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Installation, Operation and

Maintenance Manual

CLIC Series

Air-Cooled Scroll Compressor Chiller

Water Generator Unit

Model
25 to 250 RT
Refrigerant HFC-410A or 454B
50/60 Hz

IOM

Group: Chiller

Part Number: IOM CLIC

Date: 28 November 2023

Содержание Clima-Flex CLIC Series

Страница 1: ...ation and Maintenance Manual CLIC Series Air Cooled Scroll Compressor Chiller Water Generator Unit Model 25 to 250 RT Refrigerant HFC 410A or 454B 50 60 Hz IOM Group Chiller Part Number IOM CLIC Date...

Страница 2: ...Features Benefits 6 Installation and Application Information 8 Refrigeration Schematics 18 Dimensions and Weights Single Unit 21 Vacuum Refrigerant Charge 32 Drop Data 35 Electrical Data 36 R454B Elec...

Страница 3: ...ed at least 12 hours before startup Chiller components EXV Sensors Transducers installed and wired properly Wiring complies with National Electrical Code and local codes See Notes Miscellaneous Yes No...

Страница 4: ...e breaker may result in electric shock or fire WARNING If refrigerant leaks from the unit there is a potential choking danger as the refrigerant will displace air in the immediate area Be sure to foll...

Страница 5: ...ump UNITS 1 Stand alone 2 2 units 3 3 units 4 4 units 5 5 units 6 6 units 7 7 units 8 8 units 9 units 10 10 units CONDENSER FAN A Axial Fixed ANTICORROSION C Coat in Condenser I Coat in Components M T...

Страница 6: ...nt comes with a 1 year major warranty after start up Our units use R410A or R45B refrigerant which is harmless to the ozone layer and is non toxic and non flammable even in case of leakage Finally the...

Страница 7: ...water based synthetic coating with ES2 pigment applied to all areas of the coating surface with no bridging of material between fins Therefore ES2 pigments are suitable for even the most corrosive env...

Страница 8: ...he unit nameplates the serial number is unique to the unit These numbers should be used to identify the unit in case of service parts or warranty questions This nameplate also contains the unit s refr...

Страница 9: ...it on a solid base that will not settle Use a one piece concrete slab with a foundation extended below the frost line Ensure that the foundation is level to within 13 mm over its entire length and wid...

Страница 10: ...m to be installed Nipples for interconnection between mother and child equipment A pair of nipples with thermowell for placement of general temperature sensors Couplings for connection of vitaulic 2 p...

Страница 11: ...t within the space outside air temperature and many other factors may require more clearance than shown Additional clearances may be required under certain circumstances The graphs on the following pa...

Страница 12: ...ation to ensure that it has sufficient airflow characteristics and is approved by the facility s design engineer to avoid the risk of an accident Figure 5 Three or more units side by side Figure 4 Two...

Страница 13: ...ons adhering to AWWA C606 optionally with flanges PVC piping should not be used Installation and Application Information Figure 7 Typical piping of a welded plate evaporator series CLIC Tandem It is r...

Страница 14: ...er considerations All chilled water systems need adequate time to recognize a load change respond to the change and stabilize to avoid undesirable compressor short cycling or loss of temperature contr...

Страница 15: ...must not be drained in freezing tem peratures or contain glycol the chiller may be subject to cata strophic evaporator failure due to freezing Installation and Application Information FLOW SWITCH All...

Страница 16: ...water piping and drain connections on the inlet water piping Immersion heater for each auxiliary heat exchanger for freeze protection Partial heat recovery connections are listed below 1 An external...

Страница 17: ...resistance of more than 10 000 hours applied to both the coil and the coil heads Epoxy coated coils also receive a UV resistant urethane topcoat to provide superior resistance to degradation from dir...

Страница 18: ...iom clic cf eng www clima flex com 18 Refrigeration Schematics Figure 9 CLIC 25 RT heat pump refrigeration schematics...

Страница 19: ...iom clic cf eng www clima flex com 19 Refrigeration Schematics Figure 10 CLIC 25 RT heat recovery refrigeration schematics...

