Инструкции на Чиллеры Lennox серии HYDROLEAN, MWС - MRC с водяным охлаждением
Чиллеры Lennox серии HYDROLEAN (SWC-SWH-SWR), MWС - MRC (WC_CHILLER-IOM-1011-E) с водяным охлаждением. Инструкция по монтажу, эксплуатации и техническому обслуживанию.
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Installation, operating
and maintenance HYDROLEAN™ MWC™ - MRC WC_CHILLER-IOM-1011-E Water cooled liquid chillers
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WATER COOLED CHILLERS AND SPLIT UNITS
INSTALLATION OPERATION MAINTENACE MANUAL Ref: WC_CHILLER-IOM-1011-E The present manual applies to the following Chiller versions : HYDROLEAN™ Range: SWC-SWH-SWR MWC™ Range: MWC-MRC Our company is a member of the Eurovent Certification Program, all LENNOX chillers are tested and rated in accordance…
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PREFACE
1 – PREFACE You must read and be familiar with this operating manual prior to commission the chiller. Please closely follow the instructions. We would like to stress the importance of training with respect to the correct handling of the chiller. Please consult LENNOX on the options available in this…
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PED DECLARATION
All units are compliant with the following norms and standards: . DI 97/23/CE Pressure Equipment Directive. . DI 98/37/CE Machinery Directive. . DI 73/23/CE Low Voltage Directive. . DI 89/336/CE Electro Magnetic Compatibility Directive . EN 378-2 Safety and Environmental Directive. . The European…
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WARRANTY
2 – WARRANTY The warranty of the chillers is subject to the warranty definitions as agreed upon in the order. It is expected that the design and installation of the unit utilises good working practices. The warranty will be legally null and void if: - Service and maintenance have not been executed…
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3 – INSTALLATION
3.1 - Transport - Handling 3.1.1 - Controls and delivery checks After the unit has been received, when it is ready to be installed or reinstalled, and before it is started up, it must be inspected for damage. On receipt of anew equipment please check the following points. It is the customer’s…
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3.1.2 - Storage
When units are delivered on site they are not always required immediately and are sometimes put into storage. In the event of medium to long-term storage, we recommend the following procedures: - Ensure that there is no water in the hydraulic systems. - Keep the heat exchanger covers in position.…
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CAUTION
IN CASE OF REINSTALLATION OF THE UNIT, MAKE SURE THAT THE UNIT POWER SUPPLY IS PROPERLY ISOLATED AND LOCKED OUT. NOTE: SOME UNITS MAY HAVE A SEPARATE 230V CONTROL SUPPLY THAT REQUIRES SEPARATE ISOLATION. PLEASE CHECK THE WIRING DIAGRAM. WARNING: HYDROLEAN™ Size 120,135 and 165 are very narrow and…
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CLEARANCES DRAWINGS
For more details, please consult our Application Guides or the drawings supplied with the unit. HYDROLEAN™ 020 to 040 HYDROLEAN™ 050 to 100 HYDROLEAN™ 120 to 165 For any chiller, a minimum distance of 1 meter is required for the good opening and servicing of the electrical box. In case of a…
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3.4 - WATER CONNECTIONS
3.4.1 - Water connections - Evaporator/Condenser Before the system start-up check that the water circuits are connected to the right heat exchangers (e.g. no reversal between evaporator and condenser or between water in and outlets). The water circulating pump will be preferably installed upstream…
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Caution: dissolved oxygen: any sudden change in water oxygenation conditions must be avoided. The
disturbance of the oxygenation conditions encourages destabilisation of copper hydroxides and enlargement of particles. The water circuit installed must include all items necessary for treatment of the water: Filters, additives, intermediate exchangers, bleed valves, vents, isolating valves…
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treatment will be necessary. The manufacturer cannot accept liability for damage caused by the use of untreated or improperly treated water, salt water or brine. If the water circuit must be emptied for longer than one month, the complete circuit must be placed under nitrogen charge to avoid any…
