CIAT PowerCiat LX HE, Instruction Manual

Page 1: ...Instruction manual 06 2018 10256 POWERCIAT LX ST HE XE ...

Page 2: ... 26 5 4 Recommended wire sections 26 5 5 Power cable entry 26 5 6 Field control wiring 27 6 APPLICATION DATA 28 6 1 Operating range 28 6 2 Minimum chilled water flow unit without hydraulic module 28 6 3 Maximum chilled water flow units without hydraulic module 29 6 4 Variable flow evaporator 29 6 5 System minimum water volume 29 6 6 Maximum system water volume 29 6 7 Evaporator water flow rate 29 ...

Page 3: ... High pressure safety switch 46 11 4 Condensers 46 11 5 Fans 46 11 6 Electronic expansion valve EXV 47 11 7 Moisture indicator 47 11 8 Filter drier 47 11 9 Sensors 47 11 10 Service valve set option 47 11 11 Power factor correction capacitors option 47 12 MAIN OPTIONS 49 13 STANDARD MAINTENANCE 51 13 1 Level 1 maintenance 51 13 2 Level 2 maintenance 51 13 3 Level 3 or higher maintenance 51 13 4 Tig...

Page 4: ...onnel DO NOT COVER ANY PROTECTION DEVICES This applies to fuse plugs and relief valves if used in the refrigerant or heat transfer medium circuits Check if the original protection plugs are still present at the valve outlets These plugs are generally made of plastic and should not be used If they are still present please remove them Install devices at the valve outlets or drain piping that prevent...

Page 5: ...ation All welding operations must be carried out by qualified specialists Any manipulation opening or closing of a shut off valve must be carried out by a qualified and authorised engineer These procedures must be carried out with the unit shut down NOTE The unit must never be left shut down with the liquid line valve closed as liquid refrigerant can be trapped between this valve and the expansion...

Page 6: ...cause of the scanning delay applied in the control Complete an HP Test as provided by the software refer to the Control IOM for details If the machine operates in a corrosive environment inspect the protection devices more frequently Regularly carry out leak tests and immediately repair any leaks Ensure regularly that the vibration levels remain acceptable and close to those at the initial unit st...

Page 7: ...disposable non returnable cylinders or attempt to refill them It is dangerous and illegal When cylinders are empty evacuate the remaining gas pressure and move the cylinders to a place designated for their recovery Do not incinerate them Only use R134a refrigerant in accordance with AHRI Standard 700 published by the US Air conditioning Heating and Refrigeration Institute The use of any other refr...

Page 8: ... cut out pressure Unit leak test pressure Voltage frequency number of phases Maximum current drawn Maximum power input Unit net weight Confirm that all accessories ordered for on site installation have been supplied are complete and undamaged The unit must be checked periodically during its whole operating life to ensure that no shocks handling accessories tools etc have damaged it If necessary da...

Page 9: ...RNING Never push or lever on any of the enclosure panels of the unit Only the base of the unit frame is designed to withstand such stresses If a unit contains a hydraulic module the hydraulic module and pump piping must be installed in a way that does not submit it to any strain The hydraulic module pipes must be fitted so that the pump does not support the weight of the pipes 2 2 3 Checks before ...

Page 10: ...to the dimensional drawings If the installation includes several units or if this these is are close to walls please refer to chapters 3 12 Multiple chiller installation and 3 13 Distance to the wall of this document to determine the space required All dimensions are given in mm a Required clearances for maintenance see note b Recommended space for evaporator tube removal Water inlet for standard ...

Page 11: ...nal drawings If the installation includes several units or if this these is are close to walls please refer to chapters 3 12 Multiple chiller installation and 3 13 Distance to the wall of this document to determine the space required All dimensions are given in mm a Required clearances for maintenance see note b Recommended space for evaporator tube removal Water inlet for standard unit For the Br...

Page 12: ...e installation includes several units or if this these is are close to walls please refer to chapters 3 12 Multiple chiller installation and 3 13 Distance to the wall of this document to determine the space required All dimensions are given in mm a Required clearances for maintenance see note b Recommended space for evaporator tube removal Water inlet for standard unit For the Brine and evaporator...

Page 13: ...ngs If the installation includes several units or if this these is are close to walls please refer to chapters 3 12 Multiple chiller installation and 3 13 Distance to the wall of this document to determine the space required All dimensions are given in mm a Required clearances for maintenance see note b Recommended space for evaporator tube removal Water inlet for standard unit For the Brine and e...

