CLIVET WDH-3 2.160, Installation And Use Manual

Page 1: ...WDH 3 2 160 2 180 2 220 2 250 2 280 2 300 2 320 2 340 2 360 2 420 2 450 2 480 2 540 2 600 WATER COOLED CHILLERS Installation and Use Manual M03I40M7 03 15 11 07 ...

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Page 3: ...UNIT ELECTRICAL DATA 18 CONNECTION TO THE MAINS 19 CLIVET TALK MODULAR SYSTEM COMPOSITION 21 MODBUS CONVERTER CAN to MODBUS via RS 485 23 S T A R T U P 2 5 PRELIMINARY CHECKS 25 REFRIGERANT SYSTEM 25 WATER SYSTEM 25 ELECTRICAL SYSTEM 25 VERIFy tensions absorptions 25 REMOTE INPUT CONFIGURATIONS 25 SETTING THE SET POINT 25 EVAPORATOR WATER FLOW RATE 26 CONDENSER WATER FLOW RATE 26 REFRIGERANT CIRCU...

Page 4: ...RIAL NUMBER This provides unique identification of the machine It makes it possible to trace the specific features of the unit and to identify the components installed in it Without this number it is not possible to identify with certainty the spare parts that are specific to that unit When requesting assistance always provide the type of machine and the serial number Write them in the space below...

Page 5: ...ich does not respect the instructions given in this manual will cause the warranty to lapse INTENDED USE The unit must only be used for the specific purpose it was designed The unit is designed to cool heat water or a water and glycol mix for air conditioning within the limits defined in the technical bulletin and this manual Any use other than that specified does not imply any commitment or const...

Page 6: ...rized entry GENERAL RISKS A smell of burning smoke or other indications of serious irregularity could signal the onset of situations liable to cause damage to persons or property or to the unit itself Isolate the unit from the electrical power supply red and yellow switch Contact an authorized service centre so that the source of the problem can be identified and remedied Accidental contact with h...

Page 7: ...n of risk Effects on health practically non toxic Greatest physical and chemical dangers Thermal decomposition in toxic and corrosive products 04 First aid measures Inhalation Carry the victim into the open air Resort to oxygen or artificial respiration if necessary Contact with skin Frostbite must be treated in the same way as burns Contact with the eyes Immediate rinsing in abundant water Instru...

Page 8: ...skin in experiments conducted on animals rabbits Contact with the eyes practically non irritating for eyes in experiments conducted on animals rabbits Sensibilisation Contact with skin Experim ental for the animal No skin sensitizer guinea pig Chronic toxicity Studies on animal protracted inhalation do not highlight any chronic toxic effect rat years s Inhalation 50000ppm Specifical effects Genoto...

Page 9: ...retractable protection under the sun since the pressure of the circuits can assume values which activate the safety valves HANDLING The operation of handling the unit must be carried out respecting the instructions of the safety norms in force Legislative Decree 626 94 and following modifications Before starting the handling operations Value the critical points during handling stairs flights disco...

Page 10: ...f the unit see drawing Gradually bring the lifting belts under tension making sure they are positioned correctly Make sure the unit is always in steady equilibrium Start hoisting the unit Split pin for belt REMOVING THE PACKING For removing the packaging use specific personal protection for the operator gloves glasses etc While removing the packaging pay attention not to damage the unit Check for ...

Page 11: ...ositions and in areas accessible only to qualified and authorized personnel 2 SAFETY VALVE only if present on the unit the installer is responsible for evaluating the opportunity of installing drain tubes in conformity with the local regulations in force EN 378 3 Install the unit raised from the ground 4 avoid installations in places subject to flooding 5 Verify that the fixing supporting points a...

Page 12: ...tzer EN C6100032 C6100028 C6100032 C6100032 PE980025 ST C6100028 C6100028 C6100032 C6100032 PE980007 Refcomp EN C6100032 C6100032 C6100032 C6100032 PE960007 ST C6100032 C6100032 C6100032 C6100032 PE960007 2 320 Bitzer EN C6100032 C6100032 C6100032 C6100032 PE960007 ST C6100028 C6100028 C6100032 C6100032 PE980007 Refcomp EN C6100032 C6100032 C6100032 C6100032 PE960007 ST C6100032 C6100032 C6100032 ...

