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USE AND MAINTENANCE MANUAL

RCWE CLOSED CIRCUIT WATER CHILLER GROUPS -


NOT MODULAR, WITH WATER CONDENSATION

GAS: R407C
Global Heating Potential: GWP=1530
(CE LAW n.842/2006 –greenhouse effect fluoridated gas)

YEAR OF CONSTRUCTION:
SERIAL N°:

Notified Organization: PASCAL CE 1115

File: RCWEIN.00

Pag. 1
This use and maintenance manual is considered to be an integral part of the unit. It must
be read carefully before performing any operations and must be kept until the unit is
demolished.

TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................................................................... 3
2 GENERAL INFORMATION ............................................................................................................................... 3
3 TRANSPORT..................................................................................................................................................... 3
4 CONDITIONS FOR STORING THE UNIT......................................................................................................... 4
5 INSTALLATION AND CONNECTION .............................................................................................................. 4
6 START UP ......................................................................................................................................................... 9
7 NOISE .............................................................................................................................................................. 12
8 USER PROTECTION RECOMMENDATIONS ............................................................................................... 13
9 ORDINARY MAINTENANCE .......................................................................................................................... 13
10 REFRIGERANT CIRCUIT ............................................................................................................................... 14
11 SAFETY DEVICES .......................................................................................................................................... 15
12 TROUBLESHOOTING .................................................................................................................................... 16
13 EMERGENCY SITUATIONS ........................................................................................................................... 17
14 PUTTING OUT OF SERVICE AND DISPOSAL ............................................................................................. 17
15 RISKS CONNECTED TO THE MACHINE ...................................................................................................... 18

Pag. 2
1 INTRODUCTION
This manual referring to the Chiller Unit must be read by operators before starting to use the unit. They must
become fully acquainted with the information given in the following pages in order to operate the unit correctly and
to avoid misuse as described in the chapters.
Ascertain that the operator is suitably trained before starting the system.
The constructor declines all responsibility for any consequences deriving from use or installation not described in
this manual, or damage caused due to dismantling, modifications or the replacement of original pieces and
components with pieces and components of other origin without written agreement.
This manual reflects the state of the art at the time the unit is sold and cannot be considered inadequate only
because it may be updated on the basis of new experience.
The chiller unit is not designed for use in a potentially explosive atmosphere, as established by D.P.R.
N°126 of 23/03/1998 (implementing directive 94/9/CE).
The Constructor reserves all rights to this manual; it cannot be copied in full or in part, without written
authorisation from the company itself.

2 GENERAL INFORMATION
Industrial Frigo Chiller Units are fitted with the most up-to-date technological solutions, both from a structural and
functional point of view, in order to give long trouble-free working life in any environmental conditions.
The GRW chiller units have been especially studied to permit an increase in available chiller power, even at
successive moments.
It is sufficient to connect other units of the same or different capacity (in parallel) to the arranged hydraulic line.
Each Unit will conserve its own independence even if the general capacity of the plant should increase. In the
same way, it is possible to decrease the cooling capacity, by dividing the units in case the plant should be modified.
These control units are widely used in the following sectors: plastic material processing, oil cooling, galvanising,
die-casting, and for cooling various industrial processes.
All control units are assembled on an elegant galvanized or oven-painted steel frame.
Models with more than one refrigerating circuit are fitted with an electronic microprocessor thermostat provided with
automatic rotation of compressor priority calls. This allows balanced use of the compressors and thus more life,
and less fault possibility.

3 TRANSPORT
During transport the Unit must be kept in a vertical position.
On receipt of the Unit, immediately check that no damage was caused during transport. If damage is found, contact
Industrial Frigo straightaway.
The unit may transported in three different ways:
 Unit with “bubble-pack” packaging”,
 Unit with a wooden box ,
 Unit with a wooden cage.

The weight of the unit, including packaging, is given in the technical sheet.

MAXIMUM TRANSPORTED WEIGHT = EMPTY WEIGHT + PACKAGING WEIGHT

3.1 Unloading and handling


During unloading operations and handling, avoid tilting the Unit and any abrupt manoeuvres.
When unloading, to avoid injury to the head and limbs (hands, feet) operators must wear the following protective
clothing with the CE mark:
helmet, leather gloves and shoes with a reinforced tip.

