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Air Cooled Water Chillers,Air-to-Water Reverse Cycle

Heat PumpsModels ALR / MHP 15P to 35P

IMW 935.1M/08.00Supersedes : IMW 935.1E/02.00

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Table of Contents

Introduction ................................................................................................................................................ p. 3

Safety Precautions ..................................................................................................................................... p. 3

General ....................................................................................................................................................... p. 4Presentation .............................................................................................................................................................. p. 4Inspection .................................................................................................................................................................. p. 4Technical Data .......................................................................................................................................................... p. 4Electrical Data ........................................................................................................................................................... p. 5Optional Hydronic Module Data ............................................................................................................................... p. 5Optional Centrifugal Fan Data .................................................................................................................................. p. 5

Dimensional Data - Standard Units ........................................................................................................... p. 6

Dimensional Data - Units with Centrifugal Fan Module ........................................................................... p. 7

Installation .................................................................................................................................................. p. 8Unit Handling ............................................................................................................................................................ p. 8Unit Placement .......................................................................................................................................................... p. 8Service Access .......................................................................................................................................................... p. 8Vibration Isolators ..................................................................................................................................................... p. 8Water Piping ............................................................................................................................................................. p. 9Flow Switch ............................................................................................................................................................... p. 9Refrigerant Charge ................................................................................................................................................... p. 10Glycol Solution .......................................................................................................................................................... p. 10Operating Limits ........................................................................................................................................................ p. 10Optional Hydronic Module ........................................................................................................................................ p. 10Water Pressure Drop Curves .................................................................................................................................... p. 11

Controls ...................................................................................................................................................... p. 12Temperature Controller ............................................................................................................................................. p. 12High Pressure Control .............................................................................................................................................. p. 12Low Pressure Control ............................................................................................................................................... p. 12Evaporator Heater Thermostat .................................................................................................................................. p. 12Antifreeze Thermostat ............................................................................................................................................... p. 12Head Pressure Control ............................................................................................................................................. p. 12Low Ambient Operation Kit ....................................................................................................................................... p. 12

Field Wiring ................................................................................................................................................ p. 13

Start-up ....................................................................................................................................................... p. 19Pre Start-up ............................................................................................................................................................... p. 19Start-up ...................................................................................................................................................................... p. 19Unit Operation ........................................................................................................................................................... p. 19

Service and Maintenance ........................................................................................................................... p. 20

Spare Parts List .......................................................................................................................................... p. 21In-Warranty Return Material Procedure ................................................................................................................... p. 21Service and Spare Parts Order ................................................................................................................................. p. 21

Troubleshooting Chart ............................................................................................................................... p. 22

Check List ................................................................................................................................................... p. 23

1 - Introduction

The purpose of this manual is to provide the installation, start-up, operating and maintenance rules to the users of air cooledwater chillers ALR / MHP 15P-35P.

It does not give a full description of all maintenance works assuring the long life and reliability of this type of equipment.Onlythe services of qualified personnel, member of a registered maintenance company, can guarantee a reliable and durablerunning of the machine.

2 - Safety Precautions

Before installing the unit, please read the following safety precautions carefully.

Warning

Installation and maintenance must be performed by qualifiedpersonnels who are familiar with local codes and regulationsand experienced with this type of equipment.

All field wiring must be installed in accordance with thenational wiring regulations.

Ensure the rated voltage of the unit corresponds to thename plate before carrying out wiring according to thewiring diagram.

The unit must be GROUNDED to prevent possible hazardsdue to insulation failures.

All wiring must not touch the hot refrigerant piping,compressor or any moving parts of fan motor.

Confirm the unit is switched OFF before installing orservicing the unit.

Handling of the unit must be done by using the systemsdesigned to support its weight.

Caution

Avoid access of non qualified and non authorized personsat the chiller installation site.

It is forbidden to undertake any work on electricalcomponents of the unit before disconnecting the powersupply.

It is forbidden to undertake any work on electricalcomponents of the unit, if there is presence of water andhumidity.

All works on piping and components of refrigerant circuitunder pressure must be only performed by authorized andqualified persons.

When undertaking water connection, make sure that anyforeign matters will not be introduced into water piping.

Strainer must be placed in the water lines just prior tothe inlets of water pump and evaporators.

Warning

Warning

Warning

Warning

Warning

Caution Caution

Caution

Caution

Caution

Caution

ALR Unit size 15P 18P 21P 25P 30P 35PNominal cooling capacity (1) kW 37 50 61 74 100 122

Nominal power input (1) kW 12.7 18.7 22.6 25.4 36.4 45.2

Number of refrigerant circuit 1 1 1 2 2 2

R22 charge kg 8.2 9.5 10.5 7.6 + 7.6 8.5 + 8.5 10 + 10

Compressors

Type / Number Herm. / 1 Herm. / 1 Herm. / 1 Herm. / 2 Herm. / 2 Herm. / 2

Number of capacity reduction steps (standard) 1 1 1 2 2 2

Number of capacity reduction steps (option) 2 2 N/A 4 4 N/A

Condenser fans and motors

Number / Fan diameter mm 2 / 630 2 / 630 2 / 710 3 / 630 3 / 630 3 / 710

Fan rotational speed rpm 630 840 660 630 840 650

Nominal power input (each) kW 0.40 0.70 0.70 0.40 0.70 0.70

Nominal air volume m3/h 14000 17200 22000 24000 26500 33000

Condenser coils

Number / Total face area m2 2 / 2.995 2 / 2.995 2 / 2.995 2 / 5.982 2 / 5.982 2 / 5.982

Fin spacing / Number of rows mm 2.5 / 2 2.5 / 3 2.5 / 3 2.5 / 2 2.5 / 3 2.5 / 3

Evaporators

Number 1 1 1 2 2 2

Water volume dm3 3.2 4.4 5.3 2 x 3.2 2 x 4.4 2 x 5.3

Nominal water flow (1) l/s 1.768 2.389 2.914 3.536 4.778 5.828

Water pressure drop at nominal flow kPa 33.0 34.0 35.7 33.0 34.0 35.7

Water connections

Inlet 1"1/2 1"1/2 1"1/2 2" 2" 2"

Outlet 1"1/2 1"1/2 1"1/2 2" 2" 2"

Weight

Shipping weight kg 369 388 458 697 741 782

Operating weight kg 380 399 468 708 751 853

3 - General

3.1 - Presentation

The air cooled water chillers ALR / MHP 15P-35P havebeen designed for outdoor installation and for reliable andefficient operation.