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Where
: V is the minimum water content of the installation Q is the cooling capacity of the chiller Nstage is the number of control steps available in the unit Dt is the maximum acceptable temperature rise (Dt = 6°c for an air conditioning application) For MWC/MRC Chiller Unit Size Number of stages…
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3.5 - ELECTRICAL CONNECTIONS
First of all, make sure that power supplies from the building to the place where the unit is installed are properly established and that wire gauges are in keeping with the start up and running currents. Check tightness of all electrical connections. You MUST make absolutely certain that the power…
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4) For liquid risers, make sure that liquid sub cooling is sufficient to counteract the loss of static pressure and prevent gas flashing. For MWC™ units: If the refrigerant in the liquid line flashes to a gas because the pressure drops too low or because of an increase in elevation, then the…
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Units with remote condenser
Unit with remote condenser without capacity control H1: 15 m. maxi H2: 5 m. maxi H3: 0,3 m. maxi H4: 0,15 m. maxi Unit with remote condenser with capacity control 1 - Lower trap with single tube 2 - Clode coupled trap 3 - Lower trap with double tubes 4 - Higher trap with double tubes WARNING: The…
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For HYDROLEAN™ units
Minimum refrigeration capacity in kW for oil entrainments up Suction risers refrigerant R407C Tubing Nominal OD, mm Suction saturated gas temp temp °C °C 0 0,39 0,71 1,20 2,04 3,88 6,88 11,11 21,31 36,85 55,86 115,24 199,30 -5 10 0,37 0,68 1,14 1,94 3,68 6,53 10,54 20,20 34,94 52,95 109,25 189,14 10…
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3.7.4 - Pressure test
To avoid formation of copper oxide during brazing operations, blow a little dry nitrogen through the pipes. Piping must be made with tubing that is perfectly clean, plugged during storage and between connections operations. During these operations, observe the following precautions: 1) Do not work…
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4 – PRELIMINARY CHECKS
IMPORTANT - Start up and commissioning must be conducted by LENNOX authorised engineer. - Never shut off power to the crankcase heaters except for long service operations or seasonal shutdown Check that all drain and purge plugs are in place and well tightened prior to fill the installation with…
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The components are located inside the units or in a separate box and must be installed by a
qualified engineer. Note: In case of plate heat exchangers it is mandatory that a filter is installed at exchanger unit entrance. These filters must remove all particles with a diameter greater than 1 mm. 4.4 – HYDRAULIC CONNECTIONS AND OPTIONS Standard connections are Victaulic type, flange…
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4.5 - CHECK LIST BEFORE START-UP
Check that all drain and purge plugs are in place and well tightened prior to fill the installation with water or brine. Before proceeding with start up, even for a test of short duration, check the following points, after having made sure that all the valves on the refrigeration circuit are fully…
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Never start any motor while the system is under a vacuum
4.6 MASTER-SLAVE CONFIGURATION (2 units or more) - For MWC™ units only In case of 2 units or more that shall operate together, the controller allows several configurations: please consult the controller manual to enter the right parameters. WC_CHILLER-IOM-1011-E • 22 •
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5 – UNIT START-UP
5.1 - CHECKS TO BE MADE DURING START UP Before starting the unit, fill in the check list sheet of this manual and follow the instructions below to be sure that the unit is correctly installed and ready to operate. 1) Thermometers and pressure switches installed in the chilled water circuit and the…