Pag. 3
The Unit can be lifted using a fork-lift truck or crane:
FORK-LIFT TRUCK
The fork-lift truck forks must be positioned introduced at the points marked by the signs on the unit and on the
external packaging.
CRANE
When using a crane, adopt fabric rather than metal straps; attach to the lower ends of the unit at the points
indicated on the signs on the unit and on the external packaging.

Please note that when apex angle is more than 120°, weight changes widely for every small angle change. It is
better not to reach such situation, and to use for example beams.

N.B.: MAKE SURE THAT:


 THE STRAPS,
 THE CRANE HOOKS,
 THE LIFTING EQUIPMENT (CRANE, FORK-LIFT TRUCK)
HAVE THE CAPACITY TO LIFT THE MAXIMUM CARRYING WEIGHT (WEIGHT OF THE CHILLER GROUP
AND OF THE PACKAGING, WHERE PRESENT).

Fig. 1 Fork-lift truck engagement point sign

Fig. 2 Crane strap engagement point sign

4 CONDITIONS FOR STORING THE UNIT


If the Chiller Unit is not installed but is stored in the open air, it must be suitably covered, taking precautions to
protect its components from the weather (rain, frost, snow, fog, etc.).
It must also be checked regularly to detect any possible damage occurring over time.
If the machine is deposited in enclosed premises, no special precautions are required, other than a periodical
control of its correct conservation and a check that the environmental conditions are within the limits shown below:

 Minimum storage/transport temperature (without water) -5°C


 Minimum storage/transport temperature (with water) +5°C
 Maximum storage/transport temperature + 60°C
 Relative humidity  95%

If a number of units are stored in the warehouse, they must not be stacked. Nor must any materials be placed on
the top of the unit.

5 INSTALLATION AND CONNECTION

5.1 Unit Positioning


The unit is supported on wheels or fixed supports. Check that the support plane is horizontal and that it supports
the maximum weight of the machine with a full load (see technical sheet):

MAXIMUM WEIGHT OF EQUIPMENT = EMPTY WEIGHT + WEIGHT OF LIQUID IN TANK


Example: Maximum machine weight [kg] = empty weight [kg]+ tank volume [litres] x 1 [kg/litre]

The most suitable chiller position can be established by consulting our engineers and by following these
indications:
 Avoid placing the Chillers close to any sources of heat or dust.

Pag. 4
 Position the machine in a place where THE AMBIENT TEMPERATURE IS LESS THAN +60°C.
For external installations of painted units, the control unit must be protected with a roof.
The galvanized version, can be installed outside without any protection cover.
To allow the chiller group to be correctly maintained, leave a free distance of around 80-100 cm. around its
perimeter for easy operative access.
IMPORTANT (only for machines positioned outdoors).
During the winter period, it is important to add inhibited mono-ethyl glycol at a % corresponding to the minimum
presumed ambient temperature (see graph, page 8) to prevent the formation of ice and consequent damage to the
system.
Disable the automatic water charger, since the filling of water alone would reduce the % of antifreeze in the
water/glycol mixture (see enclosed diagram).
If the chiller group is installed into an automatically operating system, piloted by a main control unit with automatic
restarting, remember that this can only take place if the safety conditions for the entire system are satisfied.
In this case, the Customer, owner of the overall system, is responsible for guaranteeing the safety of operators and
persons present, by fitting suitable prevention measures to all the equipment and machines present in the system.

