SWS / SWR - c-o-k.ru · sonnel from Itelco-Industry ’s Authorised After-Sales Service....

English

Water cooled water chillers with screw compressors

Installation and maintenance manual

IOM SWS-N.2GBDate : July 2007Supersedes : IOM SWS-N.1GB

SWS / SWR

272

1148 kW

Table of contents

Eng

lish

1 FOREWORD

1.1 Introduction 3

1.2 Warranty 3

1.3 Emergency stop/Normal stop 3

1.4 An introduction to the manual 3

2 SAFETY

2.1 Foreword 4

2.2 Definitions 4

2.3 Access to the unit 5

2.4 General precautions 5

2.5 Precautions against residual risks 5

2.6 Precautions during maintenance operations 6

2.7 Safety labels 7

2.8 Safety regulations 9

3 TRANSPORT, LIFTING AND POSITIONING

3.1 Inspection 12

3.2 Lifting 12

3.3 Anchoring 13

3.4 Storage 13

4 INSTALLATION

4.1 Positioning of the unit 14

4.2 Spring Isolator Installation 14

4.3 External hydraulic circuit 15

4.4 Hydraulic connectionof the condenser 16

4.5 Hydraulic connection 16

4.6 Power supply 16

4.7 Electrical connections 17

5 START-UP

5.1 Preliminary check 19

5.2 Start-up 19

5.3 Checking the operation 20

5.4 Delivery to customer 20

6 OPERATION

6.1 General Information 21

6.2 Keyboard - Display Terminal Unit 21

6.3 Functions / Keys / Configuration 23

7 GENERAL DESCRIPTION

7.1 Introduction 26

7.2 General specifications 26

7.3 Compressors 26

7.4 Refrigerant circuits 27

7.5 Evaporator 27

7.6 Condenser 27

7.7 Power supply and control system 28

7.8 “Chiller Control” 28

7.9 Accessories 29

8 TECHNICAL DATA

8.1 Pressure drops 30

8.2 Technical data 32

8.3 Electrical data 42

8.4 Position of antivibration mountingsprings and weight distribution on supports 45

8.5 Overall dimensions and maintenance spaces 63

Table of contents

Manuale SWS-SWR EN1.qxp 05/11/06 14:18 Pagina 1

Table of contents

9 MAINTENANCE

9.1 General requirements 74

9.2 Planned maintenance 74

9.3 Refrigerant charge 75

9.4 Compressors 75

9.5 Condenser 75

9.6 Dehydrating filter 76

9.7 Sight glass 76

9.8 Thermostatic expansion valve 76

9.9 Evaporator 76

10 TROUBLESHOOTING 77

11 SPARE PARTS

11.1 Spare part list 79

11.2 Oil for compressors 79

11.3 Wiring diagrams 79

12 DISMANTLING, DEMOLITIONAND SCRAPPING

12.1 Generalities 80


Foreword

Eng

lish

1 FOREWORD

1.1 Introduction

Itelco-Industry units, manufactured to state-of-the-artdesign and implementation standards, ensure topperformance, reliability and fitness to any type of air-conditioning systems.

These units are designed for cooling water or gly-coled water (and for water heating in heat pumpmodels) and are unfit for any purposes other thanthose specified in this manual.

This manual includes all the information required fora proper installation of the units, as well as the rele-vant operating and maintenance instructions.

It is therefore recommended to read this manualcarefully before installation or any operation on themachine. The chiller installation and maintenancemust be carried out by skilled personnel only (wherepossible, by one of Itelco-Industry ’s Authorised Ser-vice Centers).

The manufacturer may not be held liable for anydamage to people or property caused by improperinstallation, start-up and/or improper use of the unitand/or failure to implement the procedures and in-structions included in this manual.

1.2 Warranty

These units are delivered complete, tested and readyfor being operated. Any form of warranty will be-come null and void in the event that the appliance ismodified without Itelco-Industry ’s preliminary writtenauthorisation.

This warranty shall apply providing that the installa-tion instructions have been complied with (either is-sued by Itelco-Industry , or deriving from the currentpractice), and the Form 1 (“Start-up”) has been filled-in and mailed to Itelco-Industry (attn. After-Sales Ser-vice).

In order for this warranty to be valid, the followingconditions shall be met:� The machine must be operated only by skilled per-

sonnel from Itelco-Industry ’s Authorised After-Sales Service.

� Maintenance must be performed only by skilledpersonnel - from one of Itelco-Industry ’s Autho-rised After-Sales Centers.

� Use only original Itelco-Industry spare parts.

� Carry out all the planned maintenance providedfor by this manual in a timely and proper way.

Failure to comply with any of these conditions willautomatically void the warranty.

1.3 Emergency stop / Normal stop

The emergency stop of the unit can be enabled usingthe master switch on the control panel (move downthe lever).

For a normal stop, press the relevant push-buttons.

To restart the appliance, follow the procedure de-tailed in this manual.

1.4 An introduction to the manual

For safety reasons, it is imperative to follow the in-structions given in this manual. In case of any dam-age caused by non-compliance with these instruc-tions, the warranty will immediately become null andvoid.

Conventions used throughout the manual:

The Danger sign recalls your attention to acertain procedure or practice which, if notfollowed, may result in serious damage topeople and property.

The Warning sign precedes those proce-dures that, if not followed, may result in seri-ous damage to the appliance.

The Notes contain important observations.

The Useful Tips provide valuable informa-tion that optimises the efficiency of the ap-pliance.

This manual and its contents, as well as the docu-mentation which accompanies the unit, are and re-main the property of Itelco-Industry , which reservesany and all rights thereon. This manual may not becopied, in whole or in part, without Itelco-Industry ’swritten authorization.

USEFUL TIPS


Safety

2 SAFETY

2.1 Foreword

These units must be installed in conformity with theprovisions of Machinery Directive 98/37/EC, LowVoltage Directive 73/23/EC, Pressure Vessels Direc-tive 97/23/EC, Electromagnetic Interference Direc-tive 89/336/EC, as well as with other regulationsapplicable in the country of installation. If these pro-visions are not complied with, the unit must not beoperated.

The unit must be grounded, and no installa-tion and/or maintenance operations maybe carried out before deenergising the elec-trical panel of the unit.

Failure to respect the safety measures mentionedabove may result in electrocution hazard and fire inthe presence of any short-circuits.

Inside the heat exchangers, the compres-sors and the refrigeration lines, this unitcontains liquid and gaseous refrigerant un-der pressure. The release of this refrigerantmay be dangerous and cause injuries.

The units are not designed to be operatedwith natural refrigerants, such as hydrocar-bons. Itelco-Industry may not be held liablefor any problems deriving from the replace-ment of original refrigerant or the introduc-tion of hydrocarbons.

Itelco-Industry units are designed and manufacturedaccording to the requirements of European StandardPED 97/23/EC (pressure vessels).– The used refrigerants are included in group II (non-

hazardous fluids).– The maximum working pressure values are men-

tioned on the unit’s data plate.– Suitable safety devices (pressure switches and safe-

ty valves) have been provided, to prevent anyanomalous overpressure inside the plant.

– The vents of the safety valves are positioned andoriented in such a way as to reduce the risk of con-tact with the operator, in the event that the valve isoperated. Anyway, the installer will convey the dis-charge of the valves far from the unit.

– Dedicated guards (removable panels with tools)and danger signs indicate the presence of hotpipes or components (high surface temperature).

The guards of the fans (only for units pro-vided with air heat exchangers) must be al-ways mounted and must never be removedbefore de-energising the appliance.

It is the User’s responsibility to ensure thatthe unit is fit for the conditions of intendeduse and that both installation and mainte-nance are carried out by experienced per-sonnel, capable of respecting all the recom-mendations provided by this manual. It isimportant that the unit is adequately sup-ported, as detailed in this manual. Non-compliance with these recommendationsmay create hazardous situations for thepersonnel.

The unit must rest on a base which meetsthe characteristics specified in this manual;a base with inadequate characteristics islikely to become a source of serious injuryto the personnel.

The unit has not been design to withstandloads and/or stress that may be transmittedby adjacent units, piping and/or structures.Each external load or stress transmitted tothe unit may break or cause breakdowns inthe unit’s structure, as well as serious dan-gers to people. In these cases, any form ofwarranty will automatically become nulland void.

The packaging material must not be dis-posed of in the surrounding environment orburnt.

2.2 Definitions

OWNER: means the legal representative of the com-pany, body or individual who owns the plant whereItelco-Industry unit has been installed; he/she hasthe responsibility of making sure that all the safetyregulations specified in this manual are compliedwith, along with the national laws in force.

INSTALLER: means the legal representative of thecompany who has been given by the owner the jobof positioning and performing the hydraulic, electricand other connections of Itelco-Industry unit to theplant: he/she is responsible for handling and prop-erly installing the appliance, as specified in this man-ual and according to the national regulations inforce.


Safety

Eng

lish

OPERATOR: means a person authorised by the own-er to do on Itelco-Industry unit all the regulation andcontrol operations expressly described in this manu-al, that must be strictly complied with, without ex-ceeding the scope of the tasks entrusted to him.

ENGINEER: means a person authorised directly byItelco-Industry or, in all EC countries, excluding Italy,under his full responsibility, by the distributor of Itel-co-Industry product, to perform any routine and ex-traordinary maintenance operations, as well as anyregulation, control, servicing operations and the re-placement of pieces, as may be necessary duringthe life of the unit.

2.3 Access to the unit

The unit must be placed in an area which can be ac-cessed also by OPERATORS and ENGINEERS; other-wise the unit must be surrounded by a fence at notless than 2 meters from the external surface of themachine.

OPERATORS and ENGINEERS must enter the fencedarea only after wearing suitable clothing (safetyshoes, gloves, helmet etc.). The INSTALLER personnelor any other visitor must always be accompanied byan OPERATOR.

For no reason shall any unauthorised personnel beleft alone in contact with the unit.

2.4 General precautions

The OPERATOR must simply use the controls of theunit; he must not open any panel, other than the oneproviding access to the control module.

The INSTALLER must simply work on the connectionsbetween plant and machine; he must not open anypanels of the machine and he must not enable anycontrol.

When you approach or work on the unit, follow theprecautions listed below:

� do not wear loose clothing or jewellery or any oth-er accessory tat may be caught in moving parts

� wear suitable personal protective equipment(gloves, goggles etc.) when you have to work inthe presence of free flames (welding operations) orwith compressed air

� if the unit is placed in a closed room, wear ear pro-tection devices

� cut off connecting pipes, drain them in order to bal-ance the pressure to the atmospheric value beforedisconnecting them, disassemble connections, fil-ters, joints or other line items

� do not use your hands to check for any pressuredrops

� use tools in a good state of repair; be sure to haveunderstood the instructions before using them

� be sure to have removed all tools, electrical cablesand any other objects before closing and startingthe unit again

2.5 Precautions against residual risks

Prevention of residual risks caused by thecontrol system� be sure to have perfectly understood the operating

instructions before carrying out any operation onthe control panel

� when you have to work on the control panel, keepalways the operating instructions within reach

� start the unit only after you have checked its perfectconnection to the plant

� promptly inform the ENGINEER about any alarminvolving the unit

� do not reset manual restoration alarms unless youhave identified and removed their cause

Prevention of residual mechanical risks� install the unit according to the instructions provid-

ed in this manual� carry out all the periodical maintenance opera-

tions prescribed by this manual� wear a protective helmet before accessing the inte-

rior of the unit� before opening any panelling of the machine,

make sure that it is secured to it by hinges� do not touch air condensation coils without wear-

ing protective gloves� do not remove the guards from moving elements

while the unit is running� check the correct position of the moving elements’

guards before restarting the unit

Prevention of residual electrical risks� connect the unit to the mains according to the in-

structions provided in this manual� periodically carry out all the maintenance opera-

tions specified by this manual� disconnect the unit from the mains by the external

disconnecting switch before opening the electricalboard

� check the proper grounding of the unit before start-up

� check all the electrical connections, the connectingcables, and in particular the insulation; replaceworn or damaged cables


Safety

� periodically check the board’s internal wiring� do not use cables having an inadequate section or

flying connections, even for limited periods of timeor in an emergency

Prevention of other residual risks� make sure that the connections to the unit conform

to the instructions provided in this manual and onthe unit’s panelling

� if you have to disassemble a piece, make sure thatit has been properly mounted again before restart-ing the unit

� do not touch the delivery pipes from the compres-sor, the compressor and any other piping or com-ponent inside the machine before wearing protec-tive gloves

� keep a fire extinguisher fir for electrical appliancesnear the machine

� on the units installed indoor, connect the safetyvalve of the refrigeration circuit to a piping networkthat can channel any overflowing refrigerant out-side

� remove and leak of fluid inside and outside the unit� collect the waste liquids and dry any oil spillage� periodically clean the compressor compartment, to

remove any fouling� do not store flammable liquids near the unit� do not disperse the refrigerant and the lubricating

oil into the environment� weld only empty pipes; do not approach flames or

other sources of heat to refrigerant pipes� do not bend/hit pipes containing fluids under pres-

sure

2.6 Precautions during maintenance operations

Maintenance operations can be carried out by au-thorised technicians only.Before performing any maintenance operations:� disconnect the unit from the mains with the external

disconnecting switch� place a warning sign “do not turn on - mainte-

nance in progress” on the external disconnectingswitch

� make sure that on-off remote controls are inhibited� wear suitable personal protective equipment (hel-

met, safety gloves, goggles and shoes etc.)

To carry out any measurements or checks which re-quire the activation of the machine:� work with the electrical board open only for the

necessary time� close the electrical board as soon as the measure-

ment or check has been completed� for outdoor units, do not carry out any operations

in the presence of dangerous climatic conditions(rain, snow, mist etc.)