Each unit consists of hermetic compressors, insulatedevaporators, air cooled condensers, direct drive propeller fanswith hoseproof motors and electrical control panel includingall safety, control and operating devices.

Every unit is completely assembled, factory wired, chargedwith oil and refrigerant. Before shipping, the units are carefully

3.2 - Inspection

Check all items carefully against the bill of lading. Inspect allunits for damage upon arrival. Report shipping damage andfile a claim with the carrier.

Check the unit name plate before unloading, making certain itagrees with the power supply available. The manufactureris not responsible for physical damage after unit leaves thefactory.

(1) Data based on chilled water of 12/7 °C and ambient air of 35 °C.

3.3 - Technical Data

checked and tested in accordance with normal operatingconditions.

MHP Unit size 15P 18P 21P 25P 30P 35PNominal cooling capacity (1) kW 37 50 61 74 100 122Nominal power input (1) kW 12.7 18.7 22.6 25.4 36.4 45.2Nominal heating capacity (2) kW 38.2 54.7 67.5 77.0 109.5 135.1Nominal power input (2) kW 11.4 16.5 20.6 22.8 33.0 41.2Number of refrigerant circuit 1 1 1 2 2 2R22 charge kg 16 17 17 12 + 12 17 + 17 22 + 22CompressorsType / Number Herm. / 1 Herm. / 1 Herm. / 1 Herm. / 2 Herm. / 2 Herm. / 2Number of capacity reduction steps (standard) 1 1 1 2 2 2Number of capacity reduction steps (option) N/A N/A N/A N/A N/A N/ACondenser fans and motorsNumber / Fan diameter mm 2 / 630 2 / 710 2 / 710 3 / 630 3 / 710 3 / 710Fan rotational speed rpm 840 660 870 840 870 870Nominal power input (each) kW 0.70 0.70 1.40 0.70 1.40 1.40Nominal air volume m3/h 14000 17200 22000 24000 26500 33000Condenser coilsNumber / Total face area m2 2 / 2.975 2 / 2.975 2 / 2.975 2 / 5.952 2 / 5.952 2 / 5.952Fin spacing / Number of rows mm 2.1 / 3 2.1 / 3 2.1 / 3 2.1 / 2 2.1 / 3 2.1 / 3EvaporatorsNumber 1 1 1 2 2 2Water volume dm3 3.2 4.4 5.3 2 x 3.2 2 x 4.4 2 x 5.3Nominal water flow (heating mode) l/s 1.825 2.613 3.225 3.678 5.232 6.454Water pressure drop at nominal flow kPa 35.2 40.7 43.8 35.7 40.8 43.8Water connectionsInlet 1"1/2 1"1/2 1"1/2 2" 2" 2"Outlet 1"1/2 1"1/2 1"1/2 2" 2" 2"WeightShipping weight kg 409 428 498 737 781 882Operating weight kg 420 429 507 749 794 895

3.4 - Electrical Data

3 - General (cont’d)

3.5 - Optional Hydronic Module Data

Notes: 1) Tolerance on supply voltage: ± 10 %. 2) All current values given in the table above are at standard voltage.

(1) The pump is adjusted for operation in cooling mode; in heating mode, the water DT will be changed and will be obtained with the followingformula : DT = Heating capacity (kW) / [4.186 x Chilled water flow (l/s)].

1) Data based on chilled water temperature of 12 / 7 °C and ambient air temperature of 35 °C.2) Data based on hot water temperature of 40 / 45 °C and ambient air temperature of 7 °C.

ALR / MHP Unit Size 15P 18P 21P 25P 30P 35PStandard voltage (V / ph / Hz)Maximum current A 31.0 42.1 52.1 63.2 82.8 100.4Nominal current A 25.9 36.6 43.4 51.6 71.8 88.6Maximum inrush current A 125.0 190.0 215.0 151.0 232.0 259.0

400 / 3 / 50 + Neutral + Ground

ALR / MHP Unit Size 15P 18P 21P 25P 30P 35PHydronic module with single pumpWater capacity dm3 170 170 170 300 300 300Water pump flow rate (cooling mode) (1) l/s 1.768 2.389 2.914 3.536 4.778 5.828Water pump external manometric head mWG 16.1 13.3 20.1 14.5 15.5 14.9Water pump nominal power input kW 0.75 0.75 1.10 1.10 2.50 2.50Water pump nominal current A 1.8 1.8 2.6 2.6 7.3 7.3Antifreeze heater capacity (optional) kW 6 6 6 8 8 8Extra heat. capacity (option for MHP only) kW 24 24 24 36 36 36Additional operating weight kg 210 210 210 360 360 360

3.6 - Optional Centrifugal Fan Data

ALR / MHP Unit Size 15P 18P 21P 25P 30P 35PFan typeMotor power (for ESP of 150 Pa) kW 2.2 3.0 3.0 4.0 5.5 7.5External static pressure PaAdditional shipping weight kg 71 81 91 98 108 119

Forward curved twin fan

100 - 150 - 200

4.1 - ALR / MHP 15P to 21P

4 - Dimensional Data - Standard Units

4.2 - ALR / MHP 25P to 35P

1"1/2 PVCconnections

Æ 14 mm holes (4 nos)

2" PVCconnections

Æ 14 mm holes (6 nos)

Electricalpanel

Electricalpanel

Dimensions in mm.

1 : Water inlet2 : Water outlet

1 : Water inlet2 : Water outlet

* 2 choices available.

Dimensions Size 15P Size 18P Size 21P Size 25P Size 30P Size 35P

A 140 140 210 140 140 210B * 199 or 37.5 199 or 37.5 199 or 37.5 202 or 100 202 or 100 202 or 100C * 637 or 960 637 or 960 637 or 960 1056 or 1260 1056 or 1260 1056 or 1260

Dimensions Size 15P Size 18P Size 21P Size 25P Size 30P Size 35PA 1700 1800 1800 2000 2300 2500A1 800 800 800 900 1000 1000A2 222 172 172 380 320 152

H (Fan vert. disch.) 1895 1895 1895 2265 2365 2365H (Fan horiz. disch.) 1895 1995 1995 2365 2365 2365

5 - Dimensional Data - Units with Centrifugal Fan Module

5.1 - ALR / MHP 15P to 21P

5.2 - ALR / MHP 25P to 35P

4 holes of Æ 14 mm

Electricpanel

Electricpanel

6 holes of Æ 14 mm

Dimensions in mm.Note : water connections are same as standard units.