Page 14: ...rrangement contact your distributor to evaluate the various possible arrangements In certain situations an accessory supplied loose at the time of purchase can be added 3 10 Distance from the wall To ensure correct operation for most cases If h H 2 3 m minimum S 3 m If h H or S 3 m contact your CIAT distributor to evaluate the various possible arrangements In certain situations an accessory suppli...

Page 15: ...m capacity 15 15 15 15 15 15 15 15 15 Air cooled exchanger Aluminium micro channel coils MCHE Fans LX ST HE Axial type with rotating impeller Quantity 6 6 6 8 8 9 11 12 12 Maximum total air flow l s 27082 98 27082 98 27082 98 36110 64 36110 64 40624 47 49652 13 54165 96 54165 96 Maximum rotation speed r s 15 7 15 7 15 7 15 7 15 7 15 7 15 7 15 7 15 7 LX ST HE Unit Xtra low noise option Maximum tota...

Page 16: ... 79 108 120 116 124 120 tCO2e 93 0 90 1 108 7 113 0 154 4 171 6 165 9 177 3 171 6 Oil Circuit A l 27 6 27 6 27 6 27 6 27 6 27 6 36 0 36 0 36 0 Circuit B l 23 5 23 5 27 6 27 6 36 0 36 0 36 0 36 0 36 0 Capacity control Connect Touch electronic expansion valve EXV Minimum capacity 15 15 15 15 15 15 15 15 15 Air cooled exchanger Aluminium micro channel coils MCHE Fans Axial type with rotating impeller...

Page 17: ...s LX XE Axial type with rotating impeller Quantity 6 6 6 8 8 9 11 12 12 Maximum total air flow l s 28920 28920 28920 38560 38560 43380 53020 57840 57840 Maximum rotation speed r s 15 7 15 7 15 7 15 7 15 7 15 7 15 7 15 7 15 7 LX XE Xtra low noise option Maximum total air flow l s 23580 23580 23580 31440 31440 35370 43230 47160 47160 Maximum rotation speed r s 11 7 11 7 11 7 11 7 11 7 11 7 11 7 11 7...

Page 18: ...t B l 23 5 23 5 27 6 27 6 36 0 36 0 36 0 36 0 36 0 Capacity control Connect Touch electronic expansion valve EXV Minimum capacity 15 15 15 15 15 15 15 15 15 Air cooled exchanger Aluminium micro channel coils MCHE Fans Axial type with rotating impeller LX XE Quantity 12 14 14 16 20 20 20 20 22 Maximum total air flow l s 57840 67480 67480 77120 96400 96400 96400 96400 106040 Maximum rotation speed r...

Page 19: ...3 304 334 410 443 498 528 574 613 709 Maximum current Un 10 2 LX ST HE Standard unit A 198 220 242 278 319 349 431 466 521 551 597 636 736 Unit Xtra Super Low Noise option A 187 209 231 263 304 334 410 443 498 528 574 613 709 Start up current 3 4 LX ST HE Standard unit A 213 224 224 346 442 442 492 492 676 691 691 733 756 Unit Xtra Super Low Noise option A 210 221 221 343 439 439 487 486 671 686 6...

Page 20: ...t 1 a A 322 368 443 473 512 Circuit 2 a A 469 512 473 508 512 Single power connection point option A 791 880 916 981 1025 Unit with Xtra Super Low Noise option Circuit 1 a A 309 355 424 454 491 Circuit 2 a A 452 491 454 489 491 Single power connection point option A 761 846 878 943 983 Start up current 3 LX ST HE Standard unit Circuit 1 a A 587 587 629 629 629 Circuit 2 a A 629 629 629 629 629 Sin...

Page 21: ...rd unit A 190 212 234 268 309 339 417 450 505 535 581 620 718 Unit Xtra Super Low Noise option A 184 206 228 260 301 330 406 438 493 523 567 606 704 Maximum current Un 10 2 Standard unit A 190 212 234 268 309 339 417 450 505 535 581 620 718 Unit Xtra Super Low Noise option A 184 206 228 260 301 330 406 438 493 523 567 606 704 Start up current 3 4 Standard unit A 207 218 218 338 434 434 481 480 664...

Page 22: ...ngle power connection point option A 751 837 870 935 974 Maximum current Un 10 1 or 2 Standard unit A Circuit 1 a A 313 359 430 460 498 Circuit 2 a A 457 498 460 495 498 Single power connection point option A 770 857 890 955 996 Unit Xtra Super low noise option A Circuit 1 a A 306 352 420 450 487 Circuit 2 a A 448 487 450 485 487 Single power connection point option A 751 837 870 935 974 Start up ...

