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OPERATING AND MAINTENANCE MANUAL

Chapter 5 - Installation

iC 215 ÷ iC 780

25

The data in this manual are not binding and they can be modified by the manufacturer without notice.

Reproduction of this manual is strictly prohibited

EN

ENGLISH

5 . 4

H y d r a u l i c c o n n e c t i o n s

NOTE

All the unit’s hydraulic connections must be made by the customer.

1. Connect the unit to the water pipes observing the water flow direction as shown in the attached dimensional

drawings.

2. Provide two valves (one at the inlet, one at the outlet) to isolate the unit in the case of maintenance work without

having to empty the user water circuit.

3. Fill the tank with water using:

•

a remote filling system, bleeding the air from the tank manually if necessary by means of the manual bleed
valve.

•

if the water circuit is subject to frequent infiltrations of air it is good practice to install an automatic bleed
valve.

4. If the unit is supplied without pump make sure the pump installed by the user has its suction port connected

directly to the tank outlet connection in the event of a closed user circuit.

5. If the unit is supplied without pump make sure the pump installed by the user has its outlet port connected directly

to the unit inlet connection in the event of a user circuit that is open to the atmosphere.

NOTE

The pump must never run dry.

ATTENTION

If the unit is not equipped with the hydraulic unit a pump must be installed for the evaporation water circuit.

For any maintenance requirements it is advisable to install a water drain cock at the lowest point of the circuit.

Evaporator water connections sizes:

NOTE

For correct operation, install a filter close to the unit’s water inlet connection. Failure to comply with this requirement may
cause irreparable damage to the evaporator.
On units with plate evaporator, clogging of even just a few plates (or the gaps between them) may result in freezing of the
clogged plate and hence failure of part of the exchanger, even if the water flow is apparently normal and the unit is cooling
effectively.

Unit model

iC 215÷220

iC 303÷305

iC 408÷416

iC 520÷535

iC 538÷540

Evaporator IN/OUT water
connections

Rp 3/4”

Rp 1”

Rp 1” 1/2

Rp 2”

Rp 2” 1/2

Unit model

iC 640÷660

iC 770÷780

Unit with tank maximum pressure [bar]

Evaporator IN/OUT water
connections

Rp 2” 1/2

Rp 3”

6

Process water inlet

Process water outlet

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Содержание iC 215

Страница 1: ...WATER CHILLERS OPERATING AND MAINTENANCE MANUAL iC 215 iC 780 38178800943 Original instructions in Italian language...

Страница 2: ...N if it was ON at the time of power loss and OFF if it was OFF 0 1 1 Start from the keypad From unit OFF stand by press and release button to switch the unit on or off in chiller mode With the unit on...

Страница 3: ...all the alarms except for the compressor thermal cut out alarms for which the password will be required 14 To open the functions menu proceed as follows Open the functions menu by pressing the button...

Страница 4: ...precautions 10 2 7 Refrigerant gases 11 2 7 1 Refrigerants safety datasheet 11 Chapter 3 TECHNICAL DATA 13 3 1 Declaration of conformity 14 3 2 Data for standard units 15 3 2 1 Dimensions 15 3 2 2 Cha...

Страница 5: ...splay and reset ALrM function 37 7 11 2 How to mute the buzzer 38 7 11 3 General alarms list 38 7 11 4 Indications table 39 7 11 5 Probe faulty 39 7 11 6 High pressure switch alarm 39 7 11 7 High pres...

Страница 6: ...17 2 Units configured with fan speed control 49 7 17 3 Fan control diagrams 49 7 18 Hydraulic unit 49 7 19 Anti freeze pump management if ambient probe is installed 50 7 20 ModBus 50 7 21 Automatic r...

Страница 7: ...s are to be found on the decals affixed to the unit and also in the dimensional drawings and refrigerant circuit diagrams The meaning of each symbol is indicated below ATTENTION This manual which is a...

Страница 8: ...nd affixed to the unit Improper operation or maintenance of the unit and auxiliary equipment can be dangerous and can cause serious or fatal accidents We cannot anticipate every possible circumstance...

Страница 9: ...g cables so that there are no sharp bends Use a spreader bar to avoid lateral loading of hooks and eyebolts When a load is lifted from the ground keep well clear of the area beneath the load and the i...

