Download Itelco-RLC-Cap. 01

RLC
AIR COOLED LIQUID CHILLER
INSTALLATION, COMMISSIONING,
OPERATION AND MAINTENANCE
R134a RLC-A & RLC-A R/P/D
R407C RLC-B
Part No. 035B09025-0GB
Subject to change without notice
ALL RIGHTS RESERVED
GB
Table of Contents
1
2
SUPPLIER INFORMATION
4
INSTALLATION
1.1
Introduction
3
4.1
Location
17
1.2
Warranty
3
4.2
External Water System
17
1.3
Safety
3
4.3
Water Connections
20
1.4
Emergency Stops/Shutdown
4
4.4
Electrical Supplies
21
1.5
About this Manual
4
4.5
Electrical Connections
22
1.6
Safety Labels
5
1.7
Material Safety Data
7
5
PRODUCT DESCRIPTION
COMMISSIONING
5.1
Preliminary Checks
25
5.2
Starting
25
2.1
Introduction
10
5.3
Performance Check
26
2.2
General Specification
10
5.4
Customer Handover
26
2.3
Compressors
10
2.4
Refrigerant Circuits
11
6.1
Regulation and Control Logic
27
2.5
Evaporators
11
6.2
Compressor Starting Logic
27
2.6
Air Cooled Condensers
11
6.3
Water Temperature
Regulation (IN)
28
2.7
Heat Recovery Condensers
11
2.8
Power And Controls
12
Water Temperature
Regulation (OUT)
28
2.9
“Chiller Control”
12
6.5
Control Panel
31
2.10 Accessories
13
6.6
Unit Starting
32
2.11 Interface Board
13
6.7
Set Point
33
2.12 Options
13
6.8
Heat Recovery Operation
33
2.13 Theory Of Operation
14
6.9
Alarm Display and Reset
33
6
OPERATION
6.4
3
TRANSPORTATION, HANDLING
AND STORAGE
3.1
Inspection
15
3.2
Handling
15
3.3
Anchorage
16
3.4
Storage
16
6.10 Unit Shutdown
33
6.11 Electromechanical Safety
Devices
33
1
7
MAINTENANCE
10 SPARE PARTS
7.1
General Requirements
35
10.1 Recommended Spares
66
7.2
Daily Maintenance
35
10.2 Recommended Compressor Oils
66
7.3
Refrigerant Charge
36
10.3 Wiring Diagrams
66
7.4
Refrigerant Circuits
36
7.5
Compressors
36
7.6
Condenser Coils
37
7.7
Condenser Fans
37
7.8
Filter Drier
37
7.9
Sight Glass
37
11 DE-COMMISSIONING, DISMANTLING
AND DISPOSAL
11.1 General
7.10 Thermostatic Expansion Valve
38
7.11 Evaporator
38
8
TROUBLE SHOOTING
39
9
TECHNICAL DATA
2
9.1
Pressure Drop Graphs
41
9.2
Safety Switch Setting
43
9.3
Operational Limits
44
9.4
Physical Data
46
9.5
Total Unit Electrical Data
49
9.6
Compressor Electrical Data
50
9.7
Fan Electrical Data
51
9.8
Sound Power Levels
52
9.9
Dimension, Weight and
Isolator Data
53
9.10 Piping and Instrumentation
Diagrams
56
9.11 General Arrangements
60
67
1
SUPPLIER INFORMATION
1.1 Introduction
RLC Series chillers are manufactured to the most
stringent design and construction standards to ensure high performance, reliability and adaptability to
all types of air conditioning installations. The unit is
intended for cooling water (and heating water in the
case of heat recovery chillers of those fitted with a
desuperheater) and is not suitable for purposes
other than those specified in this manual.
If the unit is used improperly, or for different purposes without the prior agreement of Itelco-Clima or
their agents, then such use would be outside the
scope and may be unsafe.
This manual contains all the information required
for correct installation and commissioning of the
unit, together with operation and maintenance instructions. The manual should be read thoroughly
before attempting to operate or service the unit.
With the exception of the operations detailed in this
manual, all installation, commissioning and maintenance tasks must be performed by suitably trained
and qualified personnel from an Authorised Service
Centre.
The manufacturer is not liable for injury or damage
resulting from incorrect installation/commissioning
or operation, insufficient maintenance and/or failure
to follow the procedures and instructions contained
in this manual.
1.2 Warranty
The unit is supplied finished, tested and ready to
work. The unit warranty will be void if any modification to the unit is carried out without written agreement of the manufacturer.
For warranty purposes, the following conditions
must be satisfied:
■
The initial start of the unit must be carried out by
trained personnel from an Authorised Service
Centre.
■
Maintenance must be carried out by properly trained personnel.
■
Only genuine spare parts must be used.
■
All the scheduled maintenance operations detailed in this manual must be performed at the specified times.
Failure to satisfy any of these conditions will automatically void the warranty.
1.3 Safety
The installation of the unit must be carried out
according to the Machinery Safety Directive
(CEE 98/37), to the Low Voltage Directive
(73/23/EEC), to the Electromagnetic Interference Directive (89/336/EEC) as modified by Directive (92/31/EEC) and according to normal rules
for technical matters prescribed by the applicable country regulations. Do not operate the unit
before having observed all the above.
WARNING
The unit must be earthed and no installation or maintenance work should be
attempted on the electrical equipment
without first switching off and isolating
the main power supply and any control
supplies.
Failure to observance of the above safety measures may result in fire or electrocution should a shortcircuit occur.
3
WARNING
The unit contains refrigerant vapour
and liquid under pressure within the
heat exchangers, compressors and pipework. Release of refrigerant can be a
danger and cause injury.
Fan guards must be fitted at all times
and not removed unless the main
power supply has been isolated.
1.4 Emergency Stops/Shutdown
The isolator switch on the electrical panel will shutdown the unit, when set to the 0 (Off) position.
The unit should be restarted in accordance with the
procedure detailed in this manual.
1.5 About this Manual
WARNING
WARNING
WARNING
CAUTION
CAUTION
It is the responsibility of the user to ensure that the unit is suitable for the conditions of use and that installation and
regular maintenance is carried out by
personnel with the appropriate skills
and in accordance with this manual.
Support of the unit must be provided as
indicated in this manual, failure to provide proper support may put personnel
at risk of injury.
The unit is not designed to withstand loads
or stresses from adjacent equipment, pipework and structures. Any such extraneous loads or stress may cause failure or
collapse which can be a danger and cause
injury. In such cases the warranty will be
void.
For safety reasons, the instructions contained in
this manual must be followed categorically; furthermore, damage caused by misuse is not covered by
the warranty.
This manual uses the following conventions:
WARNING
Warning messages alert you to a specific procedure or practice which, if not
followed correctly, could cause serious
personal injury.
Caution messages appear before procedures which, if not observed, could result
in damage to the unit.
CAUTION
Notes contain particularly important comments which are set off from the text.
The user should ensure that reasonable
care is taken by other trades to avoid damage/abuseto the unit during and after installation.
Hints provide useful information to improve
operation efficiency
HINTS
Do not discard or burn the packaging in the
environment.
CAUTION
4
The contents of this manual, and any other documentsupplied with the unit, are the property of Itelco-Clima which reserves all rights. They may not be
reproduced, in whole or in part, without the written
authorisation of Itelco-Clima.
1.6 Safety Labels
The following labels are fitted to each unit in the locations stated:
Refrigerant Identification - Outside Panel Door
TENERE SU QUESTA LINEA
GANCIO DI SOLLEVAMENTO
KEEP LIFT HOOK
ON THIS LINE
Centre of Gravity - Base Frame
Electrical Warning Adjacent to Isolator Switch
Unit Identification Inside of Outer Panel Door
5
QUESTO COMPRESSORE RICHIEDE UN
CORRETTO SENSO DI ROTAZIONE
RISPETTARE LA CORRETTA SEQUENZA
DELLE FASI
CAUTION
THIS COMPRESSOR REQUIRES PROPER
DIRECTION OF ROTATION
CHECK PROPER ELECTRICAL PHASING
Scroll Compressor Direction of Rotation Compressor
ATTENZIONE
INSERIRE LE RESISTENZE DI RISCALDAMENTO OLIO ALMENO
12 ORE PRIMA DI OGNI AVVIAMENTO (SE PREVISTE).
881000215/B
ATTENZIONE
PRIMA DELLA MESSA IN TENSIONE ASSICURARSI CHE LE VITI
DEI CIRCUITI ELETTRICI SIANO SERRATE COMPLETAMENTE.
WARNING
ENERGIZE THE CRANCKCASE HEATER FOR AT LEAST 12
HOURS BEFORE EACH STARTING (IF FITTED).
BEFORE TIGHTENING-UP, TO TIGHTEN ALL TERMINAL SCREWS
ESPECIALLY THOSE IN MAIN CIRCUIT.
Start up Warning Outside of Electrical Panel Door
Lifting Point - Base Frame
EIN - INLET
ENTRÉE - ENTRATA
AUS - OUTLET
SORTIE - USCITA
Connection Identification - Adjacent to Connections
Test Certificate Inside of Outer Panel Door
Earth Point - In Panel Adjacent to Connection
6
1.7 Material Safety Data
Refrigerant Data:
Safety Data:
R407C, R134a
Toxicity
Low.
In contact with skin
Liquid splashes or spray may cause freeze burns. Unlikely to be
hazardous by skin absorption. Thaw affected areas with water.
Remove contaminated clothing carefully - may adhere to skin in
case of freeze burns. Was affected areas with plenty of warm water.
If symptoms occur (irritation or blistering) obtain medical attention.
In contact with eyes
Vapour has no effect. Liquid splashes or spray may cause freeze
burns. Immediately irrigate with eyewash solution or clean water for
at least 10 minutes. Obtain immediate medical attention.
Ingested
Highly unlikely to occur - but should this occur freeze burn will occur.
Do not induce vomiting. Provided patient is conscious, wash mouth
with water and give about 250 ml (0.5 pint) to drink. Obtain immediate medical attention.
Inhalation
R407C, R134a: High atmospheric concentrat ions may lead anaesthetic effect, including loss of consciousness. Very high exposures
may cause an abnormal heart rhythm and prove suddenly fatal.
At higher concentration there is a danger from asphyxiation due to
reduced oxygen content of atmosphere. Remove patient to freshair,
keep warm and at rest. Administer oxygen if necessary. Apply artificial respiration if breathing has ceased or shows signs of failing. In
event of cardiac arrest apply external cardiac massage. Obtain
immediate medical attention.
Further Medical Advice
Symptomatic and supportive therapy is indicated. Cardiac sensitisation has been described which may, in the presence of circulating catecholamines such as adrenalin, give rise to cardiac arrhythmias and
subsequent arrest following exposure to high concentrations.
Long term exposure
R407C, R134a: A lifetime inhalation study in rats has shown that exposure to 50,000 ppm resulted in benign tumours of the testis. This is
not considered to be of relevance to humans exposed to concentrations at or below the occupational exposure limit.
Occupational exposure limits
R407C, R134a: Recommended limit: 1000 ppmv/v - 8 hr TWA.
Stability
R407C, R134a: Not specified.