6.1 - Unit Handling

6 - Installation

Sharp edges and coil surfaces are a potential hazard. Avoidcontact with them.

Be careful to avoid rough handling of the unit. Do not push orpull the unit anything other than the base. Block the pushingvehicle away from the unit to prevent damage to the sheetmetal cabinet and end frame (see Figure 1).

Fig.1, Suggested pushing arrangement

6.2 - Unit Placement

The flow of air to and from the condenser coils must not belimited. Restricting air flow or allowing air recirculation will resultin a decrease in unit performance and efficiency. There mustbe no obstruction above the unit that would deflect dischargeair downward where it could be recirculated back to the inletof the condenser coils. The propeller type condenser fans willnot operate with ductwork on the fan outlet.

Install the unit with enough side clearance for air entrance tothe coils and for servicing. Provide service access to theevaporator, compressor, electrical control panel and pipingcomponents as shown in Figure 2.

The minimum clearance above the unit must be 4 meters. Incase that two units are installed side by side, or when thereare obstructions such as walls, the side clearances forcondenser coils must be doubled to avoid hot air recirculationthat will affect the unit performance.

Fig. 2, Minimum clearance requirements

6.3 - Service Access

All sides of the unit must be accessible, after installation, forperiodic service. All operating, safety and control devices arelocated in the electrical control panel.

The compressors are accessible through the side panelsadjacent to control box.

The water piping is accessible from the back of unit (sideopposite to control box).

The refrigerant circuits are accessible either from the back ofunit or through the side panels adjacent to control box.

The condenser fans and motors can be replaced through thetop of the unit. The fan-motor assembly must be completelyremoved for maintenance purpose.

6.4 - Vibration Isolators

Vibration isolators are recommended for all roof mountedinstallations or wherever vibration transmission is aconsideration.

See page 6 for the location of each isolator.

Blocking requiredacross full width

* Dimension A: 900 mm for unit without hydronicmodule or 1600 mm for unit with hydronic module.

Warning

6.5 - Water Piping

Local authorities can supply the installer with the proper buildingand safety codes required for safe and proper installation.

Install piping with minimum bends and changes in elevation tominimize pressure drop. Consider the following when installingwater piping:

1. Vibration eliminators to reduce vibration and noisetransmission to the building.

2. Shut-off valves to isolate the unit from the piping systemduring unit servicing.

3. Manual or automatic air vent valves at the highest points ofthe chilled water piping.

4. A means of maintaining adequate system water pressure(expansion tank or regulating valve).

5. Temperature and pressure indicators located at the unit toaid in unit servicing.

6. To avoid all risks of penetration of foreign matters andto keep system performance up, it is mandatory toinstall a strainer (with mesh lower than 1 mm) at theinlet of water pump and heat exchangers. Place thestrainer far enough upstream to prevent cavitation at thepump inlet (consult pump manufacturer forrecommendations). The use of a strainer will prolong pumplife.

7. Each evaporator has a heating cable and a thermostat toprevent freeze-up down to -18 °C. During winter shut-downperiods, it is recommended to either keep the unit energizedor supply the heating cable with a separate 230 V source,although the heating cable is factory wired to the controlcircuit.

If separate disconnect is used for the 230 V supply to theevaporator heating cable, mark the disconnect clearly to ensuredisconnect is not accidentally shut off during cold seasons.

Fig. 4, Typical field evaporator water piping

Although the evaporators are equipped with freeze protection, itdoes not protect water piping external to the unit or protect theevaporators in the event of a power failure or heater cable burnout.

6.6 - Flow Switch

A water flow switch must be installed on the evaporator water inletpiping to ensure that there is sufficient water flow and cooling loadin the evaporator when the unit is started. This will protect thecompressor against any eventual liquid slugging during start-upand prevent accidental freeze-up when water flow is interrupted.

The flow switch is available as an option. It is a "paddle" typeswitch and adaptable to any pipe.

Installation should be as shown in Figure 5. Connect the normallyopen contacts of the flow switch to the terminals provided in theunit control center (See wiring diagram supplied with the unit).There is also a set of normally closed contacts on the switch thatcan be used for an indicator light or an alarm to indicate when a"no flow" condition exists. Freeze protect any flow switch that isinstalled outdoors.

Fig. 5, Flow switch installation

1 Manometer2 Flexible connector3 Test point4 Flow switch

5 Thermometer6 Isolating valve7 Circulating pump8 Filter

It is not our policy to make recommendations on water treatment.The general contractor or owner should contact a local watertreatment company regarding water treatment. However, thistopic is critical and care should be taken to make sure it is doneproperly to prevent problems related to flow. A fouled watersystem will lead to premature component failure.

Water connections could be damaged by an important stresswhen screwing them. Use a second spanner to compensatethe stress of tightening.

For additional freeze protection, it is recommended to drain theevaporators and chilled water piping if the unit will not be operatedduring winter and to add a glycol solution with an adequate % ofglycol to the chilled water system to further protect the systemduring low ambient periods.

If the BT option (low chilled water temperature option) is ordered,all water pipings must be protected and a glycol solution with anadequate % of glycol must be used.

Caution

Caution

Caution

6.7 - Refrigerant Charge

All units are designed for use with HCFC-22 and other optionalrefrigerants. See nameplate for specific refrigerant used. Unitsare shipped with an operating charge.

6.8 - Glycol Solution

The use of ethylene glycol to prevent the evaporator and thesystem water piping from freezing, will affect the unitperformance. Use the following correction factors for unitsutilizing glycol solution.

For glycol solution higher than 20 %, it is highly recommendedto consult your glycol supplier.

Ethylene glycol correction factors

Example: protect the unit against freezing for ambienttemperature down to -8 °C.

1. Determine ethylene glycol concentration: 20%.

2. Find corrected cooling capacity by multiplying thechiller's capacity (kW) by capacity correction factor0.982.

3. Determine corrected water flow rate:

Corrected cooling capacity x 860l/s =

Delta T x 3600

Corrected water flow rate = l/s x correction factor (1.04).

