the fresh water
flow stops or if it is not enough.
The flow meter switch has to be connected to the main electrical box of the unit as specified in the
electrical schematic.
Make sure that the flow meter is correctly connected to the control box. To test it, simulate a low flow
situation pressing the lever inside the cover of the switch.
MANIFOLDS

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Manifolds should be installed to be accessible for maintenance. If calibrating valves are installed, they
have to be completely opened.
HOSES
The water circuit must be as simple and straight as possible, avoiding bends, loops.
EXPANSION TANK
The expansion tank allows the water in the system to expand as it gets hot when the chiller is in heat
mode and it also acts as a cushion. The expansion tank has to be installed in the fresh water pump inlet.
AIR-BLEEDER
The automatic air bleeder must be installed on the pump outlet. This will prevent that any air in the
circuit reaches the fan coils and all the legs of the circuit.
ANTIFREEZE SOLUTION
The fresh water circuit needs to be filled with water (80%) and antifreeze (20%). Antifreeze will prevent
water and pipes from freezing. Antifreeze also reduces the corrosion inside the fresh water circuit.
Always check that the pressure gauge shows 1.5 Bar in the fresh water circuit.
We suggest two methods for filling the fresh water circuit with antifreeze:
 Calculate approximately the circuit capacity; Fill the circuit with water and add to it 20% of
antifreeze, using the second charging valve by gravity or using a pressure pump. Then connect
the circuit to the sanitary water circuit of the vessel, pressurize up to 1.5 Bar and start purging the
air. It is obvious that if purging will be difficult the percentage of antifreeze will decrease, as more
water will be needed to fill the circuit, therefore more antifreeze must be added to the circuit.
 Empty the circuit from the water used for leak test. Prepare an antifreeze solution of the quantity
needed to fill the circuit, made with 20% of antifreeze liquid; fill the circuit using a pressure pump.
Then proceed with purging air and topping up the pressure using the solution.
2.9. Electrical connections
The unit must be installed on a dedicated circuit with a rated thermal-magnetic circuit breaker. The
circuit breaker and electric cables (power supply) must be rated for the unit and comply with all local and
national codes.
The manufacturer will not be held responsible for damage or injuries due to improper installation.
Incorrect installation will void the Manufacturer’s warranty.
The electrical control box is already connected by Veco; to install the electrical box:
 Connect the power supply to the electrical box
 Connect the sea water pump to the electrical box
 Connect the circulation (fresh) water pump to the electrical box
Please refer to instruction C896 or to the Electrical schematic in this manual.
2.10. Installation checks
The following checks MUST be made during the initial field start-up:
 Check all wire connections.
 Check electrical input.
 Check the standard pressure in the refrigerant system.
 Check the expansion valve during operation.
Note: If the unit and/or remote condensing unit were not transported in an upright position, or has been
overturned during the installation process, allow them to stand, in an upright position, at least 4 hours
before starting the unit.

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3. Operating instructions
The unit can be controlled by the main electrical control box or remotely via Modbus protocol. In this
chapter only the main electrical box control is shown.
3.1. The electrical control box
The electrical control box of the chiller Climma DC is shown below.
The standard Climma DC configuration has the control box with a digital display to control the unit and a
local switch. The digital display can also be remote.
The electrical box has to be connected during the installation to the main power supply, to the sea water
pump and to the circulation pump.
The electrical box is already connected to: the inverter, the RC valve and water valve on the chiller, to the
electronic expansion valve, to the flow meter and to all the pressure and temperature sensors required by
the unit.
3.2. The display
The display has 6 buttons:
 WARNING: this will allow to access in the Warning/Error screens
 PROGRAM: this button allows to enter in the programming mode
 ESC: this button allows to exit from the current screen and go back to the previous level
 ENTER: when the cursor is on a value, the button allows to confirm the value
 UP/DOWN: these buttons allows to move between values or screens
3.3. Modes of operation
The unit has 3 possible modes:

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 SUMMER: When the unit is in SUMMER mode, the system will run in cool mode as chiller, cooling
the water until a specified set-point temperature value is reached.
 WINTER: When the unit is in HEAT mode, the system will run as heat pump, heating the water
until a specified set-point temperature value is reached.
 OFF: when unit is in OFF mode, the compressor will not run but the unit will be powered up.
When the system is powered up it will recall the previous mode of operation.
When the system starts for the first time, it will start in OFF mode.
3.4. Climma functions
When the compressor is running, the system can run with two different functions:
 AUTO function: when system is in AUTO function, the Climma Control will automatically adjust the
system power: when more power is requested, the compressor will run up to its maximum speed,
but when less power is requested, compressor will slow down.
 ECO function: when system is in ECO function, the Climma Control will automatically adjust the
system power, but this time the maximum power is limited to a specific ECO value, which allows
you to set a maximum power consumption, lower than the maximum system power
consumption.
Example.
Chiller maximum power consumption: 4,2kW
Generator: 10kW
When you are running the generator you can set the AUTO function on. If the system will run at full
power, it will still work with no problems, even at maximum speed.
When you are docked, you cannot run the generation and you have only 4kW from the harbor, then you
can set the ECO function on. This will allow the system to run up to 50% of its overall power, this means
that the power consumption will be limited around 2kW, allowing the system to run anyway.
3.5. Starting the unit
To start the unit, turn on the main power supply from the dedicated circuit breaker.
The display will show the following screens.
When the display shows the following screen, it’s possible to change the language from Italian to English
or the other way around.
To change the language from the current one, press ENTER. To confirm the current language press ESC.
If nothing is pressed, the system will start with the current language settings.
After the language settings, the system will go to the main screen.