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Evaporating pressure drops steadily, the evaporator empties itself of the liquid refrigerant accumulated in it during storage. After a few seconds, the solenoid valve opens if any. 4-b) Check on the sight glass (upstream of the expansion valve if available) that the bubbles disappear progressively…
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capacity and the heat rejection of the chiller will be different from those at design conditions. Use the chiller performance charts of the MWC AGU to find the right ∆T on the evaporator and condenser side. For a MWC selected at design conditions, this will give the nominal delta T on the evaporator…
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6 – OPERATION
6.1 – OPERATING LIMITS WARNING: It is very important ensure the units operate well inside these envelopes. 6.1.1 –HYDROLEAN™ COOLING AND HEAT PUMP VERSION SIZE 20-25-35-40-50-65-80-90 Cond Water Outlet (°C) 53°C 48°C 40°C Water + Glycol 20°C 15°C Pressure Regulated Water Valve SWC Only -10°C 3°C 5°C…
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6.1.3 –HYDROLEAN™ WITH REMOTE CONDENSER (ALL SIZES)
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6.1.4 –MWC™ (ALL SIZES)
MWC version all sizes Operating limits (Water Delta T on evap and cond: 5K) 5 Min. evap. outlet water temperature °C 20 Max evap. outlet water temperature °C 3 Min. difference water inlet/outlet °C 8 Max. difference water inlet/outlet °C 20 Min. cond. outlet water temperature °C Max. cond outlet…
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6.2 - UNIT OPERATION: REFRIGERATION CIRCUIT
6.2.1 –TANDEM SCROLL ASSEMBLIES With “NEW” tandem assemblies the oil balancing is achieved through the use of a large two phase line tube. It is IMPERATIVE that this tube is perfectly level during operation to ensure proper oil balancing between the two crankcases It is also IMPERATIVE for the…
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6.2.2 –COPELAND SCROLL DISCHARGE TEMPERATURE PROTECTION (STANDARD)
If the oil in the compressor gets too hot it will start to deteriorate and loose its ability to lubricate, and will eventually cause a compressor failure. LENNOX compressors are sometimes fitted with a specially designed sensor in the hottest part of the compression cycle, just above the discharge…
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6.2.7 –SIGHT GLASS (Standard on SWR Not available on Other Models)
This feature when fitted enables visual check of the state of the liquid refrigerant (phase liquid gas or both) in the liquid line, upstream of the thermostatic expansion valve. It also enables to some extent the detection of humidity in the circuit. 6.2.8- CRANCKASE HEATER (Standard) Every…
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6.3 - UNIT OPERATION: ELECTRICAL AND CONTROL FEATURES
cf. See the specific «Basic CLIMATIC controller» manual 6.3.1 – ANTIFREEZE PROTECTION (Standard): This feature is provided as standard by the climatic controller: and can be adjusted for brine or glycol/water chilling for which the freezing temperature depends on the concentration of the solution.…
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6.3.5 – CONTROL OF EXTERNAL SINGLE PUMP FOR EVAPORATOR (Option)
The optional control and protection of external pump for evaporator can be selected on all HYDROLEAN™ units. It consists in the addition of a circuit breaker and contactor controlled by the climatic 30. The protection is located in the main electrical panel close to the compressor protections. The…
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6.3.7 – CONTROL AND PROTECTION OF EXTERNAL FANS (Option)
The optional control and protection of external fans can be selected on all HYDROLEAN™ units. It consists in the addition of a circuit breaker and contactor per fan and controlled as standard by adjustable pressure switches. This protection can be located in the main electrical panel or in an…
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Incompatibilities between Options and Features on HYDROLEAN™
UNIT TYPE AND SIZE SW CONTROLLER MODEL Energy 211B AVAILABLE OPTIONS & FEATURES Dynamic Set Point or Remote Heat/Cool or Control on Hot Water Remote ON / OFF or Control on Hot Water SW Energy 211B Remote ON / OFF or Dynamic Set Point or Remote Heat/Cool or Control on Hot Water SW Energy 620 Remote…
