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MTA MCCY-CY013 301, Operating And Maintenance Manual

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Appendix

The data in this manual are not binding and may be changed by the manufacturer without notice. 

Reproduction of this manual, even partial, is strictly prohibited.

A

PPENDIX

G

ENERAL

 

CONDITIONS

 

CHECKLIST

Start

No

Yes

Yes

Yes

Yes

No

No

Has the unit suffered transport or 
installation damage?

Have the minimum installation clearances 
specified in this manual been observed?

Are the condensing coils free of obstructions?

General condition of unit is in compliance

Do not start the unit before repairs

Correct installation of the unit, working 
in compliance with the instructions given 
in the manual

Clean condensing coils

Are the fan grilles free of obstructions?

Clean the fan grilles

No

Summary of Contents for MCCY-CY013 301

Page 1: ...WATER CHILLERS MCCY CY 013 301 38178800800 Original instructions in Italian language OPERATING AND MAINTENANCE MANUAL ...

Page 2: ...nC during chiller operation NOTE MCCY units can be controlled by temperature probes see paragraph 5 8 3 Controlling the condensing unit from BEWOT and BEWIT temperature probes 0 2 H o w t o p u t t h e u n i t i n s t a n d b y Stand by modality is obtained every time the unit is switched off It is indicated by the symbol P lit Also in stand by modality the controller can 1 Display the measured va...

Page 3: ... in the group 0 4 4 How to modify a parameter s value 1 Enter the programming procedure 2 Select the desired parameter 3 Press button to enable the value s adjustment 4 Modify the value by means of and buttons 5 Press to store the new value and to pass to the code of the following parameter 6 To exit the procedure Press when a parameter is displayed or wait about 240 seconds without pressing any b...

Page 4: ...ions 9 2 2 3 Installation precautions 10 2 2 4 Precautions during operation 10 2 2 5 Maintenance and repair precautions 11 2 3 Refrigerant gases 11 2 3 1 Refrigerant safety schedule 12 Chapter 3 TECHNICAL DATA 14 3 1 Main technical data 14 3 2 Other data relative to the standard machines MCCY CY 15 3 3 Performance 16 3 4 Sound level measurements 16 Chapter 4 DESCRIPTION 17 4 1 General 17 4 2 Opera...

Page 5: ...tart up 34 7 8 Programming by keyboard 35 7 8 1 Access to Pr1 parameters User level 35 7 8 2 How to modify a parameter s value 35 7 9 Values displayed 36 7 10 Unit switching on off 36 7 11 How to put the unit in stand by 37 7 12 Function menu button 37 7 12 1 Access to Function menu 37 7 12 2 Exit Function menu 37 7 12 3 How to display the alarms ALrM 37 7 12 4 How to display the alarm historic AL...

Page 6: ...parameters 48 7 19 7 Antifreeze resistance supply parameters 48 7 19 8 Defrosting parameters 48 7 19 9 Alarm parameters 49 7 19 10 LASER parameters NOT ENABLED FUNCTION 49 7 20 Compressors unloading function 49 7 21 Probe description 49 7 22 Management of double pump CY 081 301 units only 49 Chapter 8 OTHER COMPONENTS SETTING 50 8 1 Refrigerant high and low pressure switches 50 8 2 Speed regulator...

Page 7: ...nufactured in conformity with ISO 9001 and CEI EN 60335 1 norms In most applications the liquid of the user circuit is water and the term WATER will be used even if the liquid of the user circuit is different from water e g a mixture of water and glycol Here below the term PRESSURE will be used to indicate the gauge pressure The following symbols are shown on the stickers on the unit as well as on...

Page 8: ...operations to ensure long life If spare parts are required this must be original Requests for SPARE PARTS and for any INFORMATION concerning the unit must be sent to the distributor or to the nearest service centre providing the MODEL and MACHINE NUMBER shown on the machine data plate and on the last page of this manual MCCY CY013 020 MODEL DESCRIPTION MC CY x x x Cooling capacity expressed in HP ...

Page 9: ...erstood by all personnel concerned Do not carry out any servicing repair or maintenance work on the unit and auxiliary equipment until the instructions in the relevant sections of this manual are clearly understood by all personnel concerned We cannot anticipate every possible circumstance which might represent a potential hazard The warnings in this manual are therefore not all inclusive If the u...