Pag. 5
5.2 Open circuit hydraulic connection
On the basis of the installation requirements both of the users and Chillers, it is possible to arrange the following
open ring hydraulic lines solutions:
 hydraulic line on the ground;
 overhead hydraulic line.
The above mentioned solutions may be installed using two different layouts:
 in line;
 in closed ring.
The following recommendations are very important, too:
 provide thermal insulation for the piping, to avoid condensation and thermal loss;
 plan the diameter of the pipes in relation to possible future enlargements, so as to avoid any future
modifications of the plant;
 install the circulating pump in a well near the tank, if possible under hydrostatic head. Otherwise fit a non-return
valve to the aspiration pipe;
 install a wide surface net filter on the suction pipe to avoid the ingress of dirt inside the evaporator;
 fit an interception valve to the pump suction pipe and a regulator to the flow;
 connect the pump delivery to the chiller “Water inlet” and connect the chiller “Water outlet” to the cold water
tank;
 fit a gauge to the circulation pump flow, before the regulation valve, to check that the pump operating pressure
falls within the rated limits;
 connect the Chiller continuous discharge to the cold water tank to assure the emptying of the evaporator in the
event of chiller stoppage and to avoid circuit icing during winter time. Neither the water discharge pipe or the
inlet pipe to the tank must not be submerged in the water, to allow water discharge in case of necessity. For
installations with a water temperature < 13°C it's necessary to add the right percentage of inhibited ethylene
glycol to the water to prevent the freezing.

Please note the following:


Filling water and the one used to integrate the first one:
- must be clean
- its hardness must be among 8 and 10°F; a lower hardness would cause unit’s metals damage, a higher
would cause scale problems.

5.3 Connecting the condenser cooling system


The cooling water supply pipes from towers, wells or batteries, must be connected to the couplings provided,
“Cooling inlet” and “Water outlet” (see technical sheet).
The following conditions must be guaranteed for the condensers:
1. the necessary cooling water flow rate (see Tab. 1 Cooling water flow rate for the condensers),
2. a pressure difference of at least 2 bar between “Cooling inlet” and “Water outlet”.
We recommend fitting a filter to the chiller inlet to withhold any suspended impurities and to avoid dirtying the
exchange surfaces. It is anyway necessary to periodically clean the condensers that can be inspected to keep the
chiller yield high.
During the winter period, if the control unit is located outdoors, an no glycol has been added to the cooling water, it
is indispensable to discharge the water from the condensers to protect them from icing.

Pag. 6
AIR BLAST TOWER WELL
RCWE COOLER ~40°C ~30°C ~15°C
3 3 3
(m /h) (m /h) (m /h)
7 2,0 1,5 0,58
13 3,7 2,8 1,1
20 5,7 4,3 1,7
25 7,1 5,4 2,1
45 12,8 9,6 3,7
55 15,7 11,8 4,6
Tab. 1 Cooling water flow rate for the condensers

A) Hydraulic circuit on tank

Fig. 3 Hydraulic circuit on tank

1 RCWE 8 USER
2 EVAPORATOR 9 HOT WATER
3 GAUGE 10 COLD WATER
4 REGULATION VALVE 11 CONTINUOUS DISCHARGE
5 AUTOMATIC FILLING 12 BROAD SURFACE BASKET FILTER
PUMP POSITION CAUTION : THE ENDS OF THESE PIPES
6 MUST NOT BE SUBMERGED,
(UNDER HYDROSTATIC HEAD)
13 OTHERWISE THE EVAPORATOR WILL
7 SUBMERGED PUMP NOT EMPTY WHEN THE CONTROL UNIT
STOPS.
Tab. 2 Key to hydraulic circuit on tank

Pag. 7
B ) Closed ring hydraulic circuit

DELIVERY CIRCUIT
RETURN CIRCUIT

Fig. 4 Closed ring hydraulic circuit


5.4 Electrical connection
Connect the electrical power supply to the operating handle installed inside the control panel (3 phases plus earth).
If neutral must be present, it must not be connected to earth. The electrical power supply voltage must not vary
beyond 5% of the rated voltage and the difference between the phases must not exceed 3%.
Remember that the user must provide protection for the electrical power supply system, according to the CEI 64/8
standards governing overloads and risks consequent on direct and indirect contacts. The power supply line must
be suitably sized and protected by a magnetic-thermal circuit breaker. The maximum input values and the technical
characteristics of the recommended magneto-thermal circuit-breakers are indicated in the technical sheet:
Contacts available :
 De-energised contact, normally open, which closes when any chiller alarm activates. This allows connection of
an audible or visual alarm.
 De-energised contact, normally open, which closes when pump starts up.
 Remote start up contact.
 A 110 V line is also present for connecting a flashing light, siren or other devices.
WARNING! IF YOU PLAN TO ADD MORE CHILLERS LATER ON, YOU MUST PROVIDE AN UP-RATED MAINS POWER
SUPPLY LINE.