Страница 10: ...el iC 770 iC 780 NOTE Weight values are guideline with the water circuit empty The values may vary in relation to the configuration of the unit pump type supply type and ventilation type 2 4 P r e c a...

Страница 11: ...ere Protect the environment by using only approved methods of disposal Keep a written record of all work carried out on the unit and the auxiliary equipment The frequency and the nature of the work re...

Страница 12: ...Refrigerants safety datasheet Denomination R410A 50 Difluoromethane R32 50 Pentafluoroethane R125 INDICATION OF HAZARDS Major hazards Suffocation Specific hazards Rapid evaporation can cause frostbite...

Страница 13: ...nium Incompatibility is more critical if the metal is present in the form of powder or if surfaces have been recently unprotected Hazardous decomposition products These products are halogen compounds...

Страница 14: ...ntained in the unit For models iC 215 305 MAX REFRIG PRESS Refrigerant circuit design pressure MAX REFRIG TEMP Refrigerant circuit design temperature For models iC 408 and higher MAX REFRIG PRESS HP S...

Страница 15: ...in accordance with Annex I of the Machinery Directive MUT012 A F A C S I M I L E ICS Cool Energy Ltd STEPHENSON ROAD CALMORE INDUSTRIAL ESTATE TOTTON SOUTHAMPTON SO40 3RY GB CE DECLARATION OF CONFORMI...

Страница 16: ...ower kW 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 Axial flow fan No of fans 1 1 1 1 1 2 2 2 total airflow m3 h 3500 3150 6500 6150 8150 14200 13600 13600 Centrifugal fan No of fans 1 1 2 2 2 2 residual pressure...

Страница 17: ...mp pressure head bar 3 8 1 5 3 3 2 5 3 3 2 5 rated power kW 4 5 5 5 5 Pump P5 water flow rate m3 h 9 4 48 12 5 72 14 9 72 pump pressure head bar 5 5 3 1 4 8 3 4 4 8 3 4 rated power kW 7 5 9 2 9 2 Axia...

Страница 18: ...rifugal 76 2 89 2 iC 410 axial 69 1 82 1 centrifugal 76 2 89 2 iC 412 axial 69 1 82 1 centrifugal 76 2 89 2 iC 416 axial 70 0 83 centrifugal 76 2 89 2 iC 520 axial 71 3 84 3 high pressure 72 0 85 0 iC...

Страница 19: ...load in nominal conditions Sound pressure level in hemispherical irradiation conditions at a distance of 1 m from the condensers side of the unit and height of 1 6 m from the ground Values with toler...

Страница 20: ...e s s o r s The compressors are of the SCROLL type and are characterised by high energy efficiency low vibration and consequent very low noise during normal operation The compressors are cooled by the...

Страница 21: ...rtently closed In this case the unit stops due to tripping of the anti freeze alarm and the shut off valves must be reopened The bypass serves exclusively to allow an anti freeze alarm to trip if pres...

Страница 22: ...All panels undergo phosphor degreasing treatment followed by epoxy polyester power coating The frame is designed to allow easy access to all components of the unit 4 9 M a t e r i a l s i n c o n t a...

Страница 23: ...eed control electrical cabinet heaters To prevent ice formation on the tank and on the pump if present instead of using glycol the unit can be equipped with the evaporator freeze protection option Thi...

Страница 24: ...om temperature 3 The ambient air must be clean avoid sea ambients brackish air and not contain flammable gas or corrosive solvents 4 The minimum and maximum working ambient temperature are specified o...

Страница 25: ...r inlet and outlet fittings shut off ATTENTION The anti freeze setting is 4 C To reduce the anti freeze setting edit parameter AL26 5 3 1 Operating limits The operating limits are decided at the time...

Страница 26: ...sed user circuit 5 If the unit is supplied without pump make sure the pump installed by the user has its outlet port connected directly to the unit inlet connection in the event of a user circuit that...

Страница 27: ...aminants If the pump runs noisily or emits anomalous noise it may be necessary to bleed the liquid circuit in order to prime the pump The procedure is as follows unscrew the filler breather plug at th...

Страница 28: ...iance with the prescriptions of IEC 364 by means of a residual current device the nominal trip current of which should normally be set to 0 03 A 3 make sure the level of protection against indirect co...

Страница 29: ...e electronic controller is able to monitor the unit s power supply stopping the unit in the case of missing phases or an incorrect phase sequence Tripping of the Phase Monitor shuts down the unit and...