Page 10: ...properly positioned Arrange lifting cables so that there are no sharp bends Use a spreader bar to avoid side loads on hooks eyes and shackles When a load is on a hoist stay clear of the danger area beneath and around it Keep lifting acceleration and speed within safe limits and never leave a load hanging on a hoist for longer than is necessary The manufacturer does not supply bars belts and liftin...

Page 11: ...cted by fuses against short circuits and overloading When mains power is switched on lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever it is necessary to carry out any work on the electrical system Do not open any electrical panels or cabinets or touch any electrical components or associated equipment while voltage is applied unless it is necessa...

Page 12: ...lugging by paint oil or dirt accumulation Precautions must be taken when carrying out welding or any repair operation which generates heat flames or sparks The adjacent components must always be screened with non flammable material and if the operation is to be carried out near any part of the lubrication system or close to a component which may contain oil the system must first be thoroughly purg...

Page 13: ...vaporates HANDLING AND STORAGE Handling technical measures precautions Ensure sufficient air change and or extraction in the work areas recommendations for safe use Do not inhale vapors or aerosols Storage Close properly and store in a cool dry well ventilated place Store in its original containers Incompatible products explosives flammable materials organic peroxide CONTROL OF EXPOSURE INDIVIDUAL...

Page 14: ...s 760 ml l R125 LC50 inhalation 4 hours lab rats 3480 mg l Local effects Concentrations substantially above the TLV can cause narcotic effects Inhalation of products in decomposition can lead to respiratory difficulty pulmonary oedema Long term toxicity Has not shown any cancerogenic teratogenic or mutagenic effects in experiments on animals ECOLOGICAL INFORMATION Global warming potential HGWP R11...

Page 15: ... 50 F PROTECTION As defined by the EN 60529 European standard REFRIGERANT This is the refrigerant fluid in the unit REFRIGERANT QUANTITY This is the quantity of refrigerant fluid contained in the unit For CY 013 071 MCCY 013 301 models MAX COOLING PRESSURE This is the design pressure of the refrigeration circuit MAX COOLING TEMPERATURE This is the design temperature of the refrigeration circuit Fo...

Page 16: ... h 3850 3850 3500 7900 7300 Model 071 081 101 131 171 for CY units Tank capacity water volume litres 70 150 150 150 150 PUMP P0 water flow rate min max m3 h 1 25 6 2 1 6 8 3 2 1 10 8 2 5 12 6 available head bar 0 89 0 33 0 73 0 48 absorbed power kW 0 61 0 61 0 82 0 82 PUMP P1 water flow rate min max m3 h 1 0 4 38 1 25 6 2 1 6 8 3 2 1 10 8 2 5 12 6 available head bar 0 92 1 70 1 04 1 58 1 30 absorb...

Page 17: ...e water flow rate of the user circuit on its temperature and on the ambient temperature These data are defined in the offer and it is to these that reference should be made 3 4 S o u n d l e v e l m e a s u r e m e n t s at distance of 1 metre 3 2 FT global Test conditions Noise levels refer to operation of the unit at full load in nominal conditions Sound pressure level in hemispherical irradiati...

Page 18: ...that checks the water inlet temperature to the machine in order to keep the outlet temperature inside the set limits 4 3 M a t e r i a l s The data relating to the materials refer to standard machines In case of particular units special materials are used so it is necessary to refer to the data on the offer 4 3 1 Casing The whole base risers panels are in galvanised carbon steel sheet fixed togeth...

Page 19: ...l models If requested the evaporator can be furnished with an antifreeze resistance to prevent risks of freezing see paragraph 4 4 6 Antifreeze resistance NOTE The motocondensing versions MCCY are not equipped with the evaporator and thermostatic valve A remote evaporator and a valve must be installed This operation have to be carried out by qualified personnel For further information see paragrap...

Page 20: ... when the chiller is off and the pump outlet pressure when the chiller in on differential pressure switch on the evaporator to inhibit compressor operation in the case of no water flow through the hydraulic section present even when the hydraulic unit is not present For the data concerning the pump and the tank see the paragraph 3 2 Other data relative to the standard machines MCCY CY NOTE For cor...

