TECHNICAL CATALOGUE
SECTION 14
Evaporator units with remote condensers.
HE-HCR 0011÷0121
GRUPPO
BOOKMARK
INDEX U
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TECHNICAL CATALOGUE
SECTION 14
Evaporator units with remote condensers.
HE-HCR 0011÷0121
GRUPPO
BOOKMARK
INDEX U
I
A
General warnings
464
A
Checking and starting up the unit
483
U
I
A
Fundamental safety rules
464
A
Activating and deactivating the unit
486
U
I
A
Identification
465
A
Setting operating parameters
486
I
A
Receiving and handling the product
465
A
Setting service parameters
487
I
A
Description of standard unit
466
I
A
Displaying operating status
488
I
Dimensional drawings
467
I
A
Displaying alarms
489
I
Installation
468
I
A
Operating characteristics
490
U
U
I
I
A
Hydraulic connections
468
A
Shutting down for long periods
490
I
A
Electrical Connections
471
A
Routine maintenance
491
I
A
Sizing of refrigerant pipes
478
A
Extraordinary maintenance
491
I
A
Refrigerant and remote condenser connections
479
I
A
Description of standard HCR unit
492
I
A
Technical data
480
I
A
Technical data HCR
492
A
Cooling performance
480
I
A
Dimensional drawings HCR
493
I
A
Recommended operating conditions
481
I
Power selection HCR
494
I
A
Hydraulic data
482
I
Troubleshooting
495
I
A
Refrigerant circuit
483
A
The following symbols are used in this publication and in the unit:
U I A
User
Important
Installer
Prohibition
Assistance
Danger voltage
Danger moving blade
70°C
Danger high temperatures
Climaveneta is part of the Eurovent certification programme. The manufacturer reserves the right to modify the data in this manual without warning.
GRUPPO
HE-HCR R407C
463 BOOKMARK
U
GENERAL WARNINGS
These units have been designed to chill water and must be used in applications compatible with their performance characteristics. Incorrect installation, regulation and maintenance or improper use absolve the manufacturer from all liability, whether contractual or otherwise, for personal injuries or property damage. Only those applications specifically indicated in this list are permitted. Read this manual carefully. All work must be carried out by qualified personnel in conformity with legislation in force in the country concerned. The guarantee is invalidated if the above instructions are not respected and if the unit is started up for the first time without the presence of personnel authorised by the Company (where specified in the supply contract) who should draw up a “start-up report”.
I
A
The documentation supplied with the unit must be consigned to the owner who should keep it carefully for future consultation in the event of maintenance or service. When the items are consigned by the transporter, check that the packaging and the unit are undamaged. If damage or missing components is noted, indicate this on the delivery note and by fax or registered letter to the After Sales Department within eight days from the date of receipt of the items.
U
FUNDAMENTAL SAFETY RULES
I
A
When using this unit, which requires electricity and water, a number of fundamental safety rules must be observed, namely: The unit must not be used by children or by unfit persons without suitable supervision. Do not touch the unit with bare feet or with wet or damp parts of the body. Do not carry out cleaning operations without first disconnecting the unit from the electricity supply by placing the mains switch on the system in the "off" position. Do not modify safety or regulation devices without authorisation and instructions from the manufacturer. Do not pull, detach or twist the electrical cables coming out of the unit, even when disconnected from the mains electricity supply. Do not open doors or panels providing access to the internal parts of the unit without first ensuring that the mains switch is in the off position. Do not stand on the appliance and/or rest any type of object on top of it. Do not spray or throw water directly on the appliance. Do not dispose of, abandon or leave within reach of children packaging materials (cardboard, staples, plastic bags, etc) as they may represent a hazard.
Respect safety distances between the unit and other equipment or structures. Guarantee suitable space for access to the unit for maintenance and/or service operations. Power supply: the cross section of the electrical cables must be adequate for the power of the unit and the power supply voltage must correspond with the value indicated on the respective units. All units must be earthed in conformity with legislation in force in the country concerned. To guarantee correct functioning of the unit, hydraulic connections must be carried out according to the instructions. Empty the water circuit or add glycol if the unit is not used during the winter. Handle the unit with the utmost care (see weight distribution table) to avoid damage.
464
HE-HCR R407C BOOKMARK
GRUPPO
U
IDENTIFICATION
Tampering with or the removal or absence of rating plates or other means enabling the unit to be identified causes problems during installation and maintenance.
The HE evaporator unit can be identified by the: De' Longhi S.p.a. - 31100 Treviso / Italia Via L.Seitz, 47 - tel. 04224131 fax 0422413659
MODEL: VOLTAGE: CODE:
Packaging label Giving the data identifying the product. Rating plate Giving the technical and performance data of the unit. If lost, ask the After Sales Service for a replacement.
COOLING CAPACITY HEATING CAPACITY TYPE OF REFRIGERANT REFRIGERANT CONTENT MAXIMUM PRESSURE MAIN ELECTRICAL POWER SUPPLY AUXILIARY ELECTRICAL POWER SUPPLY MAX. ELECTRICAL POWER ABSORBED MAX. CURRENT ABSORBED START UP CURRENT ELECTRICAL WIRING DIAGRAM OPERATING WEIGHT YEAR OF PRODUCTION
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
A
I
kW kW Kg bar V---Hz V---Hz kW A A N° Kg
I
RECEIVING AND HANDLING THE PRODUCT
A
The instruction manual is an integral part of the unit and should thus be read and kept carefully.
The HE evaporators are delivered in a single pack on a wooden pallet protected by cardboard.The unit is supplied accompanied by the following material: - instruction manual; - guarantee certificate; - CE declaration. enclosed in a plastic envelope attached to the top of the chiller. - Vibration dampers fitted on models 0011-0061 and supplied on models 0071-0121 in a plastic bag inside the electrical panel. - After removing the packaging, the unit must be handled by qualified and suitably equipped personnel only using equipment appropriate to the weight of the chiller.
It is recommended that the packaging should not be removed until the unit is located in the installation site. During transport, the chiller must be kept in the vertical position. Do not dispose of packaging materials in the environment or leave them within reach of children as they may represent a hazard.
H
P
L
Dimension
0011
0021
0025
0031
0041
0051
0061
0071
0091
0101
0121
L P H Net weight HE
420 560 1080 64
420 560 1080 65
420 560 1080 68
420 560 1080 69
420 560 1080 80
420 560 1080 81
420 560 1080 85
650 730 1080 167
650 730 1080 169
650 730 1080 212
650 730 1080 215
GRUPPO
HE-HCR R407C
mm mm mm kg
465 BOOKMARK
I
DESCRIPTION OF STANDARD UNIT The water-cooled evaporator units operate with R407C refrigerant and are suitable for indoor installation. The units conform to the essential requisites established in EC directive 89/392. They are factory tested and on site installation is limited to water, electrical and refrigerant connections, with a maximum distance of 50m between the evaporator unit and the remote condenser.All testing is performed in the factory. STRUCTURE Panels and bed plate are made from cataphoretic coated galvanised steel to ensure total resistance to atmospheric agents. Standard rubber vibration damper kit. COMPRESSORS Hermetic rotary scroll compressor with sump heater and thermal cut-out. EVAPORATOR AISI 316 steel plate exchanger. Externally insulated with closed cell neoprene anti-condensation lagging. The plate exchanger is complete with frost-protection temperature sensor and differential pressure switch.
A
REFRIGERANT CIRCUIT The unit features a refrigerant circuit with the following components: gas gate valves with pressure taps, filter, liquid flow gauge, thermostatic expansion valve with external equaliser. Safety pressure switches to control delivery and suction pressure. Unit supplied complete with non-freezing oil and R407C refrigerant, factory tested. POWER AND CONTROL ELECTRICAL PANEL Power and control electrical panel constructed in accordance with IEC 204-1/EN60204-1, complete with compressor contactor, thermal overload switch and door lock safety device. Built-in control and adjustment via "CVM 2" control panel. OPTIONAL ACCESSORIES - Remote condenser. - Removable metal mesh filter.. - Storage tank complete with pump, safety valve, filling assembly, air vent valve, expansion tank, pressure gauge and drain valve. - Remote keyboard kit. - Serial interface kit. The above accessories are optional. Consult the relative documentation for assembly instructions and technical data.