Page 23: ...2 Maximum operating current 3 Maximum compressor operating current limited by the unit current given for maximum capacity at 360 V 4 Locked rotor current for star connection connection during compressor start up 5 Locked rotor current for delta connection 6 Value at standard Eurovent conditions evaporator entering leaving water temperature 12 C 7 C condenser entering leaving water temperature 30 C...

Page 24: ... of a type suitable for power interruption in accordance with EN 60947 3 corresponds to IEC 60947 3 6 The units are designed for simplified connection on TN s networks IEC 60364 For IT networks provide a local earth and consult competent local organisations to complete the electrical installation Units delivered with one or more variable frequency drives are not compatible with an IT network LX ma...

Page 25: ...minal voltage 88 1 89 4 89 4 90 1 91 3 91 3 Nominal efficiency at 75 full load and nominal voltage 88 0 88 9 88 9 89 7 91 4 91 4 Nominal efficiency at 50 full load and nominal voltage 86 1 86 7 86 7 87 9 90 3 90 3 2 Efficiency level IE3 3 Year of manufacture This information varies depending on the manufacturer and model at the time of incorporation Please refer to the motor nameplates 4 Company n...

Page 26: ...ovided as standard for the field supplied power entry cables to the general disconnect isolator switch are designed for the number and type of wires listed in column 2 of the table on the next page The calculations are based on the maximum machine current see electrical data tables The calculations for favourable and unfavourable cases are based on the maximum current for each unit see electrical ...

Page 27: ...tage drop 5 Cable type 3 qty x mm per phase qty x mm per phase m qty x mm per phase m LX ST HE XE 0808 2 185 1 x 95 190 XLPE Cu 2 x 95 450 PVC Cu 0908 2 185 1 x 95 190 XLPE Cu 2 x 95 420 PVC Cu 1008 2 185 1 x 120 197 XLPE Cu 2 x 95 390 PVC Cu 1108 2 185 1 x 150 200 XLPE Cu 2 x 120 400 PVC Cu 1358 2 185 1 x 185 205 XLPE Cu 2 x 150 420 PVC Cu 1528 2 185 1 x 240 205 XLPE Cu 2 185 430 PVC Cu 1858 2 24...

Page 28: ... up to 40 C For operation in pure water at an inlet air temperature below 0 C the frost protection option must be provided Winter operation option If the outside temperature is below 10 C and the unit has been switched off for more than 4 hours it is necessary to wait 2 hours after the unit has been switched on again to allow the frequency converter to warm up Water heat exchanger Minimum Maximum ...

Page 29: ...ffer water tank to the circuit in order to achieve the required volume The tank must itself be internally baffled in order to ensure proper mixing of the liquid water or brine Refer to the examples below Connection to a buffer tank Incorrect Incorrect Correct Correct 6 6 Maximum system water volume Units with hydraulic module incorporate an expansion tank that limits the water volume Maximum water...

Page 30: ...low rate l s Pressure drop kPa 1 3 7 4 5 2 6 10 100 10 Sizes 2008 to 4608 Water flow rate l s Pressure drop kPa 1 2 4 5 6 9 7 8 10 3 100 100 10 10 Key B 808 C 908 D 1008 E 1108 F 1358 G 1528 H 1858 Key B 2158 C 2308 D 2528 E 2628 F 3028 G 3428 H 3828 I 4008 J 4408 K 4608 6 APPLICATION DATA ...

Page 31: ...p verify that the heat exchange fluid is compatible with the materials and the water circuit coating The use of different metals on hydraulic piping could generate eletrolytic pairs and consequently corrosion Verify then the need to install sacrificial anodes If additives or other fluids than those recommended by CIAT are used ensure that the fluids are not considered as a gas and that they belong...

Page 32: ...mperature and one pass more options Nominal diameter in 5 5 6 6 6 6 6 6 Actual outside diameter mm 141 3 141 3 168 3 168 3 168 3 168 3 168 3 168 3 1 pass less evaporator options Nominal diameter in 6 6 8 Actual outside diameter mm 168 3 168 3 219 1 The evaporator with one pass less option is not available for sizes 3428 to 4608 Typical water circuit diagram 1 2 17 16 18 1 2 9 9 9 11 10 12 14 A 5 1...

Page 33: ...o protect the installation up to a temperature of 10 K below the lowest temperature likely to occur at the installation site If the unit is not used for an extended period it is recommended to drain it and as a safety precaution add ethylene glycol to the heat exchanger using the water entering purge valve connection a purge connection is available somewhere on the heat exchanger water box in case...