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6.3.9 – HOT WATER CONTROL (OPTION)
This option can only be selected on HYDROLEAN™ Cooling only units SWC and consist in a special configuration of the program and temperatures probes fitted to the condenser It is NOT recommended to use a Pressure Regulating Valve when the Control on Hot Water Option is selected 50-65-8090-100…
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6.3.11 – REMOTE ALARM (Standard)
This feature can be installed on all HYDROLEAN™ units. WARNING: On units between 20 and 100kW this feature requires the installation of dry contacts: This implies a modification of the customer electrical installation (Max 12V 500mA on the controller). On other sizes fitted with energy 620…
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7 – MAINTENANCE
We recommend regular and thorough servicing of the LENNOX unit. The following maintenance instructions form a part of the operations required for this type of equipment. However, it is not possible to give fixed and precise rules for permanent maintenance procedures capable of keeping all units in…
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7.2 ANNUAL MAINTENANCE
On units with water cooled condensers, it is important that the unit be serviced regularly by a qualified technician, at least once every year or every 1000 hours of operation. Failure to observe this rule can lead to cancellation of the warranty and will clear LENNOX of whatever responsibility. A…
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quality of the oil. Darkening of the colour of the oil or degradation of its qualities can also be caused by the presence of humidity in the system. When the oil has changed colour or has been degraded, it must be changed. On request, LENNOX can carry out an oil analysis. Inspect the state of the…
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7.6 CORRECTIVE MAINTENANCE
MAKE SURE THAT THE UNIT IS COMPLETELY DISCONNECTED FROM THE POWER SUPPLY BEFORE CARRYING OUT ANY TYPE OF WORK ON THE UNIT. If some component in the cooling circuit must be replaced, follow these recommendations: - Always use original replacement parts. - Environment laws stipulate recovery of…
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8 – TROUBLESHOOTING – REPAIRS
8.1 LIST OF THE MOST COMMON PROBLEMS PROBLEMS – SYMPTOMS PROBABLE CAUSE RECOMMENDED ACTION A) THE COMPRESSOR DOES NOT START - Motor control circuits established, the compressor does not run - No power supply - Compressor motor burnt out - Breaker tripped or fuses blown - The system does not start…
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PROBABLE CAUSE
RECOMMENDED ACTION B) THE COMPRESSOR DOES NOT START - Normal operation with too frequent starts and stoppages due to action of the low pressure safety switch. Bubbles in sight glass. Or, normal compressor operation, but the low pressure safety switch trips out and resets frequently - Suction…
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PROBABLE CAUSE
RECOMMENDED ACTION E) THE COMPRESSOR CUTS OUT ON OIL PRESSURE SAFETY SWITCH - Oil pressure switch tripped - Check operation of the oil pressure safety switch - Oil level in sight glass is too low - - Oil pressure too low - Check the oil level in the sight glass on the crankcase, check the…
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PROBABLE CAUSE
RECOMMENDED ACTION G) THE COMPRESSOR CUTS OUT ON ITS MOTOR PROTECTION THERMAL RELAY - Thermal protection Tripped - Motor windings are not being sufficiently cooled -Compressor operating out of its application range - Check operation of thermal protection, change it if necessary - Measure superheat…
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PROBABLE CAUSE
RECOMMENDED ACTION K) DISCHARGE PRESSURE TOO HIGH - Water is far too hot at condenser outlet - Water flow to low or water temperature too high in the condenser - Condenser tubes fouled - Adjust the pressure operated water valve or the thermostat on the cooling tower - Clean the tubes - Presence of…
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8.2 CONTROL DEVICES
Operation By reacting to compressor discharge pressure, the high pressure switch monitors efficiency of the condenser. Poor efficiency, the result of an excessive condensing pressure, is usually caused by : - A dirty condenser - Low water flow - Low air flow The low pressure switch monitors the…