1 2 6 7 8
3 4
9
5
10 11 12
466
1 2 3 4 5 6 7 8 9 10 11 12
HE-HCR R407C BOOKMARK
Electrical panel Control panel Scroll compressor Low pressure switch High pressure switch Plate heat exchanger Gas valve Liquid valve Flow gauge Thermostatic valve Filter Vibration dampers (fitted on models 0011-0061, supplied on models 0071-0121)
GRUPPO
I
DIMENSIONAL DRAWINGS 3
8
B
6
E
4
7
9 N
M
L
I
H
G R
P
O
F
5
1
1 2 3 4 5 6 7 8 9
Compressor Plate heat exchanger Electrical panel Liquid valve Gas valve Installation water IN dia. 3”/4 model 0011-0031, dia. 1”1/4 model 0041-0121 Installation water OUT dia. 3”/4 model 0011-0031, dia. 1”1/4 model 0041-0121 Electrical power supply input Vibration damper feet
W2
W1
W3
W4
C
A
S
S
2
Unit connections
0011
0021
0025
0031
0041
0051
0061
0071
0091
0101
0121
Liquid connection Gas connection
3/8” 1/2”
3/8” 1/2”
3/8” 5/8”
3/8” 5/8”
1/2” 3/4”
1/2” 3/4”
1/2” 3/4”
5/8” 7/8”
5/8” 7/8”
3/4” 7/8”
3/4” 7/8”
Dimension
0011
0021
0025
0031
0041
0051
0061
0071
0091
0101
0121
A B C E F G H I L M N O P Q
400 930 450 432 138 120 200 80 50 343 57 20 364 20
400 930 450 432 138 120 200 80 50 343 57 20 364 20
400 930 450 432 138 120 200 80 50 343 57 20 364 20
400 930 450 432 138 120 200 80 50 343 57 20 364 20
400 930 450 470 120 130 200 70 50 343 57 20 364 20
400 930 450 470 120 130 200 70 50 343 57 20 364 20
400 930 450 470 120 130 200 70 50 343 57 20 364 20
600 930 600 470 130 105 200 295 78 438 84 30 546 30
600 930 600 470 130 105 200 295 78 438 84 30 546 30
600 930 600 470 130 105 200 295 78 438 84 30 546 30
600 930 600 470 130 105 200 295 78 438 84 30 546 30
0011
0021
0025
0031
0041
0051
0061
0071
0091
0101
0121
500 300
500 300
500 300
500 300
500 300
500 300
500 300
500 300
500 300
500 300
500 300
0011
0021
0025
0031
0041
0051
0061
0071
0091
0101
0121
20 14 14 20 68
21 14 14 21 70
22 14 14 21 71
22 15 15 22 74
25 18 17 25 85
26 18 17 26 87
27 18 18 27 90
53 36 35 53 177
54 36 36 54 180
56 38 37 56 187
57 38 38 57 190
Functional distances R S Weight distribution W1 W2 W3 W4 Tot.
GRUPPO
HE-HCR R407C
467 BOOKMARK
I
INSTALLATION
POSITIONING Before handling the unit, check the capacity of the lift equipment used, respecting the instructions on the packaging. To move the unit in the horizontal, make appropriate use of a lift truck or similar, bearing in mind the weight distribution of the unit. Fix the unit, making sure it is completely level; make sure there is easy access to hydraulic, refrigerant and electrical components.
CHOICE OF INSTALLATION SITE Before installing the unit, agree the site where it will be installed with the customer, taking the following points into consideration: - check that the fixing points are adequate to support the weight of the unit; - heed the safety distances between the unit and other equipment or structures; - the unit must be installed in a space designed to house technical installations dimensioned according to legislation in force in the country concerned and large enough to allow access for maintenance.
I
HYDRAULIC CONNECTIONS
A
4. A flow switch (inlet) or a differential pressure switch (inlet - outlet). 5. Two vibration damper joints (inlet and outlet); 6. An inlet filter as close as possible to the evaporator and positioned to allow easy access for routine maintenance. The flow of water to the chiller assembly must comply with the values shown on page 482. The flow of water must be maintained constant during operation.The water content of the unit must be such as to avoid disturbing operation of the refrigerant circuits. Refer to the values shown on page 482. In the event where two units are installed in the same water circuit, the minimum content of the system must be equal to the sum of the minimum contents of the individual units.
The choice and the installation of the components is the responsibility of the installer, who should follow good working practice and current legislation. It is recommended to construct a unit by-pass to enable piping to be washed without having to disconnect the appliance (see drain valves). The connection piping should be supported in such a way as to avoid it weighing on the unit. The following devices should be installed in the evaporator water circuit: 1. Two pressure gauges with a suitable scale (inlet and outlet); 2. Two vibration damper joints (inlet and outlet); 3. Two gate valves (normal in inlet and calibrating in outlet);
Diagram of water connections to the installation circuit
Installer connections
Factory connected
1
12
10
2
8
7
4
9
11
INSTALLATION RETURN 14 13
1 2
12
1 2 3 4
Pressure gauge Vibration damper joint Gate valve Calibrating valve
3
5
6
F
T
INSTALLATION DELIVERY
14
5 6 7 8
Flow switch Thermometer Pump Safety valve
9 10 11 12
Expansion tank Mesh filter Fill/top-up Temperature sensor
468
HE-HCR R407C BOOKMARK
13 Differential pressure switch 14 Drain/chemical washing valve
GRUPPO
The HE evaporator unit must be fitted with a fill/top-up system in the return line, and a drain cock in the lowest part of the installation. Installations containing antifreeze or covered by specific legislation must be fitted with hydraulic disconnectors. The manufacturer is not liable for obstruction, breakage or noise resulting from the failure to install filters or vibration dampers. Particular types of water used for filling or topping up must be treated with appropriate treatment systems. Reference values are given in the table below.
PH Electrical conductivity Chlorine ions Sulphuric ions Total iron Alkalinity M Total hardness Sulphur ions Ammonia ions Silicon ions
6-8 less than 200 mV/cm (25°C) less than 50 ppm less than 50 ppm less than 0.3 ppm less than 50 ppm less than 50 ppm none none less than 30 ppm
To connect: - Remove the plastic protection caps from the water connections
Connect the installation according to the diagram in page 468. To seal the threads, you are recommended to use hemp and jointing paste. Teflon should not be used in the presence of anti-freeze fluid. Before connecting the pipes, make sure they do not contain stones, sand, rust, dross or other foreign bodies that may damage the installation.
GRUPPO
HE-HCR R407C
469 BOOKMARK
FILLING THE INSTALLATION - Before starting to fill, place the mains switch in the “off” position - Make sure the drain cock is closed - Open all installation and terminal air vent valves - Open the installation gate valves - Begin filling by slowly opening the water filling cock outside the appliance. - When water starts leaking from the terminal air vent valves, close them and continue filling until the pressure specified for the installation is reached.
ON
OFF
Check the junctions for water tightness.
It is recommended that this operation be repeated after the unit has been operating for a number of hours. The pressure of the installation should be checked regularly.Top-up with the unit off (pump off).
EMPTYING THE INSTALLATION - Before emptying, place the mains switch in the “off” position. - Make sure the installation fill/top-up water cock is closed. - Open the drain cock outside the unit and all the installation and terminal air vent valves.
ON
OFF
If the fluid in the circuit contains anti-freeze, it should not be allowed to drain freely as it is pollutant. It should be collected for possible reuse.
470
HE-HCR R407C BOOKMARK
GRUPPO
I
POWER CONNECTIONS
A
Install, if possible near the unit, an appropriate protection device to isolate the unit from the mains supply. This should have a delayed characteristic curve, contacts opening by at least 3 mm and an adequate interruption and differential protection capacity. If this device is not visible from the electrical panel of the unit, it should be lockable. An efficient earth connection is obligatory. Failure to earth the appliance absolves the manufacturer of all liability for damage. In the case of three-phase units, make sure the phases are connected correctly, respecting the cyclical sequence of the phases.
The HE evaporators leave the factory fully wired. Installation is limited to connection to the mains electrical supply and connection of the flow switch, remote (ON/OFF) switch and pump to the terminals provided. For all electrical work, refer to the electrical wiring diagrams in this manual. You are also recommended to check that: - The characteristics of the mains electrical supply is adequate for the absorption values given in the following electrical characteristics table, bearing in mind the possibility of other equipment operating at the same time/
Power to the unit should be turned on only when installation has been completed (water, electrical and refrigeration connections). Respect instructions for connecting phase, neutral and earth conductors. Voltage must be within a tolerance of ±10% of the rated power supply voltage for the unit (for three phase units, the unbalance between the phases must not exceed 3%). If this is not the case, contact the electricity supply company. For electrical connections, use double insulation cable in conformity with current legislation in the country concerned.
Do not use water pipes to earth the unit.
ELECTRICAL DATA HE
Size
Electrical power supply (V-Ph-Hz)
0011 0021 0025 0031 0021 0025 0031 0041 0051 0061 0071 0091 0101 0121
230/1/50 230/1/50 230/1/50 230/1/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50
F.L.I.
absorbed power
F.L.A.
current absorbed
F.L.I. (kW)
Compressor rated values (1) F.L.A. L.R.A. (A) (A)
1,60 2,00 2,30 2,70 1,97 2,25 2,60 3,20 4,20 5,80 6,00 7,50 8,10 10,50
8,00 9,80 12,20 13,00 0,72 4,09 4,60 6,20 7,10 8,50 11,20 13,20 15,10 18,90
45,00 58,50 73,00 95,00 31,00 38,50 43,50 51,00 59,50 70,50 94,00 116,00 127,00 159,00
Maximum values (3) F.L.I. F.L.A. (kW) (A) 2,08 2,66 3,12 3,60 2,77 3,30 3,81 4,57 5,78 7,69 8,40 10,30 11,10 13,30
11,10 14,40 18,80 19,30 5,50 6,40 7,30 9,40 11,50 14,80 17,90 21,20 23,10 26,90
L.R.A. compressor start-up current
GRUPPO
HE-HCR R407C
471 BOOKMARK
Bringing electrical power cables into the unit and external connections. The unit is provided with cable grips for bringing electrical power cables and other external connections into the appliance. Thread the wires from outside, guiding them in the direction of the electrical panel.