Page 21: ...according to the unit model The condenser fan s is are controlled by a regulator which regulates their speed according to the condensing temperature by means of a pressure probe positioned on the coil For the smaller models CY 013 020 you can set the ON OFF regulation After the condenser the refrigerant liquid passes through a capillary completed with drying filter for models CY 013 020 a drying f...

Page 22: ...turer without notice Reproduction of this manual is strictly prohibited For the installation see paragraph 5 8 Cooling circuit connections in MCCY motocondensing units Once the remote evaporator has been installed the MCCY units will work as described in paragraph 4 7 2 Refrigerant circuit only CY models 4 8 E l e c t r i c a l c i r c u i t See annexes ...

Page 23: ... supporting its weight 5 Leave free space around the unit to permit access during service operations see chap 4 5 Overall dimension 6 Do not obstruct or disturb the condenser s flow of thermal exchanging air Position the unit in such a way that the thermal exchanging air cannot recirculate in the intake grilles 7 Ensure that the unit is not subject to warm air from the cooling systems of other mac...

Page 24: ...ations into the water circuit it is advisable to install an automatic bleed valve 4 If the unit is without pump be sure that the pump installed by the user has the aspiration directly connected to the machine so that the pressure into the tank is not too high 0 5 bar suggested Assure by checking on the pressure gauge the tank pressure with pump stopped that the pressure into the water circuit is a...

Page 25: ...sion tank required for a given installation the formula below cab be used and is valid if the pressure is less than or equal to 0 5 bar when the pump is stopped and the maximum working pressure of the expansion tank is greater than or equal to 4 bar The volume of the expansion tank V in litres is given by the formula where Example of calculation Vt 200 litres percentage of ethylene glycol in volum...

Page 26: ... 03 A 3 at the beginning of the electrical supply cable must be guaranteed a protection against direct contacts with a protection degree of IP2X or IPXXB at least 4 at the beginning of the electrical supply cable must be installed protection devices that protect against overcurrents short circuit see information in the electrical wiring 5 use conductors which transform the max current required to ...

Page 27: ...rrect phase sequence or phase failure Tripping of the Phase Monitor stops the unit and causes and A01 alarm is displayed Some measure of instability on the power feeding line can be considered to be normal If the frequency of unit shut downs caused by Phase Monitor tripping should increase contact your electricity company in order to solve the problem ATTENTION It is strictly prohibited to tamper ...

Page 28: ...le flow restrictions caused by excessively tight bends It is essential to comply with the maximum equivalent lengths and maximum level differences shown in the following table On the back site of the MCCY 081 301 units there are refrigerant connections see figure above that have to be welded the dimensions of their diameter are indicated in the table below MCCY Unit Suction line diameter mm Liquid...

Page 29: ...metres it is essential to create a siphon both at the base and also in the vertical section of the suction piping at intervals of 4 5 metres see image above 5 Gradient to facilitate the return of oil to the compressor always impart a 2 gradient to the horizontal sections of piping towards the next siphon or towards the compressor see above diagram 6 Insulation lag exclusively the gas piping for co...

Page 30: ... quantity in the compressors of the various different models 5 8 2 Controlling the condensing unit from a digital input Factory settings Model MCCY condensing units leave the factory with parameters set for control of the unit on a digital input in response to a customer signal Specifically the following contacts are provided on the terminal board see wiring diagram 1 Terminal board contact for re...

Page 31: ...r inlet outlet BEWIT BEWOT temperature probes are furnished with the machine their installation must be carried out by the customer installer BEWIT utilized for the temperature regulation BEWOT utilized for the antifreeze function For the installation see the annexed diagrams ATTENTION The maximum distance between the probes is 100m using screened cable MCCY units Remote evaporator REFRIG INLET RE...

Page 32: ...r that these three components would have the some rotation direction So if one works in the right way even the other do Check the rotation direction of each component at the first start up of the unit and after any maintenance intervention If the rotation direction is wrong for all components invert two supply phases of the electronic board If on the contrary they are not correctly connected inver...

