EN7528563-00 07 - 2017 LGN power DYNACIAT

Instruction manual

EN

CONTENTS PAGE

1 INTRODUCTION 2 15 INSTALLATION ANTIFREEZE PROTECTION 13 2 SHIPMENT OF THE UNIT 3 16 ELECTRICAL CONNECTIONS 13 3 RECEIPT OF GOODS 3 16.1 Power connection 13 3.1 Checking the equipment 3 16.2 Connection to the air-cooled condenser. 14 3.2 Identifying the equipment 3 16.3 Customer connection for remote 4 SAFETY INSTRUCTIONS 4 control functions. 15

5 MACHINE COMPLIANCE 4 17 CONTROL AND SAFETY DEVICES 16 17.1 Electronic control and display module 16 6 WARRANTY 4 17.2 Main functions 16 7 UNIT LOCATION 4 17.3 Safety device management 16 8 HANDLING AND POSITIONING 5 17.4 Phase controller kit 17 17.5 Location of the safety sensors and devices 18 9 LOCATION 6 17.6 Adjusting the control and safety devices 19 9.1 Location of the unit 6 18 COMMISSIONING 19 10 OPERATING LIMITS 7 18.1 Commissioning 19 10.1 Operating range 7 18.2 Essential points that must be checked 20 10.2 Limits 7 19 TECHNICAL CHARACTERISTICS 21 10.3 Evaporator limits 7 10.4 Minimum/maximum water flow rates 7 20 ELECTRICAL SPECIFICATIONS 22

11 LOCATION OF THE MAIN COMPONENTS 8 21. SERVICING AND MAINTENANCE 23 12 MAIN COMPONENTS OF THE 21.1 Operating readings 23 REFRIGERATING CIRCUIT 8 21.2 Unit maintenance and servicing 23

13 HYDRAULIC CONNECTIONS 9 22 ECODESIGN 25 13.1 Diameters of the hydraulic connections 9 23 PERMANENT SHUTDOWN 25 13.2 Connections 10 24 TROUBLESHOOTING OPERATING 13.3 FLANGE/VICTAULIC adapter kit (OPTION) 10 PROBLEMS 26 14 REFRIGERANT CONNECTIONS 11 25 SYSTEM SCHEMATICS 27 14.1 General information 11 25.1 ooling installation with drycooler 27 14.2 Accessories 11 14.3 Routing and sizing 11 14.4 Installation 12

ORIGINAL TEXT: FRENCH VERSION

EN - 1 1 INTRODUCTION

DYNACIATpower LGN series water chillers are designed to meet the air conditioning requirements of residential and office buildings as well as the requirements of manufacturing processes. All the units are factory tested and checked. They are delivered with a nitrogen load. These units are sub-assemblies designed for integration in an installation, and as such conform to standards EN 60-204 - EN378-2 and the following directives: - Machinery 2006/42/EC - EMC 2014/30/EU - LVD 2014/35/EU - PED 2014/68/EU: (not applicable to sub-assemblies)

DYNACIATpower LGN 700V to 1000V 1100V to 1200V 1400V to 1800V 2100V to 2400V Category II III II III

Pressure and temperature:

Test pressure (TP): because of the harmful effects it has on the unit, this test is carried out on a model representative of all 3 x PS assemblies in compliance with § 5.3.2.2 a and 6.3.3 iii of standard 378-2. Shipment temperature: DYNACIATpower 700V to 2400V → Min. -30°C - Max. +50°C. Storage temperature: DYNACIATpower 700V to 2400V → Min. -30°C - Max. +50°C. Operating temperature: Refer to the section entitled "10 Operating limits" in this manual.

Technicians who install, start up, operate and service the unit must possess the necessary training and certifications, understand the instructions given in this manual and be familiar with the specific technical characteristics of the installation site. If they are to work on the unit's refrigeration circuit, such training and certification must meet the requirements of Regulation (EC) 842/2006.

EN - 2 2 SHIPMENT OF THE UNIT

During shipment, the unit must be securely strapped in place to prevent it moving and to protect it from damage. If the unit is shipped in a container, the container must be easy to load and unload. Do not use these accessories to lift the device.

3 RECEIPT OF GOODS 3.1 Checking the equipment Check the unit for any damage or missing components upon delivery. Note any damaged or missing parts on the delivery slip. IMPORTANT: EN You must notify the carrier of any damage and/or missing parts by registered letter within three days of the delivery date. Furthermore, ensure the unit is not stored in an outdoor location exposed to the elements. 3.2 Identifying the equipment • Name plate: Each unit has a manufacturer's name plate (A) bearing the unit's identification number (serial number) and description.

A

Make sure this information matches that on the order.

Ref. produit/Item Nbr Designation/Description 3025218.286250 LGN 1100Z R410A An(Year) N. Serie/Serial Nbr No Produit 02087517/0003 Refrigerant kW Absorbee/Imput kW Poids/Weight kg R410A82 KW 1161 KG Refrigerant kg Tension/Voltage Temperature Min/Max 36 + 36 3 50HZ 400V CF NOTICE BP/LP Mini PSM/MOP Intensite/Current AIP 1.4 BAR / 22.6 BAR 204 A 44 HP Maxi PSM/MOP Pression/Pressure Test No CE 29 BAR / 29.5 BAR PT=3XPS CF NOTICE

30, av Jean Falconnier 01300 CULOZ (FRANCE) Tél.: 33-(0)4-79-42-42-42 www.ciat.com Made in France

Markings (data plate, punch marks, labels) must remain visible. They must not be altered, removed or modified. Key: - Désignation/Description: Unit type. - An(Year): Year manufactured - N° série/Serial Nbr: Production number (please state this number in all correspondence) - Refrigerant: Refrigerant fluid type. - Refrigerant kg: Refrigerant fluid, capacity in kg - BP/LP Mini / PSM/MOP: For the low pressure circuit: - BP/LP. Mini = Minimum operating pressure in bar. - PSM/MOP = Maximum permissible pressure in bar. (OP as per PED 2014/68/EU) - HP Maxi PSM/MOP: For the high pressure circuit: - HP. Maxi = Maximum operating pressure in bar. - PSM/MOP = Maximum permissible pressure in bar. (OP as per PED 2014/68/EU) - kW Absorbee/Input kW: Power input in kW. - Tension/Voltage: Power supply. - Intensite/Current A: Nominal current in A. - Pression/Pressure Test: See § "Pressure and temperature" on the previous page - Poids/Weight kg: Operating weight of the unit in kg. - Temperatures Min/Max: See § "Pressure and temperature" on the previous page. - IP: Machine electrical protection rating. - No CE: Notified Body number.

Please include the identification number in all correspondence.

EN - 3 4 SAFETY INSTRUCTIONS To avoid any risk of accident during installation, start-up and adjustments, the following equipment specifics must be taken into account: - Pressurised refrigerant circuits - presence of refrigerant - Presence of electrical voltage Only experienced and qualified persons may work on such equipment. The recommendations and instructions in this manual and on each drawing provided with the unit must be followed. In the case of units with pressure equipment or components, we recommend that you contact your professional organisation for information on the regulations that apply to operators or owners of pressure equipment or components. The specifications of this equipment or components are given on the name plate or in the regulatory documentation provided with the product. A fire protection device is fitted as standard on the units. IMPORTANT: Before working on the unit, ensure the power has been disconnected at the main disconnect switch in the unit's electrical cabinet.

5 MACHINE COMPLIANCE

Refer to the document entitled "Declaration of incorporation" supplied with your equipment. The installer is responsible for making the refrigerant connections between the CIAT unit and the condenser. He has full responsibility as Manufacturer (1) of the installation with regard to the Pressure Equipment Directive (PED). He must compile the technical dossier to allow the system to be certified in compliance with the PED and issue the customer with the certificate of conformity for the installation. The CIAT system start-up procedure is carried out once the assembly completion notice has been sent with the order acknowledgement of receipt and the installation's certificate of conformity. This official document states that the installation has been set up in compliance with the requirements of decree no. 99-1046 dated 13 December 1999 and with the installation and operating conditions set out in section II of the modified order dated 15 March 2000. The checks carried out by CIAT during system start-up are only functional and do not release the installer from his responsibilities with regard to the PED.

(1) Manufacturer: The party responsible for designing and manufacturing equipment for sale on the market under its own name.

6 WARRANTY

The warranty is effective for a period of 12 months from the date the unit is first commissioned into service provided said date occurs within three months of the invoice date. It is effective for a period of 15 months from the unit invoice date in all other cases. NOTE: Refer to our general terms and conditions of sale for further information.

7 UNIT LOCATION

These units are typically used for refrigeration and are not required to withstand earthquakes. Earthquake resistance has therefore not been checked. Before setting up the unit in its intended location, the installer must check the following points: - These units are designed to be installed and stored inside a machine room that is sheltered from frost and the elements. Failure to do so will incur the loss of the manufacturer's warranty. - The surface area of the ground or structure must be strong enough to bear the unit's weight. - The unit must be perfectly level. - There must be sufficient free space around and above the unit to allow servicing and maintenance (see dimensional drawing provided with unit). - The room housing the unit must comply with the requirements of regulation EN 378-3 and other specifications applicable at the installation site. - The selected location must not be liable to flooding. - Sound level: • Our units are designed to operate quietly. • In the installation design, you must take into account the interior environment for radiated noise and the building type for airborne and solid-borne noise transmission. • To ensure vibrations transmitted by solid materials are reduced as much as possible, it is strongly recommended to fit anti- vibration mounts between the unit support and frame (see the section on anti-vibration mounts), as well as flexible couplings on the hydraulic piping. • Have an analysis carried out by an acoustics engineer.