Electrical power supply input Electrical power supply input
The cable grips are positioned near the compressor and fastened by a clamp. Remove the clamp and fasten them to the structure after having removed the panel A. A
Electrical cables may enter the appliance ONLY in the positions specifically described in this manual. Avoid direct contact with non-insulated copper piping and the compressor.
The HE condensing units come complete with an electrical panel consisting of the following components:
SINGLE-PHASE PANEL LAYOUT
THREE-PHASE PANEL LAYOUT FU1 FU2
FU1 FU2
A1
A1
KA1 KA2
KA1 KA2 Tc
Tc
KM1
KM1
A2
A2 QM1
QM1
L
N PE
PE
L1 L2 L3 N
QS
QS
XT1
XT1
A1 A2 FU1 FU2
Radio interference suppresser Electronic controller Transformer protection fuse Auxiliary circuit protection fuse
KA1 KA2 KM1 PE
Installation water pump relay Auxiliary relay Compressor contactor Earth connection
472
QM1 QS TC XT1
HE-HCR R407C BOOKMARK
Compressor thermal overload switch Door lock disconnector switch Transformer Terminal board
GRUPPO
To connect the unit electrically: - Open the door of the electrical panel, as shown in the figure.
- Use cable grip A for the main electrical power cable and cable grip B for other external connection cables.
B
A
- Remove the protective cover from the main switch.
GRUPPO
HE-HCR R407C
473 BOOKMARK
ELECTRICAL POWER CONNECTIONS For the functional connection of the unit, bring the power supply cable to the electrical panel inside the unit and connect it to terminals U-N and PE, respecting the (U) phase, (N) neutral and (PE) earth in the case of single phase units or U-V-W phases, N neutral and PE earth in three phase units (400V-3N~ 50 Hz). ELECTRICAL CONNECTIONS All terminals referred to in the explanations below are to be found on the terminal board inside the electrical panel and described as "installer terminals".
To avoid disturbance caused by magnetic fields, use of shielded cable is recommended. The cable should not exceed a maximum length of 100 m. CONNECTING A PUMP If a pump is to be fitted on the unit or the storage tank, connect it to the terminals provided (E) and the earth of the installer terminal board. CONNECTING A FLOW SWITCH If a flow switch is to be used, connect it to the terminals provided (F2) on the installer terminal board, after removing the jumper.
REMOTE START UP AND SHUT DOWN To use a remote on/off device, the jumper must be replaced with a switch connected to the terminals provided (SA) on the installer terminal board. For timed operation, connect a daily or weekly timer between the terminals provided (SA). REMOTE ALARM For the remote display of unit lockout due to malfunctions, an audible or visual alarm warning device can be connected between the terminals provided (RD), (max load applicable 1A at 230V~50Hz). REMOTE KEYBOARD KIT The remote keyboard kit can be used to verify all unit functions and access electronic board parameters from a point located at some distance from the unit itself. It consists of a remote control module and a transformer. To install the kit, proceed as follows: - disconnect the power supply (by means of the QS door lock disconnecting switch), then access the inside of the electrical panel; - remove the jumper between terminals provided on the installer terminal board; - connect the remote control module with two wires to the terminals provided on the installer terminal board; - connect the transformer supplied with the control module to the 12V-12V terminals, powering it at 230V~50Hz; - connect jumper JMP1 onto the back of the CVM2 keyboard located on the door of the electrical panel.
474
HE-HCR R407C BOOKMARK
GRUPPO
HE-HCR R407C
BOOKMARK
1
L-N
KM1
C
Z
M 1~
1 2
S R
3
C1
N
QM1
EV1
M 1~
U3
1
FU1
0
KA2
0
2
6
0
2
5
A2
1
4
2
2
KA1
7
E
M 1~
3
8
2 KM1
FU2
TC
R1
7 6
KA1
U
4
PC
KA2
4
2
1
11 10
SA
5
RD Max 230V 1A
13 14 15
6
16
A4 OUT
IN
12V
12V
14
17
16
15
13 14 15- 16+
19 20
12V 12V
A5
IN OUT
17 18
Switch not supplied Condensing control accessory 3 Optional installation pump 4 Optional serial interface 5 Lockout indicator light not sup 6 Timer not supplied 7 Optional remote control display panel 8 Flow switch not supplied
5 14
6
2 1 3
230Vac
F N 230Vac SERIAL TTL RS232
6
9
6
10
7 11 12
KM1
12 12 12
11
9
6
QS Door lock disconnector switch R1 Compressor oil sump heater RD Shut-down warning red light SA Timer input TC Transformer U Serial interface Z Compressor
9 10
7
6
7 15
OUTPUT 13 13
8 16 17
9 18 18
24
25 19
26
19
19
230 Vac
plied
7
19
19 19
6
22 20 20
A3
19 19 F1
19
19
TTL
8
20
21
INPUT
21
F2
23 22 22
22
7 9
23
F3
21 23 24
23
6
25
F4
20 24 26
24
2
TK1 ANALOGIC INPUT 17 18 34 33 32 31 29 30 25
27 28 29 30
25
U1
2 4
A1 Radio interference suppresser F3 Water differential pressure switch A2 Electronic controller F4 High pressure safety pressure switch A3 Unit control display keyboard F5 Low pressure safety pressure switch A4 Unit control display keyboard FU1 Transformer protection fuse BT1 Installation water inlet temperature sensor FU2 Auxiliary circuit protection fuse BT2 Installation water outlet frost protection sensor KA1 Installation water pump relay BT3 Well water outlet frost protection sensor KA2 Auxiliary relay E Water pump KM1 Compressor contactor F1 Compressor protection QF1 Chiller assembly protection switch F2 Flow switch QM1 Compressor thermal overload switch
PE
QF
QS
L
A1
27 27
N
N4
28 28
L2
3
0 0
0
5 6
6
8
2
3
4
26 26 BT1
+to
GRUPPO
BT2
+to
L
WIRING DIAGRAM HE SINGLE-PHASE
Outline wiring diagram. Refer to the wiring diagram in the electrical switchboard of the unit.
475
476
BOOKMARK
L1-L2-L3+N
1
3
Z
M 1~
T1 T2 T3
1 2
L1 L2 L3
EV1
M 1~
U3
1
FU1
0
KA2
A2
1
2
5
2
6
2
2
4
KA1
E
M 1~
3
8
2 4 7
2 5 8 R1
7 6
230Vac
9
U
4
PC
F N 230Vac SERIAL TTL RS232
11 12
KA1
F N
13 14
KM1
6
2 1 10 6
7
9
6
QS Door lock disconnector switch R1 Compressor oil sump heater RD Shut-down warning red light SA Timer input TC Transformer U Serial interface Z Compressor
9 10
7
6
7
5
F1
15
KA2
12
16
4
2
1
11 10
SA
6
RD Max 230V 1A
17 18 19
7
20
A4 OUT
IN
12V
12V
14
17
16
15
29 19 20
12V 12V
A5
IN OUT
21 22
230 Vac
plied
8
24
26
25
13 14 15- 16+
Switch not supplied Condensing control accessory 3 Optional installation pump 4 Optional serial interface 5 Lockout indicator light not sup 6 Timer not supplied 7 Optional remote control display panel 8 Flow switch not supplied
5 12 12
OUTPUT 13 13
8 14
9
22
19
F2
9
24
21
INPUT
25
F3
23
27
F4
21
29
F5
20
TK1 ANALOGIC INPUT 17 18 34 33 32 31 29 30
23
26
28
30
31 32 33 34
19
3 6 11 6
0 6 6
KM1
FU2
TC 15
A3
20 20
TTL
19 19
7 9
16 17
22 22
6
18 18
23 23
2
19
24 24
U1
0 0
A1 Radio interference suppresser F3 Water differential pressure switch A2 Electronic controller F4 High pressure safety pressure switch A3 Unit control display keyboard F5 Low pressure safety pressure switch A4 Unit control display keyboard FU1 Transformer protection fuse BT1 Installation water inlet temperature sensor FU2 Auxiliary circuit protection fuse BT2 Installation water outlet frost protection sensor KA1 Installation water pump relay BT3 Well water outlet frost protection sensor KA2 Auxiliary relay E Water pump KM1 Compressor contactor F1 Compressor protection QF1 Chiller assembly protection switch F2 Flow switch QM1 Compressor thermal overload switch
PE
QF
KM1
QM1
A1
29 29
19
25 25
QS
N
N4
27 27
L2
0
0
2
3
19
26 26
BT1
+to
3
4
28 28
BT2
+to
L
WIRING DIAGRAM HE THREE-PHASE
Outline wiring diagram. Refer to the wiring diagram in the electrical switchboard of the unit.