Page 33: ...etting of parameter CF36 see 7 9 Values displayed Lower left zone The display generally presents the following information unit status condensing pressure BCP1 only in MCCY units with thermostat control digital input Condensing temperature or evaporator water antifreeze temperature heat pump hydraulic unit with relative units of measurement NOTE The displaying depends on the setting of parameter C...

Page 34: ...ir values If pressed for 5 seconds it allows to display or modify the set point During programming phase it selects a parameter of confirms a value It allows to enter Function Menu and to regulate the hour BUTTONS FUNCTION To enter programming phase pressed for 5 sec To exit programming phase LED LED STATUS MEANING LED LED STATUS MEANING 4 Steady Unit on in heat pump modality 5 Steady Defrosting e...

Page 35: ...on between the unit and the remote terminal in the upper part of the display it appears the message OP no link 7 5 D i s p l a y i n g d u r i n g a n a l a r m 7 5 1 Alarm icons There are four icons for alarm signalling 7 6 H o w t o s i l e n c e t h e b u z z e r Automatic silencing it happens when the cause of the alarm has been eliminated Manual silencing press and release one of the four but...

Page 36: ... the display It will not be possible to enter a parameter s group which is not part of this menu 4 It is possible to scroll or modify the parameters contained in the group 7 8 2 How to modify a parameter s value 1 Enter the programming procedure 2 Select the desired parameter 3 Press button to enable the value s adjustment 4 Modify the value by means of and buttons 5 Press to store the new value a...

Page 37: ... 1 In the bottom part of the display it appears the probe BEWOT Parameter CF42 CF44 2 In the bottom part of the display it appears the probe BCP1 Parameter CF42 CF44 3 In the bottom part of the display it appears the probe BAT1 Parameter CF42 CF44 4 In the bottom part of the display it appears the chiller set off when unit in stand by Parameter CF42 CF44 5 In the bottom part of the display it appe...

Page 38: ...ress or to scroll all alarms 5 To exit press or wait for time out 30 seconds 7 12 3 6 How to reset an alarm rSt 1 Press to enter Function menu 2 Select ALrM function 3 Press in the lower part of the display it appears the alarm code 4 If the alarm can be reset in the upper part of the display it appears the Label rSt it the alarm can not be reset it appears the Label NO 5 Use or button to scroll a...

Page 39: ...t appears SetC if chiller The adjusted value appears in the upper part of the display 7 13 2 How to modify the Set Point 1 Press button for 3 seconds at least 2 The set point will flash 3 Use or button to modify the set point value 4 To store the new set point value press button or wait for time out to exit programming procedure 7 1 4 S e l f a d a p t i v e f u n c t i o n e x c e p t f o r m o t...

Page 40: ... of BCP1 probe Probe damaged or resistive value power value out of range open collector outlet alarm relay is activated The buzzer is activated The icon for general alarm flashes The alarm code is displayed Automatic If the resistive value returns within the envisaged range P4 Alarm of BAT1 probe Probe damaged or resistive value out of range open collector outlet alarm relay is activated The buzze...

Page 41: ...igital input disabled and the resetting procedure is carried out A08 Flow meter alarm air water or water water units Digital input enabled enabled for time set open collector outlet alarm relay is activated The buzzer is activated The icon for flow meter alarm flashes The alarm code is displayed Automatic It becomes manual after tripping per hour Manual Disabling Digital input disabled for time se...

Page 42: ... outlet alarm relay is activated The buzzer is activated The icon for general alarm flashes The alarm code is displayed Automatic With correct re programming ACF3 Configuration alarm Two digital inputs with the same configuration open collector outlet alarm relay is activated The buzzer is activated The icon for general alarm flashes The alarm code is displayed Automatic With correct re programmin...

Page 43: ...logue input antifreeze Yes Yes Yes A07 Digital input antifreeze Yes Yes Yes A07 Motorcondensing antifreeze Yes Yes Yes Yes A08 Flow meter Yes Yes Boiler Res Yes Yes A09 Compressor 1 thermal protection Yes A10 Compressor 2 thermal protection Yes A09 A10 Compressor 1 2 thermal protection Yes Yes Yes A13 Compressor 1 maintenance A14 Compressor 2 maintenance A15 Water pump maintenance A20 Low water te...