Страница 30: ...lit 11 On three phase power supply models make sure the compressor operates correctly no anomalous noise and no overheating and check that the fans and the pump if present rotate in the correct direct...

Страница 31: ...ibited ENGLISH EN 15 The unit is now ready to start operating If the thermal load is lower than that produced by the unit the water temperature decreases until it reaches the setpoint value set follow...

Страница 32: ...umps is running FC not used AUX lit with tank auxiliary heater on Lit if heaters anti freeze heaters are on Heat pump operating mode icon not used Not used Lit if at least one condensing fan is runnin...

Страница 33: ...below Models iC 215 540 Models iC 640 780 BUTTONS FUNCTION To enter programming mode pressed for 3 seconds To exit programming phase In programming mode Press once from the main mask to display the us...

Страница 34: ...lay the measured values Manage the alarm situation by displaying and signalling Programmable When the unit is in stand by the controller shows the label W on the display 7 5 2 Start from a digital inp...

Страница 35: ...int increases proportionally as the ambient temperature rises the difference between the ambient temperature and the operating setpoint is a value which can be set by means of parameter Sd03 with valu...

Страница 36: ...nfirm the set function and proceed to the next circuit only the loads associated with the circuit are disabled To exit the CrEn function and return to normal display mode press or wait for the time ou...

Страница 37: ...the lower display with a resolution of 10 starts For example if the number 2 is displayed the compressor starts are 20 in number To display the number of starts proceed as follows Open the functions...

Страница 38: ...return to normal display mode press or wait for the time out 7 1 0 u S T a n k h e a t e r p r o b e d i s p l a y The temperature pressure value of the probes that control the auxiliary outputs can b...

Страница 39: ...rm A I X X X 1 AP5 Probe PB5 fault alarm A I X X X 1 AP6 Probe PB6 fault alarm A I X X X 1 APE1 Probe PB1 Probe Pb8 of I O expansion A I X X X APE2 Probe PB1 Probe Pb8 of I O expansion A I X X X APE3...

Страница 40: ...omp Heaters Anti freeze water heater Elements support Pump Evap Deliv Fan Cond pump Cond fan Cir1 Cir2 Auxiliary relay AEUn Evaporator unloading indication b n Cu Unloading indication from condensing...

Страница 41: ...circuit 1 low pressure digital input b2LP circuit 2 low pressure digital input Cause of trip With low pressure switch input of active circuit The alarm is not signalled 1 On compressor starting for t...

Страница 42: ...ions menu reset procedure in functions menu 7 11 14 Compressors thermal alarm Chiller Operation Display labels meaning b1AC chiller mode circuit 1 anti freeze alarm b1Ac chiller mode circuit 1 anti fr...

Страница 43: ...CO44 differential CO45 with unloading active after time setting Par CO48 Reset Automatic Icon Flashing E Action Alarm relay buzzer NOT activated Display labels meaning b1rC circuit 1 recovery disablin...

Страница 44: ...mpressor 4 maintenance request Cause of trip Compressor running hours programmed hour meter setting Reset Running hours reset in functions menu Hour function hold down set button for several seconds R...

Страница 45: ...press Scroll the alarm labels until finding ArSt in the lower display The upper display shows PASS Press Enter the deletion password the password value to reset the alarms log is 14 and press to confi...

Страница 46: ...e first label ALL 5 To select the labels press or and then press The lower display shows the label and the code of the first parameter it contains the upper display shows the associated value ATTENTIO...

Страница 47: ...t be switched off and switched on again to repeat the operation or start with normal control in this case the key must be unplugged when the instrument is off 7 13 2 Hot key programming ATTENTION Impo...

Страница 48: ...Compressors regulator operation diagram in chiller mode 7 14 6 Compressors rotation For correct operation in the compressors time the electronic controller manages rotation of compressor starts with d...

Страница 49: ...rcuit involved The unloading function is deactivated only if the condensing pressure decreases and remains below the unloading set for a preset time or if it falls below set diff 7 1 6 A n t i f r e e...

Страница 50: ...h pressure axial fans the speed controller is integrated on the fan motor 7 17 3 Fan control diagrams The following diagram illustrates the fans STEP control logic in accordance changes in condensing...