6.9 - Operating Limits

Evaporator pressures

Water and air temperatures - ALR & MHP units

(1) Without glycol.(2) For operating limits, refer to heat exchanger WPD curves.(3) For units equipped with low ambient operation kit.

6.10 - Optional Hydronic Module

4. Determine water pressure drop through evaporator,when using glycol: read the pressure drop (from waterpressure drop curve on page 11) corresponding to thecorrected water flow rate and multiply this pressuredrop by correction factor (1.129).

Principle diagram

Water and air temperatures - MHP units

(1)Refer to table of performance data indicated in unit technicalbrochure.(2) For operating limits, refer to heat exchanger WPD curves.

% ethylene glycol 10 20 30 40 50

by weightFreeze point ( C) -3 -8 -14 -22 -33

Cooling capacity 0.991 0.982 0.972 0.961 0.946

Power input 0.996 0.992 0.986 0.976 0.966

Water flow rate 1.013 1.040 1.074 1.121 1.178

Water pressure drop 1.070 1.129 1.181 1.263 1.308

Unit

size Water Refrig. Water Refrig.

side side side side

15P

to 10.5 13.0 14.0 26.0

35P

Max. operating Test pressure

pressure (bar) (bar)

All units Min. ( C) Max. ( C)Leaving chilled water temp. (1) 6 15

Water delta T (2) 4 6

Ambient air temperature 15 42

Ambient air temperature (3) -15 42

All units Min. ( C) Max. ( C)Leaving hot water temperature 25 55 (1)

Water delta T (2) 4 6

Ambient air temperature -5 25

Note : standard safety valve is calibrated at 3.5 bar.

1. Water pump2. Water capacity3. Automatic air vent4. Expansion tank (supplied loose)5. Flow switch6. Optional shut-off valves (supplied loose)7. Optional immersion heater8. Relief valve (supplied with immersion heater)9. Pressure tapping points10. Drain11. Water out12. Water in13. Return from evaporator14. Leaving to evaporator

6.11 - Water Pressure Drop Curves

The hydronic module requires no particular maintenance. However,to make sure that the evaporator and circulating pump do notbecome fouled with foreign matter, installation of a strainer onwater inlet piping is highly recommended.

Note that, to avoid any damage during transportation, theexpansion tank is supplied loose.

The installation of the latter is to screw it on the connection locatedon the water capacity. To avoid any eventual leak, make sure thegood tightness on the connection.

Remark: In case the optional antifreeze protection heater isordered, keep the unit energized to prevent water piping from

6.10 - Optional Hydronic Module (cont't)freezing. In other case, make certain all unit components areprotected for freezing caused by low outdoor temperature. Makesure that, in case of accidental power failure, this information isrecorded.

The optional electric heating (on MHP only) does not ensure thestandby heating (hot water supply when unit is shut down byfailure); but only the extra heating (in addition to thermodynamicheating supplied by the machine). The electric extra heating ispiloted by the unit controller.

Important: For all air conditioning installation with a chilled waterdistribution, it is necessary that the whole distribution system mustbe sized to restore a volume of 15 liters/kW of which the coolingcapacity to be considered corresponds to the minimum step ofcapacity reduction of the machine. In some cases, it wil benecessary to add a storage capacity on the going or the return ofthe chilled water piping system.

Curve A : ALR / MHP 15PCurve B : ALR / MHP 18PCurve C : ALR / MHP 21P

Curve D : ALR / MHP 25PCurve E : ALR / MHP 30PCurve F : ALR / MHP 35P

The controller fitted on ALR / MHP 15P-35P is factorycalibrated for operation on return water temperature. Forthis reason, the controller sensor is located at the evaporatorinlet in order to control the system cooling load.

The necessary setting of the controller is the set pointadjustment only; this can be adjusted in a setting range from-10 °C to +20 °C. The factory setting is +12 °C for ALR units.In the case of MHP units, the controller is equipped withtwo water sensors and one air sensor; it can be adjusted ina setting range from -5 °C to +55 °C with factory setting at+12 °C (cooling mode) and +40 °C (heating mode).

If the set points are lower than the factory settings, makesure that glycol solution is used in the system water circuitand that all control and safety devices are adjustedaccordingly.

Note: for set points lower than +10 °C (on return water),consult the factory about the precautions to be consideredfor a good operation of the machine.

7 - Controls

7.1 - Temperature Controller

7.2 - High Pressure Control

The high pressure control is a pressure activated switch thatopens on a rise in pressure. When the switch opens, the safetyrelay de-energizes the compressor circuit preventing the unitoperation until the high pressure control is reset.

The high pressure switch requires manual reset and is factoryadjusted to trip out at 27 bar.

7.3 - Low Pressure Control

The low pressure control is a pressure switch activated byevaporator pressure. The switch opens when the pressuredecreases abnormally.

The low pressure switch requires automatic reset and isfactory adjusted to close at 1.7 bar (on ALR units) and0.5 bar (on MHP units).

7.4 - Evaporator Heater Thermostat

The evaporator heater thermostat provides freeze protectiondown to -18 °C ambient temperature during unit shut downperiods.

It closes at +3 °C, activating afterwards the evaporator heatingcable.

7.5 - Antifreeze Thermostat

The antifreeze electronic thermostat, fitted on ALR 25P to35P only, prevents the evaporator from freezing up duringoperation.

The thermostat, manual reset type, is activated when theleaving chilled water temperature is down to +3 °C (othersetting for glycol solution, on request).

Note : on ALR 15P to 21P and MHP 15P to 35P, theantifreeze protection is assured by the controller.

7.6 - Head Pressure Control

The head pressure is controlled by a pressure switch whichenergizes and automatically de-energizes the condenser fanmotors in response to condenser pressure.

The pressure switch is factory set at 17 bar.

7.7 - Low Ambient Operation Kit (Optional)

The low ambient operation kit is available only on ALRmodel for operation from +15 °C to -15 °C ambienttemperature.

This kit includes a pressure transducer per circuit and anelectronic fan speed controller per circuit that modulatescontinuously the speed of all condenser fans in response tocondenser pressure given by transducer.

The pressure transducer is factory set for operation between14 and 24 bar.

8 - Field Wiring

Wiring must be in accordance with all applicable codes andregulations. Warranty is void if wiring does not comply withspecifications. A blown fuse indicates a short, ground oroverload. Before replacing a fuse or restarting a compressoror fan motor, find and correct the trouble.