HE-HCR R407C
GRUPPO
HE-HCR R407C
BOOKMARK
L1-L2-L3
KM1
3
Z
1~
M
T1 T2 T3
1 2
L1 L2 L3
QM1
EV1
M
1~
1
FU1
0
KA2
2
2
5
2
A2
1
4
3
0
2
6
0
KA1
7
E
1~
M
8
2
KM1
FU2
TC
10
R1
7 6
KA1
6
U
PC
F
N
F1
2
1
13 13
12 12 Max 230V 1A
RD
17 18 19
SA
20
OUT
IN
12V
12V
14
17
16
15
14 29
20
19
12V 12V
A5
IN OUT
21 22
Switch not supplied Condensing control accessory 3 Optional installation pump 4 Optional serial interface 5 Lockout indicator light not sup 6 Timer not supplied 7 Optional remote control display panel 8 Flow switch not supplied
16
A4
15
6
6
13 14 15- 16+ 16 17
11 10 18 18
2 1 3
230Vac
F N 230Vac SERIAL TTL RS232
15
5
26
25 29
plied
29
10
13 14
KA2
4 19 19
9 7
11 12
KM1
12
24 19
230 Vac
19
11
9
6
QS Door lock disconnector switch R1 Compressor oil sump heater RD Shut-down warning red light SA Timer input TC Transformer U Serial interface Z Compressor
9
7
6
OUTPUT 7 22 20 20
8
19 19
23
19
9
F2
24
21
INPUT
25
F3
23 22
26
22
6
27
F4
21 23
28
23
A3
29
F5
20 24
30
24
TTL
TK1 ANALOGIC INPUT 17 18 34 33 32 31 29 30 25
31 32 33 34
25
7 9
27 27
6
28 28
2
0 0
0
5 6
6
8
2 4
A1 Radio interference suppresser F3 Water differential pressure switch A2 Electronic controller F4 High pressure safety pressure switch A3 Unit control display keyboard F5 Low pressure safety pressure switch A4 Unit control display keyboard FU1 Transformer protection fuse BT1 Installation water inlet temperature sensor FU2 Auxiliary circuit protection fuse BT2 Installation water outlet frost protection sensor KA1 Installation water pump relay BT3 Well water outlet frost protection sensor KA2 Auxiliary relay E Water pump KM1 Compressor contactor F1 Compressor protection QF1 Chiller assembly protection switch F2 Flow switch QM1 Compressor thermal overload switch
PE
QF
QS
N
L2 U1 A1 N4 U3
3
4
26 26
BT1
+to
GRUPPO
BT2
+to
L
WIRING DIAGRAM HE 230V THREE-PHASE
Outline wiring diagram. Refer to the wiring diagram in the electrical switchboard of the unit.
477
I
SIZING OF REFRIGERANT PIPES
A
EQUIVALENT CORRESPONDING LENGTH, 90˚ CURVE AND COMPLETE SIPHON Pipe diameter Curve 90° Siphon
Øi / Øe
8/10
10/12
14/16
16/18
20/22
26/28
33/35
39/42
m eq. m eq.
0,40 1,60
0,42 1,68
0,48 1,92
0,50 2,00
0,60 2,40
0,80 3,20
1,00 4,00
1,20 4,80
DIMENSIONING REFRIGERANT PIPES IN RELATION TO EQUIVALENT LENGTH Model
0011 0021 0025 0031 0041 0051 0061 0071 0091 0101 0121
Type of pipe Discharge Liquid
0-10 m eq. Ø mm Ø mm
12 10
12 10
16 10
16 10
18 12
18 12
18 12
22 16
22 16
22 18
22 18
Type of pipe Discharge Liquid
10-20 m eq. Ø mm Ø mm
16 10
16 10
16 10
16 10
18 12
18 12
18 12
22 16
22 16
28 18
28 18
Type of pipe Discharge Liquid
20-30 m eq. Ø mm Ø mm
-
-
16 12
16 12
18 12
22 12
22 16
28 16
28 16
28 18
28 18
Type of pipe Discharge Liquid
30-40 m eq. Ø mm Ø mm
-
-
-
18 12
22 12
22 16
22 16
28 16
28 16
28 18
28 18
Type of pipe Discharge Liquid
40-50 m eq. Ø mm Ø mm
-
-
-
-
22 16
22 16
22 16
28 16
28 16
35 18
35 18
R22 CONTENT PER LINEAR METRE OF PIPE Pipe diameter Type of pipe Discharge Liquid
gr./m gr./m
10
12
16
18
22
28
35
42
63
19 96
33 170
43,5 222
70 347
115 -
-
-
NB: important, when gas is added, lubricating oil must also be added in a proportion of 10% by weight.
478
HE-HCR R407C BOOKMARK
GRUPPO
REFRIGERANT AND REMOTE CONDENSER CONNECTIONS
IMPORTANT WARNINGS Before proceeding with installation, observe the following warnings scrupulously: - use copper tubing for refrigerant use; - before installing the remote condenser, read the installation instructions in the relative manual; - when installing piping, refer to the diagram; - respect the pipe diameters indicated in the table below in relation to the distance between the evaporator unit and the remote condenser (the maximum distances indicated are in equivalent metres. When calculating pipe lengths, pressure drops must therefore be subtracted); - if there is a difference in level above or in multiples of 6 m, install a siphon in the gas pipe between the evaporator unit and remote condenser;
I
A
- follow good working practice when connecting the two units (tight joints, clean piping, efficient venting and verification of circuit tightness); - electrically connect the remote condenser fan in accordance with current legislation; - the guarantee is invalidated if the above instructions are not respected and if the unit is started up for the first time without the presence of personnel authorised by the Company (where specified in the supply contract) who should draw up a "start-up" report.
MIN 5
GAS GATE VALVE
MINI-VALVE
CONDENSING UNIT
GAS DISCHARGE PIPE
MIN
5
LIQUID LINE (RETURN) LIQUID GATE VALVE
AUTOMATIC FAN SPEED REGULATION SYSTEM (ACCESSORY)
H
INSTALL A SIPHON IN THE DISCHARGE PIPE EVERY 6 m OF LEVEL DIFFERENCE "H"
HE EVAPORATOR UNIT FIXED POINT
VIBRATION DAMPER NON-RETURN VALVE
LIQUID GATE VALVE GAS GATE VALVE MINI-VALVE
GRUPPO
HE-HCR R407C
479 BOOKMARK
I
GENERAL TECHNICAL DATA
Size
A
0011 0021 0025 0031 0041 0051 0061 0071 0091 0101 0121
Rated cooling capacity (1) Absorbed power compressor (1) Evaporator water flow (1) Evaporator pressure drop (1) Type of evaporator
kW kW m3/h kPa
4,7 6,1 7,0 8,2 10,5 12,5 15,0 19,1 22,2 26,8 32,4 1,6 2,0 2,3 2,7 3,3 4,1 4,8 6,1 7,1 8,2 10,2 0,9 1,1 1,3 1,5 1,9 2,3 2,8 3,4 4,1 4,8 5,9 22 24 26 27 19 20 20 23 22 23 23 Plates Plates Plates Plates Plates Plates Plates Plates Plates Plates Plates
Compressor type Number of compressors Number of circuits Power steps
N° N° N°
Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Refrigerant R407C Oil MMM 32 POE
Kg Kg
0,55 1,00
0,57 1,00