Страница 51: ...art stop 4milliseconds of silence approximately 3 characters Minimum time out 500 ms For further information refer to the specific manual 7 2 1 A u t o m a t i c r e s t a r t In case of a power loss...

Страница 52: ...in dual frequency models 0 2 Serial address CF64 U Serial address 1 247 Temperature control of compressors with different cooling capacity Compressors operation enabling Enabling of units with hybrid...

Страница 53: ...orced rotation function Maintenance of loads Unit capacity control Pr1 U User password 0 999 Circuit 1 auxiliary relay Circuit 2 auxiliary relay Auxiliary 0 10V proportional output 1 Auxiliary 0 10V p...

Страница 54: ...i freeze low ambient air temperature air air unit low air outlet temperature air air unit alarm is tripped from AL24 to AL25 AL24 AL25 C Dec Anti freeze alarm in heat pump mode Compressors discharge h...

Страница 55: ...on the controller If the parameter is not present in the Value column refer to the options listed on the right hand side of the table Parameter visible only on dual frequency version Parameter visibl...

Страница 56: ...it No Yes ON OFF Phase chopping control Electronic control Sp P3 P5 P3 P3 P5 P5 ST01 7 0 C U ST02 5 0 C U ST07 2 0 C U CF54 See Ch 7 22 3 U CF64 1 U Sd01 0 0 C U Sd03 4 0 C U Sd05 30 0 C U CO19 4 10 H...

Страница 57: ...HP This monitors the refrigerant compressor discharge pressure and prevents it increasing to potentially hazardous values that could harm the compressor and people within the vicinity The pressure sw...

Страница 58: ...ressure and compressor suction temperature The use of the electronic lamination device in place of the conventional system makes it possible to operate with significantly lower condensing pressure val...

Страница 59: ...can reach values that are potentially fatal for humans ATTENTION The level sensor has been calibrated to function with 250kOhm sensitivity position A 5 B H on the Empty side Calibration of the level s...

Страница 60: ...o t h e u n i t ATTENTION Any task that requires the panelling to be opened must be performed only with the unit powered off and disconnected from the electrical supply To access the refrigerant circu...

Страница 61: ...lation may fall to the point at which the water in the unit could freeze To drain the exchangers proceed as follows For units with tank and finned core exchanger When a pump is installed use special c...

Страница 62: ...pressure and suction pressure measured on the pressure gauge with pump stopped is within the prescribed range and not lower than the pump maximum flow rate value Clean the water filter The water filt...

Страница 63: ...y a qualified refrigeration engineer A6 Compressor protection trips A6 1 The head and the body of the compressor are very hot The compressor stops and attempts to restart after a short time even few s...

Страница 64: ...rm reset procedure to restart the unit see Chapter 7 Electronic controller C2 The pump does not work or rotates in the opposite direction three phase power supply C2 1 See C1 1 General alarm relay act...

Страница 65: ...r example by increasing room ventilation Perform the alarm reset procedure to restart the unit see Chapter 7 Electronic controller D3 Recirculation of warm air due to incorrect installation D3 1 Conde...

Страница 66: ...emperature higher than maximum permitted value See D1 1 Change the position of the unit or the position of any nearby obstructions in order to prevent recirculation Perform the alarm reset procedure t...

Страница 67: ...s and attempts to restart after a short time even few seconds Compressor thermal protection trips Display shows message C n tr LED of general alarm icon illuminates Call in a qualified refrigeration e...

Страница 68: ...alue of the BTWOT probe Pressure difference read on the pressure gauge with pump running and pump stopped is lower than the available pressure head with pump maximum flow rate Reset thermal cutout Inc...

Страница 69: ...ejection from pipelines and or pressure tanks in cooling circuit due to design pressure values being exceeded Contatto di parti del corpo con gas frigorigeno o residui di tubazione del circuito frigo...

Страница 70: ...ighting equipment Strictly observe all manual instructions Chapter 5 Installation 17 Hazards generated by failure to use personal protective equipment Lacerations to upper limbs during maintenance or...

Страница 71: ...fan blades or moving parts of the compressor Disconnect the machine from the electrical mains during interventions on the hydraulic circuit Strictly observe all manual instructions Chapter 2 Safety Ch...

Страница 72: ...parts contact with high pressure fluids or gas Strictly observe all manual instructions Chapter 2 Safety and 5 6 Electrical connections 33 Hazards generated by absence of and or position of measures...

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