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Itelco-Clima CWP-CO, Installation And Maintenance Manual

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Itelco-Clima CWP-CO Installation And Maintenance Manual Download Page 40

Page 39

English

Spare parts

11

SPARE PARTS

11.1 Spare part list

The table below shows the list of spare parts recom-

mended during the first two years of operation.

Component

Number

HP pressure switch 

1

LP pressure switch

1

Gas filter

2

Thermostatic valve

2

Auxiliary relays

2

Compressor’s fuses

12

Auxiliary fuses 

6

Set of compressor contactors

1

Water sensor

1

Electronic card

1

Keyboard

1

Compressor oil resistor 

1

11.2 Oil for compressors

The compressors are lubricated with polyester oil

(P.O.E.).

11.3 Wiring diagrams

The wiring diagrams are installed inside the doors of

the electrical panels of the unit. Any request for

wiring diagrams shall be forwarded to Itelco-Clima’s

Service Centre.

Manuale CWP  4.11.2005  11:56  Pagina 39

Summary of Contents for CWP-CO

Page 1: ...s de liquide à condensation par eau versions froid seul sans condenseur et pompe à chaleur Installation and maintenance manual Manuel d installation et de maintenance IOM CWP N 1GBF Date May Mai 2006 Supersedes Annule et remplace IMW 910 2M 12 01 CWP CO CWP RC CWP HP 02 35 8 136 kW 9 164 kW Français ...

Page 2: ... Delivery to the customer 15 6 CONTROL SYSTEM 6 1 CWP Control system µchiller 16 6 2 High Pressure Control 18 6 3 Low Pressure Control 18 6 4 Heat Exchanger Heater Thermostat 18 6 5 Pressostatic Valve Kit Optional 18 7 GENERAL DESCRIPTION 7 1 Introduction 19 7 2 General Specifications 19 7 3 Compressors 19 7 4 Refrigeration circuits 19 7 5 Evaporator 19 7 6 Condenser except for CWP RC 19 7 7 Switc...

Page 3: ... for this warranty to be valid the following conditions shall be met h The machine must be operated only from Autho rised After Sales Service h Maintenance must be performed only by skilled personnel from one of Itelco Clima s Authorised After Sales Centers h Use only original Itelco Clima spare parts h Carry out all the planned maintenance provided for by this manual in a timely and proper way Fa...

Page 4: ... 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 situation...

Page 5: ...ds to check for any pressure drops h use tools in a good state of repair be sure to have understood the instructions before using them h be 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 h be sure to have perfectly understood the operat...

Page 6: ...t the unit from the mains with the external disconnecting switch h place a warning sign do not turn on mainte nance in progress on the external disconnecting switch h make sure that on off remote controls are inhibited h wear 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 h work...

Page 7: ...ng identification Adjacent to fittings EIN INLET ENTRÉE ENTRATA AUS OUTLET SORTIE USCITA Safety 2 7 Safety labels The labels below will be affixed to each unit in the indicated point Identification of the unit Outside on the right hand front column Electrical warning Adjacent to the master switch Manuale CWP 4 11 2005 11 56 Pagina 6 ...

Page 8: ... 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 suppo...

Page 9: ...e 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 ...

Page 10: ...ons 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 othe...

Page 11: ...tact with them Be careful to avoid rough handling of the unit Do not push or pull the unit anything other than the base Block the pushing vehicle away from the unit to prevent damage to the sheet metal cabinet and end frame see picture 1 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 instal...

Page 12: ...ommended for all roof mounted installations or wherever vibration transmis sion is a consideration see chapter Dimensional Data for the location of each isolator Vibration eliminators in all water piping connected to the units are recommended to avoid straining the piping and transmitting vibration and noise 4 3 External hydraulic circuit The external hydraulic circuit must ensure the water flow t...

Page 13: ...btain the request ed PH Installation 4 4 Hydraulic connection of the condenser The external hydraulic circuit must ensure the water flow to the condenser under any working or adjustment conditions The cooling of the units is generally ensured by con necting the condenser to a cooling tower though the units can be cooled also with well water In the presence of a water cooled condenser it is necessa...