0,67 1,10
0,75 1,10
1,10 2,00
1,20 2,00
1,40 1,65
1,55 4,0
1,80 4,0
2,20 4,0
2,60 4,0
Machine operating weight
Kg
68
70
71
74
85
87
90
177
180
187
190
Dimension (A) Dimension (B) Dimension (C)
mm mm mm
400 930 450
400 930 450
400 930 450
400 930 450
400 930 450
400 930 450
400 930 450
600 930 600
600 930 600
600 930 600
600 930 600
Hydraulic connections in/out
Gas
3/4”
3/4”
3/4”
3/4”
dB(A)
43
43
48
48
Sound pressure level (2)
1”1/4 1”1/4 1”1/4 1”1/4 1”1/4 1”1/4 1”1/4 52
52
52
52
52
53
53
(1) installation water IN/OUT 12/7 °C - outside air 35 °C (2) measurement at 1m in open field
A
COOLING PERFORMANCE
Size Ta Tw
5
6
0011 7 8
9
Pf 4,9 5,1 5,2 5,4 5,5 Pa 1,3 1,3 1,3 1,3 1,3 40 Qev 0,8 0,9 0,9 0,9 1,0 ∆Pev 20,6 22,0 23,4 24,9 26,5 Pf 4,7 4,8 5,0 5,1 5,3 Pa 1,4 1,4 1,4 1,4 1,4 45 Qev 0,8 0,8 0,9 0,9 0,9 ∆Pev 18,8 20,1 21,4 22,8 24,3 Pf 4,4 4,6 4,7 4,9 5,1 Pa 1,6 1,6 1,6 1,6 1,6 50 Qev 0,8 0,8 0,8 0,8 0,9 ∆Pev 17,0 18,2 19,4 20,7 22,1
Size Ta Tw
5
6
0031 7 8
9
Pf 8,6 8,9 9,2 9,5 9,7 Pa 2,0 2,0 2,0 2,0 2,0 40 Qev 1,5 1,5 1,6 1,6 1,7 ∆Pev 30,9 32,9 35,0 37,3 39,6 Pf 8,2 8,5 8,8 9,0 9,3 Pa 2,3 2,3 2,3 2,3 2,3 45 Qev 1,4 1,5 1,5 1,6 1,6 ∆Pev 28,2 30,1 32,1 34,2 36,3 Pf 7,8 8,1 8,4 8,6 8,9 Pa 2,6 2,6 2,6 2,6 2,6 50 Qev 1,3 1,4 1,4 1,5 1,5 ∆Pev 25,5 27,3 29,1 31,0 33,0
10
Size Ta Tw
5
6
0021 7 8
9
5,7 Pf 6,3 6,5 6,7 6,9 7,1 1,3 Pa 1,6 1,6 1,6 1,6 1,6 1,0 40 Qev 1,1 1,1 1,2 1,2 1,2 28,1 ∆Pev 25,4 27,1 28,9 30,7 32,7 5,5 Pf 6,0 6,2 6,4 6,6 6,8 1,4 Pa 1,8 1,8 1,8 1,8 1,8 0,9 45 Qev 1,0 1,1 1,1 1,1 1,2 25,8 ∆Pev 23,3 24,9 26,5 28,2 30,0 5,2 Pf 5,7 5,9 6,1 6,3 6,5 1,6 Pa 2,0 2,0 2,0 2,0 2,0 0,9 50 Qev 1,0 1,0 1,1 1,1 1,1 ∆Pev 21,2 22,6 24,2 25,8 27,4 23,5
10
Size Ta Tw
10,0 Pf 2,0 Pa 1,7 40 Qev 42,0 ∆Pev 9,6 Pf 2,3 Pa 1,7 45 Qev 38,6 ∆Pev 9,2 Pf 2,6 Pa 1,6 50 Qev 35,1 ∆Pev
5
6
10,7 2,7 1,8 16,7 10,2 3,0 1,8 15,2 9,7 3,3 1,7 13,6
11,1 2,7 1,9 17,8 10,6 3,0 1,8 16,2 10,0 3,3 1,7 14,5
0041 7 8 11,4 2,7 2,0 18,9 10,9 3,0 1,9 17,3 10,3 3,3 1,8 15,5
11,8 2,7 2,0 20,1 11,3 3,0 1,9 18,4 10,7 3,3 1,8 16,6
480
9 12,1 2,7 2,1 21,3 11,6 3,0 2,0 19,6 11,0 3,3 1,9 17,7
10
Size Ta Tw
6
0025 7 8
9
7,3 Pf 7,3 7,5 7,8 8,0 8,2 1,6 Pa 1,8 1,8 1,8 1,8 1,8 1,3 40 Qev 1,3 1,3 1,3 1,4 1,4 34,7 ∆Pev 27,1 28,9 30,8 32,7 34,8 7,0 Pf 7,0 7,2 7,4 7,7 7,9 1,8 Pa 2,0 2,0 2,0 2,0 2,0 1,2 45 Qev 1,2 1,2 1,3 1,3 1,4 31,9 ∆Pev 24,7 26,4 28,2 30,0 31,9 6,7 Pf 6,6 6,8 7,1 7,3 7,5 2,0 Pa 2,2 2,2 2,2 2,2 2,2 1,2 50 Qev 1,1 1,2 1,2 1,3 1,3 ∆Pev 22,4 23,9 25,5 27,2 29,0 29,2
10
Size Ta Tw
12,5 Pf 2,7 Pa 2,1 40 Qev 22,6 ∆Pev 12,0 Pf 3,0 Pa 2,1 45 Qev 20,8 ∆Pev 11,4 Pf 3,3 Pa 2,0 50 Qev 18,8 ∆Pev
HE-HCR R407C BOOKMARK
5
5
6
13,2 3,3 2,3 19,0 12,6 3,6 2,2 17,3 11,9 4,0 2,1 15,5
13,6 3,3 2,3 20,3 13,0 3,6 2,2 18,5 12,3 4,0 2,1 16,6
0051 7 8 14,1 3,3 2,4 21,6 13,4 3,7 2,3 19,7 12,7 4,0 2,2 17,7
14,5 3,3 2,5 22,9 13,9 3,7 2,4 21,0 13,2 4,0 2,3 18,9
10 8,5 1,8 1,5 36,9 8,1 2,0 1,4 33,8 7,8 2,2 1,3 30,8
9
10
14,9 3,3 2,6 24,3 14,3 3,7 2,5 22,3 13,6 4,0 2,3 20,1
15,4 3,3 2,6 25,8 14,7 3,7 2,5 23,7 14,0 4,1 2,4 21,4
GRUPPO
Size Ta Tw
5
6
Pf Pa 40 Qev ∆Pev Pf Pa 45 Qev ∆Pev Pf Pa 50 Qev ∆Pev
15,8 3,9 2,7 21,1 15,1 4,3 2,6 19,3 14,4 4,8 2,5 17,4
16,3 3,9 2,8 22,5 15,6 4,3 2,7 20,6 14,8 4,8 2,6 18,6
Size Ta Tw Pf Pa 40 Qev ∆Pev Pf Pa 45 Qev ∆Pev Pf Pa 50 Qev ∆Pev
0061 7 8 16,8 3,9 2,9 23,9 16,1 4,3 2,8 21,9 15,3 4,8 2,6 19,9
0101 5 6 7 27,1 6,5 4,7 26,7 25,9 7,3 4,5 24,4 24,7 8,2 4,2 22,0
28,0 6,5 4,8 28,5 26,8 7,3 4,6 26,0 25,5 8,2 4,4 23,6
9
17,3 3,9 3,0 25,4 16,6 4,3 2,9 23,3 15,8 4,8 2,7 21,1
8
28,9 6,5 5,0 30,3 27,7 7,3 4,8 27,8 26,4 8,2 4,5 25,2
10
17,8 3,9 3,1 26,9 17,1 4,3 2,9 24,7 16,2 4,8 2,8 22,3
9
29,8 6,5 5,1 32,3 28,5 7,3 4,9 29,6 27,2 8,1 4,7 26,9
18,3 Pf 3,9 Pa 3,2 40 Qev 28,4 ∆Pev 17,5 Pf 4,3 Pa 3,0 45 Qev ∆Pev 26,1 16,7 Pf 4,8 Pa 2,9 50 Qev ∆Pev 23,6
10
30,7 6,4 5,3 34,3 29,4 7,2 5,1 31,5 28,1 8,1 4,8 28,6
Size Ta Tw
Size Ta Tw
5
6
19,5 4,8 3,4 23,0 18,7 5,4 3,2 21,0 17,7 6,0 3,1 19,0
20,2 4,8 3,5 24,5 19,3 5,4 3,3 22,4 18,3 6,0 3,2 20,3
5
31,7 Pf 6,4 Pa 5,5 40 Qev ∆Pev 36,4 30,3 Pf 7,2 Pa 5,2 45 Qev 33,5 ∆Pev 29,0 Pf 8,1 Pa 5,0 50 Qev 30,5 ∆Pev
33,8 8,1 5,8 29,5 32,3 9,1 5,6 26,9 30,8 10,2 5,3 24,4
0071 7 8 20,8 4,8 3,6 26,2 19,9 5,4 3,4 23,9 19,0 6,0 3,3 21,7
21,5 4,8 3,7 27,8 20,5 5,4 3,5 25,5 19,6 6,0 3,4 23,2
0121 6 7 8 35,0 8,1 6,0 31,5 33,4 9,1 5,8 28,8 31,8 10,2 5,5 26,1
36,1 8,1 6,2 33,5 34,5 9,1 5,9 30,7 32,9 10,2 5,7 27,9
37,2 8,1 6,4 35,7 35,6 9,1 6,1 32,7 34,0 10,2 5,8 29,7
9 22,1 4,8 3,8 29,6 21,2 5,4 3,6 27,1 20,2 6,0 3,5 24,7
9 38,4 8,0 6,6 37,9 36,7 9,0 6,3 34,8 35,0 10,2 6,0 31,7
10
Size Ta Tw
22,8 Pf 4,8 Pa 3,9 40 Qev 31,4 ∆Pev 21,8 Pf 5,3 Pa 3,8 45 Qev ∆Pev 28,8 20,8 Pf 6,0 Pa 3,6 50 Qev ∆Pev 26,3
5
6
23,4 5,7 4,0 25,6 22,4 6,4 3,9 23,4 21,3 7,1 3,7 21,2
24,2 5,6 4,2 27,4 23,1 6,3 4,0 25,0 22,0 7,1 3,8 22,7
25,8 5,6 4,4 31,0 24,7 6,3 4,2 28,4 23,5 7,1 4,0 25,8
10
26,6 5,6 4,6 33,0 25,4 6,3 4,4 30,2 24,2 7,1 4,2 27,5
27,4 5,6 4,7 35,0 26,2 6,3 4,5 32,1 25,0 7,1 4,3 29,3
condensing temperature
10
Tw [°C]
evaporator outflow water
39,5 8,0 6,8 40,3 37,9 9,0 6,5 37,0 36,1 10,1 6,2 33,7
Pf [kW]
cooling capacity
Pa [kW]
compressor power input
Qev [m3/h] evaporator water flow dPev [kPa]
evaporator pressure drop
I
A
For optimum performance, the unit must be operated inside area “A”.
t°
EXTERNAL AIR TEMPERATURE
25,0 5,6 4,3 29,2 23,9 6,3 4,1 26,7 22,8 7,1 3,9 24,2
9
Ta [°C]
RECOMMENDED OPERATING CONDITIONS
COOLING
45 43 40
0091 7 8
35 30 25
RECOMMENDED
20
WORK
15
By modifying operating parameters, the unit can also be operated inside curve “B”.