Conditions to avoid
Use in presence of naked flames, red hot surfaces and high moisture
levels.
Hazardous reactions
May react violently with sodium, potassium, barium and other alkali
and alkaline earth metals. Incompatible materials: Magnesium and alloys containing more then 2%magnesium.
Hazardous decomposition
products
R407C, R134a: Halogen acids by thermal decomposition and hydrolysis.
7
8
General precautions
Avoid inhalation of high concentrations of vapours. Atmospheric concentrations should be minimised and kept as low as reasonably practicable below the occupational exposure limit. The vapour is heavier
than air and collects at low level and in confined areas. Ventilate by
extraction at lowest levels.
Respiratory protection
Where doubt exists on atmospheric concentration, HSE approved
breathing apparatus should be worn. This should be self contained or
of the long breather type.
Storage
Keep containers dry and in a cool place away from fire risk, direct sunlight, and all sources of heat such as radiators. Keep at temperatures
not exceeding 45 deg C.
Protective clothing
Wear overalls, impervious gloves and goggles/face protection.
Spill / Leak procedure
Ensure suitable personal protective clothing and respiratory protection is worn. Provided it is safe to do so, isolate the source of the
leak. Allow small spillages to evaporate provided there is suitable
ventilation.
Large spillages: Ventilate area. Contain spillages with sand, earth or
any suitable absorbent material. Prevent liquid from entering drains,
sewers, basements and work pits since vapour may create a suffocating atmosphere.
Disposal
Best to recover and recycle. If this is not possible, destruction is to be
in an approved facility whichis equipped to absorb and neutralise
acids and other toxic processing products.
Fire extinguishing data
R407C. R134a: Non-flammable at atmospheric conditions.
Containers
Fire exposed containers should be kept cool with water sprays. Containers may burst if overheated.
Fire fighting protective
equipment
Self contained breathing apparatus and protective clothing must be
worn in fire conditions.
Refrigerant Oil Data:
Safety Data
Oil Polyester (POE)
Classification
Non-hazardous
In contact with skin
Minimally irritating. No first aid necessary. Exercise reasonable personal cleanliness including cleansing exposed skin areas several times
daily with soap and water. Launder soiled work clothes at least
weekly.
In contact with eyes
As with most foreign materials flush with plenty of eyewash solution or
clean water.
Ingested
Obtain immediate medical attention.
Inhalation
Obtain immediate medical attention.
Conditions to avoid
Strong oxidisers, caustic or acid solutions, excessive heat. May degrade some paints and rubber materials.
Respiratory protection
Use in well ventilated areas.
Protective clothing
Goggles or face shield should be worn. Gloves not necessary, but recommended, especially for prolonged exposure.
Spill / Leak procedure
Wear suitable protective equipment, especially goggles. Stop source
of spill. Use absorbent materials to soak up fluid (i.e. sand, sawdust,
and commercially available materials).
Disposal
Incinerate the oil and all associated wastes in a approved facility in
accordance with local laws and regulations governing oily wastes.
Fire extinguishing datra
Use dry chemical, carbon dioxide or foam spraying water on hot or
burning liquid, may cause frothing or splashing.
If a leak or spill has not ignited use water spray to disperse the vapours and to provided protection for persons attempting to stop the
leak.
Containers
Fire exposed containers should be kept cool with water sprays.
Fire fighting protective equipment
Self contained breathing apparatus should be worn in fire conditions.
9
2
PRODUCT DESCRIPTION
2.1 Introduction
The RLC range of twin refrigerant circuit water chillers are designed to be located outside on the roof
of a building or at ground level.
The range includes the following models:
Models
Description
RLC-A
210 to 525
Water chillers charged with
refrigerant R134a
RLC-B
210 to 800
Water chillers charged with
refrigerant R407C
The following options are available:
Option
Description
/R
100% (total) heat recovery on both refrigerant circuits tosupply simultaneous chilled and warm water. During
heat recovery the refrigerant flows via
the heat recovery condensers
/P
50% (partial) heat recovery on a single
refrigerant circuit to supply simultaneous chilled and warm water. During
heat recovery the refrigerant flows via
the heat recovery condenser
/D
Heat is recovered via a desuperheater
installed on the compressor discharge
line.
/Q
Low noise emission, using mufflers
and continuous fan speed control
2.2 General Specification
RLC models are completely assembled with all interconnecting refrigerant piping and wiring ready for
field installation.
10
The unit is pressure tested, evacuated and finally
charged with refrigerant and includes an initial oil
charge. After assembly a full run test is performed,
with water flowing through the evaporators, to verify
that each refrigerant circuit operates correctly.
The unit base and frame is of heavy gauge galvanised steel fastened with stainless steel screws and
bolts. Compressor and refrigerant circuit components are located in an acoustically lined enclosure.
All panels are easily removed for access to components. Galvanised steel parts are painted with
baked-on enamel coloured white RAL 9001.
2.3 Compressors
Model
Compressor
RLC-A da 210 a 525 Two reciprocating compresRLC-B da 210 a 800 sors with part wind starting
RLC-A 210 to 525 and
RLC-B 210 to 800
Compressor lubrication is force-fed by a reversible
oil pump to all crankshaft and bearing surfaces through a fine mesh stainless steel oil strainer.
The compressor motors are refrigerant gas cooled,
with integral temperature-sensing solid state overload protection in each phase. The motor terminal
boxes are to IP-54 weather protection.
Compressor capacity control is provided by solenoid-actuated, capacity control valves, which are
controlled by the unit microprocessor. This method
efficiently and effectively matches low load conditions as required. Gas flow is sufficient at all times
to cool the motors.
2.4 Refrigerant Circuits
2.6 Air Cooled Condensers
Two complete refrigerant circuits are supplied on
each unit. All piping is ACR copper, with brazed
joints. Refrigerant circuits include: a service valve
for refrigerant charging, suction discharge and liquid line isolating valves, sight glass with moisture
indicator, thermal expansion valve with external
equaliser. Solenoid valve, filter drier and differential
oil pressure switch on sizes 210 to 800. High and
low pressure switches and safety valves on sizes
300 to 800.
The condenser coils are seamless copper tubes,
arranged in staggered rows, mechanically expanded into corrugated aluminium fins. Integral subcooling is included. The design working pressure of
the coil is 28 bar g.
The condenser fans are direct drive with aluminium
aerofoil blades. Each fan has a painted galvanised
steel protection guard.
2.5 Evaporators
The three phase totally enclosed fan motors are to
IP-54 weather protection and have thermocontact
protection embedded in their windings.
RLC-A and RLC-B models 210 upwards each have
a single steel shell and copper tube evaporator.
2.7 Heat Recovery Condensers
The dual-circuit evaporator is a direct-expansion type, with the refrigerant in the tubes, which are formed in a hair-pin configuration, and chilled liquid
flowing through the baffled shell. The evaporator is
covered with flexible, closed-cell, foam insulation.
The heat recovery condensers are cleanable shell
and tube type with seamless high pressure shell
and external finned copper tubes rolled into tube
sheets. The condenser shell is factory insulated
with flexible closed cell insulation and has a heater
mat for antifreeze protection down to -20°C.
Water connection to the evaporator is via threaded
connections on models 210 to 360 and victualic type on models 400 upwards.
The design working pressure is 25 bar g on the refrigerant side and 10 bar g on the water side.
All evaporators have a heating element controlled
by a thermostat for frost protection to -10°C. Water
vent and drain connections are included on all evaporators.
The evaporator design working pressure on the water side is 10 bar g and on the refrigerant side 25
bar g.
Full heat recovery units have two heat recovery
condensers and partial heat recovery units have
one condenser. All heat recovery units are equipped with cooling-heat recovery mode change-over
valve(s) and controller(s). A factory wired control
sensor, not including sensor pocket, is provided for
field installation.
11
2.8 Power And Controls
The control unit implements the following logic:
All units are equipped with a “Chiller Control” microprocessor control and management system.
■
LED and visual display of unit alarms and unit
operation.
All controls and motor starting equipment necessary for unit operation are factory wired and tested.
■
Compressor start-up logic (part-winding and cut
out), power adjustment on 2 or 4 steps.
Power and control components are separated and
accessed via individual doors. The power section
has a door interlocked isolator. The total enclosure
is fitted with a second upward opening door. The
panel is designed to IP-54 weather protection.
■
Display of compressor working hours and evaporator temperature.
■
Anti-cycling and anti-start-up surge timers.
■
Automatic compressor lead/lag start-up sequence.
Fan cut out.
The power compartment contains:
■
General switch.
■
■
Main isolator, compressor contactors and fuses,
fan contactors and fuses.
Management of set points and parametric data:
■
User level - The machine operator can adjust data at the keyboard with the ‘SET’, ‘+’ and ‘-’ keys.
Service Level - System password access for
authorised Service personnel.
The control compartment contains:
■
Anti-frost thermostat; auxiliaries transformer, fuses and relays.
■
■
The “Chiller Control” microcomputer keypad and
display, mounted in the control section door.
The display panel has keypad type buttons identified by symbols, colour coded to Eurovent standards, and LED’s to display function status:
2.9 Chiller Control
The “Chiller Control” unit consists of an expandable
interface board and a control unit.
The expandable interface board monitors inputs
and provides control outputs as follows:
■
Digital inputs, such as alarms and commands.
■
Analog inputs, such as temperature and pressure
measurements.
■
Digital outputs for control relay and remote control switch operation.
12
■
Green indicates Normal operation
■
Yellow indicates Caution
■
Red indicates Stop
2.10
Accessories
2.12
Options
Flow Switch
Condenser Coil-fin Protection
Supplied loose for field installation by contractor.
Painted galvanised steel guards mounted on the
exterior of the unit.
Anti-vibration Mounts
Air Cooled Condenser Options
Open spring isolator mounts with fixing down holes,
supplied loose for field installation by contractor.
Copper fins or vinyl coated fins.
Improved Capacity Control
Gauge Kit
Six or eight step control instead of standard four
step control for semi-hermetic compressor models.
Factory fitted mechanical dial gauges for suction
and discharge pressure indication of each refrigeration circuit.
Fan-speed Control
Extra Temperature and Pressure Sensors
Maintains constant condensing temperature, during
operation in low ambient conditions.
2.11
Interface Board
An optional communications interface enables the
unit to be controlled and managed from a local station via RS232 up to 500m, or via modem and a telephone line.
Remote management and control can therefore be
met by integrating twith a Building Management System.
To display compressor suction and discharge pressures and evaporation temperature of each refrigeration circuit.
Time Programme Board
Factory mounted to programme set point hours per
day (Maximum of four different set points over 24
hours per day and 5 days). Also implements chiller
on/off schedule. Generally used with ice storage systems.