Page 13: ...028 C6100032 C6100032 PE980007 ST C6100028 C6100028 C6100028 C6100032 PE980020 Refcomp EN C6100028 C6100028 C6100032 C6100032 PE980007 ST C6100028 C6100032 C6100032 C6100032 PE980025 2 320 Bitzer EN C6100032 C6100032 C6100032 C6100032 PE960007 ST C6100028 C6100028 C6100032 C6100032 PE980007 Refcomp EN C6100028 C6100028 C6100032 C6100032 PE980007 ST C6100032 C6100032 C6100032 C6100032 PE960007 2 34...

Page 14: ...losed so they can not trap the water even after emptying o there are no low points where the water can stagnate even after emptying blow if necessary INSTALLATION EMPTYING The refilling of the water present in the installation increase the oxidation phenomena and lime deposits If necessary empty only the interested system section and anyway empty or refill the installation if necessary EXPANSION T...

Page 15: ...very The customer is responsible for the management of the circulation pump valves thermostats etc The recovery input water must not be below 25 C in the event that wrongful operations and breakages of the unit can occur Water connections must be performed carefully as for the evaporator filter circuit washing etc Perform all necessary interventions to avoid the RISK OF FREEZING tubes insulation e...

Page 16: ...ECTION SCHEMA P 8 F 2 3 5 6 1 P 4 7 8 9 10 1 Antivibration joints 2 Shut off valve 3 Safety valve 4 Flow switch 5 System min pressure manostat 6 Pressure switch thermometer 7 vent 8 Differential pressure switch 9 Pump 10 Filter EVAPORATIVE COOLING TOWER WELL ...

Page 17: ...to prevent the formation of ice Its use is also required when geothermal probes are used SYSTEM WASHING Before connecting the unit carefully wash the system by filling it and emptying it several times with clean water CONTROL OF FLOW RATE This makes it possible to limit water consumption increase energy efficiency and extend the unit s operating limits It can be modified by using 1 Modulating moto...

Page 18: ...ed according to the characteristics of the protections used SIGNALS DATA LINES Do not overpass the maximum power allowed which varies according to the type of signal Lay the cables far from power cables or cables having a different tension and that are able to emit electromagnetic disturbances Do not lay the cable near devices which can generate electromagnetic interferences Do not lay the cables ...

Page 19: ...ows the remote start and stop not by keypad It can be used to disable the unit during the night the weekend etc so with ON or OFF periods relatively longs some hours It has not to be used with ON or OFF cycles too much shorts they compromise the operating logic and they can cause malfunctions or faults In summer operating for example ON OFF cycles lower than one hour can compromise the thermoregul...

Page 20: ...ion 106 CextMaxC Max ext temp of cooling compensation parameter control compext 107 CextMinC Min ext temp of cooling compensation parameter set sensors 9 ProbeText It enables ext temp probe 0 yes 1 non SUMMER WINTER p4 p106 p107 Text C set COMPENSATO p 5 set point COMPENSATO p 94 p 93 T ext C EXTERNAL AIR HUMIDITY PROBE Optional It allows the automatic correction of the set point according to exte...

Page 21: ...er with the CAN OPEN protocol The system configuration varies according to the typology of the unit and of the accessories not always the represented electric modules are all presents on the unit INTERFACE code C5110821 The interface module allows for the control of the operations of the whole machine the programming of the different adjustment parameters and also to display the alarms and the uni...

Page 22: ...ULE code C5110701 It manages controls and safety devices relative to the circulation pumps H L gnd 8 9 10 11 JUMP4 1 2 3 4 5 6 7 DIP1 DIP2 STRIP OF F O N 1 2 3 4 OF F O N 1 2 3 4 5 6 7 8 JUMP1 JUMP2 JUMP3 1 3 5 7 9 2 4 8 10 6 CN2 CN1 16 14 12 10 8 6 4 2 15 13 11 9 7 5 3 1 J22 J15 gnd RECOVERY MODULE code C5110679 It manages the electrovalves and the pumps relative to the recovery circuit REMOTE TE...