The following precautions must be always adopted:� do not scatter the fluids of the refrigeration circuit in

the surrounding environment� when replacing an eprom or electronic cards, use

always suitable devices (extractor, antistaticbracelet, etc.)

� to replace a compressor, the evaporator, the con-densing coils or any other weighty element, makesure that the lifting equipment is consistent with theweight to be lifted

� in air units with independent compressor compart-ment, do not access the fan compartment unlessyou have disconnected the machine by the discon-necting switch on the board and you have placeda warning sign “do not turn on - maintenance inprogress”

� contact Itelco-Industry for any modifications to therefrigeration, hydraulic or wiring diagram of theunit, as well as to its control logics

� contact Itelco-Industry if it is necessary to performvery difficult disassembly and assembly operations

� use only original spare parts purchased directlyfrom Itelco-Industry or the official retailers of thecompanies on the recommended spare parts list

� contact Itelco-Industry if it is necessary to handlethe unit one year after its positioning on site or ifyou wish to dismantle it.


Safety

Eng

lish

2.7 Safety labels

The labels below will be affixed to each unit in the in-dicated point:

Identification of the refrigerant - External door

Identification of the unit -Outside, on the right-hand front column

Electrical warningAdjacent to the master switch

Gravity centre - Base

TENE

RE SU

QUE

STA

LINEA

GANC

IO D

I SOL

LEVA

MEN

TO

KEEP

LIFT

HOO

KON

THIS

LINE


Grounding connection - On the electricalboard, adjacent to the connection

Start-up warning - Outside the door ofthe electrical board

Final Test Certificate -Inside the external door

Warning - safetyvalves’ vents

Warning - high-temperature zones

Adjacent to hotpipes or

components

Lifting point - Base

Fitting identification -Adjacent to fittings

ATTENZIONEINSERIRE LE RESISTENZE DI RISCALDAMENTO OLIO ALMENO12 ORE PRIMA DI OGNI AVVIAMENTO (SE PREVISTE).

PRIMA DELLA MESSA IN TENSIONE ASSICURARSI CHE LE VITI DEI CIRCUITIELETTRICI SIANO SERRATE COMPLETAMENTE.

WARNINGENERGIZE THE CRANCKCASE HEATER FOR AT LEAST 12HOURS BEFORE EACH STARTING (IF FITTED).

BEFORE TIGHTENING-UP, TO TIGHTEN ALL TERMINAL SCREWS ESPECIALLYTHOSE IN MAIN CIRCUIT.

8810

0021

5/B

EIN - INLET

ENTRÉE - ENTRATA

AUS - OUTLET

SORTIE - USCITA

Safety


Eng

lish

Safety

2.8 Safety regulations

Refrigerant data

Toxicity Low

Contact with skin If sprayed, the refrigerant is likely to cause frost burns. If absorbed bythe skin, the danger is very limited; it may cause a slight irritation, andthe liquid is degreasing. Unfreeze the affected skin with water. Removethe contaminated clothes with great care - in the presence of frostburns, the clothes may stick to the skin. Wash with plenty of warm wa-ter the affected skin.In the presence of symptoms such as irritation or blisters, obtain med-ical attention.

Contact with eyes

Ingestion

Inhalation

Recommendations

Prolonged exposure

Vapours do not cause harmful effects. The spraying of refrigerant maycause frost burns. Wash immediately with a proper solution or with tapwater for at least 10 minutes, and then obtain medical attention.

Very unlikely - should something happen, it will cause frost burns.Do not induce vomiting. Only if the patient is conscious, wash outmouth with water and give some 250 ml of water to drink. Then, obtainmedical attention.

R407C, R134a, R22: remarkable concentrations in the air may havean anaesthetic effect, up to fainting. The exposure to considerableamounts may cause irregular heartbeat, up to the sudden death of thepatient. Very high concentrations may result in the risk of asphyxia, dueto the reduction in the oxygen percentage in the atmosphere. Removethe patient to fresh air and keep warm and at rest.If necessary, give oxygen. In case of breathing difficulties or arrest, pro-ceed with artificial respiration. In case of cardiac arrest, proceed withcardiac massage. Then, obtain medical attention.

Semiotics or support therapy is recommended. Cardiac sensitisationhas been observed that, in the presence of circulating catecholaminessuch as adrenalin, may cause cardiac arrhythmia and accordingly, incase of exposure to high concentrations, cardiac arrest.

R407C, R134a, R22: a study on the effects of exposure to 50,000 ppmduring the whole life of rats has identified the development of benign tes-ticle tumour. This situation should therefore be negligible for personnelexposed to concentrations equal to or lower than professional levels.

Professional levels

Stability R407C, R134a, R22: Not specified

R407C, R134a, R22: Recommended threshold: 1000 ppm v/v - 8hours TWA.

Conditions to avoid Do not use in the presence of flames, burning surfaces and excess hu-midity.

Safety data: R407C, R134a, R22

Hazardous reactions May react with sodium, potassium, barium and other alkaline metals.Incompatible substances: magnesium and alloys with magnesium con-centrations > 2%.

Hazardous decomposition products

R407C, R134a, R22: Halogen acids produced by thermal decomposi-tion and hydrolysis.


Respiratory system protection

Storage

Protective clothing

Accidental release measures

Disposal

Fire fighting information

Cylinders

Protective fire fighting equipment

If you are in doubt about the concentration in the atmosphere, it is rec-ommended to wear a respirator approved by an accident-preventionAuthority, of the independent or oxygen type.

Cylinders must be stored in a dry and fresh place, free from any firehazard, far from direct sunlight or other sources of heat, radiators etc.Keep a temperature below 45°C.

Wear overalls, protective gloves and goggles or a mask.

It is important to wear protective clothing and a respirator. Stop thesource of the leak, if you can do this without danger. Negligible leakscan be left evaporating under the sun, providing that the room is wellventilated. Considerable leaks: ventilate the room. Reduce the leak withsand, earth or other absorbing substances. Make sure that the liquiddoes is not channelled into gutters, sewers or pits where the vapoursare likely to create a stuffy atmosphere.

The best method is recovery and recycling. If this method is not practi-cable, dispose according to an approved procedure, that shall ensurethe absorption and neutralization of acids and toxic agents.

R407C, R134a, R22: Not flammable in the atmosphere.

In case of fire, wear an independent respirator and protective clothing.

The cylinders, if exposed to fire, shall be cooled by water jets; other-wise, if heated, they may explode.

General precautions Do not inhale concentrated vapours. Their concentration in the atmos-phere should not exceed the minimum preset values and should bemaintained below the professional threshold. Being more weighty thanthe air, the vapour concentrates on the bottom, in narrow areas. There-fore, the exhaust system must work at low level.

Safety


Eng

lish

Safety

Lubricant oil data Safety data: Polyester oil (POE)

Classification

Contact with skin

Contact with eyes

Ingestion

Inhalation

Conditions to avoid

Protection of the respiratory system

Protective clothing

Accidental release measures

Disposal

Fire fighting information

Cylinders

Fire fighting protective equipment

Not harmful

May cause slight irritation. Does not require first aid measures. It is rec-ommended to follow usual personal hygiene measures, including wash-ing the exposed skin with soap and water several times a day. It is alsorecommended to wash your overalls at least once a week.

Wash thoroughly with a suitable solution or tap water.

Seek medical advice immediately.

Seek medical advice immediately.

Strong oxidising substances, caustic or acid solutions, excess heat.May corrode some types of paint or rubber.

Use in well ventilated rooms.

Always wear protective goggles or a mask. Wearing protective glovesis not mandatory, but is recommended in case of prolonged exposureto refrigerant oil.

It is important to wear protective clothing and, especially, goggles.Stop the source of the leak. Reduce the leak with absorbing substances(sand, sawdust or any other absorbing material available on the mar-ket).

The refrigerant oil and its waste will be disposed of in an approved in-cinerator, in conformity with the provisions and the local regulations ap-plicable to oil waste.

In the presence of hot liquid or flames, use dry powder, carbon dioxideor foam. If the leak is not burning, use a water jet to remove anyvapours and to protect the personnel responsible for stopping the leak.

The cylinders exposed to a fire will be cooled with water jets in case offire.

In case of fire, wear an independent respirator.


Transport, Lifting and Positioning

3 TRANSPORT, LIFTING AND POSITIONING

Refrigerators are supplied assembled (apart fromstandard antivibrating rubber supports, that will beinstalled on site). The equipment are full of refriger-ant and oil, in the quantity required for a proper op-eration.

3.1 Inspection

When the unit is delivered, it is recommended tocheck it carefully and to identify any damage oc-curred during transportation. The goods are shippedex-factory, at the buyer’s risk. Check that the deliveryincludes all the components listed in the order.

In case of damage, note it down on the carrier’s de-livery note and issue a claim according to the instruc-tions provided in the delivery note.

In the presence of any serious damage, that does notaffect the surface only, it is recommended to informItelco-Industry immediately.

Please note that Itelco-Industry may not be held li-able for any damage to the equipment during trans-portation, even though the carrier has been appoint-ed by the factory.

3.2 Lifting

The unit must be lifted by using the hooks inserted in-to the relevant eyebolts (see the figure).

It is recommended to use a spacer to prevent cablesfrom damaging the unit.

For the minimum size of the spacer, please refer toFigure a for sizes from 1002 to 1902 (R407C) andfrom 1602 to 1902 (R134a), to Figure b for sizesfrom 2202 to 4402 (R407C) and from 2202 to4802 (R134a).

Before positioning the unit, make sure that the placeof installation is appropriate and sturdy enough tohold the weight and to withstand the stress causedby the operation of the whole assembly.

Do not displace the unit on rollers, and donot lift it with a lift truck.

To lift and displace the unit:

� Insert and secure eyebolts into the holes markedon the frame.

� Connect cables to eyebolts.

� Hook near the barycentre of the unit.

� The cables must be long enough to form, if ten-sioned, an angle of at least 45° with respect to thehorizontal plane.

Figure a Figure b


Transport, Lifting and Positioning

For lifting operations, use only tools andmaterial fit for this purpose, in accordancewith accident-prevention regulations.

It is recommended not to remove the protec-tive plastic envelope, tha should preventscraps from penetrating into the applianceand any damage to the surfaces, until theunit is ready for operation.

The lifting eyebolts protrude from the baseof the unit; it is therefore recommended toremove them once the unit has been liftedand positioned, if in your opinion they arelikely to become a source of hazard and in-jury.

The eyebolts must be mounted on the unit wheneverit shall be displaced and then lifted again.

3.3 Anchoring

It is not essential to secure the unit to the foundations,unless in areas where there is a serious risk of earth-quake, or if the appliance is installed on the top of asteel frame.

3.4 Storage

When the unit is to be stored before installation,adopt a few precautions to prevent any damage orrisk of corrosion or wear:

� plug or seal every single opening, such as waterfittings

� do not store the appliance in a room where thetemperature exceeds 50°C for the units usingR407C and, if possible, do not expose to directsunlight

� it is recommended to store the unit in a roof wheretraffic is minimized, to prevent the risk of acciden-tal damage

� the unit must not be washed with a steam jet

� take away and leave to the site manager all thekeys providing access to the control board

Finally, it is recommended to carry out visual inspec-tions at regular intervals.

Eng

lish


3) make sure that the base of the machine is restingon the flat washer (E) of the jack. To offset any dif-ference in height, work on high nut (D), using a24 wrench. Clamp in the obtain position with thegrower washer (F) and the relevant low nut (C).

At the end of this operation, check that the machineis elastic on its axes, and preset for the installation ofantivibrating joints in the water connections.

Installation

4 INSTALLATION

4.1 Positioning the unit

Before installing the unit, make sure that thestructure of the building and/or the support-ing surface can withstand the weight of theappliance. The weights of the units are list-ed in Chapter 8 of this manual.

These units have been designed for outdoor installa-tion on a solid surface. Standard accessories includeantivibrating rubber supports, that must be posi-tioned under the base.

When the unit is to be installed on the ground, it isnecessary to provide a concrete base, to ensure auniform distribution of the weights.

As a general rule, no special sub-bases are required.However, if the unit is to be installed on the top of in-habited rooms, it is advisable to rest it on springshock absorbers (optional), that will minimise thetransmission of any vibration to the structures.

To choose the place of installation of the unit, bear inmind that the place of installation must be have allthe necessary spaces for air circulation and mainte-nance operations (see Chapter 9).

4.2 Spring Isolator Installation

� Prepare the base, that must be flat and plane.

� Lift the appliance and insert shock absorbers asfollows:

1) proceed with the assembly of the jack components

2) insert the jack into the threaded seat provided onthe upper plate of the shock absorber. Then insertthe jack mounted on the shock absorber, in thehole provided on the base of the machine.

Insert


4.3 External hydraulic circuit

The external hydraulic circuit must ensurethe water flow to the evaporator under anyworking conditions and with any adjust-ment.

The external hydraulic circuit should consist of thefollowing elements:

� A circulation pump which delivers a sufficient wa-ter flow and discharge head.

� The capacity of the primary hydraulic circuitshould not be less than 7,5 litres/KW of coolingcapacity, in order to prevent the repeated start-upof the compressor and any damage to it. If the wa-ter capacity in the primary piping of the circuitand in the evaporator is lower than this value, aninsulated storage tank shall be installed.

� A membrane expansion vessel provided with safe-ty valve with vent, that must be visible.

The capacity of the expansion vessel mustallow for an expansion of at least 2% of thevolume of the fluid in the circuit (evaporator,piping, user circuit and standby tank, ifany). The expansion vessel needs not beisolated, because no water can circulate in-side it.

� A flow meter, to disable the appliance when thewater is not circulating.

Page 15

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Installation

The external hydraulic circuit must ensurethe water flow to the evaporator under anyworking or adjustment conditions.

To install the flow meter, conform to the manufactur-er’s instructions.