Page 34: ...aster and slave unit CCN communication bus Connection of two additional sensors 7 7 Pump specifications 7 7 1 Available external static pressure hydraulic module option Data applicable for Fresh water 20 C In case of use of the glycol the maximum water flow is reduced When the glycol is used it s limited to 40 Available static pressure kPa Water flow rate l s Single pump low pressure 0 20 40 60 80...

Page 35: ...1 2 3 4 5 6 0 50 100 150 200 250 300 350 400 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 1 2 3 4 5 6 Available static pressure kPa Water flow rate l s Dual pump high pressure 0 50 100 150 200 250 300 350 400 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 1 2 3 4 5 6 B LX 0808 C LX 0908 D LX 1008 E LX 1108 F LX 1358 G LX 1528 B LX 0808 C LX 0908 D LX 1008 E LX 1108 F LX 1358 G LX11528 B LX 0808 C L...

Page 36: ...In case of use of the glycol the maximum water flow is reduced When the glycol is used it s limited to 40 Available static pressure kPa Water flow rate l s Low pressure pumps 252 302 350 400 450 500 0 10 20 30 40 50 60 70 80 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 Available static pressure kPa Water flow rate l s High pressure pumps 250 300 350 400 450 500 0 20 40 60 80 100 120 140 3 5 7 9 ...

Page 37: ...s 8 2 1 LX 0808 to 1008 heat recovery option The condenser connection sleeves are not installed but supplied with the unit The sealing gaskets are in the electrics box The temperature sensors and the condenser flow switch are wired and fixed in the machine They must be installed as described in the chapter Condenser water connections NOTES Drawings are not contractually binding Before designing an...

Page 38: ...re of gravity coordinates please refer to the dimensional drawings If the installation includes several units or if this these is are close to walls please refer to chapters 3 11 Multiple chiller installation and 3 12 Distance to the wall of this document to determine the space required 8 HEAT RECLAIM CONDENSER OPTION Key All dimensions are given in mm 1 Required clearances for maintenance see not...

Page 39: ...rtified dimensional drawings available on request For the positioning of the fixing points weight distribution and centre of gravity coordinates please refer to the dimensional drawings If the installation includes several units or if this these is are close to walls please refer to chapters 3 11 Multiple chiller installation and 3 12 Distance to the wall of this document to determine the space re...

Page 40: ...nd the condenser flow switch are wired and fixed in the machine They must be installed as described in the chapter Condenser water connections NOTES Drawings are not contractually binding Before designing an installation consult the certified dimensional drawings available on request For the positioning of the fixing points weight distribution and centre of gravity coordinates please refer to the ...

Page 41: ...nic board to control this valve The valve allows bypassing of the heat reclaim condenser entering leaving circuit to ensure unit operation with heat reclaim at low entering water temperature 12 5 C It also ensures an optimal and controlled leaving water temperature 8 5 Operating limits for stable operation no mode changeover 8 5 1 Cooling mode only Please refer to the earlier chapters in this manu...

Page 42: ...n units with two circuits It has been designed with one or two single or two circuit shell and tube heat exchangers depending on the unit size The two circuits are independently controlled One circuit can be in cooling only and the other in heat reclaim mode Changeover from one mode to the other changeover from heat exchange at the air condenser to heat exchange at the water condenser and vice ver...

Page 43: ...ration of the systems by using drycoolers as a free cooling system this process uses the low temperature of outdoor air to cool the air conditioning system water This system allows substantial energy and cost savings which is the most effective when the outdoor air temperature is low The TouchPilot control of the unit includes algorithms to permit constant automatic optimization of the operation o...

Page 44: ... activate the adequate number of digital outputs to control the fans TouchPilot controls the automatic switching of all fans based on operating time and number of start up to ensure a long operating life of fan motors Compatible fans configuration 1 to 20 fans fixed speed or variable speed 1 or 2 rows of fans Refer to the drycooler electrical diagram to see the fan stages arrangement 10 1 4 Valves...

Page 45: ... and carry out internal inspections as described in EN 378 In case of re testing please refer to the maximum operating pressure given on the unit nameplate The reports of periodical checks by the user or operator must be included in the supervision and maintenance file Repair Any repair or modification including the replacement of moving parts Must follow local regulations and be made by qualified...

Page 46: ...ng with a tool are called PZHH former SDBK If a PZHH cuts out the corresponding PZH in the same compressor is faulty and must be replaced The PZHH must be reset with a blunt tool with a diameter of less than 6 mm Insert this tool into the opening on the pressure switch and push the reset button in this location These pressure switches are located at the discharge of each compressor 11 4 Condensers...