IMPORTANT: The ambient temperature must not exceed 50°C during the unit's off cycles.

EN - 4 8 HANDLING AND POSITIONING To raise the unit, attach the slings to the designated handling holes. The data relating to the centre of gravity and the position of the anchorage points are given on the dimensional drawing. Detailed view of the anchorage point for handling

Holes for handling Ø 35.2 mm

EN The unit can be handled with a forklift truck (check the - Raise and set down the unit carefully. Take care not to tilt it maximum permissible load of the forklift). by more than 15°, as this could adversely affect its operation. In this case, it is important that the necessary precautions be - To avoid damaging the casing, use textile slings with taken to avoid the unit sliding on the forks of the forklift. You shackles. must observe the instructions given on the label affixed to the - Use a frame with an adjustable centre of gravity to keep the unit. Failure to observe these instructions may result in the unit slings away from the top of the unit. tipping over and causing physical injury. - Always protect the unit casing (panels, posts, front access WARNING: door) from damage during handling. Only the base frame is - Attach the slings only to the anchorage points intended for designed to withstand handling. this purpose and which are designated on the unit. - Safety when lifting can only be guaranteed if all these - Use slings with a suitable lifting capacity and follow the lifting instructions are followed. instructions on the drawings provided with the unit. Otherwise, there is a risk of damage to the equipment and - Caution: the centre of gravity is not necessarily at the middle personal injury. of the unit and the forces applied to the slings are not always identical.

DYNACIATpower

B C

A

These diagrams are provided for illustrative purposes only. Always refer to the pictograms on the unit

DYNACIATpower LGN 700V 800V 900V 1000V 1100V 1200V 1400V 1600V 1800V 2100V 2400V A 996 B 1400 C 2580 2930 2860 For the empty weight, please refer to section 9.1.1

EN - 5 9 LOCATION 9.1 Location of the unit 9.1.1 Dimensions and ground mounting of the frame The frame may be affixed to the ground. (Mounts with studs not supplied by CIAT). The hardness is to be defined according to the unit's weight and centre of gravity.

DYNACIATpower

Free space to be maintained to allow sufficient room for maintenance of the unit. It is important that the units are installed with the necessary clearances.

DYNACIATpower LGN 700V 800V 900V 1000V 1100V 1200V 1400V 1600V 1800V 2100V 2400V A 2099 2499 3350 B 984 984 984 C 1271 1671 2366 D 916 916 916 E 414 414 492 F 34 34 34 Weight (empty) Kg 920 1019 1036 1148 1180 1223 1389 1462 1993 2071 2106 Operating weight Kg 968 1072 1096 1216 1250 1311 1476 1557 2165 2265 2314

9.1.2 Anti-vibration mounts (optional) Anti-vibration mounts must be installed beneath the unit in the case of applications with extremely low vibrations. The mounts must be placed at the locations illustrated below.

DYNACIATpower 700V to 1600V DYNACIATpower 1800V to 2400V 200 400 899 400 200 G 700 H 700 J 700 K 50

4 mounts for 700V to 1200V models 70

4 mounts for 1400V to 1600V models 50

200 700 299 700 200

DYNACIATpower LGN G H J K 1800V 100 440 585 125 2100V 100 585 440 125 2400V 125 440 585 100

EN - 6 10 OPERATING LIMITS 10.1 Operating range The graph below represents the area of application (under full load) of the units.

DYNACIATpower LGN

+55

+50

+45 EN +40

+35

Condensation temperature Glycol required

+30 -12 -8 -4 -2 0 +5 +10 +18 Evaporator outlet water temperature

10.2 Limits

DYNACIATpower LGN

Condensation temperature Min. °C / Max. °C 35/55 (R410A) Evaporator Variable according to water outlet temperature. Min. TΔ°C/max. TΔ°C See evaporator limit curves

10.3 Evaporator limits The curves show the minimum and maximum allowable temperature differences for chilled water or glycol/water solution based on the water outlet temperature.

DYNACIATpower 9 Brazed-plate 8 evaporator

7 Δ T maximum

6

(°C) 5 T Δ 4

3 Δ T minimum Acceptable water inlet/outlet 2

1 -8 -6 -4 -2 0 24681012 Water outlet temperature (°C)

Example: For a water outlet temperature of +5°C • The maximum TΔ is 6°C, which gives a water temperature • The minimum TΔ is 2.6°C, which gives a water temperature of of 11/5°C 7.6/5°C If the temperature difference calculated is outside the two curves, contact us. 10.4 Minimum/maximum water flow rates The flow rates in the exchangers must be maintained between the values given below.

DYNACIATpower LGN 700V 800V 900V 1000V 1100V 1200V 1400V 1600V 1800V 2100V 2400V min. m3/h 22 26 29 33 35 38 44 51 61 68 74 Evaporator max. m3/h 70 81 92 105 113 124 137 151 150 150 150

EN - 7 11 LOCATION OF THE MAIN COMPONENTS

DYNACIATpower LGN 700V - 1200V 1400V - 1600V

Evaporator Electrical cabinet Evaporator Electrical cabinet

Compressor 4 Compressor 1 Compressor 4 Compressor 1

Compressor 3 Compressor 2 Compressor 3 Compressor 2 1800V - 2100V - 2400V

Evaporator Electrical cabinet

Compressor 4 Compressor 3

Compressor 5 Compressor 2

Compressor 6 Compressor 1

12 MAIN COMPONENTS OF THE REFRIGERATING CIRCUIT

Compressor 1100V to 2400V models, which have a hermetically-sealed DYNACIATpower LGN units use hermetic SCROLL compressors. packaged design, are equipped with electronic expansion valves. Oil To obtain the maximum evaporation pressure in order to The compressor contains a polyester (POE) oil: protect the compressor(s), the expansion valves on 700V to - for LGN 700V to 1200V 160SZ type models 1000V models have a load for the thermostatic element (MOP) - for LGN 1400V to 2400V 3MAF type models (32 cSt) and the electronic expansion valves have an MOP setpoint. If necessary, and if 3MAF is not available, the oil level can be The factory settings are configured to maintain overheating of topped up with ICI Emkarate RL 32 CF or Mobil EAL Arctic 22 6 to 8°C under all operating conditions. CC oil. Filter dryer Refrigerant Every unit is fitted as standard with a filter dryer with a DYNACIATpower models operate using R410A. replaceable cartridge to keep the refrigerating circuit clean The Global Warming Potential (GWP) is 2088 GWP, in and free of moisture. The dryer filter consists of aluminium compliance with standard EN378-1 oxide and a molecular sieve that neutralises any acids in the refrigeration circuit. Exchangers On the DYNACIATpower, the evaporators are double-circuit Liquid sight glass brazed-plate heat exchangers. Located on the liquid line just after the filter dryer, the liquid sight The evaporators are thermally insulated with 10 mm thick glass is used to monitor the charge in the unit and to check for polyurethane foam. 19 mm insulation is available as an option moisture in the circuit. Bubbles in the sight glass mean that the (standard equipment for operation with low temperature glycol refrigerant load is insufficient or that non-condensable gases water below 0 °C). are in the refrigeration circuit. If the sight glass indicator paper The heat-transfer fluid must be filtered and internal inspections changes colour, there is moisture in the circuit. must be carried out. Warning: Some of the sight glasses may turn yellow when the Repairs or modifications of any kind to the plate heat exchangers machine is powered off, as their sensitivity is affected by the fluid are prohibited. CIAT only authorises replacement of the heat temperature. exchanger by a qualified technician using original equipment. The sight glasses should return to green after the unit has been If the heat exchanger is replaced, this must be noted in the operating for a few hours. maintenance booklet. If the sight glasses remain yellow, there is excessive moisture in Hot gas injection electronic expansion valve the circuit. A specialist intervention is required. All units are equipped as standard with a hot gas injection device on each circuit in order to maintain a minimum evaporation pressure at start-up. Expansion valves 700V to 1000V models are equipped with thermostatic expansion valves.

EN - 8 13 HYDRAULIC CONNECTIONS 13.1 Diameters of the hydraulic connections

DYNACIATpower LGN 700V - 1200V 1400V - 1600V

1 D' 1 D' L' L' D D 2 L 2 L

EN

1800V - 2100V - 2400V

1 D' L' D 2 L

DYNACIATpower shown with the noise insulation panel option

DYNACIATpower LGN 700V 800V 900V 1000V 1100V 1200V 1400V 1600V 1800V 2100V 2400V Water connection   Ø VICTAULIC DN 100 PN 16 VICTAULIC DN 125 PN 16 VICTAULIC DN 150 PN 16 D Ø (circ. 1) Male 1" 3/8 1" 3/8 1" 5/8 2" 1/8 Gas discharge pipe D' Ø (circ. 2) Male 1" 3/8 1" 3/8 1" 5/8 2" 1/8 L Ø (circ. 1) Male 1" 1/8 1" 1/8 1" 3/8 1" 5/8 Liquid return pipe L' Ø (circ. 2) Male 1" 1/8 1" 1/8 1" 3/8 1" 5/8 These values can be considered identical to the copper piping diameters for a maximum developed length of 30 m with a maximum slope of 15 m.