Страница 20: ...iom clic cf eng www clima flex com 20 Refrigeration Schematics Figure 11 CLIC 25 RT cooling only refrigeration schematics...

Страница 21: ...Unit Figure 12 Dimensional configuration 25 RT Table 4 Dimensions and weights UNIT High Length Width Weight in mm in mm in mm kg lb CLIC 25 TR R410 81 3 4 2076 43 87 1 8 2214 32 1 2 825 700 750 154 1...

Страница 22: ...iom clic cf eng www clima flex com 22 Dimensions and Weights Single Unit Figure 13 Dimensional configuration 25 RT R454B...

Страница 23: ...iom clic cf eng www clima flex com 23 Dimensions Packaged Units Figure 14 Dimensional configuration 50 RT...

Страница 24: ...iom clic cf eng www clima flex com 24 Dimensions Packaged Units Figure 15 Dimensional configuration 75 RT...

Страница 25: ...iom clic cf eng www clima flex com 25 Dimensions Packaged Units Figure 16 Dimensional configuration 100 RT...

Страница 26: ...iom clic cf eng www clima flex com 26 Dimensions Packaged Units Figure 17 Dimensional configuration 125 RT...

Страница 27: ...iom clic cf eng www clima flex com 27 Dimensions Packaged Units Figure 18 Dimensional configuration 150 RT...

Страница 28: ...iom clic cf eng www clima flex com 28 Dimensions Packaged Units Figure 19 Dimensional configuration 175 RT...

Страница 29: ...iom clic cf eng www clima flex com 29 Dimensions Packaged Units Figure 20 Dimensional configuration 200 RT...

Страница 30: ...iom clic cf eng www clima flex com 30 Dimensions Packaged Units Figure 21 Dimensional configuration 250 RT...

Страница 31: ...iom clic cf eng www clima flex com 31 Dimensions Packaged Units Figure 22 Dimensional configuration 250 RT...

Страница 32: ...om register 3 simply loosen the connection to purge the nitrogen To obtain an accurate vacuum value isolate the vacuum pump from the system by closing register 1 and waiting about 5 minutes for an acc...

Страница 33: ...frigerant Charge Figure 23 Diagram for obtaining vacuum and for refrigerant charge COMPRESSOR MODEL R410A LBS R410A GR VZH117 Microchanel 19 07 8650 0 SH295 Microchanel 19 07 8650 0 DSH295 Microchanel...

Страница 34: ...as well as high temperatures inside the area where the R 454B refrigerant charge will be carried out Figure 24 Diagram to obtain vacuum and for R454B refrigerant charge COMPRESSOR MODEL R454B LBS R45...

Страница 35: ...6 94 M E 2 75 3 180 4 47 78 M E 3 100 4 240 4 49 34 M E 4 125 5 300 4 51 86 M E 5 150 6 360 4 55 55 M E 6 175 7 420 6 49 07 M E 7 200 8 480 6 50 23 M E 8 225 9 540 6 51 73 M E 9 250 10 600 6 53 58 30...

Страница 36: ...n accordance with the NEC Refer to the unit nameplate and unit selection report for correct electrical ratings 1 The control transformer is supplied and no separate 115V power is required For single a...

Страница 37: ...r while the chiller is running can cause serious damage to the chiller The procedure required to reconnect generator power to the mains is as follows 1 Set the generator to always run five minutes lon...

Страница 38: ...iom clic cf eng www clima flex com 38 Electrical Data Figure 26 Typical field wiring diagram of the 220V fixed master single chiller unit single point connection with all options shown...

Страница 39: ...iom clic cf eng www clima flex com 39 Electrical Data...

Страница 40: ...iom clic cf eng www clima flex com 40 Electrical Data Figure 27 Typical field wiring diagram of the 220V slave single cold unit single point connection with all options shown...

Страница 41: ...iom clic cf eng www clima flex com 41 Electrical Data...

Страница 42: ...iom clic cf eng www clima flex com 42 Electrical Data Figure 28 Typical field wiring diagram of 440V slave single cold unit single point connection with all options shown...

Страница 43: ...iom clic cf eng www clima flex com 43 Electrical Data...