As a general rule, the flow meter must be mountedon a horizontal pipe, and its distance from thecurves must be 10 times the diameter of the pipe, farfrom valves or other components that may hinder thewater flow upstream of or downstream from the flowmeter.

� The air exhaust valves must be mounted in thehighest point of the piping.

� The stop valves must be mounted on the water in-let/outlet piping of the evaporator and the heat re-covery condenser.

� The drain points (provided with plugs, cocks etc.)must be positioned in the lowest point of the pip-ing.

Furthermore:� Provide the evaporator with a by-pass circuit

equipped with valve, to wash the plant.

� Insulate the piping, to prevent the risk of heat loss.

� Install a filter on the suction side of the evaporatoror the heat recovery condenser.

Legends:

I: Pressure gauge connectionS: Gate valveF1: Flow meterGA: Flexible hoses

R: Drain cockT: ThermometerF: FilterI1/I2: Pressure gauge connection to measure

pressure drop or head pressure

Flow meter installation

Unit

Connection diagramExternal hydraulic circuit


Installation

Before filling the circuit, it is important tocheck that it is free from any foreign matter,sand, gravels, rust, welding deposits, wasteand other materials that may damage theevaporator.

When cleaning the lines, it is recommended to cre-ate a circuit by-pass. It is important to mount a filter-ing medium (30 mesh) upstream of the chiller.

If necessary, the water required to fill thecircuit must be treated to obtain the request-ed PH.

4.4 Hydraulic connection of the condenser

The external hydraulic circuit must ensurethe water flow to the condenser under anyworking or adjustment conditions.

The cooling of the units is generally ensured by con-necting the condenser to a cooling tower, though theunits can be cooled also with well water.

In the presence of a water-cooled condenser, it isnecessary to check the flow rate and/or the tempera-ture of the cooling fluid that flows through the con-denser, so as to maintain the refrigerant pressure atvalues that can ensure a satisfactory operation.

When a cooling tower is used, the simplest regula-tion methods consist of checking the operation or thespeed of the fan or the air volume, by means of adamper, once the pilot thermostat has been installedin the basin of the tower.

Alternatively, or if no water from a cooling tower isused, you can adopt a recirculaton system providedwith a 3-way valve.

This circuit shall consist of:

� A circulation pump that can ensure the necessarycapacity and discharge head.

� A flow meter to turn off the appliance when no wa-ter is circulating.

The flow meter must be connected in series,as shown in the wiring diagram of the con-trol panel.

To install the flow meter, follow the manufacturer’sinstructions.

As a general rule, the flow meter shall be mountedon a horizontal pipe, at a distance from the curvesequal to 10 times the diameter of the pipe and farfrom valves or other components that are likely tohinder the water flow upstream of or downstreamfrom the flow meter.

� The bleed valves must be mounted on the highestpoint of the piping.

� The stop valves must be mounted on the piping ofthe water entering/leaving the condenser.

� The discharge points (provided with plugs, cocksetc.) must be arranged in the lowest point of thepiping.

Furthermore:

� Provide the condenser with a by-pass circuit,equipped with a shutoff valve

� Insulate piping, to prevent the risk of heat loss.

� Install a filter on the suction side of the condenser.

� A three-way valve should be installed on-site. Itpermits to bypass the condenser for correct oper-ation at low return water temperature. The best po-sition is close to the condenser.

To install the flow meter, follow the diagram illustrat-ed in paragraph 4.3.

4.5 Hydraulic connection

The water inlet/outlet fittings shall conform to the in-structions provided by the plates affixed neat theconnection points.

4.6 Power supply

Before carrying out any operations on theelectrical system, make sure that the unit isdeenergised.

It is important that the appliance is ground-ed.

The company in charge of the installationshall conform to the standards applicable tooutdoor electrical connections.


Eng

lish

Installation

Itelco-Industry may not be held liable for any dam-age and/or injury caused by failure to comply withthese precautions.

The unit conforms to EN 60204-1.

The following connections shall be provided:� A 3-phase and grounding connection for the pow-

er supply circuit.� The electrical distribution system shall meet the

power absorbed by the appliance.� The disconnecting and magnetothermal switches

must be sized to control the starting current of theunit.

� The power supply lines and the insulation devicesmust be designed in such a way that every line in-dependent.

� It is recommended to install differential switches,to prevent any damage caused by phase drops.

� The fans and compressors are supplied throughcontactors controlled from the control panel.

� Each motor is provided with an internal safetythermal device and external fuses.

� The power supply cables must be inserted intodedicated openings on the front of the unit, andthe will enter the electrical board through holesdrilled on the bottom of the board.

4.7 Electrical connections

The unit must be installed on site according to theMachinery Directive (98/37/EC), the Low Voltage Di-rective (73/23/EC), the Electromagnetic InterferenceDirective (89/336/EC) and the usual procedures andstandards applicable in the place of installation. Theunit must not be operated if its installation has notbeen carried out according to the instructions provid-ed in this manual.

The power supply lines must consist of insulated cop-per conductors, dimensioned for the maximum ab-sorbed current.

Connection to terminals must be performed accord-ing to the diagram of connections provided in thismanual and according to the wiring diagram whichaccompanies the unit.

Before connecting the power supply lines,check that the available voltage value doesnot exceed the range specified in the Elec-tric Data (Chapter 8).

For 3-phase systems, check also that the unbalancebetween the phases does not exceed 2%. To performthis check, measure the differences between the volt-age of each phase couple and their mean value dur-ing operation. The maximum % value of these differ-ences (unbalance) must not exceed 2% of the meanvoltage.

If the unbalance is unacceptable, contact the EnergyDistributor to solve this problem.

Supplying the unit through a line whose un-balance exceeds the permissible value willautomatically void the warranty.


Installation

0101 010101 01

0202 6

0303 03

0505 05

0606 6

0707 07

0606 6

11 11

22 6

33 13

44 6

111111 111

112112 6

1818 18

161161 161

162162 6

163163 163

211211 B8

212212 GND

213213 +VDC

221221 B1

222222 GND

101101 101

102102 102

121121 121

122122 122

123123 123

131131 131

132132 132

133133 133

134134 134

171171 171

172172 172

173173 173

88 4

103103 103

104104 104

QG - Y1

QG - Y2

QG - Y3

(Y) USER TERMINALS

REMOTE START/STOP SWITCH

REMOTE SUMMER/WINTER SWITCH

(SRS)

(COMMON)

(SRHP)

DOUBLE SET-POINT (DAY/NIGHT) (SDN)

PHASE VOLTAGE CONTROL (ACCESSORY) (SQZ)

FLOW SWITCH (SF)

EXTERNAL INTERLOK (OPTIONAL) CIRC PUMP ETC

(COMMON)

LOAD SHEDDING REMOTE CONTROL C.1 (1-SLS/OFF)

LOAD SHEDDING REMOTE CONTROL C.2 (2-SLS/OFF)

(COMMON)

EXTERNAL INTERLOK (OPTIONAL) REMOTE CONDENSER (SYS.1)

EXTERNAL INTERLOK (OPTIONAL) REMOTE CONDENSER (SYS.2)

(GND)(B8)

PLANT WATER TEMPERATURE PROBE(+VDC)

+REMOTE SET-POINT 4-20mmA / 0-10V

(NO)REMOTE INDICATION VOLTAGE ON

(COMMON)

GENERAL ALARM SYSTEM 1-2

(NO)

(COMMON)

(NC)

(NO)REMOTE INDICATION COMP.1 ON / START FAN DEK SYS.1

(COMMON)

(NO)REMOTE INDICATION COMP.2 ON / START FAN DEK SYS.2

(COMMON)

EXTERNAL REVERSE CYCLE VALVE

(NO)

(COMMON)

(NC)

COMMON (230Vcc)

PUMP RELAY CONTROL EVAPORATOR (MAX 0,5 AMP 230Vcc)

PUMP RELAY CONTROL CONDENSER (MAX 0,5 AMP 230Vcc)

–

Terminal box


Eng

lish

Start-up

5 START-UP

The unit must be started for the first time bypersonnel suitably trained by one of Itelco-Industry ’s Authorised Service Centre. Fail-ure to meet this requirement will immediate-ly void the warranty.

The operations carried out by Itelco-Industrypersonnel are limited to the start-up of theunit, and do not include any other opera-tion on the plant, such as, for example,electrical and hydraulic connections etc. Allthe other operations before start-up, includ-ing oil pre-heating for at least 12 hours,must be performed by the Installer.

5.1 Preliminary check

The checks listed below shall be performed beforestarting the unit and before the arrival of the person-nel authorised by Itelco-Industry .

� Check the section of power supply and groundingcables; make sure that terminals are tightened andcheck the correct operation of contactors, with themaster switch open.

� Check that any voltage and phase variation in thepower supply does not exceed the prefixed thresh-olds.

� Connect the contacts of the flow meter and thethermal relay of the pump and of the other devices(if any), to terminals 1-2 and 3-4, respectively.

� Check that the components of the external watercircuit (pump, user equipment, filters, power sup-ply tank and reservoir, if any) have been installedproperly, and according to the manufacturer’s in-structions.

� Check the filling of the hydraulic circuits, andmake sure that the fluid circulation is correct, with-out any trace of leaks and air bubbles. If you useethylene glycol as antifreeze, check that its per-centage is correct.

� Check that the direction of rotation of the pumps iscorrect, and that fluids have been circulating for atleast 12 hours for both pumps. Then, clean the fil-ters on the suction side of the pumps.

� Adjust the liquid distribution network in such away that the flow rate is within the specifiedrange.

� Check that the water quality is up to the specifica-tions.

� Check that oil heaters, if any, have been turned onat least 12 hours before.

5.2 Start-up

Start-up sequence:

� Turn on the master switch (at least 12 hours be-fore).

� Check that the oil in the compressor has reachedthe requested temperature (the minimum tempera-ture outside the pan must be approx. 40°C) andthat the auxiliary control circuit is energised.

� Check the operation of all the external equipment,and make sure that the control devices of the plantare properly calibrated.

� Start the pump and check that the water flow iscorrect.

� Set the desired fluid temperature on the controlboard.

� Start the appliance (see Chapter 6).

� After about 15 minutes of operation check thatthere are no bubbles, through the sight glass onthe liquid line.

The presence of bubbles may indicate thata part of the refrigerant charge has been re-leased in one or more points. It is importantto remove these leaks before proceeding.

� Repeat the start-up procedure after removing theleaks.

� Check the oil level in the compressor’s sight glass.


Start-up

5.3 Checking the operation

Check the following:

� The temperature of the water entering the evapo-rator.

� The temperature of the water leaving the evapora-tor.

� The level of the water flow rate in the evaporator,if possible.

� The current absorption upon the start of the com-pressor and in case of stabilised operation.

Check that the condensing and evaporation temper-atures, during operation at high and low pressuredetected by the pressure gauges of the refrigerant,are within the following range:(On the units not provided with HP/LP pressuregauges for the refrigerant, connect a pressure gaugeto the Schreader valves on the refrigeration circuit).

5.4 Delivery to the customer

� Train the user according to the instructions provid-ed in Section 6.

HP sideApprox 7 to 11°C above the inletwater teperature of condenser, forR407C units; approx 2 to 5°Cabove the inlet water temperatureof condenser, for R134a units.

LP sideApprox 3.5 to 5°C below the tem-perature of the leaving chilled wa-ter, for R407C; approx 3.5 to 6°Cbelow the temperature of the leav-ing chilled water, for R134a units.


Eng

lish

6 OPERATION

These chillers are equipped with a microprocessorcontrol logic and regulation management system.

The system consists of a unit logic board and a liquidcrystal control panel which manages the control,starting, shutdown and display functions.

6.1 General Information

� Introduction

The information and the operating instructions of theelectronic control system mounted on the unit are list-ed here below.

� Main characteristics

– Microprocessor control– User friendly easy reachable keyboard– Proportional – Integral control of return water tem-

perature (RWT)– Hysteresis type control of leaving chilled water tem-

perature (LWT)– Access code to Service Level– Acoustic and LED alarm indication– Backlighted liquid crystals display– Closed loop condensing pressure control– Start and stop pump down logic– Cooling capacity steps rotation-–Oil recovery function– Night (or Double set point) function management– Compressor and pump working hours meter– Discharge and suction pressure display– Memorized alarms history– 4 set point time programs

Possibility to connect:– Serial Communication Card RS485 Card to con-

nect the Chiller Control to a BMS net (MODBUS,LONWORK, BACNET)

– Remote Display Terminal– Remote control– Phase monitoring kit– Killer Data Logger– GSM Modem

� “Chiller Control” system two screw compressors unit

These cooling only water chillers are provided witha microprocessor board having a default programfor the management of two refrigeration circuitseach one equipped with one twin screws compres-sor, one low pressure transducer and one high pres-sure transducer. The control system consists of:- INTERNAL ELECTRONIC PCB- TERMINAL UNIT WITH DISPLAY AND KEYBOARD- CHILLED FLUID TEMPERATURE SENSORS- AMBIENT AIR TEMPERATURE SENSORS- COIL TEMPERATURE SENSOR- HIGH PRESSURE TRANSDUCER- LOW PRESSURE TRANSDUCER

6.2 Keyboard – Display Terminal Unit

� General Information

The figure which follows shows the terminal unit withopen access door.On the figure it is possible to see the microprocessormanaged 4 lines – 20 columns LCD display, the key-board and the LEDs which allow to program all thecontrol parameters as setpoints, differential band,alarm thresholds and to perform the main functions.

Operation

� Keyboard

The terminal unit allows the operator to perform thefollowing operations:– initial configuration of the unit– modification of the main working parameters– displaying of the alarms and their notification by

“buzzer”– displaying of all the measured parameters


Operation

The connection between the terminal unit and theboard is realized by a 6 ways phone cable.The connection between the terminal unit and themain board is not strictly necessary to the normal op-eration of the controller.