AREA
10 5 0
The unit must not be used outside area “B”.
-5 -10
-10
-5
0
3 5 7
10
15
20
25
30
t°
DELIVERY WATER TEMPERATURE
Limits Inflow water Outflow water Water thermal head
Evaporator Condensing air temperature
MIN
MAX
6 3(1) 3
23 15 8
20
60
(1) For water and glycol mixtures T min. = -9 °C
GRUPPO
HE-HCR R407C
481 BOOKMARK
Freezing point (°C)
ETHYLENE GLYCOL SOLUTIONS Water and ethylene glycol solutions used as a thermal vector in the place of water reduce the performance of the unit. Multiply the performance figures by the values given in the following table.
0
-5
-10
-15
-20
-25
Percentage of ethylene glycol in weight 12% 0,985 1,02 1,07
0 1 1 1
cPf cQ cdp
cPf: correction factor cooling capacity
40% 0,965 1,14 1,24
35% 0,97 1,11 1,22
28% 0,974 1,075 1,18
20% 0,98 1,04 1,11
cdp: correction factor pressure drop
cQ: correction factor flow rate
Encrustation factors (m2 °C/W)
ENCRUSTATION FACTORS The performance data given refer to conditions with clean evaporator plates (encrustation factor=1). For different encrustation factors, multiply the figures in the performance tables by the coefficient given in the following table.
4,4 x 10 0,86 x 10-4 1,72 x10-4
0,96 0,93
-5
f1
Evaporator fk1
f1
fx1
0,99 0,98
0,99 0,98
fx1 correction factor total power input
correction factor capacity
fk1 correction factor compressor power input
SOUND PRESSURE LEVEL Size
63
125
250
0011 0021 0025 0031 0041 0051 0061 0071 0091 0101 0121
51 51 56 56 62 62 62 62 62 64 64
41 41 46 46 52 52 52 52 52 54 54
40 40 45 45 51 51 51 51 51 52 52
Octave band (Hz) 500 1000 2000 Sound pressure level (dB) 39 39 44 44 50 50 50 50 50 51 51
36 36 41 41 47 47 47 47 47 49 49
33 33 37 37 43 43 43 43 43 44 44
4000
8000
Total dB(A)
27 27 31 31 37 37 37 37 37 38 38
30 30 33 33 39 39 39 39 39 40 40
43 43 48 48 52 52 52 52 52 53 53
Reference point: compressor side at 1m from the external surface of the unit and 1m above the support surface.
I
HYDRAULIC DATA
A
WATER CONTENT IN THE INSTALLATION Size
0011 0021 0025 0031 0041 0051 0061 0071 0091 0101 0121
Minimum water content Optimum water content
l l
50 140
70 150
80 180
100 240
110 290
130 350
150 410
220 500
250 610
300 740
350 940
GRAPH OF EXCHANGER FLOW-RATE - PRESSURE DROP, INSTALLATION SIDE 90 80 70 60 50
Pressure drop (kPa)
40 30 20
10 9 8 7 6
0011 0021 0025 0031
5 0,1
0,2
0,3
0,4
0,5
0041 0051 0061 0071 0091 0101 0121
0,6 0,7 0,8 0,9 1
2
3
4
5
6
7
8
9 10
Flow-rate (m3/h)
For water deriving from tower
Do not operate in the dashed section of the curves
482
HE-HCR R407C BOOKMARK
GRUPPO
I
REFRIGERANT CIRCUIT
A
4 11 3
11
14
9
5
13
11
12
10
1
2
11 13 8 1 2 3 4 5
Plate heat exchanger Water differential pressure switch Compressor Gas valve Liquid valve
6 7 8 9 10
7
6
Thermostatic valve Liquid gauge Filter High pressure safety pressure switch Low pressure safety pressure switch
The unit must be started up for the first time with standard settings. Set point values may be modified only after testing has been completed. Before starting up, power up the unit for at least two hours by positioning QF and QS to ON and the "CVM2" control panel to OFF, to allow the oil in the compressor sump to heat up.
Fill connections Sump heater Water temperature sensor High pressure connection for manostat
A
CHECKING AND STARTING UP THE UNIT PREPARING FOR FIRST START UP The chiller must be started up the first time by the Technical Assistance Service. Before starting up HE condensing unit, check that: - all safety conditions have been respected; - the chiller is adequately fixed to the surface it rests on; - there functional distances have been respected; - there are no gas leaks from the connections on the unit and the remote condenser; - the valves on the evaporator unit are open; - the hydraulic connections have been carried out according to the instruction manual; - the hydraulic circuit is filled and vented; - the hydraulic circuit valves are open; - electrical connections have been carried out correctly - voltage is within a tolerance of 10% of the rated voltage of the unit. - the unit is correctly earthed; - all electrical connections are tight and all hydraulic connections have been carried out correctly.
11 12 13 14
- Make sure the remote secondary switch SA (if present) is in the OFF position - Make sure the remote keyboard "A4" (if present) is set to OFF - Open the door of the electrical panel, as shown in the figure
- Raise the lever of the compressor thermal overload switch QM1
STARTING UP FOR THE FIRST TIME (after two hours) Before activating the unit: - Make sure the remote mains switch QF is in the OFF position; ON
OFF
GRUPPO
HE-HCR R407C
483 BOOKMARK
- Close the door of the electrical panel - Position the main unit switch QS in the ON position
- Position the mains switch QF (outside the unit) in the "ON" position - The "POWER" light on the "CVM2" control panel comes on to show the presence of voltage
For the position of internal components, see the diagrams on page 472. CONTROL PANEL The control panel enables all regulations necessary to operate the chiller to be made and the values of the main CONTROL PANEL CVM2 REMOTE KEYBOARD A5
parameters and alarms to be displayed.
TASTO MENÙ VALUES DISPLAY
INDEX DISPLAY
TASTO STATUS
MENÙ LED
STATUS LED
COMPRESSOR "1" LED COOLING OPERATION LED ALARM LED POWER ON LED
UP BUTTON DOWN BUTTON
MODE BUTTON
ON/OFF RESET BUTTON
SET BUTTON
Values display During normal operation, indicates the temperature of water entering the installation side heat exchanger. It may also indicate the value of all the parameters set and any alarm codes present alternating with the temperature and the status of all the unit’s resources. Index display: Indicates the number of the parameter or resource whose value or status appears on the "values display". ON-OFF and RESET button: Starts up and stops the chiller and resets alarms (manual reset alarms). STATUS button: Accesses the list of resources and displays their status on the "values display" and "index display" SET and UP-DOWN buttons: Enables the list of parameters and their values to be selected and scrolled.
MENU button: (with LED) Accesses programming parameters MODE button: (with LED) Selects the operating mode of the unit - LEDs off = temporary shutdown (stand-by) - LED on = operating in cooling mode Alarm LED "ALARM": Indicates the presence of an alarm state Compressor 1 LED: - On steadily: indicates that the compressor is operating - Flashing: indicates a start-up timer function is underway Power on LED "POWER": - On steadily: indicates the presence of mains voltage
484
HE-HCR R407C BOOKMARK
GRUPPO
ACTIVATING AND DEACTIVATING THE UNIT - Place the remote switch SA1(if present) in the ON position.
Deactivating: - Press the ON-OFF button on the keyboard in the figure;
ON
ON /OFF RESET OFF
the “values display” goes off and the "POWER" voltage indicator LED remains on.
- Set the remote keyboard "A4" (if present) to ON - To ACTIVATE and DEACTIVATE the COOLING and HEATING functions, use the "CVM2" control panel or the remote keyboard "A4", if present.
At every change of season, make sure the operating conditions fall within the limits specified on page 481. Make sure the current absorption of the compressor is less than the maximum given in the table of technical data. In the case of three-phase models, if compressor noise levels are abnormal, reverse one of the phases. Make sure the voltage is within the established limits and that, for three phase units, the unbalance between the phases is less than 3%. * Set not satisfied.
During this phase, if the following indications appear on the display, follow the instructions: - E00 check the connections to terminals A5 - E41 check the water flow-rate and the connection (F2) of the flow switch or differential pressure switch. STARTING UP After start up by the De Longhi Technical Assistance Service, the HE evaporator unit is set for “automatic” operation and requires no further intervention. To activate or deactivate the unit, use the control panel or the remote switch (if present). Activating: - Press the ON-OFF button on the keyboard in the figure;
Operations performed by the remote switch (if present) Activating: - Place the remote switch in the ON position ON
OFF
the temperature of the water returning from the installation appears on the "values display".