EN - 9 13.2 Connections - Insulate the pipes and tubes (after performing leak tests) in Hydraulic connections must be made in accordance with order to reduce heat losses and prevent damage from frost. the diagram delivered with the unit. This diagram shows the - Install heating elements on all pipes that could be exposed positions and dimensions of the water inlets and outlets on the to frost. exchangers. - The installer must provide the necessary systems for filling Adhere to the following points when making these connections: and draining the energy transfer fluid. - Ensure the inlet and outlet pipes are connected in the - To keep the pressure in the coolant circuit below the intended direction shown on the unit. operating pressure, avoid introducing static or dynamic - In order to meet the operating conditions (flow rates, pressure pressure into the circuit. loss), a sizing calculation must be performed. The diameter IMPORTANT: of the pipes may therefore be different to that specified on - To prevent any risk of fouling or damage to the plate heat the exchanger. exchangers (evaporator), a screen filter must be installed on - The pipes and tubes should not transmit any axial or radial the water inlets as close as possible to the exchangers, and forces to the exchangers or any vibrations. in a place which is easily accessible for removal and cleaning. - The water used must be analysed and, if necessary, treated (we The filter should have a mesh of not more than 600 to 800 µm recommend contacting a qualified water treatment specialist). (see price option) The analysis will reveal whether the water is suitable for use - Flexible couplings must be used on the hydraulic pipes with the various materials it will come into contact with and (evaporator). prevent the formation of electrolytic couples: The system pipework must be secured to the wall of the • 99.9% copper tubes brazed with copper and silver building and must not place any additional load on the unit. - Using untreated or incorrectly treated water may cause • Threaded bronze couplings or flat steel flanges, depending corrosion or erosion or the formation of scale, algae or sludge on the unit model deposits. CIAT shall not be held liable for damage resulting • Plate heat exchangers and AISI 316 - 1.4401 stainless steel from the use of untreated or incorrectly treated water, or of connections brazed with copper and silver saline or brackish water. - The water circuit must have as few bends and horizontal sections at different levels as possible. NOTE: The maximum operating pressure on the water side - Install shut-off valves near the water inlets and outlets in order should be 10 bar. The water flow sensor is supplied fitted to the to isolate the exchangers. unit. Stopping the pumps will automatically cause the unit - Install manual or automatic air bleed valves at the high points to stop to avoid any risk of freezing. The pump or pumps of the circuit(s). must be slaved to the refrigeration unit (auxiliary operation - The manual or automatic air bleed valves fitted on the switch of the pump to be wired). If the hydraulic circuit is machine are not intended to be used to bleed the rest of the drained for a period of more than one month, fill the entire hydraulic circuit. circuit with nitrogen to prevent any risk of corrosion. - A static pressure of 1 bar must be maintained at all times IMPORTANT: (machine and pump off or on) on the pump intake. If antifreeze is not added to the circuit and the unit is - Install drain connections at all circuit low point(s). not operated during periods of freezing weather, drain the - Install the accessories that are essential for any hydraulic evaporator and the outside pipes. circuit (balancing valves, expansion vessel, safety valve, thermometer pockets, etc.).

13.3 FLANGE/VICTAULIC adapter kit (OPTION) The connections to the exchangers are the VICTAULIC type. A FLANGE/VICTAULIC adapter kit can be supplied separately to be fitted on site by the installer to allow flange connection to the hydraulic system. Two kits are available: 1) FLANGE/VICTAULIC adapter kit 2) FLANGE/VICTAULIC adapter kit + flexible coupling As per standard ISO 9227 PN 10/16 As per standard ISO 9227 PN 10/16

Connection to Connection to hydraulic circuit hydraulic circuit

3 2

Plate exchanger 2 outlet 1 1 Plate exchanger 1 - Hose clamp outlet 2 - Flange adapter 3 - Vibration damping coupling

EN - 10 14 REFRIGERANT CONNECTIONS 14.1 General information 14.2 Accessories • Once the unit is fitted in place, make the refrigerant Components such as the dryer, liquid sight glass, solenoid connections between the air condenser and the unit. valve and liquid valves are fitted and wired in the factory. However, it is recommended to fit the following components: The connections must be made by a qualified refrigeration - Flexible sleeves available as options on 700V to 1600V engineer. versions and not available on larger versions. LGN units are dried and pressurised with nitrogen prior to For the brazing operation, the manufacturer recommends delivery. the use of a filler metal with a high silver content (e.g. The unit should have a full refrigerant charge. 55%) and a neutral gas in the vibration eliminators to avoid The compressor oil load is supplied (in the compressors). internal corrosion. The oil top-up required for the refrigerant connection is - Shut-off valve on the discharge pipes, fitted as standard. EN not supplied. This should only be done using one of the Refer to the brazing instruction document supplied with the oils listed in section "12 Main components of the refrigerating valves. circuit". - Safety valve on all isolatable parts. The various components that make up the refrigerant Warning: if the LGN unit is equipped with a discharge valve, it connection must be correctly sized to ensure optimal operation can be isolated from the rest of the installation. of the chilled water production unit. It is not recommended to fit a cylinder on the liquid The pipe supports must be designed to limit the amplitude as line. well as the transmission of vibrations to buildings. The pipework must be sufficiently flexible: Note: These components must conform to current regulations - To withstand variations in length caused by expansion and (CE marking, etc.) contraction 14.3 Routing and sizing - To prevent the transmission and spread of vibrations - A dimensioning study must be performed in order to meet the It must also be protected against occasional mechanical operating conditions (pressure drops, speeds). The diameter shocks. of the pipes may therefore be different to that specified on The pipe length must not exceed 30 m with a the machine. maximum height difference of 10 or 15 m, depending - The pipe routing must be as short as possible with the fewest on the configuration. elbows, connections and service valves to keep pressure drops to a minimum. For other lengths, contact our technical service. Extra - The pipes must not transmit any axial or radial forces to the precautions should be taken, for example, if there are oil machine. separators. Ø Discharge pipe: The refrigerant connection must be made using equipment and - Rising gradients: methods that conform to industry standard practice and the These must be calculated to obtain a sufficient gas speed so legislation in force: that the oil can circulate on the smallest power control stage For information: Decree no. 99-1046 dated 13 December 1999 (see table below). concerning pressure equipment, order dated 15 March 2000 For a height difference of 2.5 m or more, a siphon should be concerning the use of pressure equipment, etc. fitted at the base of the column, intermediate siphons every 5 m and a counter siphon at the top of the column. Small siphons should be used.

Column base siphon Intermediate siphon Column top siphon

Minimum cooling capacity in KW to ensure proper oil return in the vertical discharge ducts

Saturated Discharge Pipe diameter in inches temperature in °C temperature in °C 1/2" 5/8" 3/4" 7/8" 1" 1/8 1" 3/8 1" 5/8 2" 1/8 2" 5/8 3" 1/8 3" 5/8 4" 1/8 70 0.64 1.10 1.96 3.03 5.70 9.70 14.95 29.88 51.25 80.02 116.5 162.13 35.0 80 0.61 1.05 1.92 2.98 5.53 9.43. 14.55 29.05 49.81 77.82 113.06 157.59 90 0.60 1.02 1.92 2.98 5.46 9.33 14.42 28.75 49.32 77.08 111.64 155.96 70 0.66 1.27 2.10 3.21 5.95 10.19 15.66 31.14 53.69 83.88 122.01 169.55 40.0 80 0.63 1.24 2.06 3.13 5.72 9.82 15.06 29.88 51.58 80.63 117.23 162.91 90 0.61 1.21 2.06 3.12 5.58 9.63 14.74 29.17 50.56 78.86 114.62 159.33 70 0.71 1.33 2.12 3.25 6.27 10.64 16.4 32.73 56.39 87.89 128.04 177.77 45.0 80 0.67 1.28 2.03 3.11 5.96 10.14 15.61 31.16 53.66 83.66 121.90 169.24 90 0.64 1.24 1.98 3.01 5.76 9.81 15.09 30.07 51.81 80.77 117.77 163.44 70 0.74 1.34 2.16 3.34 6.51 11.00 16.98 33.95 58.52 91.06 132.73 184.29 80 0.70 1.27 2.06 3.17 6.18 10.46 16.13 32.25 55.58 86.46 126.04 175.08 50.0 90 0.67 1.23 1.98 3.05 5.95 10.07 15.53 31.04 53.42 83.15 121.30 168.46 100 0.65 1.20 1.93 2.98 5.82 9.84 15.19 30.30 52.04 81.14 118.49 164.43

EN - 11 Ø Horizontal pipe: v ≥ 2.5 m/s Note: These can have a larger diameter than vertical pipes to For a pipe length of 30 m with a height difference of 15 m compensate for the loss of pressure in the latter. (condenser above the machine) and approximately twenty 90° The pipes must slope in the fluid's flow direction. elbows, the estimated average reduction in cooling capacity is 3% and the increase in electrical power is 4%. Speeds of over 15 m/s may cause significant pressure drops, Ø Liquid pipe: as well as noise from the pipes. Rising gradients on liquid pipes must be kept to a minimum to If a selection causes a significant pressure drop on the limit pressure drops caused by the height difference. discharge line, it is essential to: Excessive pressure drops (above 1 bar) may result in - Check that the operating limits are not exceeded. (Discharge undersizing of the expansion valve on the machine. temperature, condensation pressure, etc.) Take into account the pressure drops on the entire line - Quantify the unit's drop in performance and EER. and the height difference in order to ensure that subcooling is maintained at the expansion valve inlet. A pressure drop of 1°C on the discharge pipe reduces the cooling capacity by 1.5% and increase the power input by 2%. Note: This corresponds to an overall machine efficiency reduction of Significant reduction in subcooling in the case of a condenser 3.5%. located under the chilled water production unit. The room temperature or pipe surface temperature may rise A pressure drop of 1°C equates to a pressure reduction of 0.6 bar. above the condensation temperature (due to exposure to the sun). If this is a risk, the liquid pipe should be insulated to prevent vaporisation.