Page 44: ...y with CF21 2 and CO08 1 compressor 1 starts with CF21 2 and CO08 0 a compressor required by the thermoregulator starts OnH is displayed in the upper part When the modality has been chosen the digital input enabling or disabling will switch on or off the unit and the appropriate loads compressor Only when the contact is energized if the unit was switched off by keyboard it must be switched on agai...

Page 45: ...p 2 no displaying in the top 3 BAT1 temperature is displayed in the top 4 unit set point is displayed in the top 5 unit status is displayed in the top 6 Laser set is displayed in the top NOT ENABLED FUNCTION 7 no displaying in the top 8 the operating differential is displayed in the top the chiller set is displayed when the unit is in chiller modality the heat pump set when the unit is in heat pum...

Page 46: ...ttom 8 the operating differential is displayed in the bottom the chiller set is displayed when the unit is in chiller modality the heat pump set when the unit is in heat pump modality or off with stand by unit OnC is displayed when the unit is in chiller modality OnH when the unit is in heat pump modality or off with stand by unit Pr2 Password it allows to fix a numeric code for the password from ...

Page 47: ...MCCY units with control by temperature probes see 5 8 2 Controlling the condensing unit from a digital input Factory settings 0 only in MCCY units with control by temperature probes see 5 8 3 Controlling the condensing unit from BEWOT and BEWIT temperature probes CF04 only in MCCY units BEWIT configuration 0 probe absent 1 NTC temperature at evaporator inlet 2 thermoregulator request digital input...

Page 48: ...of bottom part 0 BEWIT 1 BEWOT 2 BCP1 3 BAT1 4 unit setpoint 5 unit status 6 Laser set 7 none 8 operating differential the chiller set is displayed when the unit is in chiller modality the heat pump set when the unit is in heat pump modality or off with stand by unit OnC is displayed when the unit is in chiller modality OnH when the unit is in heat pump modality or off with stand by unit 0 8 4 CY ...

Page 49: ...and by unit OnC is displayed when the unit is in chiller modality OnH when the unit is in heat pump modality or off with stand by unit 0 8 4 CY or MCCY units with control by temperature probe see 5 8 3 Controlling the condensing unit from BEWOT and BEWIT temperature probes 2 only MCCY units with control by digital input see 5 8 2 Controlling the condensing unit from a digital input Factory setting...

Page 50: ...ompressors even when the temperature of the water at the evaporator s inlet is high summer start up with hot water accumulation preventing the possible triggering of high pressure alarms It is not present in one compressor units The following messages will flash on the display AEUn evaporator unloading function ACUn condensation unloading function 7 2 1 P r o b e d e s c r i p t i o n For the posi...

Page 51: ...rking and for people safety It is of an automatic reset type Its tripping is detected by the electronic board which will open the compressor power supply circuit and will display the alarm signal A01 see chapter 7 16 Alarm codes and actions and the fan s will be activated for 60 seconds to the max speed to contrast the alarm situation than they will be stopped When the compressor outlet pressure d...

Page 52: ...rease the regulator will increase continuously the fan speed to increase the air flow through the condenser The following graphic shows the progress of the fan rotation speed according to the condensing pressure changings ATTENTION The pressure and the fans rotation speed values are set by the electronic control 8 3 W a t e r d i f f e r e n t i a l p r e s s u r e s w i t c h o n l y C Y u n i t ...

Page 53: ...with the installation or the maintenance of these units be sure that all personnel concerned have read and understood the Chapter 2 Safety These machines will give many years of trouble free service if they are properly maintained and serviced 9 2 1 Unit access You can remove the protection panels for the maintenance of the unit To remove the panels use a screw drive and unscrew the fixing screws ...

Page 54: ...n the evaporator see FIG A Units MCCY CY 031 071 to access the refrigerant circuit and the pump remove the panel a L B to access the electric board components set the main switch on O and remove the panel C to access the water circuit components remove the panel A before you have to remove the panel D to access the fan and the condenser remove the panel D Units MCCY CY 081 101 Units MCCY CY 131 30...