The evaporator heater should preferably be energized througha separate disconnect switch from the main unit power supply,

Use only copper wire for all power lead terminations at theunit. Aluminium or copper can be used for all other wiring.Wiring must be sized in accordance with the IEC Codes.

Field wiring must be installed according to unit wiringdiagram located inside the unit control box. Unit must be grounded through terminal provided inside

electrical panel.

The supply voltage must not vary more than 10 %. theunbalance between the phases must not exceed 3 %.

so that the unit can be shut down without defeating the freezeprotection provided by the evaporator heater.

The remote on/off switch should be wired to terminals asindicated in the wiring diagram supplied with the unit. If thisoption is not used, "shunt" these both terminals.

The water flow switch must be wired to terminals as shown inthe unit wiring diagram.

Example of electrical wiring diagram, power circuit of ALR / MHP 15P to 35P

ALWAYS REFER TO THE UNIT WIRING DIAGRAMLOCATED INSIDE THE ELECTRICAL PANEL

Caution

Caution

Caution

Caution

Legend :ALIM TRI+N : 400 V/3 Ph/50 Hz + Neutral power supplyRTH C1 Thermal relay of compressor 1RTH C2 Thermal relay of compressor 2MC1 Compressor 1MC2 Compressor 2MV1 Fan 1MV2 Fan 2MV3 Fan 3RC MC1 Crankcase heater of compressor 1RC MC2 Crankcase heater of compressor 2

Remark : the sizes 15P to 21P have one compressor and twofans only.

8 - Field Wiring (cont'd)

Example of electrical wiring diagram, control circuit of ALR 15P to 21P

ALWAYS REFER TO THE UNIT WIRING DIAGRAM LOCATED INSIDE THEELECTRICAL PANEL

Installer terminal block

Constructor terminal block

Legend :µchiller compact : ControllerPI MC1 Internal protection of compressor 1ST1, ST2 Temperature sensorsM/A ON/OFF switchM/A-D Remote ON/OFF switchBP1 Low pressure switch 1HP1 High pressure switch 1PME Lack of water safety pressure switchFS Water flow switchHP5 Head pressure control pressure

switchV1, V2 Contactors of fan 1 & 2TH EVAP1 Evaporator thermostat 1R EVAP1 Evaporator heater 1EV1 Solenoid valve 1C1 Contactor of compressor 1


Example of electrical wiring diagram, control circuit of ALR 25P to 35P

ALWAYS REFER TO THE UNIT WIRING DIAGRAM LOCATED INSIDE THE ELECTRICAL PANEL

Legend :M/A ON/OFF switchM/A-D Remote ON/OFF switchPME Lack of water safety pressure switchTH EVAP1 Evaporator thermostat 1TH EVAP2 Evaporator thermostat 2R EVAP1 Evaporator heater 1R EVAP2 Evaporator heater 2IR 32W ControllerST1 Temperature sensor 1RA1 Auxiliary relay 1RA2 Auxiliary relay 2

Example of electrical wiring diagram, control circuit of ALR 25P to 35P (cont'd)



Legend :FS Water flow switchTAG1 A n t i f r e e z e

thermostat 1TAG2 A n t i f r e e z e

thermostat 2SAG1 Antifreeze sensor 1SAG2 Antifreeze sensor 2HP1, HP2 High pressure

switches 1 & 2PI MC1 Internal protection of

compressor 1PI MC2 Internal protection of

compressor 2ACC1 Anti short cycle

relay 1ACC2 Anti short cycle

relay 2BP1, BP2 Low pressure

switches 1 & 2




C1 Contactor ofcompressor 1

C2 Contactor ofcompressor 2

EV1 Solenoid valve 1EV2 Solenoid valve 2V1, V2, V3 Fan contactors

1, 2 & 3HP5, HP6 Head pressure

control pressureswitches



Example of electrical wiring diagram, control circuit of MHP 15P to 21P

Legend :µchiller compact : ControllerCV Fan boardPI MC1 Internal protection of

compressor 1ST1, ST2, ST3 : Temperature

sensorsBP1 Low pressure

switch 1HP1 High pressure

switch 1PME Lack of water safety

pressure switchFS Water flow switchM/A ON/OFF switchM/A-D Remote ON/OFF

switchE/H-D Remote Summer/

W i n t e r(Closed=Winter)

TH EVAP1 Evap. thermostat 1R EVAP1 Evap. heater 1V1, V2 Fan contactors 1 & 2HP5 Head pressure

control pressureswitch



EVDG1 Defrosting solenoidvalve 1

RM "ON" relayR E/H Summer/Winter relayC1 C o m p r e s s o r

contactor 1RA1 Auxiliary relay 1V4V1 4 way valve 1P1 Pump contactor 1


Example of electrical wiring diagram, control circuit of MHP 25P to 35P

ALWAYS REFER TO THE UNIT WIRING DIAGRAMLOCATED INSIDE THE ELECTRICAL PANEL

Legend :CV Fan boardCP Main boardCC Compressor boardC ControllerPI MC1 Internal protection of

compressor 1PI MC2 Internal protection of

compressor 2PME Lack of water safety

pressure switchFS Water flow switchM/A ON/OFF switchM/A-D Remote ON/OFF

switchE/H-D Remote Summer/

W i n t e r(Closed=Winter)

TH EVAP1 Evap. thermostat 1TH EVAP2 Evap. thermostat 2R EVAP1 Evap. heater 1R EVAP2 Evap. heater 2HP5, HP6 Head pressure

control pressureswitches

V1, V2, V3 Fan contactors1, 2 & 3

R E/H Summer/Winter relayC1 C o m p r e s s o r

contactor 1V4V1 4 way valve, circuit 1RA1 Auxil iary relay,

circuit 1EVDG1 Defrosting solenoid

valve, circuit 1




EVDG2 Defrosting solenoidvalve, circuit 2

RM "ON" relayC2 C o m p r e s s o r

contactor 2V4V2 4 way valve, circuit 2RA2 Auxil iary relay,

circuit 2

9 - Start-up

9.1 - Pre Start-up

Before starting up the unit, a certain number of verificationsmust be performed on the installation to ensure that the unitwill operate under the best possible conditions. The check listbelow is not exhaustive and should only be used as aminimum reference basis.