Access to the displaying mask of themain parameters and unit status mask.

Access to devices maintenance parame-ters (elapsed working hour of the deviceand reset of the hours meter, alarm histo-ry) (Service Level)

Not Available

Access to the displaying masks of digi-tal and Analog inputs and outputs statusand of the software release.

Access to clock programming mask

Access to the displaying / programmingmasks of the control setpoint (User Level– Setpoint)

Access to “Service level” masks

Pushing this key together it ispossible to access to the“Manufacturer Level”

Used only for unit with four compressorsor back to back configuration with mas-ter slave. Switch the displaying masterunit ontrol / slave unit control

The LEDs of each keys light up when the function re-lated to the key is active.

menu I/O set prog

info? on-off alarm enter

menu

I/O

set

prog

info?

menu prog+

1on-off

2alarm

3/4 5enter

Figure 1

1. On/Off key: it allows to switch on and off the unit.Unit status is indicated by the lighting of the greenLED.

2. Alarm key: it is used to display the alarms, to man-ually reset the alarms and to arrest the buzzer. Ifthe key is lighted in red it means that at least onealarm was detected.Pushing one time this key the buzzer is arrestedand the mask related the active alarm is dis-played.Pushing it a second time the alarm is reset.

3. Upward arrow key: it allows to program the con-trol parameters and to move between the masks(not backlighted).

4. Downward arrow key: it allows to program thecontrol parameters and to move between themasks (not backlighted).

5. Enter key: it allows to move the cursor inside themasks and to save the programmed parameters.This key is continuously backlighted (in yellow) toshow that the unit is under power.

� Display

The unit is equipped with a 4 lines – 20 columns LCDdisplay.The parameters and the operation information areshown in pages called “masks”.The navigation inside each mask is possible using asfollows the terminal unit keys.

When cursor position corresponds to the left cornerof the upper part of the display (Home) pushing the

arrow keys it is possible to access to themasks which are associated to the selected field. If amask contains parameters programming fields, push-ing the key ENTER the cursor will move to thosefields. When it reaches one of the programmingfields, using the arrow keys it is possible tomodify the relevant value within its programmingrange. The modified value must be confirmed push-ing the ENTER key.

x Riga0Home Riga1

Riga2 Riga3

+ - - - - - - - - - - - - - - - - - - - - +

+ - - - - - - - - - - - - - - - - - - - - +Line 0Line 1Line 2Line 3

4

4


Eng

lish

Operation

Code Alarm Description Comp. #1 Comp. #2 Pump Evap. Pump Cond.Status Status Status Status

AL01 Wrong power Off Off Off OffAL02 Antifreeze alarm Off Off On OffAL03 Interlock Off Off Off OffAL04 Flow switch alarm Off Off Off OffAL05 System #1 low suction pressure Off On On OnAL06 System #2 low suction pressure On Off On OnAL07 System #1 high discharge pressure Off On On OnAL08 System #2 high discharge pressure On Off On OnAL09 Compressor #1 thermal protection Off On On OnAL10 Compressor #2 thermal protection On Off On OnAL14 Remote interlock n°1 Off On On OnAL15 Remote interlock n°2 On Off On OnAL18 Clock board failure On On On OnAL21 B1 wrong signal Off Off On OffAL22 B2-LP1 sensor failure Off On On OnAL23 B3-DP1 sensor failure On On On OnAL24 B4-TEin sensor failure On On On OnAL25 B5-TEout sensor failure Off Off On OnAL26 B6-LP2 sensor failure On Off On OnAL27 B7-DP2 sensor failure On On On OnAL28 B8-Tplan sensor failure Off Off On OnAL29 B9-TCin sensor failure On On On OnAL30 B10-TCout sensor failure On On On On

AL31SYS #1 compressorMaintenance On On On On

AL32SYS #2 compressorMaintenance On On On On

AL33 Pump maintenance On On On On

AL37System #1 compressor differential pressure Off On On On

AL38System #2 compressor differential pressure On Off On On

Notes:1 = Check power phases rotation and/or minimum voltage. It works only in case the Phases Monitor (accessory) is installed.

6.3 Functions / Keys / Configuration

� Alarms Table

� “Menu” key

Pushing the “Menu” key the main mask is displayed:

U:1 RWT ................... 0.0 °CSYS#1: OFFSYS#2: OFFUnit ON

In this mask the following items are displayed:– unit serial number and control temperature– system #1 status– system #2 status– unit status.


Operation

� I/O (input / output) Status

Pushing the “I/O” key it is possible to access to allthe masks showing the values read by all the sensorsinstalled on the unit.

Sensor UseTin Entering chilled fluid temperatureTout Leaving chilled fluid temperatureTpLAN Installation control sensor (in case of

“Chiller Network”SP #1 System #1 suction pressure transducerDP #1 System #1 discharge pressure transducerSP #2 System #2 suction pressure transducerDP #2 Sys 2 : trasduttore pressione mandataTC #1 Heat recovery heat exchanger entering water temp.TC #2 Heat recovery heat exchanger leaving water temp.

The following items are also displayed:1. Chiller Control digital inputs and outputs status2. Analog outputs driving the fan speed controllers3. Code and release of the “Chiller Control” soft-

ware.

� Maintenance

Pushing the “Maintenance” key it is possible to ac-cess to the following information masks:

1. ALARM HISTORY

Pushing the “Enter” the cursor enter in the list of thememorized alarms. At this point the arrow keys al-low to scroll the masks of all the memorized alarmswhich show the date, time, code and the controlledwater temperature (entering or leaving) at the mo-ment in which the alarm itself was detected.

2. PUMP WORKING HOURS

3. COMPRESSORS WORKING HOURS

4. PASSWORD (*)

Nota (*): Contact Itelco Clima Service Department toaccess to the following masks.

RST_HOUR METERS

MSK_FILTERS

M_DISABLE

M_OFFSET1

M_OFFSET2

M_OFFSET3

HOUR_THRES

N°0000AL000 00:00 00/00/00Setpoint ......................00.0 °CTemperaturE .............. 00.0 °C

U:1Pump........................ 00000 h

U:1 SYS #1Compressor 00000 hU:1 SYS #2Compressor 00000 h

U:1DIGIT password

0000

Reset hours U:1pump ....................... NcompressorsSYS #1 N SYS #2 N

Enabling softwarefilters ........................ SThreshold .................. 00.5 °CInterval ..................... 020 sec

EnablingcompressorsSYS #1=Y SYS #2=Y

Sensor calibrationTin ............................. 0.0 °CSP #1 ........................ 0.0 barDP #1 ........................ 0.0 bar

Tair ............................. 0.0 °CTout ............................ 0.0 °CSP #2 ........................ 0.0 barDP #2 ........................ 0.0 bar

Sensor calibrationTpLAN ......................... 0.0 °C

Maintenance alarmthreshold

003X1000h


Operation

Eng

lish

� Setpoint

Pushing the “Set” key it is possible to access to user’sSetpoint level. The following table contains the de-

User’s Setpoints Control of Low Limit High Limit Default

System #1 ON/OFF – OFF ON OFFSystem #2 ON/OFF – OFF ON OFFCooling Setpoint Inlet 8 20 10

Outlet 6 20 8Heating Setpoint Inlet 20 48 43

Outlet 20 50 45Glycol Setpoint Inlet –15 20 10

Outlet –15 20 8Dead band Inlet 1 10 5

Outlet 1 6 2Language Selection — ITA ENG GER FRA SPA Italian

� Clock Key

To have access to the following mask:

DATE AND TIME

TIMING PERIODS ENABLING

U:1 ClockHour 00:00DayDate 00/00/00

Day timingperiods withsetpointvariations ...........................N

SETPOINTS TIMING

Setp1 = 00.0 - 00:00hSetp2 = 00.0 - 00:00hSetp3 = 00.0 - 00:00hSetp4 = 00.0 - 23:59h

� Remote setpoint - Input B1

When the B1 input is enabled, the remote setpoint isactivated. The active set of the machine, in cold orheat mode, is no longer the set selected on the key-

tails of the parameters which is possible to set withthe relevant limitations and default values:

board, but is a value which corresponds to the B1analog input in the 4-20mA scale, according to thefollowing curve:

REM. COLD SET (°C)

20

mCS+2

4mA 20mA (B1 mA)

REM. HOT SET (°C)

MSH

20

4mA 20mA (B1 mA)


General Description

7.2 General specifications

The SWS/SWR chillers are supplied complete andfitted with refrigerant connection pipes and internalwiring.

The refrigeration circuit of each SWS unit is subject-ed to a pressure test, drained, vacuumised, dehy-drated and filled with refrigerant, and includes thenecessary oil. On completion of the assembly, eachunit is subjected to final testing and checking of theproper operation of all refrigeration circuits.

The base and the frame of every single unit aremade of sturdy galvanised steel and fastened bystainless steel screws and bolts. Both the compressorand the components of the refrigerant circuit arelodged in a compartment coated with soundproofingmaterial (ELN versions), whose sides can be easilyremoved to provide access.

7 GENERAL DESCRIPTION

7.1 Introduction

The water chillers with two refrigeration circuits ofthe SWS series have been designed for indoor instal-lation.

For heat dissipation purposes, the SWS units must becoupled to a cooling tower, or use well water.

The series includes the following versions:

Options Description

SWS/D

The galvanised steel sections are oven-painted withwhite enamel (RAL 9001).

7.3 Compressors

The SWS/SWR units feature semi-hermetic screwcompressors. The control of the compressor’s capaci-ty is managed by solenoid capacity control valves,that are controlled by the microprocessor of the ap-pliance; every compressor has 3 working steps:25% (start only), 50%, 75%, 100%.

The compressors’ motors are cooled by the refriger-ant gas and are provided, in each phase, by a built-in temperature-sensitive solid state device for over-load protection.

The motor’s terminals are weatherproof, accordingto standard IP-54.

For each version, the corresponding moto-evaporating version is available: SWR

Available options:

The thermal recovery is ensured by a de-superheater mounted on the compressor’sdelivery line

COMPRESSOR START-UPPART - WINDING STAR - TRIANGLE

SWS/SWR 1002 - 1902 R407C SWS/SWR 2202 - 4402 R407CSWS/SWR 1602 - 2202 R134a SWS/SWR 2212 - 4802 R134a

Version Description

SWS standard version (STD)SWS low noise version (LN)SWS extra low noise version (ELN)

Chillers with water condensation, working withR407C and R134a refrigerants (with R22 refrigeranton request for extra-european countries)


Eng

lish

General Description

7.4 Refrigerant circuits

Every single SWS unit has two complete refrigerantcircuits, one per compressor. Each refrigerant circuitincludes: a service valve for refrigerant filling, shutoffvalves for suction lines (on request), as well as for thedelivery and liquid lines, a thermostatic expansionvalve with external equalizer, a solenoid valve tostart/stop the compressor, a dehydrating cartridgefilter, a sight glass with humidity indicator, a differen-tial oil pressure switch. The moto-evaporating SWRunits, which derive from the SWS versions, aremarked by the absence of condensers, are providedwith shutoff cocks on the delivery and liquid lines, soas to allow the connection of remote condensers.

Each circuit is also provided with safety devices, inaccordance with PED 97/23/EC: HP pressureswitches, pressure transducers, safety valves provid-ing protection in case of fire or in the case of a mal-function of compressors.

7.5 Evaporator

All units are equipped with a single direct-expansionrefrigerant/water exchanger of shell and tube type,with several refrigeration circuits. The tube bundlecan be removed for any inspections or maintenance.

The heat exchangers are insulated with 19mm-thickanti-condensate closed-cell polyethylene material.The insulating material is not UV-ray-proof.

7.6 Condenser

All units are provided with two condensers (one percircuit). The heat exchanger is of shell and tube type,with square plates, preset for opening for inspection,cleaning and maintenance purposes.

SWS refrigeration diagram

9 Sight glass10 Thermostatic valve11 Evaporator12 Safety valve13 Suction cock (optional)14 Nonreturn valve (optional)15 Solenoid valve (optional)16 Capillary (optional)

Components:

1 Screw compressor2 Screw compressor’s

delivery cock3 Flexible hose - absorber

(ELN version only)4 Silencer (ELN version only)5 Condenser6 Safety valve7 Liquid cock8 Filter

Safety devices:

A HP pressure switchB LP pressure switchC TransducerD Differential water pressure switch

Filling/discharge andpressure/intakes Freon

Note: the units are equipped with two re-frigeration circuits. Only one circuit isillustrated for the sake of simplicity.


General Description

7.7 Power supply and control system

All units are provided with a microprocessor and a“Chiller Control” system.

The electrical connection of the controls and the start-up units for the motor are carried out and tested inthe factory.

A door stop disconnecting switch is always avail-able, and is mounted on the door of the appliance.IP 54 protection degree.The power supply/control compartment includes:� Master switch� Network isolator, contactors, compressor fuses� A transformer for auxiliaries, fuses, relay and elec-

tronic card� The keyboard and the display of the “Chiller-Con-

trol” microcomputer, mounted on the door of thecontrol section.

7.8 “Chiller Control”

The “Chiller Control” unit consists of an expandableinterface card and a controller.

The function of the expandable interface card is tomonitor the inputs and control the outputs:� Digital inputs, such as alarm and control signals.� Analog inputs, such as temperature/pressure mea-

suring signals.� Digital outputs for the excitation of control relays

and remoto-control switches.

The microprocessor will execute the logic that con-trols:� The LED and the display of the alarm signals and

the operation of the appliance.� The compressor’s start-up logic (excitation of the

winding and stop), potential regulation (3+3steps).