Страница 44: ...iom clic cf eng www clima flex com 44 Electrical Data Figure 29 Typical field wiring diagram of 440V master cool only unit single point connection with all options shown...

Страница 45: ...iom clic cf eng www clima flex com 45 Electrical Data...

Страница 46: ...iom clic cf eng www clima flex com 46 Electrical Data...

Страница 47: ...iom clic cf eng www clima flex com 47 Electrical Data Figure 30 Typical 440V slave heat pump unit field wiring diagram single point connection with all options shown...

Страница 48: ...iom clic cf eng www clima flex com 48 Electrical Data...

Страница 49: ...iom clic cf eng www clima flex com 49 R454B Electrical Data Figure 31 Power wiring diagram for R454B master unit 230 3 60...

Страница 50: ...iom clic cf eng www clima flex com 50 R454B Electrical Data Figure 32 Analog inputs AI1 AI14 Figure 33 Analog outputs A01 A06 Electronic expansion valve...

Страница 51: ...iom clic cf eng www clima flex com 51 R454B Electrical Data Figure 34 Digital inputs DI1 DI16 Figure 35 Digital output DO1 DO15 Power supply MCX...

Страница 52: ...iom clic cf eng www clima flex com 52 R454B Electrical Data Figure 36 Fan controller gas leakage sensor Figure 37 Compressor controller circuit...

Страница 53: ...iom clic cf eng www clima flex com 53 R454B Electrical Data Figure 38 RS485 communication...

Страница 54: ...iom clic cf eng www clima flex com 54 R454B Electrical Data Figure 39 Power wiring diagram for R454B son 230 3 60 unit...

Страница 55: ...iom clic cf eng www clima flex com 55 R454B Electrical Data Figure 40 Analog inputs AI1 AI14 Figure 41 Digital inputs DI1 DI16...

Страница 56: ...iom clic cf eng www clima flex com 56 R454B Electrical Data Figure 42 Analog outputs A01 A06 Electronic expansion valve Figure 43 Digital output DO1 DO15 Power supply MCX...

Страница 57: ...iom clic cf eng www clima flex com 57 R454B Electrical Data Figure 44 Fan controller gas leakage sensor...

Страница 58: ...s if a fault occurs The controller menu contains different screens and submenus that provide the operator or service technician with a complete overview of 1 User 2 Maintenance 3 Service Manufacturing...

Страница 59: ...TC Thermistor R25 10K 1 25 85 3435K 1 discrete type No SMD U5 GENERAL INJECTION GENERAL INJECTION NTC NTC Thermistor R25 10K 1 25 85 3435K 1 discrete type No SMD U6 CONDENSER TEMPERATURE CONDENSER TEM...

Страница 60: ...ECTOR PHASE MOTOR PROTECTOR DRY CONTACT N A Table 14 Digital outputs of SLAVE unit DESCRIPTION COLD AIR TYPE DESCRIPTION HOT AIR TYPE SIGNAL TYPE EXPECTED RANGE NO1 COMPRESSOR stage 1 VENTILATOR COMPR...

Страница 61: ...RRENT YEAR 9999 YEARS WORKING HOURS DISPLAY 1 TOTAL STARTS COMP M 0 0 a 999 COMP E1 0 0 a 999 COMP E2 0 0 a 999 COMP E3 0 0 a 999 COMP E4 0 0 a 999 COMP E5 0 0 a 999 COMP E6 0 0 a 999 COMP E7 0 0 a 99...

Страница 62: ...E1 0 0 to 999 COMP E2 0 0 to 999 COMP E3 0 0 to 999 COMP E4 0 0 to 999 COMP E5 0 0 to 999 COMP E6 0 0 to 999 COMP E7 0 0 to 999 LOW PRESSURE BP METER COMP M 0 0 to 999 COMP E1 0 0 to 999 COMP E2 0 0 t...

Страница 63: ...tton on No Evaporator pump output on Is flow present No Wait the time for the start up compressor The contactor auxiliar remains on while chiller is enabled Is the protection module or frecuency varia...