Page 14: ...hrough contactors controlled from the control panel h Each motor is provided with a thermal protection and a magnetic protection h The 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 D...

Page 15: ...luids have been circulating for at least 12 hours for both pumps Then clean the fil ters on the suction side of the pumps h Adjust the liquid distribution network in such a way that the flow rate is within the specified range h Check that the water quality is up to the specifica tions h Check that oil heaters if any have been turned on at least 12 hours before 5 2 Start up Start up sequence h Turn...

Page 16: ...abilised operation Check that the condensing and evaporation temper atures during operation at high and low pressure detected by the pressure gauges of the refrigerant are within the following range On the units not provided with HP LP pressure gauges for the refrigerant connect a pressure gauge to the Schreader valves on the refrigeration circuit 5 4 Delivery to the customer h Train the user acco...

Page 17: ...its in cooling only solution shall apply also to cooling In order to set the cooling set point to a value lower than the shop setting it is essential that you add some antifreeze to the circulating water and re cali brate accordingly all the safety components of the equipment NOTE To set the entering water temperature set point to values below 10 C consult our Technical Department to become acquai...

Page 18: ...alue displays the codes list after 5 password for USER parameters stores parameters in eeprom and goes back to the display of the temperature probe B1 stores parameters in eeprom and goes back to the display of the temperature probe B1 turns off the buzzer after 5 enters quits the Summer mode scans the parameters codes increases the value after 5 enters quits the Winter mode scans the parameters c...

Page 19: ...pressure decreases abnormally 6 4 Heat Exchanger Heater Thermostat The evaporator heater thermostat provides freeze protection down to 18 C ambient temperature dur ing unit shut down periods It closes at 4 C activating afterwards the evapora tor heating cable On heat pump units both evaporator and condenser are equipped with electric heater cable and thermo stat to protect against freezing 6 5 Pre...

Page 20: ... to 30 models are equipped with two compres sors All compressors are mounted on rubber shock ab sorbers so as to minimise the sound level and the vi bration transmission 7 4 Refrigeration circuits The refrigeration circuit is provided with a thermosta tic expansion valve dehydrating cartridge filter sight glass with a colour change humidity indicator HP and LP pressure switches solenoid valve CWP ...

Page 21: ...nts 1 Compressor 2 Cock 3 Liquid receiver 4 Solenoid valve 5 Filter 6 Sight glass 7 Thermostatic galve 8 Evaporator CWP HP refrigeration circuit 02 to 05 P1 HP pressure switch P2 LP pressure switch P3 Pressure taps P4 Non return valve Components 1 Compressor 2 4 way valve 3 Heat exchanger 4 Liquid receiver 5 Filter 6 Sight glass 7 Thermostatic valve 8 Evaporator Manuale CWP 4 11 2005 11 56 Pagina ...

Page 22: ... 1 Compressor 2 Safety valve 3 Cock 4 Liquid receiver 5 Solenoid valve 6 Filter 7 Sight glass 8 Thermostatic valve 9 Evaporator CWP HP refrigeration circuit 06 to 21 P1 HP pressure switch P2 LP pressure switch P3 Pressure taps P4 Non return valve Components 1 Compressor 2 Safety valve 3 4 way valve 4 Heat exchanger 5 Liquid receiver 6 Filter 7 Sight glass 8 Thermostatic valve 9 Evaporator Manuale ...

Page 23: ...ompressor 2 Safety valve 3 Cock 4 Liquid receiver 5 Solenoid valve 6 Filter 7 Sight glass 8 Thermostatic valve 9 Evaporator CWP HP refrigeration circuit 25 to 35 P1 HP pressure switch P2 LP pressure switch P3 Pressure taps P4 Non return valve Components 1 Compressor 2 Safety valve 3 4 way valve 4 Heat exchanger 5 Liquid receiver 6 Filter 7 Sight Glass 8 Thermostatic valve 9 Evaporator Manuale CWP ...