ON /OFF RESET
When the unit is deactivated using the remote switch, power remains on to preheat compressor oil and operate the frost protection heater.
the temperature of water returning from the installation appears on the “values display”. - Press the MODE button once.
Deactivating: - Place the remote switch in the OFF position ON
MODE
OFF
the cooling mode LED lights up; after a couple of seconds, the compressor 1 LED flashes until the compressor starts up*.
the “values display” shows the signal “E00”. If electrical power to the unit is off for more than four hours, leave the unit with power on but deactivated (control panel or remote switch to OFF) for at least two hours to preheat the compressor oil.
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HE-HCR R407C
485 BOOKMARK
U
ACTIVATING AND DEACTIVATING THE UNIT
Heating and cooling functions are enabled and disabled via the control panel.
I
A
To activate and deactivate the unit, see page 485.
A
SETTING OPERATING PARAMETERS
SETTING THE SET POINTS The factory set point is 13.5 °C in cooling. To vary the set point, proceed as follows: - press the ON/OFF button on the keyboard in the figure (page 484) - press the MENU button:
MENU
- press the SET button
SET
and the MENU button.
MENU
the following values are displayed: 13.5 - 02 - press the SET button: End of setting SET
the value of the index display begins to flash (parameter "02"); to set the new Set Point press the UP/DOWN buttons;
Parameter 2 92
LIST OF ACCESSIBLE PARAMETERS Description Unit of measurement Summer set Point Password
°C Unit
486
HE-HCR R407C BOOKMARK
Factory set point 13,5 0
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SETTING SERVICE PARAMETERS
If the parameters set on the microprocessor need to be checked or modified, a password is necessary to enter a higher level, accessible only to authorised service centres.
- Press the SET button;
SET
Proceed as follow: - press the ON/OFF button; - press the MENU button; - Press the UP/DOWN buttons: ON /OFF RESET
MENU
the following values are displayed: 13.5 - 02 - press the SET button: all parameters will be visible SET
- to change the setting of a parameter, press the SET button;
SET
the value of the index display begins to flash (parameter "02"); - press the UP/DOWN buttons; - use the UP/DOWN buttons
select the parameter “92”, press the SET button: to set the new value, and press SET to move to another parameter, or the MENU button to exit.
SET
SET
MENU
the values display begins to flash; use the UP/DOWN buttons to set the password;
- to store the new value, press the SET button. - when the two displays flash, the set value is not correct, and will not be stored; - to exit the list of parameters, press the MENU button.
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HE-HCR R407C
487 BOOKMARK
U
DISPLAYING OPERATING STATUS
For the display of the status of operation of the unit perform the following instructions: - press the ON/OFF button
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A
EXITING OPERATING STATUS - Press the STATUS button
STATUS ON/OFF RESET
the STATUS LED goes off: - the temperature of water returning from the installation re-appears on the “values” display.
- press the STATUS button
STATUS
- use the UP/DOWN buttons
to select the parameter corresponding to the function you want to display.
Index display
Component
01
Compressor
02 04
Compressor Defrosting BT1 temp. sensor Plate heat exchanger inlet Remote On/Off BT2 anti-freeze temp. sensor Plate heat exchanger outlet
40 41 42 46
Pump
47 48
Pump Anti-freeze heaters
MEANING OF THE STATUS CODES Values display Meaning 01 04 06 No. hours / 100 06 Value EER On or Off Value EER 01 06 No. hours / 100 04
Operating In timing Inactive Operating hours since last reset Inactive Value in tenths of a degree Sensor error Status of remote On/Off input Value in tenths of a degree Sensor error Active Inactive Total operating hours Heaters inactive
488
HE-HCR R407C BOOKMARK
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ALARM DISPLAY
In the event of unit malfunction, the alarm LED "ALARM" lights up and codes made up of "letters and numbers" flash on the control panel values display. Some of the alarms reset automatically, others must be reset manually (see list below). AUTOMATIC RESET After the cause of the alarm has been eliminated, the control panel returns automatically to normal operating mode.
A
- Press the ON/OFF RESET button twice ON /OFF RESET
The appliance is deactivated and reactivated. - Press the MODE button MODE
MANUAL RESET After the cause of the alarm has been eliminated, to reset:
and reselect the operating mode active when the malfunction occurred.
MALFUNCTION
CAUSE
Values display indication E00
Values display indication E01
Values display indication E02
Values display indication E03
Values display indication E05
Values display indication E06
Values display indication E40
Values display indication E41
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REMEDY
Remote switch set to OFF (automatic reset)
Place remote switch in the ON position Reset switch Reset the jumper between terminals 22-23
High pressure safety pressure switch tripped (manual reset)
Check malfunction (see high discharge pressure, page 496) Reset manually
Low pressure safety pressure switch tripped (automatic reset)
Check fault
Compressor thermal cut-out tripped (manual reset)
Check compressor motor Reset manually
Frost protection device activated (automatic reset)
Check delivery water temperature Verify water flow Verify temperature set point
Faulty BT2 water delivery sensor (automatic reset)
Check electrical connections Replace component
Faulty BT1 water return sensor (automatic reset)
Check electrical connections Replace component
Differential pressure switch or flow switch tripped (automatic reset)
Check for insufficient water flow Check for air in the hydraulic circuit
HE-HCR R407C
489 BOOKMARK
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OPERATING CHARACTERISTICS
Set point in cooling (defined in factory) = 13.5°C, Hysteresis = ± 1.5°C. With water temperatures above 13.5°C+1.5°C (15°C), the compressor starts up. With water temperatures below 13.5°C-1.5°C (12°C), the compressor shuts down. In the event of temporary power failure, when the power returns, the mode set previously will be retained in the memory. COMPRESSOR START UP DELAY Two functions prevent the compressor from starting up too frequently: - Minimum time since last shut-down 180 seconds; - Minimum time since last start-up 240 seconds. PUMP The electronic board includes a pump control output. The pump starts when the assembly is powered up and at least 60 seconds before the compressor starts up and stops 60 seconds after the assembly shuts down. After the first 60 seconds of pump operation when the water flow is at full speed, the water flow alarm functions are activated (differential pressure switch and flow switch). FROST PREVENTION ALARM In order to prevent the water in the plate heat exchanger
from freezing and causing damage, the microprocessor shuts down the compressor if the temperature measured by the heat exchanger outlet temperature sensor drops below +3°C. This frost protection set point temperature can be varied only by an authorised technical assistance service and only after making sure the hydraulic circuit contains antifreeze. Tripping of this alarm shuts down the compressor, but not the pump which remains active. To reset normal functions, the outflow water temperature must rise to more than +7˚C. Reset is manual. WATER FLOW ALARM The microprocessor controls an external water flow alarm: the flow switch. This safety device may trip after the first 60 seconds of pump operation when the water flow is up to speed. Tripping of this alarm shuts down the compressor, but not the pump which remains active. To reset normal functions, the alarm contact must be deactivated for at least five seconds.
A
SHUTTING DOWN FOR LONG PERIODS
After deactivating the evaporator unit: - Make sure the remote switch SA (if present) is in the “OFF” position. - Make sure the remote keyboard (if present) is set to “OFF”. - Move QF and QS to OFF. - Deactivate the internal terminal units by placing the switch of each unit in the “OFF” position. - Close the water valves.
A
If the mains switch is turned to "off" for more than four hours, after turning it on and before reactivating the unit, leave the power on but the unit deactivated for at least two hours to preheat the oil in the compressor sump.
If there is a possibility that the outside temperature may drop below zero, there is a risk of freezing. The hydraulic circuit MUST BE EMPTIED AND CLOSED or antifreeze must be added in the proportion recommended by the manufacturer.
490
HE-HCR R407C BOOKMARK
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ROUTINE MAINTENANCE
Regular maintenance is fundamental to maintain the efficiency of the unit both in terms of operation and energy consumption. The Technical Assistance Service maintenance plan must be observed, with an annual service which includes the following operations and checks: - filling of the water circuit; - presence of air bubbles in the water circuit; - efficiency of safety devices; - power supply voltage; - electrical absorption; - tightness of electrical and hydraulic connections; - condition of the compressor contactor; - verification of operating pressure, over-heating and overcooling; - efficiency of compressor heater - check the condition of the remote condenser
To carry out maintenance, it may be necessary to remove the chiller inspection panel. If this is the case, proceed as follows: - Open the door of the electrical panel (page 483) - Undo the screws as shown in the figure - Remove the inspection panel
To replace the inspection panel, repeat the procedure in reverse.
A
EXTRAORDINARY MAINTENANCE CHEMICAL WASHING You are recommended to chemically wash the plate heat exchanger after every 3 years of operation. For instructions on how to carry out this operation, contact De’ Longhi Spa.
- Always check the superheating and subcooling values. In nominal conditions, these should be between 5 and 10 °C and between 4 and 8 °C respectively. - After a couple of hours of operation, make sure the liquid flow gauge indicates a dry circuit (dry-green).