Страница 64: ...ation run need more capacity Increase unit capacity Unit turn up full capacity Operation of circuit in stabilization Unit turn down full capacity Decrease unit capacity Is unit running at minimun capa...

Страница 65: ...LWT Evaporator saturated temperature Capacitor approach The capacitor approximation will be calculated for each circuit The equation is as follows Capacitor approximation Capacitor saturated temperat...

Страница 66: ...own A compressor must be shut down if any of the following situations occur The unit s capacity control logic commands it to shut down A discharge alarm occurs and sequencing requires this compressor...

Страница 67: ...he bulb to make sure it is properly connected to the suction line If you can move the bulb manually it is not properly secured The bulb must be perfectly insulated to protect it against the effects of...

Страница 68: ...LLED WATER CONDENSER E1 EVAPORATOR FLOW ALARM E1 E1 CONDENSER FLOW ALARM E1 E1 REFRIGERANT ALARM E1 E1 INJECTION SENSOR PROBE FAILURE E1 RETURN SENSOR PROBE FAILURE E1 SLAVE ALARMS E2 ENGINE SAVER ALA...

Страница 69: ...E E5 E6 SLAVE ALARMS E6 ENGINE SAVER ALARM LOW PRESSURE ALARM E6 HIGH PRESSURE ALARM E6 EVAPORATOR FREEZE ALARM E6 E6 CONDENSER FREEZE ALARM CONDENSER HIGH CHILLED WATER CONDENSER E6 E6 EVAPORATOR FLO...

Страница 70: ...at the moment of switching on the equipment Incorrect Form When connected in this way the equipment cannot be manipulated and the display will show EQUIPMENT NOT CONFIGURED To reset it is necessary to...

Страница 71: ...eturn readings of the main unit will be displayed In the unit section the injection and return sensor readings of all units will be displayed The trend properties that can be edited are the duration h...

Страница 72: ...r In this screen you can set the time and date of the log alarms or the information about the diagnostics This screen can check the counter of each high pressure failure low pressure failure and the w...

Страница 73: ...an extract Alarm log Injection and return temperatures of the master unit Injection and return temperatures of the slaves User log If the user presses the reset button it will be possible to reconfigu...

Страница 74: ...troller Use IP DISPLAY AND CONFIGURATION To view the IP of the unit click on the indicated point to open the menu Click About What s my IP The configured IP will then be displayed To configure IP clic...

Страница 75: ...ic cf eng www clima flex com 75 Controller Use Option 1 Option 2 For IP configuration press edit to assign the desired IP Option 1 Option 2 Presionar Show system settings el men puede variar en su int...

Страница 76: ...the equipment PGDX TOUCH 7 CAREL CONNECTION Once the connection has been made correctly the temperatures and other data of the equipment will appear on the screen as shown in the following image Corre...

Страница 77: ...iom clic cf eng www clima flex com 77 Clic R454b Unit This unit use the R454B Refrigerant...

Страница 78: ...iom clic cf eng www clima flex com 78 Control User Interface MXC controller has a LCD display where the chiller can be configured and operated Main Screen Keyboard Refrigeration Circuit Status Screen...

Страница 79: ...nds for LCD display only Note You can also access alarm visualization by pressing the ESC key from the main screen The alarm is only reset if the alarm has ended and it will return you to the main scr...

Страница 80: ...d CAN 1 100 1 RW 3009 bAU Serial baudrate Modbus 0 8 8 384 Enum 4 RW 3010 COM Serial settings Modbus 0 2 1 8E1 Enum 5 RW 3011 CFG Parameters Unit config H11 Fans in common to all condensers 0 1 0 NO E...

Страница 81: ...I01 Minimum Speed 0 0 100 0 30 0 RW 3041 I02 Maximum Speed 0 0 100 0 100 0 RW 3042 EVA Parameters Evaporator P01 Number of Evaporator Pumps 1 2 1 RW 3043 AFr Flow Switch Alarm Reset Type 1 5 3 RW 3044...