Nomenclature
R
L
C
- 360
A / R / P / D
REFRIGERATOR
LARGE CAPACITY
COOLING ONLY
COMMERCIAL USE
SIZE
DESUPERHEATER
PARTIAL RECOVERY
TOTAL RECOVERY
REFRIGERANT
A = R134a
B = R407c
13
WITH 50%
HEAT RECOVERY
CONDENSER
COIL
CONDENSER
COIL
COOLER
HEAT
RECOVERY
CONDENSER
COOLER
HP LIQUID
LP VAPOUR
LP LIQUID
HP VAPOUR
LP VAPOUR
HP LIQUID
RLC-A & RLC-B
2.13
HP VAPOUR
LP LIQUID
RLC-A /P
Theory Of Operation
Cooling Mode
Heat Recovery Mode
Low pressure liquid refrigerant enters the cooler
(Evaporator) and is evaporated and superheated
by the heat energy absorbed fromthe chilled water
passing through the cooler shell. Low pressure vapour enters the compressor where pressure and
superheat are increased. Heat is rejected via the air
cooled condenser coil and fans. The fully condensed and subcooled liquid refrigerant then enters the
expansion valve where pressure reduction and
further cooling takes place before returning to the
cooler.
During heat recovery operation the refrigerant passes to the water cooled condenser instead of the air
cooled condenser. The high pressure superheated
refrigerant vapour enters the condenser shell, whereheat is rejected to thewarm water in the tubes,
and is condensed. High pressure liquid refrigerant
then passes through the expansion valve, where
pressure reduction and cooling takes place, before
returning to the cooler. Excess heat is rejectedat
theair cooledcondenser.
WITH 100%
HEAT RECOVERY
CONDENSER
COIL
WITH DESUPERHEATERS
CONDENSER
COILS
DESUPERHEATER
DESUPERHEATER
CONDENSER
COIL
HEAT
RECOVERY
CONDENSER
LP VAPOUR
HEAT
RECOVERY
CONDENSER
HD LIQUID
RLC-A /R
14
HP VAPOUR
COOLER
LP LIQUID
LP VAPOUR
HP LIQUID
HP VAPOUR
RLC-A /D
RLC-B/D (to Model 400)
LP LIQUID
3
TRANSPORTATION, HANDLING
AND STORAGE
■
Insert a spreader bar or frame between the cables, vertical to the unit’s centre of gravity.
RLC series chillers are supplied fully assembled,
(with the exception of the rubber vibration pads
supplied with the unit) which are installed on site.
Units are pre-charged with refrigerant and oil in the
correct quantity required for operation.
■
Attach the crane hook at the unit’s centre of gravity.
■
Cable length shall be such that they do not form
an angle of less than 45 degrees to the horizontal
when under tension.
3.1 Inspection
Immediately upon receiving the unit, it should be inspected for possible damage which may have occurred during transit as goods are shipped exworks at purchaser’s risk. In addition, ensure that
all ordered components have been received.
If any damage is evident, it should be noted on the
carrier’s freight bill and a claim entered in accordance with the advice note instructions. If the damage
is other than superficial, immediately advise your
local Itelco-Clima representative.
International Lifting Lugs
Itelco-Clima accepts no responsibility for shipping
damage, even in cases where the factory has arranged for shipping.
3.2 Handling
RLC series chillers are designed to be lifted using
lifting lugs and cables. A spreader bar or frame
should be used with the cables, to avoid crushing
the unit.
L > Unit Width
L
Before moving the unit ensure that the installation
site is suitable to receive the unit and to support its
weight and mechanical impact.
During handling, avoid touching sharp parts (for
example coil fins).
Never move the machine on rollers or lift
the machine using a fork lift truck.
CAUTION
Proceed as follows to lift and move the machine:
■
Insert and secure the lifting lugs through the
marked holes in the base frame.
■
Attach the cables to the lifting lugs.
CAUTION
Care should be taken to avoid damaging
the side-mounted coil fins and panelling
when lifting and moving the unit to the installation site.
The sides of the unit should be protected
with stiff cardboard or plywood.
CAUTION
15
CAUTION
Do not remove the protective plastic wrapping and the coil protectors, which prevent
dirt, dust and other foreign matter from entering the fan grilles or damaging the external surfaces, until the unit is ready for operation.
3.4 Storage
If the unit is to be stored prior to installation, certain
precautions should be taken to prevent damage,
corrosion or deterioration:
■
Ensure that all openings, such as water connections, are securely capped or sealed.
■
Do not store where exposed to ambient air temperatures exceeding 45°C for R134a or 42°C for
R407c units, preferably out of direct sunlight.
■
The finned heat exchangers should remain covered to protect the fins from potential corrosion,
particularly where building work is in progress.
■
Store the unit in a location where minimum activity is likely to take place in order to limit the risk
of accidental damage.
■
Do not steamclean the unit.
■
Remove the keys necessary to gain access to
the control panel and deposit them with a responsible person on site.
3.3 Anchorage
RLC Series chillers are provided with 18 mm diameter holes in the base frame for retaining the
spring damper mounts if required.
It is not necessary to anchor theunit to foundations,
except in areas of high risk of earthquake, or where
the unit is located at high level on a steel mounting
frame.
Periodic visual examination during storage is recommended.
16
4
INSTALLATION
■
The unit should not be sited in air wells,
courtyards or other restricted spaces where noise would be reverberated off the walls, or where
air expelled by fans could be channelled back to
condenser inlets.
■
The installation position should ensure adequate
clearances for air circulation and maintenance,
refer to Section 9 for details.
4.1 Location
WARNING
Before installing the unit, make sure
that the building structure and/or
mounting surface can support the unit
weight. Overall weights and weight distribution is detailed in Section 9.
The unit has been designed for floor mounting in
outside locations. Rubber anti-vibration pads are
supplied as standard and they must be positioned
centrally, underneath each of the supporting plates.
When the unit is to be installed on the ground, a
concrete slab must be provided to ensure uniform
weight distribution.
Special mounts are not normally required. However, if the unit is to be installed directly above inhabited rooms, it is advisable to set the unit on spring
damper mounts (supplied as accessories, refer to
Section 9) to minimise the vibrations transmitted to
the structure.
4.2 External Water System
CAUTION
The external water system should consist of the following:
■
A circulation pump providing sufficient output and
hydraulic head.
■
To ensure that repetitive starts of compressors is
avoided, which can cause damages, the primary
system water content should be no less than 10
litres per kW of cooling capacity. If the total volume in primary system pipework and evaporator is
insufficient, an insulated buffer tank should be installed.
■
A diaphragm-type expansion tank with safety valve outlet which must be visible.
The following factors must be considered when selecting a location for the unit:
■
The units longitudinal axis should be parallel to
prevailing winds to ensure balanced air flow over
the condenser coils.
■
The unit should not besited downwind of boiler
flues.
■
The unit should not be sited downwind of sources
of grease-laden air such as extractor vents for
large kitchens. In such cases, accumulated grease on the condenser fins can trap air-borne contaminants, thus leading to rapid soiling or clogging.
■
The unit should not be sited in areas exposed to
heavy snowfall.
■
The external water hydraulic circuit must
ensure constant water flow to the evaporator under all operating or adjustment conditions.
The tank should be sized to accommodate
a 2% increase in total fluid volume in the
system (evaporator, lines, user circuits and
water reservoir where provided). The Expansion tank need not necessarily be insulated, as water does not normally circulate
therein.
■
A flow switch to deactivate the unit when water is
not circulating.
The unit should not be sited in areas exposed to
flooding or beneath downpipes, etc.
The flow switch must be connected in series with external interlocks as shown on
wiring diagram in control panel.
CAUTION
17
Follow the manufacturer’s instructions carefully when installing the flow switch.
In general, the flow switch should be installed on
the pump delivery, upstream of the unit, on a horizontal pipe run of at least 10 pipe diameters from
any bend, valve or other item which could interfere
with water flow upstream or downstream of the flow
switch.
A Normally Open differential pressure switch may
be installed instead of the flow switch. The pressure
switch senses water pressure drop across the evaporator.
In addition:
■
Install air vent valves at the highest points of the
lines.
■
Install shutoff valves on the evaporator and heat
recovery condenser inlet and outlet water lines.
■
Provide suitable drainage points (with plugs,
cocks etc.) at the lowest points of the lines.
■
Install a valved by-pass around the evaporator.
■
Insulate the pipework to prevent heat loss.
■
A filter/strainer located on the suction side of the
evaporator or heat recovery condenser.
■
A water flow measuring device.
18
FLOW SWITCH INSTALLATION
UNIT
EXTERNAL WATER SYSTEM
Typical Connection Diagram
Key
I
GA
T
S
R
F
Fl
Pressure gauge tapping
Flexible connections
Thermometer
Gate valves
Drain tap
Strainer
Flow switch
Standard evaporators provided on RLC units are
designed to chill mixtures of water and ethylene glycol with a corrosion-inhibiting additive down to
–10°C.
The amount of ethylene glycol to be added is as follows.
Amounts are shown as a percentage by weight of
the circuit design water content:
operation from + 5 to 0 °C : 20%
CAUTION
Before filling the system, ensure that it is
free from foreign matter, sand, stones, rust
flakes, solder, slag or other materials which could damage the evaporator.
operation from 0 to -5 °C : 30%
operation from -5 to -10 °C : 40%
It is advisable to by-pass the unit when flushing out
the lines. A strainer screen must be installed
upstream of the chiller.
Water used to fill the circuit may have to be
treated to ensure that the PH value is correct.
19
Where two or more units are connected in parallel it
is recommended that the connections be made through a “Reverse Return” circuit (as shown below)
in order to balance the pressure drop in each unit
circuit.
Typical Parallel Hydraulic Connection
Key
A
B
S
VG
E1
E2
E3
RLC-A 360 to 525 and RLC-B 400 to 800
From circulating pump
Chilled water to the system
Gate valves
Balancing valve
Evaporator, 1st unit
Evaporator, 2nd unit
Evaporator, 3rd unit
Connect the external water supply lines to the water
inlet and outlet fittings on the left hand side of the
unit, when viewed from the electrical panel.
The unit is provided with Victaulic fittings, refer to
section 9 for diameters and locations.
RLC-A Heat Recovery Models (/R and /P)
A factory wired control sensor (6 mm diameter x 30
mm long) is provided for field installation.
4.3 Water connections
The water inlet and outlet connections must be connected correctly as shown on the labels fitted adjacent to the fittings.
RLC-A 210 to 300 and RLC-B 210 to 360
Connect the external water supply lines to
the water inlet and outlet fittings at rear of
the unit.
CAUTION
The unit is provided with threaded pipe fittings, refer
to section 9 for diameters and locations.
20
A sensor pocket, which is not supplied, should be
installed by the contractor in the common pipework
leaving the condenser(s).
4.4 Electrical Supplies
Ensure that the power supply is off
before working on the electrical system.
WARNING
The unit must be provided with an earth
connection.
Magnetic thermal differential breakers are recommended, to prevent damage due to electrical phase
loss.
Power supplies to the compressors and the fans
are through contactors controlled by the control panel.
Each motor is provided with an internal thermal
overload cut-out and external fuses.
WARNING
CAUTION
Supply and isolating devices shall be designed so
that the lines are fully independent.
It is the installers responsibility to ensure
that all external wiring complies with applicable safety regulations.
Supply cables should be routed through the cable
entries on the unit front and enter the electrical panel through a hole at the bottom of the panel.
The Manufacturer is not responsible for injury
or damage of any kind resulting from failure to
observe these precautions.
The unit complies with EN 60 204-1.
The following connections are required:
■
One three-phase line and earth for the power circuit supply.