Pag. 8
6 START UP
CAUTION : BEFORE STARTING THE CHILLER CARRY OUT THE FOLLOWING OPERATIONS:
1) CONNECT THE SYSTEM TO THE USER.
2) CONNECT THE WATER-GLYCOL MIX FILLER TO THE CHILLER (IF FORESEEN).
3) OPEN ALL THE INTERCEPTION VALVES OF THE PLANT.

6.1 Water filling


If the working temperature exceeds +8° C, with an ambient temperature greater than 0°C, it is possible to use
water alone. Connect the water supply to the rubber hose labelled “WATER INLET”.
Wait for the pilot light “B” to go out. For 4 circuits chillers: wait until the gauge (placed outside the machine)
indicates a pressure of 0.5 bar.
When all the air in the circuit has been discharged through the air discharge valve, it is possible to start the chiller.

6.2 Water / glycol mix filling


In case of a working temperature below + 8°C, or in case of an ambient temperature below 0 °C, it is indispensable
to work with a water/glycol mixture. The glycol percentage to add to the circuit is shown in the table. It is important
to remember that the glycol percentage must be calculated considering the water volume of the chiller plus the
water quantity present in the circuit pipes.

Percentage of inhibited ethylene glycol to mix with the water for:


a working temperature below +8°C (A)
a ambient temperature below +0°C (B)
% GLICOLE

50%

45%

40%

35%

30% A
25%

20%

15% B
10%

5%

°C (A - B)

+10 0 -10 -20 -30

Fig. 6 Percentage of inhibited mono-ethyl glycol for mixing with water

30% glycol preserves the plant up to a temperature of –15°C.


The percentage of glycol refers to the total quantity of water, which is the sum of the chiller capacity of the tank plus
(see relative technical card) the amount of water in the circuit, determined from the following table:

/pipe/ Ø 3/8” 1/2” 3/4” 1” 1”1/4 1”1/2 2” 2”1/2 3” 4” 5” 6”


Litres / m 0.13 0.22 0.38 0.61 1.05 1.41 2.26 3.7 520 8.80 13.26 19
Tab. 3 Refrigerant liquid capacity in the system
WARNING!
Never add more than 60% glycol because the freezing temperature would rise instead of falling (inversion
point).
DO NOT: ADD ANY SUBSTANCES THAT ARE INCOMPATIBLE WITH THE FOLLOWING MATERIALS TO THE
WATER: ALUMINIUM, COPPER, ZINC, BRASS, BRONZE, CAST-IRON AND STEEL.
Warning!: Mono-ethylene glycol must be replaced every 3 - 4 years, as inhibitors tend to separate and thus
loose their protective properties, so important for the system.

Pag. 9
6.3 Electrical power supply
Turn the control handle to the ON position (vertical) to supply voltage to the control unit: current pilot light on. If the
chiller has semi-hermetic compressors (with pre-heating resistance), the control unit must be powered-up at least 4
hours before start-up; the current must be left on also during pause periods, above all in winter.

6.4 Start up
STANDARD VERSION
1.- Supply voltage and check that the “Incorrect phase” pilot light is not on; if it is on, invert two general supply
phases. Correct rotation is clockwise.
2.- To start the chiller, press the “I” button ; in the PcO versions, press the ON/OFF button that lights up
3.- To stop the chiller, press the “O” button; in the PcO versions, press the ON/OFF buttons
In the event of an emergency, turn the door lock to “O” to stop the system.
The control unit is already connected so that when the pump rotation direction is correct, so is that also of the
compressors.
In the GRWV versions, when connecting the pump cable it is necessary to respect the initials indicated in the
external junction box and in the pump terminal board.
Use the gauge marked with “DELIVERY WORKING PRESSURE” to check that the pump head is operating within
the rated values, also considering the static pressure (detectable when the unit is switched off); otherwise adjust the
pressure with the reducing valve on the pump delivery pipe.