ØSchematic diagram

LGN lower than the condenser LGN higher than the condenser

L D 15 m max . D L 10 m max .

14.4 Installation • Never use oxygen or acetylene instead of R nitrogen. Doing Strictly observe all the fitting instructions. Avoid allowing any so may result in a violent explosion. contaminants to enter, and carry out all brazing under an R IMPORTANT: comments on testing under vacuum. nitrogen purge. Make sure as few foreign bodies as possible • Never use the compressor as a vacuum pump; it is not (brazing) enter the refrigerating circuit. designed for this purpose. Use a vacuum pump capable of - The circuit must only be vented for less than half an hour to creating a vacuum of 1 mmHg. prevent the lubricant being contaminated with moisture The copper piping diameters are designed for a maximum - Carry out a pressure test developed length of 30 m with a maximum change in level of - Carry out a leak test 15 m. (see section 13.1 Diameters of the connections) - Evacuate the unit using a vacuum These units can be connected either to a water condenser or - Add the refrigerant fluid charge an air condenser. The test pressure may not exceed the unit's operating pressure. Important: Qualifying the connection between the LGN and the condenser. For machines with 2 refrigerating circuits having different - Brazing must be carried out by a qualified brazing technician. power ratings (2100V versions), it is essential to take into Refer to the requirements of standard EN 378-2 and the PED account the highest power rating of the 2 circuits when sizing directive. of the air-cooled condenser. • The connection and tests must be carried out in compliance The power distribution for this machine is as follows: with EN 378-2 and 3 to PED 2014/68/EU. - 2100V version → 45% on circuit 1 and 55% on circuit 2 IMPORTANT comments about testing under pressure • Charge the circuit with a mix of refrigerant and R nitrogen at If the condensers are of different sizes, it is recommended to a maximum pressure of 30 bar. connect the more powerful one to circuit 2 for a 2100V version. • Always place a regulator between the nitrogen cylinder and the refrigerating circuit

EN - 12 15 INSTALLATION ANTIFREEZE PROTECTION The table and the curves below indicate the minimum percentages of glycol with which the system must be provided depending on the freezing point. WARNING: The glycol concentration must protect the fluid at least 6°C below the water outlet temperature specified for the evaporator to allow correct setting of the minimum pressure controller at the evaporator.

Glycol concentration required

Volume concentration in % 0 10 20 30 40 Freezing point °C 0 -4 -10 -18 -27 Ethylene glycol Minimum water outlet °C 5 +3 -1 -7 -14 Freezing point °C 0 -4 -9 -16 -25 EN Propylene glycol Minimum water outlet °C 5 +4 +1 -4 -9

Important: The values are given for guidance only, according to the standard characteristics of the MEG. These may vary depending on the MEG manufacturer, therefore it is important to refer to the manufacturer's data to ensure protection is provided to the required temperature. For a glycol concentration greater than 40%, a special pump must be used

Graph of minimum freezing and operating temperatures

0

-5

-10

-15

-20 1

-25

2 -30

-35 3 4 -40

Temperature (°C) -45

-50 0 10 20 30 40 50 60 Volume concentration in %

Minimum operating temperature Freezing temperature 1 - Monopropylene glycol 3 - Monopropylene glycol 2 - Monoethylene glycol 4 - Monoethylene glycol

16 ELECTRICAL CONNECTIONS 16.1 Power connection - Phase unbalance must not exceed 2% and 10% for voltage The units are designed in accordance with the requirements of and current, respectively. European standard EN 60204-1. If any of the above requirements are not met, contact your They comply with the requirements of the machinery and power supplier immediately and make sure the unit is not EMC directives. turned on until the necessary corrective actions have been All wiring must be connected in accordance with the codes and taken. Failure to do so will automatically void the CIAT regulations that apply to the installation site (e.g. NFC 15100 warranty. in France). Wiring is to be sized by the installer to suit the characteristics In all cases: of the installation site and comply with applicable regulations. - Refer to the wiring diagram attached to the unit. Once the size of the wires has been selected, the installer must - Follow the electrical supply specifications indicated on the determine any changes needed on site to facilitate connection. data plate. - Wiring must be selected based on: The voltage must remain within the range indicated: • The maximum rated current (refer to the “Electrical – Power circuit specifications”). 400 V (+10% / -10 %) - 3 ph - 50 Hz + Earth * 230 V (+10 % / -10 %) - 3 ph - 50 Hz + Earth • The distance between the unit and its power source. - Control circuit: • The protection to be fitted at the power source. 1 ~ 50 Hz 230 V (Transformer fitted as standard on the • The neutral mode. machine) • The electrical connections (refer to the wiring diagram * Installation according to French regulations provided with the unit).

EN - 13 - The electrical connections are to be made as follows: - The external control must be connected using a potential-free • Connection to the power circuit. (dry) contact. • Connect the protective conductor to the earth terminal. - The disconnect switch has a breaking capacity of: • 40.5 kA for DYNACIATpower LGN 700V to 1200V models, • Connect the general fault display dry contact and the • 61.5 kA for DYNACIATpower LGN 1400V to 2100V models, automatic operation control dry contact (where applicable). • 70 kA for DYNACIATpower LGN 2400V models, • Interlock the compressors with the accelerator pump.

DYNACIATpower

Routing for general power cables

Wiring bundle routing Customer connection (Remote control)

The units are supplied by the upper or upper right section of the electrical cabinet with an opening for routing the supply cables. For more details concerning the connections, refer to the connection document supplied with the acknowledgement of receipt. 16.2 Connection to the air-cooled condenser. 16.2.1 Connection to a CIAT air-cooled condenser equipped with an AEROCONNECT controller. If only one LGN is connected to one air-cooled condenser, the machines are connected via the communication bus (see wiring diagram and AEROCONNECT manual). The following information is exchanged between the air-cooled condenser and the chiller.

LGN > Air-cooled condenser LGN < Air-cooled condenser LGN On/Off Air-cooled condenser On/Off Setpoint (air-cooled condenser) Fan stage fault Pressure value (air-cooled condenser) Sensor fault

All the information concerning the AEROCONNECT is available on the CONNECT2 controller, from the LGN console. The LGN's CONNECT2 controller transmits the HP control setpoint and the pressure value to the air-cooled condenser controller The Aeroconnect board:. - Controls the fan stages based on the pressure value (on/off or - Balances the motor operating times. variable frequency drive) transmitted by the LGN. - Uses the MODBUS protocol with RS 485 for CMS. - Controls the operating parameters. - Controls remote starting/stopping. - Diagnoses and stores faults.

RS 485 (2 protected wires) 1000 m max.

OPERA AéroConnect 1B

DYNACIATpower Connect2

IMPORTANT: Communication via the BUS connection is only active when one AEROCONNECT is connected to one CONNECT2. Warning: In the case of two AEROCONNECTs with one CONNECT2, it is necessary to make the air-cooled condenser self- contained and use the optional pressure sensor to independently control the condensation pressure. The condensation pressure regulation system must always be able to ensure a condensation pressure > 20 bar. If this minimum pressure is not maintained, it is necessary to add glycol to the chilled water circuit.

EN - 14 16.2.2 Connection to a non-CIAT air-cooled condenser without an AEROCONNECT controller. In this case, terminals are provided on control terminal strip X1 (potential-free contact) to control the HP control stages. On machines with a single refrigerating circuit, 2 control stages are available. On machines with two circuits, 3 control stages are available per circuit. IMPORTANT: When connecting to a separate non-CIAT air-cooled condenser, the switches and fan motor protection, as well as the condensation pressure control system (if the contacts for the stages available on the LGN terminal strip are not connected to the air-cooled condenser) must be provided by the installer. The condensation pressure regulation system must always be able to ensure a condensation pressure > 20 bar. If this minimum pressure is not maintained, it is necessary to add glycol to the chilled water circuit. 16.3 Customer connection for remote control functions. Comply with standard NFC 15-100 and Machinery directive 2006/42/EC EN Certain operating states can be wired directly to terminal X provided for this purpose: DYNACIATpower

1X terminal

add 2 board

CPU board

General fault alarm: Water pump control

Connector Connector 1 2 14 15 16 J3 (CPU) 1 2 11 12 13 14 15 16 J3 (CPU)

Pump relay No. 2 230 V - 8 A 230 V V Alarm Pump relay No. 1 230 V - 8 A Shared Remote control: Connect the unit's general fault reporting or alarm to the terminals on the unit's terminal strip (see wiring Connect the supply to the pump relays between the terminals diagram). of the connector on the main board. • Output specification: 2 A under 250 V. • Output specification: 2 A under 250 V

Automatic operation control: Setpoint 1/setpoint 2 selector control

Connector Connector 1 2 3 4 5 6 10 11 J6 (CPU)(CPU) 1 2 3 4 5 6 10 11 J6 (CPU)

CA C1 C2

Remove shunt "CA" from between the terminals on the unit Connect a “C2 ” contact to the connector on the CPU board terminal strip (see wiring diagram) and connect a "C1" contact (good quality polarity-free contact) to them (good quality polarity-free contact) . • Contact open → setpoint 1 • Contact open → unit off • Contact closed → setpoint 2 • Contact closed → unit authorised to run • Input specification: 24 V - 15 mA • Input specification: 24 V - 15 mA. Display for operation at full power Display of the operating state of pump No. 1 (if P111 = max P)

Connector J5 (CPU) 1 2 3 4 5 6 10 11 Connector J3 (CPU) 1 2 9 10 11 15 16 K

• Contact open → Pump off 230 V • Contact closed → Pump in operation Connect the signalling of the unit operating at max. • Input specification: 24 V - 15 mA. output to terminals 1 and 2 of the connector on the Other connections can be made to the CPU CONNECT2 board CPU board. • Output specification: 2 A under 250 V.