REFRIGERANT GAS CONTENT The chillers are filled with R407C refrigerant gas and tested in the factory. In normal conditions, there should be no need for the Technical Engineer to intervene to check the refrigerant gas. However, over time, small leaks may develop at the joints leading to loss of refrigerant and draining of the circuit, causing the unit to function poorly. In this case, the leaks of refrigerant must be identified and repaired and the refrigerant circuit refilled. Proceed as follows: - Empty and dry the entire refrigerant circuit using a vacuum pump connected to either the low or high pressure tap until the vacuometer reads about 10 Pa. Wait a couple of minutes and check that this value does not rise to more than 50 Pa. - Connect the refrigerant gas cylinder or a filling cylinder to the low pressure line pressure gauge connection - Fill with the quantity of refrigerant gas indicated on the rating plate of the appliance;
In the event of partial leaks, the circuit must be completely emptied before being refilled. The chiller must only be filled in the liquid state. Operating conditions other than nominal conditions may produce considerably different values. Seal testing or the detection of leaks must be carried out using R407C refrigerant gas only, checking with a suitable leak finder.
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HE-HCR R407C
The refrigerant circuit must not be filled with a refrigerant other than R407C. The use of a refrigerant other than R407C may cause serious damage to the compressor. Oxygen, acetylene or other inflammable or poisonous gases must not be used in the refrigerant circuit, as they may cause explosions. Oils other than those indicated on page 480 must not be used.The use of oils other than those indicated may cause serious damage to the compressor. 491
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DESCRIPTION OF STANDARD HCR UNIT
FINNED COIL - Coil with aluminium fins and copper tubes; - coil side panels in 2.0 mm thick aluminium; - air intake dividers in 2.0 mm thick aluminium inserted in the coil as structural reinforcing elements (one per fan). FANS - Fans with 230V~50Hz electric motor suitable for electronic speed regulation via triac; - electric motor with a minimum of 6 poles; - fan with IP55 junction box and accident prevention grill. INTERNAL STRUCTURE AND EXTERNAL PANELS - Internal structure comprising finned coil with riveted aluminium reinforcements and hexagonal inserts for cover panel attachment; - cover panels in galvanised steel on two sides and painted steel on one side; - fan draught tubes; - flared profile draught tube painted to prevent rust forming on the exposed side; - galvanised iron brackets to mount the unit with horizontal air flow.
REFRIGERANT CIRCUIT - Finned condensing coil; - copper manifolds with connections for welding; - 1/4" SAE pressure tap with SCHRADER valve and cap; - manifold closure caps; - nitrogen content at a pressure of 0.5 bars. OPERATING CONDITIONS - Condensing temperature 50°C; - external air temperature 35°C; - subcooling 5°C. ELECTRICAL WIRING - Capacitors in fan junction boxes. - junction boxes with fan terminal board and wiring in the manifold compartment ACCESSORIES - Pressure switch type condensing control.
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TECHNICAL DATA HCR Size Rated output (1)
A
A
0011 0021 0025 0031 0041 0051 0061 0071 0091 0101 0121 kW
9,7
9,7
12,5
12,5
15,2
18,0
23,0
29,2
33,1
41,7
49,8
Fan Air flow RPM
n°xØ 1x500 1x500 1x500 1x500 1x500 1x500 2x500 2x500 2x500 3x500 3x500 m3/h 3100 3100 2850 2850 4000 3200 5800 8000 7000 12000 11400 n°/min 930 930 930 930 900 880 670 900 890 900 890
Power input Absorbed current at nominal conditions Absorbed current at maximum conditions Electrical power supply
n°xkW 1x0,17 1x0,17 1x0,17 1x0,17 1x0,29 1x0,29 2x0,16 2x0,29 2x0,29 3x0,29 3x0,29 n°xA 1x0,72 1x0,72 1x0,72 1x0,72 1x1,25 1x1,25 2x0,65 2x1,25 2x1,25 3x1,25 3x1,25 n°xA 0,65 0,65 0,65 0,65 1,25 1,25 1,3 2,5 2,5 3,75 3,75 V-Ph-Hz 230/1/50
Dispatched weight
Kg
33
33
37
37
Inlet connections Outlet connections Pressure tap connection Type of connections for welding
mm mm inch
22 12 1/4”
22 12 1/4”
22 16 1/4”
22 16 1/4”
dB(A)
36
36
36
36
Sound pressure level (2) (1)
Nominal power at (tc-ti) = 15°C
(2)
Sound pressure level at 10 m
492
37
46
22 28 16 16 1/4” 1/4” a saldare 43
43
HE-HCR R407C BOOKMARK
66
66
73
93
101
28 20 1/4”
28 20 1/4”
28 20 1/4”
35 22 1/4”
35 22 1/4”
45
46
46
48
48
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DIMENSIONAL DRAWINGS HCR
A
20
706
370
B A
ø 14
746 B
Dimensions
786
0011 0021 0025 0031 0041 0051 0061 0071 0091 0101 0121
A (mm) B (mm)
895 740
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895 740
895 740
HE-HCR R407C
895 740
895 740
895 740
1595 1440
1595 1440
1595 1440
2295 2140
2295 2140
493 BOOKMARK
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POWER SELECTION HCR
Fr 1,7 1,6
Tc
=6
0°C 55
1,5
50 45 40 35 30 25
1,4 1,3 1,2 1,1 -10
-30
-20
-10
The nominal output values given in the catalogue refer to a difference of 16°C between condensing temperatures and ambient air at sea level and with noise levels in dB(A) measured at a distance of 10m in an open field. For other conditions and for nominal condensing power Qc derived from the cooling capacity Qf, the power selection method is given below: Qc = Qf x Fr x F1 x F2 x F3 Fr = heat output factor obtained from DIAG. 1, function of evaporating temperature "T" and condensing temperature "Tc" F1 = compressor type coefficient F1 = 1 for open compressor F1 = 1.08 for semi-hermetic compressor F1 = 1.14 for hermetic compressor
0
+10 Te(°C)
Example: - Cooling capacity Df = 20 kW with Te = -5°C and Tc = 40°C - Semi-hermetic compressor - Ambient temperature 27°C, unit installed at an altitude of 1000m. The condenser must operate with a ∆T = 40-27 = 13°C and with a maximum sound pressure level of 55 dB(A) at a distance of 5m.The selection method gives us: Qc = 20 x 1,25 x 1,08 x 1,27 x 1,06 = 36,3 kW The following will satisfy the required conditions: model ACCS 48 axial flow air condenser with motors with "Y" connection, from the table at 5 m distance, guaranteeing a sound pressure level of 48+6=55 dB(A).
F2 = ∆T coefficient: ∆T °C F2
7 2,17
8 1,89
9 1,69
10 1,52
11 1,37
12 1,27
13 1,16
14 1,07
15 1
16 0,93
17 0,87
18 0,82
19 0,77
F3 = altitude coefficient: m F3
0 1
500 1,028
1000 1,06
1500 1,09
2000 1,12
2500 1,15
3000 1,18
The table below gives the dB(A) values to be added to or subtracted from the catalogue value for different distances from the unit: Distance m dB(A)
4 +8
5 +6
6 +4,5
494
7 +3
8 +2
HE-HCR R407C BOOKMARK
10 0
15 -3,5
20 -6
30 -9,5
50 -14
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TROUBLESHOOTING MALFUNCTION
CAUSE
The evaporator unit does not start
A
REMEDY Check for presence of voltage Check the safety devices upstream of the appliance
No voltage
Mains switch in OFF position Remote switch (if present) in OFF position Control panel set to OFF Main unit switch in OFF position Compressor thermal solenoid switch in OFF
Position in ON
Supply voltage too low
Check power line
Contactor coil faulty Electronic board faulty Start-up capacitor faulty (if present) Compressor faulty
Replace component
Insufficient output
Insufficient refrigerant Undersized unit Operation outside recommended limits
Check
Compressor noisy
Liquid returning to compressor Inadequate fixing
Check
Reversed phase (three phase units only)
Reverse one phase
Contact between metal bodies
Check
Weak foundations
Repair
Loose screws
Tighten screws
Excessive discharge pressure Low suction pressure Low voltage Electrical connections not sufficiently tight Operation outside permitted limits
Check
Faulty operation of pressure switches
Replace component
Thermal cut-out tripped
Check supply voltage Check electrical insulation of windings
Noise and vibrations
Protection devices trip and shut down the compressor
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HE-HCR R407C
495 BOOKMARK
MALFUNCTION High discharge pressure (greater than 23 bars) *
Low discharge pressure (less than 12 bars)*
CAUSE
REMEDY
High external water temperature High water inlet temperature
Check
Insufficient air flow
Check fan operation
Faulty fan control
Check
Excessive refrigerant content
Check
Low external air temperature Low water inlet temperature
Check
Moisture in refrigerant circuit (flow gauge - moisture yellow)
Create vacuum and refill
Faulty fan control
Check
Air in hydraulic circuit
Vent
Insufficient gas content
Check
High suction pressure (greater than 10 bars)*
High external air temperature High inflow water temperature Thermostatic expansion valve faulty or excessively open
Check
Low suction pressure (less than 3.2 bars)*
Low inflow water temperature Low inflow air temperature Thermostatic expansion valve faulty or blocked Clogged water filter Blocked plate heat exchanger
Check
* Values indicative only
496
HE-HCR R407C BOOKMARK
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