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Installation, Operation and

Maintenance Manual

IOM

Group: Chiller

Part number: CLIV IOM

Date: 29 May 2023

CLIV Series

Air-Cooled Scroll Compressor Chilled

Water Chiller Unit

Model
3,5 and 10 RT
Refrigerant HFC-410A
50/60 Hz

Содержание Comfort Flex CLIV Series

Страница 1: ...on Operation and Maintenance Manual IOM Group Chiller Part number CLIV IOM Date 29 May 2023 CLIV Series Air Cooled Scroll Compressor Chilled Water Chiller Unit Model 3 5 and 10 RT Refrigerant HFC 410A...

Страница 2: ...cal Data 20 Unit Controller Operation 28 Sequence Of Operation 32 Unit Functions 34 Circuit Functions 35 Alarms 37 Controller Use 43 Startup and shutdown procedures 60 Unit Maintenance 63 Troubleshoot...

Страница 3: ...tup Cooler components EXV sensor transducers installed and wired properly Wiring complies with National Electrical Code and local codes See Notes Various Si No N A Iniciales Unit control disconnects e...

Страница 4: ...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 follo...

Страница 5: ...0 060 60 000 120 120 000 AIR DISCHARGE HD Horizontal Discharge OPERATION C Cooling Only H Heat Pump UNITS 1 Stand alone CONDENSER FAN A Axial Fixed ANTICORROSION C Coat in Condenser I Coat in Componen...

Страница 6: ...ions DANGER Improper rigging lifting or moving of a unit can result in property damage serious personal injury or death Follow the rigging and moving instructions carefully Do not stand under the unit...

Страница 7: ...ated by the unit is mainly due to the rotation of fans and compressors If the unit is properly installed operated and regularly maintained the noise levels do not require any special protective device...

Страница 8: ...wall openness is less than recommended for the distance to the unit it should be considered a solid wall The wall height is assumed to be equal to or less than the height of the unit when mounted on i...

Страница 9: ...evaporators must have a drain and vent connection at the bottom of the bottom connection piping and at the top of the top connection piping respectively see Figure 6 These evaporators do not have drai...

Страница 10: ...n percent of 200 gpm equals a change of 20 gpm per minute or a minimum of three minutes to go from the maximum flow to the desired flow If the flow rate falls below the minimum allowable large reducti...

Страница 11: ...eze set point for longer than the specified time to help prevent evaporator freeze up Connection points are shown in the field wiring diagram beginning on page 21 1 If the unit will not operate during...

Страница 12: ...t is uniformly applied to all coil surfaces by a multi step electrostatic submerged coating process Epoxy coated coils offer ASTM B117 90 salt spray resistance of more than 10 000 hours applied to bot...

Страница 13: ...iom cliv eng www comfort flex com 13 Figure 7 Refrigeration Schematics cooling only Refrigeration Schematics...

Страница 14: ...iom cliv eng www comfort flex com 14 Refrigeration Schematics Figure 8 Refrigeration Schematics heat pump...

Страница 15: ...iom cliv eng www comfort flex com 15 Figure 9 Cooling only unit dimensional configuration 3 5 RT Dimensions and Weights Packaged Units...

Страница 16: ...iom cliv eng www comfort flex com 16 Dimensions and Weights Packaged Units Figure 10 Heat pump unit dimensional configuration 3 5 RT...

Страница 17: ...ns NOTES 1 Duplex version 2 All dimensions in mm inches 3 Fan model FN 045 Top View Front View Left View Isometric View OUT IN 1935 mm 76 3 16 Total height 528 mm 20 3 4 723 mm 28 7 16 Total width 110...

Страница 18: ...then open the register1 Fig 11 2 Subsequently isolate the vacuum pump and open the register 2 3 When a value of less than 200 mecrons is obtained try to reach the lowest possible value the vacuum proc...

Страница 19: ...ant Charge Refrigerant Charge Pressure Drop Table 4 Refrigerant Charge CAPACITY MODULE EVAPORATOR DROP TOTAL DROP DP ft WG DP ft WG 3 UNIT 16 7 32 5 UNIT 16 7 32 10 DUPLEX 16 7 32 Table 5 Evaporator P...

Страница 20: ...ion of aluminum wiring in buildings ANSI 1 The control transformer is supplied and no separate 115V power is required For single and multipoint power connections the control transformer is on circuit...