The electrical distribution system must be able to
supply all the unit power, refer to Section 9.
The disconnect switches and circuit breakers must
be sized to handle the unit starting current, refer to
section 9.
21
4.5 Electrical Connections
The installation of the unit on the final site must
be carried out according to the Machinery Safety directive (98/37/EC), to the Low Voltage Directive (73/23/EEC), to the Electromagnetic Interference directive (89/336/EEC) and according
to normal rules for technical matters prescribed
by the applicable country regulations. Do not
operate the unit before having observed all the
above. Supply lines shall consist of insulated
copper conductors sized for maximum current
draw.
Terminal connections should be made in accordance with the connection diagram in this manual and
the diagram supplied with the unit.
Before connecting the supply lines, check
that the mains voltage is within the range
shown in the Electrical Data in Section 9.
CAUTION
For the 3 phase power supply, also check that the
phase unbalance does not exceed 2%. The check
is performed by measuring the difference between
the voltage of each phase pair and the average
mains voltage during operation. The maximum
measured difference (unbalance) shall not exceed
2% of the average voltage.
If the unbalance is unacceptable, the electricity
supply company must be asked to correct the fault.
Supplying the unit with a line whose unbalance exceeds the specified value will automatically void the warranty.
CAUTION
22
MORSETTIERA
DELL'UNITÁ
UNIT TERMINAL
BOARD
MORSETTIERA
ESTERNA
EXTERNAL
TERMINAL
BOARD
LINE
400-3-50
FLOW SWITCH OR
EXTERNAL INTERLOCK
(24V)
INTERLOCK
(OPTIONAL) (24V)
CIRC PUMP ETC
REMOTE INDICATION
VOLTAGE ON (VF)
REMOTE ON/OFF CONTROL
(VOLT FREE CONTACT)
COMMON
(NO)
GENERAL ALARM
VOLT FREE
(NC)
COMPRESSOR ‘1’ ON
VOLT FREE
COMPRESSOR ‘2’ ON
VOLT FREE
RLC-A e RLC-B Electrical Connections
23
UNIT TERMINAL
BOARD
MORSETTIERA
DELL'UNITÁ
EXTERNAL
TERMINAL
BOARD
MORSETTIERA
ESTERNA
LINE
400-3-50
FLOW SWITCH OR
EXTERNAL INTERLOCK
(24V)
INTERLOCK
(OPTIONAL) (24V)
CIRC PUMP ETC
REMOTE INDICATION
VOLTAGE ON (VF)
REMOTE ON/OFF CONTROL
(VOLT FREE CONTACT
COMMON
(NO)
GENERAL ALARM
VOLT FREE
(NC)
COMPRESSOR ‘1’ ON
VOLT FREE
COMPRESSOR ‘2’ ON
VOLT FREE
REMOTE ON/OFF HEAT RECOVERY
(VOLT FREE CONTACT)
RLC-A, RLC-B with Heat Recovery, Electrical Connections
24
5
COMMISSIONING
CAUTION
The unit must be started by trained personnel from an Authorised Service Centre.
failure to satisfy this requirement will void
the warranty.
The operations performed by service personnel are limited to unit starting, and do
not include other work on system such as
electrical connection, water connection,
etc. All other preparatory work, including
oil pre-heating (for at least 12 hours) must
be performed by installer.
■
Adjust the water system so that the flow rates are
as specified.
■
Check that the water quality is as specified.
■
Check the position of the safety and anti-icing
thermostat sensors.
■
Check that the oil heaters, if fitted have been
energised for at least 12 hours.
5.2 Starting
The starting sequence is as follows.
■
Turn on the master isolating switch (12 hours
before).
■
Check that the compressor oil is sufficiently warm
(minimum temperature at the oil pan exterior must be approximately 40°C) and that the auxiliary
control circuit is energised.
■
Check that all external equipment is in running
order and that the associated control equipment
is correctly calibrated.
5.1 Preliminary Checks
The following operations must be performed before
starting the unit and should be performed before
service personnel arrive.
■
With master isolating switch off, check the supply
cable cross-section, the ground connection, the
electrical terminal clamps are tight and that all
contactors operate correctly.
■
Check that the voltage and phase unbalance of
the power supply is within limits, refer to Section 4.
■
Start the liquid pump and check that the water
flow rate is as required.
■
Connect (non-energised) contacts of the flow
switch and the pump thermal overload cut-out or
other devices (where provided) to terminals 1-2
and 3-4 respectively.
■
Set the desired fluid inlet temperature on the control panel (refer to Section 6).
■
Start the unit (refer to Section 6).
Check that the external water circuit components
(pumps, user equipment, filters, expansion tank
and reservoir where provided) have been correctly installed as advised by manufacturer and that
the inlet and outlet water connections are correct.
■
Check the correct Scroll compressor direction of
rotation.
■
After around 15 minutes of operation, check that
no air bubbles are visible through the sight glass
on the fluid line.
■
■
■
Check that the external water circuit is full and
that the fluid circulates freely with no signs of
leakage or air bubbles. If ethylene glycol antifreeze is used, check that the percentage concentration is correct.
Check that the pump direction of rotation is correct, and allow fluid to circulate for at least 24
hours (12 hours for each pump). Then clean the
basket filters on the pump suction.
CAUTION
If air bubbles are visible, the unit has lost
part of its charge through one or more
leaks. The leaks must be eliminated refer
to Section 7.
■
Repeat the starting procedure after eliminating
the leaks.
■
Check that the oil level is correct.
MAX
MIN
25
MAX
MAX
MIN
MIN
MIN
RLC-A 210, 240, 300, 360,
400, 450, 525
RLC-B 210, 240, 300, 360
Sight Glass
Sight Glass
RLC-B 400, 450, 525, 600,
700, 800
Sight Glass
5.3 Performance Check
Check the following:
■
Evaporator manifold inlet water temperature.
■
Evaporator manifold outlet water temperature.
■
Evaporator manifold outlet water flow rate.
■
Compressor current at startup and stable operating conditions.
■
Fan current at startup and stable operating conditions.
Check that the saturated evaporation and condensation temperatures during operation at high and
low pressure by connecting gauges to the schrader
valves on the high and low pressure refrigerant circuits.
High pressure side
Approximately 15 to
18°C above coil inlet air
temperature
Low pressure side
Approximately 5 to 7°C
below chilled water outlet temperature
5.4
■
26
Customer Handover
Familiarise the user with the machine operating
instructions in Section 6.
6
OPERATION
RLC series chillers are equipped with a microprocessor control logic and regulation management
system.
The system consists of a unit logic board and a liquid crystal control panel which manages the control, starting, shutdown and display functions.
■
When the alarmis activated, control logic locks
out the unit. Reset is automatic.
■
Unit alarm management and display
■
High pressure alarm.
When the alarmis activated, control logic locks
out the associated refrigerating circuit and opens
the compressor control chain (fail-safe mode).
Alarmis reset from the pressure switch and manually from panel.
■
■
6.2 Compressor starting logic
Control logic automatically manages all functions
connected with compressor starting.
■
Anti-cycling timer delay.
Prevents compressor starting attempts from
being made in quick succession (360 seconds/6
minutes) (Note 1).
■
Starting delay.
Low pressure alarm.
Prevents compressors from starting simultaneously (10 seconds) (Note 1).
When the alarmis activated, control logic locks
out the associated refrigerating circuit. Alarm
operation is delayed approximately 30 seconds
after starting (Note 1). Alarm is reset manually
from panel.
Part wind starting is used to reduce starting current. Panel logic automatically manages this starting mode, in which only a part of the compressor
winding is activated during starting.
Differential oil pressure alarm.
When the alarmis activated, control logic locks
out the associated refrigerating circuit. Alarm
operation is delayed approximately 120 seconds
(Note1). Alarmis reset manually from panel.
■
Fan thermal overload cut-out alarm.
Activation of this alarm locks out the associated
circuit and fans. Alarmis triggered by fan motors.
Reset is automatic.
6.1 Regulation and control logic
Control logic automatically manages the following
functions:
External interlock alarm.
Compressor thermal overload cut-out alarm.
■
Automatic compressor starting sequence change.
Used to ensure that compressors operate for the
same number of hours.
Note 1 These parameters are variable.
Changes must be carried out by Itelco-Clima authorised personnel only.
When the alarmis activated, control logic locks
out the associated refrigerating circuit and opens
the compressor control chain. Alarm is reset manually from panel.
■
Anti-freezing alarm.
This alarm is activated when water temperature
at evaporator outlet drops below 3 °C (Note 1).
Alarm is reset manually from panel.
27
The water temperature can be controlled from the
inlet or the outlet.
6.3 Water Temperature Regulation (IN)
Regulation is performed via inlet water temperature
SET POINT as shown below. The band is divided
into a number of steps.
G1 OFF
G2 OFF
G1 ON
The control regulates the output of the compressor
as a function of the system; control is in two steps,
four steps or optionally six or eight. Depending on
the required set point and the proportional band
(pre selected to be 5°C), the controller determines
the number of functioning compressors and possible unloading.
Key
1
2
The above always refers to nominal water flow with
a dT equal to 5°C.
Tr
G1 - G8
G3 OFF
G2 ON
G4 OFF
G3 ON
G5 OFF
G4 ON
G6 OFF
G5 ON
G7 OFF
G6 ON
G8 OFF
G7 ON
G8 ON
8-step Type Regulation
SET POINT Programmed set point
Width of regulation band
(set to 5°C)
Water return temperature
Steps of unloading
6.4 Water Temperature Regulation (OUT)
Regulation is performed via outlet water temperature SET POINT as shown below:
When the temperature of the water leaving the unit
remains within the neutral zone the capacity loading of the chiller remains unchanged.
G2 OFF
G1 OFF
G2 OFF
G1 ON
G2 ON
G1 ON
2-Step Type Regulation
When the temperature of the water leaving the unit
increases and goes outside the neutral zone the
controller increases the capacity loading.
When the temperature of the water leaving the unit
decreases and goes outside the neutral zone the
controller decreases the capacity loading.
BAND
ZONE
G1 OFF
G2 OFF
G1 ON
G3 OFF
G2 ON
G4 OFF
G3 ON
4-step Type Regulation
NEUTRAL
T. WATER (OUT)
G4 OFF
TR
IMPOSTAZIONE
SET
SET
Outlet Water Temperature Regulation
28
RLC-A, RLC-B Control Panel
29
RLC-A R/P/D Control Panel (Heat Recovery)
30
6.5 Control panel
Key
Function
Display
Displays operating and fault
parameters.
SET POINT + key.
(increase temperature
SET POINT).
SET POINT - key.
(rreduces temperature
SET POINT).
Key
Funtion
Voltage indicator LED.
Indicates that unit is connected
to power supply.
Anti-freezing alarm LED.
Indicates that water temperature
at evaporator outlet is below
safe limit.
External interlock
alarm LED.
SET POINT display key.
Page key.
Calls data display pages.
Circuit 1 or 2 power key and LED.
(Select circuit 1 or 2).
100% power level indicating
LED for circuit 1 and 2
compressors.
Compressor partialisation
indicating LED for circuit
1 and 2 compressors
Circuit 1 or 2 high pressure alarm
LED. Indicates that high pressure
switch for circuit 1 or 2 has been
activated.