EN - 15 "Load shedding" function control • Precautions for connection. See manual for the regulator and the electrical diagram of the unit. Connector Communication 1 7 8 9 10 11 J6 (CPU) • In the room, a control and display console is used to run an instant check on the unit; it enables the user to stage communicate with the microprocessor, to configure the unit

N° 1 N° 2 and to adjust the setpoints. • Electronic remote control (option): Connector J2 Installed in the machine room, this will be connected to (Circuit board 2) ADD 2 1 7 8 9 J2 (Carte circuit 2) ADD 2 the unit by a pair of telephone-type wires (max. distance

stage 1000 m). Description of functions and connection: see CONNECT2 manual. N° 3 N° 4 • Relay board(s) (option): This board is installed in a cabinet in the machine room and Connect 1 to 4 contacts to the terminals of the connector of can remotely report on all the unit's operating states and the CPU board according to the number of the compressors to faults by providing contacts which are potential-free when be shed. 1 contact per compressor (contact free of any polarity closed. The board will be connected to the unit by a pair of and of good quality). telephone-type wires (max. distance 1,000 m). • Contact open → normal operation, Description of functions and connection: see • Contact closed → compressor load shedding. CONNECT2 manual. • Input specification: 24 V - 15 mA. • Communication with centralised management system NOTE: (option). • Connection to be made on site by the customer, • See possibility in CONNECT2 manual.

17 CONTROL AND SAFETY DEVICES 17.1 Electronic control and display module the short-cycle protection elapses. To ascertain the setting All units in the DYNACIATpower range and its derivatives are values of the different safety devices and the fault clearance fitted with a CONNECT2 microprocessor-controlled electronic procedures, refer to the CONNECT2 regulator instructions. control and display module. Ø Low pressure control (LP) The electronic module controls the operation of the compressors. Each unit includes one low pressure sensor per refrigerating Thus, depending on the difference between the cold water circuit as standard. This sensor enables the user to display the return temperature and the setpoint temperature, the electronic LP value and enables the electronic module to provide a safety module will activate or deactivate the compressors in series. function by ensuring that the LP value does not fall below the In the standard configuration, the cold or hot water control threshold parameter in the regulator. sensor is located on the evaporator water return Ø High pressure control (HP) 17.2 Main functions • High pressure switch. • Water temperature control: Each refrigerating circuit is equipped with an HP pressure - Evaporator chilled water switch. • 3 possible types of control: The HP safety pressure switch is the main safety device for - Water return difference. the unit during operation. It will be set according to the type of - Water outlet PID temperature. fluid. Thus, when the HP value exceeds the preset value of the - Control according to outdoor temperature pressure switch, power to the compressor(s) in the refrigerating In the standard configuration, the units use the chilled water circuit concerned is cut off and the fault is indicated by an LED return control. For PID water outlet temperature control, refer on the controller console. to the Connect2 control manual. The HP pressure switches are reset manually, thus any fault • Operating settings monitoring. will be cleared by resetting the pressure switch and by pressing the RESET button on the console. • Fault diagnosis. Note: Certain units have two pressure switches per circuit • Fault storage in the event of a power failure. (connected electrically in series). • Management and automatic equalisation of compressor • High pressure sensor operating time (multi-compressors). Each unit is equipped as standard with one high pressure sensor • Remote control (Start/stop, temperature setpoint adjustment, per refrigerating circuit. operating states, general fault) (OPTIONAL). This sensor enables: • Remote control reporting of operating states and faults using - the user to view the HP value an interface module (OPTIONAL). - the electronic module to provide a safety function and a unit For a detailed description of all these functions refer to the control function, by activating the remote condenser fans if CONNECT2 user manual these are controlled by the contacts available on the LGN's • Air-cooled condenser fan control connected to an LGN unit: 2 customer terminal strip or via a Bus connection with the stages per refrigerating circuit. aeroconnect. 17.3 Safety device management Ø Evaporator frost protection All of the unit's safety devices are managed by the electronic The evaporator is protected against freezing by two probes: circuit board in the regulator. If a safety device is triggered • Evaporator chilled water outlet sensor and stops the unit, trace the fault, reset the safety device if Each evaporator is fitted with an antifreeze protection sensor necessary, then clear the fault with the "RESET" button on the (located on the chilled water outlet) which monitors the temperature CONNECT2 console. of the fluid to be cooled. If this temperature falls The unit will restart when the minimum time required by

EN - 16 below the set value in the regulator, power to the compressor(s) and the fault is indicated by an LED on the regulator console. in the refrigerating circuit concerned is cut off and the fault is Ø Overpressure protection indicated by an LED on the regulator console. This probe acts Each refrigerating circuit in each unit is protected against the risk as a safety device and must therefore never be moved by the of overpressure resulting from fire. customer. • Safety valves • Freon sensor on evaporator inlet or on the circuit 1 or 2 - The safety valve or valves protect the HP and LP circuits pressure sensor (LP) (DYNACIATpower 1400V to 2400V) against overpressure caused by an increase in the outdoor This sensor monitors the temperature of the refrigerant at the temperature, when the unit is off. (E.g.: external fire) evaporator inlet. If this temperature falls below the set value in - This safety valve is not considered a safety device as defined the regulator, power to the compressor(s) in the refrigerating in section 2.11 of appendix 1 of the pressure equipment circuit concerned is cut off and the fault is indicated by an LED directive. on the regulator console. • Allowable pressure (PS) LP side EN - The LP value (given on the data plate) corresponds to Ø Evaporator water circulation controller the situation with the unit switched off. This value is given Every unit is fitted with a water circulation control device as according to the pressure/temperature ratio with an outdoor standard. Thus, if the water flow is insufficient, the power temperature of 50°C. These temperatures correspond to supply to the compressor(s) is cut and an LED indicates the the least favourable situation the unit could be subjected to, fault on the regulator console. excluding an external fire. Ø Internal compressor protection The pipes on the LP side are sized for the maximum authorised Every model in the LGN range is protected against overheating pressure. (PS) of the electric motor and high discharge temperatures. The LP value is linked to the relevant unit and cannot be LGN are equipped with compressors with internal protection exceeded. against missing phases and phase reversal. On all models, an optional phase controller may also be added 17.4 Phase controller kit if the customer wishes. The phase monitor kit performs the following functions: - Controls the direction of rotation of each phase Ø Discharge sensor - Detects the absence of one or more phases Each unit includes one discharge sensor per refrigerating - Monitors for overvoltage or undervoltage circuit as standard. This sensor located on the discharge piping makes it possible for the user to view the discharge The kit consists of: temperature value and enables the electronic module to - The network monitor relay + rail and mounting screw provide a safety function. - Connection cables If the discharge temperature exceeds the maximum - Assembly instructions. temperature threshold set in the regulator, the power supply to the compressor(s) for the refrigerating circuit concerned is cut

EN - 17 17.5 Location of the safety sensors and devices

DYNACIATpower LGN 700V to 1600V with electronic expansion valves COILED IN THE CABINET Service valve Schrader 12 B1 BBP2 valve BBP 12 Service valve DET 2 Pressure- Schrader reducing B15 P valve regulator A R A R A R A R BBP CP2 CP1 CP4 CP DET 1 Pressure- reducing B7B B12B OPTION BBP1 P regulator Suction valves RC2 RC1 B7A RC4 RC B12A B9

CIRCUIT 1 BHP1 BHP2 CIRCUIT 2 HP HP1 P P HP4 HP2 B2 12 12 Inlet Differential pressure switch Service Service Discharge valve valve valve WATER

CHILLED Circ. 2 Hot gas SR B11 injection valve Outlet SR Discharge Hot gas Circ. 1 valve injection valve COOLER CONNECTION

FIRE SAFETY EE R Expansion DEVICES R Circ. 2 12 Liquid valve RL R B1 4 2 valve Circ. 2 Circ. 1 B2 6 E R

Expansion Circuit 2 Circuit 1 12 Hygroscopic Cartridge valve Capillary RL B8 1 sight glasses filter dryers Circ. 1 COOLER CP4 CP CP2 CP1 tube B2 5 CONNECTION Liquid Capillary tube valve