Страница 82: ...e 1 240 15 s RW 3067 N17 Startup OD 0 100 50 RW 3068 N21 SH reference mode 0 3 0 Fixed Enum 15 RW 3069 N07 SH fixed setpoint 2 0 40 0 7 0 K RW 3070 N09 SH maximum 2 0 40 0 12 0 K RW 3071 N10 SH minimu...

Страница 83: ...0 Oil Boost Type 0 2 1 OLEV Enum 17 RW 3099 O01 Min Speed Limit Percent 0 0 O04 50 0 RW 3100 O02 Low Speed Running Time 1 O03 3 min RW 3101 O03 Fixed Oil Boost Interval O02 600 20 min RW 3102 O04 Oil...

Страница 84: ...rse Enum 21 RW 3128 VSJ Start Delay 0 0 360 0 180 0 s RW 3129 VSK Start Speed 1800 10000 1800 RW 3130 DT8 VZH Discharge Temper Serious Alarm 0 1 1 YES Enum 3 RW 3131 HS7 Heatsink Serious Alarm 0 1 0 N...

Страница 85: ...g speed 0 0 100 0 5 0 RW 3148 F11 Minimum speed 0 0 100 0 5 0 RW 3149 DTL Parameters Data Log SDL Enable SD Card Log 0 1 1 YES Enum 3 RW 3150 ICE Alarm Config ICE Water Alarm AIT Ice Water Alarm Thres...

Страница 86: ...ECF Enable Ctrl Panel Fan 0 1 1 YES Enum 3 RW 3171 CPF SP Ctrl Panel Fan 0 0 100 0 24 0 C RW 3172 DCF Dif Ctrl Panel Fan 0 0 100 0 1 0 C RW 3173 dO1 Delay OFF Ctrl Panel Fan 0 600 60 s RW 3174 DPF Pan...

Страница 87: ...arge Temperature 50 0 110 0 NTC 10K Read 18507 11 Liquid Temperature 50 0 110 0 NTC 10K Read 18509 12 Air Ambient Temperature 50 0 110 0 NTC 10K C Read 18508 13 Control Panel Temp 50 0 110 0 NTC 10K R...

Страница 88: ...d Pump 0 100 0 10 V Read 19007 6 7 EXV Valve 0 100 EXV Read 19005 8 DO DIGITAL OUTPUTS 1 2 4 Way Valve 0 1 N O Read 18010 3 Start Fan 1 0 1 N O Read 18011 4 Start Fan 2 0 1 N O Read 18012 5 Liquid Val...

Страница 89: ...hnician must select between mother or son configuration The functionality is basically the same but it changes on compressor control because on Mother unit we need to use VZH and Oil Management featur...

Страница 90: ...s validated by this block where the program identifies if a sensor has a failure or not If a sensor has a problem the logic will trip an alarm and the user has to clear and check the root cause of the...

Страница 91: ...nd actions in the MCXShape When you drag an alarm from the Resources into the logic area you retain all these settings The main logics of the alarms are Serious Alarm when phase protector trips Figure...

Страница 92: ...p is Ice Water Alarm and if the temperature continuing decreases and the unit has not stopped the Ice alarms must trip immediately Figure 56 Logic of Ice Alarm DGS Alarm When the DGS detects a leak of...

Страница 93: ...evap pump running 0 1 AUTO ACTIVE Read 1901 03 HP1 High Pressure 0 1 ALt INACTIVE Read 1901 04 LP1 Low Pressure 0 1 ALr INACTIVE Read 1901 05 C11 General Compressor 1 0 1 AUTO ACTIVE Read 1901 06 A06...

Страница 94: ...UTO ACTIVE Read 1903 00 W01 Oil Level Switch Warning 0 1 AUTO ACTIVE Read 1903 01 T27 T27 Active 0 1 AUTO ACTIVE Read 1903 02 T37 T37 Active 0 1 AUTO ACTIVE Read 1903 03 T18 T18 Active 0 1 AUTO ACTIVE...

Страница 95: ...IVE Read 1905 09 W74 DGS Modbus Fault 0 1 AUTO ACTIVE Read 1905 10 FA1 Fan 1 Inv Alarm 0 1 AUTO ACTIVE Read 1905 11 FA2 Fan 2 Inv Alarm 0 1 AUTO ACTIVE Read 1905 12 Mother Son Logic Evaporator Pump co...