DOUBLE PUMP VERSION


If a double pump chiller is required – one for operation and one as a reserve – operation will be alternate, via a
programming clock that switches pump operation.
In this way pump wear will be even.
Also, a switch permits passing from automatic operation to manual operation (if the event of programming clock or
pump failure); another switch permits switching between one pump and another.

Pag. 10
COD. ALARM

tC1 COMPRESSOR/PUMP/FAN THERMIC RELAY

HP1 HIGH PRESSURE CONTROL SWITCH

LP1 LOW PRESSURE CONTROL SWITCH

A1 ANTI FREEZE

FL FLOW/PRESSURE SWITCH

B WATER LACK

F WRONG PHASE
CONCERNING THE OTHERS CODES, PLEASE SEE THE MANUAL.

Fig. 7 Chiller with one circuit (compact)

Chiller with one circuit (compact)


1. Push the button I to start the cycle. The electronic thermostat will display the delivery water temperature
detected by the probe.
2. To set the working temperature press “set” :
 Push "SEL" key by 5 seconds, display will show : "/";
 Use "▲" (arrow) key until display shows “r”, then press “SEL”;
 First parameter you will see is “r01” (setpoint), press "SEL" and set new value with "▲" & "▼" keys, then
press “SEL” to confirm.
 Press “PRG” key repeateadly until display shows process temperature

WARNING!
It is not possible to change other parameters. The operator must contact the Constructor’s after-sales
service for further requests.

3. The following alarms are displayed:


 tC1 = Compressor thermal switch, pump, fan, internal compressor thermostat.
 HP1 = High pressure switch. D
 LP1= Circuit low pressure switch.
 FL = Flow switch / level
 A1 = Antifreeze

4. In the case of chiller stoppage, check the signalled alarm and then operate as shown in chapters 11 - 12 of the
this manual.
5. Alarm reset:
 Verify the alarm cause is not present;
 Press "▲" & "▼" together by 5 seconds.
6. When restarting the chiller, repeat the same sequence of operations described, with the exclusion of the set
working temperature, that remains memorised in the electronic thermostat
7. Pilot light F indicates a “Wrong phase” (motor rotation is inverted).

Pag. 11
6.5 Chiller stoppage
If semi-hermetic compressors are installed, it is possible to turn off the power off from the chiller only if it does not
work for a long time (one or more weeks). In this case restart the chiller 4 hours before the new start up and start
the compressors gradually.

7 NOISE
The continuous equivalent weighted sound pressure level “A” can change, depending on chiller position, the
features of the surrounding environment (noise reflection, size and structural features of the place, background
noise, etc.). The technical sheet indicates the noise level of the chillers measured in an open field (outdoors) at a
distance of 10 metres from the machine, at a height of 1.6 metres from the ground.
7.1 Control unit noise levels

The addition of two or more noises is logarithmic. Therefore, if several chiller units are placed together, it is
important to use the following correction factors to establish the noise level value.

No. of EQUAL MODULES 2 3 4 5 6


CORRECTION FACTOR 1.046 1.073 1.095 1.109 1.123

Tab. 4 Noise level correction factors


Example : No. 3 RCWE 60 control units at 10 m, ( 41 dB (A) for each control unit) :
The total value to consider will be : 41x1.073 =44 dB (A).

CORRECTION FACTOR DIAGRAM FOR BACKGROUND NOISE


L(db)

8
Lt= Total noise level measured
7 Lf= Background noise level measured
Lp= Noise level of machine alone
6
L= Deduction
5 Lp= Lt - L

4 EXAMPLE:
3
Lt=70 dB (A), Lf=65 dB (A)
2 Lt – Lf = 5 dB (A)
L=1.5 dB (A)
1 Lp=70 dB (A) – 1.5 dB (A) =68.5 dB (A)

0 1 2 3 4 5 6 7 8 9 10
(Lt - Lf) db(A)
Fig. 8 Background noise correction diagram

Pag. 12
8 USER PROTECTION RECOMMENDATIONS
The safety devices adopted are mobile panels fixed with screws to the frame, arranged along the sides of the
machine.
Users must keep them in place as arranged by the constructor, so as not to worsen machine safety conditions.
The constructor declines all responsibility for accidents deriving from the partial or complete removal of these
protection systems.
Safety signs on the machine.