Страница 21: ...mplished through a BAS interface or with the remote on off wiring connection shown in the field wiring diagrams A start signal can be given at any time after the stop signal as the three minute start...

Страница 22: ...iom cliv eng www comfort flex com 22 Electrical Data Figure 13 Typical field wiring diagram of the 220V unit son...

Страница 23: ...iom cliv eng www comfort flex com 23 Electrical Data...

Страница 24: ...iom cliv eng www comfort flex com 24 Electrical Data Figure 14 Typical field wiring diagram of 440V unit son...

Страница 25: ...iom cliv eng www comfort flex com 25 Electrical Data...

Страница 26: ...RT J4 BMS T75 CLASS 2 24 2 24 2 BP2 MC PORT J4 BMS RS485 MODBUS GND GND SYSTEM SIG SC1 SRG SI1 SC2 MS 11 SC1 C SRG C SIG C SI C SC2 C SIG SC1 SRG SI SC2 SOL2 1 SOL1 1 IF 1 MS 12 AP2 COM J2 SI C1 COM S...

Страница 27: ...DENMARK Spare part no Volt Hz Watt 10 60 BF024BS F6215 Pump Connection optional RESISTANCE 220V COMPRESSOR ONE POWER BLOCK COEL SWITCH DISCONNECTOR 2 AMP COMPRESSOR ONE 3 COMPRESSOR TWO 3 TF42 22X NC...

Страница 28: ...nd high unit efficiency The user terminal allows wireless connectivity with mobile devices and is integrated on panel mounted models and purchased separately on DIN rail mounted models SYSTEM ARCHITEC...

Страница 29: ...ssor 2 NO3 MC 95 Water pump NO4 B 24V2 4 way valve NO5 Output available for alarm connection SET POINTS When we start configuring the unit for the first time all the preload parameters have a default...

Страница 30: ...abla de supervisi n de registros modbus Variable name Holding Write Read Direction Timer_On_System_Before_Pump x 0 Timer_Flow_Detection_Pump x 2 Timer_Start_Fan x 4 Timer_Step_Compressor_on x 6 Ton_St...

Страница 31: ...er_Return_Value x 9 Status_Compressor_1 x 11 Status_Compressor_2 x 12 Status_WaterPump x 13 Status_Fan x 14 Variable name Holding Write Read Direction Reset_Alarm x 0 Switch_OnOff_Logical x 1 Switch_L...

Страница 32: ...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 33: ...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 capacity No No Yes No No Yes Yes...

Страница 34: ...saturated temperature CONTROLLER CALCULATIONS Condenser approach The capacitor approximation will be calculated for each circuit The equation is as follows Capacitor approximation Capacitor saturated...

Страница 35: ...s capacity control logic commands it to shut down A discharge alarm occurs and sequencing requires this compressor to be the next compressor to shut down The circuit status is pumping and sequencing r...

Страница 36: ...frosted equalizer line indicates internal leaks and will require valve replacement Repair or replacement of a bent equalizer will be necessary for the valve to operate properly TXVs are designed to me...

Страница 37: ...og If the alarm is automatically reset the alarm key is turned off the alarm code disappears from the list and the alarm termination event is recorded in the alarm log Procedure alarm acknowledgement...

Страница 38: ...ipment High Pressure This alarm will be present when the high pressure switch is in inactive mode to review this alarm check in the parameters section to see the current status of the switch Alarm num...

Страница 39: ...to find parameter number 12 In the previous image this parameter indicates the alarms that are active when there is no alarm inside the equipment the parameter will show a zero and depending on the al...

Страница 40: ...he above menu is selected the network address of the device can be accessed There are different options to which the device has to be adapted depending on the required network installation needs or re...

Страница 41: ...Y This is the subnet mask assigned to the device and the selection can be automatic or manual Once the above steps have been performed and the previous information has been verified the device informa...

Страница 42: ...ating the alarm it can be deleted or left in the history SYSTEM ALARMS The CLIV system has an alarm section which indicates when there is a normal behavior within the equipment as shown in the followi...

Страница 43: ...e top row the flow water temperature In the bottom row with the unit switched on the return water temperature With the unit switched off the OFF status during Bluetooth communication the text bLE flas...

Страница 44: ...rs such as direct commands and active alarms can be accessed through the user terminal without password or with password to those dedicated to unit configuration and optimization Press DOWN for 3 s to...