SWR refrigeration diagram

10 Thermostatic valve11 Evaporator12 Safety valve13 Suction cock (optional)14 Nonreturn valve (optional)15 Solenoid valve (optional)16 Capillary (optional)

Components:

1 Screw compressor2 Screw compressor’s

delivery cock3 Flexible hose - absorber

(ELN version only)4 Silencer (ELN version only)5 Delivery cock7 Liquid cock8 Filter9 Sight glass

Safety devices:

A HP pressure switchB LP pressure switchC TransducerD Differential water pressure switch

Filling/discharge andpressure intakes Freon

Nota: the units are equipped with two re-frigeration circuits. Only one circuit isillustrated for the sake of simplicity.


General Description

Eng

lish

� The display of the compressor’s working hoursand the temperature of the water to the evapora-tor.

� The anti-cycling and delay timing upon start-up.� The automatic advance/delay sequence for the

compressor start-up.

Reference and parameter control:� User level: the operator can modify any data with

the ‘ENTER’, ‘+’ and ‘-’ keys.� Service level: password protected access by the

authorised personnel.

7.9 Accessories

List of the available accessories, supplied separately,to be mounted on-site by the installer:

Water flow meter

Prevents the operation of the unit if the circulatingchilled fluid is insufficient. It is recommended to in-stall a flow meter to ensure the correct operation ofthe unit.

Antivibrating supports (AVM)

solating spring supports, provided with bolts for fas-tening onto the base. They are supplied separatefrom the unit, and shall be mounted on site at the cus-tomer’s expense.

Remote wall terminal (200 m)

Makes it possible to control the unit through the re-mote terminal, up to a maximum distance of 200 me-ters.

Chiller data logger

Records continuously the essential thermodynamicoperating parameters, during the 10 minutes thatprecede the last alarm.

GSM Modem

Makes it possible to check the working mode or theswitching on/off of the unit via SMS. In case of anyalarms, the unit sends an SMS to the user.

RS-485 serial card

A communication interface allows you to control andmanage the unit from a local station, with RS485connection, up to a distance of 1000 m.

It is therefore possible to obtain remote control andmanagement by integrating these functions into thebuilding’s control system.


Technical data

SWS R407C 1002 1202 1402 1602 1902 2202K 10

4kPa/(m

3/s)

223.5 23.5 11.3 11.3 7.8 4.6

Min. water flow rate l/s 9.9 10.7 11.8 13.4 16.7 20.5Max. water flow rate l/s 23.1 24.9 27.6 31.4 39.0 47.7Min. pressure drops kPa 23.1 26.8 15.8 20.4 21.8 19.1Max. pressure drops kPa 126.0 145.9 86.3 111.2 118.5 104.1

SWS R407C 2602 3002 3402 3802 4202 4402K 10

4kPa/(m

3/s)

24.6 3.7 3.5 3.6 3.6 3.6


8 TECHNICAL DATA

8.1 Pressure drops

Evaporator

SWS R134a 1602 1902 2202 2212 2352K 10

4kPa/(m

3/s)

226.3 18.1 12.1 6.6 5.6

Min. water flow rate l/s 9.3 12.4 15.0 18.1 19.3Max. water flow rate l/s 21.6 28.9 35.0 42.1 45.0Min. pressure drops kPa 22.7 27.8 27.4 21.5 20.6Max. pressure drops kPa 123.4 151.1 149.2 117.1 112.4

SWS R134a 2502 2652 2802 3012 3202K 10

4kPa/(m

3/s)

25.6 6.0 6.0 6.0 3.8


SWS R134a 3412 3602 4212 4602 4802K 10

4kPa/(m

3/s)

23.8 3.6 3.6 3.6 3.6



Eng

lish

Technical data

SWS R407C 1002 1202 1402 1602 1902 2202K 10

4kPa/(m

3/s)

255.7 55.7 53.0 43.1 32.4 16.5


SWS R407C 2602 3002 3402 3802 4202 4402K 10

4kPa/(m

3/s)

211.8 11.8 11.2 6.7 6.4 6.4


Condenser

SWS R134a 1602 1902 2202 2212 2352K 10

4kPa/(m

3/s)

244.8 35.3 25.3 17.1 17.1


SWS R134a 2502 2652 2802 3012 3202K 10

4kPa/(m

3/s)

213.7 13.7 13.7 12.3 12.3


SWS R134a 3412 3602 4212 4602 4802K 10

4kPa/(m

3/s)

24.9 4.9 4.9 4.9 4.5



Technical data

8.2 Technical data

SWS 1002-2202 R407C

(1) Indicative value. Always refer to the value specified on the unit’s label.

SWS R407C 1002 1202 1402 1602 1902 2202Nominal voltage V/ph/Hz 400/3/50Number of circuits 2 2 2 2 2 2Number of steps 6Capacity steps % 25/50/63/75/87/100RefrigerantType R407CCharge (1) kg 59 63 70 80 99 122CompressorsType ScrewNumber 2 2 2 2 2 2Start-up type Part-Winding Y/∆

EvaporatorType Shell & TubeNumber 1 1 1 1 1 1Water flow rate l/s 13.9 14.9 16.6 18.8 23.4 28.6Pressure drop kPa 45.4 52.5 31.1 40.0 42.7 37.5Water content l 93.3 93.3 80.2 80.2 124.7 221.7CondenserType Shell & TubeNumber 2 2 2 2 2 2Water flow rate l/s 8.9 9.6 10.6 12.1 14.9 18.2Pressure drop kPa 44.0 50.9 59.8 62.8 72.2 54.5Water content l 28.4 28.4 28.4 30.8 49.4 62.4Hydraulic connections EvaporatorType VictaulicInlet diameter inch 5" 5" 5" 5" 6" 8"Outlet diameter inch 5" 5" 5" 5" 6" 8"Hydraulic connections CondenserType Gas threaded femaleInlet diameter inch 2"1/2 2"1/2 2"1/2 2"1/2 3" 3"Outlet diameter inch 2"1/2 2"1/2 2"1/2 2"1/2 3" 3"WeightsShipping kg 1645 1659 2041 2067 2554 3005Operating kg 1768 1780 2148 2176 2728 3288DimensionsLength mm 3795 3795 3795 3795 3795 4210Width mm 950 950 950 950 950 1400Height mm 1910 1910 1910 1910 1910 2050

Manuale SWS-SWR EN.qxp 4-04-2007 15:23 Pagina 32

Eng

lish

Technical data


SWS R407C 2602 3002 3402 3802 4202 4402Nominal voltage V/ph/Hz 400/3/50Number of circuits 2 2 2 2 2 2Number of steps 6Capacity steps % 25/50/63/75/87/100RefrigerantType R407CCharge (1) kg 142 160 181 209 219 233CompressorsType ScrewNumber 2 2 2 2 2 2Start-up type Y/∆

EvaporatorType Shell & TubeNumber 1 1 1 1 1 1Water flow rate l/s 33.5 37.7 42.5 49.1 51.5 54.8Pressure drop kPa 51.3 53.0 63.4 86.5 95.1 107.7Water content l 221.7 206.5 184.4 222.2 222.2 222.2CondenserType Shell & TubeNumber 2 2 2 2 2 2Water flow rate l/s 21.2 23.9 26.9 31.1 32.7 35.1Pressure drop kPa 53.1 67.4 80.9 64.9 68.3 78.5Water content l 71.4 71.4 71.4 95.0 95.0 95.0Hydraulic connections EvaporatorType VictaulicInlet diameter inch 8" 8" 8" 8" 8" 8"Outlet diameter inch 8" 8" 8" 8" 8" 8"Hydraulic connections CondenserType Gas threaded female Inlet diameter inch 3 3 3 4” 4” 4"Outlet diameter inch 3 3 3 4” 4” 4"WeightsShipping kg 3259 3326 3460 4330 4380 4254Operating kg 3552 3604 3716 4648 4696 4572DimensionssLength mm 4210 4210 4210 4210 4210 4210Width mm 1400 1400 1400 1400 1400 1400Height mm 2050 2050 2050 2050 2050 2050

SWS 2602-4402 R407C


Technical data

SWS 1602-2352 R134a

SWS R134a 1602 1902 2202 2212 2352Nominal voltage V/ph/Hz 400/3/50Number of circuits 2 2 2 2 2Number of steps 6Capacity steps % 25/50/63/75/87/100RefrigerantType R134aCharge (1) kg 46 61 74 52 55CompressorsType ScrewNumber 2 2 2 2 2TStart-up type P/W Y/∆

EvaporatorType Shell & TubeNumber 1 1 1 1 1Water flow rate l/s 13.0 17.3 21.0 25.3 27.0Pressure drop kPa 44.4 54.4 53.7 42.2 40.5Water content l 80.2 124.7 221.7 162.0 184.0CondenserType Shell & TubeNumber 2 2 2 2 2Water flow rate l/s 8.0 10.5 12.7 15.3 16.4Pressure drop kPa 28.7 38.7 41.0 40.1 45.7Water content l 30.8 49.4 55.4 62.0 62.0Hydraulic connections EvaporatorType VictaulicInlet diameter inch 5" 6" 8" 6" 6"Outlet diameter inch 5" 6" 8" 6" 6"Hydraulic connections CondenserType Gas threaded femaleInlet diameter inch 2"1/2 3" 3" 3" 3"Outlet diameter inch 2"1/2 3" 3" 3" 3"WeightsShipping kg 2067 2554 3005 3377 3470Operating kg 2144 2688 3212 3601 3717DimensionsLength mm 3795 3795 4210 4210 4210Width mm 950 950 1400 1400 1400Height mm 1910 1910 2050 2050 2050



Eng

lish

Technical data


SWS 2502-3202 R134a

SWS R134a 2502 2652 2802 3012 3202Nominal voltage V/ph/Hz 400/3/50Number of circuits 2 2 2 2 2Number of steps 6Capacity steps % 25/50/63/75/87/100RefrigerantType R134aCharge (1) kg 59 63 66 70 77CompressorsType ScrewNumber 2 2 2 2 2Start-up type Y/∆

EvaporatorType Shell & TubeNumber 1 1 1 1 1Water flow rate l/s 28.7 30.5 32.4 34.2 37.5Pressure drop kPa 45.7 56.3 63.4 70.6 52.8Water content l 184.0 222.0 222.0 222.0 359.0CondenserType Shell & TubeNumber 2 2 2 2 2Water flow rate l/s 17.4 18.5 19.6 20.8 22.8Pressure drop kPa 41.6 47.0 50.2 50.5 60.5Water content l 68.0 68.0 68.0 71.0 71.0Hydraulic connections EvaporatorType VictaulicInlet diameter inch 6" 6" 6" 6" 8"Outlet diameter inch 6" 6" 6" 6” 8"Hydraulic connections CondenserType Gas threaded femaleInlet diameter inch 3" 3" 3" 3" 3"Outlet diameter inch 3" 3" 3" 3" 3"WeightsShipping kg 3498 3592 3605 4029 4952Operating kg 3750 3882 3895 4323 5382DimensionsLength mm 4210 4210 4210 4210 4670Width mm 1400 1400 1400 1400 1400Height mm 2050 2050 2050 2050 2050


Technical data

SWS R134a 3412 3602 4212 4602 4802Nominal voltage V/ph/Hz 400/3/50Number of circuits 2 2 2 2 2Number of steps 6Capacity steps % 25/50/63/75/87/100RefrigerantType R134aCharge (1) kg 82 88 94 102 110

CompressorsType ScrewNumber 2 2 2 2 2Start-up type Y/∆

EvaporatorType Shell & TubeNumber 1 1 1 1 1Water flow rate l/s 40.2 42.9 46.0 49.7 53.4Pressure drop kPa 60.8 65.7 75.3 88.0 101.7Water content l 359.0 359.0 359.0 399.0 399.0CondenserType Shell & TubeNumber 2 2 2 2 2Water flow rate l/s 24.4 26.0 28.2 30.4 32.5Pressure drop kPa 29.0 33.0 38.7 41.7 47.9Water content l 126.0 126.0 126.0 133.0 133.0Hydraulic connections EvaporatorType VictaulicInlet diameter inch 8” 8” 8” 8” 8”Outlet diameter inch 8” 8” 8” 8” 8”Hydraulic Connections CondenserType VictaulicInlet diameter inch 4” 4” 4” 4” 4”Outlet diameter inch 4” 4” 4” 4” 4”WeightsShipping kg 4970 4986 5112 5165 5342Operating kg 5455 5471 5597 5698 5875DimensionsLength mm 4670 4670 4670 4670 4670Width mm 1400 1400 1400 1400 1400Height mm 2050 2050 2050 2110 2110

SWS 3412-4802 R134a



Eng

lish

Technical data

SWR R407C 1002 1202 1402 1602 1902 2202Nominal voltage V/ph/Hz 400/3/50Number of circuits 2 2 2 2 2 2Number of steps 6Capacity steps % 25/50/63/75/87/100RefrigerantType R407CCompressorsType ScrewNumber 2 2 2 2 2 2Start-up type Part-Winding Y/∆

EvaporatorType Shell & TubeNumber 1 1 1 1 1 1Water flow rate L/s 13.9 14.9 16.6 18.8 23.4 28.6Pressure drop kPa 45.4 52.5 31.1 40.0 42.7 37.5Water content l 93.3 93.3 80.2 80.2 124.7 221.7Hydraulic connections EvaporatorType VictaulicInlet diameter inch 5" 5" 5" 5" 6" 8"Outlet diameter inch 5" 5" 5" 5" 6" 8"Refrigerant connectionsType To be weldedDischarge diameter inch 1” 5/8 1” 5/8 1” 5/8 1” 5/8 2” 1/8 2” 1/8

Liquid diameter inch 1” 3/8 1” 3/8 1” 3/8 1” 3/8 1” 3/8 1” 3/8

WeightsShipping kg 1370 1380 1755 1765 2065 2453Operating kg 1463 1473 1835 1845 2190 2675DimensionsLength mm 3795 3795 3795 3795 3795 4210Width mm 950 950 950 950 950 1400Height mm 1910 1910 1910 1910 1910 2050