Page 23: ...IVET TALK Local Network system allows to connect up to 6 machines in a network which all serve the same installation To interact with the network which controls the working of the system it is necessary to have a CAN to CAN converter code C5110692 for each machine Each single machine is equipped with the standard electronic devices if necessary it can function as an independent unit SpinChiller Sp...

Page 24: ...g to the Echelon classification for the type of the unit it is designed for with a number of managed variables which is a sub array of those managed originally by the machine and able to accept the Echelon standard profiles The supply of this device does not include the activity of configuration and management of the LonWorks network to which it is connected as usual they are supplied by the Super...

Page 25: ...tightening of the screws that fix the conductors to the electrical components in the board during handling and transportation the vibrations could have loosened them Verify that the unit is connected to the ground plant Control that all panels and protection devices of the unit are repositioned and blocked Charge the unit by closing the sectioning device but leave it on OFF Make sure that the tens...

Page 26: ...r absorbed by compressors kW x 860 Dt C x flow rate L h The data is shown in the table on GENERAL TECHNICAL DATA included in this manual referred to specific air water conditions or in the tables on COOLING PERFORMANCE in the TECHNICAL BULLETIN referred to various conditions of use Check for water side exchanger pressure drops Determine the water flow rate Measure the difference in pressure betwee...

Page 27: ...e higher the gap value is both negative and positive the shorter the interval among the scanning points will be The value of the scanning time is displayed at the status 6 when the status 7 has reached the value of the status 6 the request of operation of the compressor is activated The counting of the scanning time starts together with the activation of the compressor The compressor to be activat...

Page 28: ... the circulation pump tests the water temperature and even activates one or more compressors It is necessary to modify the parameters with access reserved to the assistance centres MENU NUM Parameter name meaning 25 MantCoolEn It enables Summer Maintenance PARAMETER CONTROL MAINTENANCE 114 SetMantCool Summer maintenance set point DEMAND LIMIT The function of the DEMAND LIMIT allows the limit of po...

Page 29: ...118 CEN SetCool Cooling Set Point 6 5 119 CEN SetHeat NOT USED Heating Set Point 45 272 CEN SetRecovery NOT USED 35 menu PARAMETERS THERMOREG MAINTENANCE 114 CEN SetMantCool Summer maintenance setpoint 15 117 CEN SetMantHeat NOT USED Winter maintenance setpoint 30 menu PARAMETERS THERMOREG ANTIFREEZE 115 CEN AllFreeze Antifreeze alarm set 4 121 CEN PreAF Antifreeze pre alarm set 4 5 261 CEN SetRes...

Page 30: ...ING enables disables timing bands CLOCK SETUP Set the clock ID Tast Cen ATC ONLY PASSWORD ATC ONLY To go back to the main menu ESC I HOME button HOME To enter in the SETUP menu ESC I HOME button F3 SETUP To select the submenu ESC I HOME buttons F2 F3 To access ESC I HOME button F1 ENTER To access the desired parameter ESC I HOME buttons F1 F2 To modify the parameter value ESC I HOME buttons F3 F4 ...

Page 31: ...ct ON OFF ECO mode ESC I HOME button F4 To select Setpoint ESC I HOME buttons F1 F2 Set the manual setpoint of the event ESC I HOME buttons F3 F4 SETUP SCHEDULING EnSCHEDULING enables disables timing bands CONFIGURE Set the timing bands To go back to the main menu ESC I HOME button HOME To enter in the SETUP menu ESC I HOME button F3 SETUP To select the CLOCK SETUP submenu ESC I HOME buttons F2 F3...