Fan thermal overload alarm LED
Indicates that a fan thermal
overload cut-out has been
activated.
Warm weather mode start key
and LED. Starts the unit in
the cooling mode.
Led lights up to indicate
operating in cooling mode.
Heat Recovery start key and
LED. Starts the unit heat recovery
mode. Led lights up to indicate
operating in recovery mode.
Service mode key and LED.
(For use only by authorised
service personnel).
Circuit 1 or 2 low pressure alarm
LED. Indicates that low pressure
switch for circuit 1 or 2 has been
activated.
Circuit 1 or 2 differential oil
pressure alarm LED (semihermetic compressor only).
Indicates that differential oil
pressure switch for circuit 1 or 2
has been activated.
Circuit 1 or 2 compressor thermal
overload alarm LED. Indicates
tht compressor thermal
overload has been activated
for circuit 1 or 2.
31
6.6 Unit Starting
Data and Temperature Display
Proceed as follows to start the unit:
■
■
Display 1 (Models RLC 150 to RLC 800)
Turn the master isolating switch to the ON position to energise unit.
Check that
In Tmp Wat
Out Tmp Wat
LED (voltage indicator) goes on.
The following display will appear on screen:
Evaporator inlet water temperature
Evaporator outlet water temperature
■
Wait (circa 10 sec.) for this message to disappear
and check that there are no active alarm signals.
■
key for each circuit.
unit is now in stand-by and
ciated circuits are on.
Press
Air temperature
LED’s for the asso-
key to start the unit in the cooling mode.
LED will go on.
Compressor operation and power level will be indicated by
■
LED’s for each circuit.
Check that SET POINT is as desired (SET
POINT established at the factory is 8°C).
If necessary, change the set point as described in
6.7.
32
Condenser Coils
Air Tmp
Prepare the two circuits for operation by pressing
the
■
Display 2
■
Display 3
The heat recovery function is by means of a fourway valve in the discharge line from the compressor to the condenser. The four-way valve diverts hot
refrigerant gas to the recovery condenser, when the
thermostat is calling for heat.
Hour Counter
When the leaving warm water temperature reaches
the set point of the thermostat the four-way valve diverts the refrigerant to the air cooled condenser and
the heat is dissipated to the ambient air. As the
warm water temperature leaving the recovery vessel falls below the set point of the thermostat the
four-way valve diverts the refrigerant back to the
heat recovery condenser.
Operating hours for compressors 1 and 2.
Press key
to scroll displays.
Alarm readouts are shown at the foot of display 3.
Press page key
again to return to display 1.
6.7 Set point
To display cooling mode SET POINT:
■
Press
key with unit operating in cooling mode.
To change SET POINT, Proceed as follows:
6.9 Alarm Display and Reset
Alarms are indicated by the associated panel LED’s
and by messages on the liquid crystal display. The
letters “AL” will appear in the upper right corner of
display to indicate that an alarm is active or has
been stored in memory. To display alarm, press
page key
appears.
several times until the alarm display
To reset and delete memorised alarms, press page
key
■
Display SET POINT as directed above;
■
Press page key
changed.
■
Change digit using
■
Press
■
To change SET POINT with compressors off, de-
until the following display appears:
to move onto the digit to be
and
keys;
key to confirm;
activate the two circuits by pressing
keys.
6.8 Heat Recovery Operation
The heat recovery option is activated by the heat
recovery start key on the control panel, which is illuminated when activated. Heat recovery operation is
controlled by a factory wired thermostat, mounted
by the installer, in the warm water flow from the heat
recovery condenser(s).
Then press
key to delete and reset alarms
6.10 Unit Shutdown
■
Press warm weather mode key
unit.
to stop the
■
Turn master isolating switch to OFF position to
de-energise the unit.
6.11 Electromechanical Safety Devices
Each refrigerating circuit on the RLC Series units is
protected by anti-freezing devices implemented by
the “Chiller Control” panel and a set of electromechanical safety devices including a high pressure
switch, a low pressure switch and a differential oil
pressure switch (units with semi-hermetic compressor only).
33
Ant-freezing device (supplied with unit)
Low pressure switch
Units are provided with anti-freezing device consisting of an electric heating element in contact with
the refrigerant/water heat exchanger. Heating element is activated whenever water temperature drops below 2°C, even when the unit is off. An antifreeze alarm stops the unit if outlet water temperature drops below 3°C. During the cold season, it is
advisable to drain water circuit to prevent ice damage to lines. If this is not possible, do not cut off
power supply to the unit to ensure that the anti-freeze heating element will be activated if needed.
Automatic-reset switch opens contacts.
Circuit can be reset manually through “Chiller Control” panel.
Differential oil pressure switch
This instrument is provided on circuits with semihermetic compressor. Switch senses pressure differential across compressor casing and compressor oil delivery.
Switch cut-in is delayed 120 seconds to allow pressure to rise after compressor start-up. Circuit can
be reset manually through control panel.
High pressure switch
Manual-reset switch opens contacts.
Circuit can be reset manually through “Chiller Control” panel, after resetting device.
Alarm Displays
34
Compressor 1 or 2
Thermal Overload
Cut-out
Circuit 1 or 2 Fan
Thermal Overload
Cut-out
Circuit 1 or 2 HIGH
Pressure Switch
* Circuit 1 or 2
HIGH Pressure
Limit Exceeded
Evap. Outlet 1
Water Low Temp.
Limit Exceeded
* Circuit 1 or 2 Low
Pressure Limit
Exceeded
Evap. Outlet 2
Water Temp. Limit
Exceeded
Evap. Inlet Water
High temperature
Limit Exceeded
Evap. Inlet Water
Low Temperature
Limit Exceeded
circuit 1 or 2 LOW
Pressure Switch
Compressor 1 or 2
Maintenance
Circuit 1 or 2
Differential Oil
Pressure Switch
Analogue Input for
Remote Setpoint
Out of Range
Temperature Set
Point Out of Range
External Interlock
Mistake in Interface
Managing
EPROM
Damaged
Timer Missing or
Not Working
* Only if optional pressure and temperature
sensors are fitted
Scheduled Maintenance
Operation
7.1 General Requirements
The RLC range has been designed to work continuously provided they are regularly maintained and
operated within the limitations given in this manual.
each unit should be maintained in accordance with
the schedule by the operator/customer, backed up
by regular service and maintenance visits by an
authorised Service Centre.
It is the responsibility of the owner to provide for
these regular maintenance requirements and/or enter into a maintenance agreement with a Service
Centre to protect the operation of the unit.
If damage or a system failure occurs due to improper maintenance during the warranty period, manufacturer shall not be liable for costs incurred to return the unit to satisfactory condition.
This maintenance section applies only to the basic
RLC unit and may, on individual contracts, be supplemented by additional requirements to cover any
modifications or ancillary equipment as applicable.
Daily
Unless otherwise indicated, the maintenance operations described below can be performed by any
properly trained maintenance technician.
Check evaporator leaving
liquit temperature
Check heat evaporator
pressure drop
Check electrical power
consumption
Check suction pressure
and temperature
Check discharge pressure
and temperature
Check compressor
oil level
Check for gas bubbles
in refrigerant
Check finned coil cleanliness
Check oil heater
efficiency
Check Remote
Control Unit
Check low pressure
switch
Check high pressure
switch
Check diff. oil pressure
switch
Check heat exchanger
insulation
Check clamp tightness
Check terminal screw
tightness
Clean outside surface
with soapy water
Straighten coil fins
Check density of any
circulating brine
Drain evaporator of add
antifreeze
End of Season
Never discard used compressor oil, as
it contains refrigerant in solution. Return used oil to the oil manufacturer.
The Safety Section of this manual
should be read carefully before attempting any maintenance operation on the
unit.
The maintenance checks should be carried out in
accordance with the maintenance schedule detailed
below by a competent person. Please note, however, that RLC series units are not generally user serviceable and no attempt should be made to rectify
faults or problems found during daily checks. If in
any doubt, contact an Authorised Service Centre.
Start of Season
WARNING
Never release refrigerant to the atmosphere when emptying the refrigerating
circuit. Suitable retrieval equipment
must be used. If reclaimed refrigerant
cannot be re-used. It must be returned
to the manufacturer.
7.2 Daily Maintenance
Monthly
WARNING
MAINTENANCE
Weekly
7
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
35
7.3 Refrigerant Charge
CAUTION
Never introduce liquid refrigerant in the low
pressure side of circuit. Extreme care must
be taken to ensure that circuit is correctly
charged.
An insufficient charge will lead to poor machine
performance. In extreme cases, the low pressure
switch will cut in and lock the circuit.
Excessive charge will raise the condensation pressure (which in extreme cases will cause the high
pressure switch to cut in and lock the circuit) with a
consequent increase in power consumption.
Under no circumstances must the compressor be used as a vacuum pump to purge circuit.
CAUTION
The refrigerant circuit must be charged whenever it
is emptied for maintenance purposes (leak repair,
compressor replacement, etc.). Charge quantities
are given in Section 9.
Before charging, the ci rcuit must be vacuum-purged and dried, reaching a minimum absolute pressure of 50 Pa.
The refrigerant gas must be introduced to eliminate
vacuumand to charge the circuit to 90% of the total
required gas in liquid formthrough the appropriate
charging valve on liquid line at condenser outlet.
A refrigerant container should then be connected to
the charging valve on suction line, the container
should be held so that only gaseous phase refrigerant is released.
The compressor should be started and gas allowed
to flow from the refrigerant container until liquid in
the sight glass runs clear and gas temperature at
evaporator outlet has stabilised at around 5°C.
36
7.4 Refrigerant Circuits
Each RLC Series unit is equipped with two fully independent refrigerating circuits. Units are equipped
with a single tube bundle evaporator with two separate circuits on refrigerant side and a single circuit
on water side.
7.5 Compressors
Compressors are supplied with the correct quantity
of lubricant required for operation. Under normal
operating conditions, refrigerant charge and lubricant will last the life of the machine. Fluid top-up is
not required as long as refrigerating circuit operates
correctly and no repair operations have been carried out.
Should it be necessary to replace compressor (e.g.
as a result of winding burnout or mechanical failure), contact an authorised ServiceCentre.
CAUTION
RLC models functioning with refrigerant
R407C and R134a employ compressors
charged with polyester oils. During compressor maintenance, or the opening of
any part of the refrigerant circuit, remember that this oil is extremely hydroscopic,
and, therefore, avoid long exposure to the
ambient air, which would require that the
complete oil charge be replaced.
7.6 Condenser Coils
7.8 Filter Drier
Condenser coils feature copper tubes and aluminium fins. Should refrigerant leakage take place as
a result of accidental impact or damage. The coils
must only be repaired or replaced by an Authorised
Service Centres.
Refrigerating circuits are provided with filter/driers.
To ensure high condenser coil serviceability and
heat exchange, the condenser surfaces must be
kept free of impurities such as leaves, fibres, insects, dirt etc. Soiled condenser coils will increase
power consumption. In addition, the maximum
pressure alarm may cut in and lock out the unit.
Filter/drier clogging will be indicated by bubbles in
the sight glass, or by a difference in temperature
upstream and downstreamof filter/drier.