SWR 1002-2202 R407C


Technical data

SWR R407C 2602 3002 3402 3802 4202 4402Nominal voltage V/ph/Hz 400/3/50Number of circuits 2 2 2 2 2 2Number of steps 6Capacity steps % 25/50/63/75/87/100RefrigerantType R407CCompressorsType ScrewNumber 2 2 2 2 2 2Start-up type Y/∆

EvaporatorType Shell & TubeNumber 1 1 1 1 1 1Water flow rate l/s 33.5 37.7 42.5 49.1 51.5 54.8Pressure drop kPa 51.3 53.0 63.4 86.5 95.1 107.7Water content l 221.7 206.5 184.4 222.2 222.2 222.2Hydraulic connections EvaporatorType VictaulicInlet diameter inch 8" 8" 8" 8" 8" 8"Outlet diameter inch 8" 8" 8" 8" 8" 8"Refrigerant connectionsType To be weldedDischarge diameter inch 2” 5/8 2” 5/8 2” 5/8 3” 1/8 3” 1/8 3” 1/8

Liquid diameter inch 1” 3/8 1” 3/8 1” 3/8 1” 3/8 1” 3/8 1” 3/8

WeightsShipping kg 2663 2712 2825 3495 3535 3395Operating kg 2885 2919 3009 3717 3757 3617DimensionsLength mm 4210 4210 4210 4210 4210 4210Width mm 1400 1400 1400 1400 1400 1400Height mm 2050 2050 2050 2050 2050 2050

SWR 2602-4402 R407C


Eng

lish

Technical data

SWR 1602-2352 R134a

SWR R134a 1602 1902 2202 2212 2352Nominal voltage V/ph/Hz 400/3/50Number of circuits 2 2 2 2 2Number of steps 6Capacity steps % 25/50/63/75/87/100RefrigerantType R134aCompressorsType ScrewNumber 2 2 2 2 2Start-up type P/W Y/∆

EvaporatorType Shell & TubeNumber 1 1 1 1 1Water flow rate l/s 13.0 17.3 21.0 25.3 27.0Pressure drop kPa 44.4 54.4 53.7 42.2 40.5Water content l 80.2 124.7 221.7 162.0 184.0Hydraulic connections EvaporatorType VictaulicInlet diameter inch 5" 6” 8” 6” 6”Outlet diameter inch 5" 6” 8” 6” 6”WeightsShipping kg 1765 2065 2453 2895 2985Operating kg 1845 2190 2675 3057 3169DimensionsLength mm 3795 3795 4210 4210 4210Width mm 950 950 1400 1400 1400Height mm 1910 1910 2050 2050 2050


Technical data

SWR 2502-3202 R134a

SWR R134a 2502 2652 2802 3012 3202Nominal voltage V/ph/Hz 400/3/50Number of circuits 2 2 2 2 2Number of steps 6Capacity steps % 25/50/63/75/87/100RefrigerantType R134aCompressorsType ScrewNumber 2 2 2 2 2Start-up type Y/∆

EvaporatorType Shell & TubeNumber 1 1 1 1 1Water flow rate l/s 28.7 30.5 32.4 34.2 37.5Pressure drop kPa 45.7 56.3 63.4 70.6 52.8Water content l 184.0 222.0 222.0 222.0 359.0Hydraulic connections EvaporatorType VictaulicInlet diameter inch 6” 6” 6” 6” 8”Outlet diameter inch 6” 6” 6” 6” 8”WeightsShipping kg 2995 3085 3095 3505 4421Operating kg 3179 3307 3317 3727 4780DimensionsLength mm 4210 4210 4210 4210 4670Width mm 1400 1400 1400 1400 1400Height mm 2050 2050 2050 2050 2050


Technical data

Eng

lish

SWR 3412-4802 R134a

SWR R134a 3412 3602 4212 4602 4802Nominal voltage V/ph/Hz 400/3/50Number of circuits 2 2 2 2 2Number of steps 6Capacity steps % 25/50/63/75/87/100RefrigerantType R134aCompressorsType ScrewNumber 2 2 2 2 2Start-up type Y/∆

EvaporatorType Shell & TubeNumber 1 1 1 1 1Water flow rate l/s 40.2 42.9 46.0 49.7 53.4Pressure drop kPa 60.8 65.7 75.3 88.0 101.7Water content l 359.0 359.0 359.0 399.0 399.0Hydraulic connections EvaporatorType VictaulicInlet diameter inch 8” 8” 8” 8” 8”Outlet diameter inch 8” 8” 8” 8” 8”WeightsShipping kg 4431 4441 4561 4581 4753Operating kg 4790 4800 4920 4980 5153DimensionsLength mm 4670 4670 4670 4670 4670Width mm 1400 1400 1400 1400 1400Height mm 2050 2050 2050 2010 2010


TTeecchhnniiccaall ddaattaa

8.3 Electrical data

SSWWSS//SSWWRR RR440077CC 11000022 11220022 11440022 11660022 11990022 22220022

Nominal voltage V(%)-ph-Hz 400 ±10% / 3 / 50Nominal power input kW 92 98 114 130 157 189Max power input kW 111 117 135 155 187 225Nominal current A 157 175 203 232 280 338Max. current (FLA) A 164 192 248 280 336 392Max. start-up current (LRA) A 360 440 367 449 613 455External fuses (A) 200 250 315 315 400 500Wire cross area (1) mm2 120 120 185 185 2x150 2x150CCoommpprreessssoorrss

Number n° 2 2 2 2 2 2Nominal power input kW 2x46 2x49 2x57 2x65 2x79 2x95Max. power input kW 2x55 2x58 2x68 2x77 2x94 2x113Rated current A 2x79 2x87 2x102 2x116 2x140 2x169Max. current (FLA) A 2x82 2x96 2x124 2x140 2x168 2x196Max. start-up current (LRA) A 2x303 2x373 2x280 2x351 2x495 2x318Oil treater power input W 200 200 200 200 200 200

(1) The dimensioning of the unit’s power cables is the responsibility of the installer, who shall consider: the rating, the maximum working temperaturein the room, the type of insulation and the cable laying, the maximum length of the power supply line.

SSWWSS//SSWWRR RR440077CC 22660022 33000022 33440022 33880022 44220022 44440022

Nominal voltage V(%)-ph-Hz 400 ±10% / 3 / 50Nominal power input kW 223 246 269 296 316 393Max power input kW 265 293 317 349 373 460Nominal current A 397 440 480 529 564 701Max. current (FLA) A 450 490 540 600 668 800Max. start-up current (LRA) A 512 546 642 753 829 875External fuses (A) 500 630 630 630 800 1000Wire cross area (1) mm2 2x185 2x185 2x185 2x240 2x240 2x300CCoommpprreessssoorrss

Number n° 2 2 2 2 2 2Nominal power input kW 2x111 2x123 2x135 2x158 2x158 2x197Max. power input kW 2x132 2x147 2x158 2x175 2x186 2x230Nominal current A 2x199 2x220 2x240 2x264 2x282 2x351Max. current (FLA) A 2x225 2x245 2x270 2x300 2x334 2x400Max. start-up current (LRA) A 2x354 2x374 2x453 2x543 2x595 2x595Oil treater power input W 275 275 275 275 275 275


Eng

lish



SSWWSS//SSWWRR RR113344aa 11660022 11990022 22220022 22221122 22335522

Nominal voltage V(%)-ph-Hz 400 ±10% / 3 / 50Nominal power input kW 78.8 95 114.4 158 166Max power input kW 109.6 132.4 159.4 220 230Nominal current A 141 169 204 266 279Max. current (FLA) A 192 210 260 360 395Max. start-up current (LRA) A 347.2 424.5 586 393 417.5External fuses (A) 250 250 315 400 400Wire cross area (1) (*) mm2 120 120 185 2x150 2x150CCoommpprreessssoorrss

Number n° 2 2 2 2 2Nominal power input kW 2x39.4 2x47.5 2x57.2 2x79 79+87Max power input kW 2x54.8 2x66.2 2x79.7 2x110 110+120Nominal current A 2x70 2x85 2x102 2x133 133+146Max. current (FLA) A 2x96 2x105 2x130 2x180 180+215Max. start-up current (LRA) A 2x280 2x351 2x495 2x267 267+314Oil treater power input W 200 200 200 300 300


Nominal voltage V(%)-ph-Hz 400 ±10% / 3 / 50Nominal power input kW 174 184 194 211 228Max power input kW 240 251 262 286 310Nominal current A 292 310 328 351 374Max. current (FLA) A 430 446 462 511 560Max. start-up current (LRA) A 464.5 491.5 502.7 597.7 632External fuses (A) 500 500 500 630 630Wire cross area (1) (*) mm2 2x150 2x185 2x150 2x185 2x185CCoommpprreessssoorrss

Number n° 2 2 2 2 2Nominal power input kW 2x87 87+97 2x97 97+114 2x114Max power input kW 2x120 120+131 2x131 131+155 2x155Nominal current A 2x146 146+164 2x164 164+187 2x187Max. current (FLA) A 2x215 215+231 2x231 231+280 2x280Max. start-up current (LRA) A 2x280 314+341 2x341 341+436 2x436Oil treater power input W 300 300 300 300 300




Nominal voltage V(%)-ph-Hz 400 ±10% / 3 / 50Nominal power input kW 249 270 298 315 322Max power input kW 359 408 408 426 444Nominal current A 404 434 492 519 546Max. current (FLA) A 590 620 620 670 720Max. start-up current (LRA) A 661 682 803 867 902External fuses (A) 630 630 630 800 800Wire cross area (1) (*) mm2 2x185 2x185 2x185 2x240 2x240CCoommpprreessssoorrss

Number n° 2 2 2 2 2Nominal power input kW 114+135 2x135 2x149 149+166 2x166Max power input kW 155+204 2x204 2x204 204+222 2x222Nominal current A 187+217 2x217 2x246 246+273 2x273Max. current (FLA) A 280+310 2x310 2x310 310+360 2x360Max. start-up current (LRA) A 436+465 2x465 2x586 586+650 2x650Oil treater power input W 300 300 300 300 300



Eng

lish


8.4 Position of antivibration mounting springs and weight distribution on supports

SSWWSS OOppeerraattiinnggwweeiigghhtt ((kkgg))

PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11000022 1768 442 442 442 44211220022 1780 445 445 445 44511440022 2148 537 537 537 53711660022 2176 544 544 544 54411990022 2728 682 682 682 682

Weight distribution SWS 1002-1902 R407C STD


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11660022 2144 536 536 536 53611990022 2688 672 672 672 672

Weight distribution SWS 1602-1902 R134a STD



Weight distribution SWS 2202-4402 R407C STD


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 3288 822 822 822 82222660022 3552 888 888 888 88833000022 3604 901 901 901 90133440022 3716 929 929 929 92933880022 4648 1162 1162 1162 116244220022 4696 1174 1174 1174 117444440022 4572 1143 1143 1143 1143



PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 3211 803 803 803 80322221122 3601 900 900 900 90022335522 3717 929 929 929 92922550022 3750 937 937 937 93722665522 3882 970 970 970 97022880022 3895 974 974 974 97433001122 4323 1081 1081 1081 1081



Eng

lish



PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

33220022 5382 1346 1346 1346 134633441122 5455 1364 1364 1364 136433660022 5471 1368 1368 1368 136844221122 5597 1399 1399 1399 139944660022 5698 1424 1424 1424 142444880022 5875 1469 1469 1469 1469



Weight distribution SWS 1002-1902 R407C LN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11000022 2077 519 519 519 51911220022 2091 523 523 523 52311440022 2460 615 615 615 61511660022 2488 622 622 622 62211990022 3038 759 759 759 759

Weight distribution SWS 1602-1902 R134a LN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11660022 2454 613 613 613 61311990022 3000 750 750 750 750



Eng

lish

Weight distribution SWS 2202-4402 R407C LN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 3689 922 922 922 92222660022 3952 988 988 988 98833000022 4004 1001 1001 1001 100133440022 4115 1029 1029 1029 102933880022 5047 1262 1262 1262 126244220022 5097 1274 1274 1274 127444440022 4971 1243 1243 1243 1243



PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 3611 903 903 903 90322221122 4001 1000 1000 1000 100022335522 4117 1029 1029 1029 102922550022 4150 1037 1037 1037 103722665522 4282 1070 1070 1070 107022880022 4295 1074 1074 1074 107433001122 4723 1181 1181 1181 1181





PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

33220022 5882 1471 1471 1471 147133441122 5955 1489 1489 1489 148933660022 5971 1493 1493 1493 149344221122 6097 1524 1524 1524 152444660022 6198 1549 1549 1549 154944880022 6375 1594 1594 1594 1594



Eng

lish

Weight distribution SWS 1002-1902 R407C ELN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11000022 2167 542 542 542 54211220022 2181 545 545 545 54511440022 2550 637 637 637 63711660022 2578 644 644 644 64411990022 3128 782 782 782 782

Weight distribution SWS 1602-1902 R134a ELN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11660022 2544 636 636 636 61311990022 3090 772 750 750 750



Weight distribution SWS 2202-4402 R407C ELN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 3809 952 952 952 95222660022 4072 1018 1018 1018 101833000022 4124 1031 1031 1031 103133440022 4235 1059 1059 1059 105933880022 5167 1292 1292 1292 129244220022 5217 1304 1304 1304 130444440022 5091 1273 1273 1273 1273



PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 3731 933 933 933 93322221122 4151 1038 1038 1038 103822335522 4267 1067 1067 1067 106722550022 4300 1075 1075 1075 107522665522 4432 1108 1108 1108 110822880022 4445 1111 1111 1111 111133001122 4873 1218 1218 1218 1218