DO NOT REMOVE PROTECTION


DEVICES

READ THE USER MANUAL


BEFORE STARTING WORK
DO NOT WORK ON MOVING
PARTS

9 ORDINARY MAINTENANCE
Before starting maintenance that implies opening the machine, it is necessary to turn the control handle (yellow-
red) to isolate the chiller from the electricity line.
9.1 Weekly
Check on the amount of dirt in the condenser, in the case of cooling with well water.
9.2 Six-monthly
Take water samples to check that the pH acidity is around 7.
If the PH is less than 7 damage (chemical aggression) may occur to the materials comprising the pressure
equipment. At values greater than 7 calcium and magnesium carbonates precipitate forming encrustation
9.3 Yearly
Electrical control, to be executed by qualified personnel :
 check the tightness of the terminals;
 check the wear of the remote control switch contacts;
 check the inputs of all motors;
 check the efficiency of the thermal insulation;
Mechanical and hydraulic control, to be executed by qualified personnel :
 Check the clamping of the bolts used to fix the various components;
 Eliminate any possible water leaks.

9.4 Every five years


Every five years, replace the safety valve on the chiller circuit with one with the same technical characteristics
(calibration pressure, opening diameter, outlet coefficient, inlet and outlet fittings). Have this executed by qualified
personnel.

CAUTION : the compressor oil never needs changing (as it does not deteriorate). Therefore never open the
plugs on the compressor as this will cause the both the oil and the pressurised gas to come out, with the
risk of serious damage to operators.
After long stoppages, before starting the pump, manually make sure that it turns freely, as eventual deposits could
have blocked it.
AFTER PERFORMING MAINTENANCE OPERATIONS REQUIRING THE UNIT TO BE OPENED, MAKE SURE
THAT ALL THE MOBILE HATCHES ARE CLOSED AND THAT THE LOCKING MECHANISMS ARE TIGHT.

Pag. 13
10 REFRIGERANT CIRCUIT

AG Anti-freeze thermostat
C Condenser
CP Compressor
EV Evaporator
FL Flow switch
IL Liquid indicator
M Gage
PA High pressure locking switch
PB Low pressure locking switch
PU Use pump
RI Liquid line cut-off valve
VC + RA Filling valve + suction valve
VC + RM Filling valve + delivery valve
VR Regulation valve
Pump position VS Solenoid valve
on “V” version VAG Valvola sicurezza lato gas
VAW Valvola sicurezza lato acqua
VT Expansion thermostatic valve
UT User

Fig. 9 Circuit diagram Tab. 5 Chiller circuit key

Pag. 14
11 SAFETY DEVICES

11.1 (PA) High pressure switch


The high pressure switch protects the chiller from pressure and temperature increases inside the
condenser/compressor.
Resetting : manual, by switching the machine off and on again

11.2 (PB) Low pressure switch


The low pressure switch detects any irregular drops in the gas pressure. Any gas leaks lead to a reduction in
yielded refrigeration power.
Resetting : manual, by switching the machine off and on again

11.3 Water level control (on request)


This gives the OK to the pump to start when the circuit is fully charged.
Resetting is automatic.

11.4 Anti-freeze thermostat


Prevent the formation of ice on the exchanger pipes submerged in the water (evaporator)
Resetting is automatic.

11.5 Temperature set limit


All the refrigeration systems are supplied with a lower set limit; this can be changed for the water temperature. For
R407C gas, this is +8°C. For any variations, contact the Constructor.

11.6 Motor protection


The magneto-thermic switches with a high breaking power, are devices used to protect the motor windings from
any overvoltages or input differences between the phases (short circuit).