Page 32: ... LIST Mod_Evap LIST Unit_2 Mod_comp1 LIST Mod_comp2 LIST Mod_comp3 LIST Mod_Evap LIST example Visualized stata referring to UNIT 1 COMP 2 MODULE To enter in the STATA menu ESC I HOME button F4 STATE To select the module ESC I HOME buttons F2 F3 To access ESC I HOME button F1 ENTER To scroll the stata ESC I HOME buttons F2 F3 To go back a level of the menu ESC I HOME button ESC submenu GENERALS UNI...

Page 33: ...bit map of a byte 71 BitMap connected nodes MS bit map of a byte 72 Hours pump 1 PMP 73 Hours pump 2 PMP 74 Hours pump 3 PMP Index UNIT_1 MOD COMP_1 Stata UM 29 Compressor 1 1 ON 0 OFF 30 Compressor 2 1 ON 0 OFF 31 Compressor 3 1 ON 0 OFF 32 Cp 1 timer status 1 ON 0 OFF 33 Cp 2 timer status 1 ON 0 OFF 34 Cp 3 timer status 1 ON 0 OFF 35 Valve 1 c1 status 1 ON 0 OFF 36 Valve 2 c1 status 1 ON 0 OFF 3...

Page 34: ...s show a potentially dangerous situation for the machine integrity An immediate analysis is necessary to detect the causes of the block A repeated reset can provoke irreversible damage That is why reset is MANUAL PRE ALARMS AND SIGNALIZATIONS show a situation similar to that one described above The occurrence of an alarm is acceptable if it is occasional and or in transitory situations for example...

Page 35: ...fault 3 E004 Water Reset input fault 4 E005 Outside RH probe fault 5 E006 Thermal cut out alarm pump 1 on control module 6 E007 Thermal cut out alarm pump 2 on control module 7 E008 Flow switch alarm on control module 8 E009 System pressure alarm 9 E010 Phase monitor alarm 10 E011 Antifreeze alarm on control module 11 E012 Antifreeze pre alarm on control module 12 E013 Change CENTRAL pump 13 E014 ...

Page 36: ... TEE alarm 65 E125 max TS TEE prealarm 66 E126 max TS TEE prealarm 67 E127 power fail alarm 68 E128 stepper motor error alarm PUMP MODULE Str Name 53 E501 Water flow probe fault 54 E502 Thermal pump 1alarm Pump Module 55 E503 Thermal pump 2alarm Pump Module 56 E504 Thermal pump 3alarm Pump Module 57 E505 Max flow rate signal Pump Module RECOVERY EXPANSION MODULE Str Name 50 E301 Out recovery probe...

Page 37: ...e fixing up breakdowns easier Take note of the date type of control autonomous maintenance inspection or fixing up description of the control actions taken and so on SERVICES Parts subject to intervention WATER EXCHANGER STRUCTURE WATER EXCHANGER It is very important for the exchanger to be able to provide the maximum thermal exchange Therefore it is essential for the inner surfaces to be clean of...

Page 38: ...s as well Refer to local actuation norms In Italy refer to the Ministerial Decree of 1 st December 2004 no 329 and following modifications which defines the performances to be executed the units of 1st category and those defined by the art 3 3 97 23 EC are not included in this regulation see the serial number plate on the unit Briefly and as an example see the following 1 COMPULSORY VERIFICATION O...

Page 39: ... 18 6 12 C for calculation consider the Td dew point 7 3 0 8 6 5 C SUBCOOLING condensing temperature pressure liquid temperature R22 R407C R410A Condensing pressure 18 6 bar 18 6 bar 29 6 bar Liquid temp 42 9 C 42 9 C 45 C subcooling 50 39 42 9 7 49 C 44 74 42 9 1 84 C for calculation consider the Tb bubble point 49 91 45 4 91 C It is important that the condensation pressure is detected as close a...