Page 47: ...ws when it is necessary to change the element A difference in temperature between the filter inlet and outlet shows that the element is dirty 11 9 Sensors The units use thermistors to measure the temperature and pressure transducers to control and regulate system operation Refer to the POWERCIAT Connect Touch control manual for a more detailed explanation 11 10 Service valve option The unit can be...

Page 48: ...3 2 2 2 6 2 1 2 6 LX 3828 1 1 1 5 1 6 1 2 1 3 1 7 1 4 1 8 2 8 2 5 2 8 2 4 2 7 2 5 2 3 2 2 2 6 2 1 2 6 2 7 LX 4008 et 4408 1 1 1 6 1 7 1 2 1 3 1 7 1 4 1 8 1 8 2 5 2 8 2 4 2 8 1 5 2 3 2 2 2 7 2 1 2 6 2 7 LX 4608 1 6 1 1 1 7 1 2 1 7 1 3 1 8 1 4 2 8 1 5 1 8 1 5 2 8 2 5 2 7 2 4 2 7 2 3 2 6 2 2 2 6 2 1 LX 2528 1 1 1 5 1 6 1 2 1 3 1 7 1 4 1 8 2 6 2 2 2 5 2 1 2 4 2 3 NOTE the above values do not correspon...

Page 49: ... hydraulic module frost protection down to 20 C outside temperature Sizes 808 to 1528 Total heat recovery Unit equipped with additional heat exchanger in parallel with the condenser coils Production of free hot water simultaneously with chilled water production Sizes 808 to 3028 Evaporator with one pass less Evaporator with one pass on the water side Evaporator inlet and outlet on opposite sides E...

Page 50: ...tor limit set by utilities Sizes 808 to 3028 Insulation of the evap in out ref lines Thermal insulation of the evaporator entering leaving refrigerant lines with flexible UV resistant insulation Prevents condensation on the evaporator entering leaving refrigerant lines MCHE anti corosion protection Protect2 Coating by conversion process which modifies the surface of the aluminium producing a coati...

Page 51: ...mm replace the mountings Check the water connections Purge the water circuit Clean the water filter Fully clean the condensers with a low pressure jet and a biodegradable cleaner counter current cleaning see chapter 12 6 2 Level 2 Replace the stuffing box packing of the pump after 10000 hours of operation Check the unit operating parameters and compare them with previous values Keep and maintain a...

Page 52: ...lease refer to the chapter below 13 6 Condenser coil We recommend that coils are inspected regularly to check the degree of fouling This depends on the environment where the unit is installed and will be worse in urban and industrial installations and near trees that shed their leaves For coil cleaning two maintenance levels are used based on the AFNOR X60 010 standard 13 6 1 Level 1 12 6 1 1 Reco...

Page 53: ...f filtration 5 µm required for long bearing life The filter should be checked after the first 500 hours of operation and every subsequent 2000 hours The filter should be replaced at any time when the pressure differential across the filter exceeds 200 kPa 2 bar The pressure drop across the filter can be determined by measuring the pressure at the filter service port and the oil pressure port The d...

Page 54: ...f the contact block Connection of the contactor or current transformer 1 2 2 1 Power supply bus bar with riveted contact block 2 Contactor or current transformer connection zone 13 10 Checking the power factor correction capacitors The verification consists in measuring input current of each capacitor bank Check shall be done using a true RMS meter reading Check that the input current absorbed by ...

Page 55: ... circuit wiring has been sized and installed properly Unit ground wire has been connected Electrical circuit protection has been sized and installed properly All terminals are tight All chilled water valves are open All chilled water piping is connected properly All air has been vented from the chilled water circuit Chilled water pump CWP is operating with the correct rotation Check the phase sequ...

Page 56: ...tricity supply at once and ensure that the chiller is not switched on until corrective measures have been taken Check cooler water loop Water loop volume litres Calculated volume litres 3 25 litres nominal kW capacity for air conditioning 6 5 litres nominal kW capacity for process cooling Proper loop volume established Proper loop corrosion inhibitor included litres of Proper loop freeze protectio...

Page 57: ...EN 57 POWERCIAT LX ST HE XE ...

Page 58: ... Compagnie Industrielle d Applications Thermiques S A au capital de 26 728 480 R C S Bourg en Bresse B 545 620 114 CIAT Service www ciat fr This document is not legally binding As part of its continuous drive to improve its equipment CIAT reserves the right to make any technical modifications without prior notice ...