Page 55: ... of this manual is strictly prohibited in the CY 081 301models with the hydraulic group there is a cock in the lower part of the connections side see FIG B and a second one in the evaporator see FIG A in the CY 031 071models without hydraulic group there is only one cock in the evaporator see FIG A Units CY 031 071 Units CY 081 301 FIGURE A Units CY 013 020 Units CY 031 071 Units CY 081 301 FIGURE...

Page 56: ...ing operation becomes indispensable when the unit is without antifreeze resistance and must remain OFF for a long time in an ambient with temperatures which could reach the freezing values of water inside the evaporator risk of evaporator breaking Plate evaporators Once the water has been drained from the bottom valve B use a compressed air jet inside the exchanger to remove all water residue Remo...

Page 57: ...ar is not lower than the value corresponding to the maximum flow Clean the water filter if installed We recommend to clean the filter after a week from the unit starting Check that the liquid indicator if present is full or with a small stream of bubbles when the compressor is running Check that the unit current absorption is within the values on the data plate Carry out visual inspection of refri...

Page 58: ...d the body of the compressor are very hot the compressor stops and tries to restart after a short period even a few seconds Get a technician to check for leaks and eliminate them Fill the unit B Low head values water pressure at pump delivery B1 Water flow too high The pump doesn t work properly water flow too high low head value high power absorption B1 1 Possible increase in the outlet temperatu...

Page 59: ...alternate with the value of the BEWIT probe main alarm relay tripped the led of the lights up Repair or change the fan Check the thermal protection of the fan Follow the alarm reset procedure to star up the unit again Chapter 7 Electronic Board Check the fan speed regulator system D2 Ambient temperature too high D2 1 Ambient temperature higher than the maximum value See D1 1 Reduce ambient tempera...

Page 60: ...protection device trips Alarm displayed A09 or A10 The led of the icon lights up Call a qualified refrigeration technician to check for leaks and replenish refrigerant charge F2 The scroll compressor rotation direction is wrong only three phases units F2 1 Refrigerant compressor stops the unit does not cool Invert two phases of the electrical supply G Digital display and all LEDs off main switch P...

Page 61: ...the pressure difference read on the machine gauge with the pump stopped and pump running is lower than the available head with maximum pump flow Reset the thermal protection device Increase the pressure drop in the hydraulic circuit for example by partially closing the pump output valve J2 The grille through which the pump cooling air passes is obstructed J2 1 See problem main alarm relay tripped ...

Page 62: ...the unit suffered transport or installation damage Have the minimum installation clearances specified in this manual been observed Are the condensing coils free of obstructions General condition of unit is in compliance Do not start the unit before repairs Correct installation of the unit working in compliance with the instructions given in the manual Clean condensing coils Are the fan grilles fre...

Page 63: ...r differential pressure switch working correctly Connect high and low pressure gauges to check the measured operating pressure values are correct Setting high pressure value to approx 14 bar gas leaks 3 grams year are detected Start procedure terminated Trip test Adjust the unit water gate valves to reduce the flow rate to the evaporator Stop the unit and find the cause of the problem Check and or...

Page 64: ...een removed Water flow rate to evaporator is as prescribed in the manual Any flow switches installed enabled and correctly connected Water filter upstream from evaporator installed correctly Water filter upstream from condenser installed correctly Water connections have been made correctly Adapt the connections Correct connections Fill hydraulic circuit and or bleed the air if present Adjust water...

Page 65: ...am Power feeding conductors are fit for purpose wiring diagram Protective earth connection complies with statutory legislation Protection upstream from unit is adequate Correct phase sequence Unit electrical connection is properly executed Connect the unit to the correct power supply voltage Replace conductors with conductors of an appropriate type Remake the connection in compliance with statutor...

Page 66: ...ual even partial is strictly prohibited OIL CHECKLIST Start No Yes Sufficient oil level in compressor If required has crankcase heater been switched on at least 6 hours before start up The compressor is ready to start Check the oil sight glass if present Top up as necessary Activate crankcase preheating and wait 6 hours No Yes ...

Page 67: ...T Start No Remove all unauthorised persons from the test area Power on the unit Check the display light up Contactors and devices functioning correctly Check the unit is in stand by icon unlit Start the unit by means of or button The START UP procedure has now been completed Check the component and renew if necessary Yes All On Off operations must be performed exclusively using or button ...

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