Eng

lish



PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

33220022 6052 1513 1513 1513 151333441122 6125 1531 1531 1531 153133660022 6141 1535 1535 1535 153544221122 6267 1567 1567 1567 156744660022 6368 1592 1592 1592 159244880022 6545 1636 1636 1636 1636



Weight distribution SWR 1002-1902 R407C STD

SSWWRR OOppeerraattiinnggwweeiigghhtt ((kkgg))

PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11000022 1464 366 366 366 36611220022 1472 368 368 368 36811440022 1836 459 459 459 45911660022 1844 461 461 461 46111990022 2188 547 547 547 547

Weight distribution SWR 1602-1902 R134a STD


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11660022 1844 461 461 461 46111990022 2188 547 547 547 547


Eng

lish


Weight distribution SWR 2202-4402 R407C STD


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 2676 669 669 669 66922660022 2884 721 721 721 72133000022 2920 730 730 730 73033440022 3008 752 752 752 75233880022 3716 929 929 929 92944220022 3756 939 939 939 93944440022 3616 904 904 904 904



PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 2676 669 669 669 66922221122 3057 764 764 764 76422335522 3169 792 792 792 79222550022 3179 795 795 795 79522665522 3307 827 827 827 82722880022 3317 829 829 829 82933001122 3727 932 932 932 932





PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

33220022 4780 1195 1195 1195 119533441122 4790 1198 1198 1198 119833660022 4800 1200 1200 1200 120044221122 4920 1230 1230 1230 123044660022 4980 1245 1245 1245 124544880022 5153 1288 1288 1288 1288



Eng

lish


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11000022 1773 443 443 443 44311220022 1783 446 446 446 44611440022 2145 536 536 536 53611660022 2155 539 539 539 53911990022 2500 625 625 625 625

Weight distribution SWR 1002-1902 R407C LN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11660022 2155 539 539 539 53911990022 2500 625 625 625 625

Weight distribution SWR 1602-1902 R134a LN



Weight distribution SWR 2202-4402 R407C LN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 3075 769 769 769 76922660022 3285 821 821 821 82133000022 3319 830 830 830 83033440022 3409 852 852 852 85233880022 4117 1029 1029 1029 102944220022 4157 1039 1039 1039 103944440022 4017 1004 1004 1004 1004



PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 3075 769 769 769 76922221122 3457 864 864 864 86422335522 3569 892 892 892 89222550022 3579 895 895 895 89522665522 3707 927 927 927 92722880022 3717 929 929 929 92933001122 4127 1032 1032 1032 1032



Eng

lish



PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

33220022 5280 1320 1320 1320 132033441122 5290 1323 1323 1323 132333660022 5300 1325 1325 1325 132544221122 5420 1355 1355 1355 135544660022 5480 1370 1370 1370 137044880022 5653 1413 1413 1413 1413



Weight distribution SWR 1002-1902 R407C ELN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11000022 1863 466 466 466 46611220022 1873 468 468 468 46811440022 2235 559 559 559 55911660022 2245 561 561 561 56111990022 2590 647 647 647 647

Weight distribution SWR 1602-1902 R134a ELN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

11660022 2245 561 561 561 56111990022 2590 647 647 647 647



Eng

lish

Weight distribution SWR 2202-4402 R407C ELN


PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 3195 799 799 799 79922660022 3405 851 851 851 85133000022 3439 860 860 860 86033440022 3529 882 882 882 88233880022 4237 1059 1059 1059 105944220022 4277 1069 1069 1069 106944440022 4137 1034 1034 1034 1034



PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

22220022 3591 799 799 799 79922221122 3607 902 902 902 90222335522 3719 930 930 930 93022550022 3729 932 932 932 93222665522 3857 964 964 964 96422880022 3867 967 967 967 96733001122 4277 1069 1069 1069 1069





PP11((kkgg))

PP22((kkgg))

PP33((kkgg))

PP44((kkgg))

33220022 5450 1363 1363 1363 136333441122 5460 1365 1365 1365 136533660022 5470 1368 1368 1368 136844221122 5590 1398 1398 1398 139844660022 5650 1413 1413 1413 141344880022 5823 1456 1456 1456 1456


Eng

lish


8.5 Overall dimensions and maintenance space

Overall dimensions SWS 1002 - 1902 STD R407C and SWS 1602 - 1902 STD R134a

LLeeggeenndd::* Only for shipping1 Evaporator water inlet2 Evaporator water outlet3 Condenser water inlet4 Condenser water outlet5 Power inlet

DDiimmeennssiioonnss AA BB CC DD EE FF GG 11--22 33--4411000022--11220022 800 235 715 205 275 245 315 DN125 (5”) 2” 1/2 GAS F11440022--11660022 800 235 715 205 275 245 315 DN125 (5”) 2” 1/2 GAS F

11990022 815 220 730 185 295 225 335 DN150 (6”) 3” GAS F



Overall dimensions SWR 1002 - 1902 STD R407C and SWR 1602 - 1902 STD R134a

LLeeggeenndd::* Only for shipping1 Evaporator water inlet2 Evaporator water outlet3 Condenser water inlet4 Condenser water outlet5 Power inlet

DDiimmeennssiioonnss AA BB CC DD EE FF GG 11--22 33 4411000022--11220022 800 235 715 230 320 340 150 DN125 (5”) 1 5/8” 1 3/8”11440022--11660022 800 235 715 230 320 340 150 DN125 (5”) 1 5/8” 1 3/8”

11990022 815 220 730 150 320 340 150 DN150 (6”) 2 1/8” 1 3/8”


Eng

lish


Overall dimensions SWS 2202 - 4402 STD R407C and SWS 2212 - 3012 STD R134a

eeggeenndd::* Only for shipping1 Evaporator water inlet2 Evaporator water outlet3 Condenser water inlet4 Condenser water outlet5 Power inlet

DDiimmeennssiioonnss AA BB CC DD EE FF GG HH 11--22 33--4422220022 1160 225 850 295 400 245 355 255 DN200 (8”) 3” GAS F

22660022--33000022--33440022 1160 225 850 295 400 245 355 255 DN200 (8”) 3” GAS F33880022--44220022--44440022 910 475 600 285 415 235 365 475 DN200 (8”) 4” GAS F22221122--22335522--22550022 1176 208 835 295 405 245 355 208 DN150 (6”) 3” GAS F22665522--22880022--33001122 923 460 587 295 405 245 355 490 DN150 (6”) 3” GAS F



Overall dimensions SWR 2202 - 4402 STD R407C


DDiimmeennssiioonnss AA BB CC DD EE FF GG HH 11--22 33 4422220022 1160 225 850 260 430 360 390 160 DN200 (8”) 2 1/8” 1 3/8”

22660022--33000022--33440022 1160 225 850 260 395 360 390 160 DN200 (8”) 2 5/8” 1 3/8”33880022--44220022--44440022 910 475 600 260 410 360 390 160 DN200 (8”) 3 1/8” 1 3/8”



Eng

lish

DDiimmeennssiioonnss AA BB CC DD EE FF GG HH LL 11--22 33--4433220022 888 495 682 297 407 256 366 2050 830 DN200 (8”) 3” GAS F

33441122--33660022--44221122 888 495 682 297 400 256 366 2050 830 DN200 (8”) DN100 (4”)44660022--44880022 888 495 682 297 400 256 366 2110 860 DN200 (8”) DN100 (4”)

Overall dimensions SWS 3202 - 4802 STD R134a




Overall dimensions SWS 1002 - 1902 LN/ELN R407C and SWS 1602 - 1902 LN/ELN R134aSWR 1002 - 1902 LN/ELN ad R407C and SWR 1602 - 1902 LN/ELN R134a

LLeeggeenndd::* Only for shippingRefer to the standard drawing for the dimensions of connections 5 Power inlet


Eng

lish


Overall dimensionsSWS 2202 - 4402 LN/ELN R407C and SWS 2202 - 3012 LN/ELN R134aSWR 2202 - 4402 LN/ELN R407C and SWR 2202 - 3012 LN/ELN R134a

LLeeggeenndd::* Only for shippingRefer to the standard drawing for the dimensions of connections5 Power inlet



Overall dimensions SWS 3202 - 4802 LN/ELN R134aSWR 3202 - 4802 LN/ELN R134a

DDiimmeennssiioonnss AA33220022--33441122--33660022--44221122 2130

44660022--44880022 2190

LLeeggeenndd::* Only for shippingRefer to the standard drawing for the dimensions of connections5 Power inlet


Eng

lish


Maintenance spaceSWS 1002 - 1902 R407C and SWS 1602 - 1902 R134aSWR 1002 - 1902 R407C and SWR 1602 - 1902 R134a



Maintenance spaceSWS 2202 - 4402 R407C and SWS 2202 - 3012 R134aSWR 2202 - 4402 R407C and SWR 2202 - 3012 R134a



Eng

lish

Maintenance spaceSWS 3202 - 4802 R134aSWR 3202 - 4802 R134a

DDiimmeennssiioonnss HH33220022 2050

33441122--33660022--44221122 205044660022--44880022 2110


MMaaiinntteennaannccee

9 MAINTENANCE

CCaarreeffuullllyy rreeaadd tthhee ““SSaaffeettyy”” sseeccttiioonn ooff tthhiiss mmaannuuaallbbeeffoorree ccaarrrryyiinngg oouutt aannyy mmaaiinntteennaannccee ooppeerraattiioonnss..

DDoo nnoott ddiisscchhaarrggee tthhee rreeffrriiggeerraanntt iinnttoo tthhee aatt--mmoosspphheerree wwhhiillee tthhee rreeffrriiggeerraattiioonn cciirrccuuiittssaarree bbeeiinngg ddrraaiinneedd.. UUssee aapppprroopprriiaattee rreeccoovv--eerryy eeqquuiippmmeenntt..WWhheenn tthhee rreeccoovveerreedd rreeffrriiggeerraanntt ccaannnnoott bbeerree--uusseedd,, rreettuurrnn iitt ttoo tthhee mmaannuuffaaccttuurreerr..

DDoo nnoott tthhrrooww aawwaayy tthhee wwaassttee ooii ll ooff tthheeccoommpprreessssoorr,, bbeeccaauussee iitt ccoonnttaaiinnss rreeffrriiggeerraannttiinn ssoolluuttiioonn..TThhee wwaassttee ooiill mmuusstt bbee rreettuurrnneedd ttoo tthhee mmaannuu--ffaaccttuurreerr..

Unless otherwise specified, the operations describedbelow may be carried out only by a trained mainte-nance operator.

9.1 General requirements

Itelco-Industry units have been designed for continu-ous operation, providing that they are subjected toregular maintenance, within the limits specified inthis manual. Each unit must be serviced according tothe programme by the User/Customer, and must beinspected at regular intervals by the personnel ofone of Itelco-Industry ’s authorised Service Centers.

It is the responsibility of the User to meet these main-tenance requirements and/or to enter into an agree-ment with one of Itelco-Industry ’s Service Centers, soas to properly safeguard the operation of the appli-ance.

During the warranty period, in case of damage orfailures caused by improper maintenance, Itelco-In-dustry will not refund the costs incurred to repair theappliance in its original state.

The provisions of this section apply only to standardunits; according to the order requirements, otherdocumentation may be added, concerning any mod-ifications or supplementary accessories.

9.2 Planned maintenance

Maintenance inspections must be carried out accord-ing to the program below, by a qualified person.As a general rule, units cannot be repaired directlyby the user, who shall not try to service or repair anyfailures or anomalies identified during daily inspec-tions. If you are in doubt, please contact Itelco-Indus-try Service Centre.

Scheduled Maintenance

Operations

DDaaii

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WWeeee

kkllyy

MMoonn

tthhllyy

BBeeggii

nnnniinn

gg ooff

sseeaass

oonn

EEnndd

ooff ssee

aassoonn

Check the temperature of the leaving fluid

Check the pressure dropsin the heat exchanger

Check for electricabsorption

Check suction pressureand temperature

Check delivery pressureand temperature

Check the oil levelin the compressor

Check that there are no gas bubbles in the liquid line

Check that the fins of theexternal coil are clean (if any)

Check the operationof the oil heaters

Check the remotecontrol switches

Check the operationof the LP pressure switch

Check the operationof the HP pressure switch

Check the insulationof the heat exchanger

Check that terminals are tightened

Check that the terminalsscrews are tightened

Clean the exterior of theunit with water and soap

Check the density of the antifreeze (if any)

Check the operation of the flow switches

Check the operationof the solenoid valve

•••••••

•••

••••••• ••

• •


Eng

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9.3 Refrigerant charge

Do not inject refrigerant liquid into the LPside of the circuit. Be very careful, andcharge the circuit properly. If the charge isinsufficient, the efficiency of the unit will belower than expected. In the worst of casesthe LP pressure switch may be activated, re-sulting in the halting of the unit.In the presence of an excess charge, thecondensing pressure will rise (in the worstof cases, the HP pressure switch may be ac-tivated, resulting in the stop of the equip-ment), and the consumption will increase aswell.

It is strictly forbidden to use the compressoras a vacuum pump to drain the plant.

Fill the refrigeration circuit after it has been drainedfor maintenance purposes (leaks, replacement of thecompressor etc.). The amount of the charge is indi-cated on the plate affixed to the unit.

Before refilling, it is important to drain and de-hy-drate the circuit, thus obtaining a minimum abs. pres-sure value of 50 Pa.

Inject the refrigerant fluid before removing the vacu-um, then fill the circuit up to 90% of the total gas re-quirement (in liquid form). The appliance must befilled through the filling valve on the liquid line, onthe outlet side of the condenser.

It is recommended to connect the refrigerant cylinderto the filling valve on the liquid line, and to arrange itin such a way as to inject only liquid refrigerant.

Then start the compressor and let the gas flow fromthe cylinder, up until the liquid flow, which can beobserved through the sight glass, is limpid.