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8.3 REGULAR CHECKS TO BE MADE - CHILLER UNIT ENVIRONMENT
CHILLED WATER CIRCUIT VALUE Inlet / Outlet pressure gauges for pressure drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . kPa Evaporator inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C Evaporator outlet temperature . . . . . .…
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8.4 MANUFACTURER’S RECOMMENDED INSPECTIONS
8.4.1 - LIQUID CHILLERS WITH RECIPROCATING COMPRESSOR(S) 8.4.1.1 - Number of recommended preventive maintenance visit: NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up 500/1000H visit Major technical inspection Inspection visit 15 000 h inspection Tube analysis +10 30000 h…
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8.4.1.2 - Description of inspection duties - Liquid chiller with reciprocating compressor(s)
START UP - Check unit installation - Check water flow and water circuit ancillaries - Check safety devices - Check leak tightness - Configuration of the microprocessor based management system (if used) - Verification of operating parameters and unit performance - Transmission of the machine service…
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8.4.2 - LIQUID CHILLERS WITH SCROLL COMPRESSOR(S)
8.4.2.1 - Number of recommended preventive maintenance visits : NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up 500/1000H visit Major technical inspection Inspection visit Tube analysis 1(1) +10 Every year 3 times a year Every 3 years This table is published for units operating…
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8.4.2.2 - Description of inspection duties - Liquid chiller with scroll compressor(s)
START UP - Check unit installation - Check water flow and water circuit ancillaries - Check safety devices - Check leak tightness - Configuration of the microprocessor based management system (if used) - Verification of operating parameters and unit performance - Transmission of the machine service…
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8.4.3 - LIQUID CHILLERS WITH SCREW COMPRESSOR(S)
8.4.3.1 - Number of recommended preventive maintenance visits : NUMBER OF RECOMMENDED PREVENTIVE MAINTENANCE VISITS Year Start up 500/1000H visit Major technical inspection Inspection visit Tube analysis 1(1) +10 Every year 3 times a year Every 3 years This table is published for units operating…
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8.4.3.2 - Description of inspection duties - Liquid chiller with screw compressor(s)
START UP - Check unit installation - Check water flow and water circuit ancillaries - Check safety devices - Check leak tightness - Configuration of the microprocessor based management system - Verification of operating parameters and unit performance - Transmission of the machine service log 500 H…
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CHECK LIST
9 – CHECK LIST Machine identifications : Year of manufacture : NORMAL CONDITIONS OF USE Leaving chilled water temperature : °C Outdoor air temperature : Max : °C Power supply voltage : V/Ph/Hz Refrigerant type : Date and time measurements were taken : Outdoor air temperature : °C Company responsible…
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CHECK LIST
This check list should be filled in by the contractor to make sure that unit installation takes place according to appropriate industry practices. WARNING: Disconnect the power supply before carrying out any inspections on the unit. If the unit must be left powered up, proceed with precaution to…
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APPENDIX 1: GENERAL REFRIGERATION CIRCUIT DIAGRAM: HYDROLEAN™ COOLING
ONLY Standard Components Options 01.a/ 01.b/ 01.c Compressors 07a/ 07b/ Low & high pressure gauges 02 Evaporator 08 Hot gas by-pass 03 Condenser 09 Pressure regulated water valve 04 Thermostatic expansion valve 05 Filter drier 06 Low & high pressure switch WC_CHILLER-IOM-1011-E • 58 •
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Options
01.a/ 01.b/ 01.c Compressors 07a/ 07b/ Low & high pressure gauges 02 Evaporator 08 Hot gas by-pass 03 Condenser 09 Pressure regulated water valve 04 Thermostatic expansion valve 05 Filter drier 06 Low & high pressure switch WC_CHILLER-IOM-1011-E • 59 •