1. Make certain fan rotates freely. On optional centrifugalfans, check pulley alignment and belt tension.

2. Inspect all water piping for flow direction and correctconnections at the evaporator.

3. Verify all system piping is correct for operation as perinstallation requirements.

4. Verify minimum cooling load equal or above 60 % ofmaximum load is available at the start-up.

5. Check voltage of the unit power supply and make certainvoltage is within authorized limitations.

6. Make sure unit is properly grounded.

7. Check the presence of water flow safety devices.

8. Make sure unit operation is electrically interlockedwith chilled water pump operation. Any failure of thispump or lack of water flow in the evaporator mustinevitably shut the compressor down. The noncompliance with this procedure will result insuppression of the unit warranty. Refer to wiringdiagram for this electrical interlock.

9. Check all electric connections for tightness.

10. Open all water flow valves and start the chilled waterpump. Make certain water flow rate complies withinstallation requirements.

11. Check all piping for leaks and vent the air from theevaporator as well as from the system piping beforestarting the compressor.Flush the evaporator and systempiping to obtain clean, non corrosive water in theevaporator.

12. Supply power to the unit, after having checked that theunit on/off switch is in "OFF" position. Wait at least 2 hoursbefore starting up the unit, to ensure crankcase is heated.

9.2 - Start-up

1. On MHP units, make sure that summer/winter switch ison the desired position.

2. Move on/off switch to "ON" position. On a call for coolingor heating, the compressors will start after a period of6 minutes (time delay of anti-short cycle relays).

3. Check then the good condition of operation of all controland safety devices of the unit (chilled water temperaturecontroller, high pressure switch and antifreezethermostat).

9.3 - Unit Operation

ALR units

During the unit operation, the controller display, thecompressor light and the "Sun" symbol (sizes 15P to21P) or the "ON" symbol of antifreeze thermostats (sizes25P to 35P) are fed.

When the chilled water set point temperature is satisfied,the "Sun" symbol (sizes 15P to 21P) or the "DIRECT"symbol (sizes 25P to 35P) is turned off and the unit isshut down.

The compressors are protected by a set of electric andrefrigerant safety devices. The safety shutdown of theunit will be provoked by the cutoff of one of theseprotective devices, by the antifreeze sensor (sizes 15Pto 21P) or by the cutoff of antifreeze thermostats (sizes25P to 35P) materialized by lighting of its "OFF" symbol.This condition remains unchanged as long as the failuredetected will not be manually eliminated.

MHP units

During the unit operation, the controller display, thecompressor light and the "Sun" symbol (cooling mode)or the "Snow" symbol (heating mode) are fed.

When the chilled water or hot water set pointtemperature is satisfied, the "Sun" symbol or the "Snow"symbol is turned off and the unit is shut down.

The compressors are protected by a set of electric andrefrigerant safety devices. The safety shutdown of theunit will be provoked by the cutoff of one of theseprotective devices or by the evaporator antifreeze sensor.This condition remains unchanged as long as the failuredetected will not be manually eliminated.

The safety shutdown of the unit can be materialized by anoptional remote fault relay.

All these safety devices are to be reset (manually) onlyafter having detected the failure and eliminated it.

Each compressor is fitted with an electronic anti-short cyclerelay which imposes a compressor minimum shut downtime between two start-ups. This 6 minute time delay isengaged as soon as the comprssor is turned off.

4. Check that electrical interlock, assuring compressorshut down when there is no water flow in the evaporator,is correctly done.

Check that fans rotate in the right direction (see the "arrow"symbol on the fans). Otherwise, reverse two cables of the3-phase power supply.

Warning

10 - Service and Maintenance

Service and maintenance on this equipment are to beperformed by qualified personnel. Causes for repeated trippingof safety controls must be investigated and corrected.

The units are designed to operate for long periods of time witha minimum of maintenance. However, certain preventivemaintenance operations must be performed at least evey sixmonths and after any extended shut down period (coldperiod).

These operations are mostly routine checks such asinspection of set points and cutoff points, inspection ofvoltages and currents, inspection of water flow rates andtemperatures, etc.

Extended Shutdown

The following recommendations may be considered forextended shutdown of unit:

- After the compressors have pumped down, turn off thechilled water pump(s).

- Disconnect all electrical power supply to the unit and to thechilled water pump(s).

- If glycol is not used in the system, drain all water from theunit evaporator(s) and chilled water piping, if the unit is tobe shut down during winter.

Fan Motor Bearings

The fan motor bearings are of permanently lubricated type.No lubrication is required. However, check all moving partsfor wear and tear every 6 months and replace them ifnecessary.

After a certain hours of operation, re-check the belt tensionof optional centrifugal fans and adjust it if necessary.

Electrical Terminals

Retighten all power electrical terminals every six months.

Condenser Coils

Condenser coils do not require any particular maintenanceexcept the occasional removal of dirt and debris from theoutside surface of the fins.In case of corrosive atmosphere,provide a corrosion protection accordingly. Coils may becleaned with a low pressure water supply and mild detergent.

Evaporators

Evaporators are dry expansion, high efficiency, brazed plate-to-plate type heat exchanger consisting of stainless steel

Disconnect all power before doing any service insidethe unit.

plates brazed together. No particular maintenance isrequired, but it is mandatory to install a strainer (withmesh lower than 1 mm) on the inlet of evaporator waterpiping to prevent foreign matters from entering andclogging the heat exchangers.

No mechanical cleaning operation is possible on plate-to-plate type heat exchangers.Clean them with detergents forfatty deposits. For heavier fouling, use chemicals compatiblewith copper like formic, citric, vineger or other organic acids.Never wait until the unit is heavily fouled before cleaning.

Sight Glasses

Visually check refrigerant sight glasses at least once amonth. Bubbling refrigerant in the sight glass indicates theunit is short of refrigerant charge. Refrigerant gas flashingin the sight glass could also indicate an excessive pressuredrop in the line, possible due to a clogged filter-drier or arestriction elsewhere in the refrigerant circuit. In this case,have the installation checked by qualified personnel.

The sight glasses have a humidity sensitive element thatindicates the level of humidity in the circuit through a colourreference of the element.

Thermal Expansion Valves

The expansion valves allow the proper amount of refrigerantto enter the evaporator (regardless of cooling load) bymaintaining a constant superheat (superheat is the differencebetween refrigerant temperature as it leaves the evaporatorand the saturation temperature corresponding to theevaporator pressure).