Page 24: ...2 24 23 Nominal pressure drops kPa 39 9 37 43 43 46 45 Max pressure drops kPa 110 9 102 121 119 128 126 PRESSURE DROPS IN THE CONDENSER CWP CWP HP 02 03 04 05 06 07 09 K 104 kPa m3 s 2 13246 5 13246 5 4657 0 4657 0 2472 2 2472 2 1484 9 Min water flow rate l s 0 3 0 4 0 6 0 7 0 8 1 2 1 4 Nominal water flow rate l s 0 5 0 6 0 8 1 0 1 2 1 7 2 0 Max water flow rate l s 0 8 0 9 1 3 1 6 2 0 2 8 3 4 Min ...

Page 25: ...0 7 1 1 1 1 1 7 1 7 2 2 2 2 Condenser Type Plate type Number 1 1 1 1 1 1 1 Minimum water content l 0 7 1 1 1 1 1 7 1 7 2 2 2 2 Evaporator Hydraulic connections Type Gas threaded female type Inlet diameter inch 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 Outlet diameter inch 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 Condenser Hydraulic connections Type Gas threaded female type Inlet diameter inch 1 1...

Page 26: ... Minimum water content l 2 8 4 4 5 3 6 9 8 6 10 9 Condenser Type Plate type Number 1 1 1 1 1 1 Minimum water content l 2 8 4 4 5 3 6 9 8 6 10 9 Evaporator Hydraulic connections Type Gas threaded female type Inlet diameter inch 1 1 2 1 1 4 1 1 4 2 2 2 Outlet diameter inch 1 1 2 1 1 4 1 1 4 2 2 2 Condenser Hydraulic connections Type Gas threaded female type Inlet diameter inch 1 1 2 1 1 4 1 1 4 2 2 ...

Page 27: ...1 1 1 1 7 1 7 2 2 2 2 Condenser Type Plate type Number 1 1 1 1 1 1 1 Minimum water content l 0 7 1 1 1 1 1 7 1 7 2 2 2 2 Evaporator Hydraulic connections Type Gas threaded female type Inlet diameter inch 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 Outlet diameter inch 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 Condenser Hydraulic connections Type Gas threaded female type Inlet diameter inch 1 1 4 1 1...

Page 28: ... 1 Minimum water content l 2 8 4 4 5 3 6 9 8 6 10 9 Condenser Type Plate type Number 1 1 1 1 1 1 Minimum water content l 2 8 4 4 5 3 6 9 8 6 10 9 Evaporator Hydraulic connections Type Gas threaded female type Inlet diameter inch 1 1 2 1 1 4 1 1 4 2 2 2 Outlet diameter inch 1 1 2 1 1 4 1 1 4 2 2 2 Condenser Hydraulic connections Type Gas threaded female type Inlet diameter inch 1 1 2 1 1 4 1 1 4 2 ...

Page 29: ...61 Dimensions Length mm 800 800 800 800 900 900 900 Height mm 910 910 910 910 910 910 910 Width mm 600 600 600 600 700 700 700 CWP RC 15 18 21 25 30 35 Power supply V ph Hz 400 3 50 Number of circuits 1 1 1 1 1 1 Number of steps 1 1 1 2 2 2 Compressors Type Scroll Scroll Scroll Scroll Scroll Scroll Number 1 1 1 2 2 2 Start up type Direct Direct Direct Direct Direct Direct Evaporator Type Plate typ...

Page 30: ...2 2 15 1 Max current FLA A 17 3 6 5 12 0 13 0 15 1 20 7 26 0 Max start up current LRA A 76 46 66 74 99 127 168 CWP CWP HP CWP RC 15 18 21 25 30 35 Nominal voltage V ph Hz 400 10 3 50 Max power input kW 16 4 24 2 28 1 32 9 44 5 56 2 Max current FLA A 27 8 41 0 48 0 55 6 75 3 95 0 Max start up current LRA A 198 225 272 226 300 320 Manuale CWP 4 11 2005 11 56 Pagina 29 ...

Page 31: ...sizes 02 to 09 1 1 2 female sizes 15 4 Condenser outlet 1 1 4 female sizes 02 to 09 1 1 2 female sizes 15 1 Water return from installation 2 Water leaving to installation 3 External source water outlet 4 External source water inlet Unit size A A1 A2 B B1 B2 B3 B4 B5 B6 C C1 02 to 05 800 75 650 900 110 478 135 80 567 153 480 540 06 to 09 900 100 700 900 110 478 135 80 667 153 580 640 15 1100 150 80...