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APPENDIX 2: GENERAL REFRIGERATION CIRCUIT DRIAGRAM: HYDROLEAN™ HEAT
PUMP Standard Components Options 01.a/ 01.b/ Compressors 07a/ 07b/ 02 Evaporator 03 Condenser 04 Thermostatic expansion valve 05.a 05.b 06.a 06.b A Low & high pressure gauges Filter drier & filter by-pass Low & high pressure switch 4 way reversing valve WC_CHILLER-IOM-1011-E • 60 •
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Options
01.a/ 01.b/ Compressors 07a/ 07b/ 02 Evaporator 03 Condenser 04 Thermostatic expansion valve 05.a 05.b 06.a 06.b A Low & high pressure gauges Filter drier & filter by-pass Low & high pressure switch 4 way reversing valve WC_CHILLER-IOM-1011-E • 61 •
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APPENDIX 3: GENERAL REFRIGERATION CIRCUIT DRIAGRAM: HYDROLEAN™
REMOTE CONDENSER Standard Components Options 01.a/01.b/ 01.c Compressors 07a/ 07b/ Low & high pressure gauges 02 Evaporator 08 Hot gas by-pass 03 Condenser 04 Thermostatic expansion valve 05 Removable cartridge drier filter 06.a/06.b Low & high pressure switch 10 Manual shut-off valve 11 Sight glass…
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Options
01.a/01.b/ 01.c Compressors 07a/ 07b/ Low & high pressure gauges 02 Evaporator 08 Hot gas by-pass 03 Condenser 04 Thermostatic expansion valve 05 Removable cartridge drier filter 06.a/06.b Low & high pressure switch 10 Manual shut-off valve 11 Sight glass 12 Liquid solenoid valve…
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APPENDIX 4: GENERAL REFRIGERATION CIRCUIT DRIAGRAM: MWC™
Circuit 1 & 2: 2 or 3 compressors per circuit: Main Components 1 Compressors High pressure relief valve Water cooled 2 evaporator High pressure safety switch Water cooled 3 condenser High and low pressure transducers 4 Expansion valves 5 Cartridge filter drier WC_CHILLER-IOM-1011-E Crankcase heaters…
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Circuit 1 & 2: 2 or 3 compressors per circuit
Main Components 1 Compressors 2 Water cooled evaporator 3 Manual shut off valve Expansion 4 valves Cartridge filter 5 drier Oil level 6 controller High pressure relief valve High pressure safety switch High and low pressure transducers Crankcase heaters WC_CHILLER-IOM-1011-E • 65 •
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APPENDIX 5: GENERAL MECHANICAL DRAWING
HYDROLEAN™ 20-25-35-40 Load Distribution (Kg - Operating weights) Clearances Piping - A BOX (20/25/35/40) SWC/SWH SWR EVAPORATOR CONDENSER Dimensional Data Option Rubber Antivibration Mounts Hydrolean SWC MECHANICAL DATA WC_CHILLER-IOM-1011-E • 66 •
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HYDROLEAN™ 50 65 80 90 100
Load Distribution (Kg - Operating weights) Piping - B BOX (50/65/80/90/100) SWC/SWH Clearances SWR EVAPORATOR CONDENSER Dimensional Data Option Rubber Antivibration Mounts Hydrolean SWC MECHANICAL DATA WC_CHILLER-IOM-1011-E • 67 •
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HYDROLEAN™ 120 135 165
Load Distribution (Kg - Operating weights) Piping - C BOX (120/135/165) SWC/SWH Clearances SWR EVAPORATOR CONDENSER Dimensional Data Option Rubber Antivibration Mounts Hydrolean SWC MECHANICAL DATA WC_CHILLER-IOM-1011-E • 68 •
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MWC 180
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MWC 230-380
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MWC 450-570
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MWC 650-720
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MRC 180
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MRC 230-380
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MRC 450-720
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APPENDIX 6: PRESSURE DROPS
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PRESSURE DROP OF HYDROLEAN™ PLATE HEAT EXCHANGERS WITH WATER AND
ETHYLENE GLYCOL 30% FILTERS PRESSURE DROP WC_CHILLER-IOM-1011-E • 77 •
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PRESSURE DROP OF PRESSOATIC CONTROL WATER VALVE «FULLY OPEN"
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MWC™
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CERTIFICATES – ISO 9001 : 2000
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CERTIFICATES – PED
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CERTIFICATES – DECLARATION OF CE CONFORMITY
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