All units are factory set for an average value of superheatfrom 4 to 7 K. In case of problem, the setting must be performedonly by qualified personnel.

Reverse cycle 4-way valve (MHP units)

The 4-way valve allows the cycle reversal for the defrosting(hot water production mode) and the operation in chilled waterproduction mode. This valve is factory calibrated and wired; itdoes not require any particular maintenance.

Expansion tank of optional hydronic moduleCheck annually the gas pressure inside the expansion tank.

Warning

11 - Spare Parts List

11.1 - In-Warranty Return Material Procedure

Material must not be returned without permission of ourAfter Sales Department. To return the material, contact yournearest sales office and ask for a "return voucher". Thisreturn voucher shall be sent out with the returned materialand shall contain all necessary information concerning theproblem encountered. The return of the part does notconstitute an order for replacement. Therefore, a purchaseorder must be entered through your nearest distributor orregional sales office. The order should include part name,part number, model number and serial number of the unitinvolved.

Following our personal inspection of the returned part, andif it is determined that the failure is due to faulty material or

workmanship, and in warranty, credit will be issued oncustomer's purchase order. All parts shall be returned to theour factory, transportation charges prepaid.

11.2 - Service and Spare Parts Order

The model number, the confirmation number and the unitserial number indicated on the name plate must be providedwhenever service works or spare parts are ordered.

For any spare part order, indicate the date of unit installationand date of failure. Use the part number as shown in the tableabove or, if it is not available, provide full description of thepart required.

* quantity required per unit : 1 (for sizes 15P to 21P) and 2 (for sizes 25P to 35P).** quantity required per unit : 2 (for sizes 15P to 21P) and 3 (for sizes 25P to 35P).

ALR / MHP unit size 15P 18P 21P 25P 30P 35PCondenser coils - ALR S0F015001 S0F018001 S0F018001 S0F025001 S0F030001 S0F030001Condenser coils - MHP S0F015201 S0F018201 S0F018201 S0F025201 S0F030201 S0F030201Compressor * Y3CPGF038 Y3CPGF040 Y3CPGF042 Y3CPGF038 Y3CPGF040 Y3CPGF0422-speed compressor - ALR * Y3CPGF039 Y3CPGF041 - Y3CPGF039 Y3CPGF041 -Evaporator * S1FE00015 S1FE00018 S1FE00021 S1FE00015 S1FE00018 S1FE00021Fan motor assembly - ALR ** V3XGMV181 V3XGMV181 V3XGMV138 V3XGMV181 V3XGMV181 V3XGMV138Fan motor assembly - MHP ** V3XGMV181 V3XGMV138 V3XGMV138 V3XGMV181 V3XGMV138 V3XGMV138Thermal expansion valve * R4DTHE048 R4DTHE049 R4DTHE049 R4DTHE048 R4DTHE049 R4DTHE049Filter drier * F2DCGS017 F2DCGS017 F2DCGS018 F2DCGS017 F2DCGS017 F2DCGS018Solenoid valve - ALR * R3VELM157 R3VELM157 R3VELM158 R3VELM157 R3VELM157 R3VELM158Liquid sight glass * F1WVLF127 F1WVLF127 F1WVLF128 F1WVLF127 F1WVLF127 F1WVLF128Sensor well ** SOF000035 SOF000035 SOF000035 SOF000035 SOF000035 SOF000035Condenser fan high pressure switch * R2PHPR037 R2PHPR037 R2PHPR037 R2PHPR037 R2PHPR037 R2PHPR037High pressure switch * R2PHPR036 R2PHPR036 R2PHPR036 R2PHPR036 R2PHPR036 R2PHPR036Low pressure switch * R2PBPR038 R2PBPR038 R2PBPR038 R2PBPR038 R2PBPR038 R2PBPR038Antifreeze thermostat - ALR * - - - R1TSEC130 R1TSEC130 R1TSEC130Temperature controller - ALR Consult factory Consult factory Consult factory R1TSEC122 R1TSEC122 R1TSEC122User terminal, MHP controller Consult factory Consult factory Consult factory R7TTER066 R7TTER066 R7TTER066Controller board for comp. 1 - MHP Consult factory Consult factory Consult factory R7TCAR067 R7TCAR067 R7TCAR067Controller board for comp. 2 - MHP - - - R7TCAR069 R7TCAR069 R7TCAR069Controller board for fans - MHP R7TCAR068 R7TCAR068 R7TCAR068 R7TCAR068 R7TCAR068 R7TCAR068Reverse cycle 4-way valve - MHP * R3PVPR014 R3PVPR014 R3PVPR016 R3PVPR014 R3PVPR014 R3PVPR016Silicone sensor ** R2SSDE033 R2SSDE033 R2SSDE033 R2SSDE033 R2SSDE033 R2SSDE033230 / 12 V transformer - ALR E1TTRA078 E1TTRA078 E1TTRA078 E1TTRA078 E1TTRA078 E1TTRA078Low ambient operation kit - ALR * E1RVAR009 E1RVAR009 E1RVAR009 E1RVAR009 E1RVAR009 E1RVAR009Set of HP/LP gauges * W1F000005 W1F000005 W1F000005 W0F025015 W0F025015 W0F025015Isolating valves (2 nos) F1RBTV084 F1RBTV084 F1RBTV084 F1RBTV083 F1RBTV083 F1RBTV083Flow switch W0F015006 W0F015006 W0F015006 W0F025016 W0F025016 W0F025016Rubber type vibration isolators W1F005008 W1F005008 W1F005008 W0F025008 W0F025008 W0F025008Single pump, 400 V / 3 Ph / 50 Hz Y2MELE038 Y2MELE038 Y2MELE039 Y2MELE039 Y2MELE048 Y2MELE048Expansion tank F4VRND013 F4VRND013 F4VRND013 F4VRND013 F4VRND013 F4VRND013Water capacity S0F015002 S0F015002 S0F015002 S0F025002 S0F030002 S0F030002Protective condenser coil guards W0F015003 W0F015003 W0F015003 W0F025023 W0F025023 W0F025023

12 - Troubleshooting Chart

PROBLEM

COMPRESSOR WILL 1. Main switch open 1. Close switch.

NOT RUN 2. Fuse blown, circuit breaker open 2. Check electrical circuits and motor windings for shorts.