9.4 Compressors

The frequency of the checks to be made on compres-sors depends on a variety of factors, first of all theworking conditions. Anyway, it is advisable to adoptthe following tips:� After 300 hours of work, check the conditions of

the oil: a certain amount of impurities from the sys-tem may accumulate in the oil of the compressors.

� Check the acidity of the oil every year.

� After 8000 hours of work, carry out a visual in-spection on the suction/discharge valves for wear.If necessary, replace these components. If compres-sors are started/stopped frequently or in particular-ly demanding working conditions, it is advisable toreduce this period to 5000 hours. Anyway, thistime is indicative only.

� After 24000 hours of work, carry out a generaloverhaul of the compressor. If the compressorswork for a period shorter than 40% of a year, theoverhaul can be performed every about 5 years.This period depends on the type of application, theworking conditions, the duration of start/stop cy-cles.

If it is necessary to replace the compressor(in case of burning of the winding or me-chanical failure), contact one of Itelco-Indus-try ’s Service Centres.Compressors use polyester oil, for both theversions manufactured for R134a andR407C. During maintenance operations onthe compressor, or if you have to open therefrigerant circuit in any point, rememberthat this type of oil is highly hygroscopic,and accordingly it is important that it is notleft exposed to the weather for prolongedperiods, as this would require the replace-ment of the oil.

9.5 Condenser

Check the condenser water side for cleanliness atregular intervals. This may be accomplished bychecking water side pressure drop (refer to Section9).

Soiling of the condenser results in increased con-densing pressure, which reduces efficiency and in-creases current consumption and may cause the highpressure switch to activate.

It is advisable to supply the condensers with antial-gae and anti-line treated water.

If soiled, the heat exchanger must be chemicallycleaned by Authorised service personnel.

For other types of service (special maintenance, heatexchanger replacement, etc.), contact an AuthorisedService Centre).



9.6 Dehydrating filter

The refrigeration circuits are provided with dehydrat-ing filters.The filter clogging is marked by the presence of airbubbles in the sight glass, or by the difference be-tween the temperatures measured downstream fromand upstream of the drying filter. If, once the car-tridge has been cleaned, there are still some air bub-bles, the appliance has lost a part of the refrigerantcharge in one or more points, that must be identifiedand serviced.

9.7 Sight glass

The sight glass is used for inspecting the refrigerantflow and the humidity % of the refrigerant. The pres-ence of bubbles indicates that the dehydrating filteris clogged or the charge insufficient.

A colour indicator is positioned inside the sightglass.If you compare the colour of the indicator to the scaleon the ring of the sight glass, you can calculate thepercentage of humidity of the refrigerant. If it is ex-cessive, replace the filter’s cartridge, operate the ap-pliance for 1 day and then check the humidity %again. When the humidity % is within the pre-deter-mined range, no other operations are required. If thehumidity % is still too high, replace the dehydratingfilter again, start the unit and operate it for anotherday.

9.8 Thermostatic expansion valve

The circuit of the unit is equipped with a thermostaticexpansion valve, with external equalizer.The valve is shop-calibrated for an overheating of5°C.

Procedure to check for overheating:– Measure the suction pressure with the pressure

gauges on the board of the unit o using a pressuregauge connected to the service valve on the suc-tion side.

– From the pressure gauge’s temperature scale, mea-sure the saturated suction temperature (Tsa) whichcorresponds to the pressure value.

– Using a contact pressure gauge affixed to the out-let fitting of the gas of the evaporator, measure theactual temperature (Tse).

Overheating calculation (S):

S = Tse - Tsa

Overheating is regulated through the thermostaticexpansion valve.

Make the adjusting screw follow a complete turn,and operate the appliance for five minutes.Check again and, if necessary, repeat the regula-tion.

If the expansion valve cannot be regulated, it is prob-ably broken, and shall be replaced. The replace-ment must be carried out by a Service Centre.

9.9 Evaporator

Check at regular intervals that the water side of theheat exchanger is perfectly clean. To do this, mea-sure the pressure drop, water side (see Section 8) ormeasure the temperature of the liquid leaving andentering the heat exchanger, and compare it to theevaporation temperature.

To obtain an effective heat exchange, the differencebetween the temperature of the leaving water andthe saturated evaporating temperature must be in the3.5-6°C to R134a and 3.5-5°C to R407C. A greaterdifference would indicate a low efficiency of the heatexchanger (i.e. the heat exchanger is dirty).

In this case, the heat exchanger must be subjected tochemical cleaning, an operation that shall be carriedout by authorised engineers.

For other maintenance operations (extraordinaryoverhauling, replacement of the heat exchangeretc.), contact an authorised Service Centre.


English

TTrroouubblleesshhoooottiinngg

10 TROUBLESHOOTING

The table below lists the anomalies of operation of the unit, the relevant causes and the corrective measures.For anomalies of any other type or not listed, contact one of Itelco-Industry ’s Service Centre for technical as-sistance.

AAnnoommaallyy CCaauussee

The unit continues to work,but without cooling.

Insufficient charge of refrigerant. Refill.

The dehydrating filter is clogged. Replace.

Ice on the suction line. Wrong calibration of overheating. Increase overheating.

Check the charge.

Excessive noise. Vibration of lines. Check the clamping brackets, if any.

Whistler emitted by the thermostaticexpansion valve.

Refill.

Check the dehydrating filter.

Noisy compressor. Seized bearings; replace the com-pressor.

Check that the compressor’s locknutsare tightened.

Low oil level in the compressor.

One or more gas or oil leaks in thecircuit.

Identify and remove leaks.

Mechanical failure of the compres-sor.

OOppeerraattiioonn

Request the intervention of a Ser-vice Centre.

Anomaly of the oil heater of thecompressor’s base.

Check the electric circuit and theresistor of the heater of the motorbase, and replace defective com-ponents.


TTrroouubblleesshhoooottiinngg

CCaauussee OOppeerraattiioonn

One or both compressorsare not working.

Breaking of the electric circuit. Check the electric circuit and detectany ground dispersions and short cir-cuits. Check fuses.

Inter vention of the HP pressureswitch.

Reset the pressure switch and the con-trol panel and restart the appliance.Identify and remove the cause that en-abled the pressure switch.

The fuse of the control circuit is bro-ken.

Check for ground dispersions andshort circuits. Replace fuses.

Loosened terminals. Check and tighten.

Halt caused by thermal overload ofthe electric circuit.

Check the operation of check andsafety devices. Identify and removethe cause.

Wrong wiring.

The line voltage is too low. Check voltage. If problems regard thesystem, solve them. If they are causedby the distribution network, inform theEnergy Distributor.

Short-circuit of the compressor’s mo-tor.

Check the continuity of the winding.

Seized compressor. Replace the compressor.

Gas leak. Identify and remove the leak.

Insufficient charge Refill.

Failure of the pressure switch.

Activation of the HP alarm,stop of the unit.

Failure of the pressure switch. Check the operation of the pressureswitch, replace it if defective.

The delivery valve is partially closed.

Activation of the LP alarm,stop of the unit.

Replace the pressure switch.

Open the valve and replace it, iffaulty.

Substances with condensable gasesin the circuit.

Drain the circuit.

The liquid line is too hot. Insufficient charge. Identify and remove the cause of theloss of charge and refill.

Frosting of the liquid line. The valve of the liquid line is partial-ly closed.

Check that valves are open.

The liquid filter is clogged.

AAnnoommaallyy

Check wiring of check and safetydevices.

Replace the cartridge or the filter.


Eng

lish

SSppaarree ppaarrttss

11 SPARE PARTS

11.1 Spare part list

The table below shows the list of spare parts recom-mended during the first two years of operation.

CCoommppoonneenntt NNuummbbeerrHP pressure switch 1Gas filter 2Thermostatic valve 2Auxiliary relays 2Compressor’s fuses 6Auxiliary fuses 6Set of compressor contactors 1Water sensor 1High Pressure Transductor 1Low Pressure Transductor 1Electronic card 1Keyboard 1Compressor oil resistor 1

11.2 Oil for compressors

The compressors are lubricated with:

11.3 Wiring diagrams

The wiring diagrams are installed inside the doors ofthe electrical panels of the unit. Any request for wiring diagrams shall be forwardedto Itelco-Industry Service Centre.

DEA SE 170

CPI CP- 4214-320

Compressor Refrigerant Lubricant oil

REFCOMP

BITZER

R134a, R407C

R22

R134a, R407C

R22

BITZER BSE 170

BITZER B320SH


DDiissmmaannttlliinngg,, DDeemmoolliittiioonn aanndd SSccrraappppiinngg

12 DISMANTLING, DEMOLITIONAND SCRAPPING

DDuurriinngg tthhee ddrraaiinniinngg ooff tthhee rreeffrriiggeerraattiioonn cciirr--ccuuiittss,, ddoo nnoott lleett tthhee rreeffrriiggeerraanntt oovveerrffllooww iinntthhee ssuurrrroouunnddiinngg aattmmoosspphheerree..TThhee cciirrccuuiitt mmuusstt bbee ddrraaiinneedd uussiinngg ssuuiittaabblleerreeccoovveerryy eeqquuiippmmeenntt..

DDoo nnoott ddiissppeerrssee tthhee wwaassttee ooiill ooff tthhee ccoomm--pprreessssoorrss iinn tthhee eennvviirroonnmmeenntt,, ssiinnccee iitt ccoonn--ttaaiinnss ssoommee ddiissssoollvveedd rreeffrriiggeerraanntt..

FFoorr tthhee ddiissppoossaall,, ccoonnttaacctt tthhee ccoommppeetteenntt aauutthhoorriittyy ffoorriinnffoorrmmaattiioonn..

Unless otherwise specified, the maintenance opera-tions listed below may be carried out by any trainedmaintenance operator.

12.1 Generalities

Open each line that supplies the unit, including theones of control circuits. Make sure that all discon-necting switches are secured in the off position. Thepower cables can be disconnected and disassem-bled. Refer to Chapter 4 for the position of connec-tion points.

Remove all the refrigerant from the refrigeration cir-cuits of the unit and store it in suitable containers, us-ing a recovery unit. If its characteristics have re-mained the same, the refrigerant can be used again.Contact the competent authority to obtain informa-tion about disposal. In NNOO event shall the refrigerantbe discharged into the atmosphere. The oil in eachrefrigeration circuit must be drained and collected in-to a suitable container; then it shall be disposes of inconformity with local regulations that apply to thedisposal of waste lubricants. Any oil spillage must berecovered and disposed of in like manner.

Isolate the unit’s heat exchangers from the externalhydraulic circuits and drain the heat exchange sec-tions of the plant. If no isolation valves are installedon the cooler it might be necessary to drain the com-plete hydronic system.

IIff nnoo sshhuuttooffff vvaallvveess hhaavvee bbeeeenn pprroovviiddeedd,, iittmmaayy bbee nneecceessssaarryy ttoo ddrraaiinn tthhee wwhhoollee ppllaanntt..IIff aa ggllyyccoolleedd ssoolluuttiioonn oorr aa ssiimmiillaarr fflluuiidd hhaassbbeeeenn uusseedd iinn tthhee hhyyddrraauulliicc cciirrccuuiittss,, oorr iiffcchheemmiiccaall aaddddiittiivveess hhaavvee bbeeeenn aaddddeedd ttoo tthheecciirrccuullaattiinngg wwaatteerr,, tthhee cciirrccuullaattiinngg fflluuiidd MMUUSSTTbbee ddrraaiinneedd iinn aa pprrooppeerr wwaayy..FFoorr NNOO rreeaassoonn sshhaallll aa cciirrccuuiitt ccoonnttaaiinniinnggggllyyccoolleedd wwaatteerr oorr aa ssiimmiillaarr ssoolluuttiioonn bbee ddiiss--cchhaarrggeedd ddiirreeccttllyy iinnttoo tthhee ddrraaiinnss oorr ssuurrffaacceewwaatteerrss..

After draining operations, the piping of the hydraulicnetworks can be disconnected and disassembled.

Once they have been disconnected as specified, thepackaged units can be disassembled in a singlepiece. First of all, disassemble the anchoring screwsand then lift the unit from the position of installation,and hook it to the lifting points provided, using suit-able lifting equipment.

To this end, refer to Chapter 4 for the installation ofthese appliances, to Chapter 8 for their weights andChapter 3 for handling.The units that, once disconnected, cannot be re-moved in a single piece, must be dismantled on site;in this case, be very careful with the weight and han-dling of every single component.

It is always advisable to dismantle the units followingthe installation steps, but in reverse.

SSoommee rreessiidduueess ooff ooiill,, ggllyyccoolleedd wwaatteerr oorr ssiimm--iillaarr ssoolluuttiioonnss mmaayy rreemmaaiinn iinn cceerrttaaiinn ppaarrttss oofftthhee uunniitt.. TThheessee rreessiidduueess mmuusstt bbee rreeccoovveerreeddaanndd ddiissppoosseedd ooff aaccccoorrddiinngg ttoo tthhee pprrooccee--dduurreess ssppeecciiffiieedd aabboovvee..

It is very important to ensure that, while a componentof the unit is being removed, all the others are prop-erly supported.

UUssee oonnllyy lliiffttiinngg mmeeaannss ooff aaddeeqquuaattee ccaappaaccii--ttyy..

Once disassembled, the components of the unit canbe disposed of in conformity with current regula-tions.


As part of our ongoing product improvement programme, our products are subject to change without prior notice. Non contractual photos.

ITELCO-INDUSTRYVia XXV Aprile, 2920030 BARLASSINA (MI) - ITALY

: +39 0362 6801 : +39 0362 680281

Your distributor :

SWS / SWR - c-o-k.ru · sonnel from Itelco-Industry ’s Authorised After-Sales Service....

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Transcript of SWS / SWR - c-o-k.ru · sonnel from Itelco-Industry ’s Authorised After-Sales Service....