Page 32: ...rator outlet 1 1 4 female 3 Condenser inlet 1 1 4 female 4 Condenser outlet 1 1 4 female For CWP RC 1 Evaporator inlet 1 1 4 female 2 Evaporator outlet 1 1 4 female 3 Discharge line 1 1 8 4 Liquid line 7 8 Unit Size A A1 A2 B B1 B2 B3 B4 B5 B6 C C1 18 21 1100 150 800 1000 110 518 145 100 800 200 730 790 Manuale CWP 4 11 2005 11 56 Pagina 31 ...

Page 33: ...18 145 206 1288 206 850 924 Side view Rear view For CWP CWP HP 1 Evaporator inlet 2 female 2 Evaporator outlet 2 female 3 Condenser inlet 2 female 4 Condenser outlet 2 female For CWP RC 1 Evaporator inlet 2 female 2 Evaporator outlet 2 female 3 Discharge line 1 5 8 4 Liquid line 1 1 8 Front view Manuale CWP 4 11 2005 11 56 Pagina 32 ...

Page 34: ...Page 33 English Technical data 8 5 Service Spaces Front view Side view Manuale CWP 4 11 2005 11 56 Pagina 33 ...

Page 35: ...ncurred to repair the ap pliance in its original state The provisions of this section apply only to standard units according to the order requirements other documentation may be added concerning any mod ifications or supplementary accessories 9 2 Planned maintenance Maintenance inspections must be carried out accord ing to the program below by a qualified person As a general rule units cannot be r...

Page 36: ...ressor needs to be replaced following a mechanical failure or if burnt contact one of Itelco Clima s Service Centers Compressors use polyester oil During maintenance operations on the compressor or if you have to open the refrigerant circuit in any point remember that this type of oil is highly hygroscopic and accordingly it is important that it is not left exposed to the weather for prolonged per...

Page 37: ...re the actual temperature Tse Overheating calculation S S Tse Tsa Overheating is regulated through the thermostatic expansion valve Make the adjusting screw follow a complete turn and operate the appliance for five minutes Check again and if necessary repeat the regula tion If the expansion valve cannot be regulated it is prob ably broken and shall be replaced The replace ment must be carried out ...

Page 38: ... Increase overheating Check the charge Excessive noise Vibration of lines Check the clamping brackets if any Whistler emitted by the thermostatic expansion valve Refill Check the dehydrating filter Noisy compressor Seized bearings replace the com pressor Check that the compressor s locknuts are tightened Low oil level in the compressor One or more gas or oil leaks in the circuit Identify and remov...

Page 39: ...e system solve them If they are caused by the distribution network inform the Energy Distributor Short circuit of the compressor s mo tor Check the continuity of the winding Seized compressor Replace the compressor Identify and remove the leak Insufficient charge Refill Failure of the pressure switch Replace the pressure switch Failure of the pressure switch Check the operation of the pressure swi...

Page 40: ...ry relays 2 Compressor s fuses 12 Auxiliary fuses 6 Set of compressor contactors 1 Water sensor 1 Electronic card 1 Keyboard 1 Compressor oil resistor 1 11 2 Oil for compressors The compressors are lubricated with polyester oil P O E 11 3 Wiring diagrams The wiring diagrams are installed inside the doors of the electrical panels of the unit Any request for wiring diagrams shall be forwarded to Ite...

Page 41: ...n the heat exchange sec tions of the plant If no shutoff valves have been provided it may be necessary to drain the whole plant If a glycoled solution or a similar fluid has been used in the hydraulic circuits or if chemical additives have been added to the circulating water the circulating fluid MUST be drained in a proper way For NO reason shall a circuit containing glycoled water or a similar s...

Page 42: ...prior notice Non contractual photos Dans un souci d amélioration constante nos produits peuvent être modifiés sans préavis Photos non contractuelles Itelco Industry Via XXV Aprile 29 20030 Barlassina MI Italy 39 0362 6801 39 0362 680281 www itelco clima com Your distributor Votre agent commercial ...

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