Take care not to damage aluminium fins
during cleaning.
The filter/driers are inspectable cartridge type on
models 210/800, and non-inspectable strainer type
on smaller units.
If bubbles persist after changing cartridge, the machine has lost part of its refrigerant charge through
one or more leaks which must be identified and repaired.
7.9 Sight Glass
CAUTION
The condenser should be cleaned using compressed air directed parallel to aluminium fins and in the
opposite direction to that of normal air circulation. A
vacuum cleaner may be used to clean the condenser coil from outside. The coil may also be cleaned
with soapy water using a suitable spray nozzle.
7.7 Condenser Fans
The sight glass is used to observe refrigerant flow
and moisture content. Bubbles in flow indicate that
filter/drier (where provided) is clogged, or that refrigerant charge is low.
A colour indicator is located inside the sight glass.
Compare the colour of the indicator with the scale
on the sight glass lock ring to determine the moisture content of refrigerant. If moisture content is too
high, proceed as follows:
Each condenser fan features a wing-profile impeller
and cylindrical nozzle. The fan motor bearings are
lubricated for life.
For machines with hermetic compressors, discharge the circuit without releasing refrigerant to the atmosphere. Vacuum-purge the circuit and replenish
the charge.
Ensure that fans rotate in the direction indicated by
arrowbefore starting machine following repair work
involving 3-phase disconnection (air flow up
wards).
For machines with semi-hermetic compressors,
change the filter cartridge, operate the unit for one
day and check the moisture content again.
If fan rotation is not correct, disconnect and invert
two of the three phases supplying the motor.
No further action is required if the moisture content
returns to normal. If the moisture content is still too
high, change the filter/drier again, start the unit and
operate for a further day.
37
7.10 Thermostatic Expansion Valve
7.11 Evaporator
RLC refrigerating circuits are provided with a thermostatic expansion valve with an external equaliser. Valves are calibrated at the factory for a 5°C
temperature rise.
Check the heat exchanger water side for cleanliness at regular intervals. This may be accomplished by checking water side pressure drop (refer to
Section 9) or simply by checking the fluid temperatures at heat exchanger inlet and outlet and comparing them with evaporation temperatures.
To check the temperature rise:
Read the suction pressure on the units gauge panel
or on a pressure gauge connected to charging valve on suction side.
Using the pressure gauge temperature scale, determine the saturated suction temperature Tsa corresponding to this pressure.
Determine the effective suction temperature Tse
using a contact thermometer applied to the evaporator gas outlet fitting.
Temperature rise S is given by:
S = Tse - Tsa
The temperature rise can be corrected using the
adjuster screw on the thermostatic expansion valve. Turn the adjuster screw through a single revolution and operate the unit for five minutes. Then
check the temperature rise again and correct as necessary.
If the thermostatic expansion valve does not react
to temperature rise calibration, it is probably malfunctioning and must be replaced. Valve replacement must be performed by an authorised Service
Centre.
38
For effective heat exchange, the water outlet temperature and the saturated evaporation temperature should differ by 5 to 7°C. A larger difference indicates that the heat exchanger is operating inefficiently, and is thus soiled.
If soiled, the heat exchanger must be chemically cleaned by authorised Itelco-Clima service personnel.
For other types of service (special maintenance,
heat exchanger replacement, etc.), contact an
authorised Service Centre.
8
TROUBLE SHOOTING
The following table details possible unit faults, their probable cause and suggested remedies. For any
other problems not immediately recognisable and/or for technical assistance, call an Authorised Service
Centre.
Fault
Probable Cause
Remedy
Differential oil pressure switch
cuts on, break circuit
Defective differential pressure
switch operation.
Check switch operation, replacing if necessary.
Low oil level as a result of circuit
leakage.
Determine location of leak and
repair.
Start up with cold oil.
Check oil heater operation.
Compressor lube circuit malfunction.
Call an Authorised Centre.
Low refrigerant charge.
Top up charge.
Drier/filter clogged.
Replace drier/filter
Loss of efficiency in one or both
circuits.
Check compressor valves, replacing if necessary (semi-hermetic
compressor only).
Temperature rise of thermostatic
valve out of calibration.
Increase setting.
Unit operates continuously, but
without cooling.
Suction line freezes.
Check charge.
Excessive noise.
Vibrating lines.
Secure lines.
Check line retention.
Thermostatic expansion valve
hiss.
Top up charge.
Check filter/drier, replacing if necessary.
Noisy compressor.
Check condition of valves.
Bearings have seized; replace
compressor.
Check that compressor retaining
nuts are tight.
Low compressor oil level.
One or more gas or oil leaks in
circuit
Identify and eliminate all leaks
Mechanical damage to compressor.
Call an Authorised Service Centre
Faulty crankcase oil heater.
Check electrical circuit and
crankcase heater element operation, replacing any defective
components.
39
Fault
Probable Cause
Remedy
One or both compressors not
working.
Power circuit interrupted.
Check power circuit for earth
leakage and shorts.
Check fuses.
High pressure switch activation.
Reset pressure switch from panel and re-start machine.
Identify and eliminate causes of
pressure switch activation.
Control circuit fuse blown
Check control circuit for earth
leakage and shorts.
Change fuses.
Loose terminal clamps.
Check clamp tightness.
Power circuit thermal overload
cut-out activation.
Check operation of control and
safety devices.
Identify and eliminate cause of
activation.
Incorrect wiring.
Check control and safety device
wiring.
Line voltage too low.
Check line voltage. If problem
due to system, eliminate it.
If problem is due to distribution
network, inform the electricity
supply company.
Compressor motor short-circuited.
Check motor winding continuity.
Compressor seizure
Replace compressor.
Gas leakage.
Identify and eliminate leakage.
Insufficient charge.
Top up charge.
Pressure switch failure.
Replace pressure switch.
High pressure switch malfunction.
Check switch operation, replacing if necessary.
Delivery valve partially closed.
Open valve, replacing if necessary.
Non-condensables in circuit.
Purge circuit.
Condenser fan(s) inoperative.
Check wiring and motors. Repair
or replace if necessary.
Liquid line too hot.
Insufficient charge.
Identify and eliminate causes of
charge loss and top up charge.
Liquit line freezes
Liquid line valve partially closed.
Check that all valves are open.
Receiver/drier clogged.
Replace cartridge.
Low pressure switch cuts in,
braking circuit.
High pressure switch cuts in,
braking circuit.
40
9
TECHNICAL DATA
9.1 Pressure Drop Graphs
PRESSURE DROP (kPa)
RLC-A & RLC-B All Models - Evaporator
FLOW RATE (l/s)
41
PRESSURE DROP (kPa)
RLC-A R/P Models – Heat Recovery Condenser
FLOW RATE (l/s)
Note: R Models - Pressure drop is for each Condenser
42
PRESSURE DROP (kPa)
RLC-A /D Models - Desuperheater
FLOW RATE (l/s)
Note: Pressure drop is for each Desuperheater
9.2 Safety Switch Settings
RLC-A & RLC-B All Models
Model
210
240
300
360
400
450
Low Pressure Switch
bar
0,4 (0,2)(2)
High Pressure Switch
bar
28 (22)(2)
TUV High Pressure Switch(1)
bar
25
0,8
Oil Pressure Switch
bar
Anti Freezing Thermostat
°C
Safety Valve
bar
525
600
700
800
3
None
24
Nota: 1 Also heat recovery, heat pump in the winter mode
2 RLC-A models
43
9.3 Operational Limits
RLC-B All models
210
Model
Evaporator
Water Outlet
Temperature
Evaporator
(Water)
15
6
15
Brine Outlet
°C
-5
15
-5
15
°C
l/s
3
1,5
8
10
3
2,3
8
10
kPa
7,5 to 85
bar
10
°C
-5 to 48
°C
-20 to 48
Standard Unit
Pa
0
Units with
Speed Control
Pa
0
Pa
100
Units with High
Pressure Fans
Power Supply Voltage 400 V, 3 Ph, 50 Hz
Recommended System Water Volume(1)
V
l
342 to 462
1250
300
Model
Evaporator
(Water)
450
525
600
700
800
°C
6
15
6
15
5
15
5
15
5
15
5
15
5
15
5
15
Brine Outlet
°C
-5
15
-5
15
-5
15
-5
15
-5
15
-5
15
-5
15
-5
15
°C
l/s
3
4
8
16
3
4
8
3
8
3
8
16 5,2 22 5,8 25
3
7
8
28
3
8
8
33
3
10
8
42
3
11
8
48
Maximum Pressure
Water/Brine Side
Standard Unit
Air on
Temperature
Unit with
Condenser
Speed Control
kPa
7
bar
10
°C
-10 to 48
-5 to 46
-10 to 46
°C
-20 to 48
-20 to 46
-20 to 46
Standard Unit
Pa
0
Unit with
Speed Control
Pa
0
Pa
100
Units with High
Pressure Fans
Power Supply Voltage 400 V, 3 Ph, 50 Hz
Recommended System Water Volume(1)
V
l
1350
1600
Note: 1 Table shows minimum water/brine volume of the primary water system
44
400
Water Outlet
Temperature Spread
Flow Rate Water/Brine
Maximum
External
Static
Pressure
360
1500
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
Pressure Drop Water/Brine
Condenser
(Air)
Max.
6
Maximum Pressure
Water/Brine Side
Standard Unit
Air on
Temperature
Units with
Condenser
Speed Control
Evaporator
Water Outlet
Temperature
Min.
°C
Temperature Spread
Flow Rater Water/Brine
Maximum
External
Static
Pressure
Max.
Water Outlet
Pressure Drop Water/Brine
Condenser
(Air)
240
Min.
2050
342 to 462
2450
2850
3250
3900
4480
RLC-A All Models
210
Model
Evaporator
Water Outlet
Temperature
Evaporator
(Water)
RLC-A/R/P
Desuperheater
RLC-A/D
15
5
15
Brine Outlet
°C
-10
15
-10
15
°C
l/s
3
2,3
8
10
3
2,3
8
10
kPa
7,5 to 85
bar
10
°C
-5 to 48
°C
-20 to 48
Standard Unit
Pa
0
Units with
Speed Control
Pa
0
Pa
100
°C
°C
35 to 50
3 to 10
°C
40 to 70
Units with High
Pressure Fans
Water Outlet
Temperature Spread
Water Outlet
Power Supply Voltage 400 V, 3 Ph, 50 Hz
Recommended System Water Volume(1)
V
l
Evaporator
(Water)
RLC-A/R/P
Desuperheater
RLC-A/D
400
450
525
Max.
Min.
Max.
Min.
Max.
Min.
Max.
Min.
Max.
5
15
5
15
5
15
5
15
5
15
Brine Outlet
°C
-10
15
-10
15
-10
15
-10
15
-10
15
°C
l/s
3
4
8
16
3
4
8
16
3
4
8
16
3
4
8
16
3
4
8
16
kPa
7,5 to 85
bar
10
°C
-10 to 48
°C
-20 to 48
Standard Unit
Pa
0
Units with
Speed Control
Pa
0
Pa
100
°C
°C
35 to 50
3 to 10
°C
40 to 70
Maximum Pressure
Water/Brine Side
Standard Unit
Air on
Temperature
Units with
Condenser
Speed Control
Condenser
HRC
360
Min.