Page 40: ... 98 32 4 6 19 33 15 6 59 45 26 6 82 22 37 6 98 58 4 8 20 47 15 8 59 96 26 8 82 56 37 8 98 84 5 0 21 57 16 0 60 46 27 0 82 90 38 0 99 09 5 2 22 65 16 2 60 95 27 2 83 24 38 2 99 34 5 4 23 70 16 4 61 44 27 4 83 58 38 4 99 60 5 6 24 73 16 6 61 93 27 6 83 91 38 6 99 85 5 8 25 73 16 8 62 42 27 8 84 24 38 8 100 09 6 0 26 71 17 0 62 90 28 0 84 58 39 0 100 34 6 2 27 67 17 2 63 37 28 2 84 90 39 2 100 59 6 4...

Page 41: ...to the exchanger high thermal difference between input and output 3 not CONSTANT flow for example if the pumps are turned off certain areas of the plant are excluded or included other uses are isolated etc 4 Water filter clean valves open air bubbles in the plant 5 dirty exchanger 6 Manostat transducer loose electric contacts terminals wiring cables interrupted 7 refrigerant circuit empty visible ...

Page 42: ...d must be stored in special containers When recovering the substances present in the unit all measures must be taken to avoid damaging persons and things and polluting the surrounding area Awaiting dismantling and disposal the unit can also be stored outdoors as bad weather and rapid changes in temperature will not cause damage to the environment if electric cooling and hydraulic circuits of the u...

Page 43: ...l exchanger pressure drop kPa 40 9 41 43 9 65 49 6 34 4 39 7 79 6 87 3 51 54 1 57 4 105 3 117 Water content l 277 7 233 3 248 3 233 3 418 6 409 6 409 6 409 6 409 6 451 4 451 4 451 4 493 493 EXTERNAL EXCHANGER type of external exchanger 6 S T Water flow rate l s 26 7 30 6 34 8 39 8 43 3 47 5 51 4 54 8 57 8 66 8 69 1 71 4 82 8 87 8 external exchanger pressure drop kPa 16 5 15 5 27 2 21 7 22 1 23 3 2...

Page 44: ...ger pressure drop kPa 61 56 2 51 4 61 1 75 2 66 9 58 9 39 9 43 8 78 6 52 2 66 3 79 3 70 9 Water content l 164 4 159 3 263 3 263 3 263 3 248 3 241 2 409 6 409 6 418 6 409 6 400 9 400 9 461 8 EXTERNAL EXCHANGER type of external exchanger 6 S T Water flow rate l s 23 6 26 4 32 5 35 8 40 4 44 7 48 52 1 54 9 57 4 60 8 67 7 74 8 84 4 external exchanger pressure drop kPa 31 7 29 7 34 5 33 4 34 8 33 4 30 ...

Page 45: ...col solution flow Factor Nr 1 01 1 02 1 04 1 05 1 07 1 09 1 11 1 13 Pressure drop Factor Nr 1 02 1 05 1 08 1 12 1 16 1 21 1 26 1 32 The correction factors shown refer to water and glycol ethylene mixes used to prevent the formation of frost on the exchangers in the water circuit during inactivity in winter MAX REDUCTION EXTERNAL EXCHANGER INLET WATER TEMPERATURE FOULING CORRECTION FACTOR INTERNAL ...

Page 46: ...5 10 15 20 25 30 35 40 45 50 80 15 20 25 30 35 40 45 50 60 70 80 90 100 Q l s Δ P kPa 2 1 6 0 2 2 2 0 2 1 8 0 2 2 5 0 2 2 8 0 2 3 0 0 2 3 2 0 2 3 4 0 2 3 6 0 2 4 2 0 2 4 5 0 2 4 8 0 2 5 4 0 Qmin l s Qmax l s 2 1 60 8 3 22 9 2 1 80 1 0 0 26 9 2 220 8 3 22 9 2 250 1 0 8 28 8 2 280 1 1 6 30 5 2 300 1 2 4 33 5 2 320 1 3 1 36 6 2 340 1 3 5 37 7 2 360 1 3 9 38 8 2 420 1 9 6 54 1 2 450 20 4 56 2 2 480 21...