Check for overloads and loose connections.

Replace fuse or reset circuit breaker.

3. Thermal relay tripped. 3. Reset thermal relay, check unit when back on line.

4. Defective contactor or coil 4. Repair or replace.

5. System off by safety device 5. Determine cause and correct.

6. No cooling required 6. None, should start on call for cooling.

7. Liquid line solenoid will not open 7. Repair or replace coil.

8. Motor electrical problem 8. Check motor for open or short circuit, or burnout

9. Loose wiring 9. Check all wire junction. Tighten all terminals.

COMPRESSOR NOISY 1. Refrigerant flooding compressor 1. Check expansion valve setting.

OR VIBRATING 2. Improper line support 2. Relocate or add supports.

3. Worn compressor 3. Replace.

HIGH DISCHARGE 1. Non condensables in system 1. Remove with authorized procedures.

PRESSURE 2. Refrigerant overcharge 2. Remove excess.

3. Head pressure control misadjusted 3. Check fan motor set points.

4. Fan not running 4. Check electrical circuit.

5. Dirty condenser coils 5. Clean coils.

LOW DISCHARGE 1. Faulty head pressure control 1. Check condenser control operation.

PRESSURE 2. Low refrigerant charge 2. Check for leaks. Add refrigerant.

3. Low suction pressure 3. See low suction pressure steps below.

HIGH SUCTION 1. Excessive load 1. Reduce load or add capacity.

PRESSURE 2. Expansion valve overfeeding 2. Check remote bulb. Regulate superheat. Replace

expansion valve.

LOW SUCTION 1. Lack of refrigerant 1. Check for leaks. Repair and replace refrigerant.

PRESSURE 2. Evaporator dirty 2. Clean chemically.

3. Clogged filter-drier 3. Replace it. Check humidity level via sight glass.

4. Expansion valve malfunctioning 4. Check and adjust for proper superheat.

5. Low condensing temperature 5. Check head pressure control devices.

6. Compressor will not load 6. See steps below for correcting failure to unload.

7. Low evaporator water flow 7. Adjust water flow.

COMPRESSOR FULLY 1. Faulty control thermostat 1. Replace thermostat.

LOADS OR FULLY 2. Faulty thermostat staging control 2. Replace thermostat.

UNLOADS 3. Wrong ther’stat capacity control setting 3. Modify setting.

4. Worn or broken compressor 4. Replace compressor.

MOTOR THERMAL RELAY 1. Low voltage during high loads 1. Check supply voltage.

OPEN OR BLOWN FUSES 2. Defective or grounded motor wiring 2. Replace compressor.

3. Loose power wiring 3. Check all connections and tighten.

4. High condensing temperature 4. See steps for high discharge pressure.

5. Unbalanced voltage 5. Check voltage. Contact power company.

6. High temperature inside control box 6. Provide ventilation to reduce heat.

COMPRESSOR THERMAL 1. Operating beyond design conditions 1. Add facilities so conditions are within allowable

PROTECTION SWITCH OPEN limits.

2. Faulty anti-short cycle time delay 2. Replace anti-short cycle relay.

POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS

Make a copy of this sheet, fill in it and paste it on access door of electrical panel.

Job name: Unit referencesUnit mo del:

Address: Seria l number:

Order number:

1 Is the unit damaged? (if yes, state how)

2 Unit supply voltage L1 / L2 - R/S L1 / L3 - R/T L2 / L3 - S/T Hz

V V V 50

3 Contro l circuit supply voltage V

4 Have capacitors been installed on the unit power supply? YES / NO

5 Capacito r values in KVAR YES / NO

6 Is installed power correct? (if no t, give details) YES / NO

N o minal co ndit io ns A ctual co ndit io ns7 Chilled water return temperature C

8 Chilled water leaving temperature C

9 Evaporator water pressure drop bar

10 Evaporator water flow rate l/s

11 Ambient air temperature/Condenser leaving water temperature C

12 Ambient air temperature/Condenser entering water temperature C

13 Condenser water pressure drop bar

14 Condenser water flow rate l/s

15 Job site ambient air temperature C

16 Does the flow switch operate correctly? YES / NO

17 Have the propeller/centrifugal fan drives been checked? YES / NO Type of refrigerant

18 Do the condenser fans rotate in the correct direction? YES / NO

19 Does the unit have a remote contro l? YES / NO R............................

20 If so , this must first shut the unit down, then the chilled water pump(s) YES / NO

21 Has the tightness of all electrical connections been checked? YES / NO

22 Does o il pressure switch operate correctly? YES / NO

23 Have manual resets and thermal overload settings been checked? YES / NO

24 Have motor overload device settings been checked? YES / NO

25 Has the capacity unloading sequence been checked? YES / NO

26 Do liquid line valve and so lenoid valve operate correctly? YES / NO

27 Have time delay settings been checked? YES / NO

28 Were compressor crankcase heaters energized befo re the unit was started? YES / NO

1 2 1 2 1 2 1 2

29 Oil level: 1) before startup 2 ) after startup

30 Compressor model number N 1 N 2 N 3 N 4

31 Compressor serial number

32 Discharge pressure bar

33 Suction pressure bar

34 Oil pressure bar

35 Discharge line temperature C

36 Condensing temperature C

37 Liquid line temperature at condenser outlet C

38 Sub-cooling C

39 Suction line temperature at expansion valve bulb location C

40 Suction superheat °C

41 Oil sump temperature °C

42 Compressor current draw A

43 Low pressure switch, opens / closes at bar

44 High pressure switch, opens / closes at bar

45 Temperature contro l thermostat set point C

46 Antifreeze thermostat set po int bar

47 Have condenser fan motor current draw values been checked? A

48 Compressor running hours after startup N 1 N 2 N 3 N 4

Switch-on / Switch-off (bar)49 Fan pressure switch set po int

Date of startup:By:Company:

13 - Check List

R

Your distributor :

With a concern for a constant improvement, our products can be modified without notice. Photos non contractual.

Wesper S.A. - 42 cours Jean Jaurès - 17800 Pons - Tel : +33-5 46 92 33 33 - Fax : +33-5 46 91 26 44 - www.wesper.com

R

îôèñ (095) 797-9988ñåðâèñ (095) 787-3315

ñàéò www.ventrade.ruïî÷òà [email protected]

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