°C
Temperature Spread
Flow Rate Water/Brine
Maximum
External
Static
Pressure
1500
Water Outlet
Pressure Drip Water/Brine
Condenser
(Air)
342 to 462
1250
300
Model
Evaporator
Water Outlet
Temperature
Max.
5
Maximum Pressure
Water/Brine Side
Standard Unit
Air on
Temperature
Units with
Condenser
Speed Control
Condenser
HRC
Min.
°C
Temperature Spread
Flow Rate Water/Brine
Maximum
External
Static
Pressure
Max.
Water Outlet
Pressure Drop Water/Brine
Condenser
(Air)
240
Min.
Units with High
Pressure Fans
Water Outlet
Temperature Spread
Water Outlet
Power Supply Voltage 400 V, 3 Ph, 50 Hz
Recommended System Water Volume(1)
V
l
1350
1600
342 to 462
2050
2450
2850
Note: 1 Table shows minimum water/brine volume of the primary water system
45
9.4 Physical Data
RLC-B 210 - 240
Model
210
Type
Circuit 1
Theoretical
Displacement
m3/h
107
Compressor
Evaporator
Theoretical
Displacement
Quantity
Number of Cylinders
Revs. per Minute
Oil Charge per
Compressor
Number of Loading Stages
Quantity
Type (Direct Expansion)
Number of Refrigerant Circuits
Water Volume per
Evaporator
Refrigerant Volume
Face Area
Air Cooled
Condenser
Note: 1 Per condenser
46
m3/h
107
127
rpm
2
6
1450
2
6
1450
dm3
7,4
7,7
100/50
1
100/50
1
Shell and Tube
l
dm
m2
3
Number of Rows
Fan Diameter
Number
Fans
Power Input at 890 rpm
Air Flow Rate
Refrigerant Charge R 407C
Operational Weight Aluminium Fins
Shipping Weight
Copper/Copper Coils
RLC/R
Additional
Weight
RLC/P
RLC/D
Length
Width
Dimensions
Height
127
semi-hermetic
Type
Circuit 2
240
semi-hermetic
mm
kW
m3/s
kg
kg
kg
kg
kg
kg
kg
mm
mm
mm
2
2
33
33
16,7
8,3
16,7
8,3
2
3
710
6
0,9
24
2 x 15
1780
1740
344
190
95
40
4040
2040
1730
710
6
0,9
22
2 x 21
1890
1850
344
200
100
50
4040
2040
1730
RLC-B 300 - 800
Model
300
360
400
450
525
semi-hermetic
600
700
800
151
180
202
180
180
180
180
Type
Circuit 1
Theoretical
Displacement
m3/h
semi-hermetic
Type
Circuit 2
Compressor
Theoretical
Displacement
Quantity
Number of Cylinders
Revs. per Minute
Oil Charge per
Compressor
m3/h
151
180
210
243
284
324
406
464
rpm
2
8
1450
2
8
1450
2
8
1450
2
6
1450
2
7
1450
2
8
1450
2
7
1450
2
8
1450
dm3
7,7
7,7
7,5
20
20
20
20
20
100-50
100-50
1
1
100-75
50-25
1
100-75
50-25
1
100-75
50-25
1
100-75
50-25
1
2
55
27,4
11
2
55
27,4
11
2
87
38,9
16
2
125
60
16
2
222
80
20
2
206
92,3
24,6
2
3
2
3
3
4
4
4
710
8
0,9
32
2 x 21
2430
2380
258
250
115
50
5040
2040
1730
710
8
0,9
30
2 x 30
2570
2520
389
250
125
60
5040
2040
1730
800
6
1,5
35
2 x 33
4500
4400
700
600
200
150
4860
2240
2225
800
6
1,5
34
2 x 40
4800
4700
700
800
400
200
4860
2240
2225
800
8
1,5
44
2 x 44
5200
5100
700
800
400
200
4860
2240
2225
800
8
1,5
43
2 x 50
5600
5500
736
800
400
200
4860
2240
2225
800
10
1,5
53
2 x 63
6640
6450
700
660
400
200
6100
2260
2250
800
12
1,5
64
2 x 74
7050
6900
700
660
400
200
7100
2260
2250
Number of Loading Steps
Evaporator
Quantity
Type (Direct Expansion)
Number of Refrigerant Circuits
Water Volume per Evaporator
Refrigerant Volume
Face Area
Air Cooled
Condenser
dm3
dm3
m2
Number of Rows
Fan Diameter
Number
Fans
Power Input at 890 rpm
Air Flow Rate
Refrigerant Charge R 407C
Operational Weight Aluminium Fins
Shipping Weight
Copper/Copper Coils
RLC/R
Additional
Weight
RLC/P
RLC/D
Length
Dimensions
Width
Height
180
mm
kW
m3/s
kg
kg
kg
kg
kg
kg
kg
mm
mm
mm
100-75 100-75
50-25
50-25
1
1
Shell and Tube
2
2
80
133
44,8
52,9
16
16
Note: 1 Per condenser
47
RLC-A 210 - 525
Model
210
240
300
360
semi hermetic
400
450
525
151
181
210
284
348
406
464
Type
Circuit 1
Theoretical
Displacement
m3/h
Type
Circuit 2
Compressor
Theoretical
Displacement
Quantity
Number of Cylinders
Revs. per Minute
Oil Charge per
Compressor
semi hermetic
m3/h
Evaporator
Air Cooled
Condenser
Note: 1 Per condenser
48
210
284
348
406
464
2
2
8
1450
2
8
1450
2
7
1450
2
6
1450
2
7 8
1450
rpm
1450
l
7,7
7,7
7,5
23
20
20
20
100
50
1
ED 135
2
100
50
1
ED 135
2
100
50
1
ED 220
2
100
50
1
ED 220
2
100-75
50-25
1
ED 310
2
100-75
50-25
1
ED 360
2
100-78
50-28
1
ED 420
2
l
33
33
48
48
80
95
115
dm3
m2
16,7
8,3
16,7
8,3
27,4
11
27,4
11
38,9
16
44,8
16
52,9
16
2
3
2
3
2
3
3
710
6
0,9
24
710
6
0,9
22
710
8
0,9
32
800
6
1,5
35
800
6
1,5
35
800
6
1,5
34
800
8
1,5
44
Number of Rows
Fan Diameter
Number
Fans
Power Input at 890 rpm
Air Flow Rate
Heat
RLC-A/R/P
Recovery
/R 2 Condenser
Condenser
/P 1 Condenser
Water Volume(1)
Refrigerant Volume(1)
RLC-A/D
Desuperheater
Refrigerant Volume
Refrigerant Charge R 134A
Operational Weight Aluminium Fins
Shipping Weight
Copper/Copper Coils
RLC-A/R
Additional
Weight
RLC-A/P
RLC-A/D
Length
Dimensions
Width
Height
181
2
8
1450
Number of Loading Stages
Quantity
Type (Direct Expansion)
Number of Refrigerant Circuits
Water Volume per
Evaporator
Refrigerant Volume
Face Area
151
mm
kW
m3/s
Type
l
dm3
Type
dm3
kg
kg
kg
kg
kg
kg
kg
mm
mm
mm
Shell and Tube
9,4
12,1
23,4
32,3
Shell and Tube
2 x 15
2004
1944
344
190
95
40
4040
2040
1730
2 x 21
2114
2064
344
200
100
50
4040
2040
1730
2 x 21
2430
2360
258
250
115
50
5040
2040
1730
2 x 30
5380
5280
389
250
125
60
4860
2240
2225
2 x 34
5650
5550
700
600
200
150
4860
2240
2225
2 x 40
5700
5600
700
800
400
200
4860
2240
2225
2 x 45
5880
5780
700
800
400
200
4860
2240
2225
9.5 Total Unit Electrical Data
RLC-A All Models
Model
Current
Input
(A)
Power
Input
(kW)
210
240
300
360
400
450
525
Nominal
114
140
128
175
203
241
273
Maximum(2)
128
162
160
229
257
311
347
Nominal(1)
53
65
73
95
115
134
140
Maximum(2)
65
79
89
119
145
169
194
322
387
340
424
438
569
590
(1)
Maximum Starting
Current (A)
Nota: 1 Nominal conditions 7°C chilled water outlet temperature, 35°C ambient temperature
2 Maximum condition at 14°C chilled water outlet temperature, 45°C ambient temperature
Table applicable to units with standard fans
RLC-B All Models
Model
Current
Input
(A)
Power
Input
(kW)
210
240
300
360
400
450
525
600
700
800
116
136
158
184
205
219
261
293
361
417
Maximum
138
160
190
218
255
267
323
373
439
503
Nominal(1)
59
69
82
96
113
121
144
162
199
230
Maximum(2)
77
87
101
119
137
147
170
192
239
274
237
270
354
418
467
568
734
759
947
982
Nominal(1)
(2)
Maximum Starting
Current (A)
Nota: 1 Nominal conditions 7°C chilled water outlet temperature, 35°C ambient temperature
2 Maximum condition at 14°C chilled water outlet temperature, 45°C ambient temperature
Table applicable to units with standard fans
49
9.6 Compressor Electrical Data
RLC-A All Models
Power Input
per
Compressor(1)
(kW)
Current per
Compressor(1)
(A)
Power Input
per
Compressor(2)
(kW)
Current per
Compressor(2)
(A)
Starting
Current(3)
(A)
Fuse
Size(4)
Model
Circuit
Voltage(5)
(V)
210
1+2
400
24
51
30
60
250
200
240
1+2
400
30
64
37
75
300
200
300
1+2
400
32
56
41
72
252
200
360
1+2
400
43
79
55
106
301
250
400
1+2
400
53
93
68
120
301
315
450
1+2
400
61
112
80
147
405
400
525
1+2
400
70
125
91
162
405
400
Nota: 1
2
3
4
5
Nominal conditions at 7°C chilled water outlet temperature, 35°C ambient temperature
Maximum condition at 14°C chilled water outlet temperature, 45°C ambient temperature
Compressors Starting, Part Winding
Fuse sizes stated are maximum values, smaller sizes may be used if applicable
Minimum allowable supply voltage 342 Volts
RLC-B All Models
Model
Circuit
Voltage(5)
(V)
Power Input
per
Compressor(1)
(kW)
Current per
Compressor(1)
(A)
Power Input
per
Compressor(2)
(kW)
Current per
Compressor(2)
(A)
Starting
Current(3)
(A)
Fuse
Size(4)
210
1+2
400
27
52
34
63
161
200
240
1+2
400
32
62
39
74
183
200
300
1+2
400
38
70
47
87
250
250
360
1+2
400
45
84
56
101
300
250
400
1+2
400
52
94
64
119
329
250
450
1+2
400
56
101
69
125
424
315
525
1+2
400
66
119
79
150
559
400
600
1+2
400
75
135
90
175
559
400
700
1+2
400
92
166
112
205
711
500
800
1+2
400
106
191
128
234
711
500
Nota
50
1
2
3
4
5
Nominal conditions at 7°C chilled water outlet temperature, 35°C ambient temperature
Maximum condition at 14°C chilled water outlet temperature, 45°C ambient temperature
Compressors Starting, Part Winding
Fuse sizes stated are maximum values, smaller sizes may be used if applicable
Minimum allowable supply voltage 342 Volts
9.7 Fan Electrical Data
RLC-A All Models
Model
RLC-A 210-300
RLC-A 360-525
Nominal Power
(kW)
0,9
1,5
Standard fans
Max Running
Current (A)
1,95
2,9
Max Starting
Current (A)
5,9
8,8
Nominal Power
(kW)
2,9
4,7
High Pressure Fans
Max Running
Current (A)
4,8
8,7
Max Running
Current (A)
7,6
28
Nominal Power
(kW)
0,9
1,5
Standard fans
Max Running
Current (A)
1,95
2,9
Max Starting
Current (A)
5,9
8,8
Nominal Power
(kW)
2,9
4,7
High Pressure Fans
Max Running
Current (A)
4,8
8,7
Max Running
Current (A)
7,6
28
RLC-B All Models
Model
RLC-B 210-360
RLC-B 400-800
51
9.8 Sound Power Levels
RLC-A All models