11.7 Compressor internal thermostat


The compressor internal thermostat is a device made of sensors immersed in the compressor winding. These
sensors detect any temperature increase in the motor and stop it before the winding burns.

11.8 Manual by-pass


Inside the chiller there is a manual by-pass valve (as standard) used to reduce the water delivery pressure if it is
too high.
By opening the valve, part of the water goes back to the water tank compensating possible water flow rate/pressure
variations. An automatic by-pass valve can be fitted externally to the system, on the pipes (optional).

11.9 Water flow switch


This switches off the unit when the cooling water flow rate is insufficient.
Resetting is manual.

11.10 Pressure-static switch valve


This keeps the pressure/temperature constant inside the condenser.

Pag. 15
12 TROUBLESHOOTING
To facilitate the operators’ work, we have considered a few examples of faults and anomalous working. Bear in
mind that white pilot lights indicate normal operating conditions, whereas red ones mean that something is wrong.
It is necessary to keep a register of all maintenance operations showing the results and any comments. The name
of the maintenance operator and the dates of the work done should also be clearly identifiable.
Key: [E]=work to be done by a technician qualified in electrical system;
[I]=work to be done by a technician qualified in hydraulic systems;

Noisy chiller
1. Noisy motors 1. Identify noisy components and contact the Constructor’s
assistance centre.

Thermostatic valve and/or frozen compressor suction


1. Dirty evaporator 1. Call the Constructor’s service centre.
2. Low water circulation causes ice formation ASDF on the 2. Stop the chiller and set the temperature to +18°C. Restart the
evaporator. unit (only the pump starts) to make the water circulate and to
defrost. When the real temperature reaches +18°C, set a
temperature of +15°C and restart the chiller ( the compressor
also restarts). Check to ensure that the chiller stops when set
temperature is reached.

Stoppage due to gas low pressure


1. Gas dehydration filter blocked 1. Call the Constructor’s service centre.
2. Gas solenoid valve not supplied, burned or blocked coil. 2. Call the Constructor’s service centre.
3. Thermostatic valve blocked. 3. Call the Constructor’s service centre.
4. Gas leaks. 4. Call the Constructor’s service centre.
5. Too cold air suction. 5. Call the Constructor’s service centre.

Stoppage due to high gas pressure


1. Dirty condenser 1. Clean the condenser
2. Thermal overload or chiller start up after starting the production 2. Close partially the water delivery cock and open the by-pass in
cycle; this causes an increase in water temperature. order to decrease the water flow rate to the machine and to
favour water cooling. Once normal conditions have been
3. Blocked pressure-static valve restored, re-open the cocks.
3. Clean or replace the pressure-static valve

Compressor circuit-breaker
1. Intervention of the compressor’s internal thermostat, stopping the 1. Resetting is automatic when the coil temperature returns within
compressor itself. the right limits.
2. Motor electrical phases interrupted. 2. Have the windings checked by an electrician .[E]
3. Mechanical damage. 3. Call the Constructor’s service centre.
4. Thermal overload due to excess or low voltage or the lack of one 4. Check the clamping of the cables and also check that the input of
phase. the single motor phases does not exceed the rate values. DO
NOT TRY TO RE-START THE COMPRESSOR (TO AVOID
FURTHER DAMAGE). .[E]
5. Earthed motor or short circuit. 5. Call the Constructor’s service centre.

Compressor internal circuit-breaker


1. Compressor internal thermistors trip in the case of coil thermal 1. Resetting is automatic when the coil temperature returns within
overload. the correct limits.

Pump circuit-breaker
1. The pump’s head values are out of the rated values. 1. By checking the value on the gauge, reset the head values as
per the plate, using the pump delivery valve. [I]
2. The pump motor is blocked because limestone formation (due to 2. Dismount and overhaul the pump. [I]
long production stoppages).
3. Thermal overload due to overvoltage or undervoltage 3. Check the input of the pump phases with an amperometric pair.
[E]

Flow switch
1. Any valve in the circuit is closed. 1. Check and if necessary open it. [E]
2. The pump operates but turns in the opposite direction. 2. Invert two phases of the main supply [E]
3. The evaporator is frozen or obstructed. 3. Call the Constructor’s service centre.
4. The hydraulic circuit is impeded 4. Restore the correct section of the circuit pipes. [I]
5. Low water level inside the tank or reservoir. 5. Add water.