Страница 96: ...lic cf eng www clima flex com 96 Mother Son Logic Set point Control This section defines if the set point Temperature Differential will work with heat or cooling mode Figure 59 Logic of Set point Sele...

Страница 97: ...demand according to the value of actual Leaving Water Temperature versus the Set Point defined by the user The function that calculates that value is a PI Proportional integral block The Flow chart o...

Страница 98: ...iom clic cf eng www clima flex com 98 Figure 61 Logic of Demand Calculation Figure 62 Logic of Regulation Control Box PI section Mother Son Logic...

Страница 99: ...he operation of the compressor The Boxes are EnableRegulationControl This box validates if all conditions are correct to enable the regulation Figure 63 Box for Enable Regulation CompressorControl Thi...

Страница 100: ...65 VZH Map Control sequence VZH Oil Manager only for mother unit The brick controls the oil level in VZH compressors and takes the appropriate actions to ensure the safe operation of the compressors...

Страница 101: ...orator temperature sensor TetempeatureValue and one pressure sensor suction pressure are needed The actual superheat is calculated based on these two sensor readings and the controller will adjust the...

Страница 102: ...lower than target Increase target discharge pressure when the EEV is fully open this may be happening for Data Center applications and or chiller starting in a building after being off for a long time...

Страница 103: ...s Db Ptarget Param_Db Deadband Mode enabled IF Db P_Disc Db What it does Deadband mode holds the value from when the control variable P_disc enters the Deadband range When exiting either side of the d...

Страница 104: ...verride fans if Timer Elapsed Param_Fan_Off_timer o Default 2 min test if this is too long Override the Timer if P_Disc Cutoff_overide The set point of the discharge pressure is a floating SP that wil...

Страница 105: ...iom clic cf eng www clima flex com 105 SD Card Log Control It is possible to record 32 values in the SD card with an adjustable Sample rate Factory default is 10 seconds Mother Son Logic...

Страница 106: ...displayed on the control panel The control panel The power LED is activated when the frequency inverter is supplied with mains voltage Green LED on The control section is running Yellow LED Warning I...

Страница 107: ...nal via the digital inputs has higher priority than the Hand on and Auto on control keys QUICK TRANSFER OF PARAMETER SETTINGS Once the configuration of a frequency converter has been completed store t...

Страница 108: ...The following parameter groups can be accessed 0 Operation Display 1 Load Motor 3 Reference Ramps 4 Limits Warnings 5 Digital input output 6 Analog input output 7 Controls 8 Communication and options...

Страница 109: ...heck the correct structure of the water supply Check that all pipes are filled with water and that air has been evacuated Check thermometers not included from factory Check the pressure gauges not inc...

Страница 110: ...tart If water flow is detected in the piping the internal sequence of the unit will start NOTE After completing the inspection of the above installation points and making sure that all elements of the...

Страница 111: ...e performed on a regular basis Over long periods of operation the heat exchanger will become fouled impairing efficiency and reducing the units performance Consult your local supplier about cleaning t...

Страница 112: ...ended that the unit be turned on 24 hours prior to first start up to begin warming up the compressor crankcase HYDRAULIC MAINTENANCE Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Cleaning of the hyd...

Страница 113: ...Inspection of fan blades cleaning of fan blades Quarterly Plan x x x x Real Compressor power consumption check to determine refrigerant loss quarterly Plan x x x x x x Real Compressor oil inspection m...

Страница 114: ...he solenoid Check wiring Motor electrical problems Check for open shorted or bubbled motor Loose wiring Check all wire connections and tighten all terminal screws Compressor makes noise or vibrates Co...

Страница 115: ...of regulating condenser temperature Excess oil used If the system has excess oil recover and adjust by observing the sight glass on the compressor Motor overload relays or circuit breakers open Volta...

Страница 116: ...e Loose fitting in oil line Correct to bring conditions within allowable limits Compressor staging intervals too short Control band not properly adjusted Check and correct Water temperature sensor fai...

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