Model
210
240
300
360
400
450
525
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
125
90
78
91
78
92
78
91
80
93
83
93
86
96
87
250
93
81
92
85
96
87
95
87
96
91
96
90
99
93
500
95
87
95
88
97
92
99
94
98
94
98
94
101
95
Octave Band (Hz)
1000
90
83
90
84
91
85
93
84
94
87
94
88
95
89
2000
86
77
85
77
88
77
84
77
86
77
86
74
86
75
4000
75
67
80
69
79
69
80
70
78
67
78
67
79
68
8000
69
57
70
58
70
59
71
60
73
67
73
67
74
68
2000
86
77
84
76
88
76
84
76
85
76
85
74
86
78
88
85
88
78
89
88
4000
75
67
80
69
79
69
80
70
78
67
78
67
79
68
81
77
81
72
82
74
8000
69
57
70
59
70
59
71
60
73
67
73
67
74
68
75
70
75
68
76
71
Total dB(A)
95
87
95
88
97
90
98
92
98
93
98
93
100
94
Nota: Reference data with machine operating at nominal condition 12°/7°C chilled water
1 > 38°C ambient RLC-A (Standard Version)
2 < 25°C ambient RLC-A/Q (Quiet Version)
Tolerance +/- 2 dB(A)
RLC-B All Models
Model
210
240
300
360
400
450
525
600
700
800
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
125
90
78
91
78
92
78
91
80
93
83
93
86
96
87
94
87
96
87
97
88
250
92
83
93
83
95
87
95
86
96
88
96
88
98
90
97
91
98
92
99
92
500
95
87
95
88
97
89
96
90
98
90
98
91
100
92
100
93
101
95
102
95
Octave Band (Hz)
1000
91
83
92
84
91
86
94
86
94
89
94
90
96
90
96
90
97
92
98
92
Nota: Reference data with machine operating at nominal condition 12°/7°C chilled water
1 > 38°C ambient RLC-A (Standard Version)
2 < 25°C ambient RLC-A/Q (Quiet Version)
Tolerance +/- 2 dB(A)
52
Total dB(A)
95
87
95
88
97
89
97
90
98
91
98
92
100
93
100
94
101
95
102
96
9.9 Dimension, Weight and Isolator Data
RLC-A All Models
RLC-A 300
RLC 210-240; 400-600
RLC-A 60-150
Compressor/
Control panel
Top view
Centre of
gravity
Model
Dim.
X
Y
A
B
C
D
Z
Pos.
1 and 2
3 and 4
5 and 6
7 and 8
9 and 10
210
240
1550
140
790
1468
1500
1550
140
790
1468
1500
1930
1930
2004
2114
231
366
265
140
251
376
280
150
300
360
Dimensions (mm)
2060
1860
140
140
790
790
1468
2342
1710
1277
790
1930
2090
Overall Weight (kg)
2430
5380
Weight Distribution (kg)
245
619
365
667
265
540
220
464
120
400
450
525
1880
232
783
2342
1277
1890
232
783
2342
1277
1940
232
783
2342
1277
2090
2090
2090
5650
5700
5880
668
667
580
490
870
890
580
510
860
896
625
540
53
RLC-B All Models
RLC-B 300-360; 700-800
RLC-B 210-240; 400-600
RLC-B 60-150
Compressor/
Control panel
Top view
Centre of
gravity
Model
Dim.
X
Y
A
B
C
D
Z
Pos.
1 and 2
3 and 4
5 and 6
7 and 8
9 and 10
54
210
240
300
1680
140
790
1468
1500
1670
140
790
1468
1500
1930
1930
2060
140
790
1468
1710
790
1930
1780
1890
2430
175
310
265
140
195
320
280
150
245
365
265
220
120
360
400
450
Dimensionis (mm)
2060
1980
1980
140
232
232
790
783
783
1468
2342
2342
1710
1277
1277
790
1930
2090
2090
Overall Weight (kg)
2570
4500
4800
Weight Distribution (kg)
260
585
636
385
762
805
280
496
515
230
407
444
130
525
600
700
800
1970
232
783
2342
1277
1990
232
783
2342
1277
2090
2090
2680
235
1179
1663
1440
1350
2090
3030
235
1179
1850
2160
1500
2090
5200
5600
6640
7050
725
832
567
476
776
880
631
513
720
830
740
555
475
800
835
770
600
520
SPRING ISOLATOR TABLE KIT
Kit Code
462B26050-210
462B26050-240
462B26050-300
462B26050-360
462B26050-400
462B26050-450
462B26050-525
462B26050-600
462B26050-700
462B26050-800
462B26150-210
462B26150-360
462B26150-400
462B26150-450
462B26150-525
462B26150-600
462B26200-210
462B26200-240
462B26200-300
462B26200-360
462B26200-400
462B26200-450
462B26200-525
462B26200-600
462B26200-700
462B26200-800
462B26300-210
462B26300-240
462B26300-300
462B26300-360
462B26300-400
462B26300-525
462B26350-210
462B26350-300
462B26350-360
462B26350-400
462B26350-450
462B26350-525
462B26100-210
462B26100-240
462B26100-300
462B26100-360
462B26100-400
462B26100-450
462B26100-525
462B26100-600
462B26100-700
462B26100-800
462B26400-210
462B26400-240
462B26400-300
462B26400-360
462B26400-400
462B26400-525
Chiller
R407C
210
240
300
360
400
450
525
600
700
800
Chiller/H
R22
SPRING ISOLATOR CODE
Standard Coil Al/Cu
Chiller
Chiller/H
R134A
R134A
Chiller/R
R134A
Standard Coil Cu/Cu
Chiller
R134A
240
300
210
360
400
450
525
600
210
240
300
360
400/450
525
210
240
210/240
300
360
400
450
525
210
240
300
360
400/450
525
55
9.10 Piping and Instrumentation Diagrams
RLC, RLC-A and RLC-B Models 210 to 240
56
RLC-A and RLC-B Models 300 to 360
57
RLC-A and RLC-B Models 400 to 450
58
RLC-A Model 525 and RLC-B Models 525 to 800
59
9.11 General Arrangements
RLC-A and RLC-B Models 210 to 240
1785
60
RLC-A and RLC-B Model 300 and RLC, RLC-B Model 360
61
RLC-A Model 360 and RLC and RLC-B Models 400 to 450
62
RLC-A Model 525 and RLC-B Models 525 to 600
63
RLC-B Model 700
64
RLC-B Model 800
65
10
SPARE PARTS
10.1 Recommended Spares
The table below lists the recommended spares for one unit for 2 years
Components
HP Switch
LP Switch
Differential Oil Pressure Switch
Gas Filter
Thermostatic Valve
Auxiliary Relays
Fan fuses
Compressor Fuses
Auxiliary Fuses
Compressor Contactor
Fan Contactor
Power Contactor
Sensor L4000
Sensor SS 100
Pressure Transducer
EPROM
Electronic Board
Keyboard
Flat Cable
Qty.
1
1
1
2
1
2
6
6
6
1
1
1
1
1
1
1
1
1
1
10.2 Recommended Compressor Oils
The table below lists the recommended oil type for each unit
Versione
RLC 210 to 360
RLC 400 to 800
RLC-A 210 to 240
RLC-A 300 to 360
RLC-A 400 to 525
RLC-B 120 to 360
RLC-B 400 to 800
Tipo d’olio
3GS
22A
325C
685
22A
685
10.3 Wiring Diagrams
Wiring diagrams are fitted on control panel door.
Other requests for wiring diagrams have to be required to Service Centre.
66
Marca
Wiltco Suniso
ABC
Mobile Arctic
ICI Emkerate
ICI Emkerate
Mobile Arctic
ICI Emkerate
11
WARNING
DE-COMMISSIONIG,
DISMANTLING AND DISPOSAL
Never release refrigerant to the atmosphere when emptying the refrigerating
circuits. Suitable retrieval equipment
must be used. If reclaimed refrigerant
cannot be re-used. It must be returned
to the manufacturer.
Never discard used compressor oil, as
it contains refrigerant in solution. Return used oil to the oil manufacturer.
WARNING
Unless otherwise indicated, the operations described below can be performed by any properly trained maintenance technician.
11.1 General
Isolate all sources of electrical supply to the unit including any control system supplies switched by the
unit. Ensure that all points of isolation are secured
in the ‘OFF’ position. The supply cables may then
be disconnected and removed. For connection
points refer to Section 4.
Remove all refrigerant from each system of the unit
into a suitable container using a refrigerant reclaim
or recovery unit. This refrigerant may then be reused, if appropriate, or returned to the manufacturer
for disposal. Under NO circumstances should refrigerant be vented to atmosphere. Drain the refrigerant oil from each system into a suitable container
and dispose of according to local laws and regulations governing the disposal of oily wastes. Any spilt
oil should be mopped up and similarly disposed of.
Isolate the unit heat exchanger(s) from all external
water systems and drain the heat exchanger section( s) of the system. If no isolation valves are installed it may be necessary to drain the complete
system(s).
WARNING
If glycol or similar solutions have been
used in the water system(s), or chemical additives are contained, the solution mUST be disposed of in a suitable
and safe manner. Under NO circumstances should any system containing
glycol or similar solutions be drained
directly into domestic waste or natural
water systems.
After draining, the water pipework can be disconnected and removed.
Packaged units can generally be removed in one
piece after disconnection as above. Any fixing down
bolts should be removed and then the unit should
be lifted from position using the points provided and
equipment of adequate lifting capacity.
Reference should be made to Section 4 for unit installation instructions, Section 9 for unit weights
and Section 3 for handling.
Units which cannot be removed in one piece after
disconnection as above, must be dismantled in position. special care should be taken regarding the
weight and the handling of each component. Where
possible units should be dismantled in the reverse
order of installation.
WARNING
Residual refrigerant oil and glycol or similar solutions may remain in some
parts of the system. These should be
mopped up and disposed of as described above.
It is important to ensure that whilst components are
being removed the remaining parts are supported
in a safe manner.
Only use lifting equipment of adequate
capacity.
WARNING
After removal from position the unit parts may be disposed of according to local laws and regulations.
67