Страница 45: ...pump units Press DOWN the manual defrost command dFr appears Press DOWN the command to cancel the alarm log ClrH appears Assistance level only Press DOWN the selection of units of measurement UoM app...

Страница 46: ...error inside the controller but it has 2 statuses Color the color green Means that the controller is in a healthy state according to the correct settings programmed to it Red LED It will indicate if t...

Страница 47: ...ill return to their normal state from here the value has already been modified ACCESSING FOLDER ICON MENUS In this section we will take the menus contained in the folder icon and at the same time expl...

Страница 48: ...ial will be repeated to access the root Once the previous step has been performed a menu will be accessed again and the same step of turning the dial to the right and selecting PGM1 will be repeated a...

Страница 49: ...rpose of this parameter is to modify the time at which the compressor will turn on whether 1 or 2 stages are configured Parameter number 6 Timer_Stop_Compressor_By_Switch The purpose of this parameter...

Страница 50: ...ted this procedure will not work so you will have to check in the alarms section the alarm number that the system presents so that it can be deleted Parameter number 12 Switch_OnOff_Logical With this...

Страница 51: ...on of the water flow switch to change the value of this parameter simply press the dial and turn the dial to the right until the active value changes or in case you want to deactivate the parameter si...

Страница 52: ...current workload capacity of the compressor in its default is handled from zero to 100 in case the system is with a 2 stage compressor this will calculate the percentage at which the first and second...

Страница 53: ...mter number 28 Water_Inyection_Value This parameter is used to display the temperature at which the injection temperature sensor is registering Parameter number 29 Water_Return_Value This parameter is...

Страница 54: ...isplay the status of the fan Parameter number 34 Setpoinr_Cold_Water This parameter is used to change the setpoint of the ice water alarm Parameter number 35 Remote_Enabled The parameter allows enabli...

Страница 55: ...troller through an ethernet port The first thing to do is to verify the address that contains the controller this address can be seen in the main screen After having checked this address we proceed to...

Страница 56: ...ill be able to open a web browser either Firefox Internet Explorer or another favorite search engine Once the web browser is opened the address containing the controller is typed in the address bar To...

Страница 57: ...ection menu will appear to access this submenu the user is operator and the password operator and click on login Despu s de acceder por medio del usuario y la contrase a dar click a siguiente icono Ne...

Страница 58: ...the button as shown in the image Go to Controls Page will take you to a login menu Once the previous step has been completed access will be requested to enter the Cliv equipment control monitoring pag...

Страница 59: ...l start Once the previous step is completed the system status control screen can be accessed This screen includes controls such as digital input status digital output status and the current temperatur...

Страница 60: ...ydraulic circuit is closed Check for foreign objects in the fan discharge Check that the air inlet is not obstructed and has the suggested clearance INSPECTION OF THE HYDRAULIC CIRCUIT Date Place of W...

Страница 61: ...ions Measure voltage on all units ground neutral and 3 phase line Check that motor overload protection conforms to design requirements and is in automatic mode Check voltage Motor save which is set to...

Страница 62: ...turned on Turn the switch on the CONTROL UNIT to the ON position to power the control panel with 24 volts UNIT CONTROL To start operations turn the ON OFF switch to the ON position After 6 seconds th...

Страница 63: ...nsible for the malfunction of the unit if the main cause is lack of maintenance or the operating conditions of the unit do not correspond to those recommended in this manual MAINTENANCE GENERAL Routin...

Страница 64: ...y start up and cause injury Disconnect all power sources before inspecting the fan EXPANSION VALVE The function of the expansion valve is to maintain adequate supply of refrigerant to the evaporator T...

Страница 65: ...these must be under the manufacturer s specifications Twice a month Plan x x x x x x Real Cleaning of the electrical panel monthly Plan x x x x x x x x x x x x Real PHYSICAL INSPECTION Jan Feb Mar Apr...

Страница 66: ...supports at suction or discharge Reposition add or remove hangers Compressor insulator bushing worn Replace Compressor mechanical failure Check for possible problem in compressor failure and replace...

Страница 67: ...l too high with compressor operation Confirm superheat is correct remove oil Operation or selection of expansion value Confirm superheat at minimum and maximum load conditions Compressor mechanical pr...

Страница 68: ...iom cliv eng www comfort flex com...

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