DYNACIATpower LGN 1800V to 2400V with electronic expansion valves COILED IN THE CABINET Service valve 12 B1 BBP2 Schrader BBP 12 valve Service valve DET 2 Pressure- Schrader reducing B15 P valve regulator A R A R A R A R A R A R BBP CP1 CP2 CP3 CP4 CP5 CP6 DET 1 Pressure- reducing B7B B12B OPTION BBP1 P regulator Suction valves RC1 RC2 RC3 B7A RC4 RC5 RC6 B12A B9

BHP1 CIRCUIT 1 BHP2 CIRCUIT 2 HP1 HP3 P P HP4 HP2 B2 12 12 Inlet Differential pressure switch Service Discharge Service valve valve Discharge valve WATER

CHILLED Circ. 2 Hot gas valve SR B11 injection valve Outlet SR Hot gas Circ. 1 injection valve COOLER CONNECTION

FIRE SAFETY EE R Expansion DEVICES R Circ. 2 12 valve Liquid RL R B1 4 2 valve Circ. 2 Circ. 1 B2 6 E R

Expansion Circuit 2 Circuit 1 12 Hygroscopic Cartridge valve Capillary RL B8 1 sight glasses filter dryers COOLER CP4 CP5 CP6 CP1 CP2 CP3

B2 5 Circ. 1 tube CONNECTION Liquid Capillary tube valve RL: Liquid return SE: Evaporator outlet SR: Discharge outlet EE: Evaporator inlet Sensors: B1: Outdoor temperature sensor B2: Evaporator chilled water inlet sensor B11: Evaporator chilled water outlet sensor CIRCUIT 1 CIRCUIT 2 B7A: Circuit 1 stage 1 discharge sensor B12A: Circuit 2 stage 1 discharge sensor B7B: Circuit 1 stage 2 discharge sensor B12B: Circuit 2 stage 2 discharge sensor B8: Antifreeze protection/evaporator refrigerant sensor 1 B14: Antifreeze protection/evaporator refrigerant sensor 2 B9: Circuit 1 suction sensor B15: Circuit 2 suction sensor B25: Circuit 1 liquid/refrigerant sensor B26: Circuit 2 liquid/refrigerant sensor

EN - 18 17.6 Adjusting the control and safety devices

Units Function Electrical symbol Settings

Outdoor sensor Adjust the setpoint according to the outdoor temperature B1 Chilled water inlet sensor Control of the unit on the water return B2 Chilled water outlet manifold Unit control if controller on water outlet B11 sensor CONNECT2 controller Discharge sensor Circ. 1: B7A, B7B Compressor protection circuit 1, circuit 2 Circ. 2: B12A, B12B Circuit 1 and circuit 2 evaporator Circ. 1: B8 Evaporator frost protection inlet freon sensor Circ. 2: B14 EN HP fault threshold: High pressure switch Circ. 1: HP1, HP3 R407C: 29 bar ± 0.7 Compressor safety devices circuit 1 and circuit 2 Circ. 2: HP2, HP4 R410A: 40.5 bar ± 0.7 Manual rearming + Reset button Circuit 1 and circuit 2 low Low pressure value control Circ. 1: BBP1 pressure sensor Fluid leak detection Circ. 2: BBP2 High pressure value control CONNECT2 controller Circuit 1 and circuit 2 high Circ. 1: BHP1 Controlling the unit by high pressure pressure sensor Circ. 2: BHP2 Condensing pressure control

18 COMMISSIONING Checks prior to system start-up: Always read this manual - Check the tightening torque of all electrical connections in full before attempting to commission the system. - Leave the compressor's crankcase heaters on for 6 hours Comply with applicable national regulations during testing and before operating the unit. installation. - After 6 hours, touch the crankcases to ensure that all heaters Before commissioning the system, carry out the following have been working correctly (they should be lukewarm) checks: - Make sure current is supplied to the general connection - Compare the complete system against the refrigeration and and that the voltage supplied remains within the wiring diagrams acceptable limits (+10% to -10% compared to the - Make sure that all components are as specified on the rated voltage) drawings - Make sure that no documents and safety devices required by FLEXIBLE COUPLINGS MUST BE USED ON THE applicable European standards are missing HYDRAULIC PIPES (EVAPORATOR). - Make sure that there is sufficient clearance around the 18.1 Commissioning system for maintenance and emergency purposes The system must be started and commissioned by a qualified - Check the assembled couplings technician. - Check the quality of the welds and seals and check for any - The system must be charged with refrigerant and water refrigerant leaks flowing in the exchangers when it is turned on and tested. - Make sure that all mechanical guards are in place and - Power up the main board functional - Look into the problems of specific noise generated by the installation. - After opening the water circuit valves, make sure that water is flowing in the cooler while the pump is running. - The air in the hydraulic circuit must be bled before the system is started up. For this operation, the pump(s) must have been started up. To enable operation without triggering the compressor(s), all - Check that the machine is configured for local control our machines are delivered with the parameter "compressor on (regulator selection) authorisation" set to "NO". - Select the operating mode using the button (chilled or hot The operation can therefore be carried out with no risk of water operation) starting up the compressors by setting the machine control to the "ON" position. - Enter the setpoints for Once the hydraulic circuit has been bled, the machine is Chilled water started up by switching the "compressor on authorisation" setting to "YES" which authorises start up. List of parameters concerned: - P230 Stage 1, circuit 1 "on" authorisation - P231 Stage 2, circuit 1 "on" authorisation - P232 Stage 1, circuit 2 "on" authorisation - P233 Stage 2, circuit 2 "on" authorisation - Check the operation of the circulation controller - Check for loose clamps on all pipes

EN - 19 - Air-cooled condenser: of the refrigerating circuit". If the air-cooled condenser is equipped with Hydraulic: AEROCONNECT control and a BUS connection As the exact total drop in system pressure is not known at can be used between the 2 machines, parameter commissioning, adjust the flow of water with the control valve P 116 on the CONNECT2 controller located on the LGN until the desired nominal rate is obtained. By causing the must be changed to YES in order to set the condenser pressure in the water system to drop, this control valve aligns control parameters in menu 13. (refer to the AEROCONNECT the system pressure/flow curve with that of the pump so that the controler manual) nominal flow rate corresponding to the desired operating point - Charge the refrigerant circuit: is obtained. LGN units are delivered with a nitrogen charge. The pressure drop in the plate exchanger (read using the Proceed as follows to charge the machine and the installation, pressure gauge connected to the machine inlet and outlet) is after having created a vacuum in the installation: the reference to be used to check and adjust the nominal flow rate of the system. - Close the liquid valve Follow the procedure described below: - Connect the cylinder of refrigerant to the charging valve. Do - Open the control valve completely. not tighten it. - Let the pump run for 2 hours to flush out any solid particles - Briefly open the cylinder valve to purge the coupling, then in the circuit. retighten it. - Read the pressure drop in the plate exchanger when the - Open the cylinder valve and carry out the charging of pump is switched on and then 2 hours afterwards: refrigerant of the unit. • If the pressure drop has decreased, this means that the - Close the cylinder valve and open the liquid valve. screen filter is clogged. It must be removed and cleaned • Repeat until the filter is completely clean. - Start the unit by pressing the on/off button - Once the circuit has been flushed of all contaminants, read - The unit can only be started after 2 minutes (time required the pressure drop in the plate exchanger and compare it to the to scan and enable all the safety devices). The control stages theoretical pressure drop selected. should operate in cascade mode based on the demand. If the reading is higher than the theoretical value, the flow rate is too high. In other words, the pump is delivering too much - The internal safety devices are now activated. If one of flow for the system load drop. Close the control valve one these safety devices is triggered, trace the fault, reset the complete turn and read the load drop. Continue by gradually safety device if necessary and press the RESET button on the closing the valve until the nominal flow rate for the desired console to clear the fault. operating point is obtained. - Check the flow of liquid at the liquid sight glass. However, if the system load drops far below the available - Check for overheating at the evaporator outlet and static pressure delivered by the pump, the resulting water flow subcooling at the expansion valve inlet. Top up the charge rate will be low and the difference in temperature between the (in small amounts) to adjust the overheating and subcooling. exchanger inlet and outlet will be higher. This is why load drops Recommendation: 8 to 10°C at 100% power. must be minimised. - When the charge is optimised to the required operating NOTE: conditions, remove the charging devices and ensure that the An excessively low suction pressure or an excessively liquid valve is completely open (seat to the rear). high condensation pressure may sometimes be read when Use either of the following to turn off the unit in non- commissioning the unit. These problems may have numerous emergency situations: causes. Refer to the "Troubleshooting operating problems" - The On/Off button on the console section for more information. - A dry contact on the automatic operation control.  Operation with negative temperatures Do not use the master switch as the electrical cabinet To guarantee operation of the unit, it is essential to: must remain live (antifreeze protection, crankcase heater). - Adjust the controller's safety parameters for the operating temperature (P52/P71). NOTE: - Adapt the settings of the thermostatic expansion valve to power DYNACIAT machines use R410A. It is essential that have overheating at + 7°C. technicians use equipment which is compatible with R410A - Adjust the refrigerant charge, checking that the subcooling with a working pressure which is approximately 1.5 times values are between 5 and 8°C. higher than that of units using R407C. 18.2 Essential points that must be checked Compressors: Ensure that each compressor is rotating in the correct direction, checking that the discharge temperature rises quickly, the HP increases and the LP drops. If it is rotating in the wrong direction, the electric power supply is incorrectly wired (reversed phases). To ensure rotation in the correct direction, swap the two power supply phases. - Check the compressor discharge temperature using a contact sensor. - Check the input current; it should be normal. - Check all safety devices to make sure they operate correctly. - Check the oil level of the compressors and, if necessary, top up with the oil type specified in section "12 Main components