Page 47: ... 25 30 35 40 45 50 60 70 80 90 100 120 10 15 20 25 30 35 40 45 50 Q l s Δ P kPa 2 1 6 0 2 1 8 0 2 2 2 0 2 2 5 0 2 2 8 0 2 3 0 0 2 3 2 0 2 3 4 0 2 3 6 0 2 4 2 0 2 4 5 0 2 4 8 0 2 5 4 0 2 6 0 0 5 10 15 20 25 30 35 40 45 50 60 15 20 25 30 35 40 45 50 60 70 80 90 100 Q l s Δ P kPa 2 1 6 0 2 1 8 0 2 2 2 0 2 2 5 0 2 2 8 0 2 3 0 0 2 3 2 0 2 3 4 0 2 3 6 0 2 4 2 0 2 4 5 0 2 4 8 0 2 5 4 0 2 6 0 0 Qmin l s Q...

Page 48: ... in an open field data referred to the following conditions internal exchanger water 12 7 C external exchanger water 30 35 C Acoustic configuration Standard ST Energy efficiency Efficiency class B Acoustic configuration Extremely low noise EN Energy efficiency Efficiency class B Sound Power Level dB Sound pressure Sound power Sound Power Level dB Sound pressure Sound power Octave band Hz level lev...

Page 49: ... 219 1 219 1 219 1 219 1 219 1 219 1 OD1 mm 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 169 3 169 3 169 3 169 3 169 3 Length mm 3534 3534 3601 3601 3729 4061 4361 4361 4361 4657 4657 4657 4678 4678 Depth mm 1398 1398 1398 1425 1425 1425 1425 1425 1425 1425 1425 1425 1425 1425 Height mm 1711 1711 2018 2018 2018 2018 2018 2018 2018 2146 2146 2146 2146 2146 W1 kg 694 733 1008 898 1050 1239 ...

Page 50: ...9 1 219 1 219 1 219 1 219 1 OD1 mm 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 169 3 169 3 169 3 169 3 169 3 Length mm 3831 3831 3831 3831 4250 4336 4746 4746 4746 4746 4746 4746 4746 4746 Depth mm 1398 1398 1398 1425 1425 1425 1425 1425 1425 1425 1425 1425 1425 1425 Height mm 1891 1891 1891 1891 2182 2182 2182 2182 2182 2245 2245 2245 2245 2245 W1 kg 750 784 910 966 1068 1307 1293 1298 ...

Page 51: ... 219 1 219 1 219 1 219 1 219 1 OD1 mm 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 168 3 Length mm 3526 3526 3534 3534 3534 3933 3894 3902 3902 3902 3902 4678 4678 4678 Depth mm 1398 1398 1398 1425 1425 1425 1425 1425 1425 1425 1425 1425 1425 1425 Height mm 1640 1640 1871 1871 1871 1980 1980 2083 2083 2083 2083 2083 2083 2146 W1 kg 625 633 753 761 790 833 871 1033 ...

Page 52: ...219 1 219 1 219 1 219 1 219 1 OD1 mm 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 141 3 168 3 Length mm 3820 3820 3831 3831 3831 4233 4233 4316 4316 4316 4316 4749 4749 4749 Depth mm 1398 1398 1398 1425 1425 1425 1425 1425 1425 1425 1425 1425 1425 1425 Height mm 1781 1781 1891 1891 1891 2106 2106 2182 2182 2182 2182 2182 2182 2245 W1 kg 720 738 819 853 858 891 1002 1092 ...

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Page 54: ...424 info clivet nl CLIVET TFAIRSYSTEMS P LTD Malur INDIA Tel 91 8151 232683 5 Fax 91 8151 232684 info clivettfa com CLIVET SPA BUREAUDE LIAISON EN FRANCE Verrierès le Buisson FRANCE Tel 33 0 1 69 20 25 75 Fax 33 0 1 69 20 60 76 info fr clivet com CLIVET GmbH Norderstedt GERMANY Tel 49 0 40 32 59 57 0 Fax 49 0 40 32 59 57 194 info de clivet com The data contained in this bulletin is not binding and...