Pag. 16
Anti-freeze thermostat

1. Low water circulation, causing ice formation on the evaporator. 1. Call the Constructor’s service centre.
2. The chiller is working with a set temperature lower than +8°C
without glycol addition in the circuit: this causes ice formation. 2. Add inhibited mono-ethylene glycol, as shown in the table

Low performance

1. Electronic thermostat damaged 1. Replace the electronic thermostat [E]


2. Gas leaks. 2. Call the Constructor’s service centre.
3. Obstruction of the gas filter. 3. Call the Constructor’s service centre.
4. Broken thermostatic valve. 4. Call the Constructor’s service centre.
5. Broken compressor valves. 5. Call the Constructor’s service centre.

LIQUID LEAKS

1. Connector damage: Liquid leaks (water and glycol) 1. Limit the leaks with absorbent material and prevent the
dispersion into the sewer. Contact the Constructor’s service
centre.

Other faults
If the chiller has operating defects not contemplated here, please advise us immediately, clearly specifying the
problems found.
It is extremely important to know how to communicate the codes of the alarms indicated for fast diagnosis.
The amount of refrigerant gas is shown in the technical sheet.

13 EMERGENCY SITUATIONS

13.1 Appropriate fire-fighting equipment


The parts of the machine that may catch fire are the electrical boards or other machine electrical components
(motors, cables). In all these cases use a carbon dioxide extinguisher (CO2) or ABC powder, remembering that
once used on the boards the same are no longer service worthy.

13.2 Caution over the possible emission/dispersion of harmful substances


The emission of harmful substances is produced by:
 Dispersion of the inhibited ethylene water/glycol mixture,
 Dispersion of the refrigerant gas - R 407 C,
 Lubricating oil leakage from the compressors.

14 PUTTING OUT OF SERVICE AND DISPOSAL


These components were used to construct the machine:
 Plastics 
 Ferrous (galvanised and painted steel) 
 Electrical materials 
 Insulating materials 
 Lubricating oil  Collect in drums and take to authorised disposal
sites
 Thermal insulators 
 Aluminium 
 Copper 
 Water/glycol mixture  Collect in drums and take to authorised disposal
sites
 Gas R 407 C  Collect in drums and take to authorised disposal
sites

Pag. 17
During demolition, separate the parts of the machine according to the fabrication materials.
Strictly abide by the regulations in force when disposing of these materials.
Before disassembling, check:
1. that there is no pressure in the following circuits.
 Refrigerant gas circuit,
 Hydraulic circuit.
2. that there is no electric current in the components of the machine’s electrical system.
Only dismantle the steel, load-bearing structure after eliminating all the internal components (pumps, compressors,
electrical boards, condenser, evaporator, fans); start by dismantling the upper part and work downwards.

15 RISKS CONNECTED TO THE MACHINE

Type of danger Dangerous situation


Forma During transport, the dimensions and weight could be a
Crushing cause of harm to operators.
Cutting amputation Air fans on the upper part of the structure
Ejection of compressed gas or liquid under pressure due
Fluid ejection at high pressure to the detachment or breakage of system conduits or
due to filling or topping-up operations.
The support base must guarantee the necessary
Loss of machine stability and/or of its parts
resistance in relation to the mass of the machine.
Electrical contact (direct, indirect) Cable breakage
Static electricity on the external structure with the
Electrostatic phenomena electrocution of operators and persons closet o the
machine.
Scalding from contact with high temperature objects Pipe – condenser hot/cold surface temperature
Damage to health caused by hot and cold working
Air currents generated by the machine fans
environments
Increased refrigerant gas pressure with breakage due to
Fire or explosion
an external fire.
During unloading the dimensions and mass could cause
Failure to adopt personal protection equipment
harm to the operators.
Absence of safety protection guards Accessibility to parts under pressure

Pag. 18

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