EN - 20 19 TECHNICAL CHARACTERISTICS

DYNACIATpower LGN 700V 800V 900V 1000V 1100V 1200V 1400V 1600V 1800V 2100V 2400V

Net cooling capacity  kW 203.4 235.3 263.2 293.1 323 354 401 447.9 520.5 590.4 656.9 Net power input ‚ kW 53.6 61.7 69.8 78 86.2 94.2 107.3 120.3 142.9 163 183.2 Energy efficiency rating (EER) 3.79 3.81 3.77 3.76 3.75 3.76 3.74 3.72 3.64 3.62 3.59 Discharge output kW 257 297 333 371.1 409.2 448.2 508.2 568.2 663.4 753.4 840.1 Lw / Lp Standard dB(A) 89/57 90/58 89/57 90/58 91/59 95/63 96/64 93/61 95/63 97/65 Sound power Lw / Lp Low Noise dB(A) 84/52 85/53 86/54 87/55 88/56 90/58 91/59 89/57 90/58 91/59 level ƒ Lw / Lp Xtra Low Noise dB(A) 79/47 80/48 81/49 82/50 85/53 86/54 85/53 86/54 87/55 EN Refrigeration circuit

Quantity 2 Refrigerant (GWP) R410A (2088) Refrigerant charge Refrigerant not supplied (nitrogen charge)

Compressor

Type Hermetic SCROLL (2900 rpm) Quantity 4 6 Start-up mode Direct in line in series Stage 6 4 6 4 6 4 6 4 6 8 6 number Power control 100-84-66- 100-78-71- 100-75-50- 100-78-71- 100-75- 100-78-71- 100-75- 100-78-71- 700-75-50- 100-83-66- 100-83-66- % 48-36-30- 50-28-21-0 25-0 50-28-21-0 50-25-0 50-28-21-0 50-25-0 50-28-21-0 25-0 50-33-16-0 50-33-16-0 18-15-0 Power distribution per circuit % 50 / 50 45 / 55 50 / 50 (circ. 1/circ. 2) Refrigerant oil type POE 160SZ POE 3MAF Oil capacity l. (circ.1) 13.4 14.4 12.6 18.9 Oil capacity l. (circ. 2) 13.4 14.4 12.6 18.9

Evaporator

Type Brazed plate heat exchanger Quantity 1 Water content l 20 23 26 29 32 37 50 57 64 77 77 Min / max water outlet °C -12 °C / +18 °C temperature Min/max water flow m3/h 22/70 26/81 29/82 33/105 35/113 38/124 44/137 51/151 61/150 68/150 74/150 Minimum system water volume l 636 880 844 1146 1043 1346 1286 1735 1262 1336 1595 Hydraulic connections Ø VICTAULIC DN 100 VICTAULIC DN 125 VICTAULIC DN 150 Minimum system diameter Ø DN 100 DN 125 DN 150 Max service pressure bar 10 bar water side

High pressure circuit

Type Without condenser Male gas discharge Ø See section 13.1 Diameters of the hydraulic and refrigeration connections Male liquid return Ø Max service pressure bar 40.5

Dimensions and weight

Storage temperature °C See section 1 Introduction Length mm 2099 2499 3350 Width mm 996 Height in operation „ mm 1869 1887 1970 Weight kg See section 9.1.1 Dimensions and floor mounting of the frames

 Net power for chilled water temperature + 12°C/+ 7°C and ƒ Lw: Overall power level as per standard ISO 3744 condensation + 45°C Lp: Overall pressure level measured at 10 metres in a free field, ‚ Compressor net power input. calculated using the formula Lp = Lw - 10 log (S) „ Height excluding handling mounts.

Values calculated for a 7 m refrigerant connection

EN - 21 20 ELECTRICAL SPECIFICATIONS

DYNACIATpower LGN 700V 800V 900V 1000V 1100V 1200V 1400V 1600V 1800V 2100V 2400V

Compressor

Voltage V 3 ph ~ 50 Hz/400 V (+10%/-10%) + Earth Max. rated current A 140 160 182 205 218 232 266 295 356 399 443 Starting current  A 316 334 391 414 480 494 586 615 607 720 763 Starting current A 230 248 287 310 352 366 429 453 483 562 605 with Soft Start option 

Remote control auxiliary circuit

Voltage V 1 ph ~ 50 Hz/230 V (+10%/-10%) - Transformer fitted Max. rated current A 0.8 1.3 Transformer capacity VA 160 250 Electrics box protection rating IP 21 Machine protection rating IP 21

Breaking capacity kA 40.5 61.5 70 Max. cable cross section based mm² 240 300 on the disconnect switch ‚ Max. cable cross section based mm² 95 120 185 240 2 x 185 on the calibre ƒ

 Starting current of largest compressor + maximum current of other compressors under full load. ‚ Maximum cable cross section accepted by the disconnect switch on the cable diameter and connection terminals. ƒ Minimum cable diameter to be used, determined according to maximum rated currents.

EN - 22 21. SERVICING AND MAINTENANCE 21.1 Operating readings

Date/Time

Suction pressure Bar

Intake temperature °C Compressor Condensation pressure bar EN

Condensation temperature °C

Discharge inlet temperature °C

Liquid outlet temperature °C Air-cooled condenser Air inlet temperature °C

Air outlet temperature °C

Water inlet temperature °C

Water outlet temperature °C Water evaporator Refrigerant fluid inlet °C temperature

Refrigerant fluid outlet °C temperature

Nominal voltage V

Voltage at terminals V

Compressor input current A

Fan input current A

Oil level

Frost protection trigger °C temperature

Mechanical inspection: tubes, fastenings, ...

Electrical connection tightness check

Control check

Water flow rate check m3/h

H. P. safety disconnection check bar

21.2 Unit maintenance and servicing 21.2.1 Safety instructions carried out by a qualified authorised technician. - Perform operating inspections in accordance with national - Any opening or closing of a shut-off valve must be carried out regulations. with the unit off. - Do not climb on the machine; use a platform to work at the - The liquid valve (located just before the dryer) must always be necessary height. opened completely when there is refrigerant in the circuit. - Do not climb on the copper refrigerant pipes. - Do not work on any electrical components without first turning - All work on the unit's electrical or refrigerant systems must be off the unit's main disconnect switch in the electrics box.

EN - 23 Although the compressor(s) is (are) turned off, the power If refrigerant is accidentally released, ventilate the room with circuit remains energised until the unit cutoff switch is opened. fans. Exposure levels in workplaces must be kept to a practical Other components may remain powered by external controllers minimum and must never exceed the recognised limit of 1000 connected to the orange disconnect terminals on the main ppm for an 8-hour working day and a 40-hour working week. terminal strip. Although halocarbon and hydrofluorocarbon refrigerants are Disconnect the removable portion of these terminals before not flammable, keep them away from open flames (e.g. commencing any work. cigarettes, etc.), as temperatures of over 300°C cause - The surfaces of the compressor and pipes may reach their vapours to break down and form phosgene, hydrogen temperatures of over 100°C and cause burns if touched. fluoride, hydrogen chloride and other toxic compounds. These Likewise, the surfaces of the compressor may in some cases compounds may produce severe physiological consequences drop to freezing temperatures which can cause frostbite. if accidentally inhaled or swallowed. - It is therefore important to take special care when carrying out Warning: Do not expose R410A, R407C vapours and zeotropic maintenance work. blends of refrigerants containing R32 to open flames (such as cigarettes). Refrigerants must be evacuated from pipes and - Technicians working on the unit must wear the necessary tanks before commencing any cutting or welding work. Do safety gear (e.g. gloves, eye protection, insulating clothing, not use a torch to check for leaks of refrigerants containing safety shoes). halocarbons such as R410A, R407C and its by-products. 21.2.2 Noise NOTE: DYNACIATpower LGN machines use R410A. It is essential Similarly, it is recommended that personnel working close to that technicians use equipment which is compatible with sources of high noise emission wear ear defenders. R410A with a working pressure which is approximately 1.5 The ear defenders should in no way impede the wearing of times higher than that of units using R407C. other protective equipment. 21.2.6 Servicing 21.2.3 Oil - Note down the operating readings and perform the checks Oils for refrigeration units do not pose significant health indicated in the table on the previous page at least twice a hazards if they are used in accordance with the precautions year and each time a unit is started up. for use: ● Weekly checks - Avoid unnecessary handling of components lubricated with With the unit running at full capacity, check the following oil. Use protective creams. values: - Oils are inflammable, and must be stored and handled with - Check the entire installation for traces of water or oil under or care. Disposable rags or cloths used for cleaning must be kept around the unit, and for any unusual noises. away from open flames and disposed of in the appropriate - LP compressor suction pressure, manner. - HP compressor discharge pressure, - Containers must be stored with their caps on. Avoid using oil from an opened container stored under incorrect conditions. - The water inlet and outlet temperatures in the exchangers - The charge via the liquid sight glass and the condition of the 21.2.4 Refrigerants - general information charge using the coloured indicator on the sight glass - Always remember that refrigeration systems contain - The oil level and its appearance. If the colour changes, check pressurised liquids and vapours. the quality. - All necessary measures must be taken when partially opening - Keep the unit clean the system: Make sure that there is no pressure in the part of the circuit concerned. - Also check whether the safety devices operate correctly. - Partial opening of the primary refrigerant circuit will cause ● Monthly checks a certain quantity of refrigerant to be released into the - Check all the values listed in the "Operating readings" table atmosphere. on the previous page. - It is essential to keep the amount of lost refrigerant as low - Perform a corrosion check on all the metal parts. (Frame, as possible by pumping the charge and isolating it in another casing, exchangers, electrical boxes etc.) part of the system. - Make sure that the insulating foam is not detached or torn. - The refrigerant and lubricating oil, and the low-temperature - Check the energy transfer fluids for any impurities which liquid refrigerant in particular, may cause inflammatory could cause wear or corrosion in the exchanger. lesions similar to burns if they come into contact with the skin - Check the circuits for leaks. or eyes. Always wear protective eyewear, gloves and other protective - Check whether the safety devices and the expansion valve(s) equipment when opening pipes or tanks liable to have liquids operate correctly in them. Store unused refrigerant in the appropriate containers ● Annual checks and limit the amounts stored in mechanical rooms. - Carry out the same inspections as during - Cylinders and tanks of refrigerant must be handled with care the monthly checks. and signs warning users of the related poisoning, fire and explosion hazards must be clearly visible. Refrigerant that - Test the oil for contaminants: if acid, water or metal particles reaches the end of its life must be collected and recycled in are detected in the oil, replace it in the corresponding circuit accordance with applicable regulations. and the dryer. - If the whole oil load is being changed, use only new oil of 21.2.5 Halocarbon and hydrofluorocarbon refrigerants the same grade as the original oil, which has been stored in Although non-toxic, vapours from halocarbon and a hermetically sealed container until loading. Oil type: (see hydrofluorocarbon refrigerants are still hazardous because section 12 Main components of the refrigerating circuit). they are heavier than air and can force air of the machine rooms.

EN - 24 - Check the filter dryer for clogging (measure the difference NB: The cleaning intervals are given as a guide and should be in the temperature of the pipes at the dryer inlet and outlet). adapted to each installation.

- Clean the water filter and vent air from the circuit. 21.2.7 Disassembling the compressor - Clean the exchangers and check the pressure drop in each. The compressor is fastened to the platform by four - Check the operation of the water flow switch. dia. 8 mm screws. - Check the water quality or condition of the coolant. Warning: When tightening the compressor screws, the maximum torque to apply is 16 Nm ± 1. If you do not have - Check the antifreeze concentration (MEG or PEG) a torque wrench, tighten until you feel some resistance, then - Disconnect all the cables and check the insulation of the tighten a further ¾ of a turn. motor and the resistance of the windings. IMPORTANT: - Check the electrical connections to ensure they are tight and To ensure your unit runs smoothly and to obtain service EN in good condition. under the warranty, take out a maintenance contract with - Check the condition of the contacts and the current at full load your installer or an approved maintenance company. on all 3 phases. - Check the electrical box for water seepage.

22 ECODESIGN

The sealing test must be carried out in compliance with the CE regulation no.842/2006 relating to certain greenhouse gases. R410A, R134a and R407C are refrigerant gases with the following environmental impact: 1/ No impact on the ozone layer. They have an ODP (Ozone Depletion Potential) index of 0 2/Impact on the greenhouse effect: Global Warming Potential (GWP) of each gas. - R410A ------GWP = 2088 - R407C ------GWP = 1800 - R134a ------GWP = 1430 - Operators must ensure that qualified personnel carry out periodic leak testing, according to the refrigerant load: - Every 12 months for units containing 3 to 30 kg of refrigerant. (2Kg in France, edict and decree of 7 May 2007) - Every 6 months for units containing 30 to 300 kg of refrigerant. - Every 3 months for units containing more than 300 kg of refrigerant. (Implementation of leak detection system) - For all systems which contain over 3 kg of refrigerant (2 kg in France), users are required to keep a log of the quantities and types of fluids used in, added to and recovered from the system, as well as the dates and results of the sealing tests. The name of the technician and his company must also be recorded. - A leak test must be carried out one month after any leak repairs. - System users are responsible for collecting used refrigerant and having it recycled, regenerated or destroyed.

23 PERMANENT SHUTDOWN  Shutting down  Waste electrical and electronic equipment (WEEE) ƒƒ Separate the units from their energy sources, allow them to ƒƒ At the end of its life, this equipment must be disassembled cool then drain them completely. and contaminated fluids removed by professionals and  Recommendations for disassembly processed via approved channels for electrical and ƒƒ Use the original lifting equipment. electronic equipment (WEEE). ƒƒ Sort the components according to their material for recycling -- In France, CIAT has formed a partnership with ECOLOGIC or disposal, in accordance with regulations in force. for the collection and recovery of professional waste ƒƒ Check whether any part of the unit can be recycled for governed by European Directive WEEE 2012/19/EU. another purpose. This partnership simplifies the mandatory administrative procedures and ensures that old equipment is recovered  Fluids to be recovered for treatment via an official, structured channel. In terms of renovation -- R410A refrigerant work in France (mainland and overseas), for every CIAT -- Energy transfer fluid: depending on the installation, unit installed, our partner will collect and dismantle water, glycol/water mix... your existing equipment (see conditions with Ecologic). -- Compressor oil To request collection, please contact Ecologic:  Materials to be recovered for recycling 01.30.57.79.14 - [email protected] -- Steel -- For other countries, please refer to the legislation in -- Copper force and the specific solutions available to ensure your -- Aluminium waste is processed legally. -- Plastics -- Polyurethane foam (insulation)

EN - 25 24 TROUBLESHOOTING OPERATING PROBLEMS Preliminary advice: Important: First and foremost, bear in mind that most faults - Faults detected by the safety devices are not necessarily potentially occurring on the units have simple causes that are caused by a sudden change in the measurement being often the same for all. Look for these causes first. monitored. There are three such causes in particular: - Taken regularly, readings should allow future trips to be ● The fouling level of the exchangers anticipated. ● Problems with the fluid circuits - Perform the checks listed in the table below (next page) if you ● Failures of electric components such as the relay coil or the notice that a measurement deviates from its normal value and electric valve etc. gradually moves closer to the safety limit.

Faults Probable causes Instructions

- Air in the chilled water circuit. - Purge the chilled water circuit.

- Chilled water flow insufficient. - Check the opening of the chilled water circuit valves. - Check the direction of rotation of the pump, that there is no cavitation and that the pump is not too small. Suction pressure too low - Chilled water flow rate sufficient but chilled water temperature too - Recalculate the heat load and check that the unit is not too powerful low. for this load. - Check the operation of the regulator.

- Lack of refrigerant fluid. - Trace the leak(s) and top up the charge. - Condenser malfunction. - Check correct operation of the regulator and setpoint adjustment. - Check the operation of the condenser.

- Check the condensation pressure control.

Excessive - Condenser clogged. - Clean the condenser coil. discharge pressure - Too much refrigerant - Check and adjust the load.

- Poor ventilation (suction or discharge blocked), fans turning in wrong - Check the operation of the air-cooled condenser. direction

- Suction air too hot (recirculation) - Check the operation of the air-cooled condenser

Insufficient oil - Top-ups not carried out when required. - Top up with oil.

- Water flow is either stopped or below the minimum rate. - Check that the valves on the water circuit open and check the Water flow fault pump(s). - Start-ups too close together; short-cycle protection disrupted. - Set the correct time between two starts.

Motor winding - Overload protection disrupted or defective. - Adjust or replace the overload protection. fault - Power supply voltage too low. - Check the electrical wiring; if need be, contact your electricity supplier

a) With above-normal low pressure - Controller setpoint incorrect - Correct the setpoint value

- Heat load above unit capacity. Two solutions: - Water flow rate too high - Adjust the water flow rate to the specified value using the control valve. - Bypass the evaporator to obtain a greater difference in temperature Fluid outlet with a lower flow rate to the evaporator. temperature too high - Electronic control faulty. - Check the operation of the temperature and power controllers

- Look for leaks and top up the load. b) With below-normal low pressure - Check the electrical valve and the expansion valve. - Lack of refrigerant - Ensure that the dehumidifier filter is not clogged and that the - Incorrect refrigerant supply to evaporator evaporator is not frozen

Discharge temperature - The compressor draws in too much liquid - Check and adjust the refrigerant load insufficient and - Check the expansion valve close to condensing temperature

Moisture indicator - The sight glass remains yellow: Excessive moisture in the circuit. - Refer to section 12 "Main components of the refrigerating circuit". sight glass

EN - 26 25 SYSTEM SCHEMATICS 25.1 ooling installation with drycooler

DYNACIATpower LGN

L

A EN

E I

G H I C

K

K J

D B F J

A: Chilled water circuit F : Drain K: Temperature measuring well B: Control valve G : Shut-off valve L : BUS communication connection C: Water filling H : Water filter (Compulsory) (RS 485) between CIAT drycooler D: Expansion vessel I : Flexible connections controller and chiller E: Hydraulic safety valve J : Refrigeration safety valve

EN - 27 CIAT Service www.ciat.fr

Registered address Avenue Jean Falconnier B.P. 14 This document is not legally binding. 01350 Culoz - France As part of our continuous drive to improve our products, Tel. : +33 (0)4 79 42 42 42 CIAT reserves the right to make any technical modifications Fax: +33 (0)4 79 42 42 10 without prior